sanjay b. patil - construction | mining |...

For Authorised Use Only

SANJAY B. PATILSANJAY B. PATILSANJAY B. PATILSANJAY B. PATIL

JAMBREJAMBREJAMBREJAMBRE HYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECT

1 x 2000 KW1 x 2000 KW1 x 2000 KW1 x 2000 KW

TENDER DOCUMENT TENDER DOCUMENT TENDER DOCUMENT TENDER DOCUMENT

NO.NO.NO.NO.SBPSBPSBPSBP----01010101/2016/2016/2016/2016----17171717

VOLUME VOLUME VOLUME VOLUME –––– IIIIIIII

SCOPE OF SCOPE OF SCOPE OF SCOPE OF SUPPLY,SUPPLY,SUPPLY,SUPPLY,

TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS

& GTP& GTP& GTP& GTP

NAME OF WORK :NAME OF WORK :NAME OF WORK :NAME OF WORK : JAMBREJAMBREJAMBREJAMBRE HYDRO ELHYDRO ELHYDRO ELHYDRO ELECTRIC PROJECTECTRIC PROJECTECTRIC PROJECTECTRIC PROJECT

: Design, Manufacture, Test at Shop, Supply at site including

Transport, handling, loading/unloading, Installation, Putting to

Operation and Supervision during Erection, Testing, Commissioning

and Setting to Operation of Turbine/Generator sets along with all

E&M equipment required for Hydel power station and switchyard

for JAMBREJAMBREJAMBREJAMBRE HYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECT(1X2MW)(1X2MW)(1X2MW)(1X2MW)::::

OFFICE OFFICE OFFICE OFFICE ADDRESS:ADDRESS:ADDRESS:ADDRESS: PRICE :PRICE :PRICE :PRICE : Rs. Rs. Rs. Rs. 11115000/5000/5000/5000/---- PerPerPerPer

SANJAY B. PATIL

R.S.NO.171 E WARD,

1 A Mahaveer College Chowk,

Nagala Park, Kolhapur-416003

Ph. 91-231-2650999,2657999

Email – [email protected]


TENDER DOCUMENT TENDER DOCUMENT TENDER DOCUMENT TENDER DOCUMENT

NO.NO.NO.NO.SBPSBPSBPSBP----01010101/2016/2016/2016/2016----17171717

VOLUME VOLUME VOLUME VOLUME –––– IIIIIIII

NAME OF WORK :NAME OF WORK :NAME OF WORK :NAME OF WORK : JAMBREJAMBREJAMBREJAMBRE HYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECTHYDRO ELECTRIC PROJECT

: Design, Manufacture, Test at Shop, Supply at site including

Transport, handling, loading/unloading, Installation, Putting to

Operation and Supervision during Erection, Testing, Commissioning

and Setting to Operation of Turbine/Generator sets along with all

E&M equipment required for Hydel power station and switchyard

for JAMBREJAMBREJAMBREJAMBRE HYDRO ELECTRIC PROJECT:HYDRO ELECTRIC PROJECT:HYDRO ELECTRIC PROJECT:HYDRO ELECTRIC PROJECT:

ISSUED TO M/s.ISSUED TO M/s.ISSUED TO M/s.ISSUED TO M/s. ________________________________________________________

________________________________________________________

________________________________________________________

Date:Date:Date:Date: __ / __ / ____

I N D E XI N D E XI N D E XI N D E X

Sr Sr Sr Sr

No.No.No.No. Section No.Section No.Section No.Section No. ParticularsParticularsParticularsParticulars Page No.Page No.Page No.Page No.

SECTION SECTION SECTION SECTION ––––IIII ScoScoScoScope of Supply & Spares to be pe of Supply & Spares to be pe of Supply & Spares to be pe of Supply & Spares to be

supplied by tenderersupplied by tenderersupplied by tenderersupplied by tenderer 1 – 15

SECTION SECTION SECTION SECTION ––––IIIIAAAA Recording TG InstrumentsRecording TG InstrumentsRecording TG InstrumentsRecording TG Instruments 16 – 28

SECTIONSECTIONSECTIONSECTION –––– IIIIIIII Detailed price ScheduleDetailed price ScheduleDetailed price ScheduleDetailed price Schedule 29 – 38

SECTION SECTION SECTION SECTION ––––

IIIIIIIIAAAA Price Schedule with break upPrice Schedule with break upPrice Schedule with break upPrice Schedule with break up

39 – 40

SECTION SECTION SECTION SECTION ––––IIIIIIIIIIII TECHNICAL SPECIFICATIONSTECHNICAL SPECIFICATIONSTECHNICAL SPECIFICATIONSTECHNICAL SPECIFICATIONS

AAAA.... DetailDetailDetailDetail Technical Specification Technical Specification Technical Specification Technical Specification

TurbineTurbineTurbineTurbine---- GeneratoGeneratoGeneratoGenerator with it’s r with it’s r with it’s r with it’s

auxiliariesauxiliariesauxiliariesauxiliaries 41 – 81

BBBB.... 3.3. KV Switchgear3.3. KV Switchgear3.3. KV Switchgear3.3. KV Switchgear 82 – 85

CCCC.... Power & Auxiliary TransformerPower & Auxiliary TransformerPower & Auxiliary TransformerPower & Auxiliary Transformer 86 – 122

DDDD.... 33. KV Switchgear33. KV Switchgear33. KV Switchgear33. KV Switchgear 123 – 138

EEEE.... E.O.T CraneE.O.T CraneE.O.T CraneE.O.T Crane 139 – 157

FFFF.... 110 v.d.c. Equipment110 v.d.c. Equipment110 v.d.c. Equipment110 v.d.c. Equipment 158 – 169

GGGG.... D.G SetD.G SetD.G SetD.G Set 170 – 175

HHHH.... Air Conditioning system, F.F, Air Conditioning system, F.F, Air Conditioning system, F.F, Air Conditioning system, F.F,

illumination & earthingillumination & earthingillumination & earthingillumination & earthing 176 – 194

SECTION SECTION SECTION SECTION ––––IVIVIVIV Technical specification of Technical specification of Technical specification of Technical specification of

Installation & CommissioningInstallation & CommissioningInstallation & CommissioningInstallation & Commissioning 195 – 207

SECTION SECTION SECTION SECTION ––––VVVV Acceptable makesAcceptable makesAcceptable makesAcceptable makes of various of various of various of various

equipmentsequipmentsequipmentsequipments 208 – 211

SECTION SECTION SECTION SECTION ––––VVVVIIII Guaranteed Technical Guaranteed Technical Guaranteed Technical Guaranteed Technical

ParticulaParticulaParticulaParticularsrsrsrs 212 – 239

SECTION SECTION SECTION SECTION ––––

VVVVIIIIIIII

Working Table & Tender Working Table & Tender Working Table & Tender Working Table & Tender

DrawingsDrawingsDrawingsDrawings 240 – 245



1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - I

SCOPE OF SUPPLY & SPARES TO BE

SUPPLIED BY TENDERER

SANJAY B. PATIL, KOLHAPUR JAMBRE HEP

SIGNATURE OF SUPPLIER SIGNATURE OF PURCHASER PAGE 1

SECTION - I

DETAILED SCOPE OF SUPPLY AND SCHEDULE OF EQUIPMENT

INDICATIVE LIST OF THE PLANT AND EQUIPMENT, NOT LIMITED TO, TO BE SUPPLIED BY THE

TENDERER

Sr.No

Description Qty. Unit

1.0 TURBINE & GENERATOR PLANT

1.1 Turbine:- HORIZONTA FRANCIS / SUITABLE

TURBINE of rated output not less than 2000 kW+10% for

27 meter design Head , rated discharge of 9.33 cumecs ,

with Governor and associated equipments complete with

Turbine auxiliaries comprising of compressed air system,

cooling water system, drainage and dewatering system,

H.M.C., servomotor, oil and water piping, valves, strainer,

bends, flow meter relay etc. complete.

1 Sets

1.2 Main Inlet Valve:- Butterfly type valve of suitable dia.

For suitable for connection 1800mm ID Penstock Along

with bye pass valves , drain valves , man holes , inlet pipe,

outlet pipe, dismantling joint, servomotor, O. P. U.

Control cabinet etc. complete.

1 Sets

1.3 Gear Box if required 1 no

1.4 Hydro Generator:- Horizontal shaft synchronous

alternator of capacity 2310 KVA+10% continuous

overloading facility at 0.866 p.f. under excited. 3.3 KV,

50Hz, three phase suitable for coupling to above

mentioned turbine with brushless excitation system with

Automatic voltage regulator etc. complete, with Generator

auxiliaries comprising S.S.G. unit, H.S. Lubrication

system, brake/ jack system, Fly Wheel stator encloser,

railing & coverings, coolers, heaters, cables etc. complete.

1 Sets

2.0 3.3 KV Switchgear comprising control & relay panels

suitable for computerized control system consisting of as

per SLD.

2.1 3.3 KV VCB Circuit breaker cubicle 2 No.

3.3 KV cubicle for P.T. WITH Draw out Type P.T. 2 Core 3.3 KV/√3,110 V/√3,110 V/√3 , ht FUSE etc.

1 No.



3.3 KV CT having suitable current ratio with 4 core for

protection & metering etc. 2 Sets Sets

2.2 3.3 KV neutral grounding transformer(NGT) cubicle with isolator , 3.3 KV CT having suitable current ratio with 4 core for protection & metering etc.

1 No.

2.3

3.3 KV LAVT cubicle with isolator , bus LA and capacitor 3.3 KV CT having suitable current ratio with 4 core for protection & metering etc.

1 No.

3.0 GENERATOR, TRANSFORMER & FEEDER

PROTECTION AND SYNCHRONIZING PANEL (

COMPRISING NUMERICAL PROTECTION RELAYS )

suitable for computerized control system

1. Generator Protection Panels, comprising of Protection

scheme, alarm facias, meters, relays suitable for

computerized control system complete wired & tested

as per specification.

1 Sets

2. Transformer panel comprising, Protection scheme,

alarm facias, meters, relays suitable for computerized

control system complete wired & tested as per

specification.

1 Set

3. Line protection cubicles for 33 KV lines comprising

protection scheme, alarm facia, meters, relays suitable

for computerized control complete wired & tested as

per specification.

1 Set

4. Synchronizing system comprising, protection scheme,

alarm facias, meters, relays suitable for computerized

control system complete wired & tested as per

specification.

1 Set

5. Unit control board for unit operation in auto , manual

and remote mode. 1 Set

4.0 REMOTE CONTROL SYSTEM

Complete in all respect Including INTERFACES, and other

material etc required for achieving total control of the plant

in two levels(Local And Remote) of control with complete

PLCC equipt suitable to the one installed by M.S.E.B. at

receiving sub-station.

1

Set



5.0 POWER TRANSFORMER

Power Transformer of capacity 2.5 MVA, 3 Ph., 33 KV/ 3.3

KV , 50 Hz., ONAN type with “ON” load tap changer,

RTCC cubical suitable for power cable connections on HT

and L.T. side with first filling of oil & accessories. And

Cable box.

1 No.

6.0 33 kV INDOOR SWITCHGEAR EQUIPMENTS 1 No

33 KV draw out type Switchgear with control and protection

system ( as per SLD. )suitable for computerized control

system

2 NOS -33 KV VCB DRAWOUT , Circuit breaker cubicle AS PER specification.

1 SET 1 NOS.-33 KV cubicle for P.T. WITH Draw out Type P.T. 2 Core 33 KV/√3,110 V/√3,110 V/√3 , ht FUSE etc.

1 SET -33 KV CT having suitable current ratio with 4 core for protection & metering etc. 1set

1 no- 33 KV rated insulation class BIL,170 kv Peak,50 A,

25 KA,3 Ph.,50 Hz, double break center pole rotating , Motorized outdoor isolator earth blades.

1 NO

Supply of Metering Kiosk / outdoor CT and PT as

per MSEDCL direction/ specifications. 1 SET

30 KV ,10 KA , Single Phase, 50 Hz., Valve type station

class, outdoor type lightening arrester with accessories. 3 No.

Bus Bar material including ACSR conductor, insulators etc.,

complete. L.S.

Switchyard galvanized steel structure, tack off structure

with foundations etc., complete. L.S.

Marshaling box Adequate

Junction Boxes for C.T. and P.T. Adequate

7.0 415 V A.C. SWITCHGEAR PANEL

Indoor type 415 V, A.C. Distribution board Panel

comprising of two Nos., of incoming A.C.B., of suitable

capacity with auto change over system, Bus Bars, metering

equipments and 20 to 25 Nos., of outgoing switch fuse units

with ammeters, including manual/ auto change over for

U.A.T. to D.G. Set A.C. supply complete with required

accessories.

1 Set



8.0 110 VOLT D.C. EQUIPMENTS

Lead Acid Batteries having capacity of 110 V/ 300 AH with

required accessories , wooden stand , DC volt meter, hydro

meter etc.

Battery charger suitable for 110 KV, 300 AH, capacity

Batteries, with float & float cum boost charger with

accessories.

110 KV D.C., Distribution Board with 30 Nos., of outgoing

feeders with accessories.

1 Set

9.0 UNIT AUXILIARY TRANSFORMER

Unit Auxiliary Transformer 100 KVA, 33 KV / 415 V, 3

Phase, 50 Hz., outdoor type with first filling of oil with oil

accessories. Suitable for 33 KV cable termination.

1 No.

10.0 POWER AND CONTROL CABLES

3.3 KV H.T. Power Cables single core 350 Sq. mm ,XLPE insulated copper, 5 KV (E) Grade, armored

33 KV H.T. Power Cables 3 core 185 Sq. mm ,XLPE insulated copper, armored.

L.T. Power & Controls Cables, Screened Cables, A.C. auxiliary power supply cables, Trays, Racking, Trench Covers and suitable clamps for fixing cable trays with accessories etc. complete.

All cables shall be of copper.

lot Set

11.0 OTHER ITEMS

11.1

E.O.T. Crane of suitable capacity, to be decided by bidder,

pendent operated , A.C., 415 V ± 10%, 3 Phase, 50 Hz.,

Power Supply, with down shop leads etc. ,complete.

1 No

11.2 63 KVA, D.G. Set, 415 V, 3 Phase out door type , silent. 1 No

11.3 Power House and Switchyard Earthmats , earth grid , And

lightening protection. Lot Lot

11.4 Power House & Switchyard lighting & Construction power

supply. Lot Lot

11.5 Fire Fighting Equipments , rubber mat etc. Set Set

11.6 Communication System and furniture. Lot Lot

11.7 Workshop Equipments / TOOLS Set Set

11.9 Air Conditioning for control room Lot Lot



12.0 TRAINING AND INSPECTION

12.1 Training for Purchaser’s Engineer

12.2 Inspection at Works by Purchaser’s Engineers

12.3 Factory Inspector & Electrical Inspector Inspection

Clearance of pollution board and all other clearances.

13.0

ERECTION, TESTING, AND COMMISSIONING AND

PUTTING TO SATISFACTORY OPERATION OF

SUPPLIED EQUIPMENT AND SYSTEMS. BY

PROVIDING COMPETENT ENGINEERS AND OTHER

SKILLED/ UNSKILLED/ SEMISKILLED WORKERS,

CONSUMABLES AND MAINTENANCE SPARES FOR

OPERATION AND MAINTENANCE FOR SIX (6)

MONTHS PERIOD FOR JAMBRE H.E.P. ( 1 X 2000 KW)

AFTER COMMISSIONING OF THE UNIT FOR

COMMERCIAL USE FOR SBP, KOLHAPUR

Job Lump

sum

15 Mandatory tools and spares as per list attached annexure-I & II

Lum sum

Note - The list above is indicative and supplier’s offer shall be complete in all respect for

equipment being offered.



NOTE

C. REQUIREMENTS – SPECIFIC

1) While designing entire plant the ratings/size mentioned in tech. Specifications for major

equipments viz. turbine, Generator, main power transformer & its voltage levels, size of B.F.

valve, rated voltage levels of A.C. & D.C. shall not be changed. However if ratings of other

associated auxiliaries, equipments could be changed as per contractors design, the

Tenderer/contractor should furnish the design, Engineering Drawings, technical data for prior

approval of the purchaser.

2) The Tenderer/Contractor should take cognizance of the present status of works which are

fully/partially completed & he should interface all above works to complete the entire plant in

all respect and also co-ordinate with Civil, Electrical & Mechanical works not covered in this

specification but generally needed for such power stations.

3) The Tenderer/Contractor shall carry out O & M for the period of upto six months after

successful commissioning of entire plant as per availability of water in reservoir and according

to Irrigation release programmed decided by the Irrigation Authorities/Purchaser. Six months

O & M shall be completed within one-year period after commissioning of entire plant. During

this one-year period if O & M cannot be carried out due to non-availability of water, evacuation

arrangement and decision of further extension for O & M period will be mutually decided.

4) The scope of work under this specification also includes additional Investigations, Planning &

engineering and it shall be sole responsibility of the Contractor for completely covering all the

works, equipments, accessories etc. Specified in the specification and shall also include all

necessary works, equipments, accessories, works even though not specifically mentioned in the

specification but which are essential for the satisfactory completion of the entire power station.

Design, Technical specification along and drawings of such works, equipments etc. shall be

furnished for purchaser’s approval.

5) The drawings enclosed with the tender documents are purely indicative & of tentative nature &

are prepared for tender purpose only. The Tenderer/Contractor shall have to prepare the

detailed drawings as per design & requirement of the scheme according to technical

specification. Necessary components, equipments that have not been indicated shall be added

to fulfill the requirement of the scheme.



6) Some of the limitations as per the actual site conditions, which are to be verified by

Contractor during his site visit are as below:

Pressure rise shall not exceed 25 % in the water conductor system including pipes embedded

in the dam.

7) Machines shall be suitable to be operated under following condition.

1. SANJAY B. PATIL, KOLHAPURhave appointed M/S. DIWAN KHADILKAR

CONSULTANTS PVT. LTD. Consulting Engineer, Kolhapur as their Consultants on designs,

inspections, testing, manufacture, erection, testing and commissioning, quality assurance,

performance acceptance, project management etc. Therefore all these activities shall be subject

to review of Consultant. Supplier/Manufacturer/ Contractor to note the requirement.

2. Entire plant and machinery shall be designed for thirty five years of operational life of the plant

without major modifications or repairs. Plant is susceptible for cyclic and complex loadings.

Frequent starting and stopping to meet the critical loads Automatic frequency and power

regulation mode. Frequency and voltage regulation mode.

3. Frequency and voltage regulation mode under which the unit shall develop full rated output

shall be 47.5 to 51.5 Hzs., and 3.3KV±10% of rated generator voltage respectively.

4. Total time for starting from standstill to rated full load for generating set shall not exceed for

time suitable for pressure rise and negative pressure transient of water conductor system

including starting of all auxiliaries subject to restrictions of pressure rise and speed rise.

Flywheel effect shall be accordingly designed.

5. Availability of the generating sets for first two years shall be 92% and thereafter 95%. Similarly

reliability shall be 95% first two years and 98% for rest of the life.

6. Availability in a year =

(Service hours in one year +Reserve service hours in the same year) ÷ Total hours in a year.

Reliability in a year =

(Total attempted starts–Total starts failure) ÷ Total attempted starts.

8. The turbine prototype dimensions shall be so designed that majoration of power on account of

possible efficiency step up shall be in accordance with IEC 995/1991.



9. Number of start and stop per day –max to 6 times: Number of trip out other than overspeed—

12 times per year; likely runaway conditions per year—once.

10. Maximum admissible steady state power output pulsation at generator terminals shall not be

more than ±1.5% of actual active power. Machines shall be designed for peak load, base load

and solo mode operations.

11. Manufacturer should have conducted model test from recognized laboratory on which the

design is based. Such model test results shall be furnished along with the bid.

12. Machine and equipment shall be designed to with stand earthquake forces as follows:-

Horizontal direction == 0.3g

Vertical direction == 0.15g

Where g is the gravitational acceleration.

Maximum air temperature -----46 degree Celsius.

Minimum air temperature-------6 degree Celsius.

Relative Humidity 100% during monsoon.



LIST OF I.S.S & I.E.C.

Exact applications of I.S.S & I.E.C. are enumerated in the tender documents. Following is the list of

I.S. & IEC. The EPC contractors/ Manufacturer to note these standards in executing the work of

JAMBRE HEP (1 X 2.00 MW).

List of power station equipment with their acceptable Standers, Acceptable to MNRE & AHEC Roorkee.

Sr. No. Name of Equipment Standards to which equipment conforms

1 Turbines IEC 60034-1:1983,IEC 61366-1:1998,IEC61116-1992

2 Generators IS 4889-1968,IS4722-2001,IS12800(part3)1991

3 Protective Relays ANSI 50N / 51N

4 PLC IEC 61131-3

5 SCADA System IEC 60870-5-101

6 Excitation System GB 1085-89

7 Panel IS 8623 IV & IP 51

8 MIV IS7326-1902

9 Cables IS 8130/1984

10 Pumps IS 6392

11 Power Transformers IS 2026,IS3156-1992,IS2705-1992

12 Current Transformers IS 2705

13 Potential Transformers IS 3156

14 HT, LT circuit breakers IS 2516

15 Governor IS 4889-1968,IEC-60308

16 AVR IS 4889-1968

17 Auto Synchronization IS 4889-1968

18 Motor IS 325

19 Batteries IS 9001

20 Crane IS 3815

21 Field acceptance Test IEC60041:1991



Sr. No. List of I.E.C. Standards

1 IE RULE 1956 (REV 2006)

2 ELECTRICITY Act 2003

2.1 STANDARDS

IEC 60041 International code for Field Acceptance Tests of Hydraulic Turbines

IEC 60308 International code for testing of speed governing systems for hydraulic turbines

IEC 60545 Guide for commissioning, operation & maintenance of hydraulic turbine

IEC 60994 Guide for field measurement of vibrations and pulsations of hydraulic machines

IEC 60995 Determination of prototype performance from model acceptance test of hydraulic machines with consideration of scale effects

IEC 60193 International standard – Hydraulic turbines - Model acceptance tests

IEC 60041 International standard field acceptance tests of hydraulic turbines

IEC 60609 P 1 Cavitations pitting evaluation in hydraulic turbines, storage turbines and pump-turbines, Part 1.

ASME Boiler and Pressure Vessel Code, Section VIII

IS 12800 Guidelines for Selection of Turbines, Preliminary dimensioning and layout of Surface Hydro Electric Power house

IS : 1271 Classification of insulating materials for electrical machinery

IS : 2379 Colour code for the identification of pipelines

IS : 5 Colour for ready mixed paints and enamels

IS : 226 Structural steel (standard quality) (fifth revision)

IS : 1538 Cast Iron fittings for pressure pipe for water, gas and sewage

IS : 6392 Steel pipe flange

IS : 2906 Sluice valves for water works

IS : 2002 Medium tensile steel plate used for welding, flame cutting and flanging in hot condition

IS: 2049 Colour code for identification for wrought steel for general engineering purposes

IS: 1030 Cast steel

IS: 28 Bronze

IS : 1239 G.I. pipes Part 1, Part 2

Note : The latest edition of the above codes shall be referred.



ANNEXURE I

LIST OF MANDATORY SPARES TO BE SUPPLIED BY THE CONTRACTOR

Sr.No Description Qty.

1.0 MAIN TURBINE AND GENERATOR PLANT AND ITS ASSOCIATD EQUIPMENT

1.1 TURBINE EQUIPMENT (1 Set)

1. Fully machined guide vanes with levers, bushes, housing 2 Nos. 2. Fully machined babitted pads for guide bearing. 1 Set 3. Gasket, seals & packing of each type 1 Set 4. Moulded rubber packing rings for shaft gland. 1 Set

5. Piston rings for runner servomotor & guide vane servomotors.

1 Set

6. Shear pins for the guide apparatus. 1 Set 7. Runner blade assembly 1 Set 8. Pressure gauge of each type. 1 No.

1.2 FOR GOVERNOR AND OIL PRESSURE SYSTEM (1 Set) 1. Oil pump complete with motor 1 Set 2. Pilot and control valve complete 1 Set 3. Transducers 1 Set 4. Pump unloaded and safety relief valve 1 Set

5. Float switches, pressure, flow and temperature relays of each type used.

1 Set

6. Solenoids for each type of solenoid valve used. 1 Set 7. Fuses of each type used. 2 Sets 8. Each kind of filter used. 2 Sets

9. Complete set of all packing, gasket and jointing material used.

2 Sets

10. Ten percent ( 10 % ) of all bolts, screws, nuts and washers upped and including M 30

2 Sets

1.3 HYDRO MECHANICAL CABINET (1 Set) 1. Electro hydraulic transducer 1 No. 2. Feedback potentiometers. 1 No. 3. Pilot valve sleeve & needle. 1 Set 4. Coil for electromagnetic transducer. 1 No. 5. Oil filter sleeve. 1 Set 6. Electro tachometer 1 No. 7. Balance indicator 1 No. 8. Speed setting indicator 1 No. 9. Micro switch for contact device 1 No 10. Micro switch for over speed device 1 No

1.4 MAIN INLET VALVE (1 Nos.) 1. Services seal with all fixing 1 Set 2. Servomotor piston rings and packing. 1 Set 3. Control solenoids of each type used. 1 Set 4. Limit switch of each type used. 1 Set 5. Valve of each type used. 1 Set

6. Complete set of all packing, gasket and jointing material used thought out the valve.

1 Set



7. Ten percent ( 10% ) of all bolts, screws, nuts and washers upped and including M30.

1 Set

1.6 DEWATERING AND DRAINAGE SYSTEM (common for Station) Standard spares for pumps & motors.

1 Set

1.7 COOLING WATER SYSTEM. (for 1 Set) Standard spares for pumps & motors.

1 Set

2.0 GENERATOR ( One No) - Each set consisting of following. 1. D E bearing pads. 1 Set. 2. N D E bearing pads. 4 Nos. 3. Dial type thermometers. 2 Nos. 4. Thermostat. 4 Nos. 5. Heater element. 6. Pole keys. 2 Sets.

7. Brake shoe. 1 No.

8. Plug in type oil cooler unit for combined thrust & guide bearing.

1 No.

9. Brush holders. Carbon brushes. 1 Set.

2.1 BRUSH LESS EXCITATION SYSTEM. (1 Set) - One Set consisting of following

1. Motorized potentiometer. 1 No.

2. Gate circuit. 1 No. 3. Pulse final stage of power pack. 1 No. 4. Pulse supervision. 1 No. 5. Intermediate pulse amplifier & power pack. 1 No. 6. Digital voltage regulator. ( D.V.R. ) 1 No. 7. Relays ( Latching auxiliary & time delay relays. 1 Set.

2.2 SPARE FOR FIELD contactor. 1. Closing coil. 1 No. 2. Tripping coil. 1 No. 3. Moving contact. 1 No. 4. Field discharge resistor unit 1 No. 5. Aux. Contact block. 1 No.

3.0A 3.3 KV SWITCHGEAR . (1 Set) 1. One Set consisting of following. 2. Bus insulations. Panel meters one each 12 Nos. 3. Spring charging motor one set 1 set. 4. Indicating lamp each 12 Nos. 5. 3.3 K.V., 10 K.A. lightening arrester. 1 No. 6. Surge capacitor. 1 No.

7. 3.3 KV / 110 V Voltage transformer for DVR. √3 / √3

1 No.

8. 3.3 KV / 110 V Voltage transformer for metering . √3 / √3

1 No.

9. Isolating link. 6 No.

10. C. T's of appropriate rating for Generator Differential Protection, DVR, metering, over current, Overall Differential Protection etc. 6 Nos.

3.0B 33 KV SWITCHGEAR . (1 Set) 1. One Set consisting of following. 2. Bus insulations. Panel Meters one each type 12 Nos.



3. Panel indicating lamp each 3 Nos. 4. Spring charging motor 1 set 5. 30 K.V., 10 K.A. lightening arrester. 1 No. 6. Surge capacitor. 1 No.

7. 33 KV / 110 V Voltage transformer √3 / √3

1 No.

8. 33 KV / 110 V Voltage transformer for MSEDCL metering. √3 / √3

1 No.

9. Metering C.T.’s Of Appropriate Rating For MSEDCL . 1 No. 10. Isolating link. 6 No.

11. C.T.'s of appropriate rating for Generator Differential Protection, DVR, metering, over current, Overall Differential Protection etc.

6 Nos.

4.0 GENERATOR, TRANSFORMER, FEEDER SYNCHRONISING PANEL.

One set consisting of 1. Semaphore indicator. 2 Nos. 2. ODL lamps. 6 Nos. 3. Auxiliary relays. 16 Nos. 4. Fuse & links of various rating. 20 Nos. 5. Switches. 5 Nos. 6. Push button. 8 Nos. 7. Spare for annunciation. 4 Nos. 8. Digital timer, external plug type relay meter. 1 Set. 9. MCB, Rheostat. 1 Set.

5.0 RELAY AND METERING PANEL 1. Relay - Protective Relay , Auxiliary Relay. 1 of each kind. 2. Molded case circuit breaker 1 of each kind. 3. Meter 1 of each kind. 4. Fault, operation and Symbol indicator assembly 5 of each kind. 5. Lens for Symbol 5 of each kind. 6. Indicating lamp 10 % of installed quantity. 7. Process input output 2 of each kind. 8. Fuse 20 of each kind. 9. Control selector and Cut-off switch 1 of each kin. 10. Transducer 1 of each kind. 11. Wrapping label and marking strip 100 % of installed Quantity 12. Plug – in type connection accessories 1 pair of each kind. 13. Fiber card with optical Connector 2 of each kind. 14. Temperature detector 2 of each kind.

6.0 Crane

1. Limit switches 12 nos 2. Break pad 1 set 3. Remote Pendent One no 4. Auxiliary relays. 16 Nos. 5. Fuse & links of various rating. 20 Nos. 6. Switches. 5 Nos.

7.0 D G SET 1 set



ANNEXURE. II

LIST OF WORK SHOP TOOLS TO BE SUPPLIED BY THE CONTACTOR

Sr.No. Description Unit

1. Secondary injection kit 1 Set. 2. 5 KV motorized megger 1 No. 3. 1 KV Hand operated megger 1 No. 4. 500 V Hand operated megger 1 No. 5. Analog multimeter 1 No. 6. Digital multimeter with temperature measuring facility 1 No. 7. Phase sequence meter. 1 No. 8. Grinder (Hand) 1 No. 9. Crimpling tool for cable 1 No. 10. Bearing puller set 1 No. 11. Vacuum cleaner 1 No. 12. Timer (ms) 1 No. 13. Set of plain / flat (double ended) spanner. 1 Set. 14. Set of ring spanner 1 Set. 15. Set of Torque spanner 1 Set. 16. Set of screw driver 1 Set. 17. 8" pliers. 1 Set. 18. Hydraulic crimping tool up to 400 Sq. mm 5 Nos. 19. Hand crimping tool up to 16 Sq. mm 1 Nos. 20. 300 A capacity clip ON type Ammeter 1 No. 21. Electro static on line filter 1 No. 22. Governor , Bearings and Transformer oil testing kit 1 No. 23. Earth tester 1 No. 24. Single phase & 3 Phase voltage variance. 1 Set. 25. Laptop with 24B, 15” screen inbuilt modem for Internet

connections with software for setting Testing for Numerical relays

1 Set.

26. Special equipment and tools necessary for Installation, operation & maintenance of whole plant: Special tools for turbines Special tools for Generator General tools for Electrical equipment Balance tools for the whole plant

1 Lot



TOOLS AND TOOL BOX

Supplying various Tools as per list given below.

D.E. Open Jaw fix spanner 12 pieces set, 6-32 mm 1 No.

Bi-hexagon Ring spanner 12 piece set, 6-32 mm 1 No.

Ball pin hammer with handle, 800 mm 1 No.

Combination side cutting pliers 200 mm KDPE coated 1 No.

Pipe wrench still son pattern carbon steel 600 mm – 76 2 No.

Screw driver Engineering pattern 8 x 200 mm 1 No.

Screw driver Engineering pattern 5 x 200 mm 1 No.

Screw driver with green neon bulb line tester 3.6 x 60 1 No.

Tool box fabricated from MS Sheet of 18 SWG of size 50 x 30 x 30 cm with locking arrangement.

1 No.

Bearing Puller three legs 12 inches 1 No.

Hydraulic flip flop crimping tool suitable for 6 to 500 sq.mm size

cable lugs.

2 No.

Insulation tester (Meager) cracking type having metal body of range 100 volts - 1000 ohms.

1 No.

Tong Tester (Clip on meter) of range 0-10-30-1000 and 0-300-600 mm 1 No.

SAFETY EQUIPMENT Supplying various Safety Equipments as per list given below.

Supplying rubber mating of thickness as below and of required length and breadth with good insulation property.

1 No.

Supplying standard first and box with all standard contents 1 No. First Aid Box 1 No. Supplying pair of rubber hand gloves suitable for working on 11/22/33 KV system.

1 No.

Pair of Rubber hand glove 11/22/33 KV 2 No. Providing printed instruction chart for treating persons suffering from electric shocks, printed in English and Marathi and duly framed with front glass.

1 No.

Instruction Chart 1 No. Fire Extinguisher Supplying, erecting D.C.P. type fire extinguisher cartridge type, with G.M. cap 150 gram CO2 gas cartridge powder brackets conforming to IS 2171 – 1985 and having complete erected with necessary clamps made from 50 x 6 mm MS flat with nuts and bolts grouted in wall complete.

1 No.

Fire extinguisher with 5 kg cartridge capacity 2 No.

Note - 1) List of all other items is stated under respective sections of Technical Specifications. 2) Offered rates of above shall be valid for 12 months from date of commissioning. 3) Order for above spares will be placed separately as above.



1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - IA

RECORDING TG INSTRUMENTS



SECTION – I A INDICATING & RECORDING T-G INSTRUMENTS

Sr.No. Description of Item to be indicated /

measured

Device

type

Total quantity

per unit Location

TURBINE

1 Lake Water Level Indicator

2 Turbine Water Flow Measurement

3 Position of Intake Gate

4 Position of Main Inlet Valve

5 By Pass Valve Open

6 Pressure in Main Pipeline (Before Inlet

Valve)

7 Pressure in Main Pipeline

(After Inlet Valve)

9 G V position indicator

11 Main Governor Oil Pump ON / OFF

status.

12 Standby Governor Oil Pump ON / OFF

status.

13 Pressure in governor oil pressure

system

14 Pressure of regulating oil pressure

system

15 Pressure of regulating oil pressure

system

16 Level of oil in sump tank, if any

17 Unit speed indication (Speed indicator)

18 Unit Over speed Indicator

19 Speed Level setting indicator



20 Speed Droop setting indicator

21 Governor Speed Level Setting

22 Governor Speed Droop Setting

22A 12 Point annunciator for Turbine ANN

GENERATOR / TRANSFORMER

/LINE

23

Generator Drive end Bearing

Temperature sensor (Thrust & Guide

Bearing)

24

Generator Non-Drive end Bearing

Temperature sensor (Thrust & Guide

Bearing)

24A Main Lube Oil Pump ON / OFF status.

24 B Standby Lube Oil Pump ON / OFF

status.

25 Dial thermometers for generator,

bearings for alarm / trip

26

12 points indicator ( SCn )for stator

winding temperature and bearing

temperature

27 Generator heater ON/OFF indicating

Lamps

28 Brakes On / Off indication

29 Flow meter (water) / Pressure (oil) for

bearing cooling (if applicable)

30 Unit output meter (KW)

31 Unit KVAR meter with center zero

32 Unit voltmeter

33 Unit ammeter



34 Unit power factor meter (with center

zero)

35 Unit frequency meter

36 Unit energy meter (kWh)

37 Unit Circuit Breaker Open / Closing

Indicating Lamp

37-A Field breaker ON /OFF

38 Balance Indicator of AVR

39 AVR Auto / Manual Indicating Lamps

40 Outgoing breaker

41 Transformer Oil Temp

42 Transformer Wdg. temp

43 Grid Voltage

44 Grid breaker status

45 Grid isolator status

46 Unit Auto / Manual SW

47 Unit Local / Remote SW

48 24 W Annunciator For Generator.

49 8 W Annunciator For Transformer And

Outgoing Bkr.

50 Cooling Water booster Pump ON

/Off

NOTES:

1. The list is indicative only. The bidder/supplier may add as per his assessment. Quantities may be filled up by the bidder

2. Contractor to meet the minimum requirement for satisfactory monitoring and control of generating unit etc.



Sr.

No. Item indicated/recorded

Type of

instruments/device

Number provided

Remarks On or near the

equipment/locally

Unit Control Board At Mosaic

Board in

Control

room

Total At gen.

Gauge

panel

At unit

Control

Board

1. TEMPERATURES OF

Stator Winding One set

recorder

Stator teeth + indicator

24 point with digital

Scanner

Rotor Temperature indicator

Air Cooler inlet and outlet

air and cooling RTD

Inlet and outlet Signal scanner for same?

Thrust bearing pad. guide

bearings pads

• RTD

• Digital Scanners

• Indicators

Guide bearing oil reservoir

and cooling Water outlets.

• RTD

• Indicator

• Recorder



Sr.


Type of

instruments/device

Number provided


equipment/locally


Board in

Control

room

Total At gen.

Gauge

panel

At unit

Control

Board

Cooling water at outlet of

the bearings

• RTD

• Indicator

Excitation transformer

winding • Indicator

2. PRESSURE

H.P. Oil lubrication system

Compressed air supply to

brakes

Oil in Jacking system

• PG .

• PG + RL

• PG

3. LEVELS OF

Oil in guide bearing oil

reservoir


reservoir.

Oil in jacking system.

• Sight gauge + RL

• Sight gauge + RL

• Sight gauge

4. FLOW OF

Water in common

discharge pipe of air

coolers.

Water in the discharge

pipe of lower guide

bearing oil coolers.

• Flow

• Flow



Sr.


Type of

instruments/device

Number provided


equipment/locally


Board in

Control

room

Total At gen.

Gauge

panel

At unit

Control

Board

Water in Discharge pipe of

thrust and guide bearings

oil coolers.

• Flow

5. STATUS INDICATION VIZ.

Generator brakes 'ON /

OFF' Indicating lamps

Generator h eater 'ON /

OFF' Indicating lamps

HP oil lubrication pump

running / stand-still. Indicating lamps

Field breaker close / "pen Indicating lamps

Fire fighting system

operated / healthy Indicating lamps

6. OTHER ITEMS

Indication for automatic

voltage regulator, limit

positions and control in

progress etc.

Indicating lamps

DC voltmeter and

ammeter for static

excitation system

(including starting

excitation system)

Indicating instruments



Sr.


Type of

instruments/device

Number provided


equipment/locally


Board in

Control

room

Total At gen.

Gauge

panel

At unit

Control

Board

Creep detection

equipment.

• Indicating lamps.

Generator Current • Ammeter

Generator Voltage

• Voltmeter with

Select switch for

and phase

System frequency • Frequency

Generator M V A meter • MVA meter

Generator MVH meter • MVH meter

Power Factor meter. • P.F . meter

Synchronoscope with

switches lamps etc. • Meter

Energy meter to indicate

KwH

• K.W.H . Meter

Service Hour Meter C 5 • Hr. Meter

Summated value of MW.

Generator • MW. Meter

Summated value of energy

generated • KWH meter



ABRIVIATIONS :

RTD means Resistance Temperature Detector.

PG means Pressure Gauge.

UCB means Unit Control Board.

GGB means Generator Gauge Board.

PG + RL means Pressure Gauge and Guard Relay Indicated guaranteed particulars.

NOTE :

1) Location, No. and types of instruments for indication and recording etc. are given. The Supplier shall indicate changes, if any required in No; type and

location of the instruments.

2) Provisions stated above are if not applicable may be deleted and stated accordingly.



CONTROL INSTRUMENTS:

Sr.

No. Item indicated/recorded Type of device

Number provided

Remarks Locally or in

the vicinity


Board in

Control

room

Total At gen.

Gauge

panel

At DVR

or FSC

At unit

Control

Board

1 2 3 4 5 6 7 8 9

1. Auto-off-manual Selection

for generator heaters. Selector Switch

2. Auto / manual selection for

Generator brakes Selector Switch

3. Generator brake on/off

control. Emergency. BRAKE

'ON' system

Control Switch

4. H.P. Oil lubrication pump

starting / stopping. Push Button

5. Selection of location of H.P.

Oil 1 lubrication

pump/control 'Local /

Selector Switch

6. Auto / Manual Selection for

H.P. oil lubrication pump Selector Switch

7. Generator fire fighting

equipment control.

Push Button (Guarded

type)

8. Local / Remote control

Selection for excitation Selector Switch

9. Auto / Manual Selection for

excitation system.

Selector Switch



10. Raise / Lower control of

DVR . Control Switch

11. Manual Raise / Lower

control of DVR (Voltage Control Switch

12. Field Breaker ON / OFF Push Button

13. Auto / Manual Power factor

regulator Control. Selector Switch

14. Manual Power factor

regulation Raise / Lower switch.

15. Generator Voltage phase to

phase and phase to Neutral Selector Switch

ABRIVIATIONS:

UCB means Unit Control Board.

GGB means Generator Gauge Board.

DVR means Digital Voltage Regular Panel.

NOTE:

1) The items quantities and locations are given. The Supplier shall indicate changes, if any.

2) Provisions if not applicable for the system may be deleted and accordingly stated



SAFETY DEVICE UNDER THIS ANNEXURE SHALL BE DISCUSSED DURING DESIGN STAGE IN ACCORDANCE WITH UNIT CONTROL BOARD DESIGN.

TABLE III : SAFETY FOR EACH GENERATOR AND ASSOCIATIATED EQUIPMENT

Sr. No. Description of Abnormality Sensing device Alarm/Annunciation at Remarks

Type Quantity Unit Control

Board

At Mosaic

Board in

Control Room

1. HIGH TEMPERATURE OF

Rotor

• Temperature

Indicator

Guide bearing pads NDS • RTD

Thrust bearing pads • RTD

Guide bearing pads DS. • RTD

Thrust and guide bearing oil. • RTD

Air cooler inlet air • RTD

Air cooler cutlet air. • RTD

Stator winding • RTD *

Temperature

Stator teeth • Indicator RTO

Stator Core.

• RTD 1

temperature

Indicator



2. LOW QUANTITY OF COOLING WATER

Cooling water to air cooler; Flow relay

Cooling water to lower guide

bearing oil cooler. Flow relay

Cooling water to thrust and

guide bearing oil cooler. Flow relay

3. LOW LEVEL OF:


reservoir. Level relay

Oil in thrust and guide bearing

oil reservoir, Level relay

4. HIGH LEVEL OF:


reservoir. Level relay

Oil in thrust and guide bearing

oil reservoir. Level relay

5. LOW PRESSURE OF :

Cooling water, to generator air

coolers. PG

Cooling" water to lower guide

bearing oil reservoir. PG

Cooling water to upper guide

bearing and thrust bearing oil

reservoir.

PG

Oil in H.P. oil lubricating system. PG



6. Fire fighting equipment 'ON' -

7. Generator creep Creep detector

8. Vibrations excessive. Vibration detector

9. Shaft Current abnormal Shaft current detector

10. Failure of power supply to control

scheme of generator. Voltage relay

11. Air gap less Monitor

12. Partial discharge excessive Monitor

ABRIVIATIONS:

TR means Thermostatic relay

PG means Pressure Gauge

A means Annunciation

AS means Shut-down with Annunciation.

NOTE :

1) The above list is mandatory. Any additional devices for the generator and its auxiliaries considered essential shall be supplied by the

generator Supplier.

2) The generator and turbine Supplier shall co-ordinate the provision of safety devices for unit .Suitable numbers of spares, facial windows shal1

also be provided on each enunciator at all locations.

3) Provisions if not applicable to the system may be deleted.



1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - II

DETAILED PRICE SCHEDULE



SECTION - II PRICE SCHEDULE (Amount in Indian Rupees.)

SR.NO

DESCRIPTION QTY. UNIT EXW UNIT PRICE

EXW TOTAL PRICE

TRANSPORT INSTALLATION

SERVICES & O& M.

INSURANCE

TOTAL

1.0 TURBINE & GENERATOR PLANT

1.1 Turbine:-HORIZONTAL FRANCIS

TURBINE of rated output 2000 KW+10% for 27 meter design Head compressed air system,

Cooling water system, Drainage and dewatering system, H.M.C., servomotor, oil and Water piping, valves, strainer, bends, flow meter relay etc. complete.

Mandatory Spares. Tools and Tackles.

1 Sets

1.2 Main Inlet Valve:- Butterfly type valve of

suitable dia. For suitable for connection

1800mm ID Penstock Along with

Bye pass valves , drain valves , man holes , inlet pipe, outlet pipe, dismantling joint, servomotor,

O. P. U. Control cabinet etc. complete.


1 Sets

1.3 Gear Box if required

Mandatory Spares. Tools and Tackles. 1 no



1.4 Hydro Generator:- Horizontal shaft

synchronous alternator of 3.3 KV three

phase , 50 HZs, 2310 KVA at 0.866 p.f.

Brushless excitation system. complete,

with

H.S. Lubrication system, ,

Brake/ jack system, Fly Wheel stator

encloser, railing & coverings, coolers,

heaters, etc. complete.


1 Sets

2 3.3 KV Switchgear comprising control &

relay panels suitable for computerized

control system consisting of as per SLD


2.1 3.3 KV VCB Circuit breaker cubicle

Mandatory Spares. Tools and Tackles. 2 No.

2.2 3.3 KV cubicle for P.T. WITH Draw out Type P.T. 2 Core 3.3 KV/√3,110 V/√3,110 V/√3 , ht FUSE etc. Mandatory Spares. Tools and Tackles.

1 No.

2.3 3.3 KV CT having suitable current ratio with 4 core for protection & metering etc. Mandatory Spares. Tools and Tackles.

2 Sets Sets



2.4 3.3 KV neutral grounding transformer (NGT) cubicle with isolator, 3.3 KV CT having suitable current ratio with 4 core for protection & metering etc. Mandatory Spares. Tools and Tackles.

1 No.

2.5 3.3 KV LAVT cubicle with isolator, bus LA and capacitor 3.3 KV CT having suitable current ratio with 4 core for protection & metering etc. Mandatory Spares. Tools and Tackles.

1 No.

3.00

GENERATOR, TRANSFORMER &

FEEDER PROTECTION AND

SYNCHRONIZING PANEL (

COMPRISING NUMERICAL

PROTECTION RELAYS ) suitable for

computerized control system


Generator Protection Panels, comprising of Protection scheme, alarm facias, meters, relays suitable for computerized control system complete wired & tested as per specification. Mandatory Spares. Tools and Tackles.

Transformer panel comprising, Protection scheme, alarm facias, meters, relays suitable for computerized control system complete wired & tested as per specification. Mandatory Spares. Tools and Tackles.



Line protection cubicles for 33 KV lines comprising protection scheme, alarm facia, meters, relays suitable for computerized control complete wired & tested as per specification. Mandatory Spares. Tools and Tackles.

Synchronizing system comprising, protection scheme, alarm facias, meters, relays suitable for computerized control system complete wired & tested as per specification. Mandatory Spares. Tools and Tackles.

Unit control board for unit operation in auto , manual and remote mode. Mandatory Spares. Tools and Tackles.

4.0 REMOTE CONTROL SYSTEM Complete in all respect Including INTERFACES, and other material etc required for achieving total control of the plant in two levels(Local And Remote) of control with complete PLCC equipt suitable to the one installed by M.S.E.B. at receiving sub-station. Mandatory Spares. Tools and Tackles.

1

Set



5.0 POWER TRANSFORMER

Power Transformer of capacity 2.5 MVA, 3

Ph., 33 kV/ 3.3 KV , 50 Hz., ONAN type

with “ON” load tap changer, RTCC cubical

suitable for power cable connections on HT

and L.T. side with first filling of oil &

accessories.


1 No.

6.0 33 kV INDOOR SWITCHGEAR

EQUIPMENTS 1 No

33 KV draw out type Switchgear with

control and protection system ,( as per SLD.

)suitable for computerized control system

2 NOS -33 KV VCB DRAWOUT , Circuit breaker cubicle AS PER specification.

1 SET

1 NOS.-33 KV cubicle for P.T. WITH Draw out Type P.T. 2 Core 33 KV/√3,110 V/√3,110 V/√3, ht FUSE etc.

1 SET -33 KV CT having suitable current ratio with 4 core for protection & metering etc. 1set

1 no- 33 KV rated insulation class BIL,170 KV Peak,50 A, 25 KA,3 Ph.,50 Hz, double break center pole rotating , Motorized outdoor isolator earth blades.

1 no



Supply of Metering Kiosk / outdoor CT and PT as per MSEDCL direction/ specifications.

1 set

Marshaling box Adequate No.s

Junction Boxes for C.T. and P.T. Adequate

Mandatory Spares, Tools & Tackles. 1 Set

7.0 415 V A.C. SWITCHGEAR PANEL

Indoor type 415 V, A.C. Distribution board

Panel comprising of two Nos., of incoming

A.C.B., including manual/ auto change over

for U.A.T. to D.G. Set A.C. supply’

Mandatory Spares, Tools and Tackles.

1 Set

8.0 110 VOLT D.C. EQUIPMENTS

Dry cell Batteries having capacity of 110 V/

300 AH Battery charger suitable for above

with float & float cum boost charger D.C,

Distribution Board with 20 Nos., of outgoing

feeders with accessories.

Mandatory Spares, Tools & Tackles.

1 Set



9.0 UNIT AUXILIARY TRANSFORMER

Unit Auxiliary Transformer 100 KVA, 33 KV / 415 V, 3 Phase, 50 Hz., outdoor type Suitable for 33 KV cable termination. Mandatory Spares, Tools & Tackles.

1 No.

10.0 POWER AND CONTROL CABLES

3.3 KV H.T. Power Cables single core 350 Sq. mm ,XLPE insulated ,copper, 5 kV (E) Grade, armored

33 KV H.T. Power Cables 3 core 185 Sq. mm ,XLPE insulated copper, armored .

L.T. Power & Controls Cables, copper, Screened Cables,

Trays, Racking, Trench Covers and suitable clamps for fixing cable trays with accessories etc. complete. Mandatory Spares, Tools & Tackles.

lot Set

11.0 OTHER ITEMS

11.1

E.O.T. Crane , (capacity, to be decided by bidder, 1 for Main and 1 for Auxiliary,) pendent operated , A.C., 415 V ± 10%, 3 Phase, 50 Hz., with down shop leads etc. ,complete. Mandatory Spares, Tools & Tackles for above items.

1 No



11.2

63 KVA, D.G. Set, 415 V, 3 Phase out door type , silent. Mandatory Spares, Tools & Tackles for above items.

1 No

11.3 Power House and Switchyard Earthmats , earth grid , And lightening protection.

Lot Lot

11.4 Power House & Switchyard lighting & Construction power supply.

Lot Lot

11.5 Fire Fighting Equipments, Rubber mat etc. Mandatory Spares, Tools & Tackles for above items.

Set Set

11.6 Communication System and furniture. Mandatory Spares, Tools & Tackles for above items.

Lot Lot

11.7 Workshop Equipments Mandatory Spares, Tools & Tackles for above items.

Set Set

11.8 Air Conditioning for control room Mandatory Spares, Tools & Tackles for above items.

Lot Lot

12.0 TRAINING AND INSPECTION

12.1 Training for Purchaser’s Engineer

12.2 Inspection at Works by Purchaser’s

Engineers

12.3 Factory Inspector & Electrical Inspector Inspection Clearance of pollution board and all other clearances.



Providing competent Engineers and other Skilled/ Unskilled/ Semiskilled workers, consumables and maintenance spares for operation and maintenance for Six (6) months period for JAMBRE H.E.P. ( 1 x 2000 KW) after commissioning of the unit for commercial use for SBP, KOLHAPUR

1 SET

13 Supply of mandatory tools and spares as per list attached in annexure I & II 1 LOT

GRAND TOTAL (1 TO 13)

14 TAXES AND DUTIES

A SUPPLY

a Excise Duty

b Sales Tax

c VAT or any other taxation

B Service Tax on Transportation

E Service Tax on O&M

F Erection & commissioning

a Service Tax

TOTAL - TAXES & DUTIES

GRAND TOTAL OF BID PRICE

INCLUDING TAXES & DUTIES



IMP NOTE -

All the taxes of each equipment shall be compulsory submitted in table format to the Purchaser’s office within 15 days from signing of contract.

The list above is indicative and supplier’s offer shall be complete in all respect for equipment being offered.

INSTALLATION SERVICES AND “O& M” MEANS :-

1. COMMISSIONING AND PUTTING TO PURCHASERS’S SATISFACTORY OPERATION OF SUPPLIED EQUIPMENT AND SYSTEMS

.Providing competent Engineers and other Experts.

2. COMMERCIAL OPERATION & MAINTENANCE FOR SIX MONTH AFTER SATISFACTORY COMMISSIONING Of UNIT AS

DIRECTED BY PURCHASER’ S ENGINEER.

3. Manufacturer is free to suggest any other alternative of main turbine M/C & generator with it’s auxiliaries without changing the Installed

Capacity, Generated units, Head range & Discharge range provided in the Tender Document.

SANJAY B. PATILSANJAY B. PATILSANJAY B. PATILSANJAY B. PATIL....


1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - IIA

PRICE SCHEDULE WITH BREAK UP



SECTION – II-A

DETAILED BREAK UP OF PRICE SCHEDULE OF MAIN PLANT & RELATED TO IT’S ALL MANDATORY SPARES

TO BE RECOMMENDED BY BIDDER Amount in Indian Rupees

Sr.

No. Description Qty.

Make & Country of

origin

Unit rates

Total Excise duty

VAT All

types of Taxes

Transport, Insurance, loading & unloading

Ex-factory

01 02 03 04 05 06 07 08 09 10

MAIN TURBINE AND GENERATOR

PLANT AND ITS ASSOCIATD

EQUIPMENT OR ALL TYPRS OF

MANDOTARY SPARES

1 TURBINE EQUIPMENT 1 Set

2 FOR GOVERNOR AND OIL PRESSURE SYSTEM

1 Set

3 HYDRO MECHANICAL CABINET 1 Set

4 MAIN INLET VALVE 1 No.

5 COMPRESSED AIR SYSTEMS. 1 set If Required or otherwise.

1 Set

6 COOLING WATER SYSTEM. lot Standard spares for pumps & motors.

2 Sets.

7 GENERATOR 1 No.

8 STATC EXCITATION SYSTEM. 1 Set

8a SPARE FOR FIELD BREAKER.

8b SPARES FOR FIELD FLASHING CONTACTOR

9 3.3 KV SWITCHGEAR. Lot

10 GENERATOR, TRANSFORMER, FEEDER SYNCHRONISING PANEL.

Lot



lot

11 REMOTE CONTROLL SYSTEM. 1 Set

12 E.O.T. Crane. 1 No.

13 Power Transformer 3.0 MVA. 1 No.

14 Auxiliary Transformer 100 KVA. 1 No.

15 D.G. Set. 1 No.

16 A.C. System. Lot

17 D.C. System. 1 No.

18 Indoor Switchyard. Lot

19 Air Conditioning. Lot

20 Fire Fighting System. Lot

21 Fire Hydrant System. Lot

SEALED AND SIGNED BY SUPPLIER



1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - III

TECHNICAL SPECIFICATIONS



SECTION – III - A

DETAIL TECHNICAL SPECIFICATION

MAIN TURBINE AND GENERATING PLANT AND ITS ASSOCIATED AUXILIRIES.

3.1 TURBINE:

3.1.1 The turbine called for under this specification is Horizontal Francis type moveable blades

with auxiliaries and all accessories required for its work at gross design head of 27 meter.

Tenderer shall calculate net heads based on parameters of the water conductor system actual

at site.

The turbine shall be suitable for following operating conditions.

a) The turbine shall be suitable for operating between the variable heads of about 33.50

meter to 17.40 meter. The design head shall be 27 m gross. Also, the turbine shall be

suitable for smooth operation at any discharge from minimum at 50% load at rated head

to maximum of about 9.33 m3/sec.

The rated output of turbine at rated head of 27 m is expected with a gate opening of

around 85 percent. It is desired that best efficiency of the turbine shall be obtainable at

the rated output of not less than 2000 KW with the discharge of 9.33 cumecs and the gate

opening of 85 %. The Contractor shall indicate in his tender the value of the best

efficiency of the turbine stating the output value with discharge and gate opening at

which it is obtainable.

b) The output of not less than 2200 kW at 10 % continuous over load at rated head condition

shall be obtainable with the gate opening value of around 93 percent. Besides, the

Contractor shall furnish in his tender, characteristics charts/performance curves,

tabulating therein the values of turbine outputs at gate opening of 25%, 50 %, 80 %, 90 %,

100%, and 110% for different heads from 17.40 to 33.50 m.

c) Turbine shall be suitable for trouble free continuous operations at 110% of rated

load and shall be accordingly guaranteed. The turbine shall be suitable for smooth

operating under such conditions.

3.1.2 STRESSES AND FACTOR OF SAFETY :

All parts of turbine shall be designed and constructed to safely withstand the maximum

stresses during the normal running and runaway and short circuit conditions, out of phase

synchronizing and erratic brake applications. The maximum unit stresses of the rotating

parts shall not exceed two third of the yield point of the material. For other parts, the factor

of safety based on yield point shall not be less than 3 at normal conditions. For overload and

short circuit conditions, factor of safety of 1.5 on yield point shall be permitted.

3.1.3 SPEEDRISE AND RUNAWAY SPEED :



The moment of inertia of the unit and the normal wicket gate closing time shall be so adjusted

that the maximum momentary speed rise of the unit shall not exceed 50% and the maximum

pressure rise in the penstock shall not exceed 25% of the maximum static head under any

condition of operation. The turbine manufacturer shall co-ordinate with the generator

manufacturer for limiting the speed and pressure rise values and accordingly design fly-

wheel. The maximum runaway speed of the unit under any combination of head and load

conditions shall be stated in the tender. The turbine shall be capable of running safely at

maximum runaway speed without any damage to its parts for a period of not less than 15 (

fifteen ) minutes for every such occurrence with cooling water supply on and 5 minutes with

interruptions of cooling water during such occurrence. If required pressure relief valve shall

be put into the system to arrest pressure rise to protect long water conductor system.

3.1.4 STANDARDS

IEC 60041 --International code for Field Acceptance Tests of Hydraulic Turbines

IEC 60308-- International code for testing of speed governing systems for hydraulic turbines

IEC 60545-- Guide for commissioning, operation & maintenance of hydraulic turbine

IEC 60994-- Guide for field measurement of vibrations and pulsations of hydraulic machines

IEC 60995-- Determination of prototype performance from model acceptance test of hydraulic

machines with consideration of scale effects

IEC 60193-- International standard – Hydraulic turbines - Model acceptance tests

IEC 60041-- International standard field acceptance tests of hydraulic turbines

IEC 60609 P 1--Cavitations pitting evaluation in hydraulic turbines, storage turbines and

pump-turbines, Part 1.

ASME Boiler and Pressure Vessel Code, Section VIII

IS 12800--Guidelines for Selection of Turbines, Preliminary dimensioning and layout of

Surface Hydro Electric Power house

IS : 1271--Classification of insulating materials for electrical machinery

IS : 2379--Colour code for the identification of pipelines

IS : 5-- Colour for ready mixed paints and enamels

IS : 226--Structural steel (standard quality) (fifth revision)

IS : 1538--Cast Iron fittings for pressure pipe for water, gas and sewage

IS : 6392--Steel pipe flange

IS : 2906--Sluice valves for water works

IS : 2002--Medium tensile steel plate used for welding, flame cutting and flanging in hot

condition

IS : 2049--Colour code for identification for wrought steel for general engineering purposes

IS : 1030--Cast steel



IS : 28 -- Bronze

IS : 1239--G.I. pipes Part 1, Part 2

Note: The latest edition of the above codes shall be referred.

3.1.5 GENERAL ARRANGEMENT AND CONSTRUCTION

The turbines shall be installed in a setting as indicated in the layout drawing or setting

indicated by supplier and approved by purchaser. The generator, flywheel etc. shall be

mounted on a suitable chassis/platform mounted over the turbine floor. The design shall be

such that so as to enable easy assembly and erection at site and the spacing of the equipment

should be sufficient for maintenance of turbine and generator. The statement of origin of

materials shall be confirmed in the bid. The certificate of origin must be handed over when

materials are in workshop. In the bid all sub-suppliers must be named and be approved by

the Purchaser/Client.

3.1.6 GUIDE VANES

The number of guide vanes selected shall be well matched to ensure turbine operation

without objectionable vibration. The guide vanes shall be shaped to permit smooth flow of

water through the turbine and shall be so proportioned as to maintain closing tendency

under any normal operating conditions of the turbine.

The turbine Guide Vanes and stems shall be of die cast 13-4 Cr-Ni stainless steel. Each gate

shall be machined smooth and ground to an accurate form and finish.

Each Guide Vane shall be provided with greaseless self lubricating bush type guide bearings.

Each stems shall be provided with a thrust bearing of bronze to carry the weight of the guide

vane and withstand hydrostatic thrust. Convenient means shall be provided for adjusting

and maintaining the clearances of the Guide Vanes.

The Guide Vane operating mechanism shall be of ample strength to withstand the most

severe operating conditions. All working points with relative motion shall be bronze bushed

and provisions for grease lubrication. Means shall be provided for adjusting the position of

any individual Guide Vane independently.

Each Guide Vane shall be individually connected to the Guide Vane operating ring through a

set of lever and links.

Suitable shear pin shall be provided between each Guide Vane stem and Guide Vane

operating ring which shall be strong enough to withstand the maximum normal operating

forces but will break or yield due to forces in opening or closing direction and will protect the

rest of the mechanism from damage when one or more of the Guide Vanes become jammed.

A shear pin failure check circuit shall be provided which shall be electrically continuous if all



pins are sound. If any one pin is sheared it shall furnish annunciation in the unit control

board. A shear pin break test shall be performed in the shop.

Solid stops and suitably designed friction device shall be provided for each Guide Vane to

limit the angle and rate of movement of Guide Vane stem levers while opening and closing

on shear pin failure. The loose Guide Vane and its linkage after shear pin failure shall not

interfere with the operation of other Guide Vane or turbine parts or cause progressive failure

of adjacent shear pins.

Seals shall be provided above and below Guide Vanes to effectively reduce leakage of water

or air. Segmented seals of proven design shall be used.

3.2 GUIDE VANES REGULATOR

The guide vanes arrangement must be provided with closing tendency when not operated by

power pack. The guide vanes shall be operated by one number of double-acting oil pressure

operated, fabricated or cast steel servomotor having adequate capacity to operate the turbine

Guide Vanes to full opening or closing stroke under all conditions. The servomotor shall be

capable of moving the guide vanes smoothly during full opening and closing in required time

as per pressure rise and speed rise limits given in the bid.

The servomotor shall be provided with suitable adjustable bypass connections for cushioning

to achieve retardation in the rate of closure during the portion of Guide Vane travel from

slightly below speed-no-load position to the fully closed position to prevent excessive

pressure changes in the water passages.

Manual locking devices to hold the guide vanes in the closed or open position against

maximum oil pressure shall be provided. Switches for interlocking circuits and lamp

indication of the locking device position shall be provided on local panel and on unit control

board.

Provision for connecting the restoring cable from the actuator on the piston rod of servomotor

shall be provided. A scale calibrated in tenths of Guide Vane position shall be rigidly

attached to servomotor position by means of a pointer.

3.3 RUNNER

The runner shall be Kaplan type confirming to IEEE – 810 (1987). The runner and runner

blade material shall be DIN 17.445, Material Nr 1.4113, G-X5 CrNi 13.4,ASTM A 743 CA 6

NM, The runner shall be die forged in one piece with integral labyrinths and shall be

designed to provide the best hydraulic profile so that it gives the maximum efficiency with

minimum cavitation. The composition of the material and the source of runner casting shall

be stated in the Bid. The blades of the runner including the spare shall be interchangeable. A

bolted connection shall be provided for attaching the runner to the turbine shaft. Opening

shall be provided through the runner crown to drain the water and reduce the hydraulic



thrust. It shall be housed with bearing bushes to withstand safely all forces during operation

as well as during max. Runaway speed. Runner blades shall be suitable for operation through

runner blade governing system, hydro-mechanical cabinet.

The runner with assembled blades and blade angle changing mechanism shall be statically /

dynamically balanced in the works and so designed so as to safely withstand loading due to

normal and abnormal operating conditions including effects of blade thickness reduction due

to cavitation erosion, introduction of stress due to on site welding of damaged blades,

increased pressures at transient conditions and discharge related to maximal guide vane

opening and runner blade opening. The runner shall be designed to withstand stresses due to

resonant vibrations. The Contractor shall clearly present his calculation criteria with respect

to maximal possible stresses in the runner parts including blades, related to mechanical

properties of the runner material.

The runner shall be free from internal stresses and casting imperfections. All surfaces of the

runner exposed to the flow of water shall be carefully machined and finished smooth to

templates. There shall be no hollows, depressions, waviness, projections and/or other surface

imperfections that might lead to local disturbance, erosions and/or cavitation. Other highly

stressed areas of the runner shall be finished smooth to judge the quality of the casting or

forging and evaluate possible material defects.

The conformity of the blade shape to the design drawings shall be verified by use of

templates or other shop control devices. Templates for guidance in restoring blade and

bucket shapes to original contour shall be supplied with the runners. The method for blade,

hub and runner removal shall be clearly specified. The special tools and tackle required for

dismantling and fixing of runner shall be supplied.

Alternatively, the supplier may propose a runner of fabricated construction in accordance

with modern fabrication practice as long as the runner meets the requirements of efficiency

and minimum cavitation.

3.4 SHAFT AND COUPLING

The turbine shaft (if required) shall be of hollow centrally bored for runner blade mechanism

and of forged carbon steel or alloy steel conforming to ASTM A 668 Class D or equivalent

standards. Wherever the flanges are integral with the shaft, the same should conform to

International Standard. The turbine shaft shall be connected to the runner on one side and to

the flywheel on the other side. It shall be of ample size to transmit torque at rated speed

without any vibration or any distortion. The main bearing concept of runner must be

provided in drawings with tender documents. The couple shall be elastic one for operational

comfort.



A renewable and removable sleeve of stainless steel shall be provided wherever the shaft

passes through a shaft seal or a gland. The sleeve shall be of corrosion-resisting material,

accurately machined, polished, and adequately secured to the shaft. The detail of sealing

must be provided in the bid document. (However runner directlyco0upledon on the generator shaft

shall be preferred)

3.5 BEARINGS

The turbine bearing (if the turbine shaft is provided) shall be pedestal mounted journal type

oil lubricated thrust cum guide bearing. The turbine shall be provided with adequate

number of bearings. The bearings shall be designed to withstand operation at maximum

runaway conditions without cooling water supply (if cooling water is provided) or

lubrication system for a period of not less than 15 minutes and also for operation at normal

speed without cooling water supply for 15 minutes. The bearings shall be provided with a

dial type and resistance type thermometer, a pressure gauge together with provision for

alarm annunciation / shut-down on excessive bearing temperatures and sight level gauges,

valves and piping for cooling water. The bearing temperature should not exceed 55°C under

any operating conditions. The number and type of bearings shall be stated in the bid. Type of

lubrication system provided shall be clearly indicated in the bid. The bidder may also offer

with self lubricating bearing water cooled bearings confirming to the above stated

requirements.

3.6 SHAFT GLAND

The shaft gland shall be of the stuffing box / carbon ring type with self lubricated packing

and lantern ring. Any other suitable type of shaft gland will also be considered. The gland

shall effectively prevent leakage of water along the shaft under all operating conditions and

at standstill and prevent entry of air. Details for starting and operation of the turbine and

shut-off action shall be particularly provided for in the bid. In case the location of the gland is

below maximum tail water level, an inflatable rubber seal shall be provided for attending the

main gland without dewatering the draft tube. A stainless steel sleeve with self-lubricating

type shall be provided on the shaft where it passes through the gland.

Arrangement for providing cooling water supply to the gland, if required, shall be made by

the Bidder and indicated in his Bid drawings.

3.7 S- TYPE RUNNER CHAMBER , DRAFT TUBE CASING AND STAY RING

The s-type runner chamber, draft tube and stay ring enclosure casing with runner chamber

support, side cover support etc. shall be constructed in accordance with best design practice

so as to provide efficient operation of turbine. A set of stay vanes of appropriate construction



of steel shall be provided with inside material 13:4 Cr.Ni.. The chamber shall be provided

with an air release cum anti-vaccum valve for evacuation of air.

The casing shall be fabricated from welded steel plate / mild steel plates and shall have

suitable sections for ease of shipment and to be within transport limitation. The case and

stay ring shall be designed to withstand maximum water pressure including water hammer

and shall be complete in all respects with anchors, supports, sole plates, turn buckles, hold-

down rods, all types of clamps etc. The turbine should not communicate vibrations to the

building nor any other dynamic load to be burdened.

The stay-ring shall be of cast steel or fabricated from welded steel plate and suitably stress

relieved prior to machining. Flanges shall be provided for bolted connections between the

stay ring and the side cover, and between the stay ring and the discharge ring. Alternatively

the discharge ring may be welded to the stay ring prior to stress relieving and machining.

The stay ring shall be designed to support the weight of the superimposed structures and

parts, with casing empty, and to withstand safely the forces due to maximum head, including

maximum pressure rise. For fabricated stay ring designs, the stay vanes shall protrude

through the upper and lower shroud plates and shall be shop-welded with full penetration

welds. Fabrication of the stay ring in the field will not be allowed.

3.8 SIDE COVER

The side cover shall be of cast steel or welded plate construction suitably sectionalized for

ease of transportation. Suitable replaceable labyrinth rings or similar sealing arrangements

shall be provided. The Supplier must detail the concept of sealing. The side cover shall be

designed and constructed to support all necessary seals, bearings, guide vanes assemblies,

etc. The setting of the cover and the adjustment of all relevant parts during commissioning

must be clearly described by the Bidder in his offer.

3.8.1 TURBINE FRAME, PLATFORM, WALKWAYS, HANDRAILS ETC.

A support frame on which to mount the case, bearing pedestals, generator, brakes, and

exciter shall be supplied as part of this specification and detailed in the Bid document.

3.8.2 GOVERNING EQUIPMENT

Turbine shall be equipped with suitable dedicated electronic governor conforming to IEC No.

60308. The governor shall be of proven design capable of maintaining control of speed under

all conditions of head and load in a stable manner when operating in solo or grid operating in

parallel with other generating units in the grid. Such governing system shall be complete

with actuator unit comprising speed responsive element, restoring mechanism having

adjustable temporary and permanent droop setting, load limiting device, speed level control

etc.



The speed responsive element of the governor shall be operated by a toothed wheel mounted

on the generating unit shaft with speed pick-ups or its equivalent that shall be normally used

as an input to the speed-sensing device. Standard protections like over speed device, brake

control, emergency shut down and alarms etc., shall be provided in the governing systems.

Turbine governor shall be of latest design and shall comprise of a digital electronic,

microprocessor based part for control and regulating function and a hydraulic part acting as a

power-amplifying servo unit.

The electronic part shall house all the electronic devices and circuitry of the governor viz.

microprocessor circuits, speed sensing transducer and circuits, amplifier circuits, feed back

loop circuits, parameters speed drop circuit, stabilizing circuits and other control for

adjustment of governor parameters.

A complete transfer function block diagram for the governor offered indicating the various

gains and time constants of different components, with their relationship shall be supplied

The hydraulic part shall house complete hydraulic mechanical equipment comprising of pilot

valves, auxiliary servomotor, main distributing valves, devices for, automatic shutdown,

emergency shutdown and adjustment of governor closing and opening times.

3.9 PRESSURE OIL SYSTEM

The pressure oil system shall cater to the governing system for unit and the Main Inlet

Butterfly Valve. Pressure oil system shall comprise of a separate pressure oil tank for both

generating unit and their respective Main Inlet Butterfly Valve. Two numbers of electrically

operated oil pumps will be provided, one for normal running and acting as standby.

Provision for emergency shut down of the unit without any oil pump running shall also be

made. Gauges, pressure switches etc. will be provided as may be necessary. The oil

pressuring system needs to be equipped with an oil retaining basin in case of any leakage.

3.10 NITROGEN ACCUMULATORS

Nitrogen accumulators of sufficient capacity shall be provided for maintaining the required

pressure in the system. The capacity of the accumulator should be suitable for at least one

closure of the Turbine and generator (if hydraulic brakes are provided).

3.11 OIL AND LUBRICANTS

The Contractor shall indicate the specification and quantity of the governor system oil and of

the bearing oil required for each turbine and shall supply sufficient oil for the first filling plus

10% extra of each type. Where possible, the specification for the governor oil and for the

bearing oil shall be the same.



3.12 DRAINAGE AND DEWATERING SYSTEM

DEWATERING SYSTEM

The dewatering system shall be designed for dewatering of scroll case and draft tube. Initially

the water shall be drained by gravity up to the prevailing tail water level and then the

remaining water, if any, shall be pumped to the tailrace by one portable, submergible pump,

installed in the sump provided for dewatering located in the powerhouse. The pump must be

complete with hoses, piping, and fittings etc. This pump will also be used for drainage

pump. The pump, hoses, pipe, and fittings shall be supplied by the Contractor. The capacity

of dewatering pumps shall be adequate to de-water each unit in reasonable time not

exceeding three hours.

DRAINAGE SYSTEM

The drainage system includes floor drains, leakage water drains, seepage water from all the

walls in contact of water, outside walls with backfill against them and drainage of water from

other equipment such as compressors, air conditioning plants, turbine shaft glands etc. All

the drains shall be connected through drainage header to the drainage sump located in

powerhouse.

3.13 CORROSION PROTECTION AND COATING

For all structural steel and cast iron parts including piping for areas in contact with air, oil

and water the following applies:

Surface Preparation : On all cast iron and structural steel parts the rust must be removed by

mechanical means sandblasting to obtain a bare surface as per international practice.

Prime Coat for all areas : 2 layers with "Friazinc R", dry thickness of each layer 40 microns.

Type A: Areas in contact with water: After assembling the mechanical parts in the workshop

of all items to be delivered three coats of water resistant paint must be applied with each

layer having a minimum thickness of 100 microns.

Type B: Areas in contact with oil: All those areas will receive three coats with oil resistant

paint, for example Keratol, which must be applied as finishing coat.

Type C: Areas in contact with air: All those areas still accessible after assembling on site,

receive two prime coats with different colors. The prime coat consists of a preliminary final

coat in blue for the turbine casing and red for all the moveable parts.

Areas in contact with concrete: Cast-in items do not receive any coating, but must be free of

rust and spunk.

Cast-in items exposed to air and water must be provided with a prime coat to a depth of

approximately 150 mm into the concrete.



Pipelines in contact with water: They must be provided with three coats of water resistant

paint.

Oil carrying pipelines: They must be dismantled after assembling on site, pickled in acid

solution, neutralized and oiled.

All bare surfaces, which are not in contact with oil, shall be provided with a protection coat

(removable with water) after manufacturing.

Parts located in inaccessible areas, which must not be dismantled after workshop assembling

must be protected as follows:

The electrical equipment such as electric motors, limit switches, control panels etc. must

receive corrosion protection according to specifications in the worst atmosphere.

The color coating will be determined by the client. Any coated surface damaged after or

during assembling must be reinstated.

3.14 SHOP ASSEMBLY AND WORKSHOP TESTS

3.14.1 GENERAL

Relevant IS & International standard recommendations for the selection of materials and

testing of plates, cast iron and forged items for hydroelectric power plants must be adhered

to. Samples of steel plates shall be tested by the Contractor. Metallurgical strength,

crystallographic, ultrasonic, and borescope shall be performed on the turbine shaft during

manufacture. The results of all tests shall be delivered to the Purchaser within one (1) month

after material has been tested

Cost of all tests required in the workshop as well as on site including provision of personnel

and equipment required to carry out these tests must be included in the offer.

The following assemblies and test shall be carried out on the turbines and associated

equipment at the manufacturer's works before dispatch in the presence of representative of

the Purchaser/Consultant, if desired by the Purchaser, and test certificate shall be submitted:

The turbine manufactured shall be assembled in the shop in the presence of purchaser .

Static and dynamic balancing of runners

Hydrostatic testing at 1.5 times the maximum static / working pressure including water

hammer for not less than 15 minutes for the casing, servomotor etc.

Non-destructive testing of weld joint and major castings and forgings.

Performance tests for individual auxiliary equipment

Complete assembly and simulation test of governors etc.,

All motors / pumps / compressors etc. shall be tested as per relevant Indian or other

international standards.



3.14.2 MANUFACTURING AND ERECTION OF EQUIPMENT

The design of the turbine with all the auxiliary equipment must comply with the

acknowledged technical standards. The unit must be free of vibrations with extreme low

noise level under all operating conditions. The respective requirements from the authorities

must be met. All design work required for manufacturing, delivery and erection upto

commissioning of all equipment parts are included in the Supplier's scope of work.

The Supplier guarantees that the assembly of the turbines will be carried out in an

appropriate and faultless manner. Suppliers shall delivery turbine and its auxiliaries in the

assembled condition to the maximum extend possible, subject to transport limitations if any..

3.15 PACKING AND TRANSPORT

All parts to be delivered must be packed in a proper manner and then loaded and

transported to site, unloaded and stored properly.

3.16 COMMISSIONING (TRIAL OPERATION), TEST RUN AND ACCEPTANCE TESTS

After completion of the erection and operational readiness checks of the plant, the

components supplied by the Contractor will be commissioned as part of the commissioning

of the generating unit and ancillary equipment as a whole. The commissioning will be

carried out under the direction of a Commissioning Coordinator. The commissioning will be

carried out as per a procedure approved by Purchaser. 90 days before the anticipated time of

commissioning the first unit, the Contractor shall submit to the Purchaser procedures for the

commissioning of his equipment which will be integrated into overall procedures for the unit.

3.16.1 COMMISSIONING TESTS (TRIAL OPERATIONS)

The Supplier shall carry out the trial operations / commissioning tests in accordance with IEC

545. The turbine and its auxiliaries shall be commissioned first and shall be free from

problems of leakages, over heating, failure, damage etc.

The commissioning period for each turbine is considered to be completed after the following

tests have been carried out successfully:

Minimum five start-ups and shutdowns,

The turbine with all the auxiliary equipment has been operating continuously over a

period of at least 72 hours. During the scheduled 72 hours of operation, the turbine

output may vary 40% to 110% of full load several times. The period of any shut down or

tripping of the machine or supplied auxiliaries due to fault of Bidder will further be

added to 72 hours.

After successful completion of the 72 hour test run, the machine shall be handed over &

the five year guarantee period comes into force.



3.16.2 ACCEPTANCE TESTS

These shall include capacity and efficiency tests which shall be carried out on one turbine

selected by the purchaser to verify the guarantee provided in accordance to the SCC . These

tests shall be carried out in accordance with provisions of IEC-60041.

Tests shall also be carried out to verify all contractual guarantees, which shall include load

acceptance and rejection tests, run away tests etc.

All necessary provisions on the various equipment supplied for successful completion of such

tests including labour and material required for such tests shall be provided by the

contractor. All test equipment (duly certified by recognized test houses) and instruments for

performing the various tests shall be made available by the contractor and shall remain the

property of the contractor after the fulfillment of the tests.

A test report shall be furnished by the contractor after completion of the tests for review by

the purchaser or his representative, and after its approval, shall supply sufficient number of

copies to the purchaser. The report shall include all information, analysis and presentation of

results as specified in the IEC.

3.17 SITE ERECTION

The Supplier shall depute his experts for erection, testing and commissioning of turbine and

associated equipment for supervision of erection, testing and commissioning. The rates for

the supervision personnel shall be included by the Bidder in his offer for comparison. All

costs for supervision of erection shall be deemed to be included in the offer.

The personnel responsible for the erection of the turbine on site must be experienced in the

erection of several similar turbines and shall be assisted with installation instructions

provided from the workshop. Further if person is not found competitive enough the

purchaser can ask the supplier for the replacement with more competitive and experienced

person. During the erection period of the turbine, the Purchaser will provide his personnel

for training purposes.

The Bidder's experts will be responsible reporting to the leading expert of the Purchaser.

They will train staff members of Purchaser, during the erection procedure, by training on the

job methodology.

Details must be provided for equipment required during erection together with a time

schedule for the erection period.

3.17.1 THE GOVERNOR SYSTEM SHOULD HAVE FOLLOWING QUALITIES :

i) Fast acting.

ii) Stable (No hunting.)

iii) Reliable.

iv) High sensitivity.



v) Easy control.

The governing system shall be designed to allow operation of the unit ( i.e. turbine and

generator ). Further, the system should be suitable for operation of the unit in both ways

either in ‘Individual control’ or in ‘ Joint control of the units’.

The system shall be such as to ensure ‘bump less transfer’ when the control is switched from

‘Individual control’ to ‘Joint control’ and vice versa at any load. Besides provision shall be

made to share the load equally when the units are placed in ‘ Joint control’.

The governing system shall be designed to perform the following functions.

1) Unit start-up.

2) Idling and synchronization.

3) Parallel operation of the units.

4) Normal stopping and emergency shut-down with necessary monitoring and safety

functions. And

5) Isolated operation of the unit below 47.5 Hz.

In addition the governing system must allow the operation of the unit either in ‘frequency

control’ (i.e. speed governing) function or in output control’ function. In ‘frequency control’

function, the frequency (and therefore the operating speed) shall be maintained at set point

when the unit is in isolated operation or in idling mode. In output control function, the power

output of the unit shall be maintained at set point.

CONFIGURATION

The governing system comprising of oil pressure system, the hydro mechanical cabinet

(HMC) i.e. actuator and the electronics control, shall divide functionally so as to achieve,

“Local” i.e. ‘Manual Control’ or remote control of the unit. The manual control shall be

directly from the HMC i.e. actuator cabinet. The remote control shall be from station control

room by means of operator console and programmable logic controller.

SPEED AND PRESSURE REGULATIONS :

The maximum momentary speed rise caused by sudden rejection of the rated output under

the normal head shall not exceed so as not to exceed pressure rise given below.

The maximum momentary pressure caused by sudden rejection of any load at any operating

head shall not exceed 1.25 times of the maximum pressure at project. If needed pressure relief

valve shall be used to arrest the pressure to design limit and cost thereon is deemed to have

been included in the offer of the bidder.



PERFORMANCE

The speed governor shall be of such structure that assures stable and reliable operation, high

sensitivity and easy control operation. At any load it shall regulate the turbine to a uniform

speed free from hunting or racing and shall cause each set to operate satisfactorily in parallel

with another machine in the station and in the interconnected system. The speed governor

shall be so arranged that the speed adjusting and load limiting operations can be carried out

by both the remote control by the operating ;handles provided to the control board in the

control house and the local operation by the operating handles provided to the speed

governor cabinet or regulator board.

Pressure oil for operation of the speed governor shall be supplied from the oil pressure

supply system described hereafter in this section.

The guide vane closing time shall be changeable to the corresponding stabilised values

according to generating operation. The controls and fittings shall be neatly and conveniently

grouped and, except those which are desirable to be visible, they shall be mounted within the

body of the governor cabinet so that it presents a clean and pleasing external appearance.

All hand controls shall be clearly and concisely marked as to purpose. The speed governor

shall have the following facilities and performance.

1) Speed adjusting range : 85 - 105%

2) Adjusting range of permanent droop : 0 - 06%

3) Adjusting range of incremental Momentary speed droop : 0 - 50%

4) Adjusting range of time constant Of damping. : 0 - 15 Sec.

5) Governor dead band : 0 - 02%

Protective device :

The protective device shall be capable of fully closing the guide vane in case that a trouble

occurs in the speed governor and/ or failure of AC/DC supply for governor shall stop the

turbine quickly.

Both the speed control governor and power output governor shall actuate the same servo

positioned through the opening set point. Attention shall be paid in the design so as to

achieve bump-free switchover between modes.

The electronic PID controller’s behavior shall be enhanced by special means such as

disturbance super position and secondary variable super position.

SPEED SENSING



The speed sensing for governor operation shall be taken from toothed disc method or via

transducers using residual remainance.

3.17.2 CHARACTERISTIC PARAMETERS OF PID CONTROLLERS.

( Definitions as per IEC 308/1970)

1. Permanent Droop (bp)

The permanent droop shall establish a defined relationship between the controlled variable

‘X’ and relative servo position or any other signal, in the steady state condition. e.g.

Speed control : between frequency and servo position.

Power control : between power and frequency.

2. Minimum setting range for speed control shall be 0-10% linearity ( maximum allowable

deviation of permanent droop) for any value of ‘Y’ ( servomotor stroke deviation ) from

the maximum stroke permanent droop bs < 5%.

3. Proportional gain (kp) : kp = 1/bt. Where bt = temporary speed droop , kp = adjustable

between 0.6 to 10%

4. Integral action time constant (Td.) : Minimum adjusting range 1 to 20 Sec.

5. Derivative action time constant (TV) : Setting range : between 0 and 2 Sec.

6. Command signal adjustment : ( for controlled variables speed, power output etc. and load

limiter)

a) Command signal range for speed control : +6% to – 10% with bp = 4%

b) Command signal setting times shall be adjusted so as to exceed the shortest servomotor

stroke as defined byh limiting orifices. Setting times should not be less than 20 sec.

7. Time setting range.

a) Speed setting : between 20 and 100 s

b) Power output Setting : between 20 and 80 s for full travel of servomotor.

c) Limiter. : Between 20and 80 s for full travel of Servomotor.

8. Control Inaccuracy ( IX/2) : Speed control IX /2<2 x 10 -4 ; Power output control IX /2,1 x

10 -2

9. Parameters of servo positioned :

Input : Electrical signal or position of pilot Servomotor .

Output : Relative position of the main Servomotors.

For servo positions the following applies :-

a) Minimum servomotor opening and closing times Tg and Tf shall be separately

determined to satisfy water hammer and overspend limitations. The limiting orifices shall

be so dimensioned that the actual stroke times in the presence of the highest supply



pressure and lowest required regulating capacity is not lower than the allowable stroke

time.

b) Time constant (Ty) of the main servo positioner to be introduced in digital stimulation

system shall lie between 0.1s and 0.25s. Near the zero displacement. Higher values of Ty

shall prevail due to overlap and grooves.

c) Servo positioner inaccuracy in follow up arrangement (ia/2) which has major Influence

on dead band shall be kept small i.e. ,<0.2% for the complete servo positioning system.

d) Control system dead time constant (Tq) shall be less than 0.25s.

e) Dynamic response of servo positioned : Setting of servo positioned shall be so chosen that

the dynamic response of servo positioned corresponding to a damping ratio (D) between

0.8 and 1.1 is achieved.

3.17.3 MANUAL CONTROLS.

Manual control of setting of turbine power directly via the actuators by passing the governor

control loop shall be provided. In that case, the safety of unit shall rest with over sped

protection.

3.17.4 FOLLOW – UP CONTROLS.

To achieve bump – free transition from one operational mode to another following follow-up

controls shall be provided.:

i) The power output governor command signal shall follow the actual power output signal

in the speed control mode.

ii) The speed command signal shall follow the actual frequency – signal in the power output

control mode or during the start up phase ( speed command signal pre- adjustment.)

iii) The manual control set point shall follow the actual actuator position in the various

control modes.

iv) In case of remote control, respective local control shall follow the respective command

signals.

v) It shall be possible to adjust the pre opening of varying heads to minimize start up times.

3.17.5 OPTIMISATION CONTROL :

Special control configuration shall be provided to optimise the system with respect to overall

plant efficiency smooth running or other criteria.

3.17.6 MONITORING, PARALLEL POSITIONING OF AMPLIFIERS.

The deviation of the position of each servomotor from the average of the total shall be

monitored and a warning or shut down shall be initiated when it exceeds the set limit. Also



the control deviation of the individual positioning loop shall be monitored. If it does not

return to approximately zero in a given time span a warning or a shutdown shall be initiated.

3.17.7 OPERATIONAL TRANSITIONS :

Following stipulations shall apply :

a) Synchronization Band - ( 0.995 to 1.01) f network.

b) Speed change rate for synchronization : dx /dt = 0.003 per sec.

c) ts/to.8 = no 1.5 to 3.0

Note : ts – Time at which the unit is synchronized.

to.8 – Time at which 80% speed is reached.

d) tE / tM = 2.5 to 4.0

Where tE = Regulating time after which the speed deviation from idling speed remains below

+ 1% t.M= Time after which load rejection takes place.

e) nmin = 0.85 to 0.95 n

nmax = Maximum speed after load rejection (at tM)

nmin = Lower speed after a load rejection.

n = Rated speed.

3.18 HYDRAULIC – MECHANICAL CUBICLE

It shall be consisting of following devices.

1) Electro Hydraulic transducer with hydraulic amplifier “toggle – Baffle’ type.

2) Gate opening limiter.

3) Lever transmission.

4) Feed back shaft.

5) Main slide valve.

6) Contact device of gate limiter.

7) Control mechanism of combinatory cam & limiter as per head.

8) Shaft of limiter.

9) Main feedback gear. .

10) Hydraulic Amplifier with electro magnet.

11) Control and measuring instruments.

12) Double oil filter.

13) Emergency closing solenoid valve.

14) Rotary cam switch bank.

The above units shall housed inside the cubicle mounted on a frame covered with a light

metallic casing. On the face of panel of the cubicle following control and measuring

instruments and indicators shall located which are necessary for the operation of turbine and

governor.



1) Electro-Tachometer for measuring speed of turbine.

2) Balance indicator .

3) Gate limiter and gate position indicator .

4) Speed setting indicator.

5) Gate setting indicator.

6) Gate limiter raise/lower hand wheel.

7) Speed change switch.

Inside the mechanical cabinet following shall be located.

1) Oil gauge for indicating the pressure of oil supplied to the hydraulic amplifier.

2) Scale for indicating the head.

3) Gate limiter and gate position indicator shall provided with adequate transmitters to

duplicate indications in the control room.

3.19 OIL PRESSURE UNIT SYSTEM (Common for Turbine, runner blades & MIV)

The oil pressure system shall be amply designed to meet all requirements of governor

(turbine control) system, B.F. Valve. Open-close-open cycle for wicket gates and open- open

cycle for BFV and runner vanes..

i) Purpose

Oil pressure unit system shall be used for operation of the guide vane of turbine, runner

vanes and MIV.

ii) System

a) The pressure oil supply system for each unit shall comprise of 2 sets of pressure oil

pumps directly coupled with the 415 V + 10 % A. C. Motors (1 set for normal operation

and 1 set for stand-by). 1 set of sump tank, 1 set of pressure tank and other accessories.

b) A complete set of compressed air system with one compressor sufficient to develop air

pressure for governing system shall be provided for each governor. One common

compressor shall be supplied as spare.

c) Controls shall also be made from the Unit Control Board in addition to local control.

System shall be suitable for local/ remote and auto control operations.

d) Operation method of the pressure oil pump shall be of the continuous operation type

using unloader valves.

When the normal oil pump stops during operation of turbine or in case of the first stage of oil

pressure drops, stand-by pump shall start automatically.

3.20 OIL SUMP TANK :-

It shall be of electrically welded steel plate having sufficient capacity for two closing &

Opening operations of MIV, Guide vanes and runner blades. The tank shall be totally

enclosed and shall be provided with man hole cover, oil level gauge, level switches for low



level alarm return oil strainer, suction and return connection for oil centrifugal equipment, a

filter cum air breather, a thermometer with contact for high oil temperature alarm. The

capacity of oil sump shall be 110% of the oil required for the system comprising Governor,

Guide vanes, servomotor, Pressure accumulator, MIV etc. An on line oil filtration unit shall

be provided for the whole system separately.

3.21 OIL PUMP MOTOR SET

Two triple screw pumps sump tank top mounted vertical type directly coupled to electric

motors of ample capacity to meet all the requirements of governing system shall be provided.

The pumps shall be provided with its own strainer, non-return valve safety valve, idler valve

and discharge isolating valve.

3.22 PRESSURE RECEIVER

It shall be of electrically welded steel plates. It shall have the capacity for closing & opening

operations of MIV, and Guide vanes. The receiver shall be complete with manually operated

air release valve, a fully protected oil level gauge with automatic valves for preventing air oil

loss in case of breakage of the glass. Separate independently changeover contacts to give

alarm for high/low oil level in the receiver shall be provided. A manually operated drain

valve and a pressure gauge shall be provided. The receiver shall have a manhole with door

for maintenance.

Set of pipes and valves for connecting the pressure receiver, pumping set, governor, guide

vane servomotor, MIV shall be supplied.

3.23 OIL LEAKAGE UNIT

The oil leakage unit is intended for the collection of oil leakages from the servomotor. In the

event of maintenance, it shall be used for draining the oil from servomotors, oil pipelines and

guide bearing. The oil shall be periodically pumped from this unit to the sump tank of the oil

pressure system. It shall consists of tank, pump motor set and level relay for controlling the

pump motor operation.

Alternatively Tenderer is free to offer his own design for operating mechanism for runner

vanes, guide vanes and BFV.

3.24 MAIN INLET VALVE

The main inlet valve shall be of conventional disc type butterfly valve of suitable diameter,

tested in works, designed to open under balanced condition and to close against full flow in

emergency. It shall be opened and closed by oil operated servomotor. However, in case of

emergency closing by dead weight shall be possible.



MAIN BODY

Main body shall be fabricated from steel plates in halves accurately bored out for the door &

trunnions and complete with gunmetal bushes bearings and cup seals for the trunnions and

stainless steel sealing ring for the main seal.

DOOR

Door shall be cast steel / fabricated steel with trunnion. The trunnion shall be lined with

stainless steel plates where they pass through.

SEALING DEVICE

Consisting of adequately reinforced rubber sealing ring fixed by rustless screw and sealing

against stainless steel ring in the main body.

DISMANTLING JOINT WITH DOWNSTREAM PIPE

It shall be of steel, of the telescopic type, situated on the down stream of valve. This would

facilitate dismantling of the valve during maintenance. The dismantling joint shall be suitably

designed either to transmit the hydraulic thrust in the penstock to down stream of valve or

may act as a dismantling cam expansion joint depending upon whether the thrust is required

to be transmitted down stream of valve or sustained on the upstream by some means.

LEVER

It shall be of cast / fabricated steel keyed to the trunnion and with gunmetal bush for the

servomotor connecting rod.

SERVOMOTOR

Servomotor shall be comprising of fabricated steel cylinder with covers, cast steel pistons,

stainless steel piston rod and complete with sealing gland, pipe connection, timing

diaphragms etc.

BYE-PASS VALVE AND PIPING

It shall comprise of hand operated sluice / wedge gate valve, bye pass valve, bye pass pipe

etc. The sluice/ wedge gate valve shall be provided on upstream of the bye pass valve as a

guard valve. The bye pass valve shall be oil operated or electrical actuator operated with limit

switches etc. for balancing pressure across the main inlet valve. The bye pass piping of

suitable length joining upstream to down stream of valve with necessary flanges, fasteners

and packing shall be provided. Stand by manual valve, operated manually shall also be

provided.



AIR VALVES

It shall be automatic operating type of valve to supply or release the air during draining off

and filling the spiral casing. It shall be mounted on down stream of valve.

UPSTREAM PIPE

It shall be of electrically welded mild steel with a flange for connecting to the B. F. V. on

upstream side and other side shall be prepared for welding to the penstock.

SET OF SUNDRY MATERIAL

These shall be consisting of sundry items such as foundation bolts, sole plates, lifting

brackets, jointing material etc.

3.25 DEWATERING AND DRAINAGE SYSTEM:

DEWATERING SYSTEM

One turbine dewatering system shall be provided for dewatering all the hydraulic Portion i.

e. from penstock gate to draft tube gate. The individual draft tube shall be connected to the

watering sump through pipe and isolating valve / from where water shall be pumped out

through common discharge header into tailrace. Two pump motor sets (Submersible type) of

adequate capacity shall be provided for dewatering all the hydraulic paths. The pump motor

shall be suitable for operation on 415 V +10%, volt, 3 phase, 50 Hz. Level electrode shall be

provided to start / stop the pumps automatically & to give alarm if water level rise beyond

pre set limit in sump The dewatering system shall be suitably designed & shall be complete

with adequate of isolating valve, non-return valve, pressure gauge, piping, fitting, support

etc. Motor starters, protective devices, indicating lamps etc shall be mounted on local control

panel.

DRAINAGE SYSTEM

Two drainage pumps ( one working & one standby ) of adequate capacity to remove

normal seepage & drainage water along with necessary piping, valves & fittings shall be

provided. The motors shall be of ample rating suitable for continuous duty and mounted at

the pit. The automatic control of the pump units shall be arranged through float switches to

start the pumps automatically when the water level in pit rises up to the pre-determined

level. The pump motors shall be suitable for operation on 415 + 10% volt, 3 phase, 50 Hz. The

arrangement of drainage & dewatering system shall be proposed by the Contractor.

3.26 COOLING WATER SYSTEM

The cooling water for generator & turbine bearing coolers shall be taken from upstream of

main inlet valve from penstock. The system consists of suitable size/ capacity of isolating

valves, duplex strainer, booster pump motor set, piping, fitting, supports, flow meters. The



duplex strainer shall be manually operated type fitted with pressure switch to give alarm in

case the pressure difference across it exceeds a preset value. Pressure gauges shall also be

provided to indicate the water pressure at its inlet & outlet.

Booster pump motor set, one number, is required to increases the pressure of water to desired

value for each turbine and generator. The motor shall be complete with starter, protective

device, indicating lamps, etc. One number motorized isolating valve shall be provided on

each suction line near generator barrel for automatic starting / stopping of cooling water.

The cooling water exhaust shall be discharged into the tailrace above high flood level.

3.27 CENTRALISED GREASE LUBRICATION SYSTEM

The centralized grease lubrication system shall be of adequate capacity to pressure the

turbine lubricating system periodically by timer as per requirement. The equipment

comprises of electric motor drivers grease starter, grease reservoir, pressure regulator, set of

solenoid valves ,grease dossers and piping etc One hand operated pump shall be supplied for

filling grease reservoir.

3.28 COMPRESSED AIR SYSTEM

One set of H.P. compressed air system shall be provided for complete power house for

intermittent supply of air to cater the needs of governor oil pressure for governing of turbine

& generator brakes comprises of the following .

a) Two Nos. of A.C. driven motor air cooled air compressors one acting as main and other

as a standby and each of adequate capacity to cater the above needs for complete power

house. The standby compressor shall start automatically on failure of the main

compressor.

The compressor motor shall be rated for 415 volt + 10%, 3 phase, 50 Hz and provided with

suitable starter, protective devices etc, on local motor control panel.

b) The air from individual compressor shall be passed through common air cooled after

cooler and accumulated in common H.P. air receiver fitted with pressure gauge, safety

valve & manual drain trap. For automatic starting/stopping of motor and very low air

pressure alarm, pressure switches shall be provided.

c) Piping, fitting, pipe supports, adequate numbers of isolating valve, non-return etc. shall

be provided.

OIL

The contractor shall supply all the oil required for the first filling Governor oil system and the

lubrication system of turbine. Sufficient quantities of grease and other lubricants required for

the first filling of the lubricating systems shall also be supplied by the contractor. The oil used

for the governor & oil pressure system shall be identical with that used for the lubrications of



the turbine guide bearing and also shall be identical with the oil used for the lubrication of

generator thrust & guide bearings. The contractor shall give his recommendation regarding

the type of oil.

3.29 SPECIAL TOOLS, SLINGS, CONSUMABLES

All special tools, slings, lifting devices, jacks, turn buckles, foundation plates / bolts etc.

required for erection of the equipments shall be listed & supplied. Welding electrodes as

required for site welding and paint for finishing coat shall be supplied by the supplier.

3.30 SPARES

The spare parts for the turbine and associated equipments considered necessary for five years

of operation of the generating unit shall be supplied by the supplier along with the first

turbine.

3.31 GENERATOR COOLING SYSTEM, BRAKES & PAINTING, CORROSION

PROTECTION AND COATING

3.31.1 COOLING SYSTEM

The generator shall be naturally air cooled. Fans shall be designed to give a smooth and quiet

flow of air in the stator and rotor. Bid shall indicate the various design features to control

temperature rise in the stator including the end windings, rotor, shaft and exciter.

3.31.2 BRAKES

Generator shall be provided with Hydraulic brakes which will operate automatically. The

generator brake system shall consist of suitable number of brake shoes. It is the responsibility

of the generator manufacturer to ascertain the type of system being proposed by the turbine

manufacturer. The brakes shall be capable to be applied at not more than 20% of maximum

speed. It shall be possible with the braking equipment to retard the unit, to standstill within

2 minutes from time when brake impulse is transmitted.

3.31.3 PAINTING, CORROSION PROTECTION AND COATING

For all structural steel and cast iron parts the following applies:

Surface Preparation: On all cast iron and structural steel parts the rust must be

removed by mechanical means (sandblasting) to obtain a bare surface according to

International Standard.

Prime Coat for all areas: 2 layers with "Friazinc R", dry thickness of each layer 40

microns.

Type A : Areas in contact with oil (if required): All those areas will receive three coats

with oil resistant paint, for example Keratol, which must be applied as finishing coat.



Type B : Areas in contact with air: All those areas still accessible after assembling on

site, receive two prime coats with different colors. The prime coat consists of a

preliminary final coat in blue for the generator casing and red for all the moveable

parts. The applicable RAL colours will be provided after placing of contract.

Areas in contact with concrete: Cast-in items do not receive any coating, but must be

free of rust and spunk.

Cast-in items exposed to air and water must be provided with a prime coat to a depth

of approximately 150 mm into the concrete.

Oil carrying pipelines (if required): They must be dismantled after assembling on site,

pickled in acid solution neutralized and oiled. Pipe prefabricated and pickled in the

factory then shipped to site with all holes and access points sealed, do not have to be

treated again at site but should be flushed out as part of the assembly procedures

All bare surfaces, which are not in contact with oil, shall be provided with a protection coat

(removable with water) after manufacturing. Parts located in inaccessible areas, which must

not be dismantled after workshop assembling must be protected as follows: -

The electrical equipment such as electric motors, limit switches, control panels etc. must

receive corrosion protection according to specifications for the worst atmosphere. The colour

coding will be determined by the Purchaser.

Any coated surface damaged after or during assembling must be reinstated. Internal and

external surfaces of the casing and all metal parts shall be painted with epoxy paint that will

resist corrosion due to ambient conditions. The color of external paint will be confirmed

during detailed design and must be of non-hazardous and non- toxic nature.

3.32 CONSTRUCTION

GENERATOR

Horizontal shaft synchronous alternator of capacity 2310 KVA at 0.866 p.f. 3.3 KV, 50Hz,

three phase suitable for coupling to above mentioned turbine with brushless excitation

system with Automatic voltage regulator etc. complete, with Generator auxiliaries

comprising S.S.G. unit, H.S. Lubrication system, brake/ jack system, Fly Wheel stator

encloser, railing & coverings, coolers, heaters, cables etc. complete.

3.32.1 STATOR

The stator frame shall be of fabricated steel construction. The frame shall be designed to

withstand bending stresses and deflections due to its self weight and weight of the complete

core to be supported by it. The stator core shall be built up of segmental punching of low

loss, non-oriented steel sheets and end plates. Each punching shall be carefully de-burred



and insulated on both sides with high quality varnish to reduce losses in the core. In addition

to above, stator frame shall withstand the stresses from other operating conditions stated in

this subsection.

The stator winding shall be of copper (99% purity) which can be of multi-turn or single turn

type and shall be insulated with Class F insulation and shall be so designed to suppress

harmonics to achieve a full sine wave. The stator winding shall be star connected with both

ends of conductors of each phase brought out of the stator. The outlets shall be enclosed and

the outlet box shall be adequate for connection of specified power cable.

For each generator, for stator winding (located between top and bottom coil sides)

symmetrically located embedded resistance temperature detectors shall be provided. The

connections on the resistor elements shall be well insulated and extended to a connection box

on the outside of stator frame.

3.32.2 ROTOR

The design and construction of salient pole rotor shall be in accordance with the best modern

practice. The factor of safety at maximum runaway speed based on yield point stress of

material shall be not less than 1.5.

The rotor bars shall be short-circuited with end rings by an appropriate method like

induction brazing method. The copper end rings of the rotor shall be well supported by steel

retaining rings to make the rotor sturdy to withstand runaway speeds and other operating

conditions specified under this specification. Field winding shall consist of fabricated field

coils or any other type with adequate provision for cooling purpose. The field poles shall be

provided with adequate damper windings to ensure stability under fault conditions and to

meet I22t value of 20.

3.32.3 TERMINAL BOX

The terminal box shall be located on either side of the generator-one for phase connection and

other for neutral connection. A separate terminal box for RTD’s and space heater terminals

shall be provided. The terminal box shall be suitable for taking 6.6 kV cable of adequate size

and specification.

3.32.4 PHASE MARKING

Appropriate phase marking as per IS: 325 shall be provided inside the terminal box. The

markings shall be indelible.

3.32.5 SHAFT AND COUPLING

The generator shaft shall be made of the best quality carbon steel forging properly heat-

treated. The shaft shall be of adequate size to operate at all speeds including maximum

runaway speed and shall be able to withstand short circuit stresses without any vibrations or



distortion. The generator shaft shall be accurately machined all over and polished where it

passes through the bearings and accessible points for alignment checks. Generator shaft shall

have suitable provision for coupling to turbine.

The main shaft shall have an integrally forged flange for connection to turbine shaft flange.

All coupling dimensions shall be agreed upon by the turbine and generator manufacturer and

shall essentially conform to IEEE 810 “IEEE standard for hydraulic turbine and generator

integrally forged shaft coupling and shaft run out tolerances” or an equivalent approved

standard.

The generator manufacturer shall be responsible for the alignment and balancing of the rotor

with the turbine shaft and runner after installation in accordance with the stipulations laid

down in NEMA publication LG3 latest edition.

3.32.6 BEARINGS

The generator bearings shall be preferably anti friction ball / roller bearings oil or grease

lubricated. In case pedestal type bearing are supplied these shall be pad type or sleeve type

with Babbitt metal lined with oil lubrication. These bearings shall be guaranteed for

minimum continuous working for 150,000 (one lakh fifty thousand) hours and shall be of

proven design and performance and shall require minimum maintenance. The detailed

drawings and dimensions shall be supplied by the bidder with the offer.

Bearings shall be adequately insulated to prevent any harmful circulating currents. The Drive

End bearing shall be of thrust cum journal bearing and Non Drive End bearing shall be

journal bearing. The thrust bearings shall be suitable to take axial thrusts in both the

directions. The bearings shall be designed to withstand operation of runaway speed for 15

minutes. Thermometers, grease-lubricating points, speed relays etc. as required shall be

provided.

Each of the bearings shall be provided with dial type thermometer and also provided with

two sets of contacts for annunciation and trip of the machine. The bearings may also be

provided with resistance elements. Wires shall be run from thermometer and resistor

element to the instruments and the junction box mounted on the outside of the stator frame.

3.32.7 FLYWHEEL (IF REQUIRED)

A separate flywheel of ample dimensions shall be supplied in case the required moment of

inertia for limiting the speed rise/runaway speed is not available from the generator rotor

exciter, etc. The flywheel shall be coupled to the generator directly and to the turbine (if

required)

3.32.8 VIBRATION



All rotating parts shall be designed to operate without undue vibration. The vibration level

of the machines shall be within the limits specified in IS 4729. The maximum vibration level

shall be 150 microns (peak-peak value). The balancing shall be done to a maximum extent at

the plant and shall be repeated for the entire unit before COD.

3.32.9 OIL & GREASE

The bidder shall indicate the lubrication requirement and give his recommendations with

detailed specifications regarding type of grease to be used and frequency of refilling required

for lubrication of generator bearings. The oil, if used for generator bearing lubrication shall

be, as far as possible, identical with that used for the turbine pressure oil system. The first

filling of oil with 10% extra quantity shall be supplied along with the generator.

3.33 SPEED RELAY, TOOTHED WHEEL & MECHANICAL OVERSPEED

A toothed wheel arrangement is to be mounted on the shaft of the generator and a photo

interceptive pick up has to be mounted on a bracket and connected to speed relay mounted

on turbine control panel through a special screened cable. Further, a mechanical over-speed

device shall also be provided to stop the unit during over-speed and this should directly act

on the oil pressure system to stop the machine.

3.34 EXCITATION SYSTEM

The excitation system shall be of Brushless type with digital automatic voltage regulator

(AVR) to maintain the output terminal voltage constant and reactive power within the

regulation limits. The excitation system offered shall be capable of joint control. The AVR

shall continuously sense the generator output terminal voltage and provide excitation voltage

to the field of the generator to limit the regulation within ± 1% over the entire range from no

load to full load.

It shall include excitation transformer connected directly to generator terminal (dry type),

thyristor cubicle, field breaker cubicle, flexible copper connections between field breaker and

slip rings etc. Inter connections between thyristor and field cubicles shall be in supplier scope.

The excitation system shall have redundancy facility.

The bid shall contain complete technical details of the equipment being offered for optimum

operation.

3.35 NEUTRAL GROUNDING SYSTEM (NGS)

All three phases from Generator terminal will be brought to Neutral Grounding Cubicle.

These three phases will be shorted in NG cubicle. Current transformers will be mounted on

neutral side before shorting of three phases. The neutral point of the star connected stator of

each generator shall be grounded through 3.3 KV/110 V/√3 single phase, dry type

distribution transformer with loading resistor of adequate rating connected across the



secondary winding. Suitable terminal arrangement with neutral isolating switch shall be

provided. The isolating switch shall be of manually operated type. The Generator terminal

CTs shall be mounted in this cubicle. All the above neutral grounding equipment will be

housed in a drip proof enclosure. The rating of the grounding transformer, secondary resistor

and isolating switch shall be indicated in the tender. Calculations for working out the ratings

shall be submitted by the successful bidder to the purchaser/consultant for their approval.

The following design parameter shall be considered

The transformer shall be of cast resin type

The insulation level shall be adequate for rated system voltage.

95% of stator winding are to be protected.

The load resistor shall be selected such that the total losses of the resistor are equivalent to

the generator/transformer capacitive reactive losses when phase/neutral voltage is

applied to the primary side of the transformer.

All the generator neutral earthing equipment including CT’s as shown in the Single Line

Diagram shall be installed in the sheet steel cubicle. The technical data of the equipment

such as ratio/accuracy/burden/knee voltage point shall be co-ordinated with the

protection and metering system.

The equipment shall be housed in a floor mounted cubicle, suitably compartmentalized with

steel frame and bolted panels. The cubicle is arranged and built to provide adequate natural

ventilation of the equipment. The cubicles shall be complete with base mounting

arrangement. The internal illumination for cubicles shall be provided with guarded lamps

with on/off switch. Copper conductors of appropriate size shall be used for connections in

the cubicles. The cubicle shall be drip proof. The three phase compartment shall be at the top

and shall be separated from the neutral grounding transformer and resistor.

3.35.1 3.3 kV CURRENT TRANSFORMER

The current transformers will be epoxy cast, dry type units conforming to IS: 2705. The

current transformers shall be designed to withstand the thermal and magnetic stresses from

the maximum short circuit current. The accuracy class shall be 1 for metering and Class 5 P 20

or Class PS (as applicable) for protection. The CT locations, rating, accuracy class shall be

suitable for adequate metering and protection.



CT- A

Core

No.

Transformation

Ratio/ Utilization

Acc.

Class/Burden

Knee Point

Voltage

(Volt)

Secondary

Resistance

(Ohm)

Magnetizing

Current @

Vk/2 (mA)

Core-I 600/1A, Gen. protection

5P 20/50VA NA NA NA

Core-II 600/1A, Metering CL 1/50VA NA NA NA

Core-III 600/1A,/Spare PS/NA >=300 <= 1.5 <=15

Core-600/1A, Gen. Diff. Protection

PS/NA >=300 <= 1.5 <=15

3.36 LAVT CUBICLE

One no LAVT panel for each generator shall be provided. The cubicles shall be of sheet steel,

suitably, compartmentalized with doors and shall be furnished complete with base mounting

arrangement, foundation bolts, etc. The internal illumination for cubicles shall be provided

with guarded lamps with on/off switch. Aluminum conductors of appropriate size shall be

used for bus bars and connections in the cubicles. The bus bar and main & connecting

conductors shall be suitably insulated to make them compatible with generator temperature

rise and insulation. The support insulators for the bus connection shall be provided as

necessary. GI earth bus of adequate cross-section will be provided in the cubicle. The cubicles

shall have rigid frames of rolled steel sections supported on a steel channel base. Welded

parts shall be carefully cleaned and phosphated after assembly. Panels shall be removable

single piece steel plates, with a minimum thickness of 11 gauge, bolted to the frame. No part

shall be subject to excessive heat rise and natural ventilation shall be supplied. Doors shall be

equipped with key operated locks. Clearances between live items and the mass shall provide

adequate insulation. Suitable tapping connection shall be provided for metering & protection

PT and AVR power & sensing PTs. Current transformers shall also be accommodated in

LAVT. The cables from stator shall be terminated in LAVT. Also, cables shall be emanating

from LAVT to the LV side of transformer.

3.36.1 POTENTIAL TRANSFORMERS

The potential transformers will be single phase, epoxy, cast, dry type 6.6/1.732kV/110 V

Twin core, 100 VA units. Potential Transformer will be protected on primary and secondary

side by current limiting fuses. The PT shall conform to IS: 3156 and shall have parameters as

indicated in legends sheet. One core suitable for protection and the other one for metering.



3.36.2 LIGHTNING ARRESTORS

The lightning arrestors shall be heavy duty, indoor station class and non-linear resistor

gapless types suitable for repeated operation to limit voltage surges on alternating current

power circuits and to interrupt power follow current. The arrestors shall conform to IS: 3070

(latest edition) part- I. The nominal discharge current of lightning arrestor shall not be less

than 30 KA.

3.36.3 SURGE CAPACITORS

The surge capacitors shall conform to the latest edition of IS: 2834 and shall be rated 0.25

Micro Farad. The capacitors shall be connected in parallel with lightning arrestors and shall

be provided with a built in discharge resistor. The capacitor shall be suitable for indoor

mounting.

3.36.4 CURRENT TRANSFORMER

The current transformers will be epoxy cast, dry type units conforming to IS: 2705. The

current transformers shall be designed to withstand the thermal and magnetic stresses from

the maximum short circuit current. The accuracy class shall be 1 for metering and Class 5 P 20

or Class PS (as applicable) for protection. The CT locations, rating, accuracy class shall be

suitable for adequate metering and protection. C.Ts will be used for neutral circuit.

CT- B

CoreNo.

Transformation

Ration/

Utilization

Acc.

Class/Burden

Knee Point

Voltage

(Volt)

Secondary

Resistance

(Ohm)

Magnetizing

Current @

Vk/2 (mA)

Core-I 600/1A,AVR 1/50VA NA NA NA

Core-II 600/1A, Bus-Bar

Protection PS/NA >= 300V <= 1.5 <= 15

Core-III

600/1A,

Generator Diff.

Protection

PS/NA >= 300V <= 1.5 <= 15

Core-IV Spare PS >= 300V <= 1.5 <= 15

3.37 SPARES

Spare parts of the generators considered for five (5) years of trouble free operation of the

units shall be supplied as per Schedule 1 of Schedule of Requirement Section-V.

3.38 TESTS

Each generator shall be tested in assembled condition as detailed below.



3.38.1 TESTS AT SUPPLIER'S WORKS (SHOP TESTS)

The generator shall be completely assembled at manufacturer's works and following type

tests as per IS: 4722- 1992 standards or equivalent International Standards are to be carried

out on first generator only. Test shall be carried out in presence of Purchaser/Consultant.

Measurement of winding Resistance.

Insulation resistance test (before and after the HV test)

High Voltage Test

Determination of generator characteristics

Measurement of open-circuit Characteristic.

Measurement of short-circuit Characteristic.

Temperature rise test by indirect method.

Measurement of shaft Voltage.

Dielectric strength test

Moment of inertia test

Occasional Excess Current Test; 150% of rated current at short circuit condition for 15 sec.

Phase Sequence Test.

Measurement of voltage waveform distortion factor at no-load.

Over speed test shall be done on 120% of rated speed for 2 min.

Efficiency test by summation of loss method

Line charging capacity

Temperature rise test

Type test on panels for IP: 55 protection as per IS:13947. After this test, insulation

resistance (2.5kVrms for 1 min) and functional test on control devices shall be conducted.

Additional tests as recommended by manufacturer, as mutually agreed between

Purchaser and supplier

3.38.2 ACCEPTANCE TESTS

Following acceptance tests shall be carried out on two generators in assembled condition after

shop tests:

Measurement of winding Resistance.

Insulation resistance test.

High Voltage Test

Measurement of open-circuit Characteristic.

Measurement of short-circuit Characteristic.

Measurement of shaft Voltage.

Dielectric strength test

Moment of Inertia test



Phase Sequence Test.

Additional tests as recommended by manufacturer, or as mutually agreed between

Purchaser/Consultant and Supplier

3.38.3 SITE TESTS

Prior to acceptance of the equipment, the supplier shall carry out a series of tests as detailed

below. The contractor shall provide duly calibrated test instruments and equipment including

any special test equipment that may be needed. The tests shall be conducted on each

generator as per IS, IEC or equivalent standards.

Mechanical run

Run away speed test

Measurement of winding insulation resistance (before and after HV tests )

High Voltage dielectric test

Measurement of shaft voltage

Phase sequence tests

Braking test for verifying braking time.

OCC/SCC tests

Measurement of winding resistance

Measurement of vibration & noise level

Synchronizing Test

Excitation system response test / check

Field acceptance and Efficiency test by summation of losses method or any equivalent as

per IEC(to be conducted on only one unit).

Load acceptance and rejection tests at selected load from "no load" to "full load".

Vibration measurement

Wave form analysis

Tests on excitation equipment

Operational tests on all generator auxiliary including calibration of related electrical

indicating , control and metering instruments.

Check for correctness of electrical wiring

Any additional tests as mutually agreed such as measurement of slip / power factor etc.

3.38.4 OUTPUT TESTS

Load test shall be carried out at site for seventy two hours to show rated output on each

generator before releasing for commercial operation.



3.39 TESTING EQUIPMENT

All testing equipment including HV test kit and vibration measurement equipment required

for testing of the generator at site shall be provided by the Supplier free of charge and taken

back after testing is completed.

The torque for onsite test must be measured as well. In the event repeated testing becomes

necessary, the entire expenditure on such repeat tests shall be borne by the Supplier.

3.40 CHARACTERISTIC CURVES

The generator characteristic values for determination of performance shall be arrived either

through circle diagram method or equivalent circuit method after conducting all required

tests on the generator even though they have not been specifically mentioned above.

After testing the machine, the equivalent circuit of the generator, phase diagram and the

performance characteristics like load versus efficiency; load versus power factor or load

versus magnetizing kVAR, kVA and kW output and load current shall be determined and

furnished to Purchaser/Consultant by the Supplier.

Tests on other equipment like auxiliaries, CTs, PTs, LAs shall comply with the routine tests

etc. as per relevant standards.

3.41 INDICATING INSTRUMENTS, CONTROLS AND SAFETY DEVICES

A list of indicating instruments, controls and safety devices are indicated in Schedule-l

enclosed with these specifications. The bidder shall also include those instruments, controls

and safety devices necessary for safe and efficient operation of unit even though not

specifically mentioned in the Schedule.

3.42 ERECTION, TESTING AND COMMISSIONING

The Supplier shall depute his experts to carryout erection, testing and commissioning of

generators and other associated and auxiliary equipment connected with the powerhouse

and duly hand over the same to the satisfaction of the Purchaser. This work shall be included

in the scope of contract and nothing extra shall be paid on this account. The Supplier shall

train the staff of the Purchaser on the job and instruct them during maintenance.

This covers AC generator complete with static excitation system, Automatic voltage

regulating equipment, neutral grounding and generator terminal equipments, including CTs,

PTs, surge protection equipment etc. and auxiliaries such as generator fire fighting system

equipments, lubrication system, oil, water and air piping with valves and fittings,

instrumentation controls and safety devices (as required), spares for 5 years operation of the

plant, special tools and testing devices. The scope of supply shall include all parts,

accessories, spares etc. which are essential for construction, operation and maintenance of the

complete generator even though these are not individually or specifically stated or



enumerated. Corresponding components of the generator and associated equipments and

the spares shall be of the same material, dimensions and finish and shall be interchangeable.

The position of electrical control shall be such that it is easy for operator handling the

equipments.

The generator manufacturer shall co-ordinate with the turbine supplier so that the turbine to

be coupled to the generator is matched in respect of speed , runaway speed, moment of

inertia, overload capacities, coupling and other relevant requirements.

THE RATING AND OTHER DETAILS OF THE GENERATOR ARE GIVEN BELOW:-

1) Rated continuous output - 2.0 MW + 10% continuous over load

2) Power factor - 0.866 under excited(lag)

3) Frequency - 50 Hz+3%, & -5%.

4) No. of phases - 3, neutral brought out.

5) Rated terminal voltage between phase - 3.3KV

6) Range of voltage variation between phase for rated - ± 10% output.

7) Range of frequency variation - + 3% & -5%.

8) Direction of rotation - Clockwise as seen from generator front side i.e.opp.to runner.

9) Short circuit ratio - Not less than 0.8.

10) Inertia constant - Not less than 1.0.

11) Stator winding connection - Star connection.

12) Speed - to be decided by the manufacturer

The generator will be coupled to the turbine. Generator shall be star connected and the main

and neutral leads shall be brought out of the stator frame for insertion of current transformers

for protection, metering and surge protection apparatus etc.

3.43 TYPE AND RATING

The generators shall be synchronous, & of the horizontal shaft water wheel driven alternating

current type. Generator neutral shall be grounded and the generator shall be designed to

safety withstand any mechanical/magnetic stresses resulting from either a three phase or a

single- phase short circuit fault.

The machine shall be designed to ensure continuous operation at 110% of rated output

without exceeding the max. temp. rise of stator & rotor coils specified in the specification.

The generator shall comply in all respect with the requirement of the latest issue of Indian

Standard IS : 4722 except where specified otherwise.

3.44 SPEED RISE AND RUNAWAY SPEED

The moment of inertia of the generator together with the moment of inertia of the turbine

shall be such that the maximum momentary speed rise shall not exceed 50% of the rated



speed. The generator manufacture shall co-ordinate with the turbine manufacturer to limit

the speed rise to this value.

The generator shall be designed and constructed so as to be capable of running for a period of

15 minutes at the maximum runaway speed. The runway speed test shall be considered

successful if, after undergoing the test, no injury is apparent. The runaway speed test may be

carried out at site for which suitable foundation based on the loading data to be given by the

Contractor.

3.45 INSULATION AND TEMPERATURE RISE

Insulation shall be provided as follows :

i) Stator Winding Material corresponding to Class –F

ii) Rotor winding Material Corresponding to Class – F

The output of generator should be 2310 KVA at 0.866 (lagging) p.f. with temperature rise of

the winding limited to class “B” insulation corresponding to ambient temperature of 450 C

but the actual insulation of winding should be confirming to Class-F.

3.46 TEMPERATURE RISE

The generator shall be capable of delivering its rated output continuously at any voltage

within the specified voltage limits, and frequency, within the temperature rise of any

part of the generator exceeding the values given in Indian Standard No. 4722 - 1968

(and / or latest amendment thereof) for Class “F" type insulation except where the

permissible temperature rise is otherwise modified in this section of the specification.

The temperature of the armature and field windings will be determined by resistance

method. This test shall be carried out at shop.

The generator shall be capable of operating continuously at the rated output of 2310 KVA

with 0.866 power factor under excited (lagging) in Zone-A, without exceeding the

temperature beyond 1200C corresponding to ambient temp. of 450C i.e. with in the operating

temperature limit for Class-B insulation. The generator should also be capable of operating

continuously in Zone-B as per IEC – 341 for worse combinations of terminal voltage and

frequency.

3.47 GENERATOR NEUTRAL EARTHING :

The neutral point of the generator shall be earthed independently through primary to single

phase transformer of suitable value and rating. A resistance of suitable value shall connected

across secondary. The ohmic value & kilowatt rating of the resistor and the KVA capacity &

voltage ratio of Neutral grounding transformer shall be such that the transient over voltage

on the stator winding during phase to ground fault on the generator shall be reduced to the

minimum value possible and any phenomenon such as Ferro-resonance is also avoided. The



ohmic value of the resistor shall preferably be such as to limit the fault current to a value

approximately equal to capacitive current to a ground during a single phase to ground fault

on the generator so as to minimize the transient over voltage on the stator windings. Suitable

arrangements for connection between stator neutral terminal & N.G. transformer is to be

provided by Contractor.

3.48 AUTOMATIC VOLTAGE REGFULATOR

1) Voltage regulator shall be AVR type. It shall be liberally designed so as to be as reliable

as possible and shall incorporate sufficient redundancy so that failure of any control

equipment will not cause mal operation of the system.

2) The voltage regulator should periodically reference values. Calculations should be

repeated at every short time intervals where by an apparently continues regulator output

characteristics is produced.

3) Calculations to be carried out in binary system. The analog measured values of generator

voltage and current as well as field current must be transformed in an analog/Digital

converter into binary signals. Form the calculated control signals; pulses should be

generated for firing the thyristor.

4) Various control functions like voltage regulation, limitations of field current, rotor stator

current slip stabilizing etc. shall be stored s programs to be executed in a cyclic pre-

programmed manner.

5) Control to maximum converter voltage shall be achieved in less than 10 milliseconds thus

ensuring fast reaction to network disturbances.

6) Internal conditions monitoring of devices with light emitting diode (LED) indication be

provided which means short failure detection times

7) Set values shall be digital, absolutely reproducible and not vulnerable to changes

ensuring long term stability.

8) Number of different units shall be small so that spare parts stock could be kept to a

minimum.

9) Low sensitivity to external electro-magnetic influences shall be ensured which means

high noise immunity.

10) Electrical control points shall be bare minimum to reduce potential trouble sources.

11) Comprehensive measuring and setting shall be possible which should enable direct

setting of characteristics values without the necessity of calibration instruments.

12) The l voltage Regulator shall perform following functions.

Regulation of generator voltage.

Limitation of field current.

Limitation of rotor angle.



Limitation of stator current.

Stabilization of power pulsations.

Stabilization of power pulsations.

Power factor control.

13) A local control, input and display unit shall be provided for communications with the

processing unit during operation. It should be possible, from this control unit, to call up

the stored parameters, measured values etc. and to change control parameters such as

limit values or characteristics values of the control alogorithms.

14) It should be exceptionally reliable with no changes in operating performances. If failure

should occur it should announce itself so that it can be removed fast.

15) Cross current compensated should be provided to prevent reactive current flow from one

unit to the other.

16) Active power restriction shall form a part to ensure prevention of stator core local

overheat, field and stator windings over heating

17) Frequency drop compensation shall be provided to ensure over excitation compensation

of transformer in the event of low frequency.

18) Automatic reactive power compensation or power factor regulation should be provided.

The power factor regulating range shall be manually adjustable from lagging power

factor 90% to leading power factor 90% at rated output and rated voltage.

19) Current regulating equipment :

The current regulating equipment shall be provided in order to approach the operating

power factors to unity when the generator current exceeds 105% of the rated current due

to a voltage drop during generating operation.

20) In case the load is rejected due to any external fault during generating operations at the

rated output, rated voltage and rated power factor, the voltage rise of the generator shall

be less than 20% with speed regulation of 35% without opening the field circuit breaker.

21) Emergency demagnetizing device.

Emergency demagnetizing device shall be provided so as to perform quick

demagnetization of generator in the event of electrical internal fault of the generator.

22) Two independent modes of operation are envisaged.

Automatic mode with automatic channel in service’

Emergency Manual mode with the held of manual channel.



Voltage adjusting device shall preferably, not be potentiometer but a solid state device for

example, push button controlled analog register etc.

In the automatic channel, the control shall be through A.V.R. should device to sensing signal

through voltage transformers and Current Transformers in the generator main terminal

circuit. This shall be compared with a highly stabilised auto reference value. Correction pulse

generated shall be fed to the gate of thyristors. Output of DVR should thus control the firing

angle of thyristors thereby adjusting the excitation current to the required level.

In the manual channel, the voltage variation and excitation current shall be changed

manually. While in auto mode also, the manual channel shall follow the auto channel so that

all resistances of manual channel are at the correct positions corresponding to those of auto

channel so that, if due to a minor fault, the channel changes to manual, the unit will not trip.

DVR shall have two auto channels i.e. one main. One standby together with one manual

channel only. Each channel shall be fully independent with separate pulse control unit. Pulse

amplifier and power supply units.

3.49 THYRISTOR CUBILCE:-

1) This cubile shall contain three phase thyristor bridges with its associated equipment. The

design should be modular in such a way that changing of a thyristor or part of a ridge

shall be easily possible, In case forced ventilation system is adopted, noise level outside

the panel shall be negligible.

2) Number of thyristor cubicles provided shall be such that even with failure of one thyristor

bridge, the generator should be able to supply rated output and with failure of two

bridges, should the generator trip.

3) All thyristors shall be fuse protected. Voltage safety factor for thyristor defined as the

ratio between the maximum operating voltage and the rated peak cut off voltage shall be

more than 2.5. Excitation response shall not be less than 4.0s.

4) Suitable protection shall be provided for thyristor to prevent voltage spikes form reaching

them and damaging them.

5) Over voltage protection to protect the thyristor bridges and the field circuit shall be

provided.

3.50 SWITCHGEAR EXCITATION CUBICLE

This cubicle shall contain all switchgear equipment necessary for the operation of excitation.

Field breaker and all equipment necessary for repaid supression of generator - motor field

circuit shall be provided. The principle of suppression of field shall be the reversing of

rectifier operation into an AC converter operation and shunting the generator - motor field



terminals by a discharge resister. Over voltage protection devices, start up excitation devices,

auxiliary relays and contractors be provided.

All In feeds from station battery shall be taken through D.C./D.C. converters, Redundancy

shall be bultt In, In modules.

3.51 EXCITATION TRANSFORMERS

1) Three phase, dry type, Excitation Transformers shall be of indoor type cast resin or

equivalent dry insulated for direct connection to the bus ducts and cable connection tot he

thyristor cubicle. Transformers shall conform to IEC 726.

2) They shall be totally moist proof.

3) They must be free partial discharge upto 150% of the rated high voltage.

4) They have to be resistant against sudden temperature contain any PVC material.

5) The cores shall be built up of high grade oriented crystal magnetic steel sheets, insulted

on both sides.

6) The cores shall be compressed sufficiently to avoid any undue noise generation and

vibration.

7) All metal parts shall be amply protected against corrosion.

8) Coil casting or impregnating process must be conducted under vacuum and pressure.

9) High voltage and low voltage windings shall be separated by a high grade insulating

material cylinder.

10) Adequate consideration shall be given to thermal coil dilation.

11) Transformers must be able to withstand a short circuit on their low voltage terminals

without suffering any damage. The time for which the transformer should withstand such

short circuit should not be less than the longest fault clearing time for generator.

12) Cooling system of the transformers shall be as far as possible natural or shall occupy

minimum space available on the floor.

13) Suitable built - in over heating protection device shall be provided.

14) Transformers shall be Impulse voltage tested according to IEC.

15) Short circuit Impedance shall be according to choice of design for excitation system.

16) Total losses at rated load should be minimum.

Manufacturer is free to suggest any other alternative viz, brushless system or any other

modern practice.



Manufacturer is free to suggest any other alternative of main turbine M/C & generator with

it’s auxiliaries without changing the Installed Capacity, Generated units, Head range &

Discharge range provided in the Tender Document.

SUPPLY OF ACCESSORIES FOR MAINTENANCE AS GIVEN BELOW.

Schedule –3 Mandatory Spares

Sr. No. Item of Spare Qty. Remarks

A. TURBINE 1. Spare Runner 2 Nos. 2. Shaft seal packing 2 Sets 3. Shaft Sleeves 1 Set 4. Lybrinth rings 1 Sets 5. Packing and sealings, all type and sizes 1Sets 6. Bushes / bearing for regulating

mechanism 1 Set

7. GOVERNING EQUIPMENT a) Oil pump for pressure oil supply 1 Set b) Seals/ Packings (all type) 1 Set c) Twin filters for oil 1 Set d) Solenoids Coils 1 Set e) Level Switches 1 Set f) Pressure Switches 1 Set g) Pump unloader valve 1 Set h) Safety relief valve 1 Set 8. IINSTRUMENTS AND SAFETY DEVICES a) Resistance type temp. detectors (RTD’s) 2 Nos. b) Level Switches 1 Set c) Dial type thermometers 1 Set d) Coil sp. Contracts/ Springs for auxiliary

relays, solenoids and switches etc. 1 Set

B. GENERATOR a) Stator winding complete with insulation

materials 1/3 Sets

b) Field Coils 2 Nos. (One of each type)

c) Brake liners 4 Sets d) Bearing liners 2 Sets e) RTD’s 1 No. of each type f) Dial Thermometers 2 Nos. g) Contact springs and coils for each type of

relay contractor, breaker and auxiliary switch

1 Set

C. GENERATOR TRANSFORMER a) HV Bushings 1 Nos. b) Neutral Bushings 1 Nos. c) LV Bushings 1 Nos. d) Gaskets 1 Nos.



e) Magnetic oil level gauge 2 Nos. f) Valves (1 each type) 1 No. D. SWITCHYARD a) Post Insulator 1 Set b) Breaker Closing and Trip Coils 1 Set E. CONTROL, PROTECTION &

METERING PANELS

a) Various type of meters 1 Set 1 No. – DMM

b) Bulbs / Fuses 1 Set 10% of total population

c) Lockout Relay (Master trip relay) 1 Set 1 No. d) Cards / Modules for Electronic Panels

--

N.A.

e) Selector switch 1 Set 1 No.

F. OTHER AUXILIARIES a) Spares for Pumps As required Seal- 1 set b) Piston Rings for servomotor cylinders 1 Set

Note:

The above list is min. mandatory requirement. Bidder may quote for any additional spares that

he considered are necessary.

The make of Item/Equipment are given above should give name of manufacturer name like

repotted make is not acceptable.



SECTION – III - B

3.3 KV SWITCHGEAR

2.0 3.3 KV draw out type Switchgear suitable for computerized control system consisting of as per SLD. suitable for computerized control system

2.1 3.3 KV VCB Circuit breaker cubicle 2 No. 3.3 KV cubicle for P.T. WITH Draw out Type P.T. 2 Core 3.3 KV/√3,110 V/√3,110 V/√3 , ht FUSE etc.

1 No.

3.3 KV CT having suitable current ratio with 4 core for protection & metering etc. 1

2 Sets 1 Sets

Mandatory Spares & Tools, Tackle etc. 1 Set

2.2 3.3 KV neutral grounding transformer(NGT) cubicle with isolator , 3.3 KV CT having suitable current ratio with 4 core for protection & metering etc.

1 No.

Mandatory Spares & Tools, Tackle etc. 1 Set 2.3 3.3 KV LAVT cubicle with isolator , bus LA and capacitor

3.3 KV CT having suitable current ratio with 4 core for protection & metering etc.

1 No.

3.1 3.3 KV SWITCHGEAR EQUIPMENTS

The protective system offered shall be as simple and economical as possible, consistent with

the highest degree of reliability. Besides Simplicity, these should posses both the qualities of

discrimination and stability where by it enables to isolate only the faulty circuit or apparatus,

leaving all healthy circuits intact and to operate on only under these conditions, that call for

its operation and to remain either passive of biased against operation under all other

conditions. They must also be immune from incorrect operation as a result of transient

phenomenon such as it may arise during disturbances elsewhere on the system. It is desired

that operation on all faults be as fast as possible in order to minimize fault duration and to

maintain synchronous stability.

All the protective relays covered by these specifications shall be of fully static design. The

static relays shall conform to IEC: 255 or equivalent standard.

All the relays and switch board instruments shall comply fully with the requirements of I.S.

3231 and I.S. 1248 or other equivalent national standards. Relays and instruments shall be

back connected and shall have 'Tropical' finish and be housed in dust and vermin tight flush

mounting cases. All relays shall be provided in draw - out cases, so as to facilitate testing,

commissioning and maintenance. Necessary test plug shall be included. Sufficient number

of contacts for alarm, indication of annunciation purpose shall be provided some ( about 20%)

spare contacts may also be provided in auxiliary relays so as to permit modification of

schemes at later date, if necessary, common tripping relays for similar functioning shall be

provided with lockout facilities. The necessary number of fast acting auxiliary relays for the



various annunciation / tripping functions shall be included in the scope of supply. All these

relays shall have electrically separate contacts for trip and alarm purpose and externally hand

reset type of flag indications. They should preferably be housed in draw - out type of cases

with tropical finish.

All protection schemes shall be tested for satisfactory working at the manufacturer’s works

prior to dispatch and relevant test certificates furnished to the purchaser.

3.2 CIRCUIT BREAKERS

Draw out type fast acting vaccum circuit breakers fully equipped and suitable for

synchronizing of generating units and for frequent operational cycles, with service, Test,

Isolated and maintenance positions shall be supplied.

3.3 CURRENT TRANSFORMER

All CTs shall be as specified in schedule of equipment and they will have polarity marks. The

Secondary terminals of CTs of all the three phases shall be terminated on a common terminal

board.

3.4 POTENTIAL TRANSFORMER

The PT’s shall be single phase, epoxy cast, resin, dry type and suitable for draw out

arrangement. Rated voltage, frequency, insulation etc. shall be as specified in schedule of

equipment. PT’s shall be protected by fuses of suitable rating. PT and fuse mountings shall be

housed in a draw out type compartment with primary and secondary interconnecting

switches.

3.5 CUBICLE

The cubicles from inside and outside shall be painted with seamen’s gray to shade All The

painting shall be complete at the suppliers work and sufficient quantity of paint shall be

supplied ( about 20 %) for touch up works at site after erection.

3.6 BUSBAR CONDUCTOR

The bus-bar conductor shall be of high conductivity copper, The cross sectional area shall be

adequate for normal rated current as well as short time current. Adjacent joints of the bus

conductor shall preferably be bolted providing an efficient, electrically continuous and

mechanically strong connection. All nuts, bolts, washers, etc. used for making connection

shall be of antimagnetic material and shall have high corrosion resistance.

3.7 BUS ENCLOSURE

The segregated phase bus duct shall enclose the bus conductor supported and mounted on

suitably spaced insulators separated in air space from adjacent phase by means of suitable

phase segregating fiber barrier plates. The bus bar enclosure shall be fabricated from



aluminum with rectangular cross section and shall also be suitable for indoor installation. The

enclosure shall be dust, moisture, vermin and water proof.

a) Bus Duct Constructions

The bus duct shall be made of type as stated above. The bus duct length is required to the

divided into different sections. Further the joints of enclosure shall be so staggered with

respect to the joint of bus bars that the erection can be carried at site easily.

b) Breather

Suitable and adequate No. of breathers or any other suitable arrangement shall be provided

to avoid ingress of moisture into the bus duct.

c) Inspection Openings

Inspection openings of adequate size shall be provided along the bus run near the insulator

locations to facilitate the inspection / replacement of insulator as also at the other location

where necessary, such as seal of bushings etc. with bolt type covers & gaskets.

3.8 BUS SUPPORT INSULATORS

Each phase bus bar shall be mounted and supported inside the bus duct enclosure on solid

case indoor type porcelain insulators. The insulators shall have adequate electrical and

mechanical strength to with stand stresses incidental to short circuit.

3.9 TERMINATION OF ENCLOSURE

The enclosure shall have a neoprene rubber bellow where it is terminated on to the generator

barrel and cubicles. The enclosure shall have a split cover when it is terminated on to the

cubicles to provide adequate tolerance for alignment.

3.10 GASKETS

Every joint on the bus duct assembly shall made in variably by using gaskets. The gasket

material and thickness shall be so selected as to satisfy the operating conditions imposed by

temperature, weathering, durability etc.

3.11 SUPPORTING STRUCTURE

The bus duct shall be supported on hot dip galvanized steel structure fabricated from the

standard section.

3.12 TEST BLOCKS

Test blocks shall be provided on switch boards where test facilities are required but not

provided in case of draw - out type meters or relays. The test blocks shall be of the block

connected switch semi-flush mounted switch board type with removable covers. All test

blocks shall be provided with suitable circuit identification. The case shall be dust tight.

These blocks shall be rated not less than 250 V. at 10 amps. and shall be capable of with



standing a dielectric test of 1500 V. 50 Hz for one minute All test blocks shall be arranged to

isolate completely the instruments or relays from the instrument transformers and other

external circuit so that no other device will be affected and provide means for testing either

from an external source of energy or from the instrument transformers by means of multiple

test plugs. The test blocks & plugs shall be arranged so that the C.T.secondary circuits cannot

be open circuited in any position while the test plugs are being inserted or removed.

3.13 LINE END CUBICLE AND PHASE CONNECTION

The connection between the generator phase terminals and the main bus shall be made of

flexible, copper strips. Connection from generator phase terminals shall be brought to seal off

bushings mounted on wall frame assembly where the segregated phase bus duct housing the

three phases shall be laid out to line end cubicle. In the run of bus duct, C.Ts. with bus bar

connections and C.T. terminal boards shall have mounting compartments common for three

phase complete be provided. The line end cubicle shall consist of one No. LAVT cubicle

housing potential transformer, surge absorber, fuses, miniature circuit breakers, isolating

links etc. The capacitors and lightening arrester which make up the surge protective

equipment shall be mounted in separate compartment attached to the potential compartment.

Generator transformer connections shall be achieved by XLPE cables. Terminals shall be

accordingly suitable.

3.14 NEUTRAL END CUBICLE AND NEUTRAL CONNECTION

Similar to line end phase connections, the phase connections from the generator neutral

terminal on generator frame to the seal off bushings on wall frame assembly shall be made of

flexible copper strip. A neutral terminal box housing protection and metering C.T.s, A set of

bus bar shorting arrangement, dry type single phase transformer of appropriate capacity,

loading resister of ample capacity connected across the secondary winding of above

transformer, isolating links, grounding strips, etc. shall be formed immediately at the location

where the generator neutral terminals with bus bar are brought out of the wall frame

assembly outside generator barrel.

3.15 SPARES

The spares for the generator and associated equipment considered necessary for five years of

normal operations of the generating unit shall be supplied, by the supplier along with the

equipment.



SECTION NO – III - C

POWER TRANSFORMERS.

TECHNICAL SPECIFICATIONS.

2.5 MVA, 33 / 3.3 kV, 3 phase, 50 Hz, power transformer for JAMBRE HEP.

3.1 SCOPE OF WORK

The scope of work includes design, construction, manufacture, assembly testing at

manufacture’s works before dispatch, delivery to project site, erection at site, testing, no load

testing, on load testing and performance guarantee testing of all filled transformer including

with OLTC on HV side of range + 3% to - % in 4 equal steps.

3.2 TYPE AND RATING

The details of the types and ratings of the transformers to be supplied shall be as under. Each

transformers shall have a continuous rating at rated voltage and frequency without exceeding

the temperature rise limits as specified in IS 2026. The transformers shall safely withstand the

over-voltages as specified.

Sr. No.

Description Unit Particulars

1 Quantity No. 1

2 No load voltage HV LV

KV KV

33 3.3

3 Highest system voltage HV LV

KV KV

36 7.5 ll-

4 Rated Frequency Hz 50 + 3%-5%

5 Rated capacity MVA 3

6 Type of cooling -- ONAN

7 Type -- 3 Ph, Outdoor, Core type, oil immersed

8 Vector group -- YnD 11

9 Impedance % 10

10 Tolerance on impedance % + 10

11 System short circuit level for design HV LV

MVA MVA

1000 500

12 Power frequency withstand voltage HV LV

KV rms KV rms

70 20

13 Basic insulation level HV LV

KV Peak KV Peak

170 KV peak 70 KV peak ll-

14 Type of transformer earthing HV LV

Natural effectively earthed Delta connected primary winding will be connected to generator whose



neutral is earthed through grounding transformer.

16 Maximum flux density Tesla 1.9

17 Permissible temperature rise over maximum ambient of 500C Winding Oil

0C 0C

55 50

18 HV end connections XLPE cables BOX

19 LV and connections XLPE cables BOX

20 Creepage distance of bushing HV LV

.mm .mm

900 120

21 Minimum clearance in air –HV Ph-ph Ph-E

.mm .mm

350 320

22 Minimum clearances in air – LV Ph-ph Ph-E

.mm .mm

90 ll- 70 ll-

23 Neutral CT on HV side To be provided

24 Type of tap changer (CLTC/OFTC)

OLTC

25 Tap range and step +5 to –5%, in steps of 2.5%

26 Type of HV terminal HV porcelain bushing with plain

shades as per IS 3347

27 Type of mounting On wheel, on rail fixed on Plinth

28 Over voltage operation capacity and duration

% Volt. Sec.

125% of rated voltage for 60 sec., and 140% rated voltage for 5 sec.

29 Winding insulation type HV LV

Full Full

30 System short circuit level and duration for which transformer shall be capable withstand the thermal and dynamic stresses.

KA rms/Sec.

40 KA/2 Sec.

31 Current density for HV and LV Amp./Sq.mm.

Not exceeding 3 Amp./Sq.mm.

32 Noise level at rated voltage and frequency

D.B. As per NEMA Standard

33 Transformer suitable for satisfactory operation for continuous rating as under the following conditions. 1. Max. ambient temp. (in shed) 2. Min. ambient temp. 3. Max. yearly average temp. 4. Relative humidity in rainy season 5. Max. annual rainfall 6. Max. wind pressure 7. Altitude above mean sea level

0C 0C 0C % mm

Kg/m2

Mtr. Above MSL.

45 5 34 100 2000 150 583



3.3 SUPPLY OF ACCESSORIES FOR MAINTENANCE AS GIVEN BELOW .

Sr. No. Description Qty.

1 Complete of gaskets 1 Set

2 HV kV bushing 1 No.

3 LV kV bushing 1 No.

4 Neutral bushing with CT 1 No.

5 Dial type thermometer 1 No.

6 Complete set of winding temperature indicating equipment 1 Set

7 Magnetic oil level gauge 1 No.

8 Explosion vent diaphragms 2 Nos.

9 Silica gel breather 1 No.

10 One valve of each type 1 Set

11 Buchholz relay 1 No.

12 Special tools 1 Set

13 Set of contacts for tap changing gears 1 Set

3.4 ERECTION AND COMMISSIONNG SEQUENCE

1. Erection at site.

2. Pre-commissioning at site.

3. No load testing.

4. Load testing and measurement of following guaranteed parameters

a) No load losses

b) Load losses

c) Measurement of resistance

d) Measurement of impedance

e) Oil and winding temperature rise

5. Performance as specified during which temperature rise will be monitored.

3.5 REJECTION

The PURCHASER may reject the transformer if during test or service any of the following

conditions arise:

1. No load loss exceeds the guaranteed value by 10% or more.

2. Load loss exceeds the guaranteed value by 10% or more.

3. Oil or winding temperature rise exceeds the specified value by 50C.

4. Transformer is proved to have been manufactured not in accordance with the agreed

specifications.



5. The PURCHASER reserves the right to retain the rejected transformer and take it into

service until the tenderer replaces, at no extra cost to the PURCHASER, the defective

transformer by a new transformer.

6. Alternatively, the tenderer shall repair or replace the transformer within a reasonable

period to the Purchaser’s satisfaction at no extra cost to the PURCHASER.

3.6 GENERAL CONSTRUCTIONAL FEATURES

1. The transformer and accessories shall be designed to facilitate easy operation, inspection,

maintenance and repairs. Transformer shall also be designed to ensure satisfactory

operation under sudden variations of load and voltage, which may be met with under

working conditions on the system, including those due to short circuit.

2. The design shall incorporate every reasonable precaution and provision for the safety of

all those concerned in the operation and maintenance of the equipment keeping in view

the requirements of Indian Electricity Rules.

3. All material used shall be of the best quality and class most suitable for working under

conditions specified and shall withstand the variations of temperature and atmospheric

conditions arising under working conditions without undue distortion or deterioration of

the setting up of in due stresses in any part and also without affecting the strength and

suitability of the various parts of the work which they are liable to perform.

4. Corresponding parts liable to replacement shall be interchangeable.

5. Cost iron shall not be used for chambers of oil filled apparatus or any part of the

equipment, which is in tension or subject to impact stresses. All outdoor equipment,

including bushing insulator with their mountings shall be designed so as to avoid pocket

in which water can collect.

6. Facility shall be provided for easy lubrication of all bearings and mechanisms.

7. All mechanism shall, where necessary, be constructed of stainless steel, brass or gunmetal

to prevent sticking due to rust or corrosion.

8. All taper pins used in any mechanism shall be of the split type complying with IS 2393.

9. Steel bolts and nuts exposed to atmosphere shall be galvanized.

3.7 GALVANISING

i) Galvanizing where specified shall be done by hot dip galvanizing process or by Electro-

galvanizing process for all parts other than steel wires. The thickness of zinc coating shall

be equivalent to not less than 610 gm of zinc per square meter of surface. The zinc coating

shall be smooth, clean and of uniform thickness and free from defects. The quality of

galvanizing will be established by tests as per IS 2633.



ii) All drilling, punching, cutting, bending and welding of parts shall be completed and all

burns shall be removed before the galvanizing process is applied.

iii) Galvanizing of wires shall be applied by the hot dipped process and shall meet the

requirements of relevant Indian Standard. The zinc coating shall be smooth, clean and of

uniform thickness and free from defects.

iv) Surfaces, which are in contact with oil shall not be galvanised or cadmium plated.

3.8 LABELS

i) Labels shall be provided for all apparatus such as relays, switches, fuses, contained in any

cubicle or marshalling box.

ii) Descriptive labels for mounting inside marshalling box shall be of material that will

ensure performance of the lettering. A matter satin finish shall be provided to avoid

dazzle from reflected light. Labels mounted on dark surfaces shall have white lettering on

a black background Danger notices shall have red lettering on a white background.

iii) All plates shall be of incredible material.

iv) Labels shall be attached with brass screws or with steel screws which have received rust

preventive treatment.

3.9 BOLTS AND NUTS

i) Steel bolts and nuts exposed to atmosphere with suitable finishes shall be used like

cadmium plated or zinc plated passivity shall be used for diameters above 6 mm.

ii) All nuts, bolts and pins shall be locked in position with the exception of those external to

the transformer.

iii) If bolts and nuts are placed so that they are in accessible by means of ordinary spanners,

suitable special spanners shall be provided by the contractor. All bolts, nuts and washers

in contact with non-ferrous parts which carry current, shall be of phosphor bronze, where

the transfer of current is though the bolts.

3.10 CLEANING AND PAINTING

i) Before painting or filling with oil or compound, all ungalvanized parts shall be

completely clean and free from rust, scale and grease and all external surface cavities on

castings shall be filled by metal deposition

ii) The interior of the transformer tanks, other oil shall be cleaned of all scale and rust by

sandblasting or other approved method. These surfaces shall be painted with coats of

insulating and hot oil resisting varnish or enamel.



iii) Expect for nuts, bolts and washers, which may have to be removed for maintenance

purpose, all external surfaces shall receive a minimum of three coats of paint.

iv) The primary coat of zinc chrome shall be applied immediately after cleaning. The second

coat shall be of an oil and weather nature and of a shade of colour easily distinguishable

from the primary, and final coats shall be applied after the primary coat has been touched

up where necessary. The final coat shall be of glossy oil and whether resisting non fading

paint of shade No.631 of IS 5, primer paint shall be readymade zinc chrome as per IS 104,

intermediate and final coats of a paint shall be as per IS 2932. The paint shall be suitable to

withstand tropical heat and extreme of whether. The paint shall not scale off or crinkle or

be removed by abrasion due to normal handing.

v) Nuts, bolts and washers which may have to be removed for maintenance purposes shall

receive minimum of one coat of paint after erection.

vi) All interior surface of mechanism chambers and marshalling boxes except those which

have received anticorrosion treatment shall receive three coats of paint applied to the

thoroughly cleaned metal surface. The final coat be of a light coloured anti-condensation

mixture.

vii) Any damage to paint work, incurred during transport and erection shall be made good by

the contractor by thoroughly cleaning the damaged portion and applying the full number

of coats of paint that had been applied before the damage was caused. One cost of

additional paint shall be given at site after erection testing and commissioning.

3.11 OIL The transformers and all associated oil filled equipments shall be supplied along with the first

filling of oil and 10% excess quantity of oil for each transformer in non-returnable steel

drums. The filling of the transformer oil shall be done under vacuum. Oil shall be as specified

in IS 335, it shall be free from moisture and have uniform quality throughout and must be

from one lot including spare oil also.

3.12 REVENTION OF ACIDITY The design and all materials and process used in the construction of the transformers shall

such as to reduce to a minimum the risk of the development of acidity in the oil. Special

measure, such as nitrogen selling or the use of inhibited oil shall not be resorted to.

3.13 ELECTRICAL CHARACTERSITICS AND PERFORMANCE

3.13.1 TYPE OF TRANSFORMERS AND OPERATING CONDITIONS

i) Transformers shall be oil immersed and may be core type suitable for outdoor

installation. Transformers shall be provided with conservator vessels.

The type as cooling shall be “ONAN” type.



ii) Transformers shall be capable of remaining in operation at full load for continuous

operation without winding hot spot temperature exceeding 1150C. The Contractor shall

give the information regarding the sustained load which can be carried with failure of

cooling system.

3.13.2 CONTINEOUS MAXIMUM RATINGS AND OVERLOADS

i) The transformer shall meet the temperature rise limit specified in IS 2026 on all tapings on

which the rated current is not more than 95% of the maximum rated current on the lowest

voltage tapping. On the other tapping they shall operated continuously without injurious

heating. Loading of transformer shall be in accordance with IS 6600 “guide for loading of

all immersed transformer”.

ii) The transformer shall operate without danger on any particular tapping at the rated KVA

provided that the voltage does not very by more than + -10% of the voltage

corresponding to the tapping.

iii) The transformer shall operate safely at rated output on any tap of the tapping range

specified. Transformer shall be capable of continuous operation at rated load upto 47.5Hz

frequency without exceeding permissible temperature rise.

3.13.3 ELECTRICAL CONNECTION

Transformers shall be connected in accordance with the IS vector symbol YnD 11. High

voltage side as star.

3.13.4 DUTY UNDER FAULT CONDITIONS

i) All transformers shall be capable of withstanding according to IS 2026 without damage

due to any external short circuit between phase, phase to earth, symmetrical /

asymmetrical or any other severity.

ii) Transformers shall under exceptional circumstances due to sudden disconnection of the

load be capable operating at a voltage approximately of 30% above normal rated voltage

for a period of not exceeding one minute and 40% above normal for a period of 5 seconds.

3.13.5 PENALTY FOR EXCESS LOSSES:

The measured losses shall be completed with the guaranteed losses stated in the tender. The

transformer will be accepted only when the measured losses are within permissible limits of

the tolerance (As per IS : 2026 (Part I) 1977 with upto date amendment if any) over the

guaranteed figure stated in the tender subject to the following conditions.

For the excess losses with the range of permissible limit, the price of transformers shall be

reduced at the rate Rs. 120000/= per kW for difference in losses including both no load and

load losses. Cost of losses shall be taken to determine the contract price. If the measured



losses exceeds, the guaranteed loss plus the permissible tolerance limits as per IS : 2026 (Part :

1) then it will be at the desecration of the Client to either accept the transformer or reject the

transformer, in case the transformer is accepted the rates of penalty shall be double than those

stated above .

3.13.6 REGULATION AND IMPEDANCE

i) The value of impedance voltage for the transformer at rated current shall be of the order

of 10%.

ii) The value of impedance on any other lapping shall be generally subject, to the approval of

the purchaser. Impedance values on all other tapping shall be stated in the tender.

3.13.7 VIBRATION AND NOISE

Every care shall be taken to ensure that the design manufacture of transformer and auxiliary plant

shall be such that the noise level shall not be more than 5 db above the NEMA standard

publication TR-1.

3.13.8 SUPPRESSION OF HARMONICS

The transformers shall be changed with particular attention to be Suppression of harmonic

voltage, specially the third and fifth, so as to eliminate waveform distortion and any

possibility of high frequency disturbances, inductive effects or of circulating currents between

the neutral points at different transforming stations reaching such a magnitude as to cause

interference with communication circuits.

3.14 CORES

The cores shall be constructed from high grade cold rolled non-aging oriented silicon steel

lamination of low hysterics/loss and high permeability. The design of the magnetic circuit

and the Mechanical constructions of the core assembly of the transformer shall be such as to

avoid vibrations of transformers when it is loaded.

3.14.1 MAGNETIC CIRCUIT

i) The design of the magnetic circuit shall be such as to avoid static discharges, development

of short circuit paths within itself or to the earthed clamping structure and the production

of flux components at right angles to the plane of the laminations which may cause local

heating.

ii) Every care shall be exercised in the selection, treatment and handling of core steel to

ensure that as for as is practicable, the laminations are flat and the finally assembled core

is free from distortion.

iii) Each lamination shall be insulated with a material that will not deteriorate due to

pressure and action of hot oil. Insulating material for core laminations shall not



disintegrate due to core vibrations and also due to presence of moisture in a humid and

selling atmosphere, while the material is in transit from tender’s works to the work spot at

site. Paper insulation shall not be used.

iv) Oil ducts shall be provided where necessary to ensure adequate cooling. The winding

structure and major insulation shall not obstruct the free flow of oil through such ducts.

Where the magnetic circuit is divided into pockets by cooling ducts parallel to the planes

of the laminations or by insulating material above 0.25 mm thick. Tinned copper strip

bridging piece shall be inserted to maintain electrical continuity between pockets.

v) The frame work clamping arrangements shall be earthed. Adequate lifting lugs shall be

provided to enable core and winding to be lifted.

vi) The insulation structure for the core to bolts and core to clamp plates shall be such as to

withstand a voltage of 2000 V, 50 cycles AC for one minute.

vii) The magnetic inductance with normal voltage and frequency shall be according to the

latest design practice for the type of steel laminations used and shall be mentioned in the

tender.

The tender shall state the flux density and magnetizing current that would be obtained when working

at normal and 110% normal voltage. The basic volt-amperes required for 110 percent of

maximum flux density and for maximum working flux density at rated voltages shall be

stated in the tender. Contractor shall also state the means adopted in the designs of core for

restricting volt amperes. Turns corresponding to110 percent of flux density on magnetization

curve to a safe value. Contract shall provided over fluxing equipment or it necessary state or

the reasons for not necessity.

3.14.2 MECHANICAL CONSTRUCTION OF CORES

i) All parts of the cores shall be of robust design, capable of withstanding any shock to

which they may be subjected during lifting, transport, installation and service.

ii) All steel sections used for supporting the core shall be thoroughly shot blasted after

cutting, drilling and welding. Any non-magnetic of high resistance alloy shall be of

established quality.

iii) Adequate provision shall be made to prevent movement of the core and winding relative

to the tank during transport and installation while in service.

iv) The supporting frame work of the cores, shall be as designed, as to avoid the presence of

packets, which would prevent complete emptying of the tanks through the drain valves

or cause trapping of air during filling.



v) The assembled cores shall be secured by clamps on the limbs and the yoke, so as to

prevent undue noise or vibration against mechanical displacement. The core legs shall be

securely held by means of through bolts adequately insulated. The class and type of

insulation used on the core bolts and under the nuts and side plates shall be stated in the

guaranteed particulars. The use of organic tape or pressed board wrapping to hold the

laminations will not be accepted. All clamping structure shall have adequate mechanical

strength for this purpose and No.1 element in clamping structure shall have permanent

deformation. Clamping structure shall be as so constructed that eddy currents will be

minimized. The insulation and other materials used in construction of cores shall have

been in successful use for at least five years. The clamping shall be firm to reduce

vibrations and to keep noise level within limits.

vi) Core laminations shall be free from all burs and sharp projections.

vii) All structural members of the a smelled cores shall be of steel. All coatings shall be felted

and structural steel adequately cleaned and painted before being built into the structure.

Any non-magnetic or high resistance alloy used shall be of established quality.

viii) The cores shall be connected to the tank by a metal to drawing off Electric static potential.

ix) The maximum hot spot temperature in the cores shall be non injurious to the insulation

and the materials of the core and clamping frame works.

x) Adequate figments shall be provided to enable the cores and the winding to be lifted.

3.15 WINDINGS

3.15.1 GENERAL

1) Star connected H.V. windings shall have graded insulations as defined in IS 2026. The

neutral point shall be insulated for the voltage specified in IS 2026.

2) Transformers shall be designed to withstand impulse and power & frequency test

voltages as specified in IS 2026. The impulse strength of the winding shall not less than

the following basic insulation level of the power system. High voltage winding 650 kV

peak. Low voltage winding 95 kV peak.

3) Further the transformers shall withstand the power frequency test voltage as follows:

4) High voltage winding 70 kV rms

5) Low voltage winding 20 kV rms

6) The contractor shall state the impulse strength guaranteed by him in the schedule-1.

7) The windings shall be designed to reduce to a minimum the out of balance forces in the

transformer at all voltage ratio.



8) The insulation of transformer windings and connection shall be free from insulating

composition liable to soften, coze out, shrink or collapse during transport, handling and

service and be non-cattle tic and chemically inactive in transformer oil during transport,

handling and service.

9) The stacks of windings shall receive adequate shrinkage treatment before final assembly.

Adjustable devices shall be provided for taking up an possible shrinkage of coils in

service. All similar coils shall be interchangeable.

10) Oil circulation ducts shall be provided to ensure uniform temperature gradients and the

absence of hot spots. The clamping arrangements and the finished dimensions of any ol

ducts circulation of oil through the ducts.

11) No strip conductor would on edge shall have a width exceeding six times its thickness.

12) The conductors shall be transposed at sufficient intervals in order to minimize eddy

currents and equalize the distribution of currents and temperature along the windings.

13) Windings shall be of electrolytic tinned copper conductors. Class “A” insulation shall be

used electrical and magnetic balance under all conditions of operation. Each of the coils

shall be would of insulated continuous smooth tinned copper conductor of more than

99.9% purity. Wood insulation shall a be treated seasoned.

14) High voltage winding shall have graded insulation. They shall be of the shielded layer

type to ensure uniform voltage distribution under impulse conditions.

15) Special attention shall be given to the provision of adequate insulation and clearance

between the primary and secondary windings. All clearances of windings and other live

parts shall be adequate for the maximum voltage of operation plus 10%. The minimum

clearance adopted shall be stated in the tender. The current densities in primary and

secondary windings shall be given in the tender.

16) All leads from the windings to the terminal boards and bushing shall be rigidly

supported to prevent injury from vibrations.

17) The completed coil and core assembly shall be dried in vacuum thoroughly shrunk to

final dimension and shall be immediately impregnated with oil after the drying process to

ensure the elimination of air and moisture within the isolating structures. Full details, of

drying and vacuum treatment shall be furnished by the tenderer in the tender. The

insulation resistance measured immediately, after impregnation and the temperature at

which it is measured shall be reported for purchaser’s record. All bushings with windings

after assembly must withstand full vacuum, at site inclusive of all assemblies, gaskets

H.T. / L.T. Terminals etc.



18) Final filling of the transformer with oil shall be done under vacuum. The procedure to be

adopted shall be furnished in the tender.

3.15.2 BRACING OF WINDINGS

i) The windings connections of all transformers shall be braced to withstand shocks which

may occur during transport, or due to switching, short circuit and other transient

conditions, during services.

ii) Coil clamping rings, if provided, shall be of insulated steel or of suitable insulating

material, Axially laminated material other than Bakelite paper shall not be unsaid.

iii) The neutral of H.V. winding shall be brought out to separately insulation terminal and

shall be effectively connected to the earth.

3.16 INTERNAL EARTHING ARRANGEMENT

3.16.1 GENERAL

All metal parts of the transformers with the exception of the individual core laminations, core bolts,

end associated individual clamping plats, shall be maintained at some fixed potential.

3.16.2 EARTHING OF CORE CLAMPING STRUCTURE

The top main core clamping structure shall be connected to the tank body by a copper strap. The

bottom clamping structure shall be earthed by one or more of the following methods.

a) By connection through vertical tie – rods to the top structure.

b) By direct metal to metal contact with the tank base maintained by the weight of the core

and windings.

c) By a connection to the top structure on the same side or the core as the main earth

connection to the tank.

3.16.3 EARTHING OF MAGNETIC CIRCUIT

i) The magnetic circuit shall be earthed to the clamping structure at one point only through.

ii) Magnetic circuits having an insulated sectional construction shall be provided with a

separate link for each individual section. Where oil ducts or insulating barriers paroled to

the plane of the laminations devoid the magnetic parts, ducts or barriers, shall be bridged

in accidence with clause and the magnetic circuit shall not be regarded as being of

sections construction.

3.16.4 EARTHING OF COIL CLAMPING RINGS

Where coil clamping rings are of metal at earth potential, each ring shall be connected to the

adjacent core clamping structure on the same side of transformers, as the main earth

connection.



3.16.5 SIZE OF EARTH CONNECTIONS

All earthing connection with the exception of those form the individual coil clamping rings

shall have a cross sectional area of not less than 0.8 sq.mm. connections inserted between

laminations of different section of core shall have cross sectional area of not less than 0.2

sq.mm.

3.17 TANKS

3.17.1 TANK CONSTRUCTION

1) The tanks shall complete with all accessories and shall be designed so as to allow the

complete transformers in the tanks and filled with oil, to be lifted by crane or jacks,

transported by road, without over straining any joints and without causing subset leakage

of oil.

2) The main tank body of each transformer including tap changing compartments and

radiator shall be capable of withstanding vacuum gauge pressure of (98.5 KN/m2) 740

mm of Hg. However the tank designed for full vacuum shall be tested at on internal

pressure of 3.33 KN m2 (25 mm of Hg.) for one hour. Permanent deflection of flat plate

after the vacuum specified in CBIP specification without effecting the performance of

transformer.

3) The base of each tank shall be so designed that it shall be passable to move the complete

transformer unit by skidding in any direction, without injure when using plates of rails.

4) Where the base is of a channel construction, it shall be designed to prevent retention of

water.

5) Tank stiffeners shall be designed to prevent retention of water.

6) Wherever possible the transformer tanks and its accessories shall be designed without

pocket wherein gas may collect. Where pockets can not be avoided, pipes shall be

provided to vent the gas into the main expansion pipe. The vent pipes shall have a

minimum inside diameter of 20mm except of for short branch pipes which may be 6 mm

minimum inside diameter.

7) All joints other than those which may have to broken shall be welded.

8) The tank shall be fabricated from commercial quality steel plates confirming to IS 226 and

with law carbon content suitable for welding and property reinforced. The finished

materials shall be free from excessive segregation of impurities, cracks, surface flaws,

laminations, rough jagged imperfect edges and all other harmful defects. The tenderer

shall not accept or make use of the plates and reinforcement which are hammer dressed,

patched or wherein welding of defects has been done. All seams shall be welded and



where practicable seems shall be double welded. No distortion of joints shall occur while

in service.

9) In addition to vacuum testing as per clause 8.12.1 the tank shall also be tested with oil to

the static head plus 0.35 Kg/Sq.Cm.

10) Compressible gaskets if used shall have metallic stops to prevent over compression.

11) Guide within the tanks or other satisfactory means shall be provided for directing the core

and coil as they are being lowered into or removed from the tank.

12) Ample space shall be provided above the tank bottom for collection of sediment.

13) Lugs and bosses shall be provided for lifting the transformers complete with oil. Pulling

lugs on all sides in the under frame shall be provided at suitable height for handling the

transformer in any direction.

14) Two ground pads capable of carrying for 4 seconds, the full lower voltage short circuit

current of the transformer with bolting arrangements for M.S. earthing strain shall be

welded to the transformer tanks of bases.

15) Ground pads shall be near the base of the transformer about 1.5 m above ground level

and welded to one corner of the opposite tank sides. The pads shall be completed with

threaded holes with nuts bolts etc. The tenderer shall supply complete earthing materials

which shall have to earth the transformer and accessories according to IS code practice.

16) One No. ladder for each transformer shall be provided to ascend the top of transformer

tank. The ladder shall be tubular Aluminum detachable type fitted with clamps to the

tank.

17) A minimum four jacking pads in accessible position to enable the transformer complete

with oil to be raised or lowered using hydraulic jacks. The minimum height of the lugs

above the base shall be 500 mm suitable haulage hole shall be provided.

3.17.2 TANK COVER

1) The tank cover shall be of adequate strength and shall not distort when lifted. Inspection

opening shall be provided as necessary to give easy access to bushings or changing ratio

or testing the earth connection. Each inspection opening shall of ample size for the

purpose for which it is provided and at least two openings, one at each and of the tank

shall be provided.

2) The tank cover and inspection covers shall be provided with suitable lifting

arrangements. The inspection covers shall not weight more than 25 kg. each.



3) The tank covers shall be fitted with pockets for a thermometer and for the bulbs of oil and

winding temperature indicators. Protection shall be provided for each capillary tube.

4) The thermometer pocket shall be fitted with a captive screwed for to prevent the ingress

of water.

5) The pockets shall be located in the position of maximum oil temperature at C.N.R. and it

shall be possible to remove the instrument bulbs without lowering the oil in the tank.

6) The tank covers shall be bolted on the flanged rim of tanks with waterproof hot oil

resistant and resilient gasket, for oil tightness. If gasket is compressible, metallic stops.

Shall be provided in the cover to prevent over compression and to facilities unseating of

Cover of the tanks with minimum damage to gasket.

7) Special covers required for shipping shall be supplied by the tenderer on returnable basis

after successful commissioning of transformers.

3.18 UNDER CARRIAGE

i) The transformer tanks shall be fitted with suitable under carriage.

ii) Under carriage for transformers shall be provided with wheels and the axis shall be of

such dimensions and so supported that under any service conditions they shall not deflect

to interfere with the movement of the transformers. Suitable locking arrangement parallel

to and at right angles to longitudinal axis of the tanks shall be provided to prevent the

accidental movement of the transformer in the event of horizontal and vertical force

coming in to play due to earth quake.

iii) The Wheels Shall Have Ball/Roller Bearings

iv) The wheels shall be provided suitable for use of gauge track set at 5’-6” (1676 mm and

shall be so placed that pinch bar can be used to move the transformers. The purchaser will

provide two rails at 1676 mm (5’ – 6”) gauge. Therefore the Contractor shall provide

wheels suitable for use on two rail tracks set at gauge 1767 mm (5’-6”) 90 lbs. rail

sufficient length are available with department and same would be used. Wheels shall be

of bi-directional type.

3.19 CONSERVATOR VESSELS

A vacuum proof diaphragm type conservator with inert gas mounted on tanks shall be

provided. The conservator shall/be provided in such a position as not to obstruct the

electrical connections to the transformers and shall have sufficient capacity between highest

and lowest visible levels to meet the requirement of expansion of the total cold oil volume in

the transformer and cooling equipment.



Complete supporting frame of galvanized steel structure shall be provided for the

conservator. Supporting frame shall be designed to take the full load of the conservator with

oil filled upto its maximum level. It shall be possible to take out the transformer fitting and

accessories to be provided below the conservator without fouling with conservator supports

of conservator itself.

1) The oil conservators for the cable sealing chamber shall be complete with feed pipe, read

type buchholz relay with alarm and trip contacts, drain valve, magnetic type oil level with

alarm, bottom and top isolating valves, in the feed pipe on either side of buchholz relay.

2) MAIN OIL CONSERVATOR

i. The minimum indicated oil level shall be with the feed pipe from the main tank covered

with not less than 15 mm depth of oil and the indicated range of oil level shall be from

minimum to maximum.

ii. If the sump is formed by extending the feed pipe inside the conservator vessel. This

extension shall be for at least 75 mm. The conservator shall be designed so that it can be

completely drained by means of the drain valve provided, when mounted as in service. A

filter valve t top shall be provide, for filling the conservator.

iii. Arrangement shall be provided to clean the conservator.

iv. One oil gauge magnetic type with alarm contact shall be provided.

v. The oil level at 30 0C shall be marked on the gauge.

vi. Taps or valves shall not be fitted to oil gauge.

vii. The oil connection from the transformer tanks to the conservator vessels shall be arranged

at a rising angle of 3 to 7 degrees to the horizontal and shall consist of 80 mm inside

diameter pipe as per IS 3630.

viii. A valve shall be provided at conservator to cutout the oil supply to the transformer after

providing a straight run of the pipe or at least a length of 5 times. The internal dia of pipe

on the tank side of buchholz’s relay and at least three times the internal dia of the pipe on

the conservator side of the bush’s relay.

ix. Conservator vessels shall be fitted with a breather for main conservator and the

conservator compartment in which silica gel is the dehydrating agent and designed to

that:-

a) The passage of air is though the silica gel.

b) The external atmosphere is not continuously in contact with silica gel.



c) The moisture absorption indicated by a change in colour of the tinted crystal can be easily

observed from distance.

d) All breathers shall be mounted at approximately 1,400 mm above ground level.

e) Caps shall be provided for filling and draining valves.

3.20 FILTER AND DRAIN VALVES SAMPLING DEVICES AND AIR RELEASE PLUGS

i) Each transformer shall be fitted with the following:

a) Two Nos. filter valves of size 50 mm shall be provided one on the top and the other at

bottom of the tank mounted diagonally opposite to each other for connection to oil

circulating equipments. The bottom filter valves shall be flanged to seat 1 ½” B.S.P. male

threaded adopted for filter pipe connection so fitted as to drain off oil completely. Four

Nos. oil inlet and outlet valves between cooling plant and transformer.

b) A drain valve of size 25 mm shall be fitted to each conservator.

c) A robust oil sampling device shall be provided at the top and bottom of the main tank.

The sampling device shall not be fitted on the filter valves specified under (a) above.

d) One 15 mm air release plug.

e) Drain valve of size 100 mm with cap of main transformer.

ii) All other valves opening to atmospheres shall be fitted with blank flanges.

3.21 PRESSURE RELIF DEVICE

i) The pressure relief device shall be provided of sufficient size for rapid release of any

pressure that may be generated within the tank, and which might result in damage to the

equipment. The device shall operate at a static pressure of less than the hydraulics test

pressure for transformer tank means shall be provided to prevent the ingress of water.

ii) The relief device shall be mounted on the main tank and if on the cover, shall be fitted

with skirt projecting 25 mm inside the tank and of such a design to prevent gas

accumulations.

iii) If a diaphragm is used, it shall be of suitable design and materials and situated above

maximum oil level.

iv) An equalizer pipe connecting the pressure relief device to the conservator shall be

provided for relieving or equalizing the pressure in the pressure relief device.

v) The fitting of silica gel breather to the pressure relief device, the breather being mounted

in a suitable position for access at ground level.



3.22 ACCOMODATION FOR AUXILIARY APPARATUS

The contractor shall provide supporting frame work insulators, copper conductor/strip,

clamps for formation of H.V. neutral and earthing of neutral, current transformer and its

enclosure on transformer body itself.

3.23 RATING AND DIAGRAM AND PROPERTY PLATE

The following plates shall be fixed to the transformer tank at an average height of about 1500

mm above ground level.

a) A rating plate bearing the date specified in the appropriate clause of IS 2026.

b) A diagram plate showing the internal connections and also the voltage vector relationship

of the several windings in accordance with IS 2026 and in addition, a plan view of the

transformers giving the correct physical relationship of the terminals. Approved means

shall be provided for clearly indication ratio for which the transformers are connected. No

load voltage shall be indicated for each top. All valves shall be provided with table

showing the function of valves.

c) A plate showing the location and functions of all valves and air release cocks or plugs

shall be provided. This plate shall also warn operator to refer to the maintenance

instruction before applying vacuum, treatment for drying.

3.24 RADIATOR CONNECTION

Valves and valves mounting shall be provided as specified under following clause.

They shall be full way time with internal screw and shall be opening by running counter

clockwise when facing the hand wheel.

Means shall be provided for pad locking the bottom valves in the open and closed positions.

This is required for the valves where opening device like hand of wheel, keys etc., are the

integral part.

All valves except radiator valves shall be of gunmetal. The radiator valve shall be of cost iron

plate type.

Every valve shall be provided with an indicator to show clearly the position of valve.

All valves shall be provided with flanges having machined faces.

The drilling of valve flanges shall be comply with the requirement of IS 3639.

3.25 COOLING

The transformer shall be provided with oil natural air natural (ONAN) type of cooling system

to give, the darted output at rated voltage and frequency without exceeding the limits of

temperature rise as specified in IS – 2026/1972.



The radiators shall be designed to withstand safely the pressure conditions specified for the

tank and shall be free form the defects, such as welding or cracks, impurities in radiator

material etc. the radiators shall be removable for repairs without necessitating the draining of

oil from the transformer. The radiators shall be connected to the tank by machined steel

flanges, bolted to the tank and provided with gaskets. Shut off valves shall be provided for

each radiator, which can be locked either in open or in closed position.

A separate oil tight blank flange shall also be provided for each of the tank connections to

radiator, these will be used when radiators are to be detached.

Each radiator shall have a lifting bye, an oil drain plug of adequate size at the bottom an air

release vent of adequate size at the top.

The radiators shall be so designed that they are accessible for cleaning and painting and to

prevent accumulation of water on the outer surface, and to ensure against formation of gas

pockets when the tank has been filled.

Contractor shall clearly mention in his tender the details regarding radiators, their location,

type, quantity, number of valves, cooling surface, permissible pressure and the various

accessories provided for radiators.

3.26 VOLTAGE CONTROL OFF CIRCUIT TYPE

i) Each transformer shall be provided with a manual off circuit tap changing gear for

varying its effective ratio of transformation while the transformer is de-energized and

without producing phase displacement. The tapping range shall from +5% to –5% in the

steps of2.5%.

ii) The off-circuit switch handle will be provided with a locking arrangement along with tap

position indicator thus enabling the switch to be locked in any tap position. A warning

late indicating hat switch be appeared only when the transformer is de-energined shall be

fitted.

iii) The tap changer shall be connected to the taps on high voltage star connected windings

for +5% and –5% in steps of 2.5%.

iv) A hand wheel or lever with position indicator shall be proved on the high voltages side

for operating the tap changer manually on no load without necessitation removal of the

tank cover of lowering of oil.

v) The mechanism shall be such that it will be impossible to leave a winding open of short

circuited when operating handle is place in a locked position.

vi) It shall be possible to operate the hand wheel or lever for the tap changer from the

transformer base level.



3.27 FITTINGS AND ACCESSORIES

Standard fittings, valves, gauges, pulling lugs and instruments of established quality shall be

provided and the tender shall give the complete information necessary for subsequent

replacement of these items. All valves except filter sampling and drain valves openings to

atmosphere shall be fitted with blank flanges. Valves, shall be of gunmetal having integral

opening device, padlocks, position indicators, flanges with machined faces.

1) Diaphragm type conservator with inert gas of sufficient capacity complete with filter

valve and flanges drain valve with caps complete supporting frame work.

2) One magnetic type oil level gauge with low oil level alarm.

3) Dial type oil temperature indicator with maximum pointer and two sets of contacts. The

temperature indicator shall be housed in marshalling box.

4) Dial type winding temperatures indicator one for each L.V. winding with maximum

pointer and two sets of contacts. The temperature indicators shall be hosed in respective

marshalling box.

5) One number silica gel breather with oil seal and connecting pipe.

6) One number read type buchholz relay with alarm and trip contacts, double element

arrangement, isolating valves on higher side.

7) Pressure relief devices for transformers.

8) Pocket on tank cover for thermometers.

9) Explosion vent.

10) VALVES

a) Drain valve of size 100 mm with cap for main transformers.

b) Two numbers oil filter valves of size 50 mm with caps and adopter. One at the bottom

and other at the top of the transformers on diagonally opposite corners.

c) Two numbers oil sampling valves at the top and bottom of the tank.

11) Isolating valves for conservator.

12) Two numbers earthing terminals with nuts, bolts, washers etc., for proper earthing of

transformer tank shall be provided. Earthing terminals similar to above for earthing of

fittings and accessories of the transformer such as marshalling box etc., shall be provided.

Copper strips, lugs, reverts, cleats etc., require for earthing above items with the earth mat

of power house shall also be provided.

13) Rating and diagram plates.



14) Valve schedule plate.

15) Jacking pads.

16) Lifting eyes for core frame with windings lifting bollards.

17) Haulage lugs.

18) Cover lifting lugs.

19) Bi-directional double flanged rollers. 5’-6” gauge.

20) Marshalling box.

21) Air release device.

22) Off circuit tap changing gear.

23) Radiators – detachable radiators

24) Inspection opening for the transformers suitably sealed with cover for access to the inner

and end of bushing and the off circuit tap switch.

25) H.V. Neutral bushing, current transformer with enclosure, supports copper conductor,

clamps and support insulators, strain insulators etc.

26) Ladder to ascend to top of the transformer.

27) Cable chamber suitable for connection of L.V. bushing with the end of power cables,

complete with i) Support for chamber, ii) connector with coupling and supports for

connector if any, glands, insulating material etc.

28) a) H.V. busing completely immersed in oil.

b) Neutral bushing for H.V. winding.

c) Neutral current transformer

d) Bushing for L.V. winding

29) Sufficient quantity of oil required for each transformer and all associated oil filled

equipments and extra 10% of the oil required for assembled transformer shall be supplied

in non-returnable steel drums. The oil shall be as specified in IS 335. It shall be as free

from moisture and have uniform quality through out.

30) Four Mechanical screw type jack, each having a capacity of about 33 percent of the total

weight of the transformer with oil shall be provided for the transformer.

The accessories and fittings shall include the wiring from various transformer accessories upto

the marshalling box and this wiring shall be of standard copper 660/1100 volt grade PVC



insulated cables as per relevant IS and of appropriate size enclosed in rigid steel conduits

mounted on the tank near the base by means of clamps.

31) OTHER FITTINGS

Such other fittings, which are in line with manufactures standard practice, shall be provided.

Other fittings recommended by the Conductor for satisfactory operation of the transformer

shall also be provided.

32) Special adjustable and rod gaps shall be provided for the 33 kV terminal bushing to

enable to Co-ordination of insulation level with surge diverted. The gap setting shall be

fixed with reference to the impulse strength of 170 kV class winding.

3.28 BUSHING TERMINAL ARRANGEMENT

All bushing shall be suitable for continuous operation at 10% above the nominal voltage of

the bushing. The bushings shall be in accordance with IS 2099 and 3347 and shall be suitable

for the transformer confirming to IS 2026. The clearance between live conductive parts to

earthed structure shall be

1. Phase to phase : 350 mm

2. Phase to earth : 320 mm

The bushing shall have high mechanical strength stable insulation and high puncture value to

ensure on external flash over before a break down occurs due to high voltage, a high factor of

safety against leakage to ground and shall be located as to provide adequate electrical

clearance between bushing and between the bushing and grounded parts. Bushing of

identical voltage rating shall be in for changeable. All bushings shall be equipped with

terminals of approved type and size. All porcelain used in bushing shall be wet process

homogeneous and free from cavities or other flaws. The glazing shall be uniform in colour

and free from bolsters, burns and other defects. Main terminals shall be molder less. The

insulation class of high voltage bushing, low voltage bushing and the high voltage natural

bushing shall be properly co-coordinated with the insulation class of the respective windings.

Any stress shield shall be considered as integral parts of the bushing assembly.

The bushing shall be arranged that it can be removed without disturbing the connections or

pipe work.

Special precautions shall be taken to exclude moisture for paper isolation during

manufactures identification mark and such other mark as may be required to assist in the

representative selection of batches for the purpose of the sample tests.

Clamps and fittings made of steel or malleable iron shall be galvanized. All bolt threads shall

be greased before erection.

The bushing flanges shall not be of reentrant shape which may trap air.



Bushing shall be provided with vent pipes which shall be connected to route any gas

collections through the buchholz relay.

The power factor of each bushing shall be measured at the contracts works and test

certificates furnished for approval of purchaser.

The winding side connection terminal of the bushing shall be of the cable type suitable for

brazing on the winding side and screwed on the cap side so that bushing can be removed

without opening the top cover of the transformer by sliding the load down the control

bushing tube.

3.29 H.V.BUSHING AND TERMINAL ARRANGEMENT

H.V. bushing shall be suitable for 33 kV outdoor oil immersed draw through condenser type

transformer H.V. bushing suitable for 36 kV grade per phase shall be provided the top of the

transformer tank so as to facilitate proper connections with bus.

3.30 H.V. NEUTRAL BUSHING

The Contractor shall provide for each transformer one neutral bushing ousted on top of the

tank. The bushing shall be of oil filled porcelain stem type its rated voltage shall be intimated

along with the tender.

The Contractor shall provide the equipment such as copper strip, coupling clamp for neutral

bushing and copper strip cleat/clamps, support insulator etc., for formation and earthing of

neutral. Earthing neutral to the powerhouse earth-mat shall be done by the contractor. Single

core body mounted totally enclosed type neutral current transformer shall be provided for

each transformer of accuracy class 10/1 A-30 A – 10 p – 20.

Formation and earthing arrangement of neutral shall be subjected to the approval of the

Purchaser.

3.31 L.V.BUSHING AND TERMINAL ARRANGEMENT

The Contractor shall provide for each transformer three numbers solid stem type porcelain

bushings mounted on detachable adopter on transformer body suitable for connection with

adequate size single core. XLPE copper cables, complete with coupling clamps etc., Locations

of L.V. bushing arrangement and the type of coupling/clamps shall be provided for cable

trucking around L.V. bushing along with cable terminal arrangement, insulation, and glands

etc.

3.32 TEMPERATURE INDICATING DEVICES AND ALARM

i) The tripping contacts of dial type thermometer for oil temperature indicator and winding

temperature indicators shall be adjustable to close 600C and 1200C and alarm contacts to

class between 900C and 1000C and both shall reopen when the temperature has fallen by

about 10 0C.

ii) All contacts shall be adjustable on a scale and shall be accessible on removal of the cover.



iii) The temperature indicators shall be so designed that is shall be possible or check the

operation of the contact and associated equipment.

3.33 BUCHHOLZ RELAY

i) EACH TRANSFORMER shall be fitted with one double float buchholz relays (confirming

to IS 3637) in the feed pipe for transformer tanks. The buchholz relay shall be of read type,

having upper contacts for alarm and lower element for tripping. The Buchholz Relays

provided by the tenderer shall not malapert and shall safely withstand the forces due to

earthquake acceleration suitable for earth quake zone stipulated by ISS for the region. The

design of the equipment which has a frequency i.e. between three cycles per second to 15

cycles per second shall be such as to withstand the earthquake forces of dynamic strength

noted above, taking into considerations the response acceleration due to resonance. The

tenderer shall note that buchholz relays with mercury contact would not be accepted.

ii) Each relay shall be provided with a test cock to take flexible pipe connection for checking

the operation of the relay.

iii) A machined surface shall be provided on the top of each relay to facilitate the setting of

the relays and check the mounting angle in the pipe and the cross level of the relay.

iv) The design of the relay, mounting arrangements associated pipe work and the cooling

plant shall be such that mal-operation of the relays shall not take place under normal

service conditions.

v) The pipe work shall be so arranged that all gas arising from the transformer, shall pass

into the gas and oil actuated relay. The oil circuit through the relay shall not from delivery

path in parallel with any circulating oil pipe nor shall be tied into or connection through

the pressure relief vent, sharp bends in the pipe work shall be avoided.

vi) Adequate clearance between oil pipe work and live metal shall be provided.

3.34 MARSHALLING BOX

i) Tenderer shall provide tank mounted marshalling box for auxiliary apparatus for each

transformer. Each marshalling box shall be flat topped, corrosion resisting, vermin proof,

well ventilated, weather proof, complete with Supports, lifting books, earthing terminals

and with hinged door with padlock arrangement. The marshalling box shall be of sheet

steel construction. The inside of such marshalling box shall be painted with white anti

condensation paint. The base plate shall have suitable opening for cable with necessary

cable glands to plug the holes. Glass windows shall be provided for noting readings of the

dial thermometers etc. As the marshalling kiosk is to be fitted on the transformer met for



outdoor installation. Gaskets provided for its door shall be of such type that seals the

kiosk to make it perfectly water proof.

ii) The Contractor shall state in his tender auxiliary A.C. and D.C. power requirement for

each transformers. The Contractor shall prepare cable schedules for the following cables.

1) Cables to be provided and laid by him from the marshalling box to various transformer

accessories and fittings. Cables to be provide by the Purchaser between the marshalling

box of the transformer and the auxiliary power supply panel and transformer control

panel.

A ring of copper connection of 25 mm x 6 mm strop shall be provided in the marshalling box

for its earthing. Suitable connecting bolts for connecting the earthing to the earthmat shall be

provided.

Disposition of controls, indicating instruments in marshalling box shall be subject to the

approval of the Purchaser.

Indicating instruments shall be suitable for working in tropical climatic conditions and shall

comply with relevant IS or BS.

iii) The temperature indicators shall be so mounted that the dials are not more than 1600 mm

from ground level and the doors of adequate size.

iv) To prevent internal condensation, an approved type of metal clad heater, controller by a

thermostat, shall be provided. Ventilation shall be provided.

v) All incoming cables shall enter marshalling box from the bottom and the gland plate shall

be not less than 450 mm from the based of marshalling box. The land plate and associated

compartment shall be sealed in suitable manner to prevent the ingress of moisture from

the cable trench.

vi) Underlined gland plate shall be provided for accommodation gland for incoming and

outgoing cables.

vii) The following equipment shall be housed in each marshalling box.

1) Heater with thermostat control.

2) Auxiliary transformers

3) No. volt contractors for supply failure.

4) Winding temperature indicator with alarm and trip contacts, for L.V. winding.

5) Oil temperature indicator with alarm and trip contacts.



6) Illumination lamp 60 W bulb with switch. 15-A3 pin sockets with switch.

7) Alarm and trip contacts for Buchholz relay.

8) Low oil level alarm devices.

9) Terminal block with 20% spare terminals.

10) Fuses and links.

11) Other auxiliary relays, including over load and single phase protection.

12) Danger plate.

13) On-off indication for A.C. & D.C. supply.

14) Isolating switches for the incoming circuits.

3.35 CONTROL CONNECTIONS AND INSTRUMENT WIRING TERMINAL BAORD AND

FUSES

CONTROL INDICATION AND ALARM SCHEME

Transformer control panel the transformers shall have to be provided.

The devices includes under marshalling box shall be supplied by the Contractor. In order to

repeat the function on the transformer control panel in control room, sufficient spare contacts

shall be for control indication and alarm and the same shall be wired upto the terminals strips

in the marshalling boxes.

The Contractor shall provide the schematic diagrams of connections of various alarm and trip

contact. The cabling between the terminal block of the marshalling box and that of the

transformer control panel shall be provided and shall provide the cable schedule indicating

the sizes, cores, type ratings etc., of the cables. These cable schedules shall be furnished by the

Contract along with the contract drawings.

1. All wiring connections, terminal boards, fuses and links be suitable for tropical

atmosphere any wiring liable to be in contact with oil, shall have oil resisting insulation

and the bare ends of standard wire shall sweated together to prevent curettage of oil

along with wire.

2. There shall be no possibility of oil entering in the connection boxes used for cable or

wiring.

3. Marshalling box connections shall be neatly and securely fixed to the marshalling box. All

instruments and box wiring shall be run in PVC or non resting metal cleats of the limited

compression type. All wiring of box shall be taken from suitable terminal boards.



4. Where conduits are used, the runs shall be laid with a suitable fails, and the lowest parts

of the run shall be adequately drained and ventilated. Conduit shall not be run at or

below ground level.

5. When 415 volt connections are taken through junction boxes or marshalling box they shall

be adequately screened and 415 volt danger notices must be affixed to the outside of the

junction boxes or marshalling box.

6. The marshalling box wiring shall be in accordance with relevant IS. All wiring shall be

standard copper of 1100 V // 600 V grade PVC insulated cables and size not less than 2.5

sq.mm for connections and 4 sq.mm. for C.T. connector.

7. All wires in marshalling box and all multi core cables shall have ferrules which bear the

same number at both ends.

8. The same ferrule number shall not be used on wires in different circuits on the same box.

9. Ferrules shall be insulating materials and shall be provided with glossy finish to prevent

the adhesion of dirt. They shall be clearly and durably marked in black and shall not be

affected by damp or oil.

10. Standard wires shall be terminated with tinned crimped tabular lugs. Separate lugs shall

be used for each wire. The size of lugs shall be suited to the size of the wire terminated,

separated washer of tinned copper of appropriate sizes shall be provided for each wire

wiring shall in general be accommodated on the disuse of the marshalling box and the

wires for each circuit shall be separately grouped. Back of he marshalling box wiring shall

be arranged so that access to the connections stems of relays and other apparatus is not

impeded.

11. Wires shall not be joined or tied between terminal points.

12. D.C. and A.C. circuit shall be kept physically separated form remaining wiring. The

function of each circuit shall be marked on the associated terminal boards.

13. Wherever apparatus is mounted on panel, all metal cases shall be separately earthed by

means of Cu. wire or strip having the cross section of not less than 2 sq.mm. where strip is

used, the joints shall be sweated.

a. All wiring diagram of control and relay panel shall preferably by drawn as viewed from

the back and shall show the terminal boards arranged as in service. All diagrams shall

show which view is employed.

14. Multicore cable tails shall be so bound that each wire may be traced without difficulty to

its cable.



15. The screens of screen pairs of multicore cables shall be earthed at one end of the cable

only. The position of earthing connections shall be shown clearly on the diagrams.

16. All terminal board rows shall be mounted to give easy access of termination and to enable

ferrule numbers of read without difficulty.

17. Terminal boards rows should be spaced adequately not less than 100 mm apart to permit

convenient access to wires and termination.

18. Terminal boards shall be so placed with respect to the cable gland (at a minimum distance

of 200 mm) as to permit satisfactory arrangement of multicore cable tails.

19. Terminal boards shall have pairs of terminals for incoming and outgoing wires. Insulating

barriers shall be provided between adjacent co connections. The height of the barriers and

the spacing between terminals height shall such as to give adequate protection, while

allowing case access to terminals. The terminals shall be adequately protected with

insulating dust proof covers.

20. No line metal shall be exposed at the back of the terminal boards.

21. All fuses shall be of the cartridge type.

22. Fuses and links shall be labeled.

3.36 TESTING AT MANUFACTURERS WORKS AND AT SITE

3.36.1 ROUTINE TEST (AT MANUFACTURER’S WORKS)

i. The following routine tests shall be carried out on the completely assembled transformer

and accessories in the presence, of the representative of purchaser. Oil leakage test being a

routing test shall be carried out on the transformer, in presence of Purchaser

representative.

b. Measurement of winding resistance.

c. Measurement of voltage ratio and check of voltage relationship.

d. Measurement of impedance voltage / short circuit impedance (Principal tapping).

e. Measurement of load loss.

f. Measurement of no load loss and current.

g. Measurement of insulation resistance.

h. Dielectric test specified in IS 2026 (Part III as enumerated below:)

i. Separates source power frequency voltage withstand test.

j. Induced over voltage withstand test.



k. Operational tests for off circuit tap changer switch.

l. Tests on insulating oil in accordance with IS : 335/1972.

3.36.2 OIL LEAKAGE TEST ON TANK (AT MANUFACTURER’S WORKS)

The tank and oil filled compartments shall be tested for oil tightness by being completely

filled with oil of a viscosity not greater than that of insulating oil IS : 335 at an ambient

temperature and subjected to a pressure equal to the normal pressure plus 35 KN / M2 12

hours, during which time no leakage shall occur. The test shall be witnessed by Purchaser’s

representative.

3.36.3 TYPE AND SPECIAL TEST (AT MANUFACTURER’S WORKS)

A) The Contractor should furnish type test certificates for impulse voltage withstand test and

temp. rise test, already carried out by the Contractor on similar type / rating of the

transformers along with the tender. If such above said tests are not carried out by the

Contractor earlier and hence the Contractor is unable to furnish the certificates for the

same the Contractor shall have to accept burden at the rate of Rs. 25 Lacs for evaluation

purposes.

B) The following additional type tests on tank shall also be carried out.

• PRESSURE TEST

The transformer tank together with its conservator vessel and other fittings shall be

subjected to pressure corresponding to twice the normal head of oil or to the normal

pressure 35 KN / m2 (5 lb / sq.in) whichever is lower measured at the base of the tanks

and will be maintained for one hour. The tank shall withstand this test pressure without

any abnormality.

• VACUUM TEST

The transformer tank shall be tested for an internal pressure of 3.33 KN / m3 (25 mm of

Hg) for one hour. The permanent deflection of flat plates after the vacuum is released

shall not exceed the values as stipulated in CBIP manual on transformers without

affecting the performance of the transformer.

3.36.4 TEST BEFORE COMMISSIONING (AT SITE)

After erection at site the transformer shall be subjected to the following test:

1) Insulation Resistance.

2) Ratio and Polarity Test

3) Oil test before putting transformer into operation, the oil shall be tested as per IS : 335 /

1372. Instruments and facilities etc., as available at site shall be provided by the Department.



However, special measuring instruments, tools, tackles, etc., will have to arranged by the

Contractor at his cost.

3.36.5 GENERAL

All accessories and fittings, radiators, bushings, conservator etc., shall be tested in accordance

with the relevant Indian Standards and where such Standard is not available, as per

manufacturer’s Standard practice.

For the tests specified above, the contractor shall furnish six copies of test certificates for

approval. In addition to above, the Purchaser reserves the right of carrying out at site as such

tests as he may decide upon. The reasonable charges will be mutually agreed upon in that

case.

Any other tests as may be called for by the Purchaser, Contractor shall furnish six copies of

the test certificates for the approval of the Department.

3.37 PROTECTION

It is proposed to provide the following protection for the transformer.

i) Overall Differential protection.

ii) Over current and earth fault protection.

iii) Thermal protection (winding temperature)

iv) Buchholz protection read type relays.

In spite of at above any additional protection equipment which is necessary shall be

provided.

Sr. no. Spare parts for Main Transformer 1 (25/31.5 MVA)

1. Transformer bushing of each type Set 1

2. Sets of contacts for off-load tap-changer Set 10

3. Sets of complete gaskets for one transformer Set 2

4. Pieces of complete dehydrating breather Nos 7

5. Silica gel Kg 20

6. Pressure relief devices Nos 2

7. Complete Buchholz relays of each type Nos 2

8. Fans in complete with motor Nos 2

9. Radiators Set 2

10. Oil level gauges Nos 2

11. Contact thermometers Nos 4

12. Spare for control cabinet Nos each 3

13. Volume of transformer oil % 10

14. 5% of installation bolts Lot 1



AUXILIARY TRANSFORMER :

TRANSFORMER:- 100 KVA, 3.3 KV/ 433 V.

UNIT AUXILIARY TRANSFORMER (U. A. T.)

3.1 SCOPE

The work covered under these specifications comprises of one no. 100 K. V. A., 3.3/ 0.433

K.V., 50 Hz, 3 Phase outdoor type distribution transformer complete with fittings of all

accessories and first filling of oil.

3.2 TYPE & RATING

The details regarding the type and rating etc. are as under.

Sr. No. TYPE RATING

1. Particular of specification to be

compiled with indoor or outdoor

type.

: Indoor type.

2. Type of cooling. : ONAN

3. Rated power at principal tappings : 100 KVA

4. Frequency. : 50 Hz.

5. No of phases in the system. : Three Phase

6. Rated Voltage

a) H. V. Winding. : 3300 Volts

b) L. V. Winding. : 433 Volts

7. Details of tappings. : 5 Nos from ±2 % to +5 %

in steps of 2 %.

8. Dry. Type or oil immersed type. : Oil immersed type with

mineral oil.

9. Type of Transformer. : Copper wound.

10. Connection symbol. : D^Yn 11.

11. Highest voltage of equipment

a) H. V. Side. : 7.5 KV RMS. ll-

b) L. V. Side. : 500 Volts.

12 Terminal Details

a) H. V. Side. : Through Cable end box.

b) L. V. Side. : Through cable end box.

13. Fittings. :

14. Axles & wheels : Four bi- directional plain

rollers with locking

arrangement.



15. Plinth or pole mounted transformer : Plinth mounted

transformer.

3.3 STANDARDS

Except where specified otherwise, the equipment covered under this specification shall

comply with the following Indian standards including the latest amendments if any, and the

relevant other standards mentioned therein.

1) Distribution transformer. : - IS 2026

2) Insulting oil. : - IS 335

3) Bushings & their accessories. : - IS 2099.

Any other associated equipments material such as core, laminations, winding, insulating

material, cable end box etc. confirming to relevant Indian standards.

3.4 TEMPERATURE RISE: -

The maximum temperature rise in winding and oil, core, metallic parts and Adjacent

materials when the transformer is operating at rated voltage, rated frequency, rated load and

0.866 p. f. lag shall not exceed the limits as specified in IS – 2026 (part II) 1977.

3.5 LOSSES TO BE GUARANTEED : -

The transformer shall be designed such that its iron losses (No load Losses) should be

minimum to the extent possible in considering the total design aspects. The Contractor shall

quote the guaranteed losses as detailed below : -

a) Guaranteed no load loss at rated voltage on principal and rated frequency.

b) Guaranteed full load copper losses at rated current at principal Tappings and 75 o C.

If no load losses observed to be more than the guaranteed no load losses at the time of factory

test the same shall be rejected by the department and no charges/ cost occurring out of such

rejection shall be paid to the contractor by the department. In case losses are more than 4% of

guaranteed value transformer will be rejected. This is applicable for individual transformer.

3.6 DESIGN : -

The transformer and accessories shall be designed to facilitate operation, inspection,

maintenance and repairs. All apparatus shall be designed to ensure satisfactory operation

under such sudden variation of load & voltage as may be met with under working condition

on the system including those due to short circuits.

3.7 PAINTING: -

The interior of transformer tank and other oil filled chamber and internal structure steel work

shall be cleared of all scale and rust by blasting or other approved method. These surface

shall be painted with hot oil resisting varnish or paint.



All external surfaces shall receive a minimum of three coats of paints. One coat of additional

paint shall be given at site by contractor.

3.8 OIL : -

The transformer and all associated oil filled equipment shall normally be supplied along with

first filling of oil. The oil shall be free from moisture.

3.9 TYPE OF TRANSFORMER & OPERATION CONTIDION : -

The transformer shall be oil immersed and shall be of core type suitable for outdoor

installation. The cooling shall be ONAN type.

3.10 CONTINUOUS MAXIMUM RATING AND OVER LOADS : -

Transformer shall meet the temperature rise limits specified in I. S. 2026 on all tappings on

which the rated current is more than 95 percent of the maximum rated current on the lowest

voltage tapping.

3.11 ELECTRICAL CONNECTIONS : -

Transformer shall be connected in accordance with the vector symbol – DYn 11.

3.12 DUTY UNDER FAULT CONDITION : -

The transformer shall be capable of withstanding according to IS 2026 without any damage

by any external short circuit between phases.

3.13 VIBRATION & NOISE : -

Every care shall be taken to ensure that the design & manufacture of transformer &

accessories shall be as per the NEMA standard publication TR- 1.

3.14 CORES : -

The core shall be connected from high grade cold rolled non aging oriented silicon steel

laminations.

3.14 MECHANICAL CONSTRUCTION OF CORES : -

All parts of the core shall be of robust design capable of withstanding any shocks to which

they may be subjected during lifting, transporting, installation & service.

3.15 WINDINGS : -

The windings shall be designed to reduce to a minimum the out of balance forces in the

transformer at all voltage ratios.

Windings shall be of electrolytic copper conductors, all permanent current carrying joints in

the windings and leads shall be brazed or soldered as the case may be.



The insulation of the transformer windings and connection shall be free from insulating

composition liable to soften, ooze out, shrink or collapse and be non catalytic and chemically

inactive in transformer oil during service.

3.16 INTERNAL EARTHING ARRANGEMENTS : -

All metals parts of the transformer with the exception of the individual core laminations core

bolt and associated clamping plates shall be maintained at some fixed potential.

3.17 TANK : -

The Tank shall be of conventional type construction and shall be fabricated from commercial

quality steel plates.

3.18 LIFTING FACILITIES : -

The tank shall be provided with lifting lugs suitable for lifting the transformer complete with

oil.

3.19 TANK COVER : -

The tank shall be of adequate strength and shall not distort when lifted.

The thermometer pocket shall be fitted with a captive screwed top to prevent the ingress of

water.

Ample space shall be provided at the tank bottom for collection of sediments.

3.20 AXLES AND WHEELS : -

The transformer shall be provided with the wheels and axles of such dimensions and so

supported that under any service conditions they shall not deflect sufficiently to interface the

movement of the transformer. The wheel shall be single flanged made from cast steel and

shall be detachable. The wheel shall be of bi- directional type.

Suitable looking arrangement shall be provided to prevent the accidental movement of the

transformer.

3.21 CONSERVATOR BREATHER ETC : -

A tank mounted conservator complete with sump and drain valve shall be provided in such a

position as not to obstruct the electrical connections to the transformer. Having a capacity

between highest and lowest visible levels to meet the requirement of expansion of the total

cold oil volume in the transformer and cooling equipment for minimum ambient temperature

to 90 o C. The minimum indicated oil level shall be with the feed pipe from the main tank

covered with no less than 15 mm depth of oil. One oil level gauge shall be provided to

indicate range of oil level shall be from minimum to maximum.

Conservator vessel shall be fitted with a breather in which silica gel is the dehydrating agent

and designed so that the passage of air is through the silica gel.

The external atmosphere is not continuously in contract with silica gel.



3.22 FILTER AND DRAIN VALVES : -

The transformer shall be fitted with a set of filter and drain valves. All valves shall be of gun

metal. They shall be fully way type with internal screw and shall be opened by turning

counter clockwise when facing the hand wheel.

3.23 EARTHING TERMINAL : -

Two ground pads with bolting arrangement for M. S. earthing strip shall be welded to the

transformer tank or base. Ground pads shall be near the base of transformer & welded to

opposite corner of the tank.

3.24 COOLING : -

The transformer shall be provided with oil natural air natural (ONAN) type of cooling system

to give the rated output at rated voltage and frequency without exceeding the limit of

temperature rise as specified in IS 2026.

3.25 TAP CHANGING GEAR : -

The transformer shall be equipped with manual off circuit tap change connector to the taps

on high voltage winding for varying its effective ratio of transformation whilst the

transformer is de – energized and without producing phase displacement.

The tapping range shall be from - 2 1/z % to + 5 1/z % in the step of 2 1/z % on H. V. for

voltage variation.

The facilities for looking the mechanism in any of tap position shall be provided along with

tap position indicator.

3.26 TERMINALS AND BUSHINGS : -

H. V. BUSHINGS: -

The high voltage bushing shall be of 6.6K.V. Class , indoor, cable end box type.

H. V. Bushing shall have high factor of safety against leakage to ground and shall be located

as to provide adequate electrical clearance between the bushings & ground parts. The spacing

between the bushings shall be adequate to prevent flashover between the phases under all

condition of operation.

3.27 CABLE END BOX : -

The contractor shall supply for both high and low voltage side cable terminal box for

terminating suitable size H.T. & L. T. power cables.

3.28 FITTINGS AND ACCESSORIES:-

The transformer shall be provided with the following accessories and fittings.

Inspection cover

Rating and Diagram plate

Two earthing terminals



Lifting lugs

Drain valve with plug or blanking flange

De-hydrating silica gel breather with oil seal

Oil level indicator with minimum marking

Thermometer pocket on tank cover

Oil filling hole and cap

Conservator with associated accessories

Filter valve (Two Nos. with caps and adapter one at the bottom and other at the top of the

transformer)

Single flanged bi-directional rollers

Thermometer

Detachable radiators

3 Nos. of H.V. bushings with bimetallic

L.V. cable box with disconnecting chamber with cover plate and suitable for 3 ½ core size

cable

Off circuit tap changer with padlock

3.29 Transport :-

The transformer tank with core and winding and fitting shall be dispatched duly filled with

oil, sufficient space shall be left above the oil to take care of the expansion of oil and this space

shall be filled up with pure air under atmospheric pressure.

3.30 Test at Manufacturer Works:-

A) Routine Tests :-

The following routine test shall be carried out on the complete assembled transformer and

accessories in presence of the representative of purchaser.

Measurement of winding resistance.

Measurement of voltage ratio and check of voltage vector relationship

Measurement of load loss

Measurement of no load loss and current

Measurement of insulation resistance

Test on insulating oil in accordance with I.S. 335/1972

B) Oil Leakage Test on Tank :-

The tank and oil filled compartments shall be tested for oil tightness by being completely

filled with oil of a viscosity no greater than of insulating oil to I.S. 335 at an ambient

temperature and subjected to a pressure equal to the normal pressure plus 35 K.N./ Sq. m. (5

lb/Sq. in) measured at the base of the tank. This pressure shall be maintained for a period of

not less than 12 hours during which time no leakage shall occur.



C) Vacuum Test

The transformer tank shall be tested for an internal pressure of 3.33 K.N./ Sq. m. for one hour.

The permanent deflection of flat plates after the vacuum is released shall not exceed the value

as stipulated in CBIP manual on transformer without affecting the performance of the

transformer.

3.31 Test at Site before Commissioning :-

After erection at site, the transformer shall be subjected to following tests.

Measurement of insulation resistance

Ratio and polarity test

Oil test before putting transformer into operation, the dielectric strength of oil shall be

measure at site.

The contractor shall furnish four copies of test certificate.

3.32 Erection, Testing and Commissioning

The erections, testing, filtration of oil required or demanded by the Purchaser, dry out of

transformer, pre-commissioning checks and tests, commissioning and putting into service of

transformer shall be carried out by the contractor.

Loading of transformer at suppliers works, transportation up to site, unloading of

transformer, insurance upto commissioning, storage etc. shall be done by the contractor.

Foundation work i.e. excavation RCC Plinth, fixing etc., shall be done by Contractor.



SECTION – III- D

A . 33 KV INDOOR SWITCHGEAR

3.1 SCHEME :

JAMBRE HYDRO ELECTRIC PROJECT envisages installation of 1 x 2000 kW at the foot of

JAMBRE DAM Constructed across river JAMBRE. The power Generation will be injected in to

33 kV grid. Project is likely to operate in Grid or SOLO mode operations.

3.1 SCHEME : ref SLD.

It is intended to evacuee power Generation in Jambre HEP by connecting to the evacuation

point & metering of state Electricity Board of Maharashtra state at 33 KV voltage level. The

power Generation will be stepped up from 3.3 KV to 33 KV by power Transfer of 2500 KVA

outdoor manual OLTC. It is intended to accumulate all switch gear 3.3 KV & 33 KV in side

power station switch gear room well now slated almost indoor switch gear operation, Cable

length space restrictions.

Tender to design 36 KV metal clad switch gear Indoor in a well ventilated room adjacent to 3.3

KV switch gear with all local control / Indications remote control / Indication / Alarms

compatible to numerical Protection system.

3.2 SCOPE OF WORK :

The work covered under this specification shall include as following for each project.

The metal clad shall be designed built in indoor complete 33 KV switchgear with vacuum

circuit breaker, current transformer, potential transformer, copper Bus bar of adequate charges

insulator cubicle prorated on sphere 415 volt 50 Hz AC voltage with inter locks with circuit

breaker 33 KV XLPE entries, suitable connecters, clamps lugs at a safe distance as per IS / IEC

standard, Breaker shall be draw out type with easy & safe access to for maintenances, control /

metering cable termination shall be well separated from High voltage with separate

compartment preferably cable entries shall be from bottom of the cubicle. Internal cable

connections shall have separate duct between tanks of metal clad cubicles.

Outgoing line insulator shall have Earth blade / Earth arrangement. This will be terminated by

cable to outdoor Galvanized Gantry. 33 KV line capacities shall be mounted directly on Gantry

or separate structure shall be provided. Tender have to co-ordinates with state Electrical Board

for their metering arrangement metering room suitable lugs connector structure is in the scope

of Tenderer. Suitable Designing & providing layout for cable Trenches / Gantry is in the scope

of Tenderer for approval of the purchaser.

General specification for Metal Clad switch Gear is as below.

Tenderer have to furnish along with tender Garneted Technical particular to the purchaser in

Envelope No 2.

Tenderer shall provided mandatory spares along with vaccume interrupter Chamber as spare.



3.3 SPECIFICATION FOR 33 KV INDOOR SWITCHBOARD

1.0 STANDARDS

1.1 The equipment and devices covered in this specification shall comply with

following latest IEC / Indian Standards :

IEC : 62271-100,200 : Metal enclosing Switchgear and Control

Gear

IS - 3156 : Voltage Transformers

IS : 2705 : Current Transformers

IS : 1248 : Electrical Indicating Instruments

IS : 3231 & 3842 : Protective Relays

SPECIFICATION FOR 33 kV INDOOR SWITCHBOARD

2.1 Design Basis

2.1.1 The equipment shall be suitable for operation in tropical climate considering

design ambient temperature of 40°C. Temperature rise shall be per IEC 694

2.1.2 Degree of protection shall be IP 4X.

2.1.3 The switchboard shall be suitable for Short Time Current of 25kV for 3 sec.

Breaking current and Making current shall be 25KA at 36 kV and 62.5 kAp

respectively.

2.1.4 All the HV compartments shall be tested for Internal Arc of 25kA for 0.1 sec.

2.1.5 Power frequency withstand voltage shall be 70 LV rms.

2.1.6 Impulse withstand voltage shall be 170 KV peak.

2.1.7 The circuit breaker shall be tested for cable charging and capacitor duty for

minimum "C2" category of latest IEC.

2.2 Constructional Features.

2.2.1 Switchboard shall be factory assembled, totally enclosed, metal clad, dead front

cubicles. It shall be completely wired with all electrical accessories as specified

in the tender.

2.2.2 Switchboard shall be dust, moisture and vermin-proof. All louvers shall have

screens and filters. Vent openings shall be so arranged that hot gases or other

material cannot be discharged through them in a manner that can injure the

operating personnel. Pressurized gas shall get discharged only from the top of

the respective HV compartments.

2.2.3 Sheet steel shall preferably be galvanized to avoid rusting. Sheet steel thickness

shall be as per manufacturer's type tested design. Cubicles shall be fitted with

removable gland plates of non - magnetic material with built in adjustable cable



holding clamps. It is preferable to have fabricated cubicle with riveted design.

2.2.4 Switchboard shall have separate vertical section (panel) for each circuit breaker.

2.2.5 Separate compartments shall be provided for circuit breaker, low voltage

instruments, bus bars and cables. Current transformers shall be mounted in the

cable compartment, on a roller, for ease of handling. Line potential transformers

shall be mounted at the rear side of the respective breaker panel. Bus potential

transformer shall be housed in a separate trolley, placed in a separate panel. It is

mandatory to have PT primary fuse replacement without switching OFF the

breaker. Assembly of all current carrying parts shall be such that they shall be

easily accessible for inspection and maintenance. Separate explosion vent shall

be provided for each of the HV compartments, circuit breaker, bus bar and

cable.

2.2.6 Seal off bushing shall be provided between the breaker and bus bar

compartment and also between the breaker and the cable compartment.

2.2.7 The panel shall be designed for accommodating 6 runs of 1 C x 185 sq. mm cu

cable or 1 runs of 3C x 185 sq. mm cable, without using any rear cable extension

chamber. Hear room clearance for cable termination shall be minimum of 750

mm. Power cable entry shall be from the rear bottom of the panel. Control cable

entry shall be from the front bottom of the panel, along the either side of circuit

breaker. Split gland plate with adjustable cable holding clamp shall be

provided. Motorized option for rack in / rack out with door closed shall be

preferred and if bidders can quote this option with extra price if design is

available.

2.2.8 Switchgear shall be having following interlocks

Movement of CB from test to service position shall be possible only

when all the following conditions are met with.

1 The breaker is in OFF position.

2 The auxiliary plug and socket is engaged and locked.

3 CB compartment door is closed.

4 Rear covers are closed.

5 Earth switch is OFF.

Movement of CB from Service to Test position is possible only when the CB is OFF.

Front door of breaker compartment cannot be opened unless breaker is tripped and brought to test position.

Auxiliary plug and socket cannot be opened unless the CB is brought to test position.



Earth switch in the outgoing side ( rear side) can be made ON only

when circuit breaker is switched OFF and brought to test position.

Rear cable cover cannot be opened unless breaker is OFF and brought to

test position and the earth switch is ON.

2.2.9 Metallic shutters shall be provided to prevent accidental contact with main

stationary contact or other live parts when the circuit breaker is drawn out.

When the circuit breaker is inserted back in the cubicle, it shall allow the circuit

breaker to continue its travel until it fully engages the main stationary contacts.

Suitable guides, slides and stops for proper positioning of the truck or trolley

with the circuit breaker shall be provided to ensure easy removal, replacement

and positioning of the circuit breaker. All circuit breakers of same rating shall

be interchangeable with one another. Provision shall be made to prevent entry

of circuit breaker of different rating even though the cubicle width remaining

same. It is preferable to have cubicle width not exceeding 1000 mm

2.2.10 Each circuit breaker cubicle shall be provided with cable earthling switch at the

rear side with due interlocks as started earlier. Earth switch shall be tested for

full fault making current capacity as well as short time rating. Provision shall be

made for the operation of earth switch both from front as well as rear.

2.2.11 Instruments and relays shall be mounted on the hinged type front door of the

metering compartment.

2.2.12 For galvanized structures, only the doors and side covers shall be painted with

shade RAL 7032. All MS structures shall be painted with shade RAL 7032

2.2.13 Breaker compartment door shall get locked at various points with one lever

operation. It shall not necessitate bolting at various points for safety and

reliability at all times. Doors and covers shall have several hinge points for

proper locking to avoid opening of the same in the event of internal arc.

2.3 Busbars

2.3.1 The main bus bars shall be of electrolytic copper, with tubular design for

uniform field gradient.

2.3.2 The bus bars shall be located in a separate metal clad chamber and shall be air

insulated. Bus bars shall be extendible on either side.

2.3.3 The bus bars shall be rated for continuous current, at 400C ambient temperature.

Temperature rise shall be as per IEC 694

2.3.4 The bus bars shall be adequately supported on insulators or integral epoxy spouts to withstand dynamic stress due to the short circuit current specified.



2.3.5 The bus bars shall be sleeved for full voltage. The joints shall be shrouded by

epoxy material. Corona shielding shall be provided at the terminals. Sleeve shall

be heat shrinkable BTPM type of Raychem make. No. PVC sleeving in bus bar

for 33 KV is acceptable.

2.4 Circuit Breaker

2.4.1 Switchboard shall comprise indoor, metal clad, fully draw-out, Vacuum Circuit

Breaker. The circuit breaker shall be trolley mounted and shall be operated by

motor wound spring charged mechanism.

2.4.2 Vacuum interrupters shall be housed either in epoxy cast poles with retrival of

interrupters possible for fully insensitive to adverse climatic conditions or shall

be mounted on epoxy body. Mounting of interrupters on conventional insulator

methodology will not be acceptable.

2.4.3 Each circuit breaker shall be provided with the following accessories.

a) ON – Off indicator for indicating circuit breaker position.

b) Trip push button

c) – Shunt trip coil, operating between 70% - 110% of rated control voltage.

d) – Close coil, operating between 85% - 110% of rated control voltage.

e) – Spoiling charging motor, operating between 90% - 110% of rated control

voltage.

f) – Dual tripping coils if required shall be provided in all the breakers.

Note – VA burden of coils and charging motor shall be within 250 VA.

C – Shunt trip coil, operating between 70% - 110% of rated control voltage.

2.5 Wiring

2.5.1 Wiring for all control circuits shall be carried out with 1100 volts grade PVC insulated stranded copper conductor of size not smaller than 1.5 sq. mm. CT circuits shall be with 2.5 sq. mm size conductor.

2.5.2 Color of wire shall be black, grey and green for AC, DC and earth circuit respectively.

2.6 Earthling

2.6.1 An earth bus of size 40 mm x 6 mm copper shall be provided and shall be extended throughout the length of the switchyard.

2.6.2 It shall be possible to connect each circuit (cable) of the switchgear to earth, through earthling switches suitable for fault make current.

2.6.3 Earthling switch shall be mechanically interlocked with the associated breakers, as per the interlock requirement started earlier.

2.6.4 Breaker compartment shall have scraping earth bar and spring load finger shall be provided in withdraw able truck.

2.6.5 Earthling circuit shall also be tested for 25 KV for 1 second.



3.4 TESTS:

The equipment shall be tested at independent laboratory as per IEC 62271 – 100/200 for the

following minimum tests.

a) Complete breaking duties for 25 KA at 36 KV.

b) Making current test.

c) Double line to ground fault test

d) Single-phase test.

e) Capacitor duty test for C2 category.

f) Cable charging for C2 category.

g) Internal are tests for all high voltage

h) Short time rating for 25 KV for 3 seconds

i) Short time rating of earthing circuit for 25 KV for 3 sec.

j) Fault making test of earth switch

The tests specified as per relevant Indian Standards and I.E.C. The tests shall be carried out as

specified there in and test certificates forwarded in four copies. No dispatch of any plant and

equipment shall be made before the test certificates are approved by the Purchaser’s

representative. All to and fro expenses of such representative shall be born by the Contractor.

These tests shall not, however absolve the contractor from the responsibilities for guaranteed

performance at site. In addition to the tests referred to above, the purchaser reserves the right of

carrying out such additional tests as he may decide.

3.5 TRANCHES AND FOUNDATIONS:

Detailed working drawing showing dimensions and layout of trenches, ducts etc. for cables

and foundations for the switchgear and power transformer shall be submitted after the contract

is awarded. Concrete work in formation, including trenches, preset removable slab etc. shall be

carried out by the contractor according to the approved drawings submitted by the contractor.

All conditions bolts or other metal parts required to be embodied in the concrete shall be

supplied by the contractor and included in his price tender for plant and equipment.

a) GENERAL STANDARDS:

All switchgear and all apparatus and device connected to or forming a part of the equipment

including all wiring, piping, fittings and accessories shall be in accordance with the best

modem practice and shall conform to the latest applicable standards of the Indian Standard

Institution, American standards association, British Standard Institution, IEC or other approved

standards as regards design construction, characteristics and performances tests.

b) CLEARANCES:

The minimum clearance for out door equipment between live parts and grounded structures

and between live parts of different phases shall be as per approved drawings of 33 KV



switchyard by the Electrical Inspector, Public Works and Housing Department of GOM &

clearance shall be arrange by the Contractor. The Contractor shall state in his tender the actual

clearance and spacing provided by him according to his standard practices and I.E. Rule but

not less than those given any where in the specifications herein.

3.6 INSULATION

Insulation of the various components of the system shall be suitable coordinated among

themselves and with reference to characteristic of the protective apparatus used such as

lightning arrestor, horn gaps etc. in order to ensure that breakdowns due to over voltages are

prevented in the whole system. The neutral of the 33 KV system will be solidly grounded so

that for purpose of insulation, the system may be assumed as ‘Effectively earthed system’, thus

permitting application of lightning arrestors with lower rated grounded neutral voltages viz.

80% lightning arrestors expected to be 30 KV Contractor are requested to recommend most

suitable rating of lightning arrestor after carefully studying the various aspects. The basic

insulation levels for the main transformer are proposed to be as below.

Contractor to note that transformer winding (High voltage side) is tested for :-

i) Impulse test voltage 650 KV peak

ii) Power frequency test voltage 275 KV R.M.S. for 1 min.

In order to provide adequate protection to transformer and as well as other apparatus in the

switchyard included in the drawings. The exact location of these lightning arrestors shall be

carefully studied and determined by the Contractor with view to ensuring that all equipment at

the switchyard lie within the protected zone of the lightning arrestor and shall be subject to the

approval of the Purchaser.

3.7 TEMPERATURE RISE

The maximum temperature attained by any part of the equipment when in service at site under

continuous full load conditions and exposed to direct rays of sun shall not exceed the

permissible limits fixed by respective IS/BS specifications. When the standard specifies the

limit of temperature rise this shall not exceed when corrected for the difference between the

ambient temperature at site, and the ambient temperature specified in the respective IS/BS

specification. The correction proposed shall be stated in the tender and these shall be subject to

approval of the purchaser. The ambient temperature at site shall be taken as 45º c in summer in

open yard.

3.8 GENERAL DESIGN FEATURES :

3.8.1 The design of the equipment shall incorporate the following:

1) The equipment shall be designed to ensure satisfactory operation under all conditions of

services and to facilitate under other contracts.



2) All apparatus shall operate without undue vibration and with the least practicable

amount of noise.

3) Cast iron shall not be used for chambers of oil filled apparatus or for any part of the

equipment which may be subjected to tensile stress.

4) Kiosk, cubicles and similar enclosed compartments forming part of auxiliary equipment

shall be adequately ventilated to minimize condensation. Besides, space heaters shall be

included for this purpose wherever necessary so as to withstand very damp and humid

conditions. The doors of such equipment shall be water tight with durable rubber

gaskets.

5) All Indoor apparatus, including bushing insulators and fittings, shall be designed so

that water cannot collect at any point.

6) The undersides of all tanks shall be ventilated in approved manner to prevent corrosion.

7) The Indoor equipment, all bolts, nuts and washers in contract with nonferrous parts,

shall unless otherwise approved be of phosphor bronze.

8) Means shall be provided for the easy lubrication of all bearings and where necessary of

any bearing surface of moving parts.

9) All mechanisms shall when necessary be constructed to prevent sticking due to rust or

corrosion.

10) All connections and contracts shall be of ample section and surface carrying

continuously the specified current without under beating and shall be secured by holds

or set screws of ample size, fitted with lock, nuts or lock washers of approved type.

Lock nuts shall be used on stud connection carrying current.

11) All bolts and nuts shall be used on studs of terminals which have to carry current and

shall be of rust proof hard durable and high conductivity material. They shall be locked

in position. All lock nuts or lock washers shall be of approved type.

12) All water, air, gas and oil pipe flanges shall comply with BS-10 or other approved

standard as regards both dimensions and drilling, screwed couplings and fittings shall

comply B.S. Pipe threads or for conduit suitable for continuous operation at specified

voltages. The area is prone to seismic disturbances. Project area is situated in earth

quake zone. All the equipment shall also be suitable for following operations of the

power station in the grid.

a) Generation operations

b) Spin-Generation Operations.

c) Peak load operations

Design shall take care of 4 make & 4 break operations a day.



3.8.2 DETAILS OF CT CORES:

i) TRANSFORMER H.V. SIDE Each CT with three cores and a spare suitable for per

phase.(INDOOR TYPE)

Core No Ratio/class Purpose

Core 1

Ratio 60/1, Class PS, VK 30KV,

50VA

Generator & transformer differential

protection R.E.F. protection

Core 2 60/1 Class 5

P 10 Burdan 30 VA

Over current and earth fault

protection

Core 3

Core 4

Ratio 60/1 Class 0.5 Each 50VA

Class PS

Metering Spare.

Spare

SIMILAR FOR EACH PHASE.

ii) 33 KV LINE SIDE (3 NOS IN LINE BAY) Each CT with three cores and a spare

suitable for protection.

Core No Ratio/class Purpose

Core 1

Ratio 60/1, Class PS, VK 100

KV. Imag

As low as possible

Protection

Core 2 Ratio 60/1, Class 0.5. 50VA Metering

Core 3

60/1 Class 0.5. 50VA.

Similar

E/F and over current Protection

Core 4 Class PS Spare

Note:- Knee point voltage (VK) & VA burden shown here is indicative and is to be designed by

the Contractor.

The cores 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.

3.8.3 VOLTAGE TRANSFORMER

TYPE AND RATING

The Voltage Transformers shall be Indoor type and shall be as per the following specifications

or their latest revisions.

i) I.S. 3156 (Part-I, II and III) 1965 Voltage Transformers general requirements Part-I, measuring

voltage transformer – Part-II.

ii) I.S. 3156 (Part-IV) voltage transformer (Part-IV) capacitor voltage transformers.

They shall be suitable for the following technical particulars.



a. Service voltage : 33 kV Class, 3 Phase, 50 Hz.

b. Highest system voltage : 36 kV

c. Earthing condition : Effectively earthed

d. Insulation level : 170 kV peak

e. One minute power frequency

withstand voltage kV R.M.S.

: 75 kV, R.M.S.

f. Number of phase and connections : Single phase 3 Nos. in star connection

g. Transformation ratio : 33 kV 110 V 110 V

√3 √3 √3

h. Rated output per phase : 50 VA each core

i. No. of Cores : 2

j. Voltage factor and rated time : 1.1 continuous 1.5, 30 seconds

k. Type : Magnetic

DETAILS OF CORE

Core No Purpose Accuracy Class Burden (VA)

Core – I Metering 0.5 50

Core – II Protection 0.5 50

The P. T. secondary fuses should be provided in the P.T. Marshalling box.

3.8.4 CLAMPS

The various clamps required shall confirm to the following specifications.

CONTACT PRESSURE

Sufficient contact pressure should be maintained to ensure low contact resistance, but not so

great as to cause relaxation of the joint by cold flow. The design of the joint between the clamp

and the conductor or equipment terminal should be such that the pressure is maintained within

the range under all conditions of service.

To avoid excessive local pressure, the contact pressure should be evenly distributed by the use

of pressure plates or washers of adequate area and thickness. All the edges and corners shall be

rounded off to avoid corona effect, sharp edges or corners shall not be permitted.

Bimetallic joint should be protected from the effects of electrolytic action.

The resistance of the clamps shall be vary low.

3.8.5 BUSHINGS

STANDARDS:

The high voltage bushing used in circuit breaker instrument transformers and other equipment

covered in these specifications shall confirm to the latest addition of Indian Standard

Specification 2099/1962.



TYPE AND RATING

The rating of high voltage bushing shall be properly coordinated with the ratings of

equipments for which these shall be used.

The bushings shall be of porcelain oil filled condenser type and shall have ample insulation,

mechanical strength and rigidity for satisfactory operation under climatic conditions specified

in ‘General Information’. Oil filled bushings shall be free from oil leakage and shall be provided

with suitable sight gauge to show the oil level in the bushing. Approved means shall be

provided to ensure that the correct oil level is maintained. It shall also be provided with

convenient means for sampling and draining the oil. The bushing shall also be designed to

prevent accumulation of explosive gases and to provide adequate oil circulation to remove

internal heat. The bushings shall be so designed that there will be no undue stress of any part

due to temperature variations and adequate means shall be provided to accommodate

expansion of the conductor. The bushing shall be entirely free from radio disturbances when

operating at voltage upto 10% above the rated voltage and shall also be free from external and

internal corona effect. All bushing shall be equipped with suitable terminals of approved type

and size.

The porcelain used in construction of bushing shall be homogeneous, free from laminations,

cavitations and other flaws or imperfections that might effect the mechanical or dielectric

strength. These shall be thoroughly verified through and improvises to moisture. The glazing

of the porcelain shall be free from imperfections such as blisters and burns.

3.8.6 INSULATIONS

STANDARD:

All post, suspension and tension insulators required for 33 kV switchgear and other

connections shall confirm to Indian Standard Specification No. 731, 1971 with latest

amendment thereof. The tension and suspension fittings (Hardware) shall be as per IS 2486

(Part-I & II) 1871 insulation level 220 kV peak and one minute power frequency with stand

voltage 75 kV r.m.s.

TYPE AND RATING:

All the insulators shall be supplied by the contractor and shall be complete with necessary

hardware fittings. Post insulators shall consist of at least 3 Units for 33 kV system. The

suspension and tension shall be arranged such that maximum loading does not exceed 200 kg

and 900 kg respectively. Every suspension and tension insulator string for 33 kV systems shall

be provided with arcing horns both on the conductor and disc and at the structure and disc.

The design and location of the arcing horns shall be such that it will reduce the liability of

damages to the conductor, clamps and insulator units under all flashover conditions and it

shall not present of foothold or porch for large birds.



The design of arcing horns together with complete description and data shall be submitted to

the purchaser for approval before use. Switchyard equipment shall be designed for 36 kV

system highest voltages but will be charged at 33 kV for the present.

The porcelain shall not engage directly with hard metal and where necessary an approved

yielding material shall be interposed between the porcelain and fittings. All fixing material

used shall be of approved quality and applied in a approved manner and shall not enter into

chemical action with the metal parts or cause facture by expansion in service. Where cement is

used as fixing medium, cement thickness shall be as small as possible and proper care shall be

taken to correctly enter and locate the individual parts during cementing.

Clamps and fixing mode of steel and malleable iron shall be hot dip galvanized. All bolts and

nuts unless other approved means. All bolts threads shall be greased properly before erection.

3.8.7 CONDUCTOR AND CONNECTIONS

STANDARDS:

The conductors and connections shall be of standard aluminum and shall conform to relevant

Indian Standard Specifications.

TYPE AND RATINGS:

The conductor size shall be such as to carry the rated current of 100 Amps without overheating.

The particulars are as under.-

1. Type of A.C.S.R.

i) 0.2 PANTHER conductor for connections between equipment & Line, LAS.

2. Number of Phases. : 3

3. Voltage. : 33kV.

4. Normal current of bus and connectors : 100 Amps. @ 40 degree Celsius.

5. Frequency. : 50 HZ, +3% and –5%

6. Short Time Current for 3 sec. : 16 kA (r.m.s.)

Where standard conductors are employed for the busses and connectors the sag for the

individual span shall be subjected to the approval of Purchaser. The arrangement of the

connection and method of joining them to the apparatus shall be such that the expansion or

contraction of the connections subject the associated apparatus any stress and strain. Jointed

between busses and tee of connector of individual length of the buss and between individual

apparatus shall be securely clamped to the conductor and at the same time provide ample

contact surface for carrying the full rated current of the equipment.

The design of the joints and connector shall be such as to facilitate the breaking of the joints,

when required. Special care shall be taken to avoid the possibility of any electrolytic action

between conductor clamps and material of the apparatus. The connectors should be bi-metallic

wherever necessary. As the ACSR PANTHER conductor will be used for 33kV jumpering



connections between equipment bus respectively, the suspension insulators, strings, clamps,

jumper, connection etc, shall be suitable for connection between ACSR PANTHER conductors

and is a part of scope of supply. Two/ or Three set of earthing devices for 33kV class shall be

provided to enable any portion of the bus conductor or circuit connection to be earthed. The

method of attachment and removal of the earthing device shall be by means of insulated

operating pole. Two sets of shorting devices for phases of the Power Transformer shall be

provided for Dry out run of the transformer.

3.8.8 MARSHALLING BOXES

Marshalling boxes shall be weather proof out door type, corrosion resistant, vermin proof.

Marshalling boxes of steel sheet construction, inside painted with white anti-conventional

paint, base plate suitable for cable opening and necessary cable glands, approved type metal

clad heater controlled by thermostat, complete with support frame work, lifting hooks, anchor,

terminal hinged door with locking arrangement etc complete with internal wiring from circuit

breakers, operating mechanism isolator, CTS, PTS etc, and containing 10% extra terminals etc.

3.8.9 GALVANISED STEEL STRUCTURES

The Contractor shall have to supply suitable galvanized steel structures for entire switchyard.

Galvanized steel structure shall be of lattice type and structure shall be of hot dipped

galvanized. Quantity of hot dipping shall be determined by test given in IS 728-1959. The

structure for each equipment shall be complete with necessary bolts, nuts, drills etc for

foundations and erection insulators etc. All structure shall be of galvanized steel type and shall

be designed to allow for the following conditions.

Wind pressure in any direction of 125kg per meter square. Site is in 100% humid area for

prolonged period of the year.

This will consist of dead loads due tom structure and conductors. Tension in each conductor

and earthwire shall not exceed 900kg in each conductor. Factor of safety shall be 2.5 times

under maximum loading conditions.

3.8.10 EARTHING SYSTEM

Contractor shall provide earthmat of MS flat for earthing 33 KV switchgear. Contractor shall

provide the entire earthmat material. All equipment and metal bodies shall be securely

connected to earthmat system. Earth resistance at the switchyard location is 0.75 ohms.

Earthing system shall conform to IS3034 and approved by Electrical Inspector.

3.8.11 EARTH WIRE :

The earth wire shall be made up of 8 SWG hot dipped galvanised wire. Quality of hot dip will

be in accordance to IS2633.

3.9 TESTS AT MANUFACTURES WORK :

9.1 TYPE TESTS:



Certificates of all type tests carried out by manufacturer of each equipment shall be provided.

Incase equipment is not type tested earlier Contractor shall carryout the same at his cost and

certificate furnished.

9.2 ROUTINE TESTS :

All routine tests as stipulated in relevant prevailing ISS shall be carried out in presence of the

Purchaser’s representative at the cost of the Contractor. All to and fro charges of the

representative are deemed to have been included in the cost.

3.10 DRAWINGS AND DATA TO BE FURNISHED ALONGWITH THE TENDER

Contractor shall furnish the following drawings and data’s.

1. Literature giving complete details of all equipment.

2. Dimensioned drawings of all equipment.

3. Switchyard layout plan and sections providing all details.

4. Schematics of all equipment where ever relevant.

5. Details of the supporting structure.

6. Guaranteed technical particulars of each equipment in accordance to respective ISS.

3.11 DRAWING AND DATA TO BE FURNISHED AFTER THE AWARD OF CONTRACT

On award of contract and detailed engineering following final details shall be furnished.

3.11.1 CIRCUIT BREAKER

1. Opening and closing times

2. Arching time for 50HZ supply

3. Interruption time with length of break.

4. Method of contact joints of conductor.

5. Temperature contour cycles.

6. Normal frequency recovery voltage and circuit recovery transient voltage with method of recovery.

7. Overall dimensions and weights.

8. Impulse level of insulation.

9. Quality details with chemical analysis of ingredients of SF-6.

3.11.2 DISCONNECTING SWITCH/ ISOLATOR

Detail shall be provided as follows. a. Design and graph for current carrying path. b. Max initial short circuit current. c. Maximum momentary current carrying capacity. d. Maximum secondary current carrying capacity. e. Stress in the system during short circuit. f. Physical properties. g. Weights and dimensions. h. Details of fixing.



3.11.3 LIGHTNING ARRESTORS

Following details shall be given both for station type and pole mounted LAs.

a. Surge voltage to which arrester is designed.

b. Number of gaps in service and characteristic elements.

c. Discharge current.

d. Follow current.

e. Volt-Amp characteristics.

f. Discharge capacity crest amp.

g. Magnitude and duration.

h. Weights and dimensions.

3.11.4 CURRECT TRANSFORMERS

1. Over current factor for design.

2. Peak value of initial symmetric rated primary over current.

3. Number of turns of primary and secondary winding.

4. Accuracy curves.

5. Current densities in primary at over current.

6. Weights and dimensions.

3.11.5 VOLRTAGE TRANSFORMERS

1. Number of turns and cross sections of primary and secondary windings.

2. Accuracy curves.

3. Weights and dimensions.

3.11.6 FOUNDATION

Foundation drawings with dimensions, loads, reinforcement details and methodologies of

construction.

3.12 ERECTION TESTING AT SITE AND COMMISSIONING

Detailed programme chart showing all activities viz. manufacturing period, delivery to site,

foundation works. Earthmat installation, installation of structures, instillation of equipment

item wise, testing and commissioning etc complete shall be furnished. All site tests shall be in

accordance to relevant ISS.



B . REMOTE M.S.E.D.C.L. SUB-STATION AS PER SLD ENCLOSED IN DRAWING SECTION

i)33KV, 630A, 25KA Vaccum Circuit Breaker 1 No.

ii) 33 KV, 400A Manual operated Isolator with Earth switch 1 No.

iii)33 KV, 400A Manual operated Isolator With out Earth Switch 1 No.

iv) 33 KV, 60/1/1A, 2-core CT for Trivector check Metering 3 Nos.

v) 33 KV, 60/1/1/1A, 3-core CT for Metering & Protection 3 Nos.

vi) 33 KV, 2-core PT for Trivector check Metering 3 Nos.

vii) 33 KV, 2-core PT for Metering & Protection 3 Nos.

viii)30 KV, 10KA Lightning Arrestor 3 Nos

ix) Galvanized Columns, Beams and Supporting Structures 1 Lot

x) ACSR conductor, tension insulator, Suspension Insulator, Clamps and Connectors, Isolator etc.

1 Lot



SECTION – III- E

SUITABLE CAPACITY E. O. T. CRANE

3.1 GENERAL :-

Suitable capacity EOT Crane is to be installed in the machine hall of Power Station of

JAMBRE HYDRO ELECTRIC PROJECT. Capacity will be decided by the TENDERER. The

Crane is to be used for erection, assembly and maintenance of generating plant and other

associated equipment. The plan and cross section of the power house is attached herewith.

The power house building will be provided with RCC beams over which gantry rails for the

long travels are to be fixed.

3.2 SCOPE OF WORK :-

The scope of this specification shall cover the design, manufacture, tests before dispatch,

proper packing, delivery including loading and unloading, testing, commissioning at site and

setting to work, including insurance till handling over of Crane complete with related

equipments and service as per the requirement of the specification and furnishing manuals,

documents and drawing. The scope of work shall comprise of the following.

a) Design, manufacture, tests at work of EOT Crane confirming to latest editions IS- 807, IS-

3177 and to this specification.

b) Gantry Rails, for the full length along with continuous sole plates, foundation bolts,

anchors, packing plates etc.

c) Down shop leads: Down shop leads of copper wire complete with supporting and strain

insulators brackets & other fixtures.

d) Spares and tools

e) Working out and finalizing the arrangements of supplying necessary equipment for crane

to connect main incoming supply cable to the down shop leads together with the main

switch of adequate rating, before the down shop leads. The main switch shall be located

above gantry beam level.

f) The scope of this specification shall not be limited only to the one enumerated above but

shall also include the following.

i) Preparation & finalization of layout and fixing details of gantry rails and down shop

leads.

ii) Necessary block outs required for fixing the gantry rails and down shop leads will be

provided by the contractor. Further, the civil Engineering works like grouting of

foundation bolts (to be supplied by the contractor) for gantry rails and down shop leads

will be done by the contractor.

iii) Supplying and providing proper earthing of the crane structure, motor frames and metal

cases of all electrical equipments.



iv) First filling of oil, grease etc along with equal quantity as spare.

The intent of this specification shall be to execute work on a PACKAGE DEAL- basis from the

design stage till the crane is commissioned and put into operation successfully at site as per

the terms and conditions of this specification.

NOTE: - Contractor shall specifically ascertain that the parameter of bay length, span. End

clearances are as available at site.

3.3 APPLICABLE STANDARDS :-

Except where stated otherwise E. O. T. crane & associated equipments and accessories shall

comply fully with the latest edition/ revisions of the following standards :-

a) Code of practice for design, manufacture, erection,

& testing (structure portion) of cranes hoist. IS- 807

b) Code of practice for design of overhead traveling cranes

And EOT cranes other steel work crane. IS- 3177

c) Hook. IS- 8610

d) Wrought iron and mild steel hook. B. S. - 482 or IS- 8610

e) Crane rail sections. IS – 2062

f) Wire Rope IS - 2266

All other associated equipment / material such as steel, casting, wire ropes, welding, motors,

cable, conductors, and switchgear shall confirm to the relevant British Standard or other

International Standard.

3.4 TYPE & RATING :

The E. O. T. Crane shall be designed and manufactured to comply with the following

technical particulars.

Sr. No. Particulars. E. O. T. Crane.

1. Type and class Medium duty, class II,

Indoors type, from pendent

operated through master

controllers, VVVF Drive

2. Capacity (safe working load)

a) Main hook (Rams horn type)

b) Aux. Hook (C type)

Suitable Tones.

5 M. Tones.

3. a) Span (distance between center to center

of gantry rails)

b) Number of long travel wheel.

As per design of main plant.

8 Nos.

4. a) Operating speeds (leaded) the maximum

desired speed in meter per minute for all

the four motions are indicated below.

b) Main hoist.

2 m/ Min (Max)



c) Auxiliary hoist.

d) Long travel.

e) Cross travel.

f) Micro speed for main hoist.

6 m/ Min (Max)

20 m/ Min (Max)

15 m/ Min (Max)

0.2 m/ Min (Max)

5. Clearances.

A) Distance from center line of gantry rail to

the nearest side obstruction

a) On down – streamside.

b) On upstream side

B) Height of gantry beam top from generator

floor level, (excluding rail height.)

C) Vertical distance from the beam to the

lowest overhead obstruction.

460 mm.

460 mm.

3800 mm.

6. A) Nearest position of main hook to the

center of gantry rails.

a) On down stream side.

b) On up stream side.

B) Nearest position of auxiliary hook to the

center of gantry rails.

a) On down stream side.

b) On up stream side.

C) End clearance for main hook from the

power house wall in the extreme end

position of the crane along the bay length.

a) From power house wall to service bay

side.

b) From center line to unit bay side.

2200 mm.

1200 mm.

1200 mm.

1100 mm.

3000 mm.

3000 mm.

7. Lift of hooks in mm with ref. To generator

floor level.

A) Main hoist

a) above generator floor level

b) below generator floor level

B) Aux. Hoist.

a) above generator floor level

b) Below generator floor level.

To be indicated by tenderer

To be indicated by tenderer.

As per A above.

As per A above.

8. Total length of bay. To be decided by tenderer.

9. Powers supply A. C.

Volts.

Phase.

Wires.

Frequency.

415 ± 10%

Three

Four

50 Hz. +3%,-5%

10. Restriction on wheel loading (Without

impact)

20 Tones.



3.5 SERVICE CONDITIONS :-

The crane shall suitable under worst service conditions when it is handling (i.e. lifting,

lowering, holding, traveling, and / or cross traveling at the prescribed speeds) any load from

self weight up to the maximum load and overloads for which the crane is designed.

3.6 LOAD INDICATIONS :-

The crane bottom block shall bear a permanent inscription on each side readily legible from

the floor level stating the safe working load on the main and the auxiliary hook.

3.7 FACTOR OF SAFETY :

It shall be guaranteed by the tendered that safe electrical and mechanical stresses have been

adopted in designing the equipment and the components under all specified conditions of

operation and the stresses adopted are conservative. Whenever necessary the contractor shall

provide access to all technical calculations in respect of the crane. The crane shall be so

designed and constructed that when it is working under worst conditions of loading in

service, the stresses on any part shall not exceed the permissible stresses stipulated in the

latest edition of relevant I. S. The factor of safety of all parts of the crane shall be as per

relevant BS or I. S. The relevant standards adopted for factor of safety for various parts of the

crane shall be stated in the tender along with the of safety of adopted. The successful tenderer

shall furnish the structural calculations showing clearly the calculated stresses, factor of

safety adopted and the maximum permissible stresses, in respect of end carriage assembly,

bridge assembly and crab assembly.

3.8 STRUCTURE :-

The crane structure shall be designed for the worst condition of loading, care being taken to

allow for the appropriate impact factor (inertia forces including shock) and the lateral thrust

etc, in accordance with I. S. 807. All the structural parts of the crane shall be fabricated from

tested wieldable quality steel conforming to I. S. 2062, test certificates for which shall be

furnished to the purchaser by the contractor before taking up the fabrication work. The crane

structure shall be so designed that the actual calculated stresses for the serest combination of

leads shall not exceed the permissible stresses in accordance with the above mentioned Para,

“Factor of safety”.

Crane shall be double girder box formation. Tenderer shall verify transport possibilities of

single girder on rout to project site and he will be solely responsible for the same.

3.9 CRANE BRIDGE :-

The crane bridge girders shall be designed in accordance with I. S. 807 and other relevant

standards applicable. The girder for the crane bridge shall be of “ Box” type construction and



shall be fabricated from tested wieldable quality steel conforming to I. S. 2062 welded girder

construction designed to carry safely the full rated load of the crane without undue vertical or

lateral deflection or vibration. The bridge girder shall be so designed that in edition to

complying with the requirement of allowable working stress etc. Mentioned in the clause 7 &

8 above the vertical deflection caused by the safe working load with the crab in the central

position of the bridge shall not exceed 1/ 900 the span. The main structure of the crane shall

be in one piece. No side joints shall be allowed. The ends of the main girder shall extend over

the full width of the end carriage and the extensions shall have sufficient section to take

maximum reaction from the girder.

The crane shall be of anti vibration design. The box girder shall be designed so as to limit the

natural vibration damping time to less than fifteen seconds. Appropriate calculations

showing the damping of vibratio9n in the structure will have to be submitted to the

Department.

A platform of the chequered plating minimum 750 mm in clear width and properly guarded

with double tiered tabular and railings of 1100 mm height and two guards of minimum

height of 75 mm shall be provided on both sides of the cranes through out the span.

Track shall be provided on the top of the crane bridge girder for travel of the crap.

All parts of the crane shall be readily accessible maintenance and provision should be made

in the design accordingly. For easy assembly/ erection at site all parts of the crane structure

shall be aligned and match marked at works before dispatch.

3.10 CRAB :-

The frame work shall be fabricated from the rolled steel section fully welded together and

shall carry the necessary hoisting and cross traversing equipment.

Jacking points for crab should be clearly marked and noted on the crane. Necessary jacking

pads shall be provided for this purpose. The ends of the traversing rails shall be fitted with

and stop to prevent over traversing of the crab. Rubber buffers shall be provided for the crab.

Wheel skids shall also be provided for cross travel motion.

3.11 END CARRIAGE :-

The end carriage shall be fabricated from the rolled steel sections and shall be of rigid box

section of one piece construction provided with suitable diaphrame plates. The wheel base

shall be not less than fifth of the span. The ends of the traveling rails shall be fitted with end

stops and wheel skids, to prevent over running of the crane. Rubber buffer shall be provided

on the end carriage. The end carriage shall be fitted with suitable guards to prevent the crane

from derailing. It shall be provided with suitable jack pads on both the end. The jacking

points shall be clearly marked and noted on the crane.



The end carriage shall be designed so as to enable the track wheels to be withdrawn readily.

Suitable arrangement for locking of the wheels with the gantry rails. When the crane is not in

use shall be provided on each of the end carriage at both the ends. Mechanical jack of suitable

capacity and lift shall be provided for the inspection/ replacement of wheels of end carriage

and crab.

3.12 WHEEL & BEARING HOUSING ASSEMBLY :-

All the wheels of the crane and crab shall be double flanged closed dieforged and sorbitized.

The hardness at the surface shall approximately 350BHN, gradually reducing inwards up to

280 BHN at a depth of 15 to 20 mm. The materials of the wheels shall be C- 65 confirming to

IS – 1570.

All the wheels of the crane and crab shall be housed in “L’ type bearing housing assemblies

on either side of the wheels for easy

Removal and maintenance. The bearings provided shall be spherical roller bearings.

3.13 GANTRY RAILS :-

The contractor shall supply the gantry rails with continuous sole plate, anchors and necessary

fixtures etc. for the total travel of the crane. The gantry rails shall be of appropriate size, flat

bottom type and shall be suitably clamped to the sole plate throughout the length and

anchored suitably. The detailed drawings for this shall be given by the contractor for the

approval of the Department. The contractor shall supply along with the tender the requisite

information regarding the maximum wheel loading in the most unfavorable position.

3.14 LONG TRAVEL MACHINERY :-

The long travel motion machinery system shall consist of a totally enclosed oil lubricated

horizontal type reduction gear box which is driven by an electric motor situated on the

bridge. The output shaft of the gear box shall extend on both side and coupled to the long

travel shaft which drives two wheels of the crane bridge. The entire transmission system on

the output shaft of the long travel gear boxes shall be designed with use of geared flexible

coupling.

Totally enclosed self resetting two way lever type limit switches shall be provided to limit

over traveling of the bridge in both directions. Electro hydraulic thruster operated brake shall

be current supply to crane is off and bridge end carriage to stop without any shock. In

addition, a foot operated mechanical brake shall be provided for long travel motion.

3.15 CROSS TRAVEL MACHINERY :-

The cross travel wheels of the crab shall be driven by an electric motor through totally

enclosed oil immersed speed reduction gears having machine out teeth. The entire



transmission system on the output shaft of the cross travel gear box shall be designed with

use of geared flexible coupling.

An electro hydraulic thruster operated brake which applies automatically when supply is off

and shall be provided to bring the crab to rest without shock. Totally enclosed self resetting

two way lever type limit switches shall be provided to limit over traveling of the crab in both

directions.

3.16 MAIN HOISTING EQUIPMENT :-

The main hoisting equipment shall consist of fabricated mild steel rope drums conforming to

the relevant Indian standard and driven by an electric motor through a totally enclosed oil

immersed speed reduction gear. The rope drum shall have grooves machined to suit the

hoisting rope. The drum will be of such size that there will not be more than one layer of rope

on the drum when the rope is fully wound. Also the length of the drum shall be such that

each lead of rope has a minimum of three full turns on the drum when the hook is in the

lowest position and one spare groove for each rope lead when the hook is highest position.

The coupling between the hoist gear box and rope drum shall be with flexible gear joint. The

machine cut grooves shall be similar on both sides of the drum so as to ensure equal

distribution of the load on the two main beams of the crane bridge. Grooving shall be free

from surface defects liable to injure the rope. The rope anchorage shall be easily accessible.

A pulley block with cast steel pulleys with ball or roller bearings shall provided with guards

to prevent the ropes leaving the sheaves when the hook is lowered to rest on the ground. The

sheaves shall be machine grooved to a depth of not less than 1.5 times the diameter of the

rope. The grooves shall be furnished smooth and shall be finished smooth and shall be free

surface defects likely to injure the rope.

The main hook for the crane Ramshorn type and shall be forged steel and tested for proof

load. The hook shall be carried in a thrust ball bearing with freedom to swivel and shall

conform in all respect to I. S. 5749. Special precautions shall be taken to achieve an absolutely

vertical movement of the hook. A locking device shall be fitted to prevent rotation of the

hook, whenever required. It shall be possible to lock the hook in any position. The hook and

block shall be arranged to lift or lower without twisting or horizontal shifting. The snatch

block shall be fitted with guards to prevent the rope from leaving the pulleys. Certificates

giving actual chemical composition and physical properties for the main hook material shall

be forwarded in original.

The hoisting rope shall be of the best plough steel, stranded construction having the breaking

strength in accordance with I. S. 2365/ 70. The factor of safety under working conditions shall

not be less than six (6). The diameter of outer wires of the rope and the diameter of sheaves



shall be so chosen that the wire rope shall have sufficient fatigue resistance to withstand the

effects of bending and vibrations. The diameter of outer wire, the grade of wire and the

distribution of wearing surface shall be so selected as to have sufficient abrasive resistance.

The tender shall clearly state the methods adopted for selecting the diameter of outer wires as

careful balancing of above properties is essential in selecting the same.

The lay of the rope and the number of stands shall be so selected that the rope shall have

sufficient lateral stability.

The electro hydraulic thruster operated brake shall be provided with adequate margin of

safety to hold the load to prevent it from coming down when the current supply to the

hoisting motor is cut off accidentally or intentionally. In addition a three phase solenoid brake

of air dash pot type for main hoist shall be fitted on the extension shaft of motor for

emergency use. Totally enclosed self resetting positively acting two way rotary type limit

switches shall be provided to prevent over winding and over lowering of the hooks.

3.17 MICRO SPEED ARRANGEMENT FOR MAIN HOIST :

To achieve precision while lowering and hoisting the main hook at the 10% of the speed of

main hoist, the hoisting machinery shall be equipped with micro speed arrangement through

a separate motor. The micro speed shall be achieved through planetary gear unit.

3.18 AUXILIARY HOISTING EQUIPMENT :

The auxiliary hoisting equipment shall be generally of the same type as the main hoisting

equipment except for the provision of the micro speed arrangement. The auxiliary hook shall

conform to the relevant Indian standard. It shall provide with electro hydraulic thruster

operated brake, which applies automatically when the power supply is off. The brake shall be

suitable for continuous operation.

3.19 BRAKES :

All brakes shall be designed for continuous service conditions having a brake torque of not

less than 150 % of full load torque. The rubbing surface of the brake drum, shall be accurately

machined and shall be free from surface defects. The rubbing shoes of all brakes shall be self

aligning and lined with renewable asbestos or Ferrodo lining. The temperature of the rubbing

surface should not exceed 2000 C under working conditions. The test report for this shall be

submitted by the contractor. The brakes shall be provided with simple, easy and accessible

means of adjustment of the lining. The terminals of the brake magnets shall be protected from

mechanical damages and weather exposure wherever necessary.

A) 3 phase solenoid brake for main hoist motion comprising

1. Air dash pot type solenoid

The brake shall be applied gently without giving jerks.



2. Electro magnet :

3 phase electro magnet shall be totally enclosed with removable side cover for easy

maintenance. Magnet laminations shall be high grade low magnetic steel laminations. Coils

shall be wound on thoroughly insulated bakelite bobbin.

Dash pot: Provision for adjusting the speed of upward and downward travel of the plunger

shall be made.

3. Compression springs: Springs shall be made of steel and properly heat treated to give

correct hardness.

When the power to the crane is switched off, the compression springs shall provide working

to supply the brakes. When the magnet is energized, the solenoid shall exert force against a

spring pressure releasing the brake.

B) Electro Hydraulic Thruster Brake

i) Shoes: Large cooling surface shall be provided.

ii) Electro hydraulic thruster: Class B, 3 phase, continuously rated motor shall be provided to

drive the centrifugal pump. No. of switching operation per hour for the motor shall be

stated.

iii) Compression Springs: The brake shall be released by the Electro Hydraulic thruster

exerting thrust against the spring pressure. Dust excluding seals shall be provided.

3.20 EMERGENCY BRAKING :-

All the brakes shall, irrespective of controller’s positions be applied immediately on pressing

of an emergency stop push button to be provided in the operator’s cabin. In case of failure of

electric supply the crane shall immediately come to stand still position and breaks applied to

hold full load on crane.

3.21 LUBRICATION :-

Provision shall be made for lubricating all the bearings. Ball and roller bearings shall be

suitably lubricated before assembly.

The lubrication tubes from individual points will be brought to a single board for use of

maintenance. However, the number of such groups shall not be more than five.

A lubricating points, the type of lubricant and recommended frequency of lubrication. The

lubricating nipples adopted and tubes shall conform in all respect to the relevant Indian tubes

shall be dispatched separately and not mounted on the main structure as they are liable to be

damaged in transit.

The contractor shall supply sufficient quantity of lubricant for the first filling together with

hand greasing gun free of cost.



3.22 GEARING & GEAR BOXES :-

All greasing for ‘the crane shall be precision machine cut and shall have involute tooth with a

pressure angle of 200 .

The gears and pinions shall forged from C – 55 Min 75 materials as per IS- 1570 and they shall

have minimum hardness of 250 BHN. They shall have a factor of safety of not less than 6 (Six)

under severe working conditions.

Gear boxes shall be fabricated from mild steel as per IS 226 st 427 as they shall be totally

enclosed dust proof, oil bath type, and will have un spilt oil sumps. The cross traverse gear

box will be of vertical type. The gear boxes shall be provided with inspection covers to enable

a visual inspection of the working parts. Oil level gauges shall be provided wherever

necessary. Facilities for oil filling, adequate breathing and drainages shall be provided. The

gear coupling shall be forged form BN 8 material and shall have minimum hardness of 250

BHN.

3.23 Operations:- Crane shall be suitable for operation from pendant holder suitable for

operation from each floor and operation points..

3.24 WALKWAYS, LADDERS AND RAILINGS:-

Safe means of access shall be provided to the parts of the crane and to every place where a

person is expected to examine and inspect/ perform maintenance work on the crane.

Adequate hand railings and foot bolds shall be provided wherever necessary. All walkways

shall be of chequer plates open edges of which shall be provided with toe guards of minimum

75 mm height. All hands rails shall be tabular pipe and double tiered. Fixed steed ladder shall

be provided from bridge platform to cabin. The ladder shall have non slitreads not less than

450 mm vide and shall equipped with hand rails similar to walkway hand rails. Chequered

plate platform of minimum 750 mm clear width shall be provided on both bridge and shall be

at same elevation throughout its length. Similarly Chequered plate platform attached to each

girder along with all necessary equipment shall be provided for inspection of D.S.L. The

arrangement of platforms shall be got approved from the department.

3.25 ELECTRIC MOTORS:-

All electric motors shall be FEFC type fan cooler flame proof (except motor for micro –

hoisting) shall be totally enclosed slip ring induction motor suitable for crane duty. All

motors provided shall be approved make, and flame proof. The motor shall comply with

Indian standards 325 or equivalent British Standards and shall be suitable for frequent

acceleration and braking. All the motors shall be rated at 125% of the rated output at 150

starts per hour class of duty at ambient temperature, required under worst operating

conditions and they shall have class “B” insulation and shall be half hour rated for main hoist



motion and one hour rated for all other motions with temperature rise not exceeding 50o C

over ambient temperature of 45o C rating permitting over leads and their construction and

characteristics shall be suitable for the crane service. Motors shall be so located that the brush

gear and terminals shall be readily accessible for inspection and maintenance purpose.

All motors shall be suitable for voltage fluctuating between ± 10 % of rated value and for all

motions minimum eight pole motors shall be provided. All motors shall have grease

lubricated ball and roller bearings at non-drive and drive ends respectively. Cartridge type

bearing housing shall be provided for main hoist and auxiliary hoist motion so that motor can

be dismantled without disturbing and also for protection against dirt or dust entering in

bearing. For all other motors, the bearings shall be fitted in the housing accurately bored and

machined on end seals and sealed with dust cap.

3.26 CONTORLS:-

Master control equipment, whereby the operator may control the function of the crane shall

be placed in the operator’s cabin and shall be so arranged as to provide maximum of

convenience and view of the operation. All motor controls shall be full magnetic reversing,

with definite time limit on frequency controlled acceleration devices and instantaneous

overload and under voltage protection. They shall be designed so that it will be possible to

limit the vertical movement of the hooks with full rated load and when starting from

complete stand still to within 1.5 mm for the main hooks and to limit the movements of the

bridges and trolley, with full rated load and when starting from complete stand still to within

6 mm. All hoist motor controllers shall have at least five speed control points in each direction

of operation and all other controllers shall have at least four points in each direction of

operation. The contract of all protective relays shall be wired so that the operation of any

relay will trip all motor primary contractors thus making it necessary to return all controls to

the ‘OFF’ position before any motor can be started again. Instantenous relays shall be

adjustable between 200 to 300 percent of the motor full load current; change in speed in the

lowering directions shall be under the direct control of the operator and shall permit him to

stop the motors, without time delay, from any position of the master switches. All switches

controller, levers and other operating mechanism shall be marked plainly and permanently.

When practicable, the controller handles should move in the direction of the resultant load

movement. The position of the control shall be such that when operator is operating any

control handles, he cannot operate any other control inadvertently. The control lever shall be

provided with stops and catches to ensure safety and facility of operation.



3.27 CONTRACTORS AND RESISTERS:-

The contractors and the resisters shall comply with the provision of the relevant clauses of I. S

3177/1977. They shall be of the non- breakable, corrosion resisting type with a low

temperature co- efficient and shall be air-cooled. The resistance shall be provided in well-

ventilated sheet metal boxes.

The contractors and resistors shall be adequately protected to prevent accidental contact with

live parts. Resistors shall be so arranged that they are easily accessible for adjustment

examination and replacement, care being taken to see that it is not affected by vibrations.

3.28 ELECTRICAL PTOTECTIVE GEAR:-

An air brake contractor type main circuit breaker shall be provided in the control cabin

connected by suitable cable to the air circuit breakers and fitted with magnetic type inverse

time “elements” overload relays and no volt tapping device acting instantaneously in case the

supply voltage drops below 60 % of its normal value. The no volt-tripping device shall be

capable of being used for tripping the main circuit breaker in emergency from suitable

position by hand.

The main circuit breaker shall be electrically interlocked with the controller in such a way as

to prevent the current supply, being reinstated unless all controllers are in the ‘OFF’ position.

All crane motors shall be provided with circuit breaker with instantaneous magnetic relay

fitted in two phases from protecting the motor against short circuit and against overload by

reliable type thermal relays, fitted in each phase with setting for adjustment between a range

of 90% to 150 % of the rated current.

Each crane motor shall have its own ammeter and one common voltmeter for all motors of a

fairy uniformly distributed scale and mounted on the control panel to be located in the

operator’s cabin. Three separate indicating lamps shall be provided on the electrical panel to

indicate the status (live or dead) of the three phases.

Complete wiring diagram of all electrical connections from the main switch to the respective

appliances shall be fixed in the control cabin for ready reference of the operator. On the

diagram shall be given the rating of each of the motor, the able sizes and such other

information as will facilitate inspection and maintenance. Similar diagrams but showing the

inside connection of each of the controllers and the main circuit breakers etc. shall be fixed to

the inside of the covers of the controllers and the switches. Suitable transformer, for low-

voltage supply with switch fuses shall provide. The main protective panel shall be located in

the operator’s cabin at convenient position and shall include but not limited to the following

items.



a) Main isolating switch interlocked with panel door.

b) Main air brake contractor type main circuit breaker.

c) Overload relays of magnetic type for the main incoming supply and for each outgoing

feeder of the motors.

d) Indicating lamp for main contractor.

e) Emergency push button.

f) Separate circuit breaker for individual motors.

g) Plug and socket connection to hand lamp.

h) Transformer for low voltage supply.

i) One voltmeter with selector switch and one ammeter with selector switch for the main

incoming supply.

j) Ammeter for each motor.

k) Three indicating lamps showing the status of three phase of main incoming supply (live

or dead).

The Electrical panels along with the equipments shall be of approved make.

The main supply cable from L.T. panel board upto the isolating switch fuse unit will provide.

Arrangement of approved type for the connections between the isolating switch and D. S. L.

and the cable and accessories (equipment) required for connecting cable with D. S. L. shall be

provided by the contractor. The isolating switch fuse unit and termination connections of

cables at inlet and outlet ends shall be included in the scope of supply of contract. The

arrangement shall include three indicating lamps for indicating the status of D. S. L. (live or

dead).

For the control and protective panels anti condensation heaters, anti vibration mountings and

cubicle lightings (Complete with switch) shall be provided.

3.29 LIMIT SWITCHES:-

Totally enclosed self resetting two way rotary type limit switches which cuts off current and

stops the motion when the hooks have risen to a pre- determined level shall be provided to

prevent over winding and over lowering. Totally enclosed self- resetting two way lever type

limit switches shall be provided to provided to prevent over traveling and over traversing in

both directions.

3.30 CABLING & WIRING:-

All the meters, controller,, current collector and resistances shall be factory wired. All

connections among the apparatus shall be executed by means of armoured tropodue cable

and shall be suitably clamped in trough. The cables wherever likely to get damaged should

be protected with sheet metal guards easily removable for maintenance and inspection.



Central cables shall be manufactured from electrolytic copper and power cables shall be of

copper and shall be executed as regards the adequate sections and type of insulation in

accordance with IS 3177 or equivalent British standards. The current ratings of the cables shall

be as per the provisions of the appropriate clause of IS 3177- 1977. The down shop leads shall

be of hard drawn copper and comply as regards physical and electrical properties, with the

appropriate Indian Standards or equivalent British Standards. The down shop leads shall be

tightened on ends and supported with indoor insulator and tension adjusting device. The

power to crab shall be supplied through flexible trailing cables. These shall be of copper TRS

insulated and shall be supported in loops from ball baring type trolleys running along a track

parallel to the cross traverse.

Provision shall be made for the protection of all live bare conductors against accidental

contacts. The contractor for the crane shall include in his supply all the requisite length of

down shop leads along with insulators and straining device.

The protective and control panel wiring shall be provided with ferrules with numbers and

shall be terminated on the terminal block inside the panel. Provision of 25 % spare terminal

shall be made in the terminal block. The relay, timers, contractor’s etc. shall be designated by

giving type No. which can be located in the wiring diagram.

3.31 COLLECTOR GEAR:-

The collector gear for the main down shop leads shall be spring leaded type equipped with

train angular carbon brushes. The collector gear shall be provided by the contractor. Full

constructional details of this shall be given in the tender.

3.32 WIRING DIAGRAM:-

A schematic wiring diagram for the crane, in durable form, shall be provided. On this

diagram shall be given the rating of each of the motors, the cables sizes, toes of contractors

and resistances and such other information which will facilitate inspection and maintenance

of the crane. The cable schedule giving the size of cable, terminal numbers of various

equipment the designation of various electrical components shall be supplied by the

contractor.

3.33 LIGHTING:-

The crane shall be provided with a permanent 230 V.A.C. lighting system. Four Nos 500

watts. (Halogen) bridge lights with indoor type reflectors shall be provided under each crane

bridge girder (i. e. total 8 Nos.) for illuminating the working area. These lights shall be of the

hinged self-setting type for easy removal. The contractor shall provide lights near the meters

and rope drums. HE shall also provide a hand lamp with 15 Mtr. Cable and least two nos.

three pin plug sockets along the platform at suitable positions. Apart from bridge lights all



light shall be of tungsten filament type & shall be provided with suitable indoor type

reflectors with shock absorbing sockets.

3.34 EARTHING:-

The crane and granty structures, meters frames and metal cases of all electrical equipments

shall be effectively connected to earth by the contractor in accordance with Indian Electricity

Rules. For effective earth connection, the earthing of gantry rails shall also be done by the

contractor.

3.35 SPARES:-

The contractor shall provide a list of spares that may be necessary for 3 years operation, unit

Prices of these spares shall be stated in the tender and this shall apply to such No. of each

item as may be ordered.

All spares furnished shall be of the same material and workmanship as of the corresponding

parts of the main equipment.

3.36 TOOLS & TACKLES:-

A set of tools, special tools, tackles and all other appliances necessary for complete assembly

dismantling and maintenance f the crane together with M.S. Box with locking arrangement

holding them, shall be supplied.

The spanners shall be single ended and made to fit each size of nut and bolt.

The list of the erection tools and tackles included in the supply shall be furnished along with

the tender giving their itemized prices.

3.37 PAINTING:-

Before leaving the works, crane shall be thoroughly cleaned and shall be free from scale, rust

and grease etc. and painted with one cost of best quality red oxide paint. Machinery housing

and other mechanical parts shall be painted with finishing enarnel of approved colours Bright

steel parts shall be treated with anti corrosive compound.

After erection at site, every part shall be cleaned and shall then receive two coasts of best

quality enamel machine paint of approved colour.

In case the total erection being entrusted to the contractor, cleaning, painting of the crane

after at site shall be included in his scope of work. The painting schedule and the painting

scheme shall be got approved from the purchaser before starting the painting works.

3.38 PACKING :-

The parts of the crane which are likely to be damaged during transit shall be suitably created

or packed.



3.39 TRANSPORT & ERECTION :-

Before dispatch all parts of the crane and the crane itself shall be completely assembled,

properly aligned and match marked with distinctive erection marks etched on them

corresponding to these on the drawings so as to ensure correct assembly and alignment at

site. The weight of the heaviest, Member of the structure of part of the crane that has to be

handled during erection shall be stated in the tender. The contractor shall ensure minimum

amount of assembly at site for early commissioning of the crane after delivery. Site welding of

major members of crane will not be allowed. The crane is to be erected in a surface type

power house, on R.C.C. beams. No hooks will be provided in roof structure for lifting the

crane components during erection. Contractor shall arrange for the required erection

equipment such as derricks, winches, wire – ropes, shackles, pulleys etc. at his own cost.

3.40 TESTS:

1) At Manufacturer’s work.

A) X- Ray testing of the welded joints of the girder. During the fabrication of bridge girder,

100% ‘X’ ray testing of the welding on tension and compression zones of the box girder

shall be carried out, in presence of the respective of the department and test certificates in

this regards shall be submitted to the Department.

B) Six copies of the test certificates for the chemical composition, lamination test, die

penetration test and weld ability of the steel to be used in bridge girders and other

important structural items of crane shall be submitted before the fabrication work is taken

up by the contractor.

C) All forging shall be subjected to ultrasonic tests for internal cracks and forging defects. Six

copies of the test certificates in this regards shall be submitted by the contractor.The

complete crane shall be assembled including wiring and other fittings and aligned at

Works and following tests shall be conducted in presence of the representative of the

department.

I) Deflection Tests:-

The deflection test shall be carried out with the crab in central position. The measurement

shall not be taken on the first application of the safe working load. The vertical deflection

shall not exceed 1: 900 of the span.

II) Motion test at rated load:-

All the motions except long travel motion of the crane shall be ested with the hooks

carrying the rated load to check up the compliance with the specified performance

requirement such as speed etc. For the long travel motion the idle running test for the

wheels shall be carried out.



III) Overload Test:-

The crane shall be tested to lift and sustain a test load of 125% of the safe working load,

keeping the load at the center of the span.

During this over load test, each motion except long travel shall be manourvered in both

directions and the crane shall show itself capable of dealing safety with the overload. The

contractor shall summit six copies of the complete test reports for above tests reports for

above tests to the purchaser for approval.

IV) Following operational tests shall also be carried out:-

a) Satisfactory operation of each controller, switch, contractor, relay and other control

devices including light switches.

b) Correctness of all circuits and interlocks and sequence of operations.

c) Satisfactory operation of all protective devices.

d) Satisfactory operation of each motion except the long travel motion.

e) All the gear boxes shall be run for 6 hours non stop and checked for noise, vibration and oil

leakage.

f) The contractor shall also furnish the test certificates (in quadruplicate) in respect of the

following.

i) Hooks-

The hooks shall be tested as per the relevant BS or IS. The test certificate for the chemical

compositions, yield points, tensile strength, elongation, and Brinell hardness shall also be

submitted.

ii) Wire ropes:-

Test certificates for the Breaking load tensile strength and the elongation of the wire rope.

iii) Chemical analysis of the materials of the track wheels.

iv) All electrical and mechanical equipment such as motors and other auxiliary equipment

shall be tested in accordance with the appropriate Indian Standard and also in accordance

with the requirement of the specification at either crane Makers or equivalent

manufacturers’ works.

Even when the test certificates / test reports are approved by the purchaser, or by his

representative, these shall not absolve the contractor of guaranteeing the performance at

site.

2) TEST AT PURCHASER’S PREMISES:-

a) Insulation Tests:-

After erection but before the crane is connected to supply the insulation of the electrical

equipment shall be tested by a suitable instrument, as per the I.S. 3177 of equivalent I.S.



466- 1960 and any defects revealed shall be made good, by the contractor, without any

extra cost.

b) Test of operation:-

After connection to the supply, the contractor shall carry out the test mentioned under 39

(1) D (IV) above and the correct operation of all limit switches under the most unfavorable

conditions. Satisfactory operation of the L.T. motion shall also be carried out.

C) Motion Test:-

After erection at site the crane shall be tested successfully by the contractor in all motions

with the following loads.

Main hoist rated load and 125 percent of safe working load.

Aux. Hoist: - rated load and 125 percent of safe working loads.

During overload test each motion in turn shall be manovered in both directions and the

crane shall sustain the load under full control. The specified speed need not be attached

but the crane shall show itself capable of dealing with overload without and difficulty.

The contractor shall submit the complete test reports in quadruplicate for the tests carried

out at site. The load inclusive test bed required to carry out normal and over loading load

testing at site will be arranged by the contractor at his own cost for the crane. In addition

to the tests referred to above, the purchaser reserves the right of carrying out such tests as

he may decide upon.

3.41 GUARANTEE:-

All equipment must be free from inherent defects in design workmanship and materials. In

must safety handle all required load and all parts of the equipment shall remain in

satisfactory order. Till the expiry of performance guarantee period of 24 months any part of

the equipment, that will provide to be defective inadequate shall be replaced by the

contractor without charge.

3.42 LABLES AND LETTERING:-

All apparatus, meters, controls, gears and all panels shall be clearly labled indicating where

necessary, their purpose and the “ON” and “OFF” position. The lable shall be clearly lettered

on enamalled iron or bright aluminum plates. In some case the lable shall be cast on the

apparatus. All labels shall be printed in English. Function labels shall be black letters on white

background and danger labels shall be white letters on red background.



Sr No. SPARE PARTS

1. VVVF Drive set 1

2. Set of hoist ropes per hoist Set 1

3. Brake parts subject to wear, per brake Set 2

4. Each type of ball and roller bearings, including for all electric motors Set 2

5. Current collector complete Set 1

6. Sets of sliding contacts for the current collector Set 4

7. Coils for each type of contactor Coil 1

8. Contacts for each type of contactor Set 2

9. Portable control panel, complete with control cable and steel supporting

cable

Panel 1

10. Limit switches, of each type Set 2

11. Centrifugal switches, of each type Set 2

12. Time relays, of each type Set 4

13. Complete lamps, of each type Set 2

14. Complete rope guides, per hoist Set 2

15. Set of trip apparatus with time retardation for thermal sensors of each motor Set 1

16. Set of cold conductive thermistor of each motor Set 1

17. Protecting fuses of each type Set 3

18. Set of brush holders with two sets of carbon brushes, of each slip-ring motor Set 1



SECTION – III- F

110 V. D. C. EQUIPMENT

3.1 SCOPE :

The scope of this specification is for 300 AH 110 V D. C. Batteries, Battery charges and D. C.

Distribution boards for D. C. supply for JAMBRE HYDRO ELECTRIC PROJECT.

3.2 METHOD OF OPERATION :

There will be two Float- Cum – Boost chargers. Any charger can be made to work as a float

charger to feed the load and keep the battery on trickle charge or as a Boost charger to quick

charge the batteries after the batteries are completely or partially discharged and to take over

the functions of Float – Charger in case of its failure.

The selection will be possible by means of a switch on the charger.

The D. C. Distribution board will have three bus bars viz.

1) The charge Bus (Positive). 2) The Load Bus (Positive). 3) The common negative bus. Any one

of the chargers should be able to be connected to either the charge Bus or the Load Bus by

means of a selector switch provided in the D. C. Distribution board. This selector switch (Sw-

1) will be wired such that when one charger is boost charging the batteries, the other charger

will feed the load.

2) The D. C. Circuit breakers will also be provided in the D. C. Distribution board to connect the

battery either to the Load Bus or to the Charge Bus. Thus circuit breaker ACB- 1 will connect

the battery to the Load Bus and circuit breaker ACB- 2 will connect the battery to the charge

Bus. These circuit breakers will electrically be separated and interlocked so that when MCB- 1

is ‘ON’ MCB- 2 is ‘OFF’ and VICE – E – VERSA.

3) However, the appropriate cell in the battery will always remain connected to the Load Bus,

through a blocking diode, to avoid total interruption of supply to the load due to the above

switching operation. Two numbers of 300 Amps, Feeders will have to be provided in the D.C.

distribution board. These feeders are to be used for field flashing of the Turbine – Generator

set during starting, when A. C. supply is not available. Current requirement is of the order of

300 Amps for 5 seconds maximum and arrangement to disconnect these feeders from load

after stipulated time shall be made, selection shall be provided on feeders for 1 Sec, 2 Sec, 3

Sec, 4 Sec, 5 Sec, time for each of the two feeders. During field flashing process, i. e. when the

feeder is ‘ON’ batteries shall be disconnected from both the chargers and when the feeders

trip off, after field flashing, immediately charger must start feeding batteries and bring them

to desired level. It shall not be possible to make these two feeders ‘ON’ unless batteries are

fully charged.



3.3 LEAD ACID BATTERIES :

3.3.1 The following lead Acid Batteries are required 110 Volts, 300 Ah, at 10 hrs. Rate of discharge 1

set.

The number of cell required shall depend on the Float Voltage. The contractor should indicate

the number of cells offered and corresponding float voltage. The float voltage per cell shall

however be less than 2.2 volts. The number of cells shall be so chosen as to ensure that the

battery output voltage is maintained within the acceptable limits of +5 %.

3.3.2 Special Requirement :

Generator field of machine is flashed for starting at 300 Amps for 5 second and batteries must

be able to cater this requirement without charge in circuit during the period as described

elsewhere.

Only one feeder for field flashing will be connected at a time batteries and charger connection

with batteries stand interrupted. After field flashing feeder for field flashing will stand

disconnected from load and chargers get connected to batteries.

3.3.3 General Description :

The batteries shall be confirming to IS 1651 – 1970 (Amended to date) & shall be dispatched

dry & uncharged.

Type : The batteries shall be of Lad Acid stationary closed type.

3.3.4 Positive Plates

The positive plates shall be pure lead lemelle & shall be plants type or of the tubular positive

plates

3.3.5 Containers :

The containers shall be of glass for the battery with plants type positive plates. There shall be

have ample space available below the plates for the accumulation of deposits (active material

shed). The container shall be transparent, free from foreign matter. The containers for tubular

positive plates shall be of hard rubber.

3.3.6 Spray Arrestors :

The cells shall be provided with built – float – type acid level indicators.

3.3.7 Electrolyte :

The electrolyte shall be battery grade sulphuric acid confirming to latest Indian Standards.

3.3.8 Water:

The water required for the preparation of electrolyte shall confirm to the relevant latest

Indian Standards.



3.3.9 Accessories :

The batteries shall be complete with all accessories and device including but not limited to the

following.

i) Battery stand constructed out of teak wood and painted with least 3 coats of anti acid

paint, porcelain labels indicating the cell number shall be fixed on the stand. The stand

shall be constructed without use of any metal fastening & shall be single/ double tier

formation. Set of intercell, interrow, interbank and intertier connectors as required for

complete installation plus 5 % extra.

ii) Electrolyte for first filling plus ten percent extra with containers.

iii) Hard rubber cell insulators as required with at least 10 % insulators as extra.

iv) Stand insulators as required with at least 10 % as extra.

3.3.10 Accessories for testing and maintenance :

For battery set the following accessories shall be provided.

1. One center Zero 3- 0 – 3 volts D. C. Voltmeter for cell testing.

2. Two hydrometers syringes capable of indicating specific gravity reading in steps of 0.002.

3. Two pockets thermometers with specific gravity correction scale capable of being read

correct to 1o c.

4. Two pairs of rubber gloves.

5. Cell bridge connectors.

6. Two funnels of acid resisting material.

7. Two jugs of acid resisting material of adequate capacity.

8. Two rubber syringes.

9. Two bolt connector wrenches.

The above list is only indicative. The Contractor shall however include all the items necessary

to make his offer complete.

3.3.11 Battery Terminals :

Battery terminals shall be provided in a junction box with a disconnecting chamber where

purchaser’s cable will be terminated. The junction box shall have terminals suitable for PVC

insulated aluminium conductor 2-core cable of suitable size for carrying the load current.

The size of the cables shall be designed supplied, erected & terminated at corresponding

terminals by the contractor.

3.3.12 FLOAT – CUM – BOOST BATTREY CHARGERS : (FC & FCB)

The chargers shall be capable of giving the required charge current/ voltage during float or

boost conditions. The load current required to be met of the order of 50 Amps the charger

should have adjustable potentiometer variations in output voltage and current as given

below.



3.3.13 Float charging :

Voltage range : 110 v to 60 volts.

Current range : 0 Amp to 50 Amps.

Normally the Float – Cum – Boost chargers operating in parallel with batteries will supply

the continuous D. C. loads given above, besides providing trickle charge for keeping the

batteries floating. If load is high & exceeds the charger capacity, the excess load will be

supplied by the battery.

Thus while Float charging, the charging may be designed to supply continuous loads as

given above beside a trickle charge usually of the order of 0.5 to 2.5 mA per AH capacity of

the batteries, depending upon the requirements of the batteries to keep them floating. The

chargers will be designed to float the cells at between 2.15 and 2.35 volts per cell.

The ripple content in charger D. C. output shall be limited to +1 %. Battery charging

equipment shall operate satisfactorily and deliver rated output within A.C. supply voltage

variation as given below and frequency variation of +5 % from the rated value even when

these occur simultaneously.

A.C. Supply Voltage : 415 + 10%

In case of an emergency such as when A. C. Supply fails the battery will be called upon to

meet the complete load by itself and as a result it will get heavily discharge. In such an event

the battery will need to be quickly re- charged after the A. C. supply is restored. In this case

the battery will be connected to one of the two float – cum – boost chargers which will be

used for quickly re- charging the battery and the other float- cum – boost charger will

continue to supply to permanent load.

To achieve the above, the overall charging scheme will be broadly drawn on the following

lines.

i) Two identical float- cum – boost chargers have been provided. Each charger shall be

capable of supplying either the permanent D. C. Load and the trickle charging current

required to float the battery or the boost charging current required for charging the

battery quickly. Normally the continuous D. C. load will be fed by one float- cum – boost

charger. The entire battery will remain floating across the charger output terminals which

will provide the trickle charge.

ii) In case of A.C. Supply failure the permanent load shall be supplied by the battery.

iii) When the A. C. supply is restored the battery will be disconnected from the first float

cum boost charger which will continue to supply the continuous D.C. load. The other

cum float cum boost charger will then be used for charging the battery quickly .



iv) At the same time to provide for an emergency conditions such as A.C. failure during

boost charging, the battery (but with reduced number cells) shall be automatically

connected to the load bus through a blocking diode. This will enable continuity of supply

to be maintained even during the brief interval change of from boost charging operation

to the load supply by battery, on A.C. failure.

v) The reduced number of cells will be determined in such a way that at the maximum

voltage of say 2.6 volts per cell, the battery with a reduce number of cells will develop a

voltage corresponding to a correct output voltage required to feed the load.

vi) As already explained the float cum boost charger should be capable to be used for

charging the batteries rapidly to restore the voltage and reserve capacity quickly after

extended use during the A.C. shutdown. Therefore the float cum boost charger should be

designed to enable the complete recharge to be given within one eight-hour shift.

3.4 CHARGER EQUIPMENT:

Each charger equipment will generally comprise the following.

1. One set of selenium rectifier stock three-phase type bridge of full wave rectification.

2. One dry type double wound natural air-cooled three phase main transformer with a

copper conductor of Class B insulation with temperature rise limited to class A insulation.

3. Automatic voltage regulator, current limiting circuitry, smoothing filter circuit and soft

start feature for achieving stepless, smooth and continuous voltage control.

4. One suitably rated three-pole air circuit breaker with overload protection of adequate

capacity having in built single phase preventer to control the A.C. input to rectifier.

5. One double pole air circuit breaker with over current tripping device to control D.C.

supply from the rectifier.

6. Static circuit components should be used for voltage stabilization of +1%.

7. One indicating lamp to indicate the A.C. input supply “ON” One indicating lamp to

indicate that the D.C. output supply “ON”.

8. One 72 mm square analog and digital volt meter o- 500 volts with selector switch for

measuring A.C. input voltage.

9. One 72 mm square analog and digital Ammeter meter o- 70 Amps with selector switch

for measuring A.C. input voltage.

10. One 72 mm square analog and digital volt meter o- 300 volts along with fuse for D.C.

output voltage.

11. One 72 mm square analog and digital Ammeter o- 70 Amps sent for D.C. current.

12. One blocking diode.

13. One selector switch for Float – Boost – mode.



The list given above is purely indicative and the contractor may add or delete any item, if

necessary to make the equipment complete, with full explanation or doing the same.

The cubicle, housing the above equipment shall be of steel sheets, completely dust, water and

vermin proofed, suitable arrangement shall be made sealing the cable entry holes.

The cubicle shall be complete with one set of space heater with ON/OFF switch. Internal light

with ON/ OFF switch shall also be provided.

3.5 PROTECTION :

In addition the following will be provided for earth fault and charged failure detection.

3.5.1 Earth fault detection :-

The mid point of the battery shall be brought into the battery charger board and connected to

the earth through a mille ammeter of high resistance. A single pole earth fault relate of self-

resetting type and adjustable range of0.1 Amps. Shall be provided in the circuit to operate

and along through a time delay relay.

The equipment generally comprise the following :

1. Mid point earthing switch.

2. 48 x 48 mm2 flush mounting moving coil ammeter suitable range connected between the

mid point of the battery and earth through a resistance to earth leakage current.

3. Earth Fault Relay.

4. Time delay Relay (0.5 seconds).

5. Along relay hand reset type for 110 volt D.C.

6. Alarm consolation switch.

7. A set of fuses for alarm current.

An alarm contact will be made available for actuation of annunciation in circuit in the central

control room.

3.5.2 Charger failure detection

A charger fail alarm relay of voltage reference type shall be provided.

3.5.3 Charger protection :-

A thermostat shall be provided to protect the charger from prolonged overload. The

thermostat shall operate to suitably decrease the output and the rectifier cools down

sufficiently when the thermostat is reset.

3.5.4 A. C. Supply Failure :-

An A.C. supply alarm relay shall be provided.

3.5.5 Overload relay :-

An overload relay shall also be provided.



3.6 D. C. DISTRIBUTION BOARD :-

3.6.1 The 110 V. D. C. distribution board shall have the following outgoing feeders.

Rating No. of output circuits.

1. 110 Amps MCCB ………. 2 Nos. + 1 spare

2. 15 Amps MCB ……….. 8 Nos. + 3 Spares

3. 15 Amps MCB ……….. 4 Nos.

The outgoing feeders on D. C. distribution board shall be tentatively used for following

purpose.

i) 100 Amps …2 Nos + 1 spare

(EPC contractor to select as per Generator requirement)

ii) 15 Amps … 3 Nos.

1 … Control & Relay panel.

2 … Control & Relay panel.

3 … Spare.

iii) 15 Amps … 8 Nos. + 3 spares

The MCCB and MCB shall be 2 pole DC rating.

The distribution board may be of sheet steel panel type construction built on floor-mounted

stand.

Each switch cover and operating handle shall be so interlocked mechanically that it shall not

be possible to open the cover unless the switch is in the off position.

The switches shall be of quick make and break type and capable of breaking the rated load

current.

The switchgear shall be designed to withstand the short circuit current of the battery and

charger together. The contractor should confirm the short circuit current by calculations,

which should be submitted along with the tender.

Each switch unit shall be equipped with a cable terminating gland suitable for the PVC cable

of appropriate size.

The board shall be completely enclosed, dust, whether and vermin proof.

3.7 CHANGEOVER CONTACTOR FOR EMERGENCY LIGHTING.

THE 110 Volts D.C. Distribution board shall be provided with a maintained type emergency

changeover contactor for feeding the emergency lighting circuit. The contactor shall be of 25

A rating for providing emergency lighting supply. Normally the contactor shall feed the

emergency lighting circuit when A.C. Supply fails and the operating coil (fed on A.C.) gets de

energised, the contactor shall change over to new position in which the lighting circuit is fed



from D.C. bus bars. The contactor shall be receiving separate supplies of 110 V D.C from the

D.C. bus and 110 V A.C. from the lighting board. It will be provide with indication lamp

indicating that it has change over to D.C supply. The general arrangement of the contactor

circuit is indicative in drawing of D.C. Distribution board. This arrangement is only

indicative. The contactor may offer any suitable arrangement which fulfills the above

requirement.

3.8 BATTERY LAYOUT.

Batteries will be accommodated in common battery room. Chargers and D.C Distribution

boards shall be erected outside the battery room. The Contractor shall submit along with his

tender the layout plan for the batteries, battery chargers and D.C Distribution board.

The equipment shall be required to withstand and shall not mal operate with the earthquake

acceleration of 1.0 g for protective relays and 0.5g for other equipments where ‘g’ is the

gravitational accelerations.

The height of the battery racks shall be as low as possible. The racks should be so arranged

that the batteries can be inspected easily and for two tier arrangement sufficient space

between tiers to enable the plates from lower batteries to be removed when necessary.

3.9 PANELS:

3.10.1 CONSTRUCTION OF PANELS:

The panels for the charge and D.C.D.B shall be completely enclosed and shall be constructed

from M.S. sheets of not less than 2 mm thickness with supporting channels and bracings,

angle frame work. The panel shall be provided with foundation bolts at suitable locations.

The panels shall be vermin proof. Feeders for field flashing, If possible, shall be given on

separate mini panel.

The equipment to be mounted on the panel shall be suitably located for convenience of the

operating and mountainous staff. As for as possible symmetry in the arrangement of the

equipment should be maintained. The co lour of the panel should be match with the other

panels in the power house. The details of the colour will be given to the successful Contractor

if necessary.

The panel should provided with hinged door with lock and latch on the back side. The swing

of the door shall not be less than 105o from the closed position. Unless otherwise agreed, the

joints shall be from inside only.

The panel shall not be drilled or welded for fastening of resistors, wire etc. where such

fastening or holes will be visible from the front of panel. The heavy devices should be

supported suitably to prevent warping of the panel. The required electrical and operational

clearances shall be provided with out cutting away the adjacent steel frame work. All

connections required for control / monitoring protection shall be through terminal block with



circuit identifications. The number of terminals shall be at least 10% in excess of the required

numbers. The terminals shall be provided with locking nuts.

The name of the standard device number to be marked on the rear of the panel near

corresponding device and the circuit designation of each stud of each device shall also be

marked on the device case or on the rear of the panel. The marking shall not be obstructed by

the wires and shall be printed legible with permanent marking fluid of suitable co lour but in

contrast with the panel finish.

3.10.2 CABLE ENTRY:

The switch boards shall be designed to facilitate aluminum / Copper conductor PVC

insulated, PVC sheathed power cable entry from bottom. Removable sheet plates shall be

fitted at the bottom. The bottom plates of the panels shall be fitted with removable gland

plates of adequate size for drilling the holes and fixing the cable glands at site.

3.10.3 WIRING:

The wiring shall be neat and such that it will have minimum crossings and shall run

horizontally or vertically with short radius right angle bends. The crimped eyelets or

approved equipment shall be provided at termination. As far as possible, the wiring shall be

installed in the wiring channel / ducts. The exposed wiring if any shall be formed into

compact flat groups, suitable bonded together and property supported. All wiring shall be of

Copper conductor only. The phase arrangement for A.C. and D.C. shall be as far as possible

A-B-C and positive – negative from left to right, from top to bottom and front to back

respectively.

3.10.4 LIGHTING AND EARTHING:

The panels shall also be provided with suitable lighting and earthing arrangement. The

fluorescent tube lighting with switch shall be provided. For panel and equipment earthing, a

Copper strip of not less 25x3 mm. shall be provided at back of the panel, which shall be

connected to the station earthing by the contractor.

3.10.5 PAINTING:

All steel work shall undergo a process of degreasing pickling in acid , cold rincing,

phosphatising, passivating and then Sprayed with a corrosion resistant primer. The primer

shall be baked in oven. The finishing treatment shall be by application of synthetic enamel of

approved shade and stoved.

3.10 TESTS AND INSPECTION:

The representative of the purchaser’s shall have an access to the contractor and his sub –

contractor’s works at any time during workings hours for the purpose of inspection and

progress of manufacture and tests.



The tests specified hereunder shall be carried out in the presence of the representative of

purchaser. For this purpose an advance intimation of 15 days shall be given to the purchaser.

No dispatch of equipment shall be made unless the test certificates are approved by the

purchaser.

The acceptance for approval of test certificate for any material / equipment shall not obsolete

the con tractor from the responsibility of the guaranteed performance.

3.11.1 TEST AT MANUFACTURER’S WORK.

a) Battery.

i) Capacity test.

ii) Test for loss of capacity during storages.

iii) Test to determine AH and WH efficiency.

Note : Type test shall be conducted on a minimum of one cell typical and identical to which

cells forming the complete battery offered. How ever, the test cell shall not be one of the cells

from battery offered.

b) Battery Charger.

1. Dielectric tests

2. Voltage regulation check from 0 to 100 % loads with +10% input voltage variation.

3. Ripple content measurement.

4. Heat run test on current limiting value.

5. Insulation resistance tests.

6. H.V. test at 2.5 KV for one minute.

7. Annunciation operation tests.

8. Operational test.

9. D.C. short circuit test o prove the ability of current limiter.

10. Following routine tests shall be carried out at manufacturer’s works on each printed

circuit Board (PCB).

1. Burning test for PCB’s Assembled PCB Burning test at 70 o C for 72 hours with loaded

conditions.

2. Routine tests on the components parts as per quality control plan approved by purchaser

shall be verified by the inspecting authority.

c) D.C.D.B.

I) All routine tests as per relevant IS . However type test report shall be furnished for IP 52

Degree of protection along with tender.



3.11.2 TESTS AT SITE.

a) Battery.

i) Visual inspection.

ii) Dimensional check.

iii) Capacity check.

b) Battery charger.

i) Insulation resistance test

ii) All operational tests.

iii) Voltage regulation check.

b) D.C.D.B.

I) All operational tests.

3.11 QUALITY ASSURANCE:

3.11.1 Contractor shall follow his standard procedure for quality assurance and Control. However,

said standard procedure shall be submitted to the purchaser.

3.11.2 The procedure shall be in such a form as to clearly delineate the manufacturing sequence and

major inspection points and to reference tenderers test and inspection procedures.

3.11.3 The purchaser will inform the contractor as to which of the inspection points test will be

witnessed. As a minimum, a final inspection of the equipment will be made prior to

shipment.

3.11.4 Manufacturing and quality control procedures shall be available for audit to the purchase and

/ or its representative at the place of manufacture.

3.11.5 The purchaser and / or his representative reserves the right to inspect the equipment at the

point of manufacture and witness factory and other tests as may be necessary to ensure

conformance to the specification.

3.11.6 The purchaser and / or his reprentative may inspect the contractor’s facilities prior to award

of contract.

3.11.7 The purchaser and /or his representative may witness any or all of the test described.

3.11.8 The purchaser and / or his representative may conduct surveillance of the contractor’s

facilities for compliance to his standard procedures of quality assurance and quality control

while work on the specified equipment is in progress.

3.12 SPARES :

The contractors shall supply standard spares.



3.13 APLIANCE STANDARDS :

All works covered shall be governed by the following Indian Standards in so far these are

applicable. If provision of any other standard (S) are applicable the same shall be fully

explained in the tender, and a copy of the relevant standard shall be submitted along with

tender.

APPLICABLE STANDARDS :

I. S. S. No. Particulars

a) 1651 : Specification for stationary cells and Batteries, lead acid type (with tabular positive plates).

b) 1146 : Specification for hard rubber containers for lead- acid storage

batteries.

c) 6071 : Specification for synthetic separators for lead- acid batteries.

d) 652 : Specification for wooden separators for lead- acid batteries.

e) 1069 : Specification for water for storage batteries.

f) 3116 : Specification for sealing compound for lead- acid batteries.

g) 3895 : Specification for Rectifier equipment in general.

h) 2208 : Specification for HRC fuses.

i) 1248 : Indicating Instruments.

j) 2147 : Degree of protection for cubicles.

k) 375 : Specification for Wiring &Bus bars.

l) 4540 : Mono crystalline semiconductor rectifier equipment.

m) 6619 : Safety code for semiconductor rectifier equipment.

n) 206 : Transformer.

o) 2959 : A. C. Contractors for voltage not exceeding 1000 V.

p) 4327 : General requirement for switchgear and control gear for voltages

not exceeding 1000 V.

q) 4064 & 4047 : Air breaker switches and fuse. & combination units.

r) 6005 : Code of practice for phosphating of Iron & Steel.

s) 5 : Colour for ready mix paints.

t) 5921 : Printed Circuit Board.

u) 249 : Printed Circuit Board.



SECTION – III - G

OUT DOOR TYPE DIESEL GENERATING SET

3.1 GENERAL :

One No. of 63 KVA rating Outdoor Diesel Generating Set (D.G. Set) is to be installed at site of

JAMBRE HYDRO ELECTRIC PROJECT. To cater need of emergency power supply.

The D. G. Set is intended to be used for meeting the emergency power requirements of power

attention auxiliaries such as cooling water – pumps, governor oil pumps, air compressors,

emergency lightning, pumps etc. When there is stoppage of power supply from power grid.

The associated equipments shall include base frame, control panel separate 500 Ltr. Capacity

fuel tanks with mounting stand 2.5 mtr height from ground level and piping, battery etc.

Besides, the scope shall also include the supply of set of spares (list should be submitted

along with tender) concern civil works are included under the scope of this tender.

3.2 APPLICABLE STANDARDS :

Except where stated otherwise, the D. G. Set and associated equipment shall comply with

latest editions / revisions of the following standard:

i) Diesel Engine BS 5514

ii) Alternator IS 4722/BS 2613

iii) Foundation base frame IS 226

iv) Painting IS 6005

All other equipment/material shall conform to relevant Indian Standards as applicable.

3.3 TYPE AND RATING :

The diesel generating set covered under this specification shall be designed and

manufactured to comply with the following particulars

i) Type : Weather cooled naturally aspirated.

ii) Speed : 1500 rpm.

iii) Routing of exhaust air : Through bell type duct to let out of room

iv) Alternator details : 50 KVA, 0.8 p.f. 3 phase, 50 Hz, 415 Volt.

v) Maximum overall dimensions : To be stated by Contractor

vi) Capacity of fuel tank required : 500 Liters.

vii) Radiator : With fan

vii) Canopy mounted D. G. set shall withstand ambient variations & 100 % humid climate.

3.4 TECHNICAL SPECIFICATION :



3.4.1 DIESEL GENERATING SET :

a) DIESEL ENGINE :

The Diesel Engine shall be capable to develop 50 BHP at 1500 RPM. It shall be four stroke, six

cylinder conforming to BS- 5514. The rating of the engine shall be conforming to BS 649.

The engine shall have approx. 50 BHP rating at 1500 RPM for 24 hours continuous running.

Besides, it shall have overload provisions of 10 % for a period not exceeding one hour in any

12 hours. The engine must have auto start provision in case of power failure.

The engine shall be water cooled through after radiator with exhaust fan. The circulation of

cooling water shall be through a cooling water pump of appropriate rating driven by engine.

The engine shall be equipped with the following accessories :

1. Flywheel to suit flexible coupling.

2. Flexible coupling.

3. Exhaust gas turbo charger.

4. Cooling system comprising of radiator complete with fan for radiator inbuilt water pump.

5. Air cleaner.

6. Corrosion resistor.

7. Automatic safety control in case of high water temperature.

8. Higher water pressure control in case of built in drain choking up.

9. Automatic safety control in case of low oil pressure.

10. Lubrication oil pump.

11. Lubrication oil filter.

12. Lubrication oil cooler.

13. By pass filter.

14. Fuel filters.

15. Fuel Pump.

16. Hydraulic governor.

17. Tachometer and service hour meter.

18. Silencer and silence piping.

19. Fresh Water Pump.

20. Instrument panel comprising of :

a. Water temperature gauge with contacts.

b. Lubrication oil pressure gauge with contacts.

c. Lubrication oil tempt. Gauge with contacts.

d. Starting switch with Kay.

e. Auto start facility during power failure.



21. Self started motor (12 V. or 24 V. D. C)

22. Battery charging alternator with convertor

23. Engine mounted fuel tank with hose pipe.

24. External fuel tank, 500 liters capacity with mounting structural and piping for fuel supply.

b) ALTERNATOR (GENERATING SET) :

The rating of alternator shall of 50 (63) KVA It shall be slip ring type synchronous alternator

having continues rating of 50 (63) KVA at 1500 RPM, with rated voltage of 415 V, 50 Hz, 3

phase, 0.8 p.f. The alternator shall be self excited; self regulated and shall conform to IS

4722/BS 2613. The alternator shall be provided with brush less excitation. The band of

voltage regulation shall be 2.5 % of rated voltage from no load to full load. The insulation

shall be of Class- F. The alternator shall be capable to cater an overload of 10 % of rated

output, for a period of one hour in any 12 hours.

c) BASE FRAME :

The base frame of D. G. Set shall be fabricated from mild steel channel (galvanized) with

suitable ribs/stiffeners,

It shall be welded construction. It shall be provided with lifting eyes at each and. Suitable

hole shall be provided at base, for fixing the channels with foundation bolts.

The Contractor shall furnish along with his tender, the configuration of foundation bolt holes

and foundation plan of base frame, giving all relevant dimensions.

3.4.2 DIESEL ENGINE ALTERNATOR CONTROL PANEL (WITH AMF & AVR ) :-

The panel shall be suitable for 50 (63) KVA , 3 Phase, 415 Volt, 50 Hz, A. C. diesel generating

set & complete with accessories as detailed below. Any other components required shall also

be provided.

I) Power module :

a) A pair of electro mechanically interlocked contractors (For mains & generator)

b) Overload ready for generator contractor.

c) Neutral contactor for mains and generators.

d) Power socket for connection.

II) Control and metering module :

a) Line voltage monitor.

b) Generator voltage monitor.

c) Ammeter.

d) Three times attempt start facility.

e) Air circuit breakers of suitable rating for auto/manual operation.

f) Auto/manual selector switch.

g) Emergency stop push baton.



h) Manual start push baton.

i) Frequency meter.

j) KWH meter and CT’s.

k) Two earthing studs.

l) Auto start control panel during power failure.

III) Protection module :

a) The engine shall be shutdown in the event of Low lubricant oil pressure.

b) Low lubricant oil pressure.

c) High cylinder head temperature.

d) V- Belt failure.

IV) Indicators with Alarm :

a) Load an mains.

b) Engine fails to start.

c) Emergency stop.

d) High cylinder head temperature.

e) V- Belt failure.

f) Battery charging.

The panel shall be complete with internal wiring, labeling and painting with enamel Grey

paint.

3.5 12 VOLT OR 24 VOLT BATTERY OF ADEQUATE CAPACITY (AH) & BATTERY

CHARGING EQUIPMENT TO WORK ON 415 VOLT, 3 PHASE, 50 Hz A. C. SUPPLY.

3.6 A SET OF SPARES :

Contractor shall supply standard spares.

3.7 ERECTION, TESTING AND COMMISSIONING :

The erection, testing and commissioning of all the items covered here in above is included in

the scope of the Contractor No carne facility for handling at site shall be provided by the

purchaser.

The D. G. Set is to be erected on suitable foundation plinth in a room. The height of plinth

and foundation bolt details shall be furnished along with the tender. The extra fuel tank of

500 litre capacity is to be erected on galvanized structural frame work in such a way that the

bottom of fuel tank shall be of electrically welded steel or M. S. Plate 14 gauges. The tank shall

be totally enclosed type inclusive of fuel level gauge shall also have suitable arrangement for

filling and tapping to D.G. Set and draining the fuel.



The control panel for D. G. set is to be erected in D. G. set room 3 cores, 185 Sq. mm, 1.1 kV

grade at appropriate length unarmoured PVC aluminium cable for interconnection between

D. G. set and control panel as well as changeaver and deemed to have been included in the

scope of work.

After erection of all items is completed, the testing and commissioning of the same shall have

to be carried out by the supplier at site.

Contractor shall arrange for all other requirements such as skilled and unskilled man power,

tools and tackles, testing instruments, handling equipment, consumables, power supply

cables from point of supply, transport vehicles etc. required for the work of erection, testing

and commissioning.

3.8 PAINTING AT WORKS :

Items of D. G. Set, fuel tank and control panel etc. shall be painted at works with primer

followed by synthetic enamel paint of approved shade, Suitable touch up shall be given.

3.9 GUARANTEED AND OTHER TECHNICAL PARTICULARS:

Contractor shall furnish the guaranteed and other technical particulars of equipment offered.

This schedule shall be completed in all respect.

The data about the specific fuel consumption at 75 % rated output D. G. Set shall be quoted as

‘Guaranteed Data’ and shall be subjected to tolerance as per relevant standard. Contractor

quoting higher value of tolerance of specific fuel consumption than specified in relevant

standard may be rejected.

The specific fuel consumption data shall be considered for acceptance of D. G. Set after the

result of work test.

3.10 TESTING :

A) Tests at Manufacturers Works :

i) Visual Inspection at Works :

After completion of the manufacture and assembly, the D. G. set shall be offered for

inspection at manufacturers/subcontractors works. The inspection shall be carried out by

the Engineer of purchaser and the supplier shall satisfy him about the completeness of

equipment and components as per drawings.

ii) Test to determine the guaranteed value of specific fuel consumption of D. G. Set.

The guaranteed value of specific fuel consumption at specified output of 75 % of rated

output shall be tested at works in the presence of purchaser’s Engineer, by carrying out

the load test on the D. G. Set. The necessary load, relevant circuits and the instrument of

laboratory standard shall have to be arranged by the supplier without any extra cost.



iii) Test to determine the overload rating :

The capability of D. G. Set for 10% overload rating, over continuous rating for a period of

1 hour shall be demonstrated at the time of the test described at Sr. No. (ii) above.

iv) Tests on Diesel Engine & Alternator Control Panel:

The alternator control panel shall be subjected to the following tests

i) Measurement of IR value by using 500 V meager.

ii) HV test on writing at 2 kV AC for 1 minute durian.

B) After installation of D. G. Set and associated equipment at site, the supplier shall have to

carry out the following test at site:

i) Operational test on set to cater the rated load continually for a period of not less than 12

hours.

ii) Sudden load throw off test on the set.

iii) Auto start operation.



SECTION – III - H

AIR CONDITIONING SYSTEM

3.1 AIR CONDITIONING SYSTEM

Nos A.C. units each of 2 Ton capacity split type Air Conditioning Equipments for Control

Room of Power Station.

Each unit confirming as under.

1. Make of equipment : Acceptance makes Blue Star, Voltas I

2. Capacity : 2 Ton capacity each.

3. No of Units.

a) Indoor Unit. : 1 No.

b) Outdoor Unit. : 1 No.

4. Air Circulation CFM Indoor Unit. : 750 CFM.

5. Size of Indoor Unit. : 1107 x 610 x 260 mm.

6. Size of Outdoor Unit. : 995 x 595 x 415 mm.

7. Weight of Indoor Unit. : 34 kg.

8. Weight of Outdoor Unit. : 76 kg.

9. Cooling Capacity : 6000 k. Cal/ Hr.

10. Power Supply. : 230 ± 10% V, single phase A.C

11. Fan Motor HP Indoor Unit : 1/ 20 HP.

12. Fan Motor HP Outdoor Unit : 1/ 5 HP.

13. Refrigerant. : R- 22.

3.2 FIRE FIGHTING EUIPMENT.

1) SCOPE :-

This specification of fire extinguishers various types and material required for fire

extinguishing system. Requirement of Fire Fighting equipment is for each project.

2) INFORMATION :-

Each Hydro Generator has their own fire extinguishing system. However it is proposed to

install fire extinguishers, foam generators, fire buckets, etc. at various points and places. In

the building & open switchyard for safety of other vital equipments.



3) SYSTEM :-

It is proposed to install fire extinguishers and fire buckets etc. at various points and places as

stated below.

SR. NO. LOCATION TYPE

1. Store room. F. E. 9 Ltr. Capacity, water CO2 type

fire bucket, Bucket stand.

2. Lunch Room F. E. 9 Ltr. Capacity, water CO2 type

fire bucket, Bucket stand.

3. Near Compressors. F. E. D.C.P. 10 Kg. Capacity, Fire

bucket, Bucket Stand.

4. Near D. D. Pumps.. F. E. D.C.P. 10 Kg. Capacity, Fire


5. 415 V. A.C.D.B. F. E. CO2 type 7 Kg. Capacity, Fire


6. Battery Room. F. E. D.C.P. 10 Kg. Capacity, Fire


7. Battery Charger Room. F. E. CO2 type 7 Kg. Capacity, Fire


8. Control Room F. E. CO2 type 7 Kg. Capacity, Fire


9. Service Bay. F. E. CO2 type 7 Kg. Capacity, Fire


10. N. G. C. Near Generator. F. E. CO2 type 7 Kg. Capacity, Fire


11 Power Transformer. F. E. CO2 type 7 Kg. Capacity, Fire


12. 33 kV Switchyard. F. E. CO2 type 7 Kg. Capacity, Fire


13. Near D. G. Set. F. E. CO2 type 7 Kg. Capacity, Fire


14. Near E.O.T Crane F.E. CO2 type 7kg Capacity.



4) Fire extinguishers and material of relevant I. S. is required for protection against fire of

different class to various points and places.

ITEM

NO. DESCRIPTION. I. S.

1. Water ( Gas pressure) C O2 type, fire extinguisher 9

Liters capacity for operating in upright position

complete with hose, cap assembly & discharging

nozzle, charged CO2 cartridge and suspension

clips confirming I. S. 940 with ISI Mark.

940

2. Fire extinguisher dry chemical powder type 10 kg

capacity for operation in upright position complete

with cap. Assembly, discharging hose, hand

controlled nozzle, charged CO2 cartridge, powder

and suspension clips confirming to I. S. 2171 with

ISI Mark.

2171

3. Fire extinguisher carbon dioxide type 7 kg capacity.

Consisting of high pressure steel cylinder bearing I.

S. 7285 Mark & having the approval of controller of

Explosives Nagpaur, wheel type valve bearing I. S.

3224 Mark Internal discharge tube, One meter long

high pressure discharge hose, non- conduction

horn, suspension bracket fully charged, bearing I.

S. 2878 mounted on a two wheeled light weight

trolley with I.S.I. Mark.

2878

4. 75 kg dry chemical powder (I. S. 4308) fire

extinguisher mounted on trolley having high-

pressure discharge hose with gunmetal nozzle,

shut off arrangements, gunmetal cap assembly

duly charged and with 3 kg. Capacity CO2 gas

cylinder fitted externally, confirming to I.S. 10658

latest with I. S. I. mark. 4 Numbers as standby.

4308 latest 10658 latest.

5. Breathing apparatus set.

6. Round bottom fire bucket standard 9 Ltrs. Capacity



manufactured out of 22 gauges M.S. galvanized.

After manufacture, painted post office red enarnel

out side and white inside, lettered fire.

7. M. S. fire bucket stand to hang 4 bucket.

8. M. S. fire bucket stand to hang 6 bucket.

3.2.1 APPLICABLE STANDARD :-

Each fire extinguisher and other items should be manufactured / supplied as per I.S. & carry

I.S.. mark on outer body and quantity of fire extinguisher and fire buckets shall be provided

at various at various points and places as per norms and guide lines given in.

3.2.2 INSPECTION AND TESTING AT WORK :-

A representative of the purchaser shall have access to contractor’s or sub contractor’s work at

any time during the working hours for the purpose of inspection of manufacture and tests of

items.

All the acceptance tests and routing tests, tests at the manufacturer’s works as prescribed in

I.S. with latest amendment, extinguishers as covered under. “Detailed scope of works” shall

be carried at the cost of contract in the present of the purchaser’s representative. For type

tests, contractor shall have to furnish relevant type specification. The contractor should

furnish list of such tests along with tender.

Immediately upon carrying out of the specified test at work, the contractor shall furnish to

the department, all the test certificates duly signed by the contractor and purchasers

representative. The quantities indicated in “Detailed scope of works” are the actual quantities

to be dispatched by the Contractor to site.

All the routine tests as per relevant I.S shall be carried out by the contractor at his works in

the presence of purchaser’s representative. In case of water jell blankets & water refurbishing

jell, it is responsibility of the supplier / Manufacturer to provide, necessary testing facilities to

the entire satisfaction of our inspecting authority.

Contractor shall have to inform about readiness of material at least two week in advance to

the Concern Engineer. Dispatch shall be effected after issue of dispatch instructions from the

purchaser.

In addition to routine tests mentioned above Contractor shall have to carryout at his own

cost live demonstration at his works in the presence of purchaser’s representative by causing

live fire in his test bed and extinguishing it with the fire extinguishers to be supplied by him,

Contractor shall have to refill such fire extinguisher at his own cost used in above



demonstration & if the extinguisher is not found to function properly during such tests then

he shall have to replace same extinguisher without any extra cost to purchaser.

3.2.3 PRODUCT APPROVAL CERTIFICATE :-

Contractor shall submit product approval certificate from the following authorities before

dispatching the equipments.

1. Terrify Advisory committees Mumbai.

2. Department of Explosive Govt of India.

3. Bereau of Indian standard.

Contractor shall have to furnish above-mentioned certificates in his name for the fire

extinguisher’s manufactured by him. If however these certificates are not issued in his name

but in the name of some firm. Then he shall have to furnish proper authorization from such

firm, issued in his name and valid from the date of our till the completion of satisfactorily

delivery of equipment ordered, Contractor shall therefore furnish these documents in proper

time before tests at shop are arrange by him. In case of water jell blankets & water jells,

Contractor should enclosed certificate from Directorate General of health Services New Delhi

classifying this product is life saving medicine. Tender forms received with out this certificate

will be liable for rejection.

3.2.4 PAINTING: -

Painting and anticorrosive treatment shall be carryout on each fire extinguisher as per

relevant I.S. on fire extinguisher body, foam tank, foam branch pipe, hose box etc. Painted in

post office red colour. Chassis and mudguard in black colour.

3.2.5 PACKING: -

The packing may be in accordance with the manufactures standard practice but acceptable to

the inspection authorities, however the care shall be taken that the packing shall be

sufficiently strong for protection during transit. It shall to be damaged in handling during

transit; the contractor shall be responsible for any loss or damage during transit upto the

project site. Items, which are in less quantity, should be supplied immediately.

The packing will not be returned to the contractor. Following information shall be written /

marked on packages.

1. Trade name if any.

2. Name of manufacturer.

3. Type of material contains (name)

4. Quantity.

5. Address of Consignee.



3.2.6 DETAILED TECHNICAL SPECIFICATIONS.

TECHNICAL SPECIFICATION FOR ITEM NO.2

PARTICULARS SPECIFICATION

ITEM Dry powder type fire Extinguisher

(10.0 Kg) Gas Cartridge type.

Operation Type Upright operation.

Construction

Cylindrical model complete with cap

assembly, discharge nozzle with

discharge hose, lead coating inside

the extinguisher body.

Material

Material of construction of various

parts of fire extinguisher shall be

strictly as per IS: 2171 (Latest

Edition)

Design Code

• IS; 2171 (Latest Edition)

• Gas Cartridge should confirm to

IS; 4947 (Latest Edition)

• Dry powder should confirm to

IS; 4308(Latest Edition) (ordinary

type)

Test pressure 30.0 Kg/ Cm2

Material

Certificate

• Extinguisher & Gas cartridges

both should be ISI marked.

• Dry powder charge should have

approval and certification Mark of

IS; 4308.

Inspection Pressure Test and Discharge

performance test as per IS; 2171.

Remarks Supply shall be completed with

initial charge.

3.3 MATERIAL: -

1.1 The M.S. plate used for the fabrication on body and neck ring shall confirm to IS; 2002 OR

Is; 2041 OR IS; 226. The dished and shall be forged construction.

1.2 The material of construction of other parts shall be as per IS: 10658 latest.



1.3 The dry powder used in the extinguisher shall confirm to IS: 4308 latest having ISI

certification mark.

1.4 The extinguisher shall be confirming to IS : 10658 bearing ISI certification mark.

3.4 DESIGN :-

i) The design calculation in respect of thickness of shall and head and details of construction

shall be strictly as per IS: 2825 OR ASME Section – VIII. Design calculations to be given

along with the tender.

ii) The extinguisher shall be fitted with a safety valve which shall blow at a pressure of 25.0

KGF/ cm 2.

iii) For expulsion of dry powder the extinguisher shall be fitted with suitable capacity CO 2

gas cylinder (CCE approved) confirming to IS: 72852. The CO2 Cylinder shall have wheel

valve mechanism to operate and discharge of gas.

iv) The complete unit shall be mounted suitably on trolley as per IS: 10658, however it may

be ensured that the extinguisher is easily handled by one or two persons.

3.5 EXPANSION SPACE: -

A test to check that the expansion space is adequate shall be carried out as per clause 5.4 of IS:

10658 in one of the extinguisher of each lot and the chemical powder of same quality and

volume / wt shall be maintained for the rest of the extinguisher of the lot.

3.6 ANTICORROSIVE TREATMENT AND PAINTING: -

Painting and anti – corrosive treatment shall be carried, out on each extinguisher as per clause

6 and 7 of IS: 10658, post office red colour shall be used.

3.7 MARKING: -

The name of the manufacturer, year and month of manufacture, capacity, serial No and

hydraulic test pressure shall be stamped on a metallic label and attached to the body of the

extinguisher, Method of operation shall also be written and the same shall be legible.

Due date of hydraulic testing and safety valve testing shall be painted or stenciled on the

surface. Frequency of H.P Testing is 3 year and the same shall be legible.

3.8 INSPECTION SCOPE: -

3.8.1 Check the extinguisher for conformity to IS: 10658 and above specifications.

3.8.2 Check and certify design calculations including safe CO2 quantity.

3.8.3 Check certification of CO2 cylinder confirming to IS 7285 or gas cylinder rules.

3.8.4 Identification, verification and certification of the material.

3.8.5 Stage wise inspection during fabrication of extinguisher specially while welding, sport

radiography of each extinguisher shall be carried out to ensure quality of welding required as

per IS: 2825.



3.8.6 Testing of each safety valve for correct set pressure.

3.8.7 Check the treads for quality and cap for tightness.

3.8.8 Check and test for expansion space for one of the lot and dimensional check of rest of the

extinguisher in the lot.

3.8.9 Hydraulic testing of each extinguisher at 30 Kg/ cm2 and discharge hose.

One extinguisher out of the lot shall be tested for ultimate failure test as per clause 8.2 of

IS: 10618.

3.8.10 Extinguisher shall be received along with the test certification and acceptance certificate by

our authorized inspector. Necessary documents shall be produced to our inspector while

carrying out the Inspection / testing.

3.9 FIRE HYDRANT SYSTEM

3.9.1 GENERAL: -

The Contractors are advised to acquaint them selves thoroughly with the site and other

working conditions. The Govt. will not be responsible for any lack of such acquaintance and

for consequences there form.

All equipment shall be of approved make and prior approval of the Engineer – in charge

should be obtained before erecting the same on the work.

Opening in wall and floors shall be properly patched up and finished to the complete

satisfactions of the Engineer – in charge and white or colour washed or painted to match the

surrounding. No work will be deemed to have been complete unless such damages to the

building or ground are properly made good.

All pipes rested on floors, beams, columns, trusses or girders shall be provided with clamps

or adequate strength and shall not be of size smaller than 25 x 4 mm M.S. flat (and necessary

materials) duly painted as directly by the Engineer – in charge.

The equipments such as jokey pump set, E.R.W. pipes valves fire hyderant valves. Houses

starters to be supplied and used by the contractor at site shall be complete with all original

components assembled by the manufacturers in their factory. A certificate to this effect from

manufacture or dealer if demanded shall be produced by the contractor.

The location of fire hydrant valves, pipes, pumps shall be suitable indicated .

All the accessories such as Bend, Tee etc. should be heavy gauge E.R.W. type.

The material proposed to be used on works should be got approved from the Engineer – in

charge before they are used on works and the works should be carried out in consultation

with him.



Specification :- The specification generally comprises the following items and accessories.

1. G. I. Pipes ‘C’ class ERW type of appropriate size confirming to IS- 1239 along with

necessary fittings, angle supports, bends, Tees etc.

2. Stand post of 75/ 80 mm dia, 1.8 Mtr. Height, ‘C’ class G.I. pipe ERW confirming to IS

1239 with M.s. blocks butt welded type elbow and flanges suitable for double outlet

hydrant valves.

3. Gun metals double outlet hydrant valves morries pattern obliance type confirming to IS-

5200 with G.I. blanks cap and G.I. chain.

4. Fire fighting flax canvas hose pipe confirming to IS – 4927 and 15 Mtr. Length fitted with

male and female G.M. coupling confirming to IS- 903.

5. Gun metal branch pipe of 63 mm ‘Q’ detachable hexagonal nazzle confirming to IS- 903.

6. Cabinet for housing floor hydrant valves, house pipes, sheet real and branch pipe (size

1000 mm x 736 mm x 736 mm) made from SWG sheet and angle iron frame having front

doors with visuing glass and locking arrangement with necessary fixing.

7. Gun metal gate valves having threated ends confirming to IS – 778 along with G.I.

threaded nipple.

8. Fire service main pump, multistage of TAC (Tariff Advisory Committees ) approval

having min discharge capacity of 1400 LPM at 56 Mtr. Head of horizontal centrifugal type

multistage pump of horizontal split case running at 1450 rpm with bron2 impeller, bron2

working parts EN- 80, 40 shaft directly coupled to totally enclosed fan cooled (TEFC)

squirrel cage A.C. Induction motor of suitable capacity to operate on 3 ph, 415 Volt ± 10%

50 hz, A.C. supply with ‘B’ class insulation and both the pump and motor are to be

erected on common. M.S. channel, suitable rigid foundation, nut – bolts, washers,

coupling guards and ant vibration rubber pads in an approved manner (30 H.P.).

9. Automatic star – delta starter suitable for 30 H.P. squirrel cage motor totally enclosed

with overload and no volt relay.

10. Directly operated single phasing pereventor connected to supply up to 45 Amp range.

11. Cast iron foot valve of with gun seat (flapper) for negative suction head and line strainer

fabricated out of brass perforated sheet of 14 SWG duly with brazing to flanze or pipe for

positive suction with nut- bolts, washers, gaskets, etc.

12. Double flange NRV confirming to IS- 5312 having cast iron body and gun metal working

parts with nut- bolts, gaskets etc.



13. PVC unarmoured cable 1100 V grade, with ISI mark with M.S. spacers, G.I. saddles

screwed with continuous G.I. earth wire along with cable glands, terminations, clamps

etc.

14. All pipes, valves etc. shall be tested to 1.5 times of working pressure.

15. All piping, valves, supporting structure etc. Shall be painted with one coat of red- oxide

point and two coats of post office fire red enamel paint.

3.10 ILLUMINATION SYSTEM

The Contractor has to design the A.C. and D.C. illumination system for completed power

house building & A. C. illumination for surrounding area, switchyard, approach road etc. The

detailed design for each floors, control room, switchyard area, street lightning etc. shall be

furnished for approval of purchaser. The general illumination levels & types of fixtures lamps

required are given below, but Contractor may furnish better option & got approved before

starting the work.

SR NO.

LOCATION ILLUMINATION

LEVEL FITTINGS

1. M.I.V. floor/ valve floor 150

Industrial type CFL or MHL of

Adequate lumens as per

Industrial illumination

standard.

2. Turbine floor 150

Fully enclosed CFL or MHL of



standard

3. Generator floor 150




standard.

4. Service bay 200 High bay fittings

5. Control room 300

Mirror optic type CFL or LED

of Adequate lumens as per


standard.

6. Batter /room 100

Fully enclosed CFL or LED of



standard.

7. Work shop 250




standard.



8. Switchyard and surrounding

area of power house 20 HPSV reflux type fittings

9. Approach Road from power

house to switchyard 20 HPSV reflux type fittings.

The cable/ wiring, installation and commissioning of complete A.C. & D.C. illumination

system shall comply with all currently applicable statutes, regulations, fire insurance and

safety codes. Outdoor lighting shall be carried out by using 1.1 kV grade four core cable. The

cabling for the outdoor lightning fixtures will be done in loop- in/loop – out at respective

outdoor fixture mounted junction boxes. The indoor lighting of High bay/ medium bay shall

be carried out by using 2 core, 2.5 mm2 copper cables. The indoor office area wiring shall be

carried in PVC casing & capping.

Outdoor cabling shall be buried in ground whereas indoor lighting wiring (cable/ conduit)

shall be of exposed type.

3.11 GENERAL REQUIREMENT :-

Location of lighting fixtures, switches and plugs shall be shown on the drawing and shall be

relocated if required to suit the site conditions 5A, 3 pin, 15A, 6pin plugs with switches shall

be provided on the light control switch boards.

Switch Board shall be provided with labels indicating LP number and outgoing circuit feeder

numbers.

Switch boards shall be provided at an interval of 300 – 400 mm away for horizontal runs and

400 – 500 mm for vertical runs.

Cables and condults shall be kept, wherever possible at least 300 mm away from pipes,

heating devices and other equipments.

For the purpose of calculating connected loads of various circuits, a multiplying factor of 1.25

will be made to the rated lamp voltage for lamp fixtures to take into account the losses in the

control gear.

Contractor shall supply junction boxes, pull boxes, terminal blocks, glands, conduits and

accessories (elbows, tees, bends etc) and supporting / anchoring materials, to make the

installation complete.

In all types of cabling due consideration shall be given to neatness and good appearance.

The work for installation, testing and commissioning of the indoor lighting shall include the

mounting of fixtures with necessary materials, laying of cable/ conduit through conduit and

external earth wire, providing all accessories for cable/ conduit installation, including



conduit fittings. Providing of light control switch board with switches, switch board mounted

5 A, 3 pin receptacles with switches etc.

3.12 TESTING

Lighting installation testing shall include but not be limited to the following.

• Measure the installation resistance of each circuit without the lamps being in place. It

should be not less than 1 M ohms to earth.

• Current and voltage of all the phases shall be measured at the lighting panel bus bars

with all the circuits switched on with lamps. If required , load shall be rebalanced on the

three phases.

• Check the earth continuity for all socket outlets. A fixed relative position of the phase and

neutral connections inside the socket shall be established for all sockets.

• After inserting all the lamps and switching on all circuits, minimum and maximum

illumination level shall be measured in the area with an approved industrial light meter.

3.13 WORKSHOP EQUIPMENTS

SR.

NO.

DESCRIPTION. QTY.

1. 250 mm Hydraulic Hackwaw Machine with

standard spares, suitable for 3 phase of 1.5 Hp,

Elect. Motor starter Pump (Mechanical V belt

Guard) fixed vice, two-speed etc. complete as

per standard specifications.

1 No.

2. Air compressor mounted on horizontal air

receiver Tank equipped with guard safety valve

(air drain cock, non return valve) autornatic

pressure switch, single phase electric motor 1.5

Hp. Model S- 13, Tank capacity 100 Ltrs. Single

cylinder.

1 No.

3. Lathe Machine of having 1500 mm dist.

Between centers with all accessories as per

standard specifications.

1 No.

4. 600 Amp motor generator welding set type –

KE, Ammeters, Voltmeters mounted on

separate panel with 100 Mtr welding cable,

Welding Holder, Safety glass, etc. complete.

1 NO.



5. Heavy duty Radial Drilling Machine Model

FRD- 32 complete with all standard accessories.

a) Drilling capacity in mild steel – 32 mm.

b) Drilling capacity in cast irol – 35 mm.

c) Minimum dist. From col. to spindle –

355 mm.

d) Max. Dist. From. Col. To spindle – 810

mm.

e) Diameter of column – 200 mm.

f) Max. Drilling radius – 900 mm.

g) Min. drilling radius – 455 mm.

h) Range of spindle speed - 35 – 1700 rpm.

1 No.

6. 150 mm stool mounted Grinding Machine with

two grinding wheels suitable of for 230-volt

single phase having rpm 300.

1 No.

7. Hand operated geared lever shearing machine

with angle and T cutting attachment. 1 No.

Note – All above workshop equipments shall be of standard manufacturers make like H.M.T.,

Kirloskar,Veekky, and M.K. Enterprises. The make and specifications should get approved

from the purchaser before delivery.

3.14 SPARES

Contractor shall provide 10% extra length of Patti / cordite, 10% extra for core cable, with 10%

additional switch plugs & LED lamps.

3.15 EARTHING MAT FOR POWER STATION

3.15.1 The successful contractor has to measure soil resistively in dry and wet condition of soil at the

site of Jambre Hydro Electric Project to access touch and step voltage to design of earth mat for

entire power station. The earth mesh design shall be laid weeded as protected by ant corrosive

paint on the welded joints at site. The laying of earth mesh shall start bellow zero concrete level

and shall be spread at 10 m. from all site of power station up to tailrace, the risers from third

level to all levels of power station up to EOT. Gantry shall be inter contacted by risers as to be

content to mesh at the levels. The earth math shall be of MS steel flats not less than gross

section area of 40 mm x 8 mm Minimum three earth terminal shall be brought for each room of

power station like control room 110 voltage D.C. and 415 volt. ALCT room, 36 K.V. in door

switchgear, outdoor transformer etc i.e. all electrical equipments concerned to power station.



Earth Electrodes / Earth pits shall be provided as per CBIP & IE rules to meet the statutory

requirement separately for Transform Body (tank), Neutral, 36 KV switch gear to speared etc.

The earth resistance shall be as low as possible & shall not exceed the following limits.

Power Stations - 0.5 Ohms

EHT Substations - 1.0 Ohms

3.15.2 Specification of Earthing:-

Depending on soil resistivity, the earth conductor (flats) shall be buried at the following depths.

Soil Resistivity in ohms/meter Economical depth of Burial in meters

1) 50 – 100 0.5

2) 100 – 400 1.0

3) 400 – 1000 1.5

To keep the earth resistance as low as possible in order to achieve safe step and touch voltages,

an earth mat shall be buried at the above depths below ground and the mat shall be provided

with grounding rods at suitable points. All non-current carrying parts at the Substation shall be

connected to this grid so as to ensure that under fault conditions, none of these parts are at a

higher potential than the grounding grid.

Plate Earths:-

Taking all parameters into consideration, the size of plate earths are decided as

Power Stations & EHT Station - Main - 100 x 16mm

- Auxiliary - 50 x 8mm

Small Stations - 75 x 8mm

The complete specifications for providing earth mats at EHT & 33KV Substations, Distribution

transformers & Consumers premises are reproduced below.

3.15.3 Specification for Earthing System

i) EHT Substation :-

Earthing of equipment’s in the sub-stations is taken of as discussed below:

1. Power transformers:

The transformer body or tank is directly connected to earth grid. In addition, there should

be direct connection from the tank to the earth side of the lightning arresters.

ii) The transformer track rail should be earthed separately.

iii) The neutral bushing is earthed by a separate connection to the earth grid.

2. Potential and current transformers:

The bases of the CTs and Pts. are to be earthed. All bolted cover plates of the bushing are

also to be connected the earth grid.



3. Lightning arresters:

The bases of the L.As. are to be earthed with conductors as short and straight as Possible

(for reducing impedance). The earth side of the L.As. Are to be connected directly frolJ1

the equipment to be protected. Each L.A. should have individual earth rods, which are in

turn connected to earth grid.

4. Circuit breakers:

The supporting structures, C.T. chambers, P.T. tanks, Cable glands etc., are to be

connected to earth.

5. Other equipment’s:

All equipment’s, structures, and metallic frames of switches and isolators are to be

earthed separately.

6. Fences:

Providing separate earth or connecting to the station earth depends upon the distance of

the fence the station earth. If the distance is within feet, an inter-connection made to the

station earth. If not, the metallic fences are earthed by means of earth rods spaced at not

more than 200 feet. The gates and support pans may be earthed through an earth rod. The

cable wires passing under “metallic fence are to be buried below at a depth qf 2’6 or are to

be enclosed in a insulating pipe (P. V.C or asbestos cement) for a distance of not less than

5 feet on each side of the fence.

7. Ground wires:

The ground wires over the station arc connected to the station earth. In order that the

station earth potentials during fault condition5 arc not applied to transmission line

ground wires and towers, all ground wires coming to the stations shall be broken !It an

insulated on the fir5t tower external to station by means of strain disc insulators.

The followings are the important features in earthing:

1. The earth mat shall be as per the approved layout. The earth mat shall be formed with the

steel flats buried in the ground at a depth of 750mm on edge.

2. The earth mat shall extend over the entire switchgears per the layout.

3. All the junctions of the steel flats while forming the earth mat and taking risers from the

earth mat for giving earth connections to equipment, steel structures, conduits cable

sheaths shall be properly welded. All joints shall be provided with suitable angle pieces

for proper contact between flats.

4. Provisions shall be made for thermal expansion of the steel flats by giving smooth circular

bends. Bending shall not cause any fatigue in the material at bends.

5. The earth mat shall be formed by welding 50x8 mm steel flat to the 100 x 16mm

peripheral earth conductor. The grounding grid shall be spaced about 5 meters i.e. in



longitude and about 5 meters in the transverse directions. After the completion of earth

mat, the earth resistance shall be measured. In case the earth resistance is more than one

ohm the earth mat shall be extended by installing extra electrodes, so that the earth

resistance is less than one ohm.

6. All fence corner posts and gate posts shall be connected to the ground by providing

32mm dia M.S rods of 3 meter length near the posts and connected to the main grounding

mat.

7. All paint enamel and scale shall be removed from surface of contact on metal surface

before making ground connection.

8. The risers taken along the main switchgear structures and equipment structures (upto

their top) shall be clamped to the structures at an interval of not more than one meter.

9. 50 x 8mm ground conductor shall be run in cable routes and shall be connected to the

ground mat at an interval of 10 meters.

10. Grounding electrodes of 32mm dia 3mtr. long MS rods shall be provided at the peripheral

corners of the earth mat. The grounding rods shall be driven into the ground and their

tops shall be welded to clamp and the clamp together with the grounding rods shall be

welded to the ground mat.

11. Lightening arrestors shall be provided with earth pits near them for earthing.

12. Cast iron pipes 125mm dia and 2.75 meters long and 9.5mm thick shall be buried

vertically in the pits and a mixture of Bentonite compound with Black cotton soil a ratio of

1:6 is to be filled 300 mm dia and the pipe for the entire depth. Where it is not possible to

go to a depth of 2.75 metres, 1.3 x 1.3 MMS plates, 25mm thick shall be buried vertically in

pits of 2 metres depth and surrounded by Bentonite mixture at least 2 meter away from

any building or structure foundation. The plates shall be at least 15 metres apart. These

earth pits in turn shall be connected to the earth mat.

II) Earthing at 33KV switch gear & power Transformer

1. providing of earth pit and earth matting include the following connected works:

a) Excavation of earth pits of size 21/2ft x 21/2ft x 9ft in all type of soils.

b) Providing of CI pipe of 3 inch diameter 9ft length with flange. All connections to

CI pipe shall be with GI bolts and nuts.

c) Filling of earth pit excavated with Bentonite with Black cotton soil (1:6) in

alternate layers.

d) Providing of cement collar of size 2ft diameter 2ft height 1 inch below the

ground level.



e) The top of the CI earth pipe should be at the surface level of the ground.

2. Providing of earth matting with MS flat as per Design but not less than the 40 mm

X 8 mm including the following connected works:

a) Excavation of trench in all types of soils of size 2½ ft depth and 1 ft. width.

b) Laying of M.S flat not less than 40 mm x 8mm in the excavated trench.

c) Inter connecting all earth pits and welding properly at jointing location and

junctions.

d) Back filling of earth completely.

3.15.4 EARTHING MATERIALS :-

The earth mat shall be made up of G.I. Flats in the outdoor 33 KV switchgear and also duly

connected with the power house. The earthmat risers shall be made available at the vicinity of

the foundations of the steel structures within a radius of 2 m. approx. The contractor's scope of

earthing work shall be as under-

i) To interconnect the earthing terminals of equipment with earth mat, by providing a suitable

G.I. Flats for the said interconnection.

The earthing shall confirm to IS 3043.

3.15.5 Joints

There shall be minimum joints preferably no joints enroute to earth electrodes

Where Joints are unavoidable, they shall be brazed, riveted or welded (and painted with red

lead and aluminum paints one after the other and finely coated with bitumen)

3.15.6 Earth Mat Design

Earthing System in a Sub Station comprises of Earth Mat or Grid, Earth Electrode, Earthing

Conductor and Earth Connectors.

1) Earth Mat or Grid

Primary requirement of Earthing is to have a low earth resistance. Substation involves many

Earthings thro’ individual Electrodes, which will have fairly high resistance. But if these

individual electrodes are inter linked inside the soil, it increases the area in contact with soil

and creates number of parallel paths. Hence the value of the earth resistance in the inter linked

state which is called combined earth value which will be much lower than the individual value.

The inter link is made thro flat or rod conductor which is called as Earth Mat or Grid. It keeps

the surface of substation equipment as nearly as absolute earth potential as possible.

To achieve the primary requirement of earthing system, the Earth Mat should be design

properly by considering the safe limit of Step Potential, Touch Potential and Transfer Potential.

2) Step Potential



It is the potential difference available between the legs while standing on the ground.

3) Touch Potential

It is the potential difference between the leg and the hand touching the equipment in operation.

3.15.7 Maintenance of Earthing System

Checking and Testing

The Earthing systems are to be inspected regularly. Regular checking or joints and broken

connections, if any and rectifying the same will prove to be of immense help in maintenance of

earth grid and equipment’s. The condition of the electrodes, joints are also to be checked. If the

electrodes are’ corroded immediate steps for replacement are to be taken. The earth resistance

is to be measured periodically. The mugger or testers are used for this purpose.

As discussed earlier, low earth resistance Path is a must for clearing the fault current

instantaneously. For achieving -low earth values, the following ways are followed:

A number of electrodes are connected in parallel thereby providing a low resistance.

The ground surrounding the electrodes is treated with common salt which reduces the

resistance by 80%. Calcium chloride and magnesium sulphate may also be used. In general

practice. But now the bentonite is used.

3.15.8 Definitions of General Earthing Terms

a) Soil Resistivity: This is the resistivity of a typical sample of soil

b) Earth Surface Voltage: The voltage between a specified point on the ground around the

rod and reference earth.

c) Earth Electrode

These are conductors, which are in direct contact with the soil and provide the

conductive part in electrical contact with earth. They can include rods, tape, and steel

reinforcing bars.

Definitions of Terms associated with Power Systems

d) Neutral Point

The common point of a star connected poly phase system or the earthed mid-point of a

single phase system.

e) Independent Earth Electrode

An earth electrode located at such a distance from other electrodes that its electrical

potential is not significantly affected by electric currents between Earth and other

electrodes.



f) Exposed Conductive Part

Conductive part of equipment and which is not normally live, but which can become

live when basic insulation fails.

3.15.9 Points of Earthing :-

1. See that each and every pole structure is earthed with 50 x 6 MS flat to the Earth Mat.

2. Lightening arrestor is to be connected one end directly to the earth mat and the other end

is to the nearer earth pit or to the earth mat.

3. The Power transformer body is to be connected two sides to the earth mat.

4. Neutral earthing should be done to Power Transformer as shown in the fig. one Earth flat

of size 75 x 8mm M.S flat is directly connected to the earth pit and the earth pit is again

connected to the Earth mat. The second neutral is directly connected to the earth mat,

5. Provide flexible jumpers thoroughly brazed as shown in figure

6. All AB switches operating rods are to be provided with coil earths and the AB switch

support is to be earthed to the earth mat.

7. The distance between any two earth electrodes should be twice the length of the Electrode.

8. The cable (11 x 33KV) sheaths are to be earthed with 25 x 3 GI strip to the Earth mat.

9. The neutral of the station transformer is to be connected to the Earth mat directly with 25 x

3 GI strips. The body of the Station transformer two sides to be connected to the earth mat

with 25 x 3 GI strips.

10. All the welding joints should be painted with bituminous paint.



1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - IV

TECHNICAL SPECIFICATION OF

INSTALLATION & COMMISSIONING



SECTION - IV

TECHNICAL SPECIFICATION OF INSTALLATION TESTING AND COMMISSIONING OF

GENERATING UNIT AND OTHER ELECTRICAL & MECHANICAL-AUXILIARY

EQUIPMENTS.

1.0 SCOPE

1.1 This specification covers complete erection including labor, materials, tools, instruments,

services, storage during erection, unpacking, grouting, cabling etc. and also testing,

commissioning and putting into commercial operation of 1 No. horizontal hydro

generating units along with all the electrical and mechanic auxiliary equipment and

system ( given in anx. I )The scope also includes laying, wiring, erection, testing and

commissioning of power and control cable in the power house and in the equipment

mounted in switchyard. The refurbished equipment is also included in the scope.

1.2 The work shall be carried out under the supervision , instruction and guidance of

purchasers / suppliers engineer AND OR AS PER vendor / EQUIPMENT INSTRUCTION

MAUNAL..

1.3 EXTENT AND ITEMS OF WORKS

1.3.1 Places of Erection

The installation works covered by the present specification is distributed principally in the

surface power house and the 33 KV indoor switchgear in the power house building.

1.3.2 The installation work also Includes laying of power and control cables for interconnecting

power and control circuits.

1.3.3 Items of Work

The contractor shall provide all supervision, skilled, semi-skilled and unskilled labour, all

necessary services, all construction tools, derricks, cables and slings, rigging skids,

blocking, scaffoldings, welding machines, equipment for induction/ gas heating, stress

relieving equipment, instruments appliances, materials and supplies required for handling,

storing during erection, erection and testing etc. that may be required to accomplish the

work under this contract, unless otherwise provided for Adequacy of such equipment will

be subject to final approval by the purchasers Engineer.

1.3.4 The materials to be furnished and installed by the contractor shall include but not be

limited to the following:

(a) All consumable material and devices.

(b) All joining materials like gaskets round rubber gland-packing etc.

(c) Cable identification tags, wire identification ferrules, HT & LT insulating tapes,

Bitumen tapes, solder etc..

1.3.5 The work to be performed by the contractor shall include but not be limited to the

following services as required for the complete mechanical and electrical installation and

placing the equipment in commercial operation



(a) Indenting of equipment and materials (the equipment shall be received by the

contractor from the stores and transported into the erection bay)

(b) Providing adequate mechanical and weather proof protection for the equipment

and materials.

(c) Providing all temporary power and lighting facilities inclusive of all materials

required for the installation work.

(d) Handling and assembling equipment and materials including erection leveling

aligning grouting fixing cabling wiring piping welding purifying and filling oil and

lubricants connecting start up, initial operation and placing in commercial

operation

(e) Checking of all systems and components of equipment, electrical and mechanical

pre-commissioning and commissioning tests, bringing into initial operation and

commissioning.

(f) Accounting for all material/equipment and returning all the unused items to the

suppliers Engineer.

(g) Painting of all non-galvanised steel parts and painting for phase, circuit, voltage

and equipment identification of different circuit, switches, piping etc.

(h) All incidental and auxiliary works as may be necessary of the satisfactory and

successful completion of the work in accordance with the specifications, standard

and manufacturer's/ purchaser/consultants instructions.

1.3.6 All the works shall be carried out to the satisfaction of the Engineer The contractor shall be

responsible for the correctness, alignment and positioning of the work according to the

drawing and manufacturer's/ supplier's instructions, base line and bench marks.

1.3.7 The contractor shall be completely responsible for all the works covered under the scope of

this specification not withstanding that he may have been assisted by the Engineer in

doing so.

1.4 LIST OF MAJOR EQUIPMENT TO BE ERECTED

1.4.1 The List of major equipment’s which are required to be installed within the scope of this

specification Is given in ANX -1 for the guidance of the tenderer in order to estimate the

work involved -The List does not cover all the equipment and materials required to the

generating station. The List should not be considered as defining the equipment or

limiting the extend of work.

1.4.2 i. Laying of ground mat in the power house .

(ii) All cabling and wiring connecting different equipment installed in the power house

and all HT. LT. D.C. power and control cables in the switchyard connecting power

house equipment/panels to the H.T. switchgear and transformers Erection of

embedment required for laying of cable racks .



(III) All pipes and fittings for pressure oil and other systems and device being supplied

by various suppliers for installation in the power house and switchyard including

laying jointing connections etc.

(IV) Complete erection testing and commissioning of all the equipments and systems of

the power house as well as interconnection with the transformers.

1.4.3 The procedure followed and precautions taken and the equipments/ and materials used in

the installation work shall confirm to the relevant Indian or International Standards and

also to the following wherever applicable.

I. Indian Electricity Rules, 1956/rev 2005

II. Indian Boiler Regulation and all other applicable statutory rules and regulations.

Ill. Indian Factories Act

IV. Indian Explosives Act

National-Electrical Code-Standards of the National Board of Fire Underwriters (USA).

1.5 DRAWINGS

1.5.1 The specification drawings are enclosed to facilitate understanding of the project scheme,

general power house layout and the equipment involved, etc. and of estimating the nature

and extent of work involved The drawing and the equipment/materials shown are liable

to be revised for additions, corrections and include additional drawings.

1.5.2 Construction drawing shall be prepared by the contractor on the basis of

manufacturers/suppliers drawings and furnished by the contractor for approval of

purchaser/consultant as and when the details are finalized. The contractor shall carry

out the installation work according to such drawing and instruction books issued for

construction by various manufacturer.

1.5.3 The drawing, diagrams, and manufacturer's instructions shall be read together

Disagreements and inconsistencies if any, shall be brought to the notice of the Engineer

whose decision shall be final.

1.5.4 During the progress of the work the contractor shall maintain and mark a complete set of

the latest design drawings issued for construction, in which all deviations for the drawing

in the actual execution shall be clearly marked as "as built conditions Upon completion of

all works, the contractor shall furnish the Engineer with a set of "as built drawings.

1.5.5 In case of any doubt as to correct interpretation/ understanding of design drawings/

manufacturer's drawings, the contractor shall obtain necessary clarifications for the

suppliers Engineer. Contractor shall be held responsible for any damage to the plant

equipment/ materials consequent to incorrect compliance/noncompliance of

manufacturer's/ engineer's instructions.

1.5.6 When measurements are affected by conditions already established, the contractor shall

take field measurements not withstanding scale of dimensions shown on Engineer's

drawings.



1.6 TEMPORARY POWER AND LIGHTING

1.6.1 All temporary lighting and power facilities required for the installation work shall be

furnished and installed by the contractor. These temporary installation shall include cables

outlet and conduits supports, insulators, fuses switches and other required materials.

1.6.2 The owner will arrange at a single point 415 V, three phase four wire supply for where the

contractor shall lay his distribution cables. The power will be charged at the rates

applicable as per the tariff of the power Deptt.

1.6.3 The materials used for temporary facilities shall not be reused in any permanent

installation.

1.6.4 The contractor shall remove all temporary facilities from the plant premises, after the same

have served the purpose.

1.7 STORAGE AND PROTECTION OF THE WORKS

1.7.1 The contractor shall use care an diligence to ensure that all works, equipments, materials

furnished, handled, stored and/or installed by him are at all times thoroughly protected

for the weather and for any damage. Necessary labour, tarpaulins, boards, boxes, frames,

canvas, polyethylene, sheets and other materials required to keep the materials/equipment

in first class condition shall be furnished and installed by the contractor.

1.7.2 The contractor will be responsible for the receipt, storage and protection of material

and/or equipment as received at site on behalf of the owner for installation by the

contractor. The equipment shall be suitably insured during transit, storage and erection so

that all risks of the owner are fully covered.

1.7.3 The contractor shall provide watch and ward storekeepers etc. to safeguard the materials,

tools, construction aids and equipment while in the contractor's care custody of control

during the performance of work and till its taking over by the owner.

1.8 EQUIPMENT INSTALLATION AND COMMISSIONING

1.8.1 The contractor shall check clear all dirt and rust install connect test and place the

equipment

in commercial operation all plant/machinery equipment included in this specification in

accordance with the detailed instructions/drawing of the manufacturers/suppliers of as

directed by the Engineer's All work shall be performed by qualified trained and

experienced personnel licensee where required in the various trades.

1.8.2 Extreme care shall be taken in handling equipment and in position and moving it into

place Any damage to the equipment or T & P belonging to the contractor or owner shall be

reported to the Engineer. Installation of the damaged equipment shall not proceed until

the Engineer has had an opportunity to assess the extent of damage and decide on the

procedure to be adopted. The contractor,. shall repair and replace at his expense any

equipment damaged by him during progress of work Such repair or replacement shall be

subject to the Engineer's approval.



1.8.3 All equipment shall be installed and secure in place in a workman like manner so that it is

level and true properly align and oriented. Tolerance shall be as per manufacturer's

drawings/instructions or as specify by the Engineer. No equipment shall be permanently

bolt down to foundation or structure until the alignment has been checked and found

acceptable by Engineer.

1.8.4 Contractor shall make his own arrangement for hoisting and handling the equipment. The

facility of EOT crane in the power house will be provided to the contractor. the contractor

shall satisfy himself suitability of crane for the entire Job.

1.8.5 The erection and installation of the equipment shall be subject to the supervision of the

purchaser’s Engineer. The contractor shall comply with the instructions of the

Engineer/erection supervisor regarding the procedure, method and quality of work and

shall execute the work to their satisfaction. The detailed erection schedule including the

number specialization and duration of stage of all supervisory erection and commissioning

personnel of various suppliers shall be finalised by the contractor and shall be subject to

the approval of the purchaser.

1.8.6 It shall be the responsibility of the contractor to provide and depute the required number

of first class welders, welding rods, welding sets for all types of welding work, at his cost.

All welders shall be certified welders who shall be got tested and approved by the

Engineer at site. All arrangement in regard to the tests for approval of the welders at site

will have to be made by the contractors, at his cost, Details of welding tests and acceptance

standards shall be laid out by the Engineer in consultation with the erection supervision of

the manufacturer and will be binding on the contractor, A service bay is provided in the

power house for facilitating unloading and assembly of equipment.

1.9 EQUIPMENT SPECIFICATION AND INFORMATION

1.9.1 The technical specifications of various equipment and system to be erected will be given..

The drawing indicating the general arrangement and layout of different items at various

levels in the power house are enclosed. The complete technical detail and working

drawing of these item are not yet finalized and specification are subject to variation.

1. The contractor shall familiarize him self with the constructional features of all

Electrical /Mechanical plant equipment as applicable for this Power House. The

completion Schedule of the Project has been envisaged as per agreement. The

erection schedule has to be drawn in PERT taking into consideration all the

activities involved. The bidder shall furnish the time schedule for erection, testing

& commissioning of the equipments falling in scope of this specification.

II. Cables, Racks, Tray & Accessories

(a) The power and control cable for the aforementioned equipment to be erect shall be

laid directly buried in earth, on cable racks, in build up trenches on cable trays and

supports in conduits and ducts or bares on walls, ceiling etc.

(b) The contractor's scope of work include laying, fixing, joining, bending and

terminating of power / control cables, pertaining to the generating units and its

aux. equipment such as unit control and automation boards, generator terminal and

neutral cables etc. cables for all the control and power equipment as well as

transformer and H.T. switchgear to be erected in the switchyard shall be laid



Permanent cable trenches. For laying cable underground, the excavation and back-

filling of trench and permanent reinstatement are included in the scope of work of

this contract.

(c) Standard cable grips and reels shall be used for cable pulling and care shall be

taken to avoid damage to cable end seal and cable insulation or stressing cable

beyond manufacturers recommendations in pulling.

(d) Sharp bending and linking of cables shall be avoided. The bending radius for

various types of cables shall not be less than that specified in the relevant

standards.

(e) Power and control cables shall be laid in separate cable trays in the cables trenches.

Where groups of HV & LT cables are to be laid on the route suitable barriers to

segregate them physically shall be employed.

(f) In each cable run, Some extra length shall be kept at a suitable point to enable one

or two straight through joints to be made, should the cable develop fault at a later

date.

(g) Cable as far as possible shall be laid in single layer. Cable in rack trays, conduits

etc. shall be laid in such a way as to avoid bending against edges of trays, racks,

support etc.

(h) All the cable termination all be made according to the relevant drawings in a neat

workman like and approved manner. Each cables shall be provided with non-

corrosive type identification tags on cable at the ends and at suitable intervals in

lone runs At the control cables terminations- each core shall also be provided with

ferrules designating the wire number or any other identification mark as given in

the schedule. The cable cores or wires which are not used for making connections

shall be sharply cut without exposing any conductor.

(1) All identification tags, wire ferrules etc. required shall be provided by the

contractor. Metal sheath and Armour of the cables shall be bounded to the earthing

system of station.

All power cables shall be megger tested before connecting or jointing. After

jointing all LV cables shall be megger tested an HV cables appropriately pressure

tested before commissioning. All the cable cores shall be tested for continuity,

insulation resistance to earth and between conductor.

(k) The contractor shall bring all testing equipment’s including high voltage testing kit.

The test equipment shall be calibrated by authorized lab.

1.10 GROUNDING OF EQUIPMENT:

All electrical equipment’s required to be grounded shall be connected to the station

grounding grid as per relevant drawings/ instruction of Engineer.

1.0 SCOPE

1.1 This specification covers requirement of earthing and lightening protection

system.



1.2 The earthing system shall meet the requirement of IS 3043 And also includes

local regulations in force. Lightening protection system shall be done in accordance

with IS : 2309

1.3 Generator neutral earthing panel shall be installed AND earthed as per instructions.

2.0 EARTHING SYSTEM

2..1 All electrical equipment’s as well as non electrical parts of electrical equipment

above 250 volts protecting device such as chain link fencing , motor screens cable

trays etc, shall be earthed at two independent points in earth grid.

2.2 All the material used for earthing shall be as per IS: 3043

2.3 Earth conductor shall be at lest 300 mm away form main power cables.

2.4 All underground connections and joints in earthing system shall be welded,

however connections with equipment shall be by bolted joint. All joints shall be

applied with petroleum jelly for bolted joint sand in case of welded joints by

bitumen compound.

2.5 When G I Conductor is joined with aluminum conductor , the contact surface of G I

shall be covered with bituminous compound.

2.6 Neutral connection shall not be used for earthing of equipment directly.

2.7 Earthing conductor shall be protected against mechanical damage,

2.8 Earthing running along the wall be secured to wall / cable trey every 750 meter.

2.9 Minimum size of the earth conductor shall be in accordance with IS : 3043 However

it shall be at lest half the size of main power conductor.

2.10 All earth connection shall be as short as possible an direct without links.

3.0 EARTH GRID

3.1 Earthing shall be done in tow parts and connected to gather by parallel paths. The

main earthing grid shall consists of Earth pit and electrodes, main earth conductor,

test links to measure earth electrode resistance at periodic intervals.

3.2 Minimum spacing between two electrodes shall not be less than six meters and

shall be at least one meter away from the footing of the building. Main loop for he

building shall be installed outside the boundary of the building at a depth of

minimum 600 mm.

3.3 Main earth loop inside the plant shall be run inside the cable trey along the cable to

the equipment.

3.4 All the earth electrodes shall be given treatment to reduce the earth resistivity in

grid. If necessary watering arrangement may be provided for earth electrode

where resistivity is high..

3.5 Transformer neutral when earthed shall be with two separate electrode .

Transformer body shall have two separate earth pits.

4.0 Indoor equipment earthing



4.1 Each floor of the building shall have its own earth grid embedded in concrete the

depth of grid conductor shall be 50 mm below floor level. Earth buses on different

floor and main grid shall be connected by at least two conductor of main grid

conductor size.

4.2 Every alternate column steel or RCC of the building housing electrical equipment

shall be connected to main grid.

4.3 Every conductor shall be welded at 1m interval along the run on steel structure.

5.0 Out door equipment earthing.

5.1 Each transformer neutral shall be provided with two separate earth leads to two

separate earth pits located near transformer.

5.2 Whenever earth conductor crosses the trenches , tunnels ,rail track etc, it shall run

below the trench etc.

5.3 Equipment structures shall be earthed at two diametrically opposite points.

5.4 Each pole of H V lightening arrestor and coupling capacitor shall be rounded with

minimum one direct earth pit.

5.5 CTs secondary winding shall be connected to to earthing grid by minimum two

eathing conductors. CT & VTs secondary neutral shall be earthed at the terminal

block there they enter control panel.

5.6 Every alternate post of switch shall be earthed and gate shall be earthed by flexible

G I wore.

5.7 Any two diametrical opposite legs of switch tower with lightening shield wire

protection shall be earthed at the base.

5.8 A well distributed earth mat shall be provided below ground on which operator

would stand and operate isolator or circuit breaker.

6.0 Lightening protection.

6.1 Tall structures shall be protected from lightening strokes by suitable lightening

protection scheme designed as per IS: 2309.

6.2 Down comer shall be terminated directly on nearest earth pit.

And shall be as short as possible. A test link shall be provided in downcommer at

a height of 1000 meter from ground .

6.3 No other earthing conductor shall be connected to lightening conductor or any part

of lightening protection system.

6.4 A distance of two meter shall be maintained between lightening conductor and

other electric cable .

6.5 Earthing and lightening system shall be bonded to each other to prevent side flash

over, if adequate clearance cannot be maintained.

7.0 Testing and commissioning.

7.1 Entire earthing system and lightening protection system shall be tested for

continuity by ELV tester after installation.



7.2 The connection of entire grid including test pit shall be checked.

7.3 The entire grid earth resistance shall be taken an recorded and if required improved

to acceptable limit All adjustment work shall be carried out by contractor during

testing and commissioning.

8.0 Earthing and lightening protection system.

8.1 The sizes and number of earth leads for earthing various equipment’s and technical

particulars shall be as specified.

8.2 Earthing conductors are shown diagrammatically. Exact location of earthing

conductor, Earth electrodes and test pits maybe changed to suit the site conditions.

8.3 G I pipe sleeves shall be provided when conductor passes through wall. Water

stops shall be provided if conductor is below ground.

8.4 Earthing contractor shall co-ordinate with civil contractor during entire Earthing

job and while laying concrete floor having embedded earth conductor.

8.5 lightening conductor and air terminal on roof shall be firmly secured to the Roof

structure. Similarly all down comer shall be firmly fixed to wall column.

9.0 Earthing and lightening protection table

Sr. No Description Conductor material and size

1.0 a Main Generator 50 x 10 mm G I strip.

b M V switch 50 X 10 MM G.I.

Main Earthing grid in sw. yard.

Isolator and other support.

c. 415 V switch gear 50 x 10 G I

d. Transformer neutral copper / ACSR conductor

e. Neutral Earthing resistor 50 x 10 mm G I

2.0 Cable trey control 40 x 6 mm G I strip

Supporting structure NGR

1.11 Misc. works such as fire fighting equipment , air conditioning of CR , cleaning and

painting of all plant as per the tender will be carried to the satification of plant manager /

engineer of purchaser.

1.12 As stated in the tender the contractor shall be provide and erection completed to make the

installation complete in all respect and to the satisfiction of Purchase / authorities such as

electrical inspector / MSEDCL enginer.

1.13 1. INSPECTION AND TESTS:

(a) Upon completion of the various phases of the work, or at convenient times during

the progress of the work, equipment and wiring installed by the contractor shall be

checked tested and got inspected by the suppliers Engineer/Government Inspector.

Any defects pointed out shall be corrected by the contractor at no additional cost.



(b) All checking and testing procedure shall be performed by competent and experienced

personnel employed by the contractor in the presence of and as directed by the

Engineer.

(c) All equipments and instruments required to conduct the tests shall be provided by

the contractor.

(d) The contractor shall provide all labor, materials, tools and instruments, and

supervision and shall be responsible for conducting pre-commissioning tests on all

equipments as per relevant standards. In cases where the services of the

commissioning engineer of the manufacturer/supplier of the equipment is availed

the tests shall be performed under the overall supervision of the said

commissioning engineer.

(e) The checks and tests to be made shall include but not be limited to the following :

(I) All routine and pre-commissioning tests and any other special tests required to be

conducted at site on the various system associated equipments as agreed to

between the supplier of various equipments.

(ii) All routine and pre-commissioning tests and other special tests required to be

conducted as site on each and every equipment as per the relevant standards and

manufacture's instruction and recommendation.

Visual checks for correctness of all wire and cable connections, including internal

wiring of control panels, switchgear, transformers and all other equipment.

(iv) Visual checks for correctness of all pipings and checks for leakages of air water oil

etc. as the case may be.

(v) Continuity checks for all control and power cables including each conductor of

multi conductor cables.

(vi) Insulation resistance tests of all power cables, Motors, panels,, switch gear,

instrument transformers etc.

(vil) Polarity checks of all instruments transformers.

(viii) Lead resistance measurements of current transformers circuits.

(ix) The primary and secondary injection tests for CTs and relays.

(x) Checks, for adjustment and characteristic of all control and protective relays in

accordance with manufacturer's instructions.

(xi) Setting and calibration of relays.

(xii) Cheek all equipment for proper mechanical adjustment and freedom of operation.

(xiii) Check electrical operation of all remotely operated equipment.

(xiv) Energies all control, protection, alarm and supervision circuit and cheek each

circuits for correct functional operation including all interlock devices.

(xv) Cheek all meters for proper rotation and correct measurement under load

conditions.



(xvi) Check to detect excessive vibration of equipment and foundations, misalignment,

etc.

(xvii) All other tests as specified under various sections, different relevant standards and

codes of practice, but not mentioned here.

During the course of all tests, contractor-shall keep a complete record of all tests

done and measurements taken and also record all adjustments, alterations and

repairs made to the equipment. After completion the tests, contractor shall furnish

three copies of all such records complete to the Engineer duly signed.

SCHEDULE-A

SCHEDULE OF CONSTRUCTION EQUIPMENTS WHICH WILL BE BROUGHT TO SITE BY

THE TENDERER (TO BE FILLED AND SIGNED BY THE TENDERER)

SI.NO. Equipment/Tools Type Capacity Qty.

1 Manually operated winches

2 Manually operated jacks

3 Hydraulic pulley blocks

4 Chain pulley blocks

5 Pulley blocks

6 Portable air compressor

7 Arc welding transformers

8 Arc welding MG set

9 Gas cutting sets

10 Gas welding sets

1 Manual pipe bending sets

12 Hydraulic pipe bending sets

13 Pipe cutters

14 Pipe cut die sets

15 Conduit sets

16 Oil filtration sets

17 Electric drilling machines

18 Measuring steel tape

19 Precision spirit levels

20 Cable jointer's tools box

21 Cable grip

22 Cable rollers



23 Cable crimping tools.

23 Portable power and lighting distribution boards

24 Flood lights

25 Dry battery operated telephone sets

26 2.500 V motorized' meggers

27 1000 V' meggers

28 500 V meggers

29 Relay test kit primary / secondary injection.

30 Avometers / Multimeters.

31 Line testers upto 1± kV

32 Tong testers for use on HT of adequate current carrying ,capacity.

33 Other items (to be listed by the contractor) specially precision measuring and

teasing equipment.

34 Pneumatic tools for fixing bolts , hammering fasteners. Etc.

35 Box strapping set.

36 Portable blowers . vacuum cleaners.



1.14 INITIAL OPERATION, COMMISSIONING AND COMMERCIAL OPERA TION :

1.14.1 Before putting the unit in operation, all appurtenances shall be thoroughly cleaned and

then inspected in the presence of the Engineer for correctness and completeness of

installation and acceptability for operation.

1.14.2 Following satisfactory completion of the inspection and checking of all equipment and pre-

commissioning tests, the generating unit shall be placed under trial operation during

which period all necessary adjustments, repairs, etc. shall be made as required in co-

ordination with the contractor for Turbogenerator package,

1.14.3 The procedure to be followed for completion tests, trial run and period of initial operation

shall be agreed to between the contractor and purchaser’s engineer prior to the tests being

carried out. Sufficient notice should be given by the contractor about readiness for

performing the trial run and initial operation.

1.14.4 When the contractor and engineer are satisfied that the equipment is operating properly,

test report sheets, in the form as approved by the engineer, shall be compiled for each piece

of equipment. Five copies of each report shall be submitted to the engineer.

1.15 ERECTION AND COMISSIONING SCHEDULE,

The contractor shall furnish along with the tender a detailed erection and commissioning

schedule to match the commissioning targets.

1.16 SCHEDULE OF CONSTRUCTION EQUIPMENT AND EXPERIENCE

The tenderer shall fill in as per Schedule-A, the list of construction equipment which shall

be brought by him to the site for carrying out various construction and testing activities.



1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - V

ACCEPTABLE MAKES OF VARIOUS

EQUIPMENTS



SECTION – V

A . LIST OF ACCEPTABLE MAKES FOR VARIOUS EQUIPMENTS

Standard Manufactures As acceptable to Owner.

• Bearings -- Zolnem, Germany, Rank, Germany.

• Control Panels -- ABB, Siemence, Boom System Andriz.

• Generator -- TDPS,WEG,CGL.

• Turbine -- KBL, B Fouress, Boom System, Flovel Andriz.

• Governor -- Heinzmann Hydrotech Pvt.Ltd.

• Gearbox -- Triveni Engineers & industries,Walchand

• E.O.T. Cran -- ElectroMech,Pune,Century Unique

• O.P.U. -- REXROTH/PARKER

• LAVT, NG PANEL -- Boom Systems, Poona Switch Gear, Andriz.

• BFV -- B. Fouress,KBL,BSPL,Andriz.

• Small Valves -- AUDCO,AV Valves

• Protection and Systems -- ABB.GE,Siemens

• 33KV CT’s & PT’s -- CGL,ITC

• Lightning Arresters -- Lampco,ELPRO Oblum

• Isolators -- Kiran,DANKE

• Circuit Breakers -- ABB,Areva

• Control System -- ABB

• Transformer -- Telwani,CGL Suprime power

• Cables -- Polycab

• Diesel Generator -- Cummins

• Battery & Charger -- Excide, VRLA, Universal.

Bidder is free to quote any equivalent with technical justifications. Owner will have first priority for above list.



B. LIST OF APPROVED MAKES FOR AUTOMATION

Sr No. Particulars List of Approved makes

A.

Flow measuring devices

Electromagnetic Flow meter

(EMFM-2) Upto 700 mm size

Krohne, Siemens, ABB, E & H.

B. Level measurement devices

Differential pressure sensor

Siemens, Emerson, Yokogawa

Siemens, JN Marshall

C. Level measurement devices

1. Level Indication sensor

(Capacitance)

Toshniwal, SB, Electromech,

Levetrol, R K Dutt

2.

Level Indication Sensor (Ultrasonic) With GSM modem for transmission

Krohne, Siemens Orbit E & H

LIST OF APPROVED MAKES OF MACHINERY TO BE PROVIDED

Vertical Turbine Pumps

No Limit Kirloskar, Joyti, WPIL, KSB, Mather and platt Voltas

Vaccum Pumps

5HP and above Kirloskar

Below 5 HP Kirloskar & makes approved at local level

Valves

600 mm dia above Kirloskar, IVI, IVC

50 to 200mm dia All above and BSJ Shahu

Reflux Valve

600 mm dia above Kirloskar IVI, IVC

Kinetic Air Valves IVI, IVC, Hawa, Mayur, Durga

Foot valve upto 80mm dia Kirloskar & makes approved at local level

Butterfly Valves Foress.KBL, Jyoti

Actuators auma,

Pipes

G. I. Pipes and special Zenth, Tata, Jindal,

C. I. Pipes and special Reputed makes approved at a local level

Tools Gedore, Jhalani, Tapara



Pressure / Vaccum Gauges Walchand , H-Guru ,marshall

Lifting equipments

Chain pulley block monorail with travelling trolley

Indef, Mooris, , W.H. Brady (5 T Only)

HOT, Cranes W.H. Brady (5 T only) Harculas, Anupam

EOT, Cranes W.H. Brady (5 ton) Anupam, Herculas.

Motor

L.T. Motors

1) Horizontal Motors Kirloskar, Jyoti, Crompton, Alstom,, Siemens,L

2) Vertical Solid shaft motors Kirloskar, Jyoti, Crompton, Alstom, , Siemens,

3) Vertical hollow shaft motors Kirloskar, Jyoti

H.T. Motors Kirloskar, Jyoti, Crompton, Alstom, , Siemens,

Starter L&T , Siemens ,

ELECTRICAL EQUIPEMNT MAKES

Over current and earth fault relay high speed tripping relay.

EE, ABB, , ALSTHOM / AREVA

Static Relay ABB,C &S , ALSTHOM / AREVA

Ammeter / Voltmeter AE, , RISHABH, ENERCON,

Capacitor

L. T. Capacitor 25 k VAR and above Madhav, Prabhodhan Sudarshan

L.T. Capacitor 25 k VAR All above & as approved by MSEB

Cables

i) PVC Submersible ( Copper Conductor) Finolex, Perfect, Calama

Cable

ii)1.1KV armored & Unarmored cable Finolex KEI ,Polycab

iii) 1.1 Kv XLPE cable Finolex KEI ,Polycab

iv) 3.3 kV/6.6kV/11kV/22kV/33kV XLPE Cable

, Gloster , Universal.

v) Control Cable Finoles Gloster Polycab , Deltron,

vi) Cable Termination Rayeechem, Mahindra & Mahindra

H.T. & L.T. Panel ABB, , ALSTHOM / AREVA approved equipments only.

a) D.O.L. L&T., Siemens SEIL, Kirloskar, Teleme - cartique MEI, (BCH)

b) Star Delta L&T., Siemens, SEIL, Bhartiya industries Ltd. Kirloskar Teleme - cartique



SWITCHES & FUSE

a) Rotary Thakoor Kaycee L&T Siemens And make as Approved at local level

b) Iron clad Stanley, Ashok, KEW Crompton and make as approved at local level

c) Metal Clad CPI, L&T Elecon Ashok Standard Crompton And make as approved at local level

d) Fuses Switch L&T, Crompton Control & Switch gear, standard electrical, (Upto 30.04.2005)

e) Change over switch on load offload Havells, Control & Switchgear

f) HRC Fuses L&T Alstom Standard, Siemens, Control & Switchgear

OIL CIRCUIT BREAKERS

Moulded Case Circuit Breakers

No Limit L&T, ABB, SEIL, Jyoti, Alstom, Andrew Yule, Havell’s Control & Switchgear, Schneidar.

Upto 630 AMP All above

Air Circuit Brakers

No Limit L&T, Siemens, Control & Switch Gears

Upto 1000 Amp All above & ABB SGIL

Upto 630AMP All above and Easun,

Vaccume Circuite Braker 22 kv/33kv ABB, Crompton, , Siemence, AREVA ,

11Kv All above)

Vaccume Contactors ABB 1.1kv amp to 630 amp - cromton 7.2 & 11 kv-400 amp, Crompton, Alstom,

Earth Leakage Circuit Braker Reputed makes to be decided at local level

Motor Protection relay for LT Motors Reputed Makes to be decided at local level


JAMBREJAMBREJAMBREJAMBRE HYDRO ELECTRIC PRHYDRO ELECTRIC PRHYDRO ELECTRIC PRHYDRO ELECTRIC PROJECTOJECTOJECTOJECT

1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - VI

GUARANTEED TECHNICAL PARTICULARS


1 Full Reservoir Level. 737.00 m Above Mean Sea Level.

2 Minimum Draw Down Level 720.30 m MDDL (I)Above Mean Sea Level.

3 Minimum Draw Down Level 708.00 m (Power) Above Mean Sea Level

4 Minimum Tail Water Level 703.10 m

5 Maximum Tail Water Level 703.5 m (At end of rising Apron)

6 Maximum Gross Head 33.50 M

7 Minimum Gross Head. 17.40 M

8 Design Gross Head 27.00M

9 Diameter of Penstock 2.00 m

10 Thickness Of Penstock. 12.00 mm

11 River bed level 702.935 m Above Mean Sea Level

I TURBINE AND AUXILIARIES:

SR NO. DESCRIPTION UNITS

1 Name of the Manufacturer

2 Type of Turbine

3 Shaft Orientation.

4

Guaranteed rated output of each turbine at rated nethead of 27 m (Gross head-losses in water conductorsystem. Net Design head to be ascertained by Tendererof model tests for discharge.

Head in Meter Min Rated Max

Discharge (Cumecs) & Output (KW) Q P Q P Q P

Percentage Gate Opening

25%

50%

75%

100%

110%

GUARANTEED TECHNICAL PARTICULARS.

The particulars of turbine rated output and efficiency (At Sr.No. 4 & 5) marked with asterisk (*) below shall be guaranteed.

SIGNATURE OF TENDERER SIGNATURE OF PURCHASER 212



5Performance curves, model particulars and

efficiencies

a) Performance curves for output, efficiencies anddischarge verses percentage gate opening underdifferent head conditions shall be submitted along withtender

b) Bonafied turbine efficiencies at rated head for the following outputs

Output

110%

100%

75%

50%

25%

c)Best efficiency of turbine

(It shall be obtainable at the rated Output of not lessthan 2000 kW at design discharge and around 85%gate opening)

%

d) Model Particulars

i) Drawings of model turbine which meets The designdata of this specification shall be Submitted withtender in triplicate.

Yes/No

ii) Latest test reports of above model (to be enclosed)Model tests data duly corrected Along withcalculation of correcting factors Shall be enclosed.

Yes/No

iii) Name & full address of the customers executed Orders on the basis of this model tests . (Along with order number and technical details

Yes/No

iv) Acceptance certificate from above customer Yes/No

6 Discharge:

Turbine discharge at rated head for the followingPercentage of rated output:

110% Cumecs

100% Cumecs

75% Cumecs

25% Cumecs

7 Speed:

a)Specific speed in M.K.S. Units

b)Rated speed in R.P.M. rpm

c)Maximum runaway speed in R.P.M rpm

d)Direction of rotation when viewed from GeneratorEnd.

e)Momentary rise in speed on suddenly reducing loadat 110 % of Rated to rated speed.

f)Time of gate closing for regulation in item-7aboveSeconds

Seconds




8

a)Momentary drop in speed in increasing load fromzero To full load

% of rated speed.

b)Time of gate opening for regulation at (a) above Seconds.

9 Flywheel effect of: -

a) The generating unit for regulation stated above kgm²

b) Turbine runner & shaft. kgm²

10 Factor of Safety:-

a)Guaranteed minimum factor of safety under worstConditions based on yield point of the material.

b)Name & location of the part having the factor ofSafely in (a ) above.

11Maximum water hammer pressure (Not to exceed 25%

of Max. head)%

12 Thrust bearing loads:-

a)Load due to turbine rotating parts kg

b)Maximum axial hydraulic thrust down words kg

c)Total down words load on thrust bearing Originatingfrom turbine.

kg

13 Runner:-

a)Material and composition

b)Number of runner blades Nos

c) Runner outlet diameter mm

d)Weight of runner kg

f)Source of runner casting.

e)Method of load regulation.

14 Shaft:-

a)Material and composition.

b)Diameter.

c) Length

d) Weight kg

f)Type of coupling]

e) Material of renewable shaft gland

15 Guide apparatus:-

a) Material of guide vanes

b) Number of guide vanes. Nos.

c)Guide vane PCD mm

d)Height of guide vane mm

e) i.Maximum guaranteed leakage through full closedgated.

LPMs

ii.Torque on runner due to leakage.

f)Description of the method of lubrication

g) Weight of each guide vane




16 Casing & speed ring:

Inlet diameter of casing mm

b)Dimensions of casing.

c)Maximum/Design/Working pressure. kg/cm²

d)Test pressure kg/cm²

e)Material of casing.

f) Number of sections of casing Nos

g)Material and construction of speed ring.

h) Number of vanes in speed ring. Nos.

i)Weight of casing. Kg.

j) Dimensions of Man Hole. Mm dia.

17 a)Elevation of Center line of distributor RL above mean sea level

b)Suction head for turbine m

18

a)Critical Value sigma

b)Cavitations guarantee in Kg/1000 hrs.of operation hours

c)Runner throat diameter. mm

d)Guaranteed depth of pitting at any point. mm

19 Draft Tube:

a) Type

b) Elevation of lowest point in draft tube. RL above mean sea level

c) Total length of draft tube. mm

d) Velocity under full load at Draft Tube exists.

20 Guide Vane Servomotor:

a)Number of servomotor Nos.

b) Material of servomotor body and piston.

c) Rating. Kgm.

d)Range of oil pressure of satisfactory operation.

e) Dia of servomotors mm

f) Stroke of servomotors mm

21 Guide Bearing:

a) Type

b) Bearing area. m²

c) Composition of lining material for bearing shell

d) Lubricant.

e) Amount of lubricant in the filling. Lits

f) Maximum temperature of the oil --º C.

g) Method of Lubrication (forced, self, etc.)

h)Type of pumps, offered for pressure lubrication.

i) Type of motor.

j) Rating of motors. H.P.

k)Description of arrangement for preventing loss of oil.

l)Description of arrangement for cooling and changingoil.

m) Amount of cooling water LPMs.




22 Turbine Shaft Sealing Gland:

a)Quantity of water required for turbine sealing gland. LPMs

b) Quantity of water required. Liters.

c) Pressure required for sealing water at inlet to sealinggland.

kg/cm²

d) Type of gland offered.

23

Maximum noise level in decibels at different load operations

Db (A)

24 Governing System:

a) Make

b) Type.

c) Rating.

d)Guaranteed sensitivity (Minimum speed range Towhich governor will respond.

e) Range of adjustment in speed setting.

f) Range of adjustment of permanent speed drop.

g) Governing opening & closing times.

h) Description and method of operation.

i) Adjustment range in governor opening and closingtime.

j) Operating Pressure.

k) Provision of gate opening limiter for higher

25 Oil Pump and Sump Tank if any:

a) Number of oil pump per unit. Nos.

b) Type of Pump.

c) Capacity of each pump. H.P.

d) Dimensions of sump tank. ----mm(W)x----mm(L)x---mm(H)

e) Effective volume of sump tank cum.

f) Total volume of oil in the governing system cum.

26 Oil Pressure Vessels if required:

a) Number of vessels per unit Nos

b) Dimension of pressure vessels. ----mm(W)x----mm(L)x---mm(H)

c) Normal volume of oil in vessels. Cum.

d) Normal working pressure. kg/cm²

e) Min. working pressure. kg/cm²

f) Weight of oil pressure vessels. kg.

g) Grade of oil recommended

27 Oil leakage Tanks & Pumps if applicable.

a) No. & type of oil leakage pumps. ----Nos x------

b) Capacity of each pump. H.P.

c) Capacity & speed of pump motor ---H.P. x ----rpm.

d) Dimension of leakage tank ----mm(W) x---mm(L) x----mm(H)

e) Effective volume of tank Ltrs.




28 Butterfly Valve :

a) Type.

b) Normal diameter mm

c) Material of valve

d) Material of valve gate.

e) Test pressure. Kg/cm²

f) Factor of safety over yield point.

g) Time of opening. >45sec secs.

h) Time of closing. >30sec. Secs.

i)Leakage through closed valve. Lps.

j) Method of opening.—preferred oil pressure

k) Method of closing------preferred by self weight

i) Weight of valve kg.

m) Weight of heaviest part to be transported.

n) Dimension of largest part to be transported. ---mm (W) x---mm(L) x---mm(H)

o) Length and angle of taper piece. mm

p) Length of inlet pipes For connection to Client'spenstock.

mm

q) Number of servomotor. Nos.

r) Diameter of servomotor. mm

s)Stroke of servomotor. mm

29 Grease Lubrication Equipment if required:-

a) Number of pumps. Nos

b) Capacity & pressure of each pump. –HPx---kg/cm²

c) Type & make of pump.

d) Capacity & No. of grease tank. ---Cum x---Nos.

e) Piping material.

f) Number of grease distributors. Nos.

g) Number of points fed by grease. Nos.

30 Compressed Air System if needed:-

a) Number of compressor. Nos.

b) Type of compressor.

c) Maximum pressure. kg/cm²

d) Rating of motor. HP

e) Number of Air receiver. Nos.

31 Cooling Water System:-

a) Source --- penstock tapping preferred.

b) Capacity of duplex strainer.

c) Material and size of strainer element.

32 Dewatering System:-

a) Number of Pumps. Nos.

b) Type.

c) Discharge of each pump. LPM.

d) Total dynamic head. m

33 Drainage System:-

a) Number of drainage Pump. Nos.

b) Type of drainage pump.

c) Discharge of each pump. LPM




34 Heaviest Package of Shipment:-

a) Name

b) Weight. kg

c) Dimensions. ---mm(L) x---mm(W) x------mm(H)

35 Largest Package for Shipment:-

a) Name.

b) Weight. kg

a) Dimensions. ---mm (L) x----mm (W) x---mm (H)

36Heaviest Assembly to the lifted By power house

crane.

a) Name.

b) Weight kg

c) Dimensions. ---mm(L) x---mm(W) X---mm(H)

6.2 GENERATOR AND AUXILIARIES

Note

I

The particular of the each Generator rated output,maximum temperature rise and efficiency marked withasterisk below ) shall be guaranteed. These values willbe applied for evaluation and performance penalization

1 Name of manufacturer.

2 Type of reference.

3Speed and direction of rotation. when viewed from sideopposite to turbine.

–-----rpm x ------

4 a) Normal voltage between phases. 3.3 kV

b) Voltage variation. ±10%

5 a) Frequency. 50 Hz

b) Frequency variatiation +3% and.-5%

6

a) *Guaranteed rated output and total losses Of eachgenerator when operating at rated Voltage of 3300 V.frequency. 50 Hz. p.f. 0.866 Under excited (lagging) andtemperature rise limited to zone A- Operation.

Guaranteed output kw

Guaranteed losses(total) watt .

b) Guaranteed data about each generator output Andlosses at full load of 2309.47KVA @ 0.866 P.F. Underexcited when Continuously operating under Zone-BOutput losses

kw watt.

7Rated Power factor. p.f. 0.866- Over excited-O-0.866Under excited

8Guaranteed maximum temperature.Rise for outputguaranteed in item 7 Above over ambient temperatureof 45° C.

a)Stator winding by RTD/ ETD. -- º C.

b)Rotor winding by resistance. -- º C.

c) Bearing by RTD/ ETD. -- º C




9Guaranteed maximum output under Temperature riseas specified in the Specifications under rated conditions.

kw

a) Stator winding by RTD/ ETD. -- º C.

b)Rotor winding by resistance. -- ºC.

c) Bearing by RTD/ ETD. -- º C.

10

Guaranteed weighted average efficiency Frequency and 75° C winding temperature Computed by thesummation of losses Method in accordance with IS 4889-1968 Subject to tolerance in IS: 4722-1968

A) *Bonafied efficiency at

a) 110% full load %

b) 100% full load. %

c) 75% full load. %

d) 50% full load %

e) 25 % full load. %

A) *Guaranteed weighted average efficiency .

11Inherent regulation i.e. increase in voltage at Constantspeed and excitation on taking of

a) 110%full load. %

b) 100% full load. %

c) 75% full load. %

d) 50% full load %

e) 25% full load

12 Generator reactances:-

a) Synchronous reactance ( saturated )

i) Direct axis PU

ii) Quadrature axis. PU

b) Direct axis transient reactances.

i) Saturated. PU

ii) Quadrature axis. PU

c) Sub transient reactance.

i) Saturated. PU

ii) Quadrature PU

13 Negative phase sequence reactance. PU

14 Zero phase sequence reactance. PU

15 Resistance of armature winding per phase.

16 Resistance of field winding.

17 Generator time constant.

i) Direct axis transient open circuit.

ii) Direct axis transient short circuit.

18 Generator characteristics curve.

i) Open circuit saturation curve.

ii) Short circuit saturation curve.

iii)Full load saturation curve at rated power factor.

19 Short circuit ratio.

20 Synchronizing power at KV full load 50 Hz.

p.f. 0.866 . under excited (lagging.)




21 Flywheel effect of

a)The rotating parts of the generator kgm²

b) Flywheel GD² kgm²

22Duration for which all part are guaranteed to withstandsafely maximum runaway Ω speed.

Minutes

23

Guaranteed minimum factor of safety Based on yieldpoint of material under Runaway/short circuitconditions and Name & location of part having theminimum Factor of safety.

24 Maximum I x R value. MΩ

25 Inertial constant.

26Maximum runaway speed which all parts Areguaranteed to withstand for 15 minutes.

Rpm

27 Embedded temperature detectors

a) Number. Nos.

b) Type.

28 Excitation Equipment.

a) Name of the manufacturer

b) Type

c) Accuracy of voltage regulation

d) Range of voltage level setting.

e) Range of compounding/reactance Dropcompensation.

f) Range of control in auto mode.

g) Range of control in manual mode.

h) Frequency range of operation. ----------

i) Excitation power feed. K.V.A.

j) Maximum continuous current Rating. Amps.

k) Normal voltage. Volts.

l) Ceiling voltage. Volts.

m)Response ratio.

n) Ambient temperature --º C.

o) Protection class of excitation cubicles.

29Field current for full load on generator At rated powerfactor & terminal voltage.

Amps.

30 Stator.

a) Material of stator core.

b) Insulation of laminations.

c) Number of sections in which stator is divided for transport, if required

d) Insulation of winding.

e) Maximum temperature rise. --º C.

B) Generator Stator Barrel.

a) Height. mm.

b) Inside dimensions. mm




31 Rotor:-

a) Construction of field poles.

b) Method of attaching field pole.

c) Rotor material & constriction.

d) Field winding construction.

e) Insulation of field winding.

f) Construction of damper winding.

g) Air gap. mm

h)Diameter of assembled rotor. mm

i) Factor of safety at maximum runaway Speed basedon yield point of material.

j) Maximum temperature rise of field Winding whenoperating at rated conditions.

--º C.

32 Generator Coolers. :-

a) Number of air coolers. Nos.

b) Number of oil coolers. Nos.

c) Cooling water requirement

d) Cooling water pressure. kg/cm²

33 Bearing:-

i) Thrust Bearing.

a) Type.

b) Number--one. Bearing oil specification. Nos

c) Quantity of oil required for first filling.Liters

d) Location.

d) Number of thrust pads. Nos.

e) Bearing I/D mm

f) Bearing O/D mm

g) Total load on thrust bearing kg

(Including hydraulic thrust)

h) Type of oil coolers.

i) No. of oil coolers.

ii) Guide Bearing DE:-

a) Type

b) Location

c) Bearing journal diameter. mm

d) Bearing pad size. ---mm(W)x—mm(L) x—mm(H)

e) No. of pads. Nos.

iii) Guide BearingNDE:

a) Type.

b) Location.

c) Bearing journal diameter mm

d) Bearing pad size. ---mm(W) x---mm(L) x---mm(H)

e) No. of pads. Nos.

f) No of oil coolers. Nos.




iv) Lubrication system oil specification

v)Amount by which rotor must be raised to Dismantle

the thrust bearing.mm

34 Generator Brakes/Jacks:-

a) Type and mode of operation.

b) Speed at which brakes are applied.rpm

c) No. of brakes/ jacks. Nos.

d) Air pressure of brakes. kg/cm²

e) Oil pressure of jacking.

35 Main Shaft:-

a) Material

b) Details of coupling flange.

c) Total weight. kg

36 Weight of generator rotating parts. kg

37 Weight of complete generator kg

39 Current Transformers:-

a) Type

b) Name of manufacturer

c) Rated transformation ratio

d) Output at rated current and accuracy.

e) Accuracy class.

f) Rated over current factor.

i) Times rated current.

ii) Time in seconds. Sec.

g) Knee point voltage.

h) Basis insulation level. kv

i) Winding temperature rise. --º C.

j) Secondary winding resistance. --º C.

40 Neutral grounding equipment.

I) Resistor.

a) Type

b) Name of manufacturer.

c) Material

d) Continuous rating. kA

e) One minute rating. kA

f) Secondary load resistance ( Ohms) Ώ

g) Current rating of resistor.

h) Duty cycle of resistor and cooling medium.

i) Overall dimensions and weight. ---mm(W)x—mm(L)x—mm(H)-----kg

II) Neutral isolating Switch.

a) Type


c) Voltage rating. Amps.

d) Frequency. Hz.

e) Normal current Amps.

f) Short time rating

g) 1.2/50 Micro second impulse level

h) 1 minute power frequency dry withstand voltage.

i) Dimensions and weight. ---mm(W)x—mm(L)x—mm(H)-----kg




III) Grounding Transformer.

a) Type

b) Name of manufacturer.

c) Standard to which if conforms.

d) Voltage ratio. ----kV/---V.

e) Rating K.V.A.

f) Secondary load resistance. Ώ

g) Frequency. Hz.

IV) Seal of Bushing.

a) Rated voltage. kV

b) One minute dry and wet withstand powerFrequency/voltage

c) Impulse withstands voltage. KV

d) Creepage distance.

e) Bushing height.

41 Generator Terminal Equipment (LAVT)

A) Lightning Arresters:-

a) Type.



d) Number of units. Nos.

e) Rated voltage kV

f) Normal discharge current Amps.

g) Power frequency spark Over voltage kV (rms)

h) impulse spark over Voltage (1.2/50 us wave) KV (peak )

i)Virtual steepness of front of wave For above Micro Seconds.

j) Maximum front of wave impulse Spark over voltage kV (peak)

k) Maximum residual voltage for 10KV dischargecurrent (of µ/20 Micro second wave)

kV (peak)

l) On duration current tests.

a) Current Peak Amps.

b) Virtual duration Micro

m) Overall height mm

n) Total weight. Kg

o) Mounting details.

p) Tests.

B) Protective Capacitors:-

a) Type



d) Voltage rating V.

e) Capacitance. µ Farad

Total weight kg.

f) Mounting details

g) Tests.




C) Potential Transformers:-

a) Type.


c) Standard to which if conforms

d) Manufacturer’s type. Designation.

e) Rated primary voltage. V

f) Rated secondary voltage V

g) Rated burden VA

h) Accuracy class.

i) Temperature rise at 1.1

Time rated voltage with rated Burden and frequency

j)One minute power frequency withstand test Voltageon primary.(rms)

kV

42 Bus Duct of cubicles:-

a) Type.

b)Name of manufacturer

c) Standard to which if conforms

d) Shape and cross section of bus conductor

e) Rated voltage. kV

f) Impulse test withstand voltage.

i) 1.2/50 Micro second wave kV

ii) one minute power frequency Hz.

iii) Dry withstands test voltage. KV rms

g) Continuous 110% of full load rating Amps

h) Max Temp. rise of bus conductor

At continuous 110 % of full load current rating Amps

i) Bus conductor material

j) Heatlostin segregated phase Bus duct at 110% of fullload

i) Middle phase WATT/meter.

ii) Each other phase --do--

iii) Total heat loss. kW

k) Bus duct enclosure material

l) Phase to phase spacing. mm

i) Standard section length m

m)Minimum creepage distance of insulators. mm

o) Bus bar supporting insulators.

i) Rated voltage. kV

ii) One minute dry & wet withstand power

Frequency voltage... kV

iii) Impulse withstands voltage.

iv) Creep age distance. mm

v) Insulator material

vi) Insulator spacing.

43 Heaviest package:-

For shipment

a) Name

b) Weight kg

c) Dimensions ---mm(L) x----mm(W) x---mm(H)

--º C.




44 Largest package :-

For shipment.

a) Name

b) Weight kg

c) Dimensions --mm(L) x ---mm(W) x ---mm(H)

45 Heaviest assembly to be lifted. :-

by power house crane.

a) Name

b) Weight kg

d) Dimensions ---mm(L) x ---mm(W) x ---mm(H)

6.3 UNIT CONTROL PANELS:-

Relays:

1 Maker¢s Name

2 Type

3 Rated Voltage

4 Maximum permissible current loading

i) Continuous

ii) L Second thermal

iii) Dynamic

5 Fixed tripping time lag

6 Range of adjustment of tripping Time

7 a) Retarded tripping

b) Instantaneous tripping

8 Relay pick up and basis setting range available

9 Fall back ratio

10 Power consumption of measuring circuits

a) Normal Service

b) Tripping condition

11 Temperature range

12 Test Voltage

13Power consumption at rated auxiliary D.C. SupplyVoltage

i) During normal service

ii) During Tripping

14 Current Coil Rating

15 Maximum V.A. Burden

i) Operating Coil

ii) Restraining Coil

16 Power Consumption

i) Operating Coil

ii) Restraining Coil

17 Is the slope setting variable Yes/No

18 Harmonic restraint provided or not With details.

19 Is 5th Harmome by pass provided

20 Range of HT/ ratios over which the relay can be used .

21 Details of Auxiliary




22 Operating Time

a) AT 2 x In

b) AT 10 x In

Auxiliary Ac and Dc power supply requirement

i) Rated Voltage

ii) Tolerance on rated voltage above and frequency

iii)a) Rated current or rated output voltage

b) Peal load

iv)Details of protection and monitoring providing forthe equipement

6.3.2 Instruments and Meters:

1 Maker’s name and type of instrument

2 Size.

3 Whether magnetically shielded or not Yes/No

4 Limits of error in the effective range

5 Maximum scale length

6 Total deflection angle

7 Whether treated for tropical

8 Auxiliary supply

9 Short time overload

10 V.A. Burden VA.

i) Current Coil

ii) Potential Coil

11 Power Consumption Watt

i) Current Coil

ii) Potential Coil

12 Continuous overload rating of current Coil Amps

13 Continuous over voltage rating of potential Coil Amps

14 Short time over voltage rating of the same.

15 Limits of error at U.P.F.

i) 125%, 25% or rated current

ii) 10% of rated current

16 Limits of error at 0.5 P.F. under excited (lag)



17Suitability for measurement of unbalanced 3 phases, 3wire system

18 Number of digit on the meter

19 Speed of rotor rev/kwh.

20 Reverse running stop provided Yes/No

21 Reference conditions of influencing quantities

22 Temperature of calibration ---º C.

23 Accuracy



iii) Active energy measurement KWH

iv) Reactive energy measurement KVAR

24 Weight

25 Other details, if any

26 Description Leaflet tolerance Nos. submitted.




6.3.3 Terminal Block:

1 Make and country of manufacture

2 Construction details

3 Voltage grade kV

4 Current rating Amps.

5Numbers of 2.5 mm copper cables that can beconnected

Nos.

6Whether shrouding provided for terminals at voltagemore than 220 V. AC DC.

Yes/No

7 Number of spare Terminal Nos.

8 Marking

6.3.4 Panel Wiring:

1 Insulation of wiring

2 Size of wiring conductor

a) P. T. Circuits Sq. mm

b) C. T. Circuits Sq. mm

c) D. C. Supply Circuits Sq. mm

d) Other Circuits Sq. mm

3 Sizes of earthing bar for safety earthing --mm x --mm

4 Type of terminals provided on wiring

5 Wiring conductor aluminum / copper

6.3.5 Unit Control Panels:

1 Maker’s Name

2 Type of Construction

3 Thickness of sheet steel

a) Front mm

b) Back mm

c) Side mm

4 Weight of each panel section kg

5 Tentative overall dimensions of panel ---mm(L) x----mm(W) x ---mm(H)

6 Total weight of panel kg

7 Space required of installation panel --mm(L) x---mm(W) x----mm(H)

8 Details of tropical treatment

9 Details of painting

10 Largest package for transport

a) Gross weight kg

b) Overall dimensions --mm(L) x---mm(W) x---mm(H)

6.4 Earthing:

1 Conductor of material

2 Size --mm x ---mm

3 Type of end connection


SANJAY B. PATIL,KOLHAPUR JAMBRE HEP

Sr. No. Description Unit

1Name of manufacturer

2 Service

3 National standard applicable

4 Vector group

5 Guaranteed no load voltage ratio

6 Normal turns ratio

7 Type of cooling.

8 Guaranteed continuous maximum Rating for specified

cooling temperature Rise as per IS 2026 and ambient.

9 Guaranteed equipment continuous maximum rating as per IS

2026 Standard temperature rise and ambient temperature.

10 Continuous overload capacity for 2 Hrs. after continuous

rated full load run.

11 Short time thermal rating of L.V. winding in KVA and

duration.

12 Thermal time constant in hours.

13 Guaranteed temperature rise limits when tested according

to IS 2026

i) Winding measured by resistance

ii) Oil measured by the thermometer in top oil

iii) Core

14 Guaranteed maximum temperature rise, after full load run

followed by two hours. Overload of 20 percent Of all by

thermometer above ambient temp. 450C

15 Guarantee withstands time without injury with three phase

short circuit at the terminals.

16 Guaranteed no load loss without tolerances permissible as

per IS 2026.

i) At rated voltage and frequency

ii) At 90% rated voltage and frequency

iii) At 110 percent rated voltage and frequency

17 Guaranteed full load copper loss at rated current at 750

temperature, in kW without tolerances permissible as per IS

2026

18 Total guaranteed losses at maximum continuous rating at

rated voltage and frequency.

19 Efficiency at 750 C at unit power factor

at 100% rating

at 75% rating

at 50% rating

at 25% rating

20 Guaranteed efficiency at 750 C at 0.866 power factor lagging

at 100% rating

at 75% rating

POWER TRANSFORMER




at 50% rating

at 25% rating

21 Maximum efficiency and the load at which maximum

efficiency accure

22 Guaranteed magnetizing current at rated frequency at

At rated voltage

At 90% rated voltage

At 110 percent rated voltage

23 1. Reactance at rated current and frequency

2. Reactance drop on full load

3. Resistance at rate current and frequency

4. Resistance drop on full load

5. Guaranteed impedance at rated current and frequency

at 750 C on each tap

6. Guaranteed impedance drop on full load

7.Guaranteed regulation on full load at 750

C, 0.866 power

factor. Expressed as a percentage of normal secondary drop

8. Guaranteed regulation on full load 750

C, 0.866 power

factor. Expressed as percentage of normal secondary voltage.

9. Zero phase sequence impedance

24 Nature of tap changing gear provided total range, number of

steps variation on each steps of transformation ratio

provided on H.V. winding and position of tap on H.V.

winding.

25 Maximum flux density at normal voltage and 110

percent normal, voltage and frequency

a) Core

b) Yoke

26 Volt. Ampere turns corresponding to maximum working flux

density and 110 percent maximum working flux density.

27 Exciting kW per kg. Of iron at

1. Rated induction

2. Induction corresponding to 110 percent normal voltage.

28Maximum current density in winding in amp. Sq.cm.

i) H.V. winding

ii)L.V. winding

28A. Nature of insulation of

1. Laminations of core

2. L.V. winding




29 Nature of insulation of

i) Laminations of core

ii)Core bolts, washers and end plates

30 Maximum clearance to earth in mm for winding in and

out of oil

i) winding

ii) winding

31 Minimum clearance between

i) H.V. winding to earth in oil

ii H.V. winding to tank in oil

32 Impulse withstand voltage with 1/50 micro sec. Wave in

accordance with IS

i) H.V. winding

ii) L.V. winding

33 Impulse chopped wane from withstand valve

i) H.V. winding

ii L.V. winding

34 Applied voltage valve

i) H.V. winding

ii) L.V. winding

35 Type of winding

i) High voltage

ii) L.V. voltage

36 No. of turns

i) H.V. winding

ii) L.V. winding

37 Type of joints in the winding

38 Insulation materials

i) Turn insulation high voltage

ii) Turn insulation low voltage

iii) Insulation core to low voltage

iv Insulation high voltage to low voltage

v) Tapping

vi) Weight of paper insulation in Kg.

39 i) Materials of core laminations

ii) Thickness of core laminations

iii)Bolt insulation test voltage

iv) Type of transformer core construction

40 Type of transformer tank

41 Materials of transformer tank and cable sealing end

chamber. Minimum thickness of transformer tank.

i) Sides

ii) Bottom

iiiTop

42 i)Details of special arrangement provided to improve surge

voltage distribution in the winding

ii) Heat radiation loss to the surrounding from each

transformer at

a)rated load KW

b)over load KW





i) at works

ii) at site

44 Noise level at rated output DbA

45 Cooling media

i) Grade of oil

ii) Quantity of oil on transformer Lit.

iii) Whether 10 percent extra oil is supplied

iv) Test pressure for oil, pipes valves etc.

46 Bushings

a. Type

b. Make

c. Standard specification

d. Country of origin

e. Test procedure

1. Guaranteed impulses withstand voltage for 1/50 micro

second impulse wave.

HV L.V HV

2. Guaranteed one minute dry withstand power frequency Neutral

3.Guaranteed one minute wet withstand power frequency

voltage

Hz Hz Hz

4.Momentary power frequency dry withstand voltage KV KV KV

5. Visible power frequency discharge voltage KV KV KV

6. Under oil flashover or puncture withstand power

frequency voltage

KV KV KV

7. Under oil flash over or puncture withstand impulse

voltage

KV KV KV

8. Creep-age distance KV KV KV

9. Maximum current ratings MM MM MM

10. Power factor of bushing Amp. Amp. Amp.

11. Terminal arrangement

12. Grade of oil

13. Quantity of oil Lt. Lt. Lt.

14. Material of condenser

15. Weight of assembled bushing Kg. Kg. Kg.

47 Minimum phase to phase and phase to earth clearness in

air live parts at the top of bushing

1. H.V. neutral of earth Mm

2. L.V. to earth

48 Dimensions and other particulars

1) Net weight in Kg. Of

1. Core and frame

2. H.V. winding

3. L.V. winding

4. Copper in H.V. winding Kg.

5. Copper in L.V. winding Kg.

6. Tank Kg.

7. Complete transformer with oil, fitting and accessories Kg.

8. Conservator with oil Kg.

9. Marshalling box Kg.

10. Oil Kg.




2) Approximate weight in kg. Of

1. Insulated copper conductor Kg.

2. Electrical steel laminations Kg.

3. Constructional steel Kg.

3) Dimensions in mm of length, breadth, height, weight

1.Tank with core and winding arranged for transport

2. Largest package for transport

3. Heaviest package for transport

4. Assembled transformer

49 Additional information

1. Whether oil temperature indicator provided

2. Type and size of temperature indicator and whether

supervisory alarm and trip contacts provided.

3. Type of oil level indicator and whether supervisory alarm

and trip contact provided.

4. Type of gas operated relay and whether supervisory alarm

and trip contact provided

5. Whether local and remote winding temp. Indicator with

supervisory alarm and trip contact provided and its

type/make.

6. Type and size of thermostat used.

7.No. of breather provided their make and sizes.

8. Type of dehydrating agent used for breather

9.Capacity of conservator raised in liters and as percent age

of the main tank.

10.Valve sizes and numbers

a) Drain valve cms.

b) Filter valves cms.

c) Sampling valve cms.





1Name of manufacturer

2Service

3 National standard applicable

4 Vector group

5 Guaranteed no load voltage ratio

6 Normal turns ratio

7 Type of cooling

8 Guaranteed continuous maximum Rating for specified

cooling temperature Rise as per IS 2026 and ambient

9 Guaranteed equipment continuous maximum rating as per IS

2026 Standard temperature rise and ambient temperature

10 Continuous overload capacity for 2 Hrs. after continuous

rated full load run

11 Short time thermal rating of L.V. winding in KVA and

duration

12 Thermal time constant in hours

13 Guaranteed temperature rise limits when tested according

to IS 2026

i) Winding measured by resistance

ii) Oil measured by the thermometer in top oil

iii) Core

14 Guaranteed maximum temperature rise, after full load run

followed by two hours. Overload of 20 percent Of all by

thermometer above ambient temp. 45 deg C

15 Guarantee withstands time without injury with three phase

short circuit at the terminals.

16 Guaranteed no load loss without tolerances permissible as

per IS 2026.

i) At rated voltage and frequency

ii) At 90% rated voltage and frequency

iii) At 110 percent rated voltage and frequency

17 Guaranteed full load copper loss at rated current at 750

temperature, in kW without tolerances permissible as per IS

2026

18 Total guaranteed losses at maximum continuous rating at

rated voltage and frequency.

19 Efficiency at 750 C at unit power factor

at 100% rating

at 75% rating

at 50% rating

at 25% rating

AUXILIARY TRANSFORMER




20 Guaranteed efficiency at 750

C at 0.866 power factor

lagging

at 100% rating

at 75% rating

at 50% rating

at 25% rating

21 Maximum efficiency and the load at which maximum

efficiency accure

22 Guaranteed magnetizing current at rated frequency at

At rated voltage

At 90% rated voltage

At 110 percent rated voltage

23 1. Reactance at rated current and frequency

2. Reactance drop on full load

3. Resistance at rate current and frequency

4. Resistance drop on full load

5. Guaranteed impedance at rated current and frequency at

750 C on each tap

6. Guaranteed impedance drop on full load

7. Guaranteed regulation on full load at 750

C, 0.866 power

factor. Expressed as a percentage of normal secondary drop

8. Guaranteed regulation on full load 750

C, 0.866 power

factor. Expressed as percentage of normal secondary voltage.

9. Zero phase sequence impedance

24 Nature of tap changing gear provided total range,

number of steps variation on each steps of

transformation ratio provided on H.V. winding and

position of tap on H.V. winding.

25 Maximum flux density at normal voltage and 110

percent normal, voltage and frequency

a. Core

b.Yoke

26 Volt. Ampere turns corresponding to maximum working

flux density and 110 percent maximum working flux

density.

27 Exciting kW per kg. Of iron at

1 Rated induction

2. Induction corresponding to 110 percent normal voltage.

28Maximum current density in winding in amp. Sq.cm.

1. H.V. winding

2. L.V. winding

28A. Nature of insulation of


2. L.V. winding

29 Nature of insulation of


2. Core bolts, washers and end plates




30 Maximum clearance to earth in mm for winding in and

out of oil

i)winding

ii) winding

31 Minimum clearance between

i) H.V. winding to earth in oil

ii) H.V. winding to tank in oil

32 Impulse withstand voltage with 1/50 micro sec. Wave in

accordance with IS

i) H.V. winding

ii) L.V. winding

33 Impulse chopped wane from withstand valve

i) H.V. winding

ii) L.V. winding

34 Applied voltage valve

i) H.V. winding

ii) L.V. winding

35 Type of winding

i) High voltage

ii) L.V. voltage

36 No. of turns

i) H.V. winding

ii) L.V. winding

37 Type of joints in the winding

38 Insulation materials

i) Turn insulation high voltage

ii) Turn insulation low voltage

iii Insulation core to low voltage

iv Insulation high voltage to low voltage

v) Tapping

vi) Weight of paper insulation in Kg.

39 i) Materials of core laminations

ii) Thickness of core laminations

ii Bolt insulation test voltage

iv) Type of transformer core construction

40 Type of transformer tank

41 Materials of transformer tank and cable sealing end

chamber. Minimum thickness of transformer tank.

i) Sides

ii) Bottom

iii) Top

42 i) Details of special arrangement provided to improve surge

voltage distribution in the winding

ii) Heat radiation loss to the surrounding from each

transformer at

a) rated load KW

b) over load KW


i) at works

ii ) at site

44 Noise level at rated output DbA




45 Cooling media

i) Grade of oil

ii)Quantity of oil on transformer Lit.

ii )Whether 10 percent extra oil is supplied

iv) Test pressure for oil, pipes valves etc.

46 Bushings

a. Type

b. Make

c. Standard specification

d. Country of origin

e. Test procedure

1. Guaranteed impulses withstand voltage for 1/50 micro

second impulse wave. HV L.V HV

2. Guaranteed one minute dry withstand power frequency Neutral

3. Guaranteed one minute wet withstand power frequency

voltage Hz Hz Hz

4.Momentary power frequency dry withstand voltage KV KV KV

5. Visible power frequency discharge voltage KV KV KV

6 Under oil flashover or puncture withstand power

frequency voltageKV KV KV

7. Under oil flash over or puncture withstand impulse

voltageKV KV KV

8. Creep-age distance KV KV KV

9. Maximum current ratings MM MM MM

10.Power factor of bushing Amp. Amp. Amp.

11. Terminal arrangement

12. Grade of oil

13. Quantity of oil Lt. Lt. Lt.

14 Material of condenser

15. Weight of assembled bushing Kg. Kg. Kg.

47 Minimum phase to phase and phase to earth clearness in

air live parts at the top of bushing

1. H.V. neutral of earth Mm

2 L.V. to earth

48 Dimensions and other particulars

1) Net weight in Kg. Of

1.Core and frame

2.H.V. winding

3.L.V. winding

4.Copper in H.V. winding Kg.

5.Copper in L.V. winding Kg.

6. Tank Kg.

7. Complete transformer with oil, fitting and accessories Kg.

8. Conservator with oil Kg.

9. Marshalling boxKg.

10. Oil Kg.




2) Approximate weight in kg. Of

1. Insulated copper conductor Kg.

2. Electrical steel laminations Kg.

3. Constructional steel Kg.

3) Dimensions in mm of length, breadth, height, weight

1. Tank with core and winding arranged for transport

2. Largest package for transport

3. Heaviest package for transport

4. Assembled transformer

49 Additional information

1. Whether oil temperature indicator provided

2. Type and size of temperature indicator and whether

supervisory alarm and trip contacts provided.

3. Type of oil level indicator and whether supervisory

alarm and trip contact provided.

4. Type of gas operated relay and whether supervisory

alarm and trip contact provided

5. Whether local and remote winding temp. Indicator with

supervisory alarm and trip contact provided and its

type/make.

6. Type and size of thermostat used.

7. No. of breather provided their make and sizes.

8. Type of dehydrating agent used for breather

9. Capacity of conservator raised in liters and as percent age

of the main tank.

10 Valve sizes and numbers

a) Drain valve cms

b) Filter valves cms

c) Sampling valve cms



1 General Information

a) Name of Company As per our attached supplier list.

b) Model No. and name of

manufacturerAs per our manufacturer standard.

2 Type and class of Crane EOT Type M2 Class

a) Crane Structure I Section

b)Main hoist and Aux. Hoist

to be design by manufacturer of

main plant.c) Cross traverse 8 m/m

d) Long travel 15 m/m

3 Safe working load (Main / Aux.

Hoist)as per requirment.

4Center to center of track rails (Span) as per requirment of TG plant.

5 Operating Speed (loaded)

a) Hoisting (Main & Aux.) 2 m/m

b) Cross travel To be furnished by bidder.

c) Long travel To be furnished by bidder.

d)Micro Speed for all motions To be furnished by bidder.

6 Minimum working clearance

requiredi. Distance from center of runway rail

to nearest side Obstruction1200mm

ii.Vertical distance from top of runway

rail to nearest side Obstruction2600mm

iii. Distance from floor to top of runway

rail

9 m (Approx from Service Bay

Floor)iv. Nearest position of hook to center

line of runaway rail1.3 m (Approx)

v. Vertical clearance to underside of

bridge girder800mm

7Type of hook supplied / Make

C type-auxialy hook.Ramshorn for

main hook.8 Height of hook above floor level 6 m (Approx)

9 Drop of hook below floor level 7.5 m (Approx)

10Section of runway rail recommended 60 Ponds rail

11 Type of main girder to be decided by manufacturer.

i. Braced, plain or rolled steel hoist

ii. Riveted or fusion welded

12 End Carriages

a) Wheel base 4 m

b) Material of wheels EN 9 Forged

c) Maximum load excluding impact on

traveling wheelsto be decided by manufacturer.

JAMBRE HEP 1 X 2000kW

SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS OF CRANE

Sr No.. Particulars

to be decided by manufacturer.



13 Crab. Center to Center of Traverse

wheels2 m (Approx)

14 Hoisting rope

a) Diameter 18 mm (Approx)

b) Construction Fabricated steel

c) Quality of steel To meet IS Standards

d) No. of falls 8 Fall on Main 4 Fall on Aux.

e) Minimum breaking load to be decided by manufacturer.

f) Factor of safety 1.5 to 2

15 Description of brakes for

a) Traversing brakes

b) Traveling brakes

16 Particulars of safety devices / limit

switchesTwo way rotary type.

17 Electrical Equipment

a) Details of controls and protections for

power supply to hoist motor and

lighting from crane


b) Motor for hoist / Trolley travel

bridge traveli. Make As per our supplier standard.

ii. Type Squirrel Cage Type

15.27 HP Hoist

7.64 HP A. Hoist

3 HP C.T & L.T

iv. Insulation class

v. Enclosure type

vi. Brushes – type, number

vii. Maximum torque (pull out torque)

viii. Full load speed to be decided by manufacturer.

ix. Maximum temperature rise of stator

windinga) By resistance Method

b) By Thermometer Method

c) Details of motor controllers like

make, steps or points in each

direction of motion and control &

protective equipment


d)National Standards to which the

above would conform

IS 807, 3177 More clarity can be

given during detailed engineering.

e) i.Make of electro-magnetic brake

Will be as per our supplier

standard.ii. Make of electro-hydraulic thruster

brake

SOC / AMAG / SA or any other as

per our supplier standard.f) Details of runway conductors and

collectorsto be decided by manufacturer.

18 Net weight

i. Complete unladen crane to be decided by manufacturer.

ii. Complete unladen crab to be decided by manufacturer.

19 Tools and accessories supplied to be decided by manufacturer.

20 General arrangement drawing

enclosed Yes

100- 18 AC EHT Type

iii. Capacity / rating


1 Name of

manufacturerAs per enclosed vender list

2 Type of gears Helical, Hardened & Ground3 Shaft Orientation Vertical4 Shaft off set Horizontal off set5 Number of stages Single Stage6 Input speed To be furnished by bidder.7 Output speed 750 RPM8 Gear Ratio To be furnished by bidder.9 Service factor 2

Overall Efficiency of

gear box100%80%60%40%

11 Runaway speed To be furnished by bidder.

JAMBRE HEP 1 X 2000kW

GUARANTEED TECHNICAL PARTICULARS OF GEAR BOX

Sr No.. Particulars

10

239 a



1 x 1 x 1 x 1 x 2020202000 KW00 KW00 KW00 KW

SECTION - VII

WORKING TABLE & TENDER DRAWINGS

JAMBRE HYDRO ELECTRIC PROJECT

(1 x 2000 kW)

WORKING TABLE FOR POWER GENERATION AT (75% YIELD)

Year - 1989 - 1990

Annexure- V

Rl. in m. Capacity in Mcum

FRL 737.000 Content 23.230 Say 23.23

MDDL (Irri) 708.000 Content 0.028 Say 0.03

MDDL (P) 721.000 Content 6.80

River Bed 702.935 -

TWL 703.500 -

RELEASESWater from

Spill

CONTINUOUS

POWER

R.L. in Capacity

in

Irrigation +

W.S.

Additional

water for

power

R.L. Capacity 8 x Q x H

Metres In Mcum In Mcum In Mcum In Mcum In Mcum In Mcum In Cumecs Cumecs In Mcum In Mcum M. In Mcum M. M. M. kW MKWH kW

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1 Jun 30 5 30 718.12 3.82 19.80 23.62 0.56 3.86 4.42 8.185 11.21 0.01 4.43 733.49 19.19 725.805 703.500 22.31 1460.56 0.22 2000.00 73.03

2 Jul 31 24 31 733.49 19.19 27.02 46.21 0.56 22.38 22.94 8.565 7.88 0.04 22.98 737.00 23.23 735.245 703.500 31.75 2175.12 1.62 2000.00 108.76

3 Aug 31 19 31 737.00 23.23 15.67 38.90 0.56 15.04 15.60 7.357 7.46 0.07 15.67 737.00 23.23 737.000 703.500 33.50 1971.70 1.16 2000.00 98.59

4 Sep 30 6 30 737.00 23.23 4.82 28.05 2.76 1.99 4.75 7.330 7.46 0.07 4.82 737.00 23.23 737.000 703.500 33.50 1964.51 0.35 2000.00 98.23

5 Oct 31 3 31 737.00 23.23 1.20 24.43 2.76 0.00 2.76 8.244 7.69 0.24 3.00 735.03 21.43 736.015 703.500 32.52 2144.36 0.20 2000.00 107.22

6 Nov 28 3 30 735.03 21.43 0.00 21.43 2.20 0.00 2.20 7.275 8.16 0.23 2.43 733.28 19.00 734.155 703.500 30.66 1784.15 0.15 2000.00 89.21

7 Dec 27 4 31 733.28 19.00 0.00 19.00 3.31 0.00 3.31 8.513 8.80 0.22 3.53 730.55 15.47 731.915 703.500 28.42 1935.26 0.21 2000.00 96.76

8 Jan 30 3 31 730.55 15.47 0.00 15.47 3.05 0.00 3.05 9.414 9.74 0.20 3.25 727.80 12.22 729.175 703.500 25.68 1933.55 0.17 2000.00 96.68

9 Feb 28 3 28 727.80 12.22 0.00 12.22 2.36 0.00 2.36 7.804 10.82 0.19 2.55 725.39 9.67 726.595 703.500 23.10 1441.91 0.12 2000.00 72.10

10 Mar 28 3 31 725.39 9.67 0.00 9.67 2.63 0.00 2.63 8.697 13.33 0.38 3.01 719.13 6.66 722.260 703.500 18.76 1305.26 0.11 2000.00 65.26

11 Apr 0 0 30 719.13 6.66 0.00 6.66 2.42 0.00 2.42 0.000 16.44 0.31 2.73 718.29 3.93 718.710 703.500 15.21 0.00 0.00 2000.00 0.00

12 May 0 0 31 718.29 3.93 1.68 5.61 1.58 0.00 1.58 0.000 17.00 0.21 1.79 718.12 3.82 718.205 703.500 14.70 0.00 0.00 2000.00 0.00

70.19 24.75 43.27 68.02 2.17 70.19 4.32

Maximum Head is 33.5 m & Minimum is 14.94 m.From observation of the working table head variation for entire year for 75% dependable yield is 33.50 m to 14.70

Power Generation which can be catered for is about 2000 kW. is about 2000 kW. This machine can operate upto about 30% of power at lower range. Generation shown is at peak discharge for few hours during rotation days.

This is a range slightly wider for Francis turbine. Francis Turbine with a design head of 26.8 m can operate between 33.50 m Maximum Head to 17.4 m Minimum Head.

Heads lesser than 17.4 occurs only for last two months and Power Generation during the period is very low.Hence Francis Turbine is opted as against costly Kaplan Turbine.

Annual energy generation is bout 4.32 Mus. Machine is overloaded in July upto 2174 kW & hence load factor is above 109%. Machine will be designed for continuous overload to the extent to cater this extra power generation.

At the end of the monsoon reservoir reaches FRL & there after the full irrigation is utilised which leves closing level of RL 718.12m. The same level is treated as opening level while preparing the working table.

This working table is prepared on the basis of information provided by the Executive Engineer, Medium Project Division II Kolhapur.

HEAD

AVAILA

BLE

UNITS

Total

Release

Water

for

Power

Discharge

for power

Power

DischargeTWL

MEAN

LAKE

LEVELS

Load

Factor in %

Installed

Capacity in

kW

Sr.No. MonthPower

Days

Hours of

operationNo of Days

OPENING CLOSING

INFLOWTOTAL

CONTENTS

LAKE

LOSSES

TOTAL

WITHDRAW

AL

CONTROL ROOM

RL 710.000M

OFFICE

D.G. ROOM

(5.8X4.5)

RL 710.000M

TOILET

RL 710.000M

STORE

RL 710.000M

5.8

75

5.000

3.000

25

.0

00

9.000

SWITCH YARD

RL 710.000M

SERVICE BAY

RL 710.000M

ROLLING SHUTTER

ROLLING SHUTTER

4.325 6.700 6.700

6.5

00

6.5

00

5.0006.700

6.000

6.7006.1506.050

25.600

6.1

50

6.1

50

12

.3

00

13

.4

00

0.5

50

0.5

50

10

6.7

00

6.7

00

TAIL CANAL

RL 700.450M

1:6 UPTO 18000

UNLINED THEREAFTER

POWER HOUSE PLANNAME OF DRG :-

[email protected]

JAMBRE HEP (1 X 2.0 MW) TAL - CHANDGAD DIST - KOLHAPUR

email : - [email protected],

FINALREVISIONORIGINAL

DATE :- 2009 - 16 - 07DRG NO - DKA/JAMBREHEP/2009-10/1-1 Er. S.L.DIWANCHECKED BY

Er.SAGAR YALUGADE Er.AMOL P. JADHAV

AUTOCAD BY:-

252,'E' 9, Deepti Park, Assembly Road, Tarabai Park, Kolhapur

221B/1A, CENTER ONE, E WARD, TARABAI PARK, KOLHAPUR-416 003DIWAN KHADILKAR CONSULTANTS PVT. LTD.

SANJAY PATIL, Class I Regd. Govt. Contractors,

12345678

B

C

D

E

F

G

HH

G

F

E

D

C

B

A

8 7 6 5 4 3 2 1

A

6700

POWER HOUSE SECTIONNAME OF DRG :-

[email protected]






AUTOCAD BY:-




46

90

85

50

35

00

13400

20

00

.0

GENERAL SECTIONNAME OF DRG :-

[email protected]





Er.AMOL P. JADHAVAUTOCAD BY:-




EL 706.500

EL 708.000

MDDL (I)

EL 721.000

MDDL (P)

EL 739.000

MWL

EL 739.000

MWL

EL 741.000

6000

EL 729.500

EL 718.000

4000

4000

4000

4000

31000

INTAKE GATE

APPROCH CHANNEL

EMBEDDED PIPELINE STEEL LINED

2800M,14MM

POWER HOUSE

TAIL RACE CHANNEL

IRRIGATION BY-PASS

70000 15000 13400 60000

172000

187000

GENERAL SECTION OF DAM

AT WATER CONDUCTOR SYSTEM

Er.PRIYANKA S. RAUT

NOT TO SCALE

723.39

3

723.24

5

722.98

7

723.00

6

722.90

3

722.59

7722

.3

722.58

1

722.46

9722

.62722

.563

722.30

8

721.99

4

721.68

1

721.36

7721

.36

722.17

6

721.99

2

722.08

3

722.23

4

722.22

4

721.98

4

721.70

5

721.39

2

721.07

8

720.76

5

720.45

1

720.41

4

720.42

721.77

721.58

6

721.54

5

721.69

7

721.84

8

721.88

4

721.64

5

721.40

5

721.10

3

720.78

9

720.47

6

720.16

2

719.84

9

719.53

5

719.46

9

719.47

4

721.36

5

721.18

1

721.00

8

721.15

9

721.31

1

721.32

6

721.48

2

721.25

9

721.04

8

720.81

3720

.5720

.187

719.87

3

719.56

719.24

6

718.93

3

718.61

9

718.52

4

718.52

9

718.53

4

720.95

9

720.77

5

720.59

1

720.62

1

720.77

3

720.75

3

720.71

9

720.94

9

720.86

5

720.63

720.42

720.21

719.92

2

719.59

3

719.27

4

718.95

9

718.64

4

718.33

718.01

7

717.70

3

717.57

8

717.58

4

717.58

9

720.55

4720

.37720

.186

720.08

4

720.23

5

720.17

9

720.06

5

720.18

7

720.41

7

720.49

2

720.11

2

720.02

6

719.79

9

719.58

4

719.36

8

719.03

8

718.70

9

718.37

9

718.05

1

717.73

6

717.42

717.10

5

716.82

1

716.63

3

716.63

8

716.64

4

716.64

9

720.14

9

719.96

4719

.78719

.596

719.69

8

719.60

6

719.49

1

719.42

4

719.65

4

719.88

5

719.67

7

719.47

8719

.41719

.342

719.22

6

719.0

718.77

6

718.53

2

718.20

6

717.87

9

717.55

3

717.23

2

716.94

6

716.66

9

716.37

3

716.07

2

715.77

2

715.52

6

715.69

8

715.70

4

715.70

9

719.74

3

719.55

9

719.37

5

719.19

1

719.14

7

719.03

3

718.91

8

718.80

3

718.89

2

719.12

3

719.35

5

719.15

1

719.11

4

718.97

7

718.83

9

718.70

1

718.57

2

718.43

718.22

2

718.01

4

717.76

4

717.43

7

717.12

716.80

3

716.51

6

716.22

5

715.92

4

715.63

6

715.34

7

715.04

2

714.87

3

714.70

4

714.63

9

714.76

4

711.75

6

711.83

4

711.91

1

712.29

7

714.27

6

716.17

3

718.06

5

718.23

718.12

9

718.36

1

718.59

3

718.82

6718

.79718

.801

718.72

718.58

2

718.44

4

718.37

6

718.28

8

718.05

7

717.82

2

717.58

6

717.35

4

717.02

1

716.69

1

716.37

4

716.07

7

715.82

7

715.59

5

715.16

7

714.84

2

714.67

4

714.50

6

714.33

9

714.17

1

714.04

1

713.95

9

713.87

7

711.75

8

711.83

5

711.91

3

711.99

712.06

9

711.79

9711

.52711

.241

710.99

8

710.94

3

710.88

7

710.83

2

710.96

1

718.44

718.45

1

718.32

6

718.34

8

718.39

9

718.19

2

717.97

1

717.73

5

717.51

7

717.31

8

716.99

1

716.65

8

716.31

6

716.00

4

715.77

5

715.51

5

715.16

4

714.71

7

714.52

8

714.36

1

714.19

3

714.01

7

713.88

2713

.8713

.738

713.75

6

711.75

9

711.83

7

711.91

5

711.99

4

712.07

3

711.79

3

711.51

4

711.24

5

711.00

2

710.95

3

710.89

8

710.81

4

710.70

9

710.50

8

710.30

8

709.35

706.76

706.96

5

709.89

8

717.88

6

716.32

3

717.58

1

716.79

8

715.49

3

716.60

3

716.23

6

715.94

1

715.69

8

715.29

2

715.01

7

714.71

3

714.38

2

714.21

5

714.04

6

713.85

8

713.72

4

713.64

3

713.66

713.67

8

711.76

1

711.83

9

711.91

8

711.99

7

712.06

6

711.78

7711

.52711

.253

711.00

1

710.96

4

710.88

8

710.79

5

710.75

2

710.55

2

708.61

4705

.8705

.8705

.8705

.882

705.91

8

705.83

5

705.81

8

706.29

2

706.24

2

716.53

4

716.15

7

715.87

9

715.46

7715

.07714

.768

714.56

9

714.26

3

714.06

9

713.88

8

713.69

9

713.56

5

713.56

5

713.58

2713

.6713

.617

714.01

8

713.78

2

713.08

9

712.39

5712

.06711

.794

711.52

8

711.26

2711

.0710

.963

710.86

9

710.77

6

710.73

2

709.86

6

706.70

5

705.88

6

707.64

5

706.91

3

706.07

6

705.86

3

705.95

5

706.00

5

705.81

1

708.44

7

715.96

9

715.70

6

715.64

2

715.24

5

714.84

7

714.51

8

714.32

714.12

1

713.91

7

713.72

9

713.54

713.43

8

713.43

5

713.43

2

713.42

9

713.46

1

718.26

718.23

3

718.16

5

717.18

5

716.75

4

716.19

9

715.31

8715

.12713

.112

711.98

8

711.14

8

711.02

6

716.32

6

716.71

4

717.17

8

716.21

9714

.49711

.86709

.524

705.79

4

706.10

4

707.07

1

712.94

1713

.69714

.29714

.502

715.08

1714

.63714

.268

714.09

713.92

3

713.75

1

713.56

2

713.38

1

713.23

4

713.23

1

713.22

8713

.24713

.323

718.01

5

717.98

6

717.95

9

717.93

2

717.85

7

717.80

8717

.78717

.691

717.25

7

716.07

5

714.65

4

714.84

5

716.04

6

716.60

5

717.08

4

717.22

9717

.29717

.285

712.27

5

706.15

4

705.79

3

712.55

8

714.75

7

714.26

4

714.16

4

714.51

5

714.52

6

714.53

6

714.12

2

713.92

3

713.75

3

713.58

4

713.39

5

713.23

4

713.07

4

713.02

7

713.02

4

713.10

2

713.18

6

717.42

2

717.26

1

716.82

6

716.39

2

716.31

1

716.48

5

716.49

3

716.87

3

716.95

6717

.04717

.122

711.21

9

706.68

8

705.99

7

709.71

9

715.10

5

714.64

4

714.26

5

714.47

3

714.50

2

714.32

8

714.00

6

713.80

2

713.60

4

713.41

5

713.24

7

713.08

7

712.92

6

712.82

3712

.88712

.964

713.02

1

713.07

5

716.28

6

716.48

5

716.64

1

716.72

6

716.81

1

716.87

4

715.56

9

705.86

9

705.85

3

705.82

1

713.56

4

714.71

1

714.60

7

714.55

8

714.33

9

714.11

2

713.91

9

713.68

2713

.48713

.273

713.09

4

712.93

4

712.77

5

712.62

3

712.61

9

712.65

9

712.69

9

712.78

3

716.27

1

716.45

7

716.54

2

716.53

1

716.33

8

715.99

6

707.23

8

705.8

705.79

8

709.07

7

714.80

2

714.67

4

714.46

8

714.26

2

714.02

3713

.77713

.549

713.34

2

713.13

5

712.93

8

712.77

8

712.61

9712

.47712

.372

712.33

7

712.37

8

712.42

8

715.62

7

715.96

5

716.27

1

716.18

7

715.99

5

715.80

2

715.42

6

714.02

7

705.79

9

705.79

5

705.79

2

714.71

1

714.53

714.34

1

714.20

4

713.90

2

713.64

2

713.41

4

713.20

5

712.99

7

712.79

1

712.62

2

712.46

9

712.32

712.20

6

712.12

1

712.05

6

712.09

6

715.92

2

715.87

7

715.66

7

715.21

7

715.28

8715

.19706

.485

705.79

1

705.79

3

709.79

8

714.41

2

714.27

5

714.13

5

713.80

9

713.51

5

713.27

9713

.07712

.861

712.65

3

712.46

7

712.31

9712

.17712

.04711

.955

711.87

1

711.78

6

712.30

7

715.20

1

715.53

9

714.60

1

714.77

2

714.94

3

715.03

4

714.96

2

714.87

705.79

8

705.79

2

705.75

8

712.73

1

714.29

5

714.06

3

713.73

7

713.41

1

713.14

4

712.93

5

712.72

3

712.50

8

712.28

5

712.13

6

711.98

7

711.87

6

711.81

3

711.73

2

711.65

712.10

1

715.11

715.15

7

714.55

4

714.59

7

714.66

9714

.78714

.717

714.67

1709

.17705

.796

705.77

3

706.71

8

714.31

6713

.99713

.649

713.29

6

712.99

9712

.78712

.565

712.34

3

712.09

9

711.93

5711

.79711

.701

711.66

1

711.59

7

711.51

5

711.74

7

714.94

5

714.77

5

714.51

1

714.55

4

714.59

7

714.57

5

714.50

4

714.45

9

714.03

3

705.79

9

705.77

1

705.73

4

713.91

2

713.66

3

713.46

5

713.17

2

712.88

3

712.62

2

712.40

7

712.16

9

711.92

4

711.73

4

711.62

711.53

1

711.48

2

711.44

5

711.38

711.39

2

714.75

8

714.6

714.46

8

714.67

6

714.60

3

714.45

714.35

8

714.28

1

714.20

4

710.75

7

705.83

4

705.82

7

707.27

3

709.50

1

713.24

2

712.99

7

712.75

2

712.47

8

712.23

9

711.99

4

711.75

711.53

8

711.45

711.36

1

711.30

3

711.26

7

711.23

5

711.13

5

711.53

8

714.57

714.41

3

714.53

3

714.62

9

714.48

5

714.33

2

714.21

8

714.14

1

714.05

8

713.97

6

705.82

2

705.78

9

705.77

1

710.60

9

713.00

9

712.76

4

712.58

4

712.29

1

712.08

6

711.84

4

711.60

1

711.37

3

711.28

5

711.20

3

711.16

6

711.12

7

711.09

5

711.00

1

711.41

9

714.45

714.22

6

714.32

2

714.27

7

714.19

9

714.12

714.07

3

714.01

1

713.94

8

713.88

5

709.85

705.76

7

705.75

1

706.12

4

712.93

2

712.63

9

712.34

6

712.06

5

711.93

1

711.70

5

711.46

2

711.22

711.12

1

711.08

6

711.05

3

710.99

1

710.95

4

710.86

6

711.06

5

714.44

1

714.07

5

714.00

5

713.92

6

713.91

1

713.89

9

713.88

4

713.82

1

713.75

9

713.74

7

713.66

7

705.72

7

705.75

2

705.80

5

708.03

3712

.4712

.107

711.87

7

711.74

3

711.56

6

711.32

4

711.08

1

710.98

4

710.96

8

710.94

1

710.87

9

710.81

7710

.73710

.711

714.43

1

714.06

6

713.80

7

713.74

3

713.71

2

713.7

713.68

9

713.63

2

713.55

7

713.44

5

713.35

8

710.90

3

705.77

6

705.83

709.51

9

710.66

2

711.49

9

711.69

6

711.57

3

711.42

5

711.18

2

710.94

710.88

4

710.86

5

710.84

6

710.79

8

710.75

710.59

710.48

2

714.21

7

714.05

6

713.82

9

713.76

5

713.70

1

713.63

6

713.54

4

713.44

713.33

5

713.24

8

713.16

2

713.07

5705

.8705

.856

707.13

6

712.02

711.82

6

711.57

5

711.45

3

711.28

2

711.03

8710

.85710

.805

710.78

6

710.79

1

710.73

8

710.69

710.45

710.34

7

710.73

7

714.04

7

713.99

4

713.94

1

713.84

6

713.74

7

713.64

8

713.55

713.45

1

713.34

9

713.24

2

713.13

5

713.02

8

712.92

1

706.51

9

705.86

5

705.86

4

710.44

1

711.78

9

711.50

5

711.33

2

711.13

9

710.89

3

710.77

9

710.72

6

710.71

4

710.73

2

710.68

2

710.63

1

710.34

3

710.21

3

710.38

3

713.77

1

713.71

9

713.65

8

713.58

9

713.52

713.45

2

713.35

8

713.25

7

713.15

713.04

1

712.93

1

712.82

2

712.71

3

705.87

8

705.83

9

707.23

5

711.77

4

711.46

9

711.21

1

710.99

6

710.76

5

710.70

8

710.64

7

710.65

2

710.67

710.62

7

710.57

710.27

7

710.07

4

710.02

9

713.53

5

713.49

6

713.43

6

713.36

7

713.29

9

713.23

713.26

4

713.14

5713

.04

712.93

4

712.82

8

712.72

2

712.61

3

712.33

2

706.15

3

706.78

6

711.13

3

711.35

8

711.08

7

710.91

9

710.70

7

710.59

8

710.55

4

710.57

3

710.58

5

710.45

7

710.32

9

710.21

2

709.93

4

709.82

8

713.13

8

713.27

3

713.21

4

713.14

6

713.12

3

713.26

6

713.14

5

713.02

3

712.91

5

712.80

9

712.70

3

712.59

7

712.47

1

712.30

8

706.04

3

705.80

8

708.24

8711

.09710

.953

710.81

6

710.65

1

710.47

5

710.44

2

710.46

2

710.34

4

710.21

6

710.10

2

710.14

6

709.81

7

709.69

4

709.98

4

712.90

7

712.91

7

712.99

3

713.24

7

713.26

7

713.14

5

713.02

3

712.90

1712

.79

712.68

4

712.55

4

712.39

1

712.22

8

712.06

5

711.90

2

707.08

1

708.47

8

710.57

5

710.66

710.68

1

710.54

4

710.38

4

710.33

710.23

710.10

2

709.97

5

709.88

1

709.96

7

709.75

2

709.55

8

709.70

1

712.76

1

712.58

1

712.95

2

713.19

6713

.09712

.983

712.87

7712

.77712

.643

712.49

3

712.34

3

712.19

3

712.04

3

711.89

2

711.82

3

707.55

9

707.70

8

709.23

1

709.71

7

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706.34

1

705.53

2

704.68

7

704.64

3

704.50

9

704.55

5

704.42

9

705.96

4

706.17

8

706.25

2

706.32

6

706.65

5

705.31

7

704.63

7

704.68

2

704.61

3

704.72

1

704.54

4

705.93

9

706.23

7

706.31

1

706.38

5

707.25

6

705.26

5

704.61

9

704.66

8

704.75

6

705.91

4

706.29

6706

.37706

.443

705.21

3

704.66

7

704.71

7

704.76

7

705.88

9

706.35

5

706.42

8

706.92

6

705.18

7

704.71

4

704.76

5

704.81

6

705.86

4

706.41

4

706.48

7

707.52

2

705.22

3

704.76

1

704.81

2

704.86

4

705.83

9

706.47

2

706.57

5

705.25

8

704.80

8

704.87

2705

.1706

.011

706.48

5

707.19

7

705.29

3

704.92

7

705.15

5

705.38

2

706.56

2

707.78

8

706.97

707.46

7

708.05

5

706.73

5

706.50

3

706.74

9

706.99

6

707.24

3

707.48

9

707.64

707.57

8

707.34

707.43

5

707.53

707.62

5

707.72

707.81

6

707.91

1

708.00

6

708.10

1

708.19

6

708.25

4

708.27

2

708.29

708.30

8

708.32

6

708.34

4

708.15

1

708.13

7

708.13

2

708.13

4

708.13

6

708.13

9

708.14

1

708.14

3

708.14

6

708.15

9

708.18

3

708.20

7

708.23

1

708.25

4

708.27

8

708.30

2

708.32

6

708.34

9

708.37

3

708.39

3

708.41

1

1.

LEGEND :-

2.

S.NO.

CANAL

5.

4.

3.

DESCRIPTION

RIVER

BUND

FENCING

TBM

7.

8.

9. WELL

HARD ROCK AREA

FREE BOARD LINE

ROAD6.

SIGN.

TAMRAPARNI RIVER

707.54

707.61

LAYOUT PLANNAME OF DRG :-

[email protected]



APPROVED


DATE :- 16 - 11 - 2010 DRG NO - DKA/JAMHEP/2009-10/1-1

Er. S.L.DIWANCHECKED BY

Er.PRIYANKA RAUTAUTOCAD BY:-




PREPARED BY:- Er.AMOL JADHAV

ELECTRICAL CLEARANCES

ENT

RA

NCE

PLAN

'B'

'B'

'A' 'A'

SECTION 'B'-'B'

'A''A'

NOTE:-

'C'

'C'

SECTION 'C'-'C'

'B'

'B'

PLAN - SWITCHYARDNAME OF DRG :-

[email protected]






AUTOCAD BY:-


221A/1B, CENTER ONE, 'E' WARD, TARABAI PARK, KOLHAPUR-416 003DIWAN KHADILKAR CONSULTANTS PVT. LTD.


SECTION 'A'-'A' SECTION 'B'-'B'

SECTION - SWITCHYARDNAME OF DRG :-

[email protected]






AUTOCAD BY:-

252,'E' 9, Deepti Park, Assembly Road, Tarabai Park, KolhapurSANJAY PATIL, Class I Regd. Govt. Contractors,


33 KV LINK

L. A.

P T

33 KV

3

110 V

3

ISOLATOR WITH EARTH SWITCH

C T

L. A.

CIRCUIT BREAKER

POWER TRANSFORMER 3000 KVA

3.3 KV / 33 KV, 3 PHASE, 50 Hz

3.3 KV CABLE

ISOLATOR

CIRCUIT BREAKER

C T

L. A.

G

SELF EXCITATION SYSTEM

GENERATOR, 2000 KW,

3 PHASE, 3.3 KV, 50 Hz

C T

L K

N G R

N G T

C T

415 FEEDERS

A C L T PANEL BOARD

D.G SET 63KVA, 415V, 3PHASE,

50HZ

AUX TRANSFORMER 100KVA,

3.3KV/415V,3PHASE,50Cs

ISOLATOR

L.T

A.C.B

L.T

A.C.B

DG

P T

3.3 KV

3

110 V

3

CIRCUIT BREAKER

EXPORT IMPORT

METERING

SINGLE LINE DIAGRAM

NAME OF DRG :-

[email protected]




DATE :- 2009 - 16 - 07

DRG NO - DKA/JAMBREHEP/2009-10/1-1

Er. S.L.DIWANCHECKED BY

Er.SAGAR YALUGADE

Er.AMOL P. JADHAV

AUTOCAD BY:-


221B/1A, CENTER ONE, E WARD, TARABAI PARK, KOLHAPUR-416 003

DIWAN KHADILKARCONSULTANTS PVT. LTD.


sanjay b. patil - construction | mining |...

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