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HINDUSTAN PETROLEUM CORPORATION LIMITED

10” & 8” x 15 KM BAHADURGARH TIKRIKALAN

PIPELINE OIL PIPELINE PROJECT

(Electrical Package)

MECON LTD, DELHI

OF 1 © 2009 MECON Limited All rights reserved

CONTENTS

Sl. No Description

01.00 Basic Engineering Design Basis

02.00 Tender Drawings

03.00 Electrical Works

04.00 Particular Job Specification

05.00 Standard Specification

06.00 Standard Drawings

07.00 Schedule of Quantity

08.00 Quality Assurance Plan





MECON LTD, DELHI

Page 1 OF 1 © 2009 MECON Limited All rights reserved

BASIC ENGINEERING DESIGN BASIS

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MECON LTD, DELHI

ENGINEERING DOCUMENT NO. Page 1 of 11 TITLE BASIC ENGINEERING DESIGN BASIS (ELECTRICAL)

MEC/23LK/05/E9/E/000/0001 REVISION 0

BASIC ENGINEERING DESIGN BASIS (Electrical Package)

10” & 8” x 15 KM BAHADURGARH TIKRIKALAN OIL PIPELINE PROJECT

Prepared By

Checked By

Approved By

Saurabh Singh D K Pande D K Pande

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C O N T E N T S Sl. No. Description 1.0 INTRODUCTION 2.0 CODES AND STANDARD 3.0 OPERATING REQUIRMENT 4.0 LIGHTING SYSTEM 5.0 SITE CONDITIONS 6.0 AREA CLASIFFICATION & EQUIPMENT SELECTION

7.0 ENCLOSERE PROTECTION OF EQUIPMENT 8.0 EARTHING AND LIGHTNING PROTECTION SYSTEM 9.0 CABLES 10.0 UPS 11.0 DC BATTERY CHARGER & BATTERY BANK 12.0 AC SYSTEM 13.0 SWITCH SOCKET

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1.0 INTRODUCTION

1.1 The project envisages laying of 10’” & 8” NB and 15 Km long petroleum product pipeline from dispatch terminal at Bahadurgarh to receiving terminal at Tikrikalan for supplying of MS, SKO/ HSD to the marketing terminal of HPCL at Tikrikalan.

1) Dispatch terminal at Bahadurgarh 2) Receiving terminal at Tikrikalan

1.2 This document presents design criteria for electrical system for the dispatch terminal & receiving station. It indicates minimum requirements for detailed design of electrical system and equipments.

1.3.1 The following electrical equipments / systems are envisaged at Bahadurgarh

Terminal.

i) 11kV 4 pole switchyard to accommodate one(1) no. 11KV incoming and two(2) no. 11KV outgoing feeders complete with switch-disconnector, ES, LA, horn gap Fuses etc as required.

ii) 11 KV, 350 MVA, 630 A VCB panel with all accessories as required.

iii) 11kV, 350 MVA 1250 A VCB switch board(HT Panel) as per single line diagram to

provide 11kV feeders to VSD.

iv) 11/0.433 KV, 500 KVA Dyn11 ONAN outdoor type distribution transformer with all accessories.

v) Power & Motor Control Centre (PMCC), MOV DB and MLDB, LDB, LCS etc for

receiving & distribution of normal power.

vi) 30 kVA UPS system, ACDB & DCDB for supply of emergency power to critical loads.

vii) Battery charger & battery bank for 110V DC supply to switchgear.

viii) HT & LT Power cables and control cable.

ix) Indoor & outdoor lighting.

x) Earthing and Lightning protection system.

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xi) Structural steel, cable tray, erection accessories etc as required.

1.3.2 The following electrical equipments / systems are envisaged at Tikrikalan Terminal. i) 415V 3Ph-TPN power shall be taken from owner’s existing distribution board. ii) LT power and cables. iii) Power and Motor Control Center(PMCC), MOV DB, LDB etc. iv) Indoor & Outdoor Lighting. v) Earthing and Lightning Protection System. vi) Structural steel, cable tray, erection accessories etc vii) 20 kVA UPS system, ACDB & DCDB for supply of emergency power to critical

loads . 2.0 CODES AND STANDARDS

Electrical equipment and system design, manufacture, testing, installation and commissioning will comply with all the latest applicable standards, regulations and codes as mentioned below: BIS - Bureau of Indian Standards CMRI - Central Mines Research institute DGMS - Director General Mines Safety OISD - Oil Industrial Safety Directives IEEE - Institute of Electrical & Electronics Engineer IER - The Indian Electricity Rules ANSI - American National Standards Institute

3.0 OPERATING REQUIRMENT

A.C. Power Supply At Bahadurgarh terminal (i) High voltage - (From state Electricity board for distribution transformer and VFDs of main pumps.)

a) Voltage - 11KV +/- 12.5 %

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3.3KV +/- 12.5 % b) Frequency - 50 Hz +/- 5 % c) Phases and Wire - 3 Ph (3W) d) Fault level - 26.3 KA for 1 Sec.

(ii) Low voltage - From 500 KVA transformers 11/0.433 V transformers for LT loads and VFDs of booster pumps.

a) Voltage - 415 V +/- 10 % b) Frequency - 50 Hz +/- 5 % c) Phases and Wire - 3 Ph & N (4W) d) Fault level - 30 KA for 1 Sec. For 3 Ph ckt. 10 KA for 1 Sec. For 1 Ph ckt. e) Neutral Earthing - Solidly Earth

(iii) 415V, 50Hz voltage supply from 140 KVA DG set for critical loads. (iv) UPS output Power supply a) Voltage

i) 230V AC +/-1%. : For instrumentation ii) -48V DC +/-1%. : For Telecom iii) -48 V DC +/- 1% : For SCADA

b) Frequency : 50 Hz +/-1% c) Fault level : 10 KA for 1 Sec

If any equipment requires any other voltage, it shall be derived within the respective equipment.

4.0 LIGHTING SYSTEM

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4.1 Lux level in the plant area for calculation of lighting fixture are as follow:

Control room - 400 lux Electrical room - 250 lux Office room - 250 lux Process area - 50 lux Battery room - 100 lux Periphery of building - 20 lux Transformer Yard - 50 lux Pump House Shed - 200 lux DG/Car Parking Shed - 200 lux Utilization factor - As per manufacturer catalogues. Maintenance factor - 0.6 for Outdoor / 0.7 for Indoor

4.2 Type of Lighting fixture

Control room, Offices -1x11 W or 2x11 W FL Recessed fixtures. & SCADA Room Electrical room - 1x36 W or 2x36 W FL Industrial fixtures with reflector. Other room Battery room - 2x36w water/vapour proof lighting fixture.

Process area/Pump House Shed (Unsafe area) -200 W HPMV, FLP Well Glass fixture. Road/Outside the building -250 W HPSV Street light fixture. (safe area) Industrial building(safe area) -250 W HPMV non FLP well glass fixture.

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5.0 SITE CONDITIONS

a) Max / Min Temperature : 45 / 5 0 C b) Relative Humidity : 100 % c) Altitude above sea level : Less than 1000 M above mean sea level d) Atmospheric condition : Tropicalized to withstand the site Condition, dust, vapor etc. e) Hazardous area Classification : Zone-1, Gas group IIA & B, Temp. Class T3 f) Control Room/Electrical : Safe Area HT Switch Yard/battery room

/D.G Area/Transformers Yard 6.0 AREA CLASIFFICATION AND EQUIPMENT SELECTION

6.1 Classification of hazardous area will be in accordance with BIS and IS: 5572.

6.2 Following selection will be considered for proper selection of electrical equipment for use in hazardous area:

a) Area Classification : Zone-1 b) Gas Group : IIA and IIB c) Temperature Classification: T3 All electrical equipment installed in hazardous area will be selected as per IS: 5571.

6.3 All electrical equipment for hazardous area will have CMRI certification

7.0 ENCLOSURE PROTECTION OF EQUIPMENT

7.1 Enclosure Protection:-

The electrical equipment installed outdoor

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will have the following enclosure Protection -IP 55 The equipment installed indoors will: have the following enclosure

VCB and PMCC panels etc. - IP 43 The above enclosure protection will be in accordance with Indian standard.

7.2 Enclosure Protection in hazardous areas:- The type of enclosure in the plant / process area shall be Flame proof (Ex-d)

8.0 EARTHING AND LIGHTNING PROTECTION SYSTEM

8.1 No. of earth pit will be provided as per IS: 3043. 8.2 All equipment earthing to be carried out as per IS: 3043,minimum size of GI/Copper

earth conductor to be used will be as given below. Equipments Earthing Conductor size

Grid & equipment such as: 50 x 6 mm GI Flat Transformer, VCB & PMCC panel etc Utility building MLDB,Switch Socket DB, 25 x 3mm GI/16 sq. mm GI rope

UPSDB, Lighting DB etc.

Motors up to 2.2 kW 6 sq mm solid GI Wire Motors 3.7 kW to 11 KW 16 sq. mm GI rope Motors 15 kW to 45 KW 25 x 3mm GI Flat Motors 55 kW to 90 KW 25 x 6mm GI Flat Motors 110 kW & Above 50 x 6mm GI Flat FLP – WP lights/control station 6 sq mm solid GI Wire Product pipe line 16 sq mm flexible copper wire

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8.3 Earthing Electrode will be GI pipe for electrical system & Copper plate for instrument/SCADA &Telecom system

8.4 Minimum 2 Nos each for DG set and Transformer neutral earthing.

8.5 Lightning protection system shall be provided as per IS-2309.

9.0 CABLES Power & Control cables will have the following specification: 9.1 Power cable a) HT Power cable (11kV UE grade)/(3.3kV UE grade)

• Screened Stranded Aluminum Conductor (screening with non-metallic semi conducting tape or by extrusion of semi-conducting compound)

• XLPE Insulated by extrusion with insulation screening. • Inner sheath will be ST2 by extrusion or wrapping. • Steel strip / wire armoured • Outer sheath of cable will be FRLS PVC, ST2 type by extrusion • Voltage grade – 11 kV/3.3kV (UE) • Applicable standard: IS-7098 part II

b) LT Power Cable (1.1kV grade)

• Stranded Annealed Copper Conductor up to 16 mm2. • Stranded Aluminum Conductor from 25 mm2 and above. • PVC insulation – Type A insulation • Inner sheath will be ST2 • Inner and outer sheath will be extruded. • Steel strip / wire armoured. • Outer sheath of cable will be FRLS PVC, ST2 type. • Voltage grade – 1100 V • Applicable standard: IS-1554 Part I

9.2 Control Cable (1.1kV grade)

• Stranded Annealed Copper Conductor 2.5 sq mm • PVC insulation type A. • Inner sheath will be ST2

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• Steel strip/wire armored • Outer sheath of cable will be FRLS PVC, ST2 type. • Voltage grade – 1100 V • Applicable Standard: IS-1554 Part I.

9.3 Lighting Cable / Wire in conduit

• 2.5 mm2 stranded Copper PVC insulated wire in concealed PVC conduit will be used in Lighting fixtures. • 3 core 2.5 mm2 stranded copper cable (YWY) will be used for flameproof fixtures. • 4 core 6 mm2 stranded copper cable (YWY) will be used from outdoor lighting DB to junction box on the lighting poles. • 3 core 2.5 mm2 stranded copper cable (YWY) will be used from junction box on the lighting poles to lighting fixture.

10.0 U.P.S. SYSTEM AT DESPATCH & RECEIVING STATION

a) DESPATCH TERMINAL BAHADURGARH Rating - 30 KVA, 230 V AC, 1 Ph, N. Dual redundant UPS with

Static stabilizer. Redundancy - Dual redundant

Back – up Time of Ni-Cd Battery - 2 Hrs.

Facility to isolate battery bank. b) RECEIVING TERMINAL AT TIKRIKALAN Rating - 20 KVA, 230 V AC, 1 Ph, N. Dual redundant UPS with

Static stabilizer. Redundancy - Dual redundant

Back – up Time of Ni-Cd Batte - 2 Hrs.

Facility to isolate the battery bank.

11.0 110 V DC BATTERY CHARGER AND BATTERY BANK

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Battery charger & battery bank (12 V 200 Ah, Lead Acid Sealed Maintenance Free Battery) for 110V DC supply to switchgear.

12.0 SPLIT A.C. SYSTEM

12.1 All A.C. will be 230V, 50 Hz, 1 Ph & N. 12.2 Control room temperature will be maintained 220 C+20C.

13.0 SWITCH SOCKET

13.1 5/15A, 5 pin, Switch Socket (PNE)

• Control Room - 8 Nos. • Electrical Room - 2 No. • Battery Room - 2 No. • Substation Room - 2 No.

13.2 20A/16A, 230V AC (PNE) Industrial Switch Socket unit fully interlocked with plug with 16

A SP MCB for Air Conditioners.

13.3 Piano reed type socket for telephone

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TENDER DRAWINGS

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ELECTRICAL WORKS

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CONTENTS

Sl. No Description Page No.

01.00 Introduction

02.00 Intent of Specification

03.00 General Conditions of Contract

04.00 Scope of Work

05.00 Technical Specifications-11kV Outdoor FP

Structure / Equipment

05.01 11 kV Disconnecting Switch (Including

earth switch)

05.02 Lightning Arresters

05.03 Four Pole (FP) Structure

05.04 Distribution Transformer

05.05 Battery

05.06 Battery Charger

06.00 Technical specifications of Cables

07.00 LT Equipment

08.00 Feeder Pillar & LDB / SDB/ DB

09.00 Illumination system

10.00 Hazardous Area

11.00 Earthing & Lightning protection

12.00 Erection Guidelines

13.00 Testing and commissioning

14.00 Data, Drawings & Documents

15.00 Preferred makes

16.00 Applicable standards and codes

17.00 Quality Assurance, Inspection and Testing

18.00 List of tender drawings

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19.00 Questionnaire

20.00 Deviation statement

21.00 Time schedule

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01.00 INTRODUCTION

1.1 The project envisages laying of 10’” & 8” NB and 15 Km long petroleum product pipeline from dispatch terminal at Bahadurgarh to receiving terminal at Tikrikalan for supplying of MS, SKO/ HSD to the marketing terminal of HPCL at Tikrikalan. 1) Dispatch terminal at Bahadurgarh 2) Receiving terminal at Tikrikalan

1.2 This document presents design criteria for electrical system for the dispatch terminal & receiving station. It indicates minimum requirements for detailed design of electrical system and equipments.

02.00 INTENT OF THE SPECIFICATION

The intent of this specification is to describe in detail the entire Electrification and Illumination works required for the above terminals, which the tenderer shall undertake in full compliance with the contract documents. This document elaborates the tenderer’s work involved in erection, testing and commissioning of the electrical Equipment supplied by owner/ testing and commissioning of the motors and other items to be installed by other agency. This document also includes tenderer’s scope of work involved for items to be supplied, erected, tested and commissioned. These items are elaborated under different schedules under this TS.

03.00 GENERAL CONDITIONS OF CONTRACT

a) These instructions shall be read in conjunction with all the commercial documents appended to this document. In case of contradictions in the clauses under TS the most stringent one shall prevail.

b) All the equipment supplied by the contractor shall be new and conforming to relevant latest BIS, safe engineering practices and codes. These shall be tested and commissioned as required and no separate payment shall be made unless otherwise specified in the schedule of rates.

c) Any work not conforming to the execution drawings, Specification or codes shall be rejected forthwith and the contractor shall carryout the rectification at his own cost.

d) The contractor shall carry out the various tests as enumerated in the technical specification and the technical documents, which, may be furnished to him during the performance of the work.

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e) Before an electrical system is made live, the electrical contractor shall carry out suitable tests to establish to the satisfaction of owner that installation of all equipment, wiring and connections have been correctly done and are in good working condition and will operate as intended.

f) All tests shall be conducted in the presence of the Engineer-in- charge or his authorized representative unless he waives this requirement in writing. All the testing equipment required, to carry out the tests must be supplied by the contractor. The tests shall be recorded on approved pro-forma and certified records of the tests shall be submitted to the owner / Engineer –in- charge.

g) After completion of all tests and rectification of all defects pointed out during final inspection, plant start up trials would be commenced. During the start-up trials, contractor shall provide skilled / unskilled personnel & supervise the same.

h) All debris / unserviceable materials shall be disposed off as per the direction of engineer-in–charge and the premises shall be kept clean & tidy. The rate for the same is deemed to be included in the offer.

i) The contractor shall supply skilled technicians / laborers as per job requirement to ensure compliance with standards / specifications.

j) The offered price for supply & erection of electrical equipment is deemed to include expenses towards testing and inspection at manufacturer’s works, documentation, operating manuals, drawings, statutory approvals, clearing of site / building all unserviceable materials etc.,

k) All the works, covered under this specification shall be executed on ‘Unit Rate’ basis.

l) Although every required item of work may not be explicitly described in the specification, it is the owner's intention to furnish the tenderer with every detail necessary to complete the specified work with the exception of those items of work listed under "work by others".

m) It is the responsibility of the tenderer to assess the type and magnitude of work involved based on information furnished by the owner / Consultant in the schedules of this document and general field conditions.

n) It is the tenderer’s responsibility to specially list out in his quotation, all items and any other items left out in the schedule of units, but which

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are necessary for the completion of work assigned, along with unit prices. If the unit price is not already indicated then all such items are deemed to be included in tenderer’s scope.

o) Tenderer shall clearly indicate deviation, if any, from this specification, in the offer.

p) Tenderer shall quote for complete work specified in the document. Incomplete quotation or quotation for part of work will not be considered even though the quoted rates/prices are lower.

q) Tenderer shall obtain from Owner / Consultant additional details / data, if any, required to submit proper quotation. If required the tenderer shall also visit site and assess the conditions prevailing before submitting the offer.

r) The word 'installation' wherever mentioned in this document shall mean erection, testing and handing over of item /equipment after successful commissioning.

s) Information and documents furnished by the tenderer for each item of work shall be complete, without any cross reference to other parts.

t) The owner reserves the right to omit any one or more items of work at any item of the contact without assigning any reason whatsoever.

u) The Successful tenderer has to make his own arrangements for construction power, water, workshop office etc., at site. The cost of the same is deemed to be included in the offer.

03.01 Data / Information to be furnished by tenderer with tender

List of works executed similar to the one covered under this tender along with contract value and the period of completion.

Compliance in totality,or list of exceptions, for each item / clause of the tender specification. Failing to do so may result in rejection of their offer. Technical details of all the equipment offered.

Makes of equipment/components offered (from the list of preferred makes only). Detailed specifications, drawings and technical literature of the equipment/components offered as above. List of tools and tackles, testing / handling equipment available with tenderer and required for completion of job detailed in this specification.

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Bar chart, indicating schedule of manufacture, delivery at site, erection, testing and commissioning of individual equipment.

List of consumable / spares, recommended by manufacturer, for all equipment, for 2 years normal operation.

03.02 Price

Prices quoted shall be firm without any escalation till completion of the job assigned and shall be inclusive of all taxes, duties & incidental charges/expenses whatsoever including safe storage at site, handling /transportation, erection, testing and commissioning.

Also tenderer shall indicate and justify quantity for cables, cable trenches, earthing strips etc., assessed by him, if it is more than the tender quantity.

All consumables and spares, required for the installation, testing and commissioning, shall be supplied by the contractor. Unit rates for installation shall include such consumable. Tenderer shall furnish list of consumable / spares recommended by manufacturer, for each equipment, for two years normal operation.

Quoted Prices shall be applicable for Variations in quantities, without any ceiling limits

Price Adjustment for excess/extra items, where applicable will be paid, based on rates derived from rates of similar items in the contract. If, Similar items does not exist in the contract rates for such items shall be worked out based on prevailing market rates with an overhead of 10% on overall derived rate The contractor will not be compensated in any manner other than as mentioned above for any reduction or increase in the scope specified. The Decision of owner/consultant in this regard shall be binding on the contractor

The contractor's responsibility shall be for the complete work including supply of materials and he shall not avail, him-self of any unintentional errors or omissions in the description of the scope.

Prices indicated by the tenderer shall also be deemed, to include and cover, but not limited inter-alia, the following:

Providing touch up final paint etc., wherever required after installation. Working during day or night or continuously for long hours/days,

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Handling & transportation of materials, at stores/ place of work. Cost of tools & tackles etc.

03.03 Training

Contractor shall train the work force of customer with his technical and supervisory personnel for safe, and efficient operation and maintenance of the equipment and system installed by the contractor. The Number of personnel to be trained and the duration and structure of the training shall be mutually discussed and finalized.

03.04.00 Spares 03.04.01 Commissioning Spares

The tenderer shall include in his offer sufficient quantity of commissioning spares required for commissioning of all equipment and for their efficient operation until their provisional acceptance after demonstration of satisfactory performance.

03.04.02 Operational Spares

The tenderer shall submit along with the main offer a separate quotation for supply of spare parts for two (2) years' normal working of all equipment after provisional acceptance of the same. The offer shall include item wise list of all spares indicating their unit rates and quantities. This list will be finalized with the successful tenderer.

03.05 Modifications and Statutory Compliance

The owner/consultant shall be at liberty to make modifications in the original scope awarded to the contractor and also in the designs that may appear to be necessary due to various reasons while awarding the contract or during the progress of work. (The Offer submitted shall be valid for the revised scope if any). The contractor should not object to this and he shall be bound to carry out all such alterations, within the time schedule even if this results in excess work over the estimated quantities or in supply of extra items. Modification required by the owner/consultant/statutory bodies, to correct, defective workmanship, non-standard installation and non-compliance of statutory regulation by the contractor, shall be carried out free of cost by the contractor within the time schedule.

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Contractor shall furnish drawings/sketch/corrected print indicating the modifications to be carried out at site for approval of consultant/owner. If permitted to carry out the modification, contractor shall furnish the revised drawing/corrected print to the consultant/owner with proper revision number, date of revision, after carrying out the modification. All the modifications shall be incorporated before submitting copies of as built drawings.

The contractor shall complete and fulfill all formalities with the statutory

licensing board having jurisdiction in the area before commencement of work and for getting installation energized.

It shall be the responsibility of the contractor to comply fully with

requirements of relevant standards, Indian Electricity Act / Rules, Regulations of Insurance Association of India and Factories Act, Chief Controller of Explosives while carrying out work as per this specification. Further, it shall be responsibility of the contractor to prepare and submit to the electrical Inspectorate and statutory agencies all necessary drawings, calculations, test certificate for commencing the work. He shall submit completion report to Statutory Authority (after completing the particular work) and arrange for inspection of the work completed.

Further, he shall obtain the final approval and safety certificate for the works thus completed. Owner shall however bear the necessary inspection fee levied by statutory authority other than which the owner shall bear no responsibility. Any modifications suggested by the Statutory bodies either during drawing approval or during inspection of the installation shall be carried out, by the contractor, free of cost and without affecting agreed milestone.

No separate payment will be made for any installation accessories like

Junction boxes, pull boxes, nails, screws, bolts, nuts, clamps, mounting brackets/down-rods, rawl-plugs (Anchor bolts), Fan hooks/boxes, cable trough required for complete lighting installation. As such the cost of the installation accessories shall be included along with respective equipment.

03.06 Foundation channels / minor civil & structural works The frames of equipment shall be secured by means of anchor bolts to

the foundation or Channel frame tag welding to the embedded plates in floor / foundation. Minor civil works like closing of pockets / openings in floors / walls, chipping of foundation, leveling, grouting, patching and finishing required for proper installation of equipment or earth wire / strip for earthing shall be done by the contractor himself without any additional charges. All structural supports for electrical equipment /

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cable structures etc., as required by site condition shall be provided by the contractor.

The cost of all the above works is deemed to be included in the overall quoted price.

03.07 License & Supervisory Personnel Contractor shall have valid license and before commencement of

execution of the work shall post senior personnel having necessary technical, financial and administrative power as in charge of site office, to carry out the site work satisfactorily at required pace within time schedule.

Contractor shall deploy skilled and supervisory personnel required for

the work and shall furnish resumes showing background and experience of supervisory personnel he intends to deploy.

All line men, wire men, electricians, supervisors and engineers engaged

by the contractor or his sub-contractor shall possess necessary authority & the same shall be submitted for verification if called for.

03.08 Sub Contracting The contractor shall execute the erection, testing, commissioning of the

work assigned to him through his own experienced, qualified personnel only. Sub-contracting of the work in part or whole to other contractor is not permitted without Owner’s / Consultant approval.

If the contractor sub-contracts his work (prior permission for sub-

contracting the work shall be obtained from the owner / engineer. The sub-contractor should also have competent valid license. Licenses of all wiremen / electricians / supervisors whom the contractor intends to deploy, shall be submitted for verification if called for by the owner/engineer.

The contractor shall ensure that all the terms and conditions applicable

to him are also applicable to his sub-contractor. 03.09 Co-ordination with other Agencies at site.

Contractors & their sub-contractors shall work harmoniously with other Agencies working at site to ensure smooth timely execution of the project. Contractors shall adhere to site orders / written instructions issued by Engineer-in-Charge / Owner. Non-compliance of site instructions by the contractor will be treated as breach of contract and

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recovery from bills and other penal actions will be affected solely at the discretion of Engineer-in-Charge / Owner.

03.10 Work by Others

The following works (included in the scope of other agencies) are excluded from the scope of the tenderer.

• All Civil buildings • Roads and culverts • Concrete and RCC trenches inside Building • Fire Alarm, Telecommunication and Instrumentation. • Technological equipment • Motors, Motor Operated Valves & other Driving Equipment. • DG sets/ AMF panels • TR panels for Cathodic protection.

03.11 Offer for Operation and Maintenance Operation and Maintenance of the complete plant for six months after

final acceptance by owner shall be quoted optionally.

03.12 Drive Ratings

The rating of drives, indicated in SLD / Specification are tentative. The Exact rating of drives will be confirmed during detailed Engineering stage. As such the rating / size of components in outgoing motor feeders shall be provided based on final rating as per approved Drawings / Data sheet. Tenderers shall note that no extra claims will be entertained for such modifications / alterations.

03.13 In case of any contradiction between various referred standards/specification/data sheet and statutory regulation etc, the following order of priority shall govern :

(i) Statutory Regulations. (ii) Schedule of Rate. (iii) Design Basis. (iv) Scope of Work/Job Specifiaction. (v) Data Sheet. (vi) Standard Specification. (vii) Codes of & Standards.

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04.00 SCOPE OF WORK

The scope of work for all the sites at Bahadurgarh and Tikrikalan shall be as listed below, but not limited to these.

04.01 Design, manufacture, shop testing, inspection, transportation to site,

proper storage and handling at site, erection, testing and commissioning of Electrical equipment & auxiliaries briefly listed below (but not limited to) on Item rate Basis in line with Estimated quantities, approved Drawings / Data sheets, site orders and statutory regulations, however only relevant clauses in Technical Specifications(Clause no. 5) is applicable

a) Extension/Modification of existing 11kV 4 pole switchyard to

accommodate one(1) no. 11KV incoming and two(2) no. 11KV outgoing feeders complete with switch-disconnector, ES, LA, horn gap Fuses etc including civil works as required.

b) 11KV/0.433KV , 500KVA transformer with all accessories.

c) 11 KV, 350 MVA, 630 A VCB panel with all accessories as required.

d) 11kV, 350 MVA 630 A VCB switch board(HT Panel) as per single

line diagram to provide 11kV feeders to VSD.

e) Power & Motor Control centre (PMCC), MOV DB and MLDB, LDB’S, LCS’s etc for receiving & distribution of normal power.

f) HT and LT power cable, Control and illumination cables, wires

for illumination works and instrumentation cables as per requirements.

g) UPS system, ACDB & DCDB for supply of emergency power &

critical loads.

h) Battery charger and battery bank for 110V Dc supply to switchgear and other auxiliary loads.

i) Weather proof / flame proof push button stations for VCB

emergency stop from local and remote locations.

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j) Illumination Equipment as detailed below but not limited to

• Main, Sub, UPS Lighting, A/C Distribution Boards for normal-

cum-emergency lighting System. • Various types of Lighting Fixtures with lamps & all accessories

and suitable for Hazardous and Non-Hazardous Areas. • GI pipe brackets for Post top Lantern Fittings. • Industrial and decorative type Switches and sockets. • Low Voltage- Sockets/Lamps/Switches/Transformers. • Aviation Obstruction Lighting with neon lamps. • PVC Conduits in ceiling –N-Capping, GI Conduits in

floor etc., required for wiring inclusive of copper wires and co-ordination with civil contractor for laying of PVC/GI conduits in ceiling/floor trespectively.

d) Laying, testing and commissioning of 11 kV (UE) XLPE , 6.6

kV(UE) XLPE &1.1 kV grade PVC insulated armored power / earthing / lighting / control / any other special cables / wires, in Concrete, Brick lined / buried cable trenches, pipes, Structures, road crossing and on cable tray , including supply and filling / laying of sand ( up to 75 mm below and above cables) in trenches and of Concrete slabs (75 mm thick) / Brick lined (over sand layer above cables) before back filling in interplant cable channels.

e) Excavation of cable trenches and back filling, supplying and

spreading of bricks and sand in trenches / Making RCC cable trenches with RCC removable cover slabs, for out-door and in-door cabling as per site condition.

f) Submission of, test Certificates and Technical Catalogues for

all equipment and accessories for use in Hazardous and Non hazardous areas.

g) Installation of complete earthing network for sub-station,

Pump Houses, Illumination system, including preparation of earthing pit, supply of all earthing material, testing etc., including supply of single core armored cables.

h) Lightning Protection as applicable. i) Supply and fixing of safety equipment (i.e.) caution boards, fire

extinguishers, sand buckets with stand etc., Supply and installation of other miscellaneous items like rubber mat, rubber gloves etc.,

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j) Installation of any other accessory not specified herein but

nevertheless necessary for the completion of work. k) Electrical facilities and civil works connected with grouting of

equipment to the installed. This shall also include breaking of walls / floors and chipping of concrete foundations necessary for the installation of equipment /laying of cables / laying of earthing conductors etc. and making good the same.

l) Supply of all labor, supervision, tools and tackles,

consumables, materials and all other erection accessories, not specifically mentioned herein but required to complete in all respects, installation & testing and commissioning of all the equipment covered under this contract.

m) Storage / Transportation of all equipment from store to

erection site / contractor’s store, unpacking, checking and proper storing etc.

n) Supply and erection of galvanized prefabricated or ladder type

cable trays including all materials, fittings / fixtures and hardware.

o) Fabrication, supply & erection of MS support, for miscellaneous

electrical equipment / cable tray support including welding, bolting etc., and necessary supplies and connected works all inclusive of painting as specified.

p) Supply, fabrication, erection of MS base frame / installation

structure for VCB panel / PMCC / switchgear / CPDB / MLDB / MOVDB / TR units panel / Auxiliary DB / LCS / PBS and miscellaneous electrical equipment including welding / bolting etc., and necessary supplies & connected works all inclusive of painting as specified.

q) Supply and installation of connected items like nickel-plated

brass cable glands, FLP Glands, tinned copper lugs. r) Supply of steel (including fabrication) & installation of

canopies for outdoor boxes , LCSs, LDB / SLDBs, motors etc. and other associated requirements.

s) Supply and installation of steel metal junction box / Cast

Aluminum for control cable / power cable / illumination cable with power and control terminal as specified / required.

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t) Supply, installation of GI sheet cable tray cover / chequered

plate / RCC slab covers for trenches. u) Supplying & filling of sand in outdoor Cable trench / RCC cable

Channels. v) All liaison work with Haryana SEB right from submission of

application for sanction of H.T. Power for the Plant until completion of erection of Haryana SEB portion of work and getting Installation energized. All Statutory Deposits made to Haryana SEB in this regard shall be re-imbursible on production of receipt.

w) Supply, Erection, testing and commissioning Air Conditioners. x) Drawings & documentation: The scope also includes

submission of Detailed dimensional layouts of equipment, lighting (Area and premises lighting) / Single line Diagrams and General Arrangement Drawings for power distribution/ Illumination system / Control Schematics, Comprehensive cable layouts (for power, control and lighting),Design Calculations, (for Component ratings, illumination levels, cable sizes etc,) Cable List for approval by owner / consultant, operating & instruction manuals for information and records and 6 sets of ‘As built drawing’ for all the electrical / Illumination system / installation, testing & commissioning of which was carried out by the contractor under the scope of this contract.

The quantities of the above items / equipment at both the terminals shall be as per PART-A -Price schedule for Contractor supply items / equipment (to be erected, tested and commissioned also).

04.02 Installation, testing and commissioning of owner supply

equipment: • Variable frequency drives /soft starter panel with built

in PLCs and CIU for measurements. • Local Control Stations .(weather proof / flame proof

types)

All the above equipment shall be erected by the Contactor and testing and commissioning shall be carried out by the Contactor under the supervision / guidelines of respective

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equipment suppliers as will be available at site. The storage and transportation from stores to point of erection of the above owner supply equipment shall also be included in contractor’s scope of work. The quantities of the above items / equipment at various terminals shall be as per PART-B -Price schedule for free issue items / equipment.

04.03 Construction of suitable covered equipment storage building /

sheds and site construction office with all required facilities, illumination etc.

04.04 Watch & ward at contractor’s store / working place, working place at plant site, erection sites for safe custody of equipment erected by contractor till the equipment are handed over to purchaser. Contractor shall be held responsible for any theft of equipment, components etc. kept under their custody.

04.05 Transportation of equipment and materials from plant / contactor’s stores to the site for erection and commissioning purpose. Provision of proper handling equipment e.g. winches, lifting jacks, slings, pulleys, ropes etc. as well as all erection tools and tackles, welding and gas cutting machines, power tools, hand lamps, pipe bending machine, cable crimping tools, gauges, scaffoldings, ladders, local illumination etc. including cables required for connection of these items.

04.06 Provision of construction power supply including supply of construction power supply boards, cables etc. & maintenance of same during contract period. Purchaser shall not provide any construction power but shall be arranged by contractor.

04.07 The scope of work of the contractor shall also include co-ordination with other contractors at site, pre-commissioning no load / load tests, integrated on load testing & commissioning, handing over, conducting PAT / FAT and liquidating defects etc. for the complete installation work carried out by the contractor.

04.08 Obtaining Statutory approvals for the entire electrical installation Supplied, installed, tested and commissioned or owner supply items installed, tested and commissioned under this Contract.

05.00 TECHNICAL SPECIFICATIONS

11kV OUTDOOR FP STRUCTURE / EQUIPMENT ( ONLY FOR

BAHADURGARH TERMINAL)

05.01 11 kV DISCONNECTING SWITCH (Including earth switch)

05.01.01 Design Criteria

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Nominal system voltage : 11 kV Rated voltage of isolator : 11 kV (RMS) Rated frequency : 50 Hz Voltage variation : + 12 1/2% Frequency variation : + 5% Design ambient air temp. : 45 degrees C Service : Outdoor Type : Horizontal / double Break Rated continuous current : 400 Amps Rated short time current : 26.3 kA for 3 seconds. Rated peak through fault : 67kA peak current Operating mechanism : Local / manual Dry and Wet one minute power frequency withstand voltage for the isolator and earthing switch a) Between phase and between : 28 kV RMS phase & earth b) Across isolating distance : 32 kV RMS

05.01.02 TECHNICAL FEATURES A) GENERAL

i) The disconnecting switch shall be Manual operated air break, triple pole, gang operated, double break suitable for horizontal, upright mounting on galvanized steel structures, Isolators having contacts moving in horizontal plane are preferred.

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ii) The disconnect switch shall be capable of interrupting small inductive

and capacitive currents such as those while disconnecting lines at no load or transformer no load currents. The isolator blades shall be able to carry the rated current continuously without exceeding temperature limits mentioned in design criteria.

B) Operating mechanism i) a) The operating mechanism for disconnect switches shall be

suitable for local manual operation. b) A signaling device for all poles of the isolator shall be arranged

both for closed and open position, to indicate isolator position on remote panel in control room.

ii) The manual operation should be easy but not easily accessible.

There should be proper locking arrangement for manual operation.

iii) The operating mechanism shall have positive control of blade movements at all times and under most hazardous conditions. Linkages shall be fitted free from slack and lost motion.

iv) All bearings shall be sealed against dust and moisture heavy-duty

type lubricated for life and

v) The manual operating handle shall be mounted on the base supporting structure. Guide bearings shall be provided at a height of 750mm above ground level. All brackets, angles, guides, guide bearings & other members necessary for attaching the operating mechanism & operating handles to supporting structure, shall be supplied as an integral part of disconnect switch. The moving blades of isolator shall turn 90 degree after making the contact for ensuring sufficient contact pressure. Flexible jumper connection shall be provided for earthing of operating handle.

. C) Earth switch The isolator shall be provided with Manual operated earth switch

forming integral part. The rating of earth switch shall be same as that of isolator with respect to rated peak short circuit current and making current. The earth switch shall be operated by a separate operating mechanism, shall be electrically and mechanically (castle key interlock) interlocked with the isolator, so that, the grounding blade

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can be closed only, when the isolator is open and the isolator can be closed only when the earth switch is open.

D) Additional interlocks The isolator shall be electro-magnetically interlocked with the

associated circuit breaker. Even manual operation of isolator shall be possible only when the associated breaker is in the open position. The interlock shall be so designed that it shall not be possible to operate the isolator even locally when the associated circuit breaker is in the closed position. The interlock shall be fool proof in all respects. The interlock relay/solenoid shall be provided in the cabinet for operating mechanism. Necessary auxiliary contacts for interlocks with vacuum circuit breaker shall be provided.

E) Auxiliary contacts

3 NO + 3 NC auxiliary contacts shall be provided for the main isolator and 3 NO + 3 NC for earthing switch. It shall be possible to convert NO to NC and vice versa at site. The auxiliary contacts shall have a continuous current carrying capacity of at least 10 Amps.

F) Constructional features

i) The switch-blade of main and earth switch shall be copper. It shall be of one solid piece construction and shall be assembled that no part of the blade can move relative to the other. The thickness and section of the blade shall be such that it retains its form and straightness under all conditions of operation including the flow of system fault current for the period specified. It shall also be capable of withstanding all torsional and bending stresses due to the operation of switches.

ii) The isolators shall have high-pressure self-aligning adjustable

contacts. The contacts shall be well protected all round by a metal cover which provides not only electrostatic screening but also prevents coarse dust from entering between the contacts. The contacts shall be designed such that the contact pressure is released before any movement of blades in the opening direction takes place and is applied after the closing travel is completed. There shall be sufficient wiping action of the contacts to make them self-cleaning. The contacts shall be made of high grade high conductivity heat resistant material and shall be silver plated.

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iii) The earthing switch of disconnect switch shall be complete with all parts that are necessary or essential for the efficient operation. Such parts shall be deemed to be within the scope.

iv) Disconnect switch and earth switch including their operating

mechanism shall be such that they cannot be dislodged from their open or closed position by gravity, wind pressure, vibrations shocks etc.

v) The disconnect switch/earthing switch contacts shall be of

silver faced copper. vi) All live parts shall be of non-rusting and non-corroding metal.

Current carrying parts shall be of non-ferrous material such as copper or Aluminum. Bolts, screws shall be provided with lock washers, keys or equivalent locking facilities and if provided on current carrying parts shall be made of non-rusting and non-corroding metal such as copper/silicon alloy.

vii) Base channels and other structural members such as operating

pipes, phase coupling rods etc., operating mechanism boxes, bolts, pins etc., shall be hot dip galvanized. The thickness of galvanizing shall not be less than 100 microns.

viii) All similar parts shall be interchangeable. ix) The disconnect-switch shall be such that no lubrication of any

part is required except at very infrequent intervals. x) During the course of normal operation it is likely that the

disconnect switch/earth switch may be left in the open/closed position for long periods.

xi) Disconnect switch shall be such that it is free from visible

corona discharge in both closed and opened positions.

xii) The clearance between live parts and grounded structures shall not be less than those specified in relevant standards. The inter-phase clearance shall be as per switchyard layout. Inter phase clearance and mounting height shall be more than 1.5m. The length of break in open position shall be such that there is absolutely no possibility of arc over from the live parts to the de-energized parts on which any maintenance work may have to be done. The speed of opening or closing the switch shall be designed to ensure that the arcing during the operation is reduced to the minimum.

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G) INSULATORS

i) Insulators shall be made of high strength porcelain and shall

be suitable for the service voltage and BIL specified. ii) Porcelain used for the manufacture of insulators shall be

homogeneous and free from flaws or imperfections that might affect the mechanical and dielectric quality. They shall be thoroughly vitrified, tough and impervious to moisture. Glazing of porcelain shall be uniformly brown colour, free blisters, burs and other similar defects. Insulators of the same rating and type shall be interchangeable.

iii) The porcelain and metal parts shall be assembled in such a

manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced smoothly and galvanized. Insulators shall be stack types.

H) ACCESSORIES i) Stainless steel nameplate shall be provided on disconnecting

switches, earthing switches and operating devices. The nameplate shall contain the information set out in IS-9920 & 9921.

ii) Suitable locking arrangement with lock (Godrej/Navtal - 5

levers) shall be provided for the isolator operating mechanism, so that, it can be locked in either fully open OR fully closed positions.

iii) Each pole of the, disconnect switches shall be provided with

two grounding pads at opposite ends, brazed to the base channel. Flexible copper ground connectors shall be provided, for connecting operating handles of disconnect switches and earthing switches to the grounding system.

iv) Suitable adjustable arcing horns made of tinned electrolytic

copper shall be provided on disconnecting switches.

05.02 LIGHTNING ARRESTERS

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Lightning Arresters shall be station class non-linear resistor type for

protection of switchyard equipment and transformers against lightning and switching surges. The lightning arresters shall be self-supporting type in single pole Assembly suitable for outdoor installation

05.02.01 DESIGN CRITERIA

Service : Outdoor Nominal system voltage : 11 kV Highest system voltage : 13.2 kV System frequency : 50 Hz Ambient temperature : 45°C Rated arrestor voltage : 10.5 kV Nominal discharge Current of 8 x 20micro-seconds wave

: 10 kA (heavy duty)

Maximum front of wave impulse Spark-over voltage.

: Not more than 44 KVP

Front steepness for front of wave impulsespark over voltage

: 87 kV/Micro sec.

Maximum residual voltage at ratednominal discharge current.

: Not more than 38 kV

Pressure relief class : Class A Impulse current withstand a) High current low duration test value (4x 10) m seconds wave

: 100 kA peak

b)Low current, long duration test value

: Not < 150A peak

c) Virtual duration of rectangular wave : 2000 Micro sec. One minute power frequency withstand voltage of arrester insulation a) Dry : 29 kV RMS b) Wet : 29 kV RMS A) Constructional features

i)The arresters shall be suitable for mounting on outdoor structures.

ii)The arrester shall adequate thermal discharge capacity for switching surges, long duration surges and multiple strokes. The arrester shall be capable of withstanding internal pressures developed due to the above discharges without operation of pressure relief vents.

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iii)The arrester shall be provided with pressure relief devices, which will prevent shattering of porcelain in case of excessive gas pressure build up.

iv)The insulator housing of the arrester shall be of porcelain with high mechanical strength and rigidity suitable for operation under site conditions listed in design criteria.

v)All metal shall be non-rusting and non-corroding metal. Bolts, screws etc., shall be provided with lock washers.

vi)Arresters shall be capable of spark over on frequent switching surges.

05.03 FOUR POLE STRUCTURE

FOUR pole structure with bracing’s and cross arms for supporting installing the pin and / or strain insulators shall be designed as per the following specification.

i) Each pole shall be heavy-duty rail (IRS-HSB) of length 9 metres minimum, having a unit weight of 52 kg/ metre.

ii) The Four Pole structure shall be designed suitable for receiving / terminating 11 kV overhead conductors or Cables of Haryana SEB.

The structure shall designed for mounting one lightning arrester per phase at incoming as well as two outgoing feeders and Two triple pole Air-break disconnecting switches. Further this FP structure shall be provided with extra cross arm(s) arrangement to erect / install HT XLPE Aluminum cables with outdoor termination. It shall facilitate termination of each core of the HT cable directly without any further links. The arrangement of all the components on this FPS shall be furnished along with the offer separate double channel (ISMC-100) cross arms shall be provided for installing sets of lighting arresters and two 3 pole Air Break switch with bus.

iii) Earth shall be excavated to make pits size 1M X 1M X 2.5M (depth) for each pole of the Four pole structure. The rail pole shall be placed over a small (50-100 mm thick) padding of concrete in perfectly vertical position and then the entire pit shall be concreted & compacted using a concrete mix of '1 cement: 3 coarse sand: 6, graded stone aggregate" including curing thereafter Compacting the soil around, using boulders / earth shall be carried out if required at no extra cost.

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iv) The FP structure shall be complete with bracing’s (ISA 50 x 50 6), channels ISMC-100 as cross arms for pin insulators and additionally double channel (ISMC-100) cross arms for tension / strain insulators, bus and connection conductors (DOG) wherever applicable.

v) Each rail pole of the FPS shall be provided with anti-climbing devices.

vi) Each FP structure shall be earthed as per the rules of IE / DDMS (E)

vii) Danger boards (Normal) indicating the voltage and in three languages (English, Hindi & Local language ) shall be provided for each FP structure.

viii) Manual operating mechanisms for each Load break Isolator with provisions for pad locking.

ix) HRC fuses, insulators, contacts, connectors for Cables and conductors etc. mounted on the structure

A) STAYS

i) Number of stays shall be designed as per the layout, site conditions and static & dynamic forces that arise due to severe stormy / cyclonic conditions. Where required 4 nos. of stays per FP structure shall be supplied / provided.

ii) Each stay set shall be galvanized complete with 25 mm diameter x

1.85 meter long stay rod, anchor plate of size 300 x 300 x 10 mm thimble, stay clamps, bow tightener, 7 x 4.0 mm diameter GI wire, strain insulators etc. If required, size of gay wire & accessories shall be increased.

iii) The stay wire shall usually make an angle of 30 degrees to 45

degrees with the vertical depending upon the alignment of the line.

iv) Pits of size 1M x 2.5M(depth) shall be excavated for placement of anchor plate and the pit shall be concreted & compacted using a concrete mix of "1 cement : 3 coarse and : 6 graded stone aggregate", including curing thereafter. Compacting the soil around using boulders / earth shall be carried out if required at no extra cost. Estimated Quantity of concrete per pole is 1.5 M3 & per tray 1 M3

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v) GI stranded wires shall comply with the specific requirements of IS 2141-1979, IS 4826-1979 & IS 6594 -1974.

05.04 DISTRIBUTION TRANSFORMERS

a)A - GENERAL

Instruments

Dial type Oil Level Gauge with Alarm Contacts. Dial Type Oil and winding Temperature Gauges With Indication/ Trip

Contacts.

Outdoor Installation 3 Phase Core Type Generally as per IS 2026 Parts 1, 2 & 4: 1997; Part 3:1981

Rated Output, Voltage Ratio 500KVA , 11KV/0.433KV Rated Frequency 50 Hz Insulation level Shall be designed according to following

Voltages Nominal System Voltage 11 kV Unearthed System Maximum System Voltage 12 kV One Minute Power Frequency with Stand Voltage (kV)

28 kV

Peak Impulse Test with Stand Voltage (kV) 75 kV Clearance in Air (mm) As per relevant IS Short circuit Level 500 MVA Short Circuit Withstand Time 3 Seconds Type Cooling Natural (ONAN) Oil Natural Air Natural Winding Connection Delta Star Vector Group Dyn11 Tap Changer Off Load 10% in 5 steps of 2.5% each Neutral Grounding Solidly Earthed Accessories As per IS 2026 Protections Over Current / Earth Fault / Gas Pressure

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Transformers shall be capable of delivering rated current at an applied

voltage upto 105% of the rated voltage without exceeding the

temperature limits.

Overload capacity as per IS 6600-1972 unless otherwise specified. Shall be operable at its rated capacity at any voltage within +/-10% of

rated voltage of the particular tap. Permissible maximum temperature at rated output & principal tap:

a) Two Oil (By Thermometer) : 85 Degrees C

b) Windings (By Resistance Method) : 95 Degrees C

c) Maximum hot Spot Temp. : 105 Degrees C

Transformers shall be designed to withstand the thermal and dynamic

stresses due to short circuits at its terminals. Unless otherwise specified the duration of short circuit shall be 3 seconds. The maximum temperature at the end of the specified duration shall not be more than 250 degrees C with the temperature prior to short circuit corresponding to maximum permissible overload. Transformers shall be capable of withstanding thermal and mechanical stresses during 3 phase, line to line, double line to earth and line to ground dead short circuits at the transformer terminals, for the period specified, without any injury. Temperature of the windings prior to the short circuit shall be considered as maximum permissible value in the normal operation. For this purpose, infinite supply system and solidly earthed systems shall be considered.

Transformers shall be designed for suppression of harmonics

especially 3rd & 5th. Off circuit tap switch, terminal bushings, other auxiliary components / equipment shall be designed for maximum permissible overloading. Short time over loading to the extent of 50% shall be considered for this purpose, for all transformers, unless specified otherwise. Hot spot temp specified in the data sheet shall be based on design ambient temp.

As an information, it is to be noted that the distribution transformers

will be supplying general purpose loads including lighting and VFD / soft starter supplied Pump Motors.

Insulation

Inter-turn and inter coil insulation shall be designed such that dielectric stress is uniformly distributed throughout the windings under all operating conditions.

Earthing

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All metal parts of the transformer with the exception of

individual core laminations core bolts, and clamping plates shall be maintained at fixed potential by earthing.

Two tinned copper earthing terminals.

One end of bushing CTs shall be earthed.

Vibration and noise level

Design and manufacture of transformer shall be such as to reduce

noise and vibration level. The noise level shall not be more than 5 dB above NEMA standard publication TR-1 or as specified.

Off-Circuit tap Switch

Tappings as specified shall be provided on the higher voltage winding

of transformer and shall be arranged so as to maintain as far as possible electromagnetic balance of the windings.

Externally hand operated.

- Designed for sustained over current of at least 150% of the

rated current winding

- Shall not occupy any intermediate position between clearly marked tap position.

Capable of repeated operation and withstanding short circuit forces. Integral handle with pad locking facility at every tap position.

Tap position indicator Inspection and I or repair shall not require removal of transformer

from tank nor major draining

Windings Windings shall be suitable for isolated/non effectively earthed

neutral system as specified.

Material shall be electrolytic grade copper. Shall be subjected to shrinkage treatment.

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Completed core and winding to be vacuum dried in full vacuum and

impregnated immediately.

Shall be braced to withstand shocks due to rough handling and

forces due to short circuit.

Permanent current carrying joints in winding & leads shall be brazed.

Coils shall be supported using dried and high pressure compressed

wedge insulation spacers.

Insulating materials shall be compatible with transformer liquid

under all service conditions.

Leads to the terminal board and bushings shall be rigidly supported.

Oil tight welds and joints Fully assembled transformer with its radiators, conservator and other

fittings shall withstand for one hour a pressure corresponding to twice the normal head of liquid or the normal pressure plus 35 kg I sq. m whichever is higher, measured at the base of the tank.

Plates shall be protected internally against corrosion due to insulating

liquid. Provided with inspection opening & cover with handling equipment

to provide access to bushing connections for inspection &

maintenance of tap changer.

Form of cover shall be such as to prevent any stagnant water deposit and to drain gas bubbles towards the buch-holz relay.

Tank (with radiators when welded to tank) shall be capable of

withstanding 250 mm of mercury p.a. vacuum.

DP Test I Radiography test shall be carried out for welded portion.

Lifting and haulage facilities Lifting lugs shall be suitable for lifting the transformer with oil.

Minimum of 4 jacking lugs, in accessible positions shall be provided to raise or lower the complete transformer with oil using hydraulic or screw jacks. Minimum height of the lugs above base shall be 300 mm

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excluding under base dimensions if detachable for transformers upto 10 t weight and 500 mm for transformers above 10 t. Transformer shall be provided with detachable, bi-directional flanged wheels or rollers as specified. Means shall be provided for locking the 90 degrees swivel movements in positions parallel to & at right angles to the longitudinal axis of the tank.

Cooling

The cooling system provided shall be ONAN -Oil Natural, Air Natural.

-Radiators Radiators may be detachable type directly mounted or separately

mounted. Bolted, gasketed and flanged connections shall be used for connecting the radiators to the Tank. The following accessories shall be provided for each radiator I radiator bank:

a) Top and bottom shut off valves and blanking plates.

b) Bottom drain plug and top filling plug, air release plug.

c) Lifting lugs.

d) Thermometer pockets with thermometers in the inlet and

outlet pipes (for separately mounted radiator banks).

Tank

- Shall be designed so as to allow the complete transformer

filled with oil, to be lifted by cranes/jacks, transported by road, rail or water without over straining any joints & without causing subsequent leakage of oil.

- The base of each tank shall be so designed that it shall be

possible to move the complete transformer unit by skidding in any direction without injury when using plates or rails.

- Tank cover shall be of adequate strength & shall not distort

when lifted. Inspection openings shall be provided as necessary to give easy access to bushings, testing earthing connection without removing tank cover.

- Tank covers shall have pockets for bulbs of oil and winding

temperature indicators. Wherever specified, thermometer pockets shall have captive screwed top to prevent ingress of water. The pockets shall be located in the position of maximum oil temperature and it shall be possible to remove the instrument bulbs without lowering the oil in the tank.

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- Welded thick gauge high quality low carbon steel plates

stiffened & reinforced to withstand without deformation all stresses applied during transport and operation or short circuit conditions.

- Inside tank will be painted with oil resistant paint. Bushings

Electrical characteristics of bushings shall be in accordance with

IS3347 and IS-2099. Minimum rated current of the line end bushing shall be 1.5 times the current of the corresponding winding. Where repeated peak loads are specified, bushing rating shall be selected accordingly.

- Oil communicating type bushings shall be used for voltage

ratings up to 36 kV. Oil used in bushings shall conform to IS335.

- Oil gauge shall be provided when oil in bushings is not in

communication with that in the transformer. - Clamps and fittings made of steel or malleable iron shall be hot

dip galvanized. Bushings rated more than 400A shall have nonmagnetic clamps and fittings only.

- When bushing CTs are specified, the bushing shall be so

arranged that it can be removed without disturbing the current transformers, secondary terminals and connections or pipe work.

- Clearances in air between live conductive parts and live

conductive part to earthed structure shall be as follows:

- For altitude exceeding l000m above sea level, the clearance should be increased by 3% for every additional 300m.

Terminations

HV Side

Cable box

Nominal System Voltage kV (rms)

Impulse Test Voltage kV (Peak)

Phase to Phase Clearance mm

Clearance Phase to earth mm

11 75 As per IS 2026

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The cable box shall be air-insulated type suitable for the

type and number of cables specified (max size 1 No. 3C x

185 sq. mm XLPE cable). The size of cable box shall meet

the minimum dimensional requirement of cable termination.

Cable termination kits, Double Compression type brass cable

glands and tinned copper lugs shall be supplied. Cable

boxes shall be air-insulated type with clearances as

specified. Also air insulated disconnecting chamber shall be

provided with inspection opening. Transformer may thus be

withdrawn from its pen without disturbing cable connection.

The gland plate shall be bolted type & shall be sufficiently

big to remove trifurcated cable from the cable box, without

damaging the terminations.

Cable sealing kits of specified type along with associated

accessories like stress relieving cones, insulating tapes,

trifurcating boot, HT insulating paste etc., shall be supplied

along with transformer.

It shall be possible to withdraw the transformer easily

after disconnecting the connections without disturbing

the cable terminations.

For cable termination:

- Air insulated cable box suitable for the type & number

of cables specified. - Air insulated disconnection chamber with inspection

opening.

- Compression type brass cable glands with tinned

copper lugs.

- Bolted type gland plates.

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- Sealing kits with associated like stress relieving cones. - Insulating tape, trifurcating boot, HT insulating tape,

etc. LV SIDE - Suitable LV Cable box The cable box shall be air-insulated type suitable for the type

and number of cables specified. The size of cable box shall meet the minimum dimensional requirement of cable termination. Double compression type brass cable glands and tinned copper lugs shall be supplied. Cable boxes shall be air-insulated type with clearances as specified. Also air insulated disconnecting chamber shall be provided with inspection opening. Transformer may thus be withdrawn from its pen without disturbing connection.

For all the terminals, the LV side— Neutral bushing I BD

connecting box shall have provisions for mounting 2 sets of Current transformers of specified rating for REF protection and backup EF protection. Sizing shall take into account all the statutory air clearances required.

Conservator and Breather

- Conservator shall be located in such a position as not

to obstruct the electrical connections to the transformer. The conservator volume shall be sufficient to maintain the oil level between minimum and maximum levels, from ambient temperature of 5 degrees centigrade to oil temperature of 90 degrees centigrade

- Conservator mounted on frame, integral with tank in such a manner that under all conditions and the lowest oil level the bushings remain under the head of liquid.

- Oil filling hole with cap, a drain valve to drain the oil

completely shall be provided. One end of conservator shall be bolted into position so that it can be removed for cleaning purposes. If the sump is formed, by extending the feed pipe into the conservator vessel the extension shall be for at least 25 mm.

- Silica gel breather with inspection window and oil seal

shall be mounted at 1.4 m from ground level and connected to conservator.

- Prismatic type oil-level gauge with maximum and

minimum levels marked. Tap and valves shall not be fitted to oil gauge. 150 mm, diameter dial-type

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magnetic level gauge with alarm and trip contacts shall also be provided.

Marshalling Box

- Sheet steel of 3 mm thick/cast aluminium enclosed,

transformer mounted, outdoor weather proof marshalling box conforming to IP55 enclosure shall be provided for auxiliary equipment of the transformer.

- Marshalling box shall accommodate control and

protection equipment of transformer, temperature indicators, bushing CT secondary terminals, terminal blocks, etc.

- All outgoing connections from the transformer i.e.

buch-holz relay, temperature indicators, level indicators, CT secondaries, fault contacts for annunciations shall be wired to the marshalling box.

- Mechanical indications, temperature indicators, brass

glands for terminating cables etc., shall be provided in each box. All auxiliary equipment, protection and signalling contacts shall be wired, to these transformer mounted cabinets.

Valves and connections

- AII valves shall be of gun metal/cast steel, full way

type with internal screw and shall be opened turning counter clockwise when facing the hand wheel.

- All valves opening to atmosphere shall be fitted with

blank flanges. - Oil sampling valves shall be provided at top and

bottom of the main tank and these shaII not be

fitted on the filter valves.

- All transformers shall have bottom drain valve, top

and bottom filter valves suitable for connecting to oil

filtration unit.

- Valves of sluice type with hand wheels. - Clear indication of open and closed position. - Provided with blanking plates or screwed plugs. - Padlocking facility to lock in closed I open position.

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Buchholz relay

- The transformer shall be provided with double float buchholz relay fitted in the pipe connecting the tank and the conservator. Pipe shall be 25mm diameter. Pipe shall be arranged at a rising angle of 3 to 9 degrees to the horizontal, up to the buch-holz relay. Valves shall be provided on either side of relay after providing necessary length of straight pipes. The relay shall have petcocks at the top and bottom, drain plug, inspection windows, calibrated scale to indicate gas present, built in test facility and terminal box with oil tight brass gland. The relay shall have electrically separate potential free self-reset contacts for alarm and trip. Contacts shall be rated to make carry & break 0.5 Amperes at 220 V DC. The contacts shall be wired to marshalling box. Oil and Gas actuated relay shall conform to IS 3637.

Thermometers

- 150 mm dial-type top oil thermometer and winding

temperature

indicator for the LV windings shall be provided for transformer.

- Each Thermometer shall have potential free N.O. alarm

contact and trip contact. No multiplying contactor / relay shall be used. Temperature setting of each contact shall be independently adjustable at site. A manual reset type maximum temperature indicator shall be provided for each thermometer. Each winding temp indicator shall have temperature-sensing element, image coil and bushing mounted auxiliary current transformer, lamp calibration device. The temperature sensing element mounted in a pocket of oil shall be connected to the indicator through capillary tubing.

- Each thermometer shall be provided with remote

temperature indicator with resistance type temperature detector, along with associated accessories.

- All contacts shall be rated to make 0.5A(min) and break

0.2 A (min) at 220 V DC. All contacts shall be wired to marshalling box.

Fittings and Accessories

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Transformer shall be provided with fittings and accessories as specified in the data sheet.

05.04.01 Tests for Transformers All the transformers shall be subjected to the routine tests as

per IS 2026 at manufacturer’s works. Type test certificates for similar design has to be submitted for approval. Test procedures as specified in IS-2026 shall be adopted.

05.04.02 Spares Itemised unit prices for the following spares shall be indicated

in the offer. Recornmended quantities for two years of operation shall also be indicated in the offer.

1. 1 Set of Gaskets 2. Bushings

- One HV Bushing - One LV Bushing - One LV Neutral Bushing

3. Oil Temperature Thermometer with Accessories 4. Breather 5. Explosion Vent Diaphragm 6. One Set of Bushing CTs.

05.04.03 Transformers Data Sheet

Specification : IS 2026-Part 1, 2 &4-1977, Part 3-1981

Type : Out door use, mineral oil immersed, natural cooling type. Air natural cooled

Voltage : Primary – 11 kV / Secondary 433 V

Frequency : 50 Hz

Number of Phases : 3

Continuous Rating : As per BOQ

Insulation Class : Class A

Cooling : ONAN

Winding Connection : Delta / Star

Vector Group : Dyn 11

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Neutral Grounding : HV Non Effectively earthed LV – Solidly grounded

Percentage impedance : 5.00%

Termination : Primary – HT Cable from VCB. Secondary – LT Cables (Multiple runs).

Neutral Bushing Mounted 5P 20 Class & Class - PS CTs for E/F Protection

: 400/1 & 800/1

WTI CT : 1 No

Losses: 500 KVA a. No Load Loss (W) 950 W b. Full Load Loss ( KW at 750 C) 9.0 KW

05.04.04 List of fittings and accessories - Name Plate

- First fill of oil as per IS 335 - 1983 with 10% excess in drums.

- Cooling system complete with accessories as specified.

- Conservator.

- Dehydrating breather.

- Buch-holz relay. - Oil filter valves at top and bottom of tank.

- Drain off valve at lowest location to allow complete

draining.

- Oil sampling device at top and bottom.

- Explosion vent with double diaphragm.

- Pockets with thermometers for oil temperature and

winding temperature indicators.

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- Dial type magnetic level gauge with alarm and trip

contacts.

- Bushing CTs. - Dial type oil and winding temperature indication

and alarm and trip contacts.

- Lifting lugs and jacking pads.

- Rating and diaphragm plates.

- Air Release plug

- Earthing terminals.

- Pressure relief valve

- Inspection Cover.

- Bidirection Roller

- FIat base and foundation bolts. - Emergency Push button Station in sheet steel enclosure

for tripping the VCB and indirectly disconnecting the Transformer from H.T. supply.

05.04.05 PREFERRED MAKES OF EQUIPMENT

Makes of the equipment offered shall be generally limited to the following only. However, while offering the make shall be selected justifying the quality and economy. Technical literature and publications of items to be offered by the tenderer shall be enclosed with their quotation. Makes of all the equipment and accessories must be clearly mentioned against each item. In case rating, type, make and other details of all these

items are not mentioned by the tenderer, their quotation is

likely to be treated as incomplete.

The purchaser reserves the right, to select an item of any make, based on Standardization needs, in case he has not indicated make specifically or has indicated more than one make.

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The tenderer shall ensure that equipment and components are from indigenous sources to the maximum possible. Imported equipment/components shall be resorted to only in case of Non availability of equipment/ component from Indigenous sources and with prior approval of owner/Consultant.

1.OTI / WTI : Sukurt I Precise 2.MOG : Sukurt I Precise 3.Bushings : CJI I LC I Western 4.Transformer Oil : Apar I Savita 5.CTs : Precise I Pragati I Gilbert

05.04.06 APPLICABLE CODES & STANDARDS

All applicable Indian and lEC codes, regulations and standards shall govern the work hereunder. In the event of the requirements of the specification, exceed the requirements of the, corresponding codes, regulations or standards, the specification shall govern. Where there are more than one applicable codes or standards for any item, the most stringent will apply. All parts issued against a standard/code shall be referred to wherever specific Part No is or not given. Equipment covered by this specification shall conform to the latest editions and revisions of all relevant applicable codes, and standards in addition to the ones listed below: Latest revision of all applicable codes, regulations and standards shall govern the design, manufacture, installation, testing & commissioning of individual equipment and total installation even when the requirement of the specification is less stringent than the codes, regulations & standards. In the event of conflict between specification & codes, the most stringent shall govern. In the event of conflict between codes, regulations and

standards referred to in the specification, the

owner’s/consultant’s decision is final and binding.

Wherever IS are not available, relevant lEC standards are to be

followed: Equipment covered by this specification shall conform to the latest

editions and revisions of all relevant applicable codes, and

standards in addition to the ones listed below:

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It may Please, be noted that the above list is not exhaustive.

1. IS2026-1977 Parts 1,2 & 4 1977 reaffirmed in 2001 Part - 3 1981, reaffirmed in 2001

: Power Transformers.

2. IS 2032 : Graphical Symbols used in electrical technology.

3. IS 2099 – 1966 : Bushing for alternating voltage above 1000V

4. IS 3156-1 992 Parts 1 to 4

Voltage transformers.

5. IS 3639-1966 Re-affirmed 1991

Fittings and accessories for Power transformers

6. IS 3722-1983 Re-affirmed 1991

Letter symbols and signs used in electrical technology

7. IS 5571—1979 Re-affirmed 1991

Guide for Selection of electrical equipment for hazardous area.

8. IS 6600-1972 Re-affirmed 1991

Guide for loading of oil immersed transformers.

9. IS 6792-1992 Method of determination of Electrical strength of insulating oils

10. IS 7689—1989 Guide for control of undesirable static electricity.

11. IS 8603 Parts 1 to 3 - 1977 Re-affirmed 1991

Dimensions for porcelain transformer bushings for use in heavily polluted atmosphere

12. IS 8923 – 1978 Re-affirmed 1997

Working symbols for dangerous voltages.

13. IS 9676-1980 : Re-affirmed 1987

Reference ambient temperature for electrical equipment.

14. CBIP — Sec A Manual on Transformers— General 15. CBIP — Sec B Manual on Transformers—

Specification for Distribution transformer

05.05 D.C. BATTERY (LOCATION- INDOOR) 05.05.01 TECHNICAL SPECIFICATION

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1.

Rated voltage : 110 V DC

2.

Type of cell : Stationary lead acid cell maintenance free type (SMF).

∗3.

No. of cells/Battery : 10 of 12V nominal battery voltage

4.

AH capacity : 200 AH at 10 hour discharge rate at 27°C to final voltage of 1.85V per cell of 200 AH, 110 V.

5.

Type of container : Hard rubber/plastic conforming to IS : 1146 –

1981.

6.

Nominal voltage per cell : 2.0 V

7.

Voltage at the end of 10 hour discharge : 1.85 V per cell.

∗8.

Quick/boost charging voltage : 2.55 to 2.70 V per cell

∗9.

Trickle charging voltage : 2.55 to 2.18 V per cell

10.

Boost charging rate for fully charging the battery from 1.85 V PC for 8 hour charging

25A/12A-Start/finish

11.

Mounting arrangement : Double row, Single tier

12. Applicable standard : IS 1651 – 1991 13.

Accessories

∗ Manufacturer’s recommendation to be met by the tenderer

05.05.02 The purpose of Battery & Charger is to provide reliable and uninterrupted D.C. control supply for 11 kV / 3.3 KV VC breakers. Control supply power requirement, drive motors of operating mechanism, spring charging mechanism for VC breakers, and Protection relay. Further, quality of control supply shall be maintained within specified limits under all operating conditions

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05.05.03 The system comprises 1set of DC Battery, 1 set of automatic float (trickle) cum boost chargers with associated protection, control and annunciation equipment and D.C. distribution board.

. 05.05.04The battery shall be suitable for frequent charging and discharging

without affecting the life of cells, materially. The battery shall be suitable for two rate automatic charging. Under emergency requirements, it shall be possible to charge the battery at higher charging currents. The battery shall be suitable for continuous trickle charging.

05.05.05The battery shall comprise station class, lead acid cells with

tubular +ve plates in hard rubber container conforming to IS : 1651-1991. AH capacity and number of cells shall be as specified in design criteria. AH capacity shall correspond to 10-hour discharge rate to final voltage of 1.85 VPC at 27°C.

05.05.06The battery shall be suitable for two-rate automatic charging

with constant current controller and constant potential controller. It shall also be suitable for manual charging. In case of emergency, it shall be permissible to charge the battery at a current rate more than two rate charging.

05.05.07 TESTS

Type tests – Test reports of all the type tests as per relevant IS on identical units shall be furnished along with the tender. All materials and each part of the apparatus shall be subjected to routine tests as per the accepted standards.

05.05.08 At works.

Visual inspection Dimensional test

Checking of terminal markings. Air pressure test One of the cells of same type shall be tested for capacity.

05.06 D.C. BATTERY CHARGER (LOCATION- INDOOR)

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05.06.01 TECHNICAL SPECIFICATION Charger shall be rated to supply total DC load The same charger shall be suitably rated to fully charge the battery to full capacity, from fully discharged condition with final voltage of 1.85V PC, within 8 hours. Charger rating shall also satisfy the requirement that the discharged battery can be charged to full capacity within 4 hours. The minimum rating of charger in float and boost mode shall be as specified in design criteria. However, tenderer shall calculate the rating of charger to meet the above requirements.

05.06.02 Charger shall be suitable for operation on 415V +/- 10%, 50Hz +/- 5%, Or 240V +/- 10%, 50Hz +/- 5%,3 phase 4 wire, neutral solidly earthed system with max. 3 phase fault level of 40 kA (RMS).

05.06.03 The charger cubicle shall contain transformer, thyristors, control protection, metering, signaling equipment etc.

The charger cubicle shall be sheet steel enclosed, dust and vermin proof, self-standing, floor mounting type with bottom cable entry through removable gland plates. All the equipment shall be so mounted that adequate space is provided for accessibility to each component. All the components shall be accessible on opening front or backside door. Min. thickness of cold rolled sheet steel shall be 2.0 mm and cubicle shall have angle iron frame fabrication. All meters, control switches, indicating lamps. ON/OFF switches, protection relays shall be mounted on the hinged front door. Power transformer chamber shall be fully compartmentalized.

05.06.04 The charger shall be rated for continuous operation in float mode (Trickle mode). The constant potential controller shall maintain output voltage within +1% of set voltage for variation of + or – 10% in input AC voltage and 0 – 100% load variation, and for both occurring simultaneously. The output voltage shall be adjustable from 100 to 130 V, through a continuously adjustable controller. The dial of controller shall be graduated in steps of 5 volts maximum.

The charger shall be rated for continuous operation in boost mode. It shall have constant current controller suitable for two rates charging. Provision shall be made to set the charging current, continuously varying from 5A to 25A. The dial of the controller shall be graduated in steps of 1A (max.).

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The ripple content in the output waveform without battery shall not exceed 0.5% in float mode and 3% in boost mode measured at any voltage and under any load conditions.

It shall have built-in current limiting protection. Each diode, thyristor shall be provided with semi-conducting HRC fuses, selected based on its protection requirement. HRC fuses shall have trip indicator and micro switch contacts of trip indicator shall be wired for annunciation. The charger shall have automatic charge terminating device to terminate the charging as soon as battery is fully charged and the same shall be indicated through alarm.

05.06.05 Instruments, indications and relays

The following shall be provided in charger panel.

A) Indicating instruments

a) AC input voltage and current

b) DC output voltage and current

B) Signal lamps

a) AC supply ON lamps - 3Nos. b) DC supply ON lamp c) Float mode ON lamp d) Boost mode ON lamp

C) Relays

a) AC input supply failure

D) The following faults shall be provided with audiovisual annunciation.

a) AC supply failure

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b) Battery earth fault c) Failure of diodes/thyristers for charger

E) Terminations

All power and control cables shall be terminated using tinned copper lugs of adequate mechanical strength. Compression type brass cable glands shall be supplied for all power and control cable terminations. Gland plate shall be removable type.

F) Fuses

All fuses used for protection of power circuits, voltage circuits shall be link type HRC fuses in insulating base and holder. Power fuses shall have trip indicator with micro switch contacts for annunciation diode thyrister protection fuse shall be semiconductor type with matching protection characteristics. Necessary discrimination shall be considered while selecting fuse ratings.

G) Indicating lamps

All indicating lamps shall be led type with built-in series resistor. All the lamps shall be flush mounting type.

H) Cubicle wiring

All busbars, all connections within the charger shall be carried out with copper busbars/insulated copper conductors. Min. cross section for power wiring shall be 6 sq.mm. copper and 2.5 sq.mm copper for control. All terminations shall be ferruled and numbered in accordance with the schematic diagram.

I) Terminal boards

AC and DC terminals shall be segregated. All power and control terminals shall be stud type. Each terminal shall be numbered as per approved control diagrams.

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I) Inscriptions All components shall be provided with unscription plates asper approved drawings.

05.06.06 Tests

The equipment shall be subjected to routine test as per relevant IS. The chargers shall be subjected to factory tests to verify its rating, ripple factor and control scheme.

06.00 TECHNICAL SPECIFICATIONS OF CABLES ( H.T. / L.T. /

CONTROL / LIGHTING) AND ACCESSORIES

06.01 GENERAL CONSTRUCTION

The cables shall be suitable for laying in trays, trenches, ducts and conduits and for underground buried installation with uncontrolled backfill and possibility of flooding by water and chemicals. Also cables shall be suitable for system particulars, site conditions and environment conditions specified. The conductor shall be stranded and compacted circular / shaped for all cables. Outer sheath of all PVC and XLPE cables shall be black in colour. In addition suitable chemicals shall be added in to the PVC compound of the outer sheath to protect the cable against rodent and termite attack. The outer sheath of PVC and XLPE cables shall possess ST-2 PVC properties meeting requirements as per IS.

Sequential marking of the length of the cable in metres shall be provided on the outer sheath at every one-metre. The embossing shall be legible and indelible. The overall diameter of the cables shall be strictly as per the values indicated in the technical information furnished along with bid subject to a maximum tolerance of ± 2 mm up to overall diameter of 60 mm and + 3 mm for beyond 60 mm.

PVC / Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per thousand metre length. In addition, ends of the cables shall be properly sealed with caps to avoid ingress of water during transportation and storage.

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The vendors shall specifically note that any of the make of cable accessories listed in tender documents will be used for termination or jointing of the cable offered. But for total project only one make of these shall be adopted.

06.02 XLPE CABLES

Power cables for 11kV (UE) / 3.3 kV (UE) shall 3 core, with compact

circular / sector shaped stranded electrical Aluminium conductor, H tamper with extruded conductor shielding of semi-conducting material. XLPE insulated, with insulation shielding over individual cores consisting of extruded semi-conducting compound followed by lapped semi-conducting material and copper tape, cores stranded together with a holding tape provided with a common covering of extruded inner sheath of type ST2 compound, galvanised round steel wire / strip armoured and PVC outer sheath of type ST2 compound system as per IS: 7098 (Pt-II)-1973 as amended upto date suitable for unearthed system and as detailed below. 11kV (UE) Cables shall be used at Bahadurgarh terminal and 6.6kV (UE) at all other terminals as per the drgs shall be provided.

All cables rated 3.3 kV and above shall be provided with both conductor screening and insulation screening. The conductor shall be provided with non-metallic extruded semiconductor screen. The core insulation shall be with cross-linked polyethylene insulating compound dry cured applied by extrusion. It shall be free from voids and shall withstand all mechanical and thermal stresses under steady state and transient operating conditions. It shall conform to property given in table-1 of IS: 7098 (Part-II). The insulation screen shall consist of non-metallic extruded semi-conducting compound with a non-magnetic metallic screening of copper.

The copper screen for all the three cores together shall be capable of carrying the single line to ground fault current for the duration specified in the design criteria. Vendor shall furnish calculation in support of selection of the size of copper screen along with bid.

The conductor screen, XLPE insulation and insulation screen shall all be extruded in one operation by ‘Triple Extrusion’ process to ensure perfect bonding between the layers. The core identification shall be coloured strip or by printed numerals.

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The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the requirements of type ST2 compound of IS: 5831. The extruded inner sheath shall be of uniform thickness. For multicore cables, the armouring shall be by galvanised steel wires as per method (b) of IS: 7098 (part-II). The outer sheath shall be applied by extrusion of over armouring and shall be of PVC compound conforming to the requirement of Type ST2 compound of IS: 5831. The thickness of outer sheath shall be as per IS: 7098 (Part-II). for armoured and unarmoured cables. The dimensions of the insulation, inner sheath and armour materials shall be governed by values given in IS : 7098 (Part-II).

06.03 PVC CABLES

All Power / Control cables for use on medium voltage systems shall be heavy duty type, 1100 V grade with 3 1/2, 4 core electrical purity aluminium conductor (for power cables) / electrolytic grade high conductivity annealed copper conductor (for control cables), PVC insulated, PVC extruded inner sheathed, armoured and overall PVC sheathed suitable for 415 V neutral solidly earthed system and as detailed below. The conductors shall be solid for conductor of nominal area upto and including 6 mm2 and stranded beyond 6mm2. Conductors of nominal area less than 25 mm2 shall be circular only. Conductors of nominal area 25 mm2 and above may be circular or shaped. Cables with reduced neutral conductor shall have sizes as per Table 1 of IS: 1554 (Part-I). circular solid or stranded copper conductor with a minimum size of 2.5sq.mm The core insulation shall be with PVC compound applied over the conductor by extrusion and shall conform to the requirements of type ‘C’ compound as per IS: 5831. The thickness of insulation and the tolerance on thickness of insulation shall be as per Table-2 of IS: 1554 Part-I. Control cables having 6 cores and above shall be identified with prominent and indelible Arabic numerals on the outer surface of the insulation. Colours of the numerals shall be contrast with the colour of insulation with a spacing of maximum 50 mm between two consecutive numbers. Colour coding for cables upto 5 cores shall be as per Indian standards. The PVC insulation used shall be suitable for

continuous conductor temperature of 85oC.

The inner sheath shall be applied over the laid up cores by extrusion and shall be of PVC conforming to the requirements of Type-ST2 PVC

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compounds as per IS: 5831. The minimum thickness of inner sheath shall be as per IS: 1554 Part-I.

Armouring for multicore cables shall be single round galvanised steel wires where the calculated diameter below armouring does not exceed 13 mm and by galvanised steel strips where this dimension is greater than 13 mm. Requirement and methods of test for armour material and uniformity of galvanisation shall be as per IS : 3975 and IS : 10810 (Part-41). All Cables shall have round wire GI armour only.

The dimensions of armour shall be as per method (b) of IS: 1554 Part-I. Armouring for single core cable shall be with H4 grade hard drawn aluminium round wire of 2.5 mm diameter. The outer sheath for the cables shall be applied by extrusion and shall be with Type – ST2 PVC compound as per IS : 5831.

The minimum thickness of outer sheath shall be as per IS : 1554 Part-I for both armoured and unarmoured cables. It shall be possible to continuously operate the cable at a maximum conductor temperature of 850 C. The insulation of phase conductors shall be coloured red, yellow and blue and the neutral black. 1.1 kV grade control cables shall be of circular solid / stranded electrolytic grade high conductivity annealed copper conductor with a minimum size of 2.5sq.mm, PVC insulated, Round wire armoured and PVC overall sheathed.

All cores of control cables shall be continuously identified by tracer numbers i.e. tracer numbers either embossed or printed continuously on each individual core.

06.04 FLAME RETARDANT LOW SMOKE (FRLS)

These shall be as per specification mentioned above but with protective system of inner and outer sheath specially designed with thermoplastic or thermosetting materials, superior resistance to ignition and flame propagation with smoke emission and toxicity or corrosive characteristics.

06.05 CABLES / WIRES FOR ILLUMINATION WORKS FOR FIXED WIRING :

i) Type I : Single core 650 V / 1100 grade Cables With

Copper conductor, PVC insulated and

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Unsheathed. Minimum 1.5 Sq. MM Size. ii) Type II : Single core 650 V / 1100 V grade cables with copper conductor, PVC insulated and PVC sheathed. iii) Type III: Circular multicore 650 V / 1100 V grade cables with copper conductor, PVC insulated and PVC sheathed.

iv) Type IV: Same as Type I above but having aluminum conductor. Minimum

4 Sq. mm Size

v) Type V : Same as type II above but having aluminium conductor.

FLEXIBLE CORD :

i) Type I: Single core 650 V / 1100 V grade

cables with copper conductor, PVC insulated and unsheathed. Minimum 1.5 Sq. Mm size

ii) Type II : Single core 650 V / 1100 V grade

cables with copper conductor, PVC insulated and PVC sheathed.

iii) Type III: Two core twisted, 650 V / 1100 V grade cables with copper conductor, PVC insulated and unsheathed.

iv) Type IV: Circular, Multicore, 650 V / 1100 V grade with copper conductor, PVC insulated and PVC sheathed.

CONDUCTOR

Conductor shall be composed of plain annealed high conductivity copper wires or aluminium wires. Wires up to 1.5.mm2 shall be either solid or stranded in case of copper conductor and solid in case of aluminium conductor. Wires above 1.5 Sq. mm shall have stranded conductors. Conductors having cross sectional area up to 25 mm2 shall be circular and above 25 mm2 may be circular or shaped.

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INSULATION

The insulation shall consist of an extruded layer of suitably compounded high quality PVC. The insulation shall be so applied that it fits closely on the conductor and it shall be easily removable without damage to the conductor.

CORE IDENTIFICATION

The individual cores of single core and multi-core cables shall be identified by different colour of PVC insulation as indicated below: Cables for fixed wiring

Flexible cords

1. Core: Red, Black, Yellow, blue, white or gray

Red, Black, Yellow, blue, white or gray

2. Cores: Red & Black

Red & Black

3. Cores: Red, Yellow & Blue

Red, Black & Yellow / Green

4. Cores: Red, Yellow, Blue & Black

Red, Yellow, Blue & Yellow / Green

SHEATHING

i) Sheathing of black, white or grey shall be applied by extrusion over the insulation in case of single core cables and over the laid up cores in other cases.

ii) The colour of sheath shall be Black, white or grey.

06.06 Cable Accessories

The termination and straight through jointing kits for use on the systems shall be suitable for the type of cables. Heat shrinkable type or cold setting type of kits offered shall be mentioned in the offer clearly. The accessories shall be supplied in kit form. Each component of the kit shall carry the manufacture’s mark of origin. The kit shall include all stress grading, insulation and sealing materials apart from conductor fittings and consumable items. An installation instruction sheet shall also be included in each kit.

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The contents of the accessories kit including all consumable shall be suitable for storage without deterioration at a temperature of 45 0 C, with shelf life extending to more than 5 years.

06.07 TERMINATION KITS

The termination kit shall be suitable for termination of the cables to an indoor switchgear or to a weatherproof cable box of an outdoor mounted transformer. For outdoor terminations, weather shields / sealing ends and any other accessories required shall also form part of the kit. The termination kits shall be one of the makes / types mentioned in the preferred make.

06.07.01 JOINTING KITS

The straight through jointing kits shall be suitable for installation on overhead trays, concrete lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility of flooding by water and chemicals. These shall have protection against any mechanical damage and suitably designed to be protected against rodent and termite attack. The inner sheath similar to that provided for cables shall be provided as part of straight joint. The jointing kits shall be one of the makes / types mentioned in preferred make.

06.08 TESTING AND INSPECTION

06.08.01 CABLES

The cables shall be tested and inspected at the manufacturer’s works. All the materials employed in the manufacture of cable shall be subjected, both before and after manufacture, to examination, testing and approval by Owner. Manufacturer shall furnish all necessary information concerning the supply to Owner’s inspectors. The inspector shall have free access to the manufacturer’s works for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject any material which appears to him to be of unsuitable description or unsatisfactory quality. The vendor shall give at least 4 weeks advance notice to the purchaser, regarding the date of testing to enable him or his representative to witness the test. After completion of manufacture of cables and prior to dispatch, the cables shall be subjected to type, routine, acceptance and special tests as detailed below. Owner reserves the right to witness all tests with sufficient advance notice from Vendor.

The test reports for all cables shall be got approved from the Engineer before dispatch of the cables.

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All routine tests, acceptance tests, type tests and additional tests for improved performance shall be carried out on cables as listed in IS: 1554 Part- I and IS: 7098 Part- II.

The inner and outer sheath of XLPE cables shall be subjected to all

the tests applicable for PVC cables. The test requirements for insulation and sheath of PVC cables shall be as per latest revision of IS: 5831. Acceptance tests as per IS:1554 (part-I) and IS:7098 (part-II) and the following special testes to be performed on the cables as per sampling plan. These tests are required to be witnessed by owner before dispatch of cables. Accelerated water absorption test for insulation as per NEMA-WC-5 (for PVC insulated cables) and as per NEMA-WC-7 (for XLPE insulated cables). Sampling for this test to be done randomly once for each order, provided the type of insulation remains same.

A) Dielectric Retention test

The dielectric strength of cable insulation tested in accordance with NEMA-WC-5 at 75 ± 10 C shall not be less than 50 % of the original dielectric strength (for PVC insulated cables). Test certificates with respect to this test (not older than one year) from recognised testing laboratory to be furnished for review by Owner before dispatch clearance of cables. In case test certificates are not available, test to be conducted by vendor at his own cost at any recognised testing laboratory or in house testing laboratory, before dispatch clearance of cables. Sampling for this test is to be done randomly and once for each size per order.

B) Flammability test.

The test shall be carried out on finished cable as per IS:10810 and same shall meet following :

The cable meets the requirement if there are no visible damages on the test specimen within 300 mm from it’s upper end. Sampling for these tests to be done randomly once for each order, provided the type of outer sheath remains same. Test for rodent and termite repulsion property. The Vendors shall furnish the test details to analyse the property by chemical method. Sampling to be done for every offered lot/size as per sampling plan. All Routine tests & acceptance tests as per relevant IS shall be carried out on every cable size in presence of purchaser or his representative.

The following minimum tests shall be carried out on all types of cables:

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C) Acceptance test

Annealing test (for copper) Tensile test (for aluminium) Wrapping test (for aluminium) Resistance test Test for thickness of insulation and sheath Partial discharge test for 6.6 kV cables Insulation resistance test High voltage test

D) Routine test

Conductor resistance test Partial discharge test for HT cables. High voltage test Insulation resistance test

06.08.02 Cable Accessories

Type tests shall be carried out to prove the general qualities and design of a given type of termination / jointing system / kits as per IS: 13573. The type test certificates shall be submitted along-with the offer. In case type test certificates are older than 5 years, vendor shall carry out the type at his own cost.

06.09 PACKING AND MARKING

Cables shall be dispatched in non-returnable wooden drums of suitable barrel diameter, securely battened, with the take-off end fully protected against mechanical damage. The wood used for construction of the drum shall be properly seasoned, sound and free from defects. Wood preservatives shall be applied to the entire drum. Ferrous parts used shall be treated with suitable rust preventive finish or coating to avoid rusting during transit or storage. Cable drums shall be suitable for storage in the open yard at site where it will be subjected to rains and other climatic variations. The wooden drums shall not deteriorate and collapse during storage for at least 2 years. On the flange of the drum, necessary information such as project title, manufacturer’s name, type, size, voltage grade of cable, length of cable in metres, drum No., cable code, BIS certification mark, gross weight etc. shall be printed. An arrow shall be painted on the drum with suitable instructions to show the direction of rotation of the drum. HT, LT Power and control cables shall be procured in suitable drum lengths considering actual route length of cables, to avoid straight

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through joints. Maximum tolerance of -5% shall also be considered while specifying drum lengths. Cables shall be supplied in drum lengths as follows , if not specified

• Power cables upto and including 6 sq. mm -1000 m.

• Power cables from 10 sq. mm upto and - 500m.

including 300 sq. mm

• Control cables -1000 m.

H.V Power Cables:

• Up to 3.3 kV (UE) grade, 3 X 120 mm2 -500 m.

• Up to 11 kV (UE) grade, 3 X 185 mm2 -500 m.

A tolerance of plus or minus 5 % shall be permissible for each drum. However overall tolerance on each size of cable shall be limited to ± 2 %. Offers with short / non-standard lengths are liable for rejection. If non-standard drum lengths are specified in the tender documents, the same shall be supplied

06.10 DESIGN CRITERIA

CABLE TYPE ® Sl. No.

PARAMETER HT LT CONTROL

1 System voltage 11 and 3.3 KV for (UE), 3ph., isolated neutral(for Bahadurgarh Terminall

415V, 3ph., solidly earthed neutral

2 Highest system voltage 12KV / 7.2kV 1.1kV 3 System neutral Unearthed Solidly earthed

Fault level Symmetrical RMS 40 kA 105 4 Peak 100 KA kA -

5 Installation Indoor /outdoor (buried directly in ground) laid oncable trays in open air cable channels

Ambient temperature Maximum daily average 6 Design ambient

As per site conditions

7 Ground temperature 35 degrees C 8 Insulation XLPE TYPE-C TYPE-C 9 Conductor material Aluminium Copper 10 Armour Steel Wire armour. Roundwire

armour. 11 Sheath material Extruded inner and outer sheath, type ST2

12 Voltage variation + or -10%

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13 Frequency variation + or – 3% 14 Cable size As specified in BOQ and drgs. 15 Voltage rating of the cable 11kV (UE) / 3.3kV (UE) 1.1 kV 1.1 kV 16 Number of cores 3 core 4 / 3 ½ core Multi-

core

06.11 SELECTION Size and type of cables for specific applications shall be selected

giving due consideration for the following : - The size selection of HV cable shall be done on the basis of system

fault level in addition to current rating of the cable and voltage drop on the cable.

- Thermal heating effect / permissible current carrying capacity - Allowable voltage drop as per Technical specification - Short time current / overload requirement - Protection system grading and short circuit current carrying

capacity - Ambient conditions - Cable grouping factors - Cross-sectional area of the cables used in LT power circuits shall

be - minimum 6 sq mm per core with aluminium conductor or 4 sq

mm per core with copper conductor - Maximum core size shall be 185 sq mm for motors and 240 sq mm

for incomers - For Lighting cabling shall be carried out with PVC insulated, PVC

sheathed 1.1 kV grade armoured cables with copper conductors of minimum size 2.5 sq mm.per core.

- LT cables where laid in ducts / tunnels / basements or taken

through pipes or conduits may be unarmoured type, if indicated in Technical specification.

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- Current carrying capacity of the power cables shall be calculated considering de-rating factor of 0.6.

- All control cables shall have stranded copper

conductors. - For control circuits, PVC insulated and PVC sheathed multi-core

cables with copper conductors having a minimum cross-sectional area of 2.5 sq mm per core shall be used.

- The number of cores may be standardized as 3, 5, 7,10, 14, 19,

24 .Each core of control cable with 7 core and above shall be numbered at every 1 meter intervals.

- In multi-core control cables, the following minimum reserve cores shall be kept at the engineering stage :

* Up to 7 cores - One reserve core * 10 cores - Two reserve cores * 14,19 & 24 cores - Three reserve cores - Sequential length marking shall be provided in outer sheath of all

power and control cables. - Standard drum length for all types of power and control cable shall

be offered. - ISI marking at every meter of cable length shall be provided.

- Cores of multi-core control cables shall be serially numbered.

- The wires shall be suitable for voltage up to and including 1100 V with copper / aluminium conductor (as specified), PVC insulated, PVC sheathed or unsheathed as specified, unarmoured.

07.00 L.T Equipment 07.01 Design Criteria

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Power supply system 1 Voltage 415V +/- 10% 3 phase and neutral 2 Frequency 50 Hz +/- 5% 3 Combined variation +/- 10% of voltage & frequency 4 System Neutral Solidly earthed 5 Insulation level 2.5 kV for 1 minute 6 System S.C. Level 35 / 25 kA for 1 second 7 Control Voltage 110V, 1 phase, 50 Hz AC through control

transformers (minimum 2.5 kVA) 08.01 MLDB AND LDB / SDB / DCDB

• Suitable for 415 / 230V with Aluminum / copper TPN & E busbar. Totally enclosed, non-drawout, front operable

• Enclosure IP: 42. • Incomer chamber housing MCCB / SFU / MCB / ELCB / Contactors/

Busbars, indicating lamps. • Outgoing chambers housing SP/DP/TP/TPN MCB’s /TIMER/SFU • Shrouding of all live parts. • Suitable mounting bracket / pedestal / base frame. • Continuous earth bus with earthing studs, Phase barriers. • Aluminum / copper busbars as per approved SLD. • Neoprene gasket for all door and frame shutters. • Link between neutral and earth. • Hinged door with pad locking arrangement. • Brass cable-glands for all incoming and outgoing feeders. • Double Door construction. • SLD to be pasted inside the door. • Board designation plate to be fixed. • Danger board to be provided. • Inscription plate with inscriptions for all feeders. • The finish paints for the boards shall be indicated during approval of GA

drawing.

Ambient conditions

1 Maximum ambient temperature 45 degrees C

2 Humidity 100% not occurring with maximum temperature

3 Height Less than 1000 M

4 Environment Completely laden with dust & gases

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08.02 FEEDER PILLAR(Deleted)

08.03 MOULDED CASE CIRCUIT BREAKERS

1. Type : Motor/feeder duty as required 2. Reference standard : IS:13947 (Pt-3), 1993, IS:2516 3. Rated current : As per approved SLD 4. Feature required : Adjustable inverse time (O/L)

and/or instantaneous magnetic releases as per approved SLD

Operating handle : Yes Door interlock : Yes Padlocking in ON/OFF : Yes position 5. Withstand capability : Symmetrical breaking

capacity not less than the system short circuit level specified.

6. Auxiliary contacts : 1 NO + 1 NC 7. Performance category : P2 08.04 HRC FUSES 1. Type : Link type 2. Rated Voltage : 500 V AC 3. Rated current : As specified in SLD 4. Operation indicator : Required 08.05 AC CONTACTORS 1. Service : Indoor within steel cubicle for

maximum system voltage, starting of motors and miscellaneous loads.

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2. No. Poles : 3/4 3. Rated Voltage : 415V +/- 10% voltage 4. Rated frequency : 50 Hz +/- 5% 5. Control circuit : 110 V +/- 10% l phase 50 Hz +/-5% derived from 415 / 110 V control transformer 6. Utilisation category : AC2/3 for unidirectional motors AC4 for bi-directional motors 7. Aux. contact requirement : Minimum 2 NO. + 2 NC contacts 8. Limits of operation a. Closing (pick-up) : 85% to 110% b. Dropout : Shall not be higher than 75% and lower than 10% of rated control supply voltage 9. Rating : 16 A or 125% of rated motor current whichever is Higher 08.06 CURRENT TRANSFORMERS 1. Service : Indoor 2. System : 415V, 3 phase, 4 wire, 50 Hz,

Solidly earthed neutral 3. Type : Resin cast encapsulated,

window type, bar primary 4. Rated voltage : 415 V +/- 10% 5. Quantity required : As per requirements of

individual feeders or as mentioned in the specification

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6. Ratio and burden : CT secondary rating shall be 5 A for protection and 1A for metering, Burden 15VA.

7. Accuracy : 5P10 or better for protection

and Class - 1 for Metering 8. Power frequency with : 2.5 kV (RMS) for one minute stand voltage 9. Mounting : in stationary portion of

switchgear cubicle 08.07 CONTROL TRANSFORMER 1. Service : Indoor 2. Primary Voltage : 415V, 3 phase, 4 wire, 50

Hz solidly earthed neutral 3. Type : Cast resin, dry type 4. Rated secondary voltage : 110 V 1 Phase 50 Hz 5. Rated burden : As per requirement.

Minimum 5 kVA 6. Tappings : ± 10% on Primary side in

steps of 2.5 % 7. Power frequency with : Primary 2.5 kV for 1 Minute

stand voltage Secondary 1.0 kV for 1 Minute

8. Mounting : Bottom of panel with Air

Blow Louvres 9. Quantity : As per approved SLD 08.08 ELCBs

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The ELCB shall be current operated type 4 pole with sensitivity of 30 to 300 mA sensitivity quick break trip free rating and provision to connect cable as per approved single line diagram.

08.09. Name Plates Name plates showing switchgear / feeder designation shall be

provided of anodised aluminium of 3 mm thick. Individual panel nos. / designation plate shall be fixed both at back and front of the panel on fixed portion. All components shall have distinct labels.

08.10 TESTS Type test certificates carried out on the similar equipment as per

applicable codes & standards shall be furnished during inspection. All routine tests as per Standards shall be carried out in the presence of purchaser's representative during inspection.

08.11 Earthing

Two earth terminals shall be provided on each cubicle, at back. An earth bar of specified cross section shall be fixed to the terminals. The earth bar shall be electrically continuous and shall run the full extent of each board. Terminals shall be provided for external earth connections. The minimum cross section of aluminium earth bar shall be as per approved SLD specified. All relay and meter bodies shall be earthed by one separate green earth conductor.

08.12 Special tools

A set of special tools required for the normal operation and maintenance shall be supplied with each switch board. The tenderer shall include along with each switch board one height adjustable circuit breaker trolley for handling with drawable circuit breaker carriage.

09.00 ILLUMINATION SYSTEM 09.01 DESIGN PHILOSOPHY

The Illumination system shall cater to the following.

• Normal cum Emergency AC Lighting

• Normal cum Emergency Lighting shall be provided by AC Lighting fixtures distributed through the plant.

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• Normal power shall be from SEB.

• In case of failure of normal supply the D.G set shall be started automatically (AMF operation) and take over lighting load of the plant until the SEB power Supply gets restored

• Road lighting and area lighting is envisaged using 400W HPSV flood

light fittings mounted on swaged and welded steel tubular poles or High mast.

• HPSV street light fittings are envisaged on the entry of all the civil

buildings.

• HPSV post top lanterns are envisaged on all gate pillars.

• All the civil buildings shall be provided with fluorescent tube light fittings using colour designation – 86 fluorescent lamp (Similar to Philips truelite type ) controlled through decorative control switches. Adequate Number of Ceiling fans, 5A & 5/15A socket outlets with control switches shall be provided. All toilet blocks and Sub- station building shall be provided with exhaust fans.

• Hazardous area like product Product Pump House shed, meter room

etc., shall be provided with flame proof HPMV well glass/ Bulk head fitting with HPMV/MLL/incandescent lamps.

• Surface/concealed wiring using PVC casing N capping / MS conduit /

PVC conduit with multi strand PVC insulated copper wires shall be carried out in all the buildings in non-hazardous area. Surface wiring using multi stand PVC insulated armoured copper cable shall be provided in buildings of hazardous area with suitable FLP junction boxes, cable glands etc.

• The tenderer / contractor shall consider Guide lines/data as per Table

‘B’ for design of the lighting system TABLE B

SL. NO. AREA ILLUMINATION

LEVEL (LUX) Maintenance

Factor TYPE OF LIGHT

FITTINGS

1 Road and area lighting 5-15 0.6 400W flood light fittings (Non FLP) with HPSV lamp

2 Pipe Manifolds 50 0.6 FLP, 200W, HPMV

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well glass fittings

3

Electrical rooms / offices / LT substations,

Amenities Block, Security Room

250-300 0.7

Decorative / rail / Trough type

fluorescent tube light fittings

4 Control room, instrumentation room 400 0.7

Decorative Surface/recess mounting type


5 Battery room 100 0.7 Vapour proof


6 Pump House shed 200 0.6 FLP 200W, HPMV

well glass/BH fittings

7 Periphery of buildings 20 0.6 Non FLP, 70W/150

W, HPSV Street Light Fittings

8 DG Shed 200 0.6 Non FLP, 200W, HPMV well glass

9 Transformer yard 50 0.6

Non FLP, 70W, HPSV well glass

fittings/street lighting

NOTE : Based on the area of different premises indicated in tender drawings the tenderer shall estimate depending on illumination levels specified and taking into account various design factors and indicate (with back up calculations building wise) quantity of various types of fittings/Switches/sockets/fans and other Accessories required as per Schedule of Quantity.

09.02 LIGHT FIXTURES, LAMPS AND ACCESSORIES 09.02.01 GENERAL

• All the luminaires shall be designed, manufactured and tested in accordance with relevant IS specifications so far as they are applicable.

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• All the luminaires shall be commercial / industrial type as per specific requirement. Specification for the various types of incandescent, mercury vapour, sodium vapour and fluorescent fittings mentioned in the schedule of quantities shall be followed. All the lighting fixtures shall be complete with all parts, including earthing arrangement and accessories for efficient performance whether specifically asked in the specification or in the schedule of items or not.

• Individual light fittings shall be provided with suitable arrangements

for GI threaded conduit entry of 19 mm dia unless otherwise specified. Terminals of all fittings shall be suitable for taking 2.5 sq. mm flexible, copper conductor PVC insulated, PVC sheathed cable.

• Fittings shall be supplied with all inter – connections made and fully

wired upto the terminal block and shall be suitable for mounting on wall / column / ceiling / suspension (from the ceiling including suitable bracket).

• All types of light fittings shall be supplied with lamps.

• All live parts shall be provided with suitable sleeves to prevent

accidental contacts. The earthing terminal in the fitting shall effectively earth the body of the entire luminaires.

• The clearance between the live parts and the enclosures earthing and

other safety factors shall be governed by the latest revisions of the relevant IS specification and IE rules.

• The fixing arrangement of various components and lamps shall be in

such a way that the maintenance and replacement jobs can be easily carried out.

• The luminaires shall be suitably designed to provide economically the

required level of illumination on the working plane when mounted at normal standard height in accordance with the type of fixtures.

• The luminaires shall be suitable for operating at normal supply

voltage of 240 V, single phase, 50 Hz with voltage variation of +/- 6% or at voltages as specified.

• The lamp holders of the fittings shall be suitable to take the lamp

supplied.

• All types of Flourescent lamp fittings shall be supplied with necessary controlgear housing polyester filled copper wound ballast, P.F

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improvement capacitor spring loaded rotary lamp holders starter holders metallic starters all pre wired to suitable terminals

• All types of fluorescent and well glass fittings shall be suitable for

mounting on wall / column or suspension from ceiling/false ceiling as required.

• The light fittings/fans shall include the mounting accessories like

chain, down rods for fittings mounted in false ceilings anchor bolt and all erection accessories required for complete installation.

• Ballast with copper winding only shall be used.

• Wherever inserts are available in the roof slab/column/wall, the same

shall be used for supporting the mounting accessories like downrod/brackets/chains etc., and in other places where there are no inserts. Anchor bolts shall be used for supporting the mounting brackets from the ceiling and grouting on wall / column shall be provided for mounting the fitting on wall / column in consultation with the site engineer.

• For exact location of inserts, relevant civil drawings shall be referred.

• GI/MS/PVC conduits shall be complete with all accessories as

required.

• Due to the highly corrosive atmosphere the fittings shall be provided with two coats anti corrosive epoxy painting over two coats of primer.

• Bulk head Luminaires suitable for GLS or Compact Flourescent

fittings.

• Decorative Wide Spread (Mirror Optics) Fluorescent Light Luminaires

• Anti-Corrosive Type Fluorescent Light Fitting

• Rail Mounting Type (Strip) Luminaire

• Industrial Fluorescent Light Luminaire With Stove/Vitreous Enamelled Reflectors

• Compact Fluorescent Lamp & Fittings

• Flame proof well glass & bulkhead luminaires suitable for HPMV

fitting.

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09.02.02 STREET LIGHT LUMINAIRE (SUITABLE FOR HPSV LAMPS)

The integral type street light fittings shall be of single piece construction from die cast aluminium. The control gear compartment shall have the necessary ballast, ignitor, p.f. improvement capacitor and connector block apart from the brackets for fixing the fitting to the mast / arm.

09.02.03 STEEL TUBULAR POLE (FOR MOUNTING STREET LIGHT /

FLOOD LIGHT)

Steel tubular street light pole shall be swaged and welded construction as indicated in the schedule. Each pole shall be comprising of a looping / terminal box clamped with top level 550 mm above ground level along with suitable earth terminal. A base plate 300 x 300 x 10 mm welded to the bottom of the pole. The looping box shall be provided with a suitable busbar arrangement to loop 3 to 4 cables 2 Nos. 10A fuse cutout and an earthing terminal.

The pole shall be provided with a cap having 3 Nos. fixing bolts at 120 degrees apart and GI pipes in the foundation for taking incoming and outgoing cables.

The pole shall be provided with necessary cross arms GI pipe brackets street light fittings for mounting one or two numbers of flood light fittings where required. Both underground cable and earth wire shall be terminated at the terminal / looping box. The earth terminal at the terminal box shall be further connected to the earth terminal on the pole by GI wire.

Earth pole shall have coil earthing using GI wire. The steel tubular pole shall be suitable for erecting with necessary concrete foundation, painted with black bituminous paint internally and externally up to the portion which goes inside the concrete and remaining part of exterior shall be painted with two coats of red oxide and 2 coats of epoxy paint.

09.02.04 FLOOD LIGHT LUMINAIRE (SUITABLE FOR HPSV LAMPS)

The flood light fitting shall be of non – integral type, complete with suitable weather proof control gear box made of cast aluminium. The fitting shall consist of a cost aluminium lamp holder housing a

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reflector made of spun aluminium electro-chemically brightened and anodised. Flat toughened front glass suitable to withstand the high temperature and humid conditions shall be fixed to the housing using neoprene gasket. Focusing knob to help in adjusting the lamp centre shall be provided. Mild steel cradle shall be mounted on the control gear. The control gear shall consist of heavy duty polyester filled copper choke suitable for lamp wattage specified, p.f improvement condensors, connector and fitting is duly wired with provision of cable entry provided. The provision for relamping is to be made in such a way that aiming angles are not disturbed.

The chokes shall be manufactured from high quality silicon laminations with tappings at 200/220/240V. this shall conform to IS : 6616. Holders shall be made out of porcelain and shall have brass contacts. These shall be rated for 240V. the tip of the holder shall be spring loaded. Capacitors shall be of 250V rating. This shall conform to IS : 1569. Internal wiring shall be done with fibre glass covered wire of suitable cross section to withstand high temperature generated in the control gear / lamp holder. The main supply shall be connected to the terminal block made out of porcelain / bakelite of suitable quality. The terminal block housing shall have flexible conduit for taking the main supply leads.

The control gear and lamp h older housing shall be provided with a sufficient number of vertical fins to dissipate heat produced. A protractor plate with degrees marked on it shall be provided to enable the fitting to be tilted to any required angle. Rotation of the fitting shall be limited to 360 degree horizontal and 180 degree vertical and locking arrangement shall be provided for both vertical and horizontal position. All hardware shall be made of mild steel and passivated.

The fitting shall be complete and suitable for taking HPSV lamp, provided with gaskets to make the unit weather proof. All the cast aluminium parts shall be finished in hammer stone stove epoxy painting. 3 x 2.5 sq. mm PVC cable, copper conductor shall connect the terminals of the luminaire with sub circuit at 240V via the control gear unit. 1 No. earthing terminal shall be provided.

Both the luminaire and the control gear box shall conform to IP 54 and suitable for outdoor application.

The control gear box shall have the required electronic ignitor for starting of the lamp.

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09.02.05 POST TOP LANTERNS (Deleted)

09.02.06 SOCKET OUTLETS FLUSH / SURFACE MOUNTING SOCKET

OUTLETS (DECORATIVE TYPE)

5A / 15A, 5A, 240V, single phase, 3 pin (two pole and one earth) socket outlet shall be flush / surface mounting type along with decorative control type switch. If indicated, the socket shall be 5A / 15A combined (universal type) having 6 pin with suitable piano type switch. Adequate No. of Socket outlets shall be provided in areas like control rooms Sub-station, office, amenities block and similar other buildings.

09.02.07 JUNCTION AND OUTLET BOXES

Junction and outlet boxes fabricated with sheet steel shall having a minimum thickness of 1.6 mm unless otherwise specified The JB shall have earthing terminals & terminal block, number of knockouts for cable entry etc., as required. The exact size of knockout and cable gland shall be as per actual requirement.

09.02.08 CONTROL SWITCHES

DECORATIVE TYPE

Single pole decorative type, 5A, or 15A switches shall be used for light/fans/socket outlets points in office premises / non plant buildings and shall be of approved type, make and colour. All branch switches shall be placed in line conductor of the circuit and no single switch or fuse shall be inserted in the neutral conductor of the circuit.

09.02.09 SWITCH BOARDS (for decorative switches and sockets)

The switch board shall be made of 1.6 mm thick sheet steel & painted including supports for switches, sockets, fan regulator etc., but excluding front cover in case of decorative switches & sockets which will be of FRP sheet of approved quality, design and colour. Clear depth of the box shall not be less than 60 mm, but adequate for easy mounting of fan regulators. All fittings shall be in flush pattern in case

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of concealed wiring. The FRP cover sheet thickness shall not be less than 3 mm.

09.02.10 CEILING FAN

• Ceiling fans shall be 3 Blades type.

• Ceiling fans shall be hung at 150mm above the light fitting level or as per as per layout DRGS. The length of the down rod supplied shall be suitable for this purpose.

• 1 No. 1400mm Sweep Ceiling fan for every 15 Square meter area

(max)shall be provided wherever required. 09.02.11 EXHAUST FAN

All Switchgear rooms/D.G rooms/ toilet blocks shall be provided with Exhaust fans.

Exhaust fan shall have totally enclosed highly efficient heavy duty motor mounted on ball bearing, precisely dynamically balanced blades/impeller to ensure smooth & trouble free operation, rigid frame with rubber frames for silent operation finished with stove enamelled/epoxy powder coated for better chemical, mechanical & corrosion resistant. The exhaust fan shall be supplied with wire guard/bird-mesh screen, and earthing terminal.

The exhaust fan shall be provided with earthing terminal.

09.02.12 Flame Proof Push Button Stations for motors, Light Fittings

and Accessories like Boards switches Junction Boxes, cable glands etc.,

FLP Push Button stations in Pump houses for motors, different types of light fittings such as well glass, Bulkheads and accessories Boards cable glands etc., shall be suitable for group IIA and II B( where Petroleum, oil, lubricants are stored and Handled.) All these equipment shall have test certificates issued by CCE Nagpur.

09.02.13 ENERGY SAVING DEVICE FOR ILLUMINATION SYSTEM

Energy Saving Device shall be connected at the incoming side of the Main Lighting Board. The Cable from PMCC (for MLDB) shall be

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first terminated in Energy Saving Device panel and the out going from this shall be connected to 630A MCCB incomer module of MLDB and the out going feeders of MLDB will feed power to lighting fittings, fans (Ceiling, Pedestal, Exhaust),hand tools through switch socket units and Spilt type room Air Conditioners. The system offered shall be suitable for energy saving in this system with very low internal losses(ie. High efficiency- 99% or better) and maintenance free type and safeguard the equipment from power supply system and voltage fluctuations without affecting the performance of the illumination system mentioned above and without introducing harmonics and surges. The following are brief specifications of the equipment.

• Shall have three numbers low loss transformers mounted in a sheet steel enclosure (2mm thick for load bearing parts and 1.6mm thick for doors and covers. Sheet steel duly treated in seven tank process and powder coated / painted with colour RAL 7032), free standing with base channel of 75mm and with separate cable alley for bottom entry of incoming / outgoing cables each 3 nos of 3.5X185 mm2 , AYRY. The panel shall also have the other items / components mentioned in following paragraphs.

• Incoming power supply 3phase, 415 + 10% V, 50 + 5% Hz, 4 wire AC with fault level of 35 KA for 1 sec. The control voltage shall be 110V,AC.

• Incoming isolator with fuses and neutral links with RYB on /

off LED lamps (22.5mm), CTs with ammeter and ammeter selector switch, voltmeter with selector switch and fuses etc.

• Local / selector switch, control MCB, Contactors etc. as

required for automatic tap changer and automatic bypass of the unit in case of problem in unit / abnormal under voltage/fuse failure etc.

• If the unit offered is forced cooling type then the starter for

the fans shall also be included in the panel. The rating of the unit with fan failed condition shall also be indicated in the offer.

• Contractor shall indicate the assured / guarantee amount of

saving in the system. The system will be checked for the same at manufacturer’s works. The vendor’s reference list

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where such units are supplied and amount of energy being saved shall be indicated with user’s certificates,

• The vendor shall submit all the relevant drawing for our

approval before manufacture.

10.00 HAZARDOUS AREA

GENERAL

All the equipment’s installed and accessories used shall conform to the requirements stipulated under relevant Indian Standards and STEC regulations for the type / category of installation. All the equipments and accessories installed in these areas shall be certified by CMRS, Dhanbad for using in that particular type of hazardous atmosphere like flammable gas / vapour or hazardous dust. All the equipments installed shall not attain more than the maximum permissible surface temperature specified for that area elsewhere in the specification, if not the maximum permissible temperature may be assumed as 100 degree C. It shall be ensured that overheating / sparking whether in normal use or under fault condition is confined within the approved housing of wiring system and electrical item concurred. If any equipment is likely to produce more than the prescribed maximum permissible surface temperature due to abnormal conditions of operation or during fault conditions, all such fittings shall be fitted with a thermal device to disconnect the appropriate circuit before the maximum safe temperature is exceeded. This bimetal thermally operated cutout device shall preferably be included in the enclosure containing choke and other control gears liable to be over heated. THIS THERMAL DEVICE SHALL NOT BE AUTOMATIC SELF-RESETTING TYPE. If control gears are not integral with the fitting the enclosure for the control gears also shall be suitable for use in that particular type of hazardous atmosphere and certified by CMRS, Dhandbad. For all the equipments where cast iron body is specified, cast aluminium alloy (LM-06) is also acceptable. All the equipments if constructed out of aluminium alloy, its external surfaces shall be smooth finished to be free from frictional sparking hazard. All the equipments shall have markings, warning inscriptions and interlocks, specified as per relevant I.S, inscribed either by raised lettering or cast integrally with or by a plate permanently attached to the body of the fitting. Copy of CMRS, Dhandbad, and certificate for each type of fitting should be submitted.

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10.01 LIGHT FITTINGS

FLAME PROOF BULK HEAD FITTING The fitting shall have a cast iron/aluminium enclosure with integral control chamber housing the terminal box. The toughened impact resistant clear glass cover provided in the front shall be cemented to retaining ring. The retaining ring shall be suitable for fixing to the main body with the help of screws, which can be opened, only with the help of special tools. The ES porcelain lamp holder shall be suitable for the type of lamp specified. The fittings shall have suitable cable entry provision as required. Suitable plugs to close the non-used entries shall also be provided along with the fitting. A suitable chrome plated integral reflector shall be supplied along with the fitting.

In case the above fitting suitable for HPMV lamps are specified suitable flame proof control gear is to be supplied along with the fitting. Earthing studs one inside the terminal box and one outside shall be provided.

FLAME PROOF TUBE LIGHT FITTING

The fitting shall be integral type enclosing all the control gears like polyester filled copper wire round ballast, p.f. improvement capacitor, starter, starter holder and lamp holder in cast iron or cast aluminium alloy enclosure along with suitable terminals for incoming cable. The fluorescent tubular lamp shall be enclosed in a special toughened glass tube cemented at each end to an aluminium alloy ferrule. The ferrule shall be attached to the control gear chamber on one end and other end to a cast iron or cast aluminium alloy end cover by special bolts. The lead wire between the two lamp holders shall be enclosed in brass tubes.

Suitable suspension arrangement for mounting the fitting on down rods or fixing to wall / ceiling shall be provided. The fitting shall be supplied with suitable wire guard. Two earthing studs one inside the control gear chamber and one outside shall be provided. Suitable cable entry provision also shall be provided.

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FLAME PROOF WELL GLASS FITTING

The fitting shall be integral type enclosing all the control gears like polyester filled copper wires round ballast, p.f. improvement capacitor terminal box and lamp holder in a cast iron or cast aluminium enclosure with suitable cable entry provision. The fitting shall be provided with heat resistant and toughened clear well glass bowl with painted MS wire guard cemented to the retaining ring fixed to the main canopy. The ES porcelain lamp holder shall be suitable for the type of lamp specified.

A specially designed neoprene gasket protects the inside of the luminaire from harm full accumulation of any explosive dust and provides reliable weather proof. Earthing studs one inside and two outside shall be provided. Eyebolt is provided for suspending the fitting on down rods.

FLAME PROOF, DUST TIGHT WELL GLASS FITTING

The fitting shall have cast iron / cast aluminium LM6 enclosure enclosing all control gears such as copper wound ballast, lamp holder and terminal box. The fitting is provided with mild steel vitreous enameled / aluminium anodised reflector and toughened heat resistant well glass with painted MS wire guard welded to the retaining ring fixed the main canopy. A specially designed neoprene gasket protects the inside of the luminaire from harmful accumulation of any explosive dust and provides reliable weatherproof. Suitable cable entry shall be provided. The ES lamp holder shall be suitable for the lamp specified. The fitting shall be provided with two number external and one number internal earth terminals. Suitable integral eye hooks shall be provided for suspending the fitting an a down rod. The flitting shall conform to IP:65 protection or better. INTRINSICALLY SAFE PORTABLE HAND LAMP

The fitting shall be made of cast iron / cast aluminium LM6. The fitting shall be provided with toughened heat resistant glass and white epoxy coated MS wire guard. The fitting shall be provided with integral cable terminal box with one No. 3/4th ET entry and extended and made sturdy enough to be used as a convenient

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carrying handle. The fitting shall be provided with 2 Nos. external and 1 No. internal earth terminals. The fitting is provided with BS/ES porcelains lamp holder suitable for GLS lamp. The fitting shall be of dark gray / light gray shade epoxy powder coated finish. The fitting shall conform to IP 55 protection.

10.02 LAMPS

HIGH PRESSURE MERCURY VAPOUR LAMP

These lamps shall be suitable for universal burning positions and shall have E-40 with ES/GES threaded cap. These lamps shall be of ovoid shaped outer glass bulb and the inner surface is coated with phosphor.

SWITCHES SOCKETS AND OTHER ACCESSORIES

The enclosures shall be of cast iron construction having an integral terminal chamber. The front cover shall be secured to the body either by a threaded joint or by special type screws. The box shall have minimum two earthing provision outside and preferably one more inside. The switches and sockets shall be supplied with suitable double compression FLP type cable gland and cable entry / exit provisions shall be as per specific requirements. The enclosure shall have suitable provision for mounting on wall / column. The contact of the switches shall be suitable for heavy duty and shall be able to make and break the specified rated current effectively. The enclosure shall be suitable to contain the spark / arc created during the operation of the switch effectively from the outside atmosphere. The entire equipment shall conform to the relevant standards and certified by the appropriate authorities for use in hazardous areas having flamable gases or vapour and explosive dust. All the accessories such as Pull/anchor/ceiling/junction/outlet boxes specified for use in hazardous areas should conform to the relevant standards and certified by CMRS, Dhanbad. The body of all the above boxes shall be made of cast iron or cast aluminium alloy and shall have a removable cover plate. The cover plate shall have either a threaded joint or a screwed joint with the body. The number of cable entries shall be as per the requirement. FLAME PROOF EXHAUST FAN

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Exhaust fans shall have flame proof, highly efficient heavy duty motor mounted on ball bearing, precisely dynamically balanced blades / impeller to ensure smooth to trouble free operation, rigid frame with rubber pads for mounting to reduce vibrations for silent operation, finished with stove enameled epoxy powder coated for better chemical, mechanical and corrosion resistant. The exhaust fan shall be supplied with wire guard / bird mesh screen as required. FLAME PROOF MCB DISTRIBUTION BOARDS All equipments shall be designed suitable for operation in hazardous areas having flammable gases or vapour and explosive dust. The distribution board shall be wall / floor mounted type made of cast iron / cast aluminium LM6 with anti corrosive and light grey epoxy coated finish. The incoming cable terminals, outgoing cable terminals and the switch are all housed in separate chambers. The operating handle of the incomer shall be suitably inter locked mechanically with the door of the incomer. The boards are provided with neoprene gasket. Suitable cable entries shall be provided for incomer and outgoing. The boards are provided with 2 Nos. external and 1 no internal earth terminals. The entire equipment shall conform to the relevant standards and certified by the appropriate authorities for use in hazardous areas.

10.03 WIRING

GENERAL

For general requirements for wiring refer to the details stipulated under specifications for wiring for Ordinary (non-hazardous) area elsewhere in this specification.

Additional requirement for carrying out wiring in the hazardous areas are as specified below :-

A) USING ARMOURED CABLES

i) 1100V grade HR PVC insulated PVC sheathed round wire armoured PVC overall sheathed cable with copper conductors shall be used for wiring wherever surface laid cables are specified for connecting from distribution board to light fittings and other equipment.

ii) While carrying out surface wiring using armoured cables, cable shall

be supported 500mm apart to avoid sag. The cables shall be neatly clamped and should not create a shoddy appearance.

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iii) Nylon/rawl plugs shall be used for fixing cables to ordinary wall /

ceiling. The plugs shall be fixed using the correct size of drills and screws as specified by the manufacturer. Using of wooden plugs are not permitted.

iv) Cables shall be laid in such a manner to avoid crossing / jumping of

cables and shall provide a very neat and tidy appearance. v) Suitable size double compression brass glands (Approved by CMRS as

suitable for flameproof area) shall be provided for cable entry / exit to any of the flameproof apparatus.

vi) The cables used shall have multistrand copper conductor. vii) The rate quoted shall include the cost of accessories required like FLP

junction boxes, saddles, consumables, etc., for supply and installation of complete wiring system.

B) WIRING USING PIPES

i) Wiring in the hazardous areas can be carried out using 1100V grade PVC insulated PVC sheathed cable with copper conductor in surface laid solid drawn or ERW welded pipe, if specified, for connecting from distribution board to other equipments in flame proof areas.

ii) Conduits shall be supported at a minimum distance of 1000mm

horizontally and 500mm vertically, Nylon / rawl plugs shall be used for fixing conduits on wall / ceiling. The plugs shall be fixed using correct size of drills and screws as specified by the suppliers. Using of wooden plugs are not permitted.

iii) Conduits shall be laid in such a manner to avoid crossing of

conduits. iv) Metal conduits are to be screwed tight to the apparatus. Conduit

unions only are to be used for jointing and couplers are not allowed.

v) Flexible conduits are NOT allowed for use in hazardous areas. vi) Cables with multistrand conductors only are permitted for use in

conduit wiring system for hazardous areas.

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vii) The rates quoted for the conduit system shall include the cost of accessories required for supply and installation of a complete conduit system eg., saddles, consumables etc.,

CONTROL OF ELECTRICAL SUPPLY CIRCUITS

The supply of electricity to a building or underground site containing explosives is to be controlled by one or more master switches outside the building or underground sites. Master switches should be close proximity to each other, identified and capable of isolating every conductor entering the building including the neutral of switches, starters, etc., If installed inside the building, these should confirm to the category of installations.

All circuits are to be provided with protection against over load and earth leakage. Over current protection may be given by automatic circuit breakers complying with IS : 3842 (Part-I) 1967.

11.00 EARTHING AND LIGHTNING PROTECTION

11.01 EARTHING

1 Entire system shall be earthed in accordance with the provisions of

the relevant IEC recommendations / IS 3043 - 1987 and Indian Electricity Rules, so that the values of the step and contact potentials in case of faults are kept within safe permissible limits.

2 Parts of all electrical equipment and machinery not intended to be

alive shall have two separate and distinct earth connections 3. All exposed metal parts such as HT / LT switchgear / power

distribution board/Lighting boards/feeder pillar enclosure, metal clad switches enclosure, lamps brackets, lamp holder, plug sockets enclosure, lighting poles, junction box etc., shall be properly earthed by connecting these to the earth electrode by means of bare GI wire/flat or single core cable of approved size to pass the fault current safely to earth in case of leakage at the apparatus or in the system. The minimum size of earthing wires is indicated below:

a) Main earthing ring (connecting the earth pits) 50 x 6mm GI

strip or equivalent, laid at a depth of not less than 700 mm.

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b) Loop earthing ring for main distribution board/LDB/ sub distribution board earthing - minimum size of 20 x 3 mm GI strip buried in floor/wall/trench etc., in side the shop.

c) Light point earthing - same size as point wiring single core

PVC insulated copper wire / bare copper wire in case of GI / MS conduit wiring of same size or equivalent.

4 A common grounding system network will be made underground by

using 50 mm x 6 mm GI earthing strip connected to earth electrodes in loop-in & loop-out system and connecting the electrical equipment to network. In RCC cable trench one number earth strip of size 50 x 6 mm shall be run throughout the length of the trench.

5 The ring earthing system around each building shall be laid at a

distance of approximately 1.5 m from the building and at a depth of approximately 0.8m. The ring shall be bonded at intervals to the building steel structures, reinforcement of building columns and also to pipes, wherever they are crossing. The earth ring shall further be connected at intervals to deep earthing electrodes to achieve a combined earth resistance of less than one ohm.

6 For the purpose of dimensioning the earthing lines / conductors,

the duration of the earth fault current shall be taken as 0.3 seconds.

7 The power supply cables (LT) from the sub-station and the

distribution cables to individual motors shall have 4 / 3.5 cores. 8 LT power supply cables shall have four cores and the fourth core

shall have cross-sectional area of 50% of the other cores generally. The fourth core of the main supply lines shall be connected to the solidly earthed neutral bar in the substation switchgear as well as at the earth bars in power distribution boards.

9. All the equipment will be connected to earthing grid by using

conductors as per Table - A. TABLE A

Sl. No.

Equipment Conductor Type & Size

Number of conductors

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1 Motors upto 2.2kW 6 mm2 stranded GI wire 2 2 Motors of 3.7KW to

11KW 16 mm2 stranded GI wire 2

3 Motors of 15KW to 45KW

25mm x 3mm GI strip 2

4 Motors of 55KW to 90KW


5 Motors of 110KW & above


6 HT SWBD panel 50mm x 8mm GI strip 2 7 PCC/MCC/LDB Panel 50mm x 8mm GI strip 2 8 Street light poles 16 mm2 stranded GI wire 2 9 Rail car/truck tanker 25mm x 3mm GI strip

gantry 2

10 Filling / unloading hoses

16mm2 flexible copper cable with jaw clip

1

11 Utility building PDBs 25mm x 6mm GI strip 2 12 FLP-WP lights /

control station 6 mm2 stranded GI wire 2

13 Product pipe lines 16 mm2 flexible copper wire

2

11.02 EARTH STATIONS

A. EARTHING ELECTRODES

All the earth electrodes will be made of test pit type made with B-class GI pipe ( 3.0 m long 65mm/40 mm dia) driven to ground, pit filled with charcoal and salt. Bottom half of the pipes shall have holes drilled at intervals on its surface. Removable caps shall be provided at the top of the pipes to facilitate pouring of water. Suitable clamps shall be provided with the electrodes for connecting earth conductors.

B.EARTHING PITS

The pit for an earth electrode will be of size not less than 600 mm x 600 mm x 4000 mm and will be dug with its centre at minimum 2.5 metres away from the edge of any building/masonry work.

Homogeneous mixture of charcoal, salt and sand shall be made on ground and poured into pit covering the electrode. The minimum requirement shall be 20 kg charcoal and 30 kg salt per pit.

The space above the salt/charcoal layers will be filled with loose sandy soil, upto a level of 550 mm from ground level.

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A cement concrete chamber of inner dimension 350 x 350 mm will be erected around the top of the earth electrode so that top surface of the chamber is flushed with the outside finished ground level.

Earthpits shall be located as per approved grounding layout drawing.

Distance between two earth pits shall not be less than 6 Meters.

Masonry work of the earthpit shall be carried out only after well ramming of riddled soil and complete settling of loose soil. As such, electrodes shall be fixed in ground before commencement of any other work of the installation and masonry work shall be taken only at the end after completion of all other works in the installation.

C.RESISTANCE OF EARTHING ELECTRODE

The earth resistance of each electrode will be measured by an approved earth testing apparatus and recorded. In case the earth resistance is more than the required value, as per IS: 3043 additional earth pits, earthing ring as required shall be installed. The resistance of earth grid shall be less than 3 (three) Ohms.

D.CHECKING PROCEDURES TO BE FOLLOWED

The contractor shall keep ready the pit of proper dimensions and various materials for the earthing installation, for checking by the engineer. The contractor shall also arrange all measuring/testing instruments at his cost for testing. In case the pipe is buried without the above check being carried out, the contractor will be liable to open out filled up earth and re-do after proper check at his own cost. The earth pit is to be erected in all kinds of soil including rocky soil and the party shall quote their rate accordingly.

11.03 EARTHING RING MAIN

The earthing ring shall be made by GI strip/wire of specified size. The ring shall be laid in the cable trench along with lighting cable and connected to all the earthing pits as shown in the drawing.

Installation of Earthing Circuit. Earthing of HT/LT switch gear, Power Transformer, PDB/MLB/LDB/DFB Etc.

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Each of the above equipment shall be provided with two separate earth terminals. An earth busbar of appropriate cross section shall be provided inside the equipment board and connected to the earth terminals provided on either side of the board.

Adequate number of holes/terminals shall be provided on earth bus with suitable provision for terminating the earth wire. GI strip / Armored Aluminum conductor single core cable of suitable size shall be used for connecting the two earth terminals of the equipment independently to the earthing main in the shop.

Earthing cable sizes (single core armored aluminum conductor PVC insulated)

11.04 EARTHING OF LIGHT FIXTURES AND SOCKET OUTLETS

The single core PVC insulated/bare coper wire of same size as the phase conductor or 14 SWG GI wire and the third core of the flexible wiring cable shall be used for earthing the light fixtures and single phase socket outlets etc.

Earthing of metal boxes and brackets

Not less than 14 SWG GI wire shall be used for earthing all metal boxes and brackets.

11.05 LIGHTNING PROTECTION

All buildings and plant structures vulnerable to lightning strokes owing to their height or exposed situation shall be protected against atmospheric flash-overs and lightning strokes in such a manner as to eliminate any danger to the personnel employed therein.

Sl. No. Equipment Size (Sq.mm)

1. Power cum control board 300

2.

Motors upto 3.7 kW Motors upto 5.5 to 30 kW

Motors upto >30 to 110 kW Motors upto > 110

10 25 120 185

3. Instruments 10 4. SFUs Sockets (Welding / Power) 25

5. For Lighting Same size as that of circuit & point wiring

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The installation shall conform to IS:2309-1969 as amended up to date.

Conductors on parapet: The conductors shall be coursed along ridges, parapets, edges of the flat roof, over flat roof where necessary in such a way as to join each air terminal to the rest. The conductors shall be fixed securely with galvanized iron staples 40mm (1 1/2") long and spaced not more than 4' (1.3m) apart.

Vertical down conductors: These conductors, shall originate direct from earth station, shall be connected to parapet conductors or air terminals and shall be coursed through shortest possible routes without abrupt turns or kinks. While passing through cornices, these shall pass through GI pipe (Class 'B') having adequate bore. These conductors shall be fixed securely with galvanized iron staples 40 mm (1 1/2") long and spaced not more than 3' (1.0 m) apart.

Protection against damage and corrosion: No upturns are permitted and any bend necessary shall have a permissible radius. The end of GI pipe projections on wall shall be properly sealed with bitumen compound to prevent corrosion.

Metallic objects near conductors: The conductors shall be so laid as to maintain a separation distance exceeding 2 metres (6' 6") between:

(a) Any electric conductors running in parallel. (b) Metallic objects, viz. iron girders, water tanks, iron stair

case, water/gas pipes inside or by the side of the building.

All external metallic objects viz. water tanks, gutters, rainwater down pipes, water mains etc., shall be bonded to the nearest conductor by means of a short tail.

Joints and bonds: All joints between conductors shall be made after cleaning and tinning the ends of conductors to be joined, binding them together for about 100 mm (4") with No.14 SWG GI wire and then soldering them together. Bonding shall be as short as possible. All joints and bonds are to be mechanically and electrically sound.

Earth stations: Similar to installation earths as specified elsewhere. Minimum number of earth station is two. The resistance to earth of individual earth stations shall be tested by earth testing megger and must not exceed 5 Ws.

11.06 Lightning protection of product tanks

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12.00 ERECTION GUIDELINES

12.01 GENERAL

All electrical equipment shall be erected, tested & commissioned as per relevant IS standards, codes of practices and good engineering practice. Civil aspects mentioned in following specification shall be adhered to while planning civil work. Though major Civil Work will be done by other agency but minor Civil Works shall be included in the scope of work of the electrical contractor as mentioned in the following paragraphs and the same shall be included in the rates quoted.

The scope includes receiving and storage of equipment at site transportation, handling, installation, testing and commissioning of all units/items under the scope of supply of the contractor. His scope also includes installation and termination of cables to / between owner's electrical equipment and sealing of cable conduits, floor / slab openings, minor civil works required for erection etc.,

Unpacking shall be properly done at site. Break-age, defects, missing (if any) items shall be made good immediately. All packing materials shall be removed and components shall be thoroughly cleaned.

Transportation to respective foundation, after checking and unpacking, shall be done by the contractor. Transportation shall be done systematically using wall / floor openings, provided exclusively for the purpose, using proper lifting tackles. No part of GI piping, structures, ducts shall be used for lifting equipment without prior consent of owner / engineer.

Contractor shall be fully responsible for claiming any damages from insurance company wherever required.

Shipping sections of equipment supplied at site shall be assembled correctly (with proper alignment) and all electrical connections shall be done between various shipping sections as per manufacturer’s drawings/ instructions.

Base frames of equipment shall be fixed to foundations by anchor bolts or by welding to embedded steel inserts.

Equipment / cabling / earthing and other electrical system installation shall be carried out in accordance with the latest editions of relevant Indian Standards and codes of practice and the installation shall fully

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comply, with the requirement of the Indian Electricity Rules and statutory regulations, that are in force, at the place of installation.

12.02 SUB-STATION SAFETY EQUIPMENT

RUBBER MAT

Front and rear of all switch boards / VCB panel where daily routine

operation are done shall be provided with 12 mm thick rubber mat of 11 kV grade.

CO2 FIRE EXTINGUISHER

Each substation & switch room shall be provided with minimum 2 numbers of CO2 fire extinguishers.

FIRE SAND BUCKETS

Each substation will additionally be provided with 4 nos. Fire river sand filled buckets with stand.

SHOCK TREATMENT CHART Each substation & switch room shall be provided with Minimum two numbers of nicely framed shock treatment charts at easily viewable and readable place. CAUTION BOARDS & DANGER PLATES The substation panels, transformer yards and switch board panels shall be provided with caution boards & danger plate to avoid unauthorized entries. SINGLE LINE DIAGRAM All the substation shall be provided with nicely framed as built Single Line Diagram indicating system voltage, current rating, fault level, feeder number and capacity, fuse rating, connected equipment tag no. etc.

12.03 CLEARANCES All electrical equipment shall have adequate clearances from the point

of view of operation and maintenance & conform to IE Rules

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The clearance between the ceiling of the electrical room and top of the Tallest equipment shall not be less than 1 meter.

Back clearance - Minimum 1000 mm Front to front clearance between boards - Minimum 2000 mm Clearance between two panel boards in a row -Minimum 1000 mm Clearances between front of the panel to - Minimum 2000 mm the wall of the room Clearance between the wall & end of - Minimum 1000 mm Switchgear / PDB Back to back clearance - Minimum 1500 mm Back to front clearance - Minimum 2000 mm Clearance between the bottom of the - as per statutory ventilation duct & top of the electrical requirement and equipment regulations 12.04 HT / LT SWITCHGEAR Scope under equipment erection shall include:

a) Physical inspection and handling b) Installation on the foundations or supports as the case may be

as per general guidelines given in section. c) Assembly and interconnection of shipping sections as per

supplier's instructions. d) Mounting and connection of wiring of loose supplied items if

any. e) Checking of components, wiring and interlocks as per approved

drawings. f) All moving parts shall be checked for easy and free movement.

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g) Applying touch up paints. h) Making the equipment ready for energizing after completing all

associated works, PAT etc.,

Fixing / foundation bolts, nuts, lock nuts, washers etc., shall be properly fixed/ grouted in the pockets already provided or to be provided by the contractor.

HT / LT switchboards,/ PMCC / power distribution boards shall be tack welded to steel bars / plates provided in the floors. Cross support structures, if required be welded to inserts. If tack welding is done, foundation bolts are not required for the equipment.

The equipment shall be installed on the foundations / supports / floors firmly in such a way that there will not be any vibration during operation of the components on the boards.

Normally equipment like remote push button stations will be supplied without pedestals. The push button stations shall be mounted at convenient places like walls, columns, cable rack supports etc. Pedestals wherever required, shall be fabricated from the steel sections used for fabrication of cable supports/racks and installed properly.

For mounting of equipment like SFUs, Plug and Sockets on the walls/ column suitable support brackets shall be fixed/grouted by the contractor. After installation of equipment, all interconnected wiring shall be checked thoroughly for correct connections, with the wiring and schematic drawings of the manufacturer and the drawings supplied by the engineer/owner before energizing.

All cable/bus bar connections shall also be thoroughly inspected and checked for correctness, absence of foreign materials, tightness etc., before energizing the equipment. All labeling shall be checked against drawings. Distinct duplicate earthing shall be done for the metallic bodies of the equipment.

All components within the main equipment shall be tested for proper performance & correct operation before commissioning of the equipment.

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12.05 LIGHTING BOARDS

MAIN LIGHTING DISTRIBUTION BOARD / FEEDER PILLAR

The main distribution board shall be floor-mounting type. Suitable base channel shall be supplied and the floor inserts if necessary, incorporated in the civil works by the contractor. G.A drawing shall indicate foundation details and insert requirement also along with general arrangement of panel boards for approval. Contractor has to carry out chipping of floor etc., without any extra cost, installation of equipment includes supply and installation of necessary hooks/arms for cable support and all other connected works.

Feeder Pillars shall be installed on Civil foundations to be constructed by the contractor. There shall be pipe inserts for taking the cable in/out of the feeder panel. This shall be included in price quoted for installation of Feeder Pillar.

12.06 MLB / Lighting Distribution Boards/Sub-distribution boards

The lighting distribution boards/sub-distribution boards shall be generally mounted on wall or structural column. The distribution board shall be mounted in such a way that the operating handle of the incomer and outgoing switchgears shall not exceed 1800 mm from the finished floor level for easy operation. The panel will be fixed on the wall/column securely by means of suitable bracket and fixing clamps/bolts etc. The contractor shall also design and incorporate in the civil works, necessary pipe inserts etc., for cabling to the board.

12.07 LIGHT FIXTURES, FANS ETC.

All light fittings such as well glass, fluorescent tube light fittings, street light fixtures, flood light fixtures etc., are to be installed as per approved layout drawings, and direction of site engineer conforming to Standard installation norms and practices. Apart from the technical requirements, aesthetic requirement also to be satisfied while designing supporting arrangements & fitting layout. Depending on the location and type of fittings the mounting arrangements has to be made. Usually MS brackets / MS hooks / GI pipe brackets / MS conduits / chains slotted channels etc., will be used. Suitable inserts shall be provided in the civil works for supporting heavier fittings or where continuous row of tube light fittings mounted on slotted channels are to be hung. For mounting lighter fittings like One No. tube light or decorative fittings etc., regular inserts are not necessary. Anchor fasteners shall be used for

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this purpose. However, care shall be taken to use correct size of drills specified by the manufacturer for each different type of bolts. Care shall be taken to avoid angulation which, will weaken the installation Wherever concealed wiring is provided concealed type fan hook boxes (2 mm thick M.S. box with 10 mm rod) shall be provided for suspending ceiling fans.

All brackets, hooks, fan hook boxes etc., made of MS shall be finished with two coats of ‘Red-oxide’ paint and one coat of final finish of approved colour.

All the M.S / G.I supporting brackets supplied /fabricated & installed

Supply & installation of Brackets down rods / chains for suspension of light fixtures & fans irrespective of length are included in the Scope.

12.08 CONTROL SWITCHES, SOCKET OUTLETS AND SWITCH

BOARDS

All the control switches, sockets and switchboards are to be installed as per approved drawings, and as per specification, standard norms and direction of site engineer. The switch controlling a socket shall be connected on live side of the socket.

12.09 JUNCTION BOX, OUTLET BOX, ANCHOR BOX ETC.

All junction boxes including terminal blocks wherever required outlet boxes are firmly fixed to walls/ceiling/structures using MS bracket and bolt and nuts. The front cover of these boxes shall be flush with the wall/roof finish in case of concealed mounted type. The location of these boxes shall be selected in such a way that easy accessibility is available for maintenance.

12.10 CABLE TRAYS / RACKS STRUCTURES FOR CABLE LAYING Cable Trays/ racks (GI/FRP) shall be installed, complete with all

necessary coupler plates, drop out trays, horizontal elbows vertical elbows, tees, reducers, hangers, supports at every 1.5 meter length.

Constructional details and supporting arrangement for the cable trays, shall be furnished by the contractor. Cable racks for cable trays shall be fixed at a maximum interval of 1.5 m.

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Cables leaving the ground / floor shall be protected upto 2m height by conduits / metallic guards.

Ladder type cable racks and trays shall be provided to lay cables. Cables shall be laid in separate racks according to the voltage / application classification.

All necessary frame works and fixings for the support of cables and accessories shall be supplied.

Cables shall be suitably protected against heat and mechanical damages.

Cables shall be laid on ladder type cable trays. Ladder type cable trays shall be selected from sizes 150mm, 300 mm, 450 mm & 600 mm. width. They shall be fabricated from 50 x 50 x 6 mm MS angles for longitudinal members and 30 x 6 mm flats for cross members placed at an interval of 300 mm along the length of cable tray.

Supporting vertical racks and horizontal hooks shall be of 50 x 50 x 6 mm MS angles. Cable racks and hooks shall be welded construction.

To avoid damage during cable laying, cable structures shall have no scales, abrasive or rough surfaces for cutting edges.

If galvanizing is spoiled at any place, the same shall be painted with cold galvanized paint.

12.11 CABLING INSTALLATION

The cables shall be laid in RCC cable trenches / GI pipes / cable trays / directly buried in the ground. In paved area cable shall be laid in GI pipes only.

Except civil work of RCC cable trenches, Excavation of trenches of required width and depth in all types of soil Clearing natural obstructions including rock cutting if any required along the cable routing , Laying of cable on 8 cm of riddled sand and covered with 8 cm of riddled sand providing 75mm thick RCC cover slabs back filling with earth (after cable laying), and finally compacting to original ground level of cable trenches, all other equipment, materials and components required for cable laying is included in the scope of work.

The maximum trench depth shall normally be 1.5m If the trench is to cross railway tracks / roads or any load bearing area the cables shall betaken through suitable GI conduits/ pipes / ducts. Installation of

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cables directly buried in ground shall generally conform to the requirements given in IS:255.

Cables laid directly in underground trenches ( where permitted by owner/consultant) shall be in one layer only, more than one layer is not permissible.

For crossing the road / rail track, cables shall be laid in concrete cable ducts/ hume pipes/ GI pipes. 25% spare duct /pipe openings / pipes shall be available.

The scope includes but not limited to,

i) Cable inspection and handling. ii) Laying, meggering, termination, dressing and clamping of

cables. iii) Tagging and marking of cables. iv) HT/LT tests on cable. v) Identification of phases. vi) Connection of equipment. vii) Making of cabling ready for charging after completing all

associated works.

12.12 IMPORTANT NOTE

For cable installation/laying, if cutting of foundations or structures is required, prior permission shall be obtained from the owner/ engineer.

Wherever a cable crosses a temperature expansion joint in structure, a sufficient sag shall be provided. Cables of different voltage levels and noise classification if any, shall be taken on different trays/racks (or other means specified). When cables of different voltage levels or noise classes are installed on the same tray/ rack/place, the same shall be

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separated by grounded steel barrier. In no case instrument cables are to be run along with power cables. Cable trays / racks shall not be used as a walkway or ladder either during installation or while cable pulling or at any other time of installation.

12.13 CABLE INSPECTION AND HANDLING

On receipt of cable drums at site, the contractor shall inspect each cable drum and check for size, length and type with respect to supplier's seal and marking / documents. Loading and unloading of cable drums shall be done by crane and drums shall be carefully lifted and deposited on ground. If crane is not available then the drum shall be carefully rolled down on a suitable ramp of rails. The drum shall be rolled as per the direction indicated by the arrow on the drum in order to prevent the turns of the cable from loosening on the drum. Under no circumstances shall a drum be dropped to the ground as the shock may cause serious damage to the inner layer of cables. No cable drum shall be slung, except, by a bar or spindle through the center of the drum. In no case, the drum be stored on the flat i.e with the flanges horizontal. Only cable jacks shall be employed for removing the cable from the drum. For removing the cables from the drums, the drum should be properly mounted on jacks on a cable wheel, making sure that the spindle is strong enough to carry the weight without bending and that it is laying horizontally in the bearings so as to prevent the drum creeping to the one side or the other while it is rotating. The drums should be mounted such that when the drum is turned against the direction of arrow, the cable is payed out from the top of the drum to avoid any danger of bending and breaking the cable if unreeled from the bottom.

12.14 CABLE PULLING AND LAYING

Cable rollers shall be used for pulling and laying of cables. Cable shall be properly handled while laying to avoid damage to the cables.

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Cables may be pulled by hand or by the use of pulling eye securely clamped to the conductors. Jacket armour or outer jacket shall be secured to the clamp to prevent relative movement. If mechanical means are used to pull on the conductors, force must not exceed values recommended by the manufacturer. The pulling eye shall be securely fastened to the ends of all the conductors so that the load is evenly distributed. The ends of all cables to which pulling eyes are attached shall be cut off before terminations are made. Bending radius for permanent bends shall not be less than 15 (fifteen) times outer diameter of the cable. When pulling cables, the bending radius, pulling tensions and wall pressure at bends shall be strictly in accordance with cable manufacturer's recommendations.

12.15 CABLE CUTTING AND SPLICING

Cables cut from the drums, and distributed for various route lengths shall be carefully planned bearing in mind that splices shall not be allowed except on specified approval for larger length (cable splices are not permitted normally). All cables shall be cut to required lengths only after assessment of correct lengths required, by actual measurement at site. The contractor shall ensure that wastage of cables as short lengths is minimized, by resorting to most economical cable cutting schedule.

12.16 CABLING ON TRAYS/RACKS

Cabling may have to be carried out

a) on ladder type (GI/FRP) cable trays/slotted channels; b) in rigid steel conduits; c) in perforated type GI trays; d) in duct banks or embedded conduits; and e) buried underground/in concrete cable trenches.

Lighting, Power and control cables shall be properly segregated and clamped on the trays/racks.

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A clearance equal to one diameter of the bigger cables shall be maintained between two adjacent higher rated power cables on the trays/racks/ risers and clamped by separate clamps which shall follow the profile of the cable. Common clamping/ strapping shall be done for a bunch of control cables and small power cables. Cables shall be clamped at every 1.5 meters on the trays/racks slotted channels in trenches. Cable leading to cable box of an equipment shall be supported at a distance of 450 mm from cable gland/cable box and cable gland shall be suitably earthed. Cable shall be clamped only after the cables are neatly arranged, dressed and kept in position.

12.17 CABLING IN CONDUITS/PIPES

Cables through floor slabs/walls are to be passed through rigid, galvanized steel conduit. Cables entering or leaving the conduits shall be sealed with non-hardening silicon compounds. It is also contractor's responsibility to satisfy him-self regarding the conditions of the embedded conduits. Prior to pulling cables, each duct shall be rodded by suitable means. After rodding a 8 gauge pulling wire is to be left in each duct. The ends of the conduits shall be plugged when work is halted for any period of time. Laying of cables(in trenches in ground subject to owner’s Consultant’s permission) Cables shall be laid direct in ground in all kinds of soil or in the prepared RCC ducts. If required, 100 mm dia (min.) GI pipe shall be provided wherever these cables cross the roads/water lines, sewerage lines etc. GI pipe shall also be provided wherever the cables enter the building. Cables terminating to any equipment shall also be encased in a GI pipe raising from the ground level to the equipment connection. Cable racks for cable trays shall be fixed at a maximum interval of 1.5m

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Cables leaving the ground / floor shall be protected upto 2m height by conduits / metallic guards. Ladder type cable racks and trays shall be provided to lay cables. Cables shall be laid in separate racks according to the voltage / application classification. All necessary frame works and fixings for the support of cables And accessories shall be supplied. Cables shall be suitably protected against heat & Mechanical damages.

12.18 The sizes of GI pipes shall be as given below :

Size of cable

GI pipe

Upto 4 x 50 sq.mm 65 mm dia

3 1/2 x 70 - 3 1/2 x 90 sq.mm 80 mm dia 1/2 x 120 - 3 1/2 x 185 sq.mm 100 mm dia 3 ½ x 240 to 400 sq.mm 125 mm

Approximately 3 m of surplus cable shall be left on each end of the cable, on each side of the underground joint, at entries and places as may be decided by the engineer-in-charge. The surplus cable shall be left in the form of a loop. The trench cut through the road-ways or other paved areas inside building shall be restored to the same density and materials as in the surrounding areas at no extra cost. Black-toping of the road will, however, be not done by the contractor. Cable route markers shall be provided along straight runs of the cable and at locations approved by the engineer-in-charge, at intervals generally not exceeding 30 meters. Wherever cables are taken in conduits both ends of the conduits shall be sealed after laying the cable to avoid the ingress of water. All associated materials like sand, bricks, clamps and route markers etc., shall be supplied by the contractor. The cost for laying of cables shall be inclusive of all these items. Laying of cables on walls/columns/ceiling/structures

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All the lighting cables are to be neatly bunched and laid on surface of walls/ columns/ ceiling / structures. All the cables laid on surface of walls / columns / ceiling shall be supported by using clamps / rawl plugs and screws / cable hooks. No wooden plugs shall be used. All the cables laid on structures shall be fixed with suitable clamps. Cables are to be supported at minimum regular intervals of 0.5 m horizontal and 1 m vertical run. Care is to be taken while laying/pulling so that insulation of cables does not get damaged.

12.19 CABLE ENTRY AT BUILDINGS

Pressure seals and fire barriers shall be provided at the places where cables enter pressurized electrical rooms. All wall openings shall be effectively sealed after installation of cables to avoid water leakage. Wherever buried cables enter the buildings the same shall be taken through GI pipes embedded at the entry portion. After taking cables through the above pipes, the same shall be sealed by using suitable compound so as to avoid ingress of water.

12.20 CABLE JOINTING

Cable joints shall not be allowed, unless permitted by the owner / engineer in very exceptional cases.

12.21 CABLE TERMINATION:

Scope of Erection shall include cable termination to all equipment supplied by contractor as well as to field equipment likes motors, stations, I/o cabinets etc. Unit rates shall be applicable for temperature equipment not supplied by the contractor. Cable shall enter motor terminal boxes through the bottom if this is not practical through the side. Top entry to motors to be avoided. Connection of feeders in motor terminal boxes shall be done in accordance with standards. Cable shall enter switch boards, distribution boards etc., from top or bottom depending on equipment feature. Drops/ risers to individual

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cubicles shall be neatly laid out and may be supported on channel type frame work. Conductors of control cables where applicable shall be carefully and neatly arranged in a compact group at point of termination. The entire group shall be laced and tied with nylon strips to the point of fan out for connection of individual conductors to terminal blocks. Spare conductors shall be terminated with sufficient length to permit future connection to the terminal block. All the cables shall be terminated to the switch terminals, sockets, busbars etc., by means of suitable size of cable socket/lugs/ferrules preferably of tinned copper. Crimping tools shall be used for fixing the ferrules / sockets to the cable ends. (This shall be applicable even in case of single strand cable ranging from 1.5 sq. mm). For connections to busbars etc., brass or cadmium plated nuts / bolts and washers shall be used. Suitable measures shall be taken to avoid heating due to bimetallic contacts.

12.22 CONDUIT AND CABLE IDENTIFICATION

All conduit and PVC cable runs shall be identified at all terminations, including junction boxes, exposed points etc. Each conductor termination shall have an identification. Where cables are laid in trays identification tags shall be provided at least once in every 15 metres. Colour coding for conductors The colour coding for conductors of power cables shall be as per IS 1554 Part (I)-1976. The colour coding shall be applied to for power and lighting feeders terminating in a) 415V switchboard including all feeders. b) 415V isolators and socket outlets and junction boxes. Joints/terminations of earth conductor

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All joints of bare earth strips shall be welded to form a rigid earthing ring. All such welded joints shall be given necessary coating of bitumen compound to prevent corrosion. Welded joints shall be considered as a part of laying of earth conductor and they shall not be considered as terminations for payment purposes. No extra costs shall be applicable for joints in the earth buses. Crimping type lugs shall be used for termination of round earth conductors. Contractor shall make his own arrangements for necessary welding equipment, crimping tools, drilling machine and other tools/tackles necessary for completing the installation. Any modification suggested by the Electrical Inspector shall be done by the contractor at no extra cost. All the earth electrodes in the plant will be interconnected by flat GI earthing conductors buried directly in ground. In all switch board rooms earthing flats will be run along walls, column and horizontal and vertical structural members using clamps/GI hardware.

12.23 ELECTRICAL WIRING FOR ILLUMINATION

POINT WIRING

Point wiring is inclusive of Circuit wiring The Scope includes: The Circuit wiring from Distribution boards (LDB/SDB) to Switch boards using 2.5 Sq. mm copper Wires in case of Circuits for light fittings/ fan/ 5 A socket outlet Circuits Point wiring between switchboards and the relevant light/fan/5A socket outlet points using 1.5 Sq. mm Copper wires Circuit/point wiring using 4 Sq. mm copper wires in case of circuits for 15 A Socket outlets/exhaust fans/widow Air Conditioners. a)"Power and Heating" wiring shall be kept separate and distinct from "Lighting"/ "Fan" wiring. All conductors shall be run as far as possible along the walls and ceiling, so as to be accessible and capable of being thoroughly inspected.

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b)Light and fans may be wired on a common circuit. However, such circuit shall not have more than 10 points of light /fan, 5A socket outlets in a single phase circuit or 1000 Watts whichever is less. Surface laid /Concealed PVC Conduits/casing-N-capping for the above circuit and point wiring as per approved drawings. All materials /labour/consumables are to included for carrying out the ‘point wiring’ upto the light fittings ,fans and 5A/15A socket outlets as described above. However the cost of lighting fixtures(lamps)/fans/socket outlets only shall be paid separately as per unit rates quoted.

12.24 DISTRIBUTION

The balancing of circuits in the poly-phase installations shall be ensured. In large rooms, light and socket outlet points

shall be distributed over more than one circuit.

12.25 JOINTS AND LOOPING BACK

Unless otherwise specified the wiring shall be done in the "Looping" system. Both the phase and the neutral conductors shall be looped at the switch box/junction box nearest to the point of entry. Jointing of cables at junction boxes located on ceiling are not allowed. No bare or twisted joints are allowed at any point. Looping neutrals between different circuits in point wiring is not allowed. No joints in conductors shall be made at intermediate points in the through run of cables unless the length of a final sub-circuit, sub-main or main is more than the length of the standard coil, in which case, jointing shall be done by soldering.

12.26 CONDUIT SYSTEM

a) G.I conduit Conduit shall be of galvanized iron, rigid, screwed type. The

internal bore of all conduits must be smooth and the ends free from burrs. The conduits upto 32 mm dia shall be 1.6 mm thick and conduits above 32 mm shall be of 2mm thick.

b) M.S. Conduits Conduit shall be of mild steel, rigid, screwed type and should

be stove enameled. The internal bore of all conduits must be

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smooth and free from burrs. The conduits shall be 1.6 mm thick upto 32 mm dia and above 32 mm, it shall be 2 mm thick.

c) PVC conduit Rigid PVC conduit suitable for electrical wiring may also be

used wherever approved by Engineer. It will be of approved make of minimum 1.8 mm thickness.

The length of the conduit (MS/GI/PVC) will also include all

accessories like joints, bends, junction/pull box etc., required as per site conditions and fish wire for drawing-in cables.

12.27 Casing ‘N’ capping

The casing ‘N’ capping wiring shall be done in accordance with the specification laid down as per standard practice.

12.28 USE OF PIPES

All the GI pipes supplied shall be suitable for cable drawing, without any internal burrs, smooth internal surface and threaded at both ends with coupling at one end. The installation work of cable includes making the necessary bends using suitable bending machine without damage to the pipe, making additional threading at cut ends, jointing with coupling including supply and installation of all required accessories like junction/pull box etc.

Class `B' type GI pipes as per IS: 1239 shall be used at the

following locations:

a) Cables running on floor shall be laid in buried GI pipes. b) All cables laid upto a level of + 2000 mm from floor level

shall be laid in GI pipes. c) Cables crossing road, entering buildings from outside

through wall/foundations etc., shall be laid in GI pipes. d) GI pipes shall be used for taking the cable to feeder pillar

through foundation or for taking cable to street light poles.

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e) All GI pipes laid shall have a suitable fish wire for drawing in cable.

Number of wires in a conduit/radius of conduit bending

The number of wires in each conduit shall be as per relevant IS.

Draw-in-boxes must be provided so that the wires are not drawn round more than two right angle bends or their equivalent. The radius of ends must not be less than the standard normal bend. The standard radius of normal bends shall be as tabulated below (For single core wires):

Normal radius of conduit bends

Outside dia. Of conduit

Radius of Normal bends Remarks

20 mm 50 mm 25 mm 60 mm 32 mm 80 mm 40 mm 95 mm 50 mm 125 mm

Radius measured from centre of curvature to axis

12.29 INSTALLATION OF TRANSFORMERS

In case of transformer, the accessories shipped loose by the manufacturer shall be assembled by the contractor at site

The contractor shall place the transformer on the rails at allocation indicated in the layout drawing of the substation then arrangement shall be made to prevent movement of transformer in any direction. All accessories shall then be properly mounted both and both mechanical and electrical connections shall be made as per the manufacturer’s drawing and owner’s drawing. Two samples of oil from transformer, one from the conservator and the other from the tank through drain valve shall be tested as per section 8-4 of IS:1886 for dielectric strength and if it is observed the values are low, the oil has to filtered and if required drying of transformer shall be carried out to get required dielectric strength as per relevant Indian standard. Dielectric strength shall be checked again be fore energizing.

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The joint between the flange of transformer and the transformer terminal box of the bus duct / cable shall be checked for air tightness. Whenever the power / control cables project above ground, for termination of cable box / marshalling box, the same shall be run in GI conduits of suitable cross section and the same shall be supported properly and the pipe ends shall be sealed with bitumen compound. The contractor shall follow the following sequence of erection of transformers :

1. Unpack the closed / packed case and compare with packing

list. 2. Physical checks and inspection, pay particular attention to :

b) Tank sides or cooling sides dented. c) Protruding fitting damaged. d) Oil sight glass broken. e) Bushings cracked or broken. f) Bolts loose due to vibration in transit. g) Oil Leakages

3. Transportation to erection site. 4. Erection of foundation / Rails. 5. Assembly of transformer. a)Radiator Bank b)Cooling fans.

c)Buchholz relay d)Conservator Tank. e) Explosion Vent f) Air Breather Silica-gel h) Marshalling Box. i) Tap Changer j) Bushing k)Thermometer etc.

6. Checking of oil level filteration / drying of oil. 7. Alignment 8. Anchoring and tack welding 9. Mechanical Checks 10. Wiring and sealing of wiring of assembled parts. 11. Laying, meggering, termination, dressing and clamping of

cable. 12. Tagging and marking of cables. 13. Testing of cables.

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14. Earthing – Earthing station, earthing of transformers, earthing strip, earth resistance to comply with IER (latest revision).

15. Testing of assembled parts 16. Testing and calibration of meters, relays, CTs, PTs,

thermometers etc. 17. Connection of Bus duct / bus bars / Cables to primary and

secondary of transformers. 18. Series of tests on transformer as per supplier’s / engineer’s

instructions, IS:1886 and manufacturer’s recommendations. 19. Submission of complete report in the format. 20. Charging of transformer 21. Loading of transformer 22. Painting work 23. Handing over to Owner / engineer.

13.00 TESTING AND COMMISSIONING

13.01 GENERAL

The successful tenderer, based on the broad outline procedure indicated in this specification, shall finalize with owner / engineer, the detailed procedure for testing and commissioning along with time schedules for both. The contractor shall adhere to the general guidelines given for testing & commissioning of the equipment/items implicitly covered under heading special instructions to contractor general condition of contract and technical specification. The intention of specifying below, the procedure for testing and commissioning and different tests to be conducted, are only to give guideline to the contractor. The contractor shall not restrict himself in carrying out only the tests specified here, but all tests as per relevant Indian Standards shall satisfactorily be conducted on each equipment. On successful completion of erection of each item /equipment, a final inspection will be carried out at site by owner /engineer, for correctness and completeness of erection. The successful tenderer shall provide adequate supervisory/ skilled personnel and all tools and tackles, testing equipment and instruments required for complete checking of installations and testing and commissioning of all equipment and accessories.

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The tenderer shall furnish with the offer a complete list of equipment, tools and tackles, instruments etc. which he intends bring in to site for erection, start up, testing and commissioning of equipment. The testing and commissioning of all equipment under the scope of the tenderer shall be carried out in accordance with the latest edition of relevant Indian Standards and IE Rules. The testing of all sub systems as well as the equipment as a whole shall be carried out to ensure that the equipment and its components are in satisfactory condition and will successfully perform their functional operation. Test reports shall be submitted in required number of copies duly signed by the TENDERER, MECON and OWNER. The results of all tests shall confirm to the requirements of the specification as well as any specific performance data guaranteed during finalisation of the contract. All equipment after testing shall be energized only After certification by the qualified testing engineer that the equipment is ready for energisation and with \ the concurrence of OWNER. The testing and commissioning of all equipment under the scope of the tenderer shall be carried out in accordance with the latest edition of relevant Indian Standards and IE Rules. The testing of all sub systems as well as the equipment as a whole shall be carried out to ensure that the equipment and its components are in satisfactory condition and will successfully perform their functional operation. All tests shall be carried out by the tenderer using his own tools, instruments, personnel etc. The tests to be carried out on each equipment shall be indicated by the tenderer in the offer and shall be mutually agreed before placement of order. Test reports shall be submitted in required number of copies duly signed by the tenderer, MECON and OWNER. The format for test reports shall be mutually agreed.

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The results of all tests shall confirm to the requirements of the specification as well as any specific performance data guaranteed during finalisation of the contract. All equipment after testing shall be energized only after certification by the qualified testing engineer that the equipment is ready for energization and with the concurrence of OWNER.

13.02 MECHANICAL INSPECTION AND CHECK UP OF THE EQUIPMENT

After installation, but before any power supply is connected, the contractor shall make a complete mechanical check & clean all erected electrical equipment & systems. This shall include, but not limited, to the following:

i) Visually inspect all equipment/item for defects if any & check

equipment numbers against drawings to ensure that equipment has been correctly located and proper installation is done.

ii) Check name-plates of individual feeders & others, distribution boards, distribution fuse boards etc., for conformity with data given on the supplier's drawings/standards/specification sheets.

iii) Check that motors turn freely by hand. iv) Remove, clean & replace if necessary, drain plugs of all

motors. v) Check connections to all equipment for tightness. vi) Check correctness of cabling and its terminations. vii) Check phasing, polarity. viii) Check all electrical & mechanical interlocks & other equipment

for safety and to ascertain that those are functioning as per intention and accomplish their purposes.

ix) Check all plug in contacts for alignment and grip. x) Check all contactors for free manual operation xi) Remove all blocking devices installed for shipment. xii) Check all the coils for their continuity & proper voltage. xiii) Check that the fuses are correctly rated & installed are clean

undamaged &fit for operation.

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xiv) Check, that all disconnect switches are clean, undamaged & operate properly. Ensure that all contacts are tight/ joints, linkages & contacts properly lubricated (where applicable). Check interlocks and auxiliary devices and also the operation of the circuit breakers with the protection relay circuit connected

xv) Vacuum clean equipment before energizing.

13.03 HT / LT switchgear power distribution boards, distribution fuse boards, plug and sockets, switch fuse and like equipment

All interconnected wiring shall be checked thoroughly for correct connections with the wiring and schematic drawings of the manufacturer and the drawings supplied by the owner before energizing. All cable / bus bar connections shall also be thoroughly inspected & checked for corrections, foreign materials, tightness etc., Before energizing the equipment, all labeling shall be checked against Drgs All components within the main equipment shall be tested for proper performance & correct operation before commissioning the equipment. Continuity and insulation tests shall be conducted. Switchgear/ MCC rated 415 volts shall be tested with a 1000 volts megger. Auxiliary wiring rated less than 415 volts shall be tested with 500 volts megger. Equipment giving insulation resistance readings of less than 10 mega Ohms shall not be energized. Necessary steps shall be taken for improving the I.R value. All protective relays shall be tested at sufficient points to establish their proper functioning in accordance with the manufacturer's specification.

13.04 AC MOTORS

1. IR test of stator and rotor windings 2. Heating of both windings with heating curve (only for HT motors)

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3. Ensure that checking / testing of associated switchboard, cables,

relays / meter interlocking as mentioned in relevant chapters are completed.

4. Check tightness of cable connection 5. Winding resistance measurement of stator and rotor. 6. Checking continuity of winding 7. Check tightness of earth connections 8. Check space heaters and carryout heating of winding (if required) 9. Check direction of rotation in de-coupled condition during kick-start 10. Measure no load current for all phases 11. Check for temperature rise of body in no load and on load

conditions 12. Check for tripping of motor from local / remote switches and from

electrical / technological protection including differential protection 13. Checking of vibration 14. Checking of noise level during load running, 15. Measurement of stator and bearing temperatures (if applicable)

for every Half an hour interval till saturation comes 16. Checking tightness of foundation bolts 17. Check operation of speed switch (if there) 18. Check continuity of temperature detectors 19. Check alignment, paralleling of shafts, level of lubricating oil etc.

as per manufacturer's manual 20. Check contact of slip ring brush and measure brush pressure 21. For CACW drive check cooling water and system piping,

availability of pressure, cleaning and pressure testing of pipelines etc.

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All Product tanks shall be Adequately protected against lightning strikes, by connecting them to the earth grid with adequate size of GI Earth continuity Conductors as per relevant norms/codes/standards.

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22. Check for polarization index of stator winding. R10 / R1 by motorised megger (The value should not be less than 1.5).

23. Dielectric test (only for HT motors)

13.05 PRE-COMMISSIONING TESTS

All pre-commissioning tests at site on all the equipment/items shall be carried out as per relevant standards and as directed by the owner/ engineer. High voltage tests and primary and secondary injection tests on all components/ equipment shall form part of pre-commissioning tests. All cables, heating cable units, immersion type heaters, correction type unit heaters and metallic conduits shall be tested to ensure electrical continuity. Circuit breakers, contactors, relays, remote devices and other electrical operation equipment shall be functionally tested. Relays, thermisters, photo-cells and other equipment requiring operational setting shall be set and checked.

13.06 OPERATIONAL TESTING

Upon completion of the electrical installation & at such time as the owner/ engineer may direct, the contractor shall conduct apparatus and system operating tests for approval and acceptance purposes. All apparatus control schemes, interlocking safety & protective devices etc., shall be demonstrated to operate and function in accordance with the requirements of this specification. All malfunctions & improper operations disclosed through these tests, shall be corrected to the satisfaction of the owner/engineer. All necessary corrections to the contractor-supplied equipment shall be at contractor's expense. The contractor shall provide all electrical skill & labour required during the course of this operational testing.

13.07 INSULATION RESISTANCE TEST FOR LIGHTING

INSTALLATION

The insulation resistance shall be measured by applying 500 V DC between earth and the whole system of conductor or any section thereof (with all fuses in place, all switches closed and all lamps in position) by a megger of suitable range.

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The insulation resistance of the installation shall be not less than 50.0 meg ohms divided by the number of outlets on the circuit except that it need not exceed 1 meg ohm for the whole installation. The insulation resistance shall also be measured between all conductors connected to one phase conductor of the supply and all the conductors connected to the neutrals or other phase conductors of the supply with all lamps in position and switch off and its value shall be not less than that specified above.

13.08 TESTING OF POLARITY OF NON-LINKED SINGLE POLE

SWITCHES

In a two wire installation, test shall be made at each point to verify that cutouts and all non-linked single pole switches have been fitted in the same conductor throughout and such conductor shall be labeled or marked for connection to the phase conductor only and not on the neutral or earthed conductor. In a three wire or a four wire installation a test shall be made to verify that every non-linked single pole switch or cutout is fitted in a conductor which is labeled or marked for connection to the phase conductors of the supply. Acceptance of the electrical contractor's work described herein is contingent upon the successful testing of all electrical apparatus, systems and associated wiring, (testing methods shall be in accordance with procedures readily recognizable by the owner/engineer and the contractor). All tests shall be performed in the presence of the contractor and the owner/ engineer. For all types of visual inspections, checking, pre-commissioning, commissioning tests and acceptance tests, relevant IS for the tests given therein shall be followed in addition to the instructions of engineer/owner for such tests.

13.09 TESTING AND COMMISSIONING OF EARTHING SYSTEM

The contractor shall inspect and test all earthing works carried out by him, including all interconnections between group loops, earthing of electrical rooms and grounding of equipment and ensure that the connections are permanent and that the earthing circuit is continuous. The contractor shall test the buried earth grids supplied by him and others within the zone assigned to him.

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The contractor shall measure and record earth resistance at various earth connection points. Equipment earthing internal to each equipment such as fourth core earthing in the motor terminal boxes shall be shown to the owner/engineer. Only after checking of such connection by the owner/ engineer, the terminal boxes shall be closed.

Earthing system & connections shall be tested as follows :

a) Resistance of individual earth electrode shall be measured after

disconnecting it from the grid. b) Earthing resistance of the grid shall be measured after

connecting all the electrodes to the grid and generally the test value shall conform to IS code of practice unless otherwise specified. The earth resistance shall be 2 Ohms for the grids constructed by the Contractor.

The resistance to earth shall be measured at the following :

a) At each earth electrode independently. b) At each earth system provided for structure lightning

protection c) Combined earthing system used to earth electrical equipment

enclosures, metal structures etc., 13.10 TESTING AND COMMISSIONING OF CABLING SYSTEM

The contractor shall inspect & test all cabling works carried out by him. All cables shall be tested before and after jointing/ termination as per relevant Indian Standards. Jointing/termination shall be redone, if found unsatisfactory without any extra cost to the owner. For testing, all cables shall be megger tested before jointing. After completion of jointing, all LV cables shall be megger tested. The cable cores should be tested for continuity absence of cross phasing, insulation resistance to earth and insulation resistance between conductors.

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Before energizing, the insulation resistance of every circuit, circuit cable shall be measured from phase to phase and from phase to ground. Where splices or terminations are required in circuits measure insulation resistance of each length of cable before splicing and/or terminating. Repeat measurements after splices and/or terminations are complete. Measure the insulation resistance of directly buried cable circuits before trenches are back filled. Repeat measurement after back filling. DC high voltage test shall be made after installation of the following - a) All 1100 volts grade cables in which straight through joints have

been made. b) All cables above 1100 V grade. For record purposes test data shall include the measured values of leakage current. The DC high voltage test shall be performed as detailed below : Cable shall be installed in final position with all the straight through joints complete. Termination shall be kept unfinished so that motors switchgear, transformer etc., are not subjected to test voltage. The test voltage and duration shall be as per relevant codes and practice of Bureau of Indian Standards. The result of all the tests conducted at site shall be furnished in a tabulated form given below, to the purchaser for their approval. All tests shall be performed with genuine instruments. The tenderer shall, therefore, submit a list of all such instruments proposed to be used for testing the installation.

13.11 COMPLETION CERTIFICATE FOR TESTING & REQUEST FOR COMMISSIONING

I/We certify that the installation detailed below has been installed by me/us and tested and that to the best of my/our knowledge and

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belief, it complied with I.E Rules, 1956, as well as MECON Technical Specifications for Electrical Works. All pre- commissioning checks / tests have been completed and test certificates are enclosed. Approval from Statutory authority has also been obtained and is enclosed. Now we request for regular commissioning clearance.

Electrical installation at : .....................

Voltage and system of supply : ....................

I Particulars of instruments used

1. Insulation tester Make ..................... Type ..................... Sl. No ..................... 2. Earth tester Make ..................... Type ..................... Sl. No. ..................... 3. Any other instrument Make ..................... Type ..................... Sl. No. .....................

II. Particulars of works

A. Equipment details Sl. No.

Equipment Description Rating Remarks (Enclose site test certificate)

1.

2.

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3.

4.

5.

B. Internal electrical installation No. System of wiring Total i) Light point

ii) Fan point iii) Plug point a) 3 pin 5 Amps. b) 3 pin 15 Amps. C. Cables a) Total length of under- : .................... ground cable and its size b) No. of joints : ..........end joints ........tee joints .......straight-through joints

D. Earthing a) Description of earth electrode b) No. of earth electrode c) Size of main earthing lead III. Test result a) Insulation resistance

i) Insulation resistance of the whole system

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of conductors to earth ........Meg-ohms. ii) Insulation resistance between the phase conductor and neutral Between phase R & N - Meg-ohms Between phase Y & N - Meg-ohms Between phase B & N - Meg-ohms iii) Insulation resistance between phase-conductors in case of three phase supply Between phase R & Y - Meg-ohms Between phase Y & B - Meg-ohms Between phase B & R - Meg-ohms b) Polarity test Polarity of all single pole branch switches and cutouts i) Cutout ii) Switch No.1 No.2 c) Earth continuity tests Maximum resistance between any point in the earth continuity conductor including metal conduits and main earthing lead ........................ ohms. d) Earth - Electrode Resistance No.1 ......................... ohms No.2 ......................... ohms No.3 ......................... ohms

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No.4 ......................... ohms

e) Cable testing i) Before laying Date of test ........

Insulation resistance in Meg-ohms Sl. No.

From .......

Size in sq. mm

Voltage grade Length At the time of issue During laying & before

covering

Between RY ...... RY ....... YB ...... YB .......

BR ...... BR ....... Between RN ...... RN ...... YN ...... YN ...... BN ...... BN ...... Between RE ...... RE ...... YE ...... YE ...... BE ...... BE ...... NE ...... NE

...... ------------------------------------------------------- ii) Before commissioning a) Whether high voltage test conducted YES/NO b) If conducted, system of supply................ test voltage at ........... KV .............for ........ minutes, result of test : Satisfactory/unsatisfactory.

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c) If not conducted, Voltage of megger used : Earth temperature : Result of megger testing : Between R & Y : Y & B : B & R : Between R & N : Y & N : B & N : Between R & E : Between Y & E : Between B & E : SIGNATURE OF SUPERVISOR SIGNATURE OF CONTRACTOR SUPERVISOR'S LICENCE NO. CONTRACTOR'S LICENCE NO. NAME & ADDRESS NAME & ADDRESS

The system and equipment as above has been checked / verified along with test documents and Statutory Authority’s clearance. The system / equipment may be commissioned

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(ENGINEER) (ENGINEER) MECON HPCL 14.00 DATA,DRAWINGS AND DOCUMENTS 14.01 Data / Drawings to be submitted with tender.

a) Single Line diagram of the proposed Power Distribution Scheme. ( H.T./L.T./ Lighting ) b) confirmation of the drawings enclosed with the tender. c) List of Makes offered for all Equipment d) List of Spares offered

i) Commissioning ii) Insurance

iii) Operational

e)List of tools and tackles to be deployed during execution

14.02 INFORMATION TO BE SUBMITTED BY SUCCESSFUL TENDERER

Drawing and information to be submitted within one month from the

date of placement of order for approval of the Owner / Consultant before manufacture / procurement of equipment and components:

• Outline & general arrangement drawings incorporating the principal

dimensions of all equipment ( H.T / L.T. / Lighting/ other Switchgear Equipment ) covered under Part-A of price schedule.

• Control & interlocking scheme with write up. Co-ordinated Protection / Control Schemes.

• Elementary diagrams. • Complete coordinated layout drawing indicating types of

underground communication such as electrical cable ducts. • Layout of Electrical Equipment in Sub- station, and Electrical Room,

Pump Houses, rooms / buildings, loading stations etc..

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• Earthing layout drgs • Lightning protection drgs • Illumination layout, bill of materials, single line diagrams of all

lighting boards • Design Calculations • Single Line diagram of distribution Scheme. ( H.T./L.T./ Lighting )

For main equipment.

• SLD for HT Four pole structure and feeder details along with control requirements.

• GA drawing of above boards & distribution transformer, battery and

battery charger panel, indicating front view, dimensional details. • Cable routing drgs with various section as indicative locations and

arrangement of trenches. However the actual works as will be actually executed by contractor as per site conditions and as per owner or site engineer’s instructions will be indicated in contractor drgs.

• Cable schedules and interconnections drawings. • Earthing layout drgs • Lightning protection drgs. • Lighting layout drgs. Final drgs showing actual layout and wiring

arrangement. • Control Scheme drawings of various electrical equipment vendor

whose equipment are included in free issue items.

• Interconnection and external connection diagram and cable schedule

• Installation, operation and maintenance manual for reference. • Termination diagrams. • Layout drawing for switchgear rooms, cable routing and

earthing. • Data sheet for HT / LT Cables and other cable and termination

kits. • Data sheets for Battery, Battery Charger, Transformer, load

break isolators lighting energy saving device, lighting fixture / sockets / boards, Cables (all types), HT cable termination kits, field devices (local control station etc) etc.

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• List of 2 years maintenance spares, commissioning spares.

14.03 Documents to be submitted along with supply of equipment.

i) Material test certificates. ii) Reports on shop tests and test certificates and certified test

characteristics. iii) The instruction manual shall furnish the following information in

practical and comprehensive manner prepared for use by operating and / or maintenance personnel.

• Instructions for initial installation. • Instructions for operation, maintenance and repair. • Recommended inspection points and period of

inspection. • Ordering information for all replaceable parts etc.,

iv) The instruction shall be arranged in a logical and orderly

sequence. A general description of the equipment including significant technical characteristics shall be included to familiarize operating and maintenance personnel with the equipment.

v) Necessary drawings and other illustrations shall be included or appropriate drawings shall be bound in the manual. Test, adjustment and calibration information, as appropriate, shall be included and shall be identified to the specific equipment, safety and other warning notices and installation, maintenance and operating cautions shall be emphasized.

vi) A parts list shall be included showing part nomenclature manufacturer’s part No. and / or other information necessary for accurate identification and ordering of replaceable parts.

vii) The instruction manuals shall be bound in durable folder. viii) If a standard manual is furnished covering more than the

specific equipment purchase, the applicable model (or other identification) number, parts number and other information for the specific equipment purchased shall be clearly identified.

ix) The instruction manuals shall include list of all special tools and tackles furnished with complete drawings and instructions for use of such tools and tackles.

14.04 Drawings / documents to be submitted for information

during execution of project

a)Erection/Installation Manuals

b)Manufacturing Drawings

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c)Factory test reports

d)Technical literatures/ Product data /catalogues.

e)Cable layout drawing/Cable Schedule.

14.05 Drawings Documents to be submitted before final

Acceptance.

a) As Built Drawings for Entire Plant Electrics.

b) Operation and Maintenance Manuals

c) Detailed Bill of Quantity for all Equipment.

d) As Built Cable routing drawings/ interconnections drawings / Cable Schedules.

e) Testing and commissioning Reports.

f) Statutory Approval Documents.

15.00 PREFFERED MAKES OF EQUIPMENT

Makes of the equipment offered shall be generally limited to the Following only. However, while offering the make shall be Elected justifying the quality and economy.

Technical literature and publications of items to be offered by the tenderer shall be enclosed with their quotation. Makes of all the equipment and accessories must be clearly mentioned against each item.

In case rating, type, make and other details of all these items are not Mentioned by the tenderer, their quotation is likely to be treated as incomplete. The purchaser reserves the right, to select an item of any make, based on Standardization needs, in case he has not \indicated make specifically or Has Indicated, more than one make. The tenderer shall ensure that equipment and components are from Indigenous sources to the maximum possible. Imported equipment/components shall be resorted to only in case of Non

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availability of equipment/ component from Indigenous sources and with prior approval of owner/Consultant.

Sl. No. Item Description PREFERRED MAKES

1. BATTERY CHARGER : CHABBI ELECTRICALS /

SABNIFE/AUTOMATIC ELECTRIC/EXIDE 2. HT , LT AND CONTROL

CABLES : NICCO/RPG/UNIVERSAL/

TORRENT/INDIAN CABLE CO.,/CABLE CORPORATION OF INDIA/FORT GLOSTER INDUSTRIES/ASIAN CABLES/POLYCAB

3. LIGHTING FIXTURES : PHILIPS /CGL/BAJAJ/CANARA 4. MCBs : MDS/GE POWER/INDO ASEAN/HAVELS 5. 11 KV/ 3.3 kV TERMINATION

KIT & STRAIGHT THROUGH JOINTS

: CCI/RAYCHEM/MAHINDRA ENGG.

6. PROTECTIVE RELAYS, AUXILIARY RELAYS & SEMAPHORES

: ALSTOM/ABB/GE-MULTILIN/EASUN REY ROLLE/SEG/ ENGLISH ELECTRIC

7. INSTRUMENTTRANSFORMERSCurrent Transformers

: AUTOMATIC ELECTRIC / KAPPA / JYOTHI / PRAGATHI / INSTRANS /KALPA

8. INDICATING/RECORDING Meters

: AUTOMATIC ELECTRIC/MECO/IMP / RISHAB/ UNIVERSAL/SIMCO/BHEL

9. CONTROL SELECTOR SWITCHES PUSH BUTTONS

: KAYCEE/ALSTOM/SALZER/SIEMENS /EASUN REY ROLLE/L & T / EE / BCH/ VAISHNO

10. AUXILIARY CONTACTORS Timers/SWITCH FUSE UNITS

: SIEMENS/L&T/TC/ABB / GE POWER CONTROL / BCH / TELEMECHANIQUE

11. CONTROL CONTACTORS HRC FUSES

: GEC – ALSTOM/ BCH/L&T/SIEMENS

12. CABLE TRAY : PATNY & CO / TECHNOFAB /INDIANA /SADHANA

13. CABLE GLANDS : SMI / COMET / MAYUR/JANSON 14. CABLE LUGS / SOCKETS /

FERRULES : DOWELLS / CONNECT WEL / ISMAL

15. ELCB/MCB : GEC ALSTHOM/MDS/HAVELS/S&S/Indo Asean

16. MCCB, ACB : ABB/L&T/CGL/GE POWER 17. G. I. CONDUITS : TATA / JINDAL / APOLLO / ZENITH 18. MS CONDUITS : NICCO / BEC / APOLLO 19. EXHAUST FANS : KHAITAN/USHA/GEC/BAJAJ/CROMPTON 20. CELING FANS : KHAITAN/USHA/GEC/BAJAJ/CROMPTON 21. COPPER WIRES

(lighting) : FINOLEX /OMEGA /FINECORE / WINCAB

/ POLYCAB, RAVICAB/RAJANIGANDHA 22. PVC CONDUITS AND PVC : AVON PLAST / MODI / UNIVERSAL

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CASING ‘N’ CAPPING PRECISION 23. DECORATIVE SWITCHES &

SOCKETS : ANCHOR/ELLORA/KINJAL/NORTHWEST/L

ISHA 24 DIGITAL METERS : L & T/ SEM / ENERCON 25 POWER PLUG & SOCKET

(INDUSTRIAL TYPE) CROMPTON GREAVES/BEST&

CROMPTON /EE/GEC/BCH 26 INDICATING LAMPS L& T/BCH/VAISHNO/SIEMENS/ESSEN 27 SOLID STATE ANNUNCIATOR L&T, PROCON,INSTALLARM, MINILEC 28 BATTERIES EXIDE/STANDARD/AMCO/AMAR RAJA 29 Street Lighting Poles Rajan/KL Industries/Shubham 30 High Mast Philips/CGL/BAJAJ 31 DISTRIBUTION

TRANSFORMER CGL,VOLTAMP,KIRLOSKAR

32 11 KV HT (VCB) BOARD SIEMENS,AREVA,CGL 33 415 V LT PMCC,MOV DB, L&T,SIEMENS,BCH,Control & Switchgear 34 Variable Speed Drive for 1.1

KW AC Motor BCH/L&T/SIEMENS/ABB

16.00 APPLICABLE STANDARDS & CODES

All applicable Indian and IEC codes, regulations and standards shall govern the work hereunder. In the event of the requirements of the specification, exceed the requirements of the, corresponding codes, regulations or standards, the specification shall govern. Where there are more than one applicable codes or standards for any item, the most stringent will apply. All parts issued against a standard/code shall be referred to wherever specific Part No is or not given. Equipment covered by this specification shall conform to the latest editions and revisions of all relevant applicable codes, and standards in addition to the ones listed below: Latest revision of all applicable codes, regulations and standards shall govern the design, manufacture, installation, testing & commissioning of individual equipment and total installation even when the requirement of the specification is less stringent than the codes, regulations & standards. In the event of conflict between specification & codes, the most stringent shall govern. In the event of conflict between codes, regulations and standards referred to in the specification, the owner's/consultant's decision is final and binding.

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Wherever IS are not available, relevant IEC standards are to be followed: Equipment covered by this specification shall conform to the latest editions and revisions of all relevant applicable codes, and standards in addition to the ones listed below: It may Please, be noted that the above list is not exhaustive.

1 BS 4999

(Parts 1,4,31,32,33,60) : General requirement of rotating

Electrical machines 2 IEC 34-1 Part – 1 : Rotating Electrical Machines Rating and

Performance 3 IEC 34-2 Part - 2 : Methods for determining losses and efficiency

of rotating machine from tests 4 IEC 34-2 Part - 3

: Methods for determining losses and efficiency

of Rotating machine from tests 5 IS 0325-1996 : 3-phase induction motors. 6 IS 0900 –1965

: Code of practice for induction motors

installation and maintenance. 7 8 IS 0005-1994 : Colours for ready mixed paints and enamel

9

IS 2026 - 1977 Parts 1,2 & 4 1977 Part – 3 1981

: Power transformers

10 IS 0335-1993 : New insulating oils 11 IS 0374 – 1979 : Electric Ceiling type Fans & Regulators 12 IS 0396 Part I to V

Reaffirmed 1992 : Aluminum conductors for over-head

transmission purpose. 13 IS 2121

Part 1,2 1981 Part 3-1992 Part 4-1991

: Conductors and earth wire accessories for overhead power lines.

14 IS 0731-1971

: Specification for porcelain insulator for overhead power lines with a nominal voltage greater than 1000V.

15. IS 1651-1991 : Stationary cells and batteries, lead acid type (with tubular positive plates)

16. IS 1652-1991

: Stationary cells and batteries, lead acid type (with plante’ positive plates)

17 IS 0732 – 1989, IS – 3854-1988/1990

: Code of practice Electrical wiring installations

18 IS 1239 Part-1 1190 /Part-2 1992

: Mild Steel tubes, tubulars and other wrought steel fittings.

19 IS 0722 Part 1 to 9 : Alternating current Electricity meters 20 IS 1248-1993 : Direct acting analogue electrical measuring

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Instruments and their Accessories 21. IS 2419-1979

Re-affirmed 1991 : Dimensions for panel mounted indicating and

recording electrical instruments 22 IS 1255 – 1983

Reaffirmed 1991 : Code of practice for installation & maintenance

of power cables up to 33 kV rating 23 IS 694 – 1990 : PVC insulated electric cables for working

voltages upto and including 1100 Volts 24 IS 1554 Part 1&2 1988 : PVC Insulated (Heavy duty)electric cables for

working voltages upto and including 11000 Volts

25 IS 1271-1985 Re affirmed 1990

: Thermal evaluation and classification of Electrical Insulation

26 IS 3691 Part 1 to 5 1976,1986

: Recommended current ratings of cables.

27 IS 1777–1978 Reaffirmed 1990

: Industrial luminaires with metal reflectors

28 IS 1913-1978 Re-affirmed 1992

: General & safety requirement of luminaires

29 DIN EN 50014 : Explosion proof light fittings50019 for Group II C areas (German Specification)

30. IS 1293 – 1988 Reaffirmed 1990

: Plug & socket outlets for rated voltages upto and including 250 Volts and rated currents upto and including 16 Amperes

31. IS 2032 : Graphical symbols used in electrical technology32 IS 2099-1986

: Bushing for alternating voltages above 1000V.

33 IS 2147-1962 Reaffirmed 1990

: Degrees of protection provided by enclosures for LV switchgear & control gear.

34 IS 2148-1981 Re-affirmed 1993

: Specification for Flame proof, enclosure of electrical apparatus.

35 IS 2206

: Specification for Flame proof, electrical light fittings.

36 IS 2418-1977 parts 1-4 Reaffirmed 1990-1993

: Tubular flourescent lamps for general lighting service, requirements & tests

37 IS 2448-1963 Re-affirmed 1995

: Adhesive insulating tapes for electrical Purposes

38 IS 2544-1973 Re-affirmed 1991

: Specification for porcelain post insulators for systems with nominal Voltage greater than 1000V. warning symbols

39 IS 2551-1982 Re-affirmed 1990 IS 8923-1978

: Danger boards, warning symbols

40 IS 2705 1992 Parts 1 to 4

: Current transformers.

41 IS 2721-1979 : Galvanized steel chain link Fencing

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Re-affirmed 1991 42 IS 3043-1987

Re-affirmed 1991 : Code of practice for earthing

43 IS 3070-Part-1 1985 re-affirmed 1990, Part –3 1993

: Lightning arresters for alternating current systems

44 IS 3156-1992 Parts 1 to 4

: Voltage transformers.

45 IS 3231

: Electrical relays for power system protection.

46 IS 3427-1997 : Metal enclosed switch gear and control gear for voltage above 1000V but not exceeding 52 kV.

47 IS 3480-1966 Re-affirmed 1990

: Flexible steel conduits for electrical Wiring

48 IS 3637-1966 Re-affirmed 1991

: Gas operated relays

49 IS 3638-1966 Re-affirmed 1991

: Application guide for gas operated relays.

50 IS 3639-1966 Re-affirmed 1991

: Fittings and accessories for Power transformers

51 IS 3646 Part-1 1992 Parts 2 & 3 1966 Re-affirmed 1992

: Code of practice for Interior Illumination

52 IS 3722-1983 Re-affirmed 1991

: Letter symbols and signs used in electrical technology

53 IS 3842 Part I toXII

: Application guide for electrical relays for AC systems.

54 IS 4004-1985 Re-affirmed 1990

: Application guide for non-linear resistor type surge arrester for A.C systems

55 IS 4160 – 1967 Re-affirmed 1990

: Interlocking switch socket outlet

56 IS 4483-1968 Re-affirmed 1991

: Preferred Panel cut out dimension for electrical relays.

57 IS 4691-1985 Re-affirmed 1991

: Degrees of protection provided by Enclosures for rotating electrical machines.

58 IS 4722-1992 : Rotating electrical Machines 59 IS 4728-1975 : Terminal markings for rotating electrical

machines. 60 IS 4770-1968 : Hand gloves 61 IS 5216 - 1982

Re-affirmed 1990 : Guid for safety procedures & practices in

Electrical work

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62 IS 5424-1969 : Rubber mats for electrical purposes 63 IS 5571 – 1979

Re-affirmed 1991 : Guide for Selection of electrical equipment for

hazardous area. 64 IS 5578-1984

Re-affirmed 1991 : Guide for marking of insulated conductors

65 IS 5613 Parts 1 to 3 1985/1989

: Code of practice for Design installation and maintenance of over head power lines

66 IS 5621-1980

: Hollow insulators for use in electrical equipment

67 IS 5831-1984 Re-affirmed 1991

: PVC insulation & sheath for electric cables

68 IS 6071-1986 Re-affirmed 1992

: Synthetic separators for lead acid batteries.

69 IS 6262-1971 Re-affirmed 1991

: Method of test for power factor & dielectric constant of electrical insulating liquids.

70 IS 6304-1992

: Stationary batteries lead acid type with pasted positive plates.

71 IS 6600-1972 Re-affirmed 1991

: Guide for loading of oil immersed transformers.

72 IS 6665 – 1972 Re-affirmed 1990

: Industrial lighting code of practice

73 IS 6792-1992

: Method of determination of Electrical strength of insulating oils

74 IS 6875-1980 Re-affirmed 1982

: Control switches for voltage upto including 1000 V

75 IS 7098 - 1983 Part 1

: Cross linked polyethylene insulated PVC sheathed cables for working Voltages upto 1100 Volts

76

IS 7098-1981 Part 2 Re-affirmed 1988

: Cross linked polyethylene insulated PVC sheathed cables for working Voltages from 3.3 kV upto 33 kV

77 IS 7132-1973 Re-affirmed 1991

: Guide for testing synchronous machine

78 IS 7689 –1989

: Guide for control of undesirable static electricity.

79 IS 7752 Part I-1975 Re-affirmed 1991

: Guide for improvement of power factor at consumer’s installation.

80 IS 8061-1976 Re-affirmed 1991

: Code of practice Design, installation & maintenance of service lines up to and including 650V.

81 IS 8084-1976 Re-affirmed 1992

: Interconnecting busbars for AC voltage above 1 kV up to & including 36 kV

82 IS 8130-1984 Re-affirmed 1991

: Conductors for insulated electric cables & flexible cords.

83 IS 8197-1976 : Terminal markings for, electrical measuring

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Re-affirmed 1987 instruments. 84 IS 8603

Parts 1 to 3 –1977 Re-affirmed 1991

: Dimensions for porcelain transformer bushings for use in heavily polluted atmosphere.

85 IS 8623-1993(Part1 to 3)Re-affirmed 1991 (IEC 439-1973)

: Low voltage switch gear & control gear assemblies

86 IS 8686-1977 Re-affirmed 1991

: Static protective relays.

87 IS 8923 – 1978 Re-affirmed 1997

: Working symbols for dangerous voltages.

88 IS 9249 part 1 –1979 Re-affirmed 1991 Part 2 – 1982 Re-affirmed 1987

: Safety requirements for indicating and recording electrical measuring Instruments and their accessories.

89 IS 9385 Part I- 1979 : High voltage fuses (current limiting fuse) 90 IS 9511-1980

Re-affirmed 1991 : Earthing knob for neutral conductors.

91 IS 9537 Part-1 1980 Part-2 1981 Part-3 1983 All parts Re-affirmed 1990

: Conduits for electrical installation

92 IS 9676-1980 Re-affirmed 1987

: Reference ambient temperature for electrical equipment.

93 IS 9920 Part-1 1981 Part-2 1982 Part-3 1982 Part-4 1983 All parts Re-affirmed 1992

: Switches and Switch Isolators for voltage above 1000V

94 IS10000 Parts 1 to 12 : Methods of tests for IC engines 95 IS10002-1981

Re-affirmed 1991

: Performance Requirements for constant speed compression Ignition engine for general purposes (above 20 kW).

96 IS10028 Part 1- 1985 Part 2- 1981 Part 3- 1981 All parts Re-affirmed 1991 Part I,II & III selection, installation andmaintenance.

: Code of practice for selection installation and maintenance of transformers

97 IS10118-1982 : Code of practice for design, installation and

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Parts 1 to 4 Re-affirmed 1991

maintenance of switch gear and control gear.

98 IS10810 – 1984 Parts 1 to 63 Re-affirmed 1991-98

: Method of tests of cables

99 IS10918-1984 Re-affirmed 1990

: Vented type Nickel-Cadmium batteries.

100 IS12021-1987

: Control transformers for switchgear & control gear for voltages not exceeding 1000V

101 IS13118-1991 : High voltage Air circuit breakers 102 IS13703 –1993

Parts 1 to 4 Re-affirmed 1998

: Low voltage fuses for voltage not Exceeding 1000VAC or 1500VDC

103 IS13947-1993 Parts 1 to 5

: Specification for low voltage switchgear and control gear.

17.00 QUALITY ASSURANCE, INSPECTION & TESTING 17.01 GENERAL REQUIREMENT OF QUALITY ASSURANCE

All materials, components and equipment covered under the technical specification for this Project shall be procured, manufactured, tested, erected and commissioned as per a comprehensive Quality Assurance Programme. It shall be the primary responsibility of the contractor to draw up and implement such a programme which shall be duly approved by the Owner / Consultant/their authorised Inspection Agency.

The detailed Quality Assurance Plan (QAP) for manufacturing and testing of equipment shall be prepared by the contractor and submitted for approval by the Owner/their aurhorised Inspection Agency.

17.02 Inspection and Testing

17.02.01 The equipment shall be inspected by the Owner and / or their

Inspection Agency at the manufacturer’s works prior to despatch. The equipment will be inspected as per the tests pre-identified in the approved QAP to ensure conformity of the same with relevant approved drawings, data sheets, technical specification, National/International Standard.

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17.02.02 The contractor shall finalise the QAP within the stipulated schedule mentioned in the Purchase Order and the QAP shall be submitted in four sets (Blank QAP formats enclosed shall be adopted). In case of any sub-contracting, the QAP shall be prepared by the contractor in consultation with his sub-contractor to avoid any lapse in quality and disputes and misunderstanding.

17.02.03 The contractor shall provide full and free access of the Inspection

Agency to the manufacturer’s works to carry out any stage inspection to ensure the quality of the equipment being manufactured.

17.02.04 Only on readiness of the equipment and approval of all relevant

drawings & QAP, the contractor shall give “Inspection Call” (Blank format enclosed shall be adopted) to the Owner & the Inspection Agency with a clear notice of 10 days for inspection. The Inspection Call shall be accompanied by the manufacturer’s internal inspection report, test certificates, purchase order, sub-purchase order, technical specification, approved QAP and approved drawings / data sheets. The Inspection Call without above documents shall be ignored. In case of any approved sub-contracting, only the main contractor shall give the Inspection Call enclosing internal inspection/ test reports of the sub-contractor duly verified by the main contractor. In case the equipment offered for inspection is found not ready, all the cost of the visit of the Inspection Agency shall be borne by the contractor.

17.02.05 The contractor shall furnish all relevant documents and test

certificates as required by the Inspection Agency during inspection. Materials shall be tested only in recognised Test House/Laboratory.

17.02.06 The contractor shall delegate a representative/ coordinator to

coordinate with the Inspection Agency on all inspection matters. 17.02.07 No equipment shall be offered for inspection in the painted condition

unless otherwise agreed to the Owner. 17.02.08 The contractor shall ensure that the equipment and materials once

rejected by the Inspection Agency are not reused in the manufacture of plant and equipment. Where parts rejected by the inspection Agency have been rectified as per pre-agreed procedure, such parts shall be segregated for separate inspection and approval before being used in the work.

17.02.09 The contractor shall carry out their internal inspection and obtain

clearance from Statutory bodies, like IBR, CCE, TAC, Weights & Measures, Safety, IE Rules, etc., as required for the equipment prior to offering any such equipment for Owner’s inspection.

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17.02.10 The contractor shall carry out their internal inspection and obtain clearance from Statutory bodies, like IBR, CCE, TAC, Weights & Measures, Safety, IE Rules, etc., as required for the equipment prior to offering any such equipment for Owner’s inspection.

17.02.11 The contractor shall carry out their internal inspection and obtain

clearance from Statutory bodies, like IBR, CCE, TAC, Weights & Measures, Safety, IE Rules, etc., as required for the equipment prior to offering any such equipment for Owner’s inspection.

17.02.12 The contractor shall provide all required instruments, tools, necessary

testing and inspection facilities free of cost to carry out the inspection. These instruments and testing machines shall be calibrated by an agency of National/ International recognition and the calibration shall be valid during inspection period.

17.02.13 The inspection Agency shall have the right to demand for re-testing of

any material re-calibration of the instrument and testing machine & the charges for the above will be borne by the contractor.

17.02.14 Performance tests of any particular equipment which cannot be

conducted / demonstrated either partially or wholly at the manufacturer’s works, shall be conducted after erection at site in the presence of Owner and their Inspection Agency. In all the cases, prior approval of the Owner shall be obtained.

17.02.15 No equipment shall be dispatched before inspection and issue of

Inspection Certificate and dispatch clearance from the Owner / Inspection Agency.

17.02.16 In case of waiver category items, the same shall be pre-identified in

the QAP itself. For such items, the contractor shall furnish necessary certificate, test reports, etc., as agreed upon and indicated in the QAP. For these items also the contractor shall obtain “Inspection Waiver Certificate” and dispatch clearance from the Owner Inspection Agency before effecting dispatch of equipment.

17.02.17 The issue of Inspection Certificate / Waiver Certificate for any

equipment or component thereof does not absolve the contractor from his contractual obligations towards subsequent satisfactory performance of the equipment at site. Should any equipment be found defective, In whole or part thereof after receipt at site or during erection/ commissioning and testing shall be made good by the contractor free of cost.

17.02.18 Owner shall be given minimum four weeks advance notice for witnessing the final testing. The minimum testing / inspection

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requirements for all components/equipment shall conform to the requirements stipulated in applicable codes and standards. Test certificates including test records and performance curves etc. shall be furnished by the Contractor.

17.03 TESTING

• Contractor shall provide test certificates for Type and Routine tests carried out on the equipment / boards etc. as specified in the relevant standards and tests as specifically mentioned in this TS.

INSPECTION FORMAT

PAGE:1 OF 1 REVISION - 1 DATE:

OWNER

CONTRACTOR’S ORDER NO. & DATE

PLACE OF INSPECTION WITH ADDRESS PHONE NO. / FAX NO.

NAME & DESIGNATION OF CONTACT PERSON WITH PHONE NO.

QUANTITY (NO./T/M) QAP & DRG NO WITH REVISION

QAP & DRAWING APPR STATUS (A/AAN/INF)

TOTAL ORDERED

TOTAL ACCEPTED

REF NO & DATE DESCRIPTION REFERENCE &

DATE

______________________________________________________________

(FOR CONTRACTOR / SUB-CONTRACTOR)

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18.00 LIST OF TENDER DRAWINGS The following drawings are enclosed with this tender.

Sl. No.

Drawing No. Rev. Description

1.

MEC/23LK/05/E9/E/001/1081

R 0

SLD of Bahadurgarh Terminal.

2. MEC/23LK/05/E9/E/004/1081

R 0 SLD of Tikrikalan Terminal.

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19.00 QUESTIONNAIRE Also the following questionnaires Shall be duly filled up and

submitted

A. Motors (Furnish details for each application)

B. L.T Switch gear/ MLDB /LDB 1. Protection relays Make & Type 2. Current transformer a) Make & Type b) Accuracy class 3 Meters a) Make b) Type c) Size

4 Fuse switch unit a) Make & Type b) Operating mechanism

5. Indicating lamps a) Make & Type b) Rated voltage, watts c) Series resistor Ohm /Watts 6. Contactors

Make Type and Duty Minimum rating Coil Voltage Number of Auxiliary contacts/rating

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7 Control Transformer

Make Type Rating Rating k VA ratio ( Vp / Vs)

C) BATTERY

Maker’s name. :

Maker’s type designation. :

No. of cells per battery. :

Tap position at which cell. :

No. of plates per cell. :

Types of positive plates. :

Types of negative plates. :

Type of separators. :

No. of separators per cell. :

IS followed. :

Nominal voltage per cell. :

Type of connectors and material. :

Ampere-hour rating at 10 hour

discharge rate. :

Permissible continuous load on the

battery with final discharge voltage

of 1.85V per cell.

a) For 1 hour duration. :

b) For 3 hour duration. :

c) For 5 hour duration. :

Max. permissible peak current that the battery can supply.

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Voltage at the end of 10 hour discharge.

Charging rate for fully charging the battery from 1.85 V per cell.

in 10 hours. :

In 8 hours. :

In 4 hours. :

Quick charging voltage per cell. :

Trickle charging voltage per cell. :

Trickle charging current. :

Type of cell container. :

Qty. of acid per cell. :

Weight of each cell without acid. :

Weight of each cell with acid. :

Overall dimension of each cell. :

Distance between centres of adjacent cells. :

Minimum distance between two rows. :

Overall dimensions of battery stand

L X W X H mm. :

No. of stands. :

Minimum dimensions of the room required. :

Internal resistance of battery in fully charged condition. :

Floor loading. :

Total weight of battery and stand. :

Specific gravity of electrolyte for first filling. :

Recommended specific gravity of electrolyte

at the end of full charge. :

Expected specific gravity of electrolyte at the

end of 10 hour discharge. :

Recommended max. period of storage before

the fist charge. :

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List of accessories. :

D) Charger

Input voltage :

Max. AC load in kVA :

During float charging :

During boost charging :

System fault level considered :

Design ambient temperature :

Charger

a) Make and type :3 phase half controlled SCR type

b) Rating of charger in Amps

Float mode at 110V

Float mode at 130V

Boost mode at 160V

Boost mode at 130V

c) Mode of control

i) Float mode : Manual and auto

ii) Boost mode : Manual and auto

d) Float charging control: Constant potential

in auto mode controller

e) Boost charging control: Two rate charging with

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constant current control in

auto mode

D). CABLES (furnish Details separately for H.T./L.T./Power/Control/Special cables) 1 Cable type reference 2 Cable voltage class 3 Type of earthing for which cable insulation is suitable Earthed / unearthed 4 System fault level (for HT) 5 Continuous current ratings (Amps) for different cables

when laid in

5.1 Ground (direct) 5.2 Air 5.3 Ducts 6 Zero sequence impedance of cable at 20ºC for range

of sizes anticipated

6.1 Ro

6.2 Xo

7 De-rating factors for variation in air temperature

(ambient) between 10º C in steps of 5 degrees Cwhen cable laid in

7.1 Formed cable trenches Chart enclosed/ not enclosed 7.2 Ground (direct -do- 7.3 Overhead cable stockade -do- 7.4 Pipes & trays -do- 8 De-rating factors for grouping of cables 8.1 When laid with clearance as in IS with one diameter of

Cable Chart furnished/ not furnished

8.2 When cables laid touching each other -do- 8.3 When cables are bunched together -do- 9 List of applicable standards and codes 10 Short circuit capacity

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10.1 Amps (RMS) 10.2 Duration in seconds 10.3 Maximum conductor temperature after short circuit º C 10.4 Applicable formula for calculating S.C capacity for

different duration

11 Conductor 11.1 Material 11.2 Annealed 11.3 Tinned 11.4 Shape 11.5 Number of strands and wire dia in mm 11.6 Conductor cross section in sq.,mm 11.7 Number of cores 12 Conductor insulation 12.1 Material 12.2 Material composition 12.3 Thickness 12.4 Tolerance on thickness 12.5 Specific insulation resistance at 60º C 12.6 Wrapped or extruded 13 Fillers 13.1 Fillers provided Yes / no 13.2 Materials of fillers 14 Inner sheath 14.1 Material 14.2 Material composition

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14.3 Thickness 14.4 Tolerance on thickness 14.5 Specific insulation resistance at 60º C 15 Armour 15.1 Type of armour 15.2 Armour material 15.3 Wire armoured / strip armoured 15.4 Nominal dimensions of round / strip armour 16 Overall jacket 16.1 Material 16.2 Material composition 16.3 Colour 17 Overall diameter 18 Weight per 100 metres 20 Minimum bending radius permissible 20 Safe pulling force when pulled by pulling eye 21 Constants 21.1 Resistance(20ºC)per core for 100 meters 21.2 Inductance at 50 Hz per core for 100 meters 21.3 Capacitance at 50 Hz per core for 100 meters 22 Tests 22.1 Whether all tests as per latest Standard will be

carried out and test certificates furnished for type testYES / NO

If 'NO', list of all the tests which will not be conducted. List enclosed / not enclosed 23 Cable drums 23.1 Dimensions and weight 23.2 Maximum drum length 24 List of test certificates enclosed with the quotation

E) DISTRIBUTION TRANSFORMER 1. Name of the Manufacturer

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2. Power Supply System in which Transformer is to be used a) Primary Side (HV) Maximum Volt. b) Secondary Side (HV) Maximum Volt.

3. System Earthing HV Side LV Side

4. 3 Phase line to ground fault maximum / minimum - Primary Side (HV) MVA - Secondary Side (LV) MVA

5. Applicable Standards

6. Design Ambient Temperature Degree in Centigrade.

7. If Altitude above sea level in excess of 1000m indicate correction factors for rating and test voltages.

8. Transformer Application

9. Transformer Type

a. Indoor / Outdoor b. Dry Type / Liquid Filled / Oil filled c. Core Type / Shell Type

10. Auto Wound / Two Winding / Three Winding

11. Number of Phases

12. Rated Frequency Hz.

13. Rated no load voltage kV

a. HV Winding b. LV Winding

14. Cooling

a. Cooling Liquid b. Method of Cooling

15. Rated kVA at rated Voltage ONAN and principal tap :

16. Whether designed for over loading as per IS 6600.

17. Maximum Temperature rise at rated KVA Principal Tap ONAN:

a. Top oil by thermometer method over design ambient temperature deg:

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b. HV & LV winding by resistance method over design ambient temperature deg:

c. Hot spot temperature (based on design ambient) deg C:

18. Maximum permissible variation in Voltage and frequency for continuous operation at rated kVA on any tap. a. % Variation in Voltage on any tap with rated frequency: b. % Variation in frequency on any tap with rated voltage:

19. % Impedance voltage at base MVA, rated current, voltage, frequency principal tap and 75 deg C.

20. % Reactance Voltage at rated current, frequency, voltage, base MVA principal tap:

21. Tappings a) Off circuit/on Circuit b) Manual/automatic c) No. of steps

d) %Variation per step e) Winding on which tappings are provided.

22. External dead short circuit withstand capability of transformer on any tapping for 3 phase, 2 phase, Line to ground fault across LV windings (Assuming infinite system on both sides)

23. Losses at rated voltage, current (ONAN rating) frequency at principal tap:

Shall be clearly specified as Guaranteed Losses Without Positive Tolerance

a) No load loss kW b) Load loss at 75 deg C kW c) Total losses at 75 deg C kW

24. Permissible tolerances for a) Component losses b) Total losses c) Rated voltage ratio d) Impedance voltage for principal tapping e) No load current 25. Winding data a) Number of windings b) Winding connection

- HV winding

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- LV winding

c) Vector group d) Insulation materials

- HV winding - LV winding - Windings to core - HV winding to LV windings

e) Resistance of winding per phase at 75 degree C-

-HV winding ohms -LV winding ohms f) Min. cross section of winding: -HV winding mm square

-LV winding mm square 26. Winding insulation category: a) HV – uniform / non-uniform b) LV – uniform / non- uniform 27. Insulation Level: a) One Min. PF withstand voltage / 1.2/50 micro second

impulse withstand voltage - HV Winding - LV Winding b) Induced over voltage withstand: - HV Winding kV (rms) - LV Winding kV (rms) 28. Minimum Clearance in Air: - Phase – Phase mm - Phase – Ground mm

29. Magnetic Circuit

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a. No load current on HV side at rated frequency

- At principal tap with rated voltage amps. - At extreme +ve tap with voltage corresponding to principal tap- amp - At extreme –ve tap with voltage corresponding to principal tap- amp

b. No load current on HV side at rated frequency and principal tap at

11.0% rated voltage-amps. c. Core Laminations - Type - Material - Thickness mm - Maximum permissible flux density wb/m square: - Loss/Kg at 75 deg C - Total Weight Kg. d. Material Test Voltage - Insulation of Core Lamination - Insulation of Core Bolts - Insulation of Core Bolt Washers - Insulation of Core clamping plates e. Maximum Flux Density at Principal Tap, Rated Frequency - At Rated Voltage wb/m square - At 110% Rated Voltage wb/m square

- At 125% Rated Voltage wb/m square - At 140% Rated Voltage wb/m square f. Core loss vs flux density characteristic at 50 Hz for core

material shall be furnished 30. Bushings Line Bushings Neutral Bushings HV LV LV a. Manufacture

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b. Type c. Catalogue d. Voltage Class KV as per IS e. Current Rating Amps f. Impulse withstand (1.2/50 micro second wave) g. 1 Minute pf withstand voltage Wet kV (RMS) Dry kV(RMS)

h. Creepage Distance

Total mm Protected mm Quantity of oil

31. L. V neutral Bushing Current Transformers - Location - No. of Cores - Type - Ratio - Taps - Class - Knee Point Voltage - CT Secondary resistance at 75oC - Short Time Raising Section - Magnetising Current at vk/2.vk/4 - Accessibility without removing active parts

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32. Buch-holz relay a. Manufacturer’s name b. Alarm Volume of gas: cm cube c. Trip minimum oil / liquid velocity cm/sec. d. Alarm and trip contact rating at 220 V dc.

33. Thermometers – Top Oil / Windings a. Manufacturer b. Type : Indoor / Outdoor c. Accuracy Class d. Temp. Indicating range e. Alarm Contact setting range f. Trip contact setting range g. Alarm and trip contact rating at 220V dc. h. Maximum Temperature Indicator i. Provision of accessories for remote indication specified. 34. Terminal Arrangement a. High Voltage b. Low Voltage c. LV Neutral 35. Tank construction conventional / shell shape 36. Vacuum Withstand Capability - Main Tank with active parts mm of hg - Main Tank without active parts mm of hg

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- Radiators and accessories mm of hg 37. Gauge pressure withstand capability - Main Tank without active parts kg/cm square - Radiators & Accessories kg/cm square - Fully assembled tank including - Accessories kg/cm square. 38. Gasket Material Type 39. Approximate Masses a. Tank fitting & accessories kg b. Liquid Kg c. Liquid (Litres)

40. Total quantity of liquid for first filling (litres) 41. Maximum Limiting overall dimensions without positive tolerances a. Height mm b. Breadth (along the line connecting HV & LV Bushings) mm c. Length mm 42. Distance between bi-directional rollers or flanged wheels. 43. List of fitting & accessories: Provided as per data 44. Noise level in dB scale when measured 4 ft. from the Transformer

edge at height of 5 ft above the floor at rated voltage and load. 45. Routine tests at works. 46. Type test on one unit 47. Pre-commissioning site tests 48. Efficiency at 75 degree C: upf 0.8pf

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a. At rated kVA …… % b. At ¾ rated kVA……. % c. At ½ rated kVA ….. % 49. Regulation at 75 degree C upf 0.8 pf

a. At rated kVA …… % b. At ¾ rated kVA……. % c. At ½ rated kVA ….. %

50. Time constants of windings: ONAN HV LV 51. Time constant of Transformers ONAN - Minutes

52. Shipping Section - Size of largest package ( l x b x h) mm - Weight of largest package tonnes - Weight of largest package tonnes

53. Minimum clearance height for tank. F). Contactor 1. Manufacturer's name 2. Manufacturer's type designation 3. Rated voltage 4. Rated current 5. Minimum capacitor switching duty

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6. Coil rated voltage 7. Whether mechanical ON/OFF indication provided 8. Number of auxiliary contacts 9. Applicable standards G). Fuse switch units 1. Manufacturer's name 2. Manufacturer's type designation 3. Type of break 4. Rated voltage 5. Rated current of switch offered for different ratings of bank .... kVAR/........Amperes,(furnish for different ratings) 6. Minimum capacitor switching duty of ranges of switches offered 7. Number of auxiliary contacts a) Applicable standards

b) Breaking current of switch at L/R equal to 0.5

10. Whether quick make quick break mechanism provided for the switch

H). Illumination System

Make and type of fittings Catalogues Enclosed (Yes/No) Lux Levels Considered for various Area

i) Plant area ii) Sub-Station

iii) Electrical and Other Control rooms iv) Control Pulpits I). Details of Air Conditioning Units offered

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J). LIST OF DOCUMENTS / DRAWINGS ENCLOSED WITH TENDER (furnish list for all major equipment) 20.00 Deviation Statement

Sl No. Specification Clause No./Page No.

Brief description Deviation From Specification with reasons

21.00 Pre-Amble To Schedule Of Quantities

1.The items for supply shall also include supply of termination accessories like compression type brass glands, tinned copper lugs, terminal connectors, earth conductors for duplicate earthing of equipment.

2.The supply of structures shall include design of structures.

3. The term Installation shall include receiving of equipment at site, storing erection, interconnection, testing, commissioning, preparation of drawings for submission to inspectorate, obtaining approval from statutory bodies, preparation of as-built drawings, supply of consumables and site levelling.

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PARTICULAR JOB SPECIFICATION

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TECHNICAL SPECIFICATION

FOR

11 kV, 7 PANEL BOARD VACUUM TYPE SWITCHGEAR (1250A)

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CONTENTS


01.00 Scope 3

02.00 Standard 3

03.00 Climatic Conditions 3

04.00 Type and Rating 4-5

05.00 General Design of Switchgear panels 5-14

06.00 Test 14-15

07.00 Drawings 15

08.00 Special Tools 15

09.00 Deviation from Specification 15

10.00 Guaranteed & Other Technical particulars 15-22

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TECHNICAL SPECIFICATION FOR 11 kV SWITCHGEAR PANELS VACUUM TYPE (1250A)

1.0 SCOPE:

This specification covers the design, manufacture, assembly, testing at manufacturer's works before despatch, supply and delivery F.O.R. destination as per requirement of Vacuum Type, 7 Panel 11 kV Switch boards having normal current rating of 1250 Amps. with rupturing capacity of 350 MVA.

2.0 STANDARDS: 2.1 The circuit breakers shall conform to the latest revisions with amendments

available at the time of testing of relevant standards, rules and codes, some of which are listed herein for ready reference.

Sr. No.

STANDARD TITLE

1 IEC-56 Specification for alternating current circuit breakers 2 IS-5578 & 11333 Making and arrangement for switch gear bus-bar

main connection and auxiliary wiring. 3 IS- 2147 Degree of protection provide for enclosures for low

voltage switch gear. 4 IS- 13118 Specification for circuit breakers. 5 IS- 3427 Disconnectors of circuit breaker & their interlocking

. 6 IS-2099 High voltage porcelain bushings.

3.0 CLIMATIC CONDITIONS :

The equipment is required to operate satisfactorily under the following site conditions :

3.1 Max. temperature 450C 3.2 Min. Temperature 50C 3.3 Max. relative humidity 100% 3.4 Average number of rainy days per Nearly 120 days

annum. 3.5 Average annual rainfall 900mm 3.6 Average number of dust storm days 35

per annum. 3.7 Isoceraunic level 45 3.8 Max. wind pressure 195 kg/Sq.mt. 3.9 Altitude above mean sea level Less than 1000

mts.

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3.10 AUXILIARY POWER SUPPLY:

Auxiliary electrical equipment shall be suitable for operation on the following supply system.

a DC alarm, control and

protective devices i) 110 V DC, underground 2 wire. b lighting 240 V, single phase ,50 Hz AC supply. 4.0 TYPE & RATING:

The panels 11 kV switchgear panels shall comprise of 11 kV Vacuum Type circuit breakers, instrument panels and instrument transformers etc. suitable for indoor use. The equipment shall be totally enclosed in a metal clad cubicle, dust and vermin proof with necessary isolation arrangement. Each panel shall be easily extensible on either side and should be complete with necessary internal copper connections, small wiring, L.T. fuses and supporting framework with bolts to secure it to the floor. The Circuit Breakers shall be draw out type in horizontal position and horizontal isolation.

Principal parameters

The breakers shall have the following ratings:

4.1 Type Vacuum 4.2 No of poles 3 4.3 Nominal system voltage 11 kV 4.4 Highest system voltage 12 kV 4.5 Rated frequency 50 +/- 1.5 Hz 4.6 Rated continuous current 1250 Amp for incoming & 630 Amp rating at an ambient for outgoing feeders. temp. as specified in IS : 13118-1991 (Latest edition) 4.7 Symmetrical breaking 350 MVA capacity 4.8 Impulse withstand test 75 kV (Peak)

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voltage 4.9 One minute power 28 kV (rms) frequency withstand test voltage 4.10 Short time current Not less than 26.3 kA current rating 4.11 System neutral unearthed. 5.0 GENERAL DESIGN OF SWITCHGEAR PANELS: 5.1 OPERATING MECHANISM:

The vacuum type circuit breaker shall be draw out type & trip free. The VCBs shall be suitable for operation from 110 V DC auxiliary supply. The operating mechanism shall be motor operated spring charged type. There shall be provision(s) for manual charging of closing spring and emergency hand trip. The motor used for the purpose will be suitable for 110 V DC. The operating mechanism shall work satisfactorily at 85 % - 110 % of rated supply voltage. The VCB shall have 8 normally open & 8 normally-closed auxiliary contacts over & above the ones required for various control & supervision circuits.

5.2 INSTRUMENT PANELS:

Each unit shall have its own instrument panel provided at the top & complete with small wiring connections from relays, instrument transformers, metering instruments, indicating instruments, selector switches & circuit breaker control switch. All wiring shall be carried out by using stranded single annealed copper conductor insulated with poly vinyl chloride insulation suitable for 1.1 kV service. CT/PT circuit shall use wire of not less than 4.0 mm2 cross-sectional area whereas control/alarm/supervision circuit shall use wire of not less than 2.5 mm2 cross-sectional area. All wires will be continuous from one terminal to the other and, also will have no Tee-junction enroute. The connections shall be securely made with the help of connecting lugs duly crimped on to the copper conductor. The meters and relays shall be mounted in a convenient position so as to be readily accessible for inspection or repair. The terminal board provided in the instrument panel of VCBs will be made of moulded dielectric having brass studs, washers, holding nuts & locking nuts. All holding nuts shall be

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secured by locking nuts. The connection studs shall project 6 mm from the lock nut surface. NO OTHER TYPE OF TERMINAL BOARD IS ACCEPTABLE. Earthing of current free metallic parts or metallic bodies of the relays/switches mounted on the instrument panel and metal enclosed switchgear shall be done by a suitably sized copper conductor. Earth bus made of 25x3 mm bare copper flat will be extended through entire length of 11 kV switch-board with suitable provision to connect it to the sub-station earth at the extremities. The earthing arrangement will meet with the requirements laid down in IS : 3427 read with its latest amendment.

5.3 VACUUM INTERRUPTER:

The Vacuum interrupter of 12 kV minimum 26.3 kA short time current rating, 1250 Amp. normal current rating capable of withstanding minimum 100 full short circuit operations as per test duty 1 to 5 of IEC-56. Vacuum Interrupters for incomers as well as outgoing shall be of same type. These vacuum interrupters shall be of approved make only.

5.4 INSTRUMENT TRANSFORMER:

The secondary voltage & current rating of the instrument transformers shall match with the metering or protective equipment. The CTs shall have ratio & accuracy class as mentioned in the SLD. The CTs shall be wound/ring type in accordance with their ratings. The terminal boards associated with differential CTs, REF CTs & over current / earth fault protection CTs will be of disconnecting type having short circuiting facility & thus facilitate secondary testing of concerned protective relay without disturbing the associated small wiring. Inter- changeability of housing of CTs from one panel to another must be ensured.

A resin cast potential transformer of ratio (11000/√3)/(110/√3) volts having 100 VA output per phase with accuracy class 1.0 as per ISS : 3156 (part-II)-1965 shall be provided on the incoming side of each panel set and shall be star/star connected.

The neutral point of star connected secondary windings of instrument transformers shall be earthed to the main earth bus referred to in the concluding paragraph of clause 5.2. Multiple earthing of any instrument transformers shall be avoided.

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5.5 BUS - BARS:

All the panels shall be provided with one set of 3 phase 1250 Amps. Heat shrunk PVC sleeves insulated Main electrolytic copper bus bars for all switchboards and shall be connected in a separate moisture and vermin proof sheet metal chamber. The cross sectional area of bus bar should however not be less than 1200 mm2 per phase. The bus-bars connections & insulator supports shall be mechanically strung & rigidly supported so as to withstand the stresses generated by vibrations, variations in temperature and due to severe short circuits. The bus bars shall be heat shrunk PVC sleeves insulated type and supported on insulators at short intervals keeping adequate clearance as per IE rules between bus bars and earth. The bus bar chamber shall be provided with inspection covers with gaskets & bus bar shutters. Provision shall be made for future extension of bus bar & switchboard.

5.6 LIMIT OF TEMPERATURE RISE:

The temperature rise of the current carrying parts shall not exceed the permissible limits above the ambient temperature as per relevant standards (latest edition). However, the reference maximum ambient temperature may be taken as 450C.

5.7 BUSHING INSULATORS:

These shall comply with the latest issue of IS : 2099 in all respects. 5.8 DISCONNECTORS OF CIRCUIT BREAKER & THEIR INTERLOCKS

All disconnectors (isolators) of the 11 kV VCBs & interlocks between different pieces of apparatus provided for reasons of safety & for convenience of operation of switchgear shall meet with the requirement of IS : 3427-1969 read with its latest amendment. Efficient mechanical interlocking shall be provided to meet the following conditions i) It shall be possible to insert/withdraw the breaker only after circuit

breaker has been opened. ii) It shall be possible to insert/withdraw the breaker only when it is

fully open position as well as it is in Isolated/test position.

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iii) It shall not be possible to remove the breaker until the moveable plug unit having secondary connections has been withdrawn.

iv) It shall not be possible to replace in position moveable plug unit unless the circuit breaker has been racked in.

v) Provision of shutters or locks shall be made to prevent access to bus bar chambers and receptacles when the circuit breaker is withdrawn.

vi) Provision shall be made for locking the circuit breaker closing mechanism in open position.

5.9 CABLE BOXES:

Each 11 kV incoming and outgoing VCB shall be provided with cable termination arrangement suitable for receiving 1 sets of 3Cx 185 mm2, 11 kV (UE) three core XLPE insulated, outer PVC sheathed cables. Each cable box shall have vertical entry from below. These cable boxes shall be complete in all respects including cable glands of requisite size. The cable boxes should only be either heat shrinkable or push on type.

5.9A Earthing Truck

One no. earthing trolley should be provided for each incomer panel. Earthing trolley must be full fault make type device which is capable of making fault at 46.2 KA(peak) and carry 26.3 KA for one second. The earthing truck for incoming panel must be so designed that it is impossible to earth a live circuit. However manufacturers offering this a standard inbuilt feature of Breaker Trolley is also acceptable

5.10 SUPERVISION SCHEME: 5.10.1 Instrument panels on each of the 11 kV VCB covered by this specification

shall be provided with the following indicating lamps/relay:-

Circuit breaker `open' Green Circuit breaker `close' Red Auto trip White Circuit breaker spring charged Blue For monitoring of trip circuit both in pre-close and post- close position of the circuit breaker, 1 no. automatic trip circuit supervision relay will be provided on each of the 11 kV (incoming and outgoing) instrument panel. In case of trip circuit becoming faulty, the operation of this relay shall be accompanied by visual and audio annunciation in accordance with clause 5.10.1 of the specification.

However, the trip circuit of each of the 11 kV incoming/outgoing / capacitor / Stn. VCB will be monitored `on demand' with the help of an

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indicating lamp & a push button both when the VCB is òpen & closed'. The lamp will be àmber' coloured.

5.11 ALARM SCHEME: 5.11.1 NON TRIP ALARM SCHEME :

Each of 11 kV (incoming and outgoing) panel will be provided with a non-trip alarm scheme comprising suitable auxiliary relay (rated for 110 V DC), accept push button, reset push button & a buzzer. It will cater to non-trip condition such as trip circuit faulty & PT secondary fuses blow òff'. The non-trip alarm scheme will meet with the following requirements:- i) The closing of an initiating contact shall actuate a buzzer and will

be accompanied by a flag indication on the concerned auxiliary relay.

ii) The closing of an initiating contact shall glow a lamp which will not

reset until the fault has cleared.

iii) It shall be possible to silence the buzzer by pressing àccept' push button. If after cancelling the alarm but before resetting the visual signal, the same fault persists the buzzer shall be suppressed.

iv) If after canceling the alarm but before resetting visual signal some

other fault takes place, the alarm accompanied by flag indication on appropriate auxiliary relay shall take place.

v) If after canceling the alarm and after resetting the visual signal,

the same fault appears or some other fault take place, the alarm, flag indication and non-trip lamp indication shall reappear as usual.

vi) The non-trip alarm acceptance shall be by means of a push button

and resetting of visual signal may also preferably be done through a push button.

vii) Means shall be provided for test checking the lamp and alarm

circuit at frequent intervals.

viii) The equipment shall be suitable for 110 Volts DC operation. 5.11.2. TRIP ALARM SCHEME:

Trip commands due to operation of protective relay on any of 11 kV VCB constituting the switchboard will trip the concerned VCB. Its auxiliary

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contact will actuate a bell (provided in each of the 11 kV incoming and outgoing VCB) & will be cancelled by the associated circuit breaker control handle. Auto trip lamp will glow on the concerned 11 kV VCB & there will be flag indication on the concerned protective relay.

5.12 PT FUSE FAIL ALARM SCHEME:

Each of the 11 kV (incoming and outgoing) instrument panel is to be provided with a relay to monitor the fuses on the secondary side of 11 kV metering PT. The failure of any of secondary fuse on the 11 kV PT will be accompanied by visual & audio indication in accordance with clause 5.10.1 of the specification.

5.13. METERING SCHEME: 5.13.1 Each of the 11 kV VCB will be provided with a suitably sealed ammeter

(additional dials, if any, required to cover all the taps of the CTs shall be included at the time of bidding) with a selector switch facilitating measurement of phase currents as well as unbalance current. The coil of ammeter shall be rated for 5 Amp. The instrument shall be of moving iron spring controlled type of industrial grade `A' classification having accuracy class 1.0 & shall conform to IS:1248 (1968).

5.13.2 Each of the 11 kV (incoming and outgoing) VCB will be provided with a

suitably sealed voltmeter with a selector switch. The selector switch shall facilitate the measurement of phase to phase & phase to neutral voltage of all the three phases one by one. The coil of the voltmeter shall be rated for 110 V (phase to phase). The instrument shall be of moving iron spring controlled type of industrial grade `A' classification with accuracy class 1.0 & shall conform to IS:1248(1968).

5.13.3 Each of the 11 kV VCB will be equipped with MFM (Multifunctional) meter.

The MFM (Multi function Meter) shall be SEMS/Enercon make microprocessor based Electronic type having load survey facility and RS 485 communication port with necessary software / hardware for connectivity to SCADA. The multi function meter shall have the following minimum features.

• Ammeter • Voltmeter • Frequency meter • Power Factor meter • KW meter • KWH meter • KVA meter • KVAR meter • 30 min or 15 min maximum demand meter

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• Maximum Demand controller

Note:- Major primary relays and multifunction meter shall be microprocessor based numerical and communicable type(IEC 61850 compliant). All auxiliary and multiplier relays are of electromechanical type.

5.13.4 Each of the 11 kV (incoming or outgoing) VCB will be provided with a

power factor meter. The PF meter having a range of 0.5Lag - one - 0.5lead shall be of 2 element type suitable for use on three phase three wire unbalanced system. It shall be rated for 5 A CT secondary & 110 V (phase to phase) available from 11 kV PT mounted on each of the 11 kV incoming VCB. The instrument shall be iron-cored dynamometer type having accuracy class 1.0.

5.13.5 Each of the 11 kV (outgoing) VCB will be provided with a KW meter &

Kvar meter. N.B. Routine test certificates of all the indicating & integrating instruments will

be submitted alongwith the routine test certificates of 11 kV switchgear. 5.14 CONTROL SCHEME: 5.14.1 The instrument panel of each of the 11 kV VCB will be equipped with a

circuit breaker control handle of pistol grip type with spring return to neutral position and having bell alarm cancellation contacts. The control handle shall be so designed that after being operated to `close' a VCB the operation can not be repeated until the control handle has been turned to `trip' position making it impossible to perform two closing operation consecutively.

5.14 .2 The rating of the control handle shall be suitable for the duty imposed by

the closing and opening mechanism of VCB. The moving and fixed contacts shall be of such a shape & material to ensure good contact and long life under service operating duty. All contacts shall be readily renewable.

5.14.3 The number of contacts in the control handle will be decided by the bidder

keeping in view the requirements of this specification. Two pairs of contacts shall be kept spare. The total number of contacts proposed to be provided shall be stated in the bid.

5.14.4 Safety against inadvertent operation due to light touch on the control

handle shall be ensured.

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5.15 PROTECTION SCHEME: 5.15.1 FOR INCOMING PANELS:

Each incoming instrument panel shall be provided with a single pole restricted earth fault relay suitable for 5 A CT (Secondary) with a setting range of 10 % to 40 % of 5 Amp.( Strictly in steps of 5%). In case, the bidder offers voltage-operated REF relay, the same shall be technically justified with aid of sample calculations which will also form a part of the instruction manual for the said relay. The relay shall be housed in draw out flush mounting case. The back up protection shall be in the form of a combined over current and earth fault relay (two over current and one earth fault). This shall be triple pole having Inverse Definite Minimum Time (IDMT) characteristics with a 3/10 time current curve i.e. the relay operating time shall be 3 second at 10 times the plug setting at TMS 1. The outer element of the relay shall be arranged for over current protection and shall have a setting range of 50-200 % of 5 A and adjustable in suitable equal steps by means of a plug board. The central element shall be used for earth fault protection with a setting range of 20-80 % of 5 A adjustable in suitable equal steps by means of a plug board (for station transformer panels, the setting range shall be 10-40% of 5 A ) Each of the three elements shall be fitted with shunt reinforcing unit with hand reset operation indicator.

5.15.2 FOR OUTGOING FEEDERS PANELS :

Each outgoing feeder panel shall be provided with a triple pole IDMTL type combined over current and earth fault relay (two over current and one earth fault element) conforming to the technical specification stated in the clause : 5.15.1 above and one set of triple pole instantaneous relay (high set element) in the form of two over current and one earth fault element.

The outer element of the relay shall be arranged for over current protection and shall have a setting range of 500-2000 % of 5 A (The relay for station transformer shall have a setting range of 200-800 % of 5 A) and adjustable in suitable steps.

The central element shall be used for earth fault protection with a setting range of 200-800 % of 5 A adjustable in suitable steps.

The relay shall have low transient over reach with a high pick-up/ drop of ratio. The relay will be connected in series with the triple pole combined over-current and earth fault relay referred to above and shall be so wired

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so as to take this (instantaneous) out, if so desired by the purchaser at any time during operation of the equipment.

5.15.3 COMMUNICATION COMPATIBILTY OF RELAYS

All relays shall conform to the requirements of IS:3231/IEC-60255/IEC 61000 or other applicable standards. Relays shall be suitable for flush or semi-flush mounting on the front with connections from the rear. All protective relays shall be in draw out or plug-in type modular cases with proper testing facilities. Necessary test plugs/test handles shall be supplied loose and shall be included in contractor’s scope of supply.

All main protective relays (viz over current and earth fault, Restricted Earth Fault, Over voltage and neutral displacement) shall be numerical type and communication protocol shall be as per IEC 61850. Further, the test levels of EMI as indicated in IEC 61850 shall be applicable to these.

For numerical relays, the scope shall include the following : a) Necessary software and hardware to up/down load the data to/from the relay from/to personal computer installed in the control room. However,

the supply of PC is not covered under this clause. b) The relay shall have suitable communication facility for future connectivity

to SCADA. The relay shall be capable of supporting IEC 61850 protocol (with optical port).

N.B. The relay shall be suitable for 110 V DC auxiliary supply. The relay cover

& case shall be dust proof, water proof & vermin proof. Operating indicators shall be provided on all protective relays/ on their immediate auxiliary units to indicate the type of fault & phase / phases involved. It shall be possible to reset the operation indication without opening the relay case. The routine test certificates of all protective & auxiliary relays will be submitted alongwith routine test certificates of 11 kV switchgear covered by the specification.

5.16 D.C. FAIL ALARM SCHEME:

A suitable relay for monitoring the DC supply to the 11 kV switchboard shall be mounted on each of the 11 kV incoming instrument panel. The operation of DC fail scheme shall be accompanied by visual (indicating lamp on the instrument panel) & audio (ringing of hooter) annunciation. It shall be possible to silence the hooter by pressing the `accept' push button while the lamp shall continue to glow till the fault has been attended to & DC supply restored. A DC fail `Test' push button may be provided to test the lamp circuit of the scheme.

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6.0 TEST

All routine tests shall be carried out in accordance with IS : 13118-1991 (latest edition thereof).

6.1 TYPE TESTS The equipment offered should be type tested. Type test report should not be more than seven years old, reckoned from the date of bid opening, in respect of the following tests, carried out in accordance with ISS-13118/IEC-56, from Govt./ Govt. approved test house, shall be submitted along with bid:

i) Impulse with-stand voltage tests.

ii) Power frequency voltage dry & wet tests on main circuits.

iii) Short circuit with stand capability tests.

iv) Mechanical endurance tests.

v) Temperature rise test.

The remaining type test report as per clause 6.0 of ISS-13118/IEC-56 shall be submitted by the successful bidder with in three month from the date of placement of Purchase Order. These type test reports will also be from Govt./ Govt. approved test house & shall not be more than seven years old reckoned from the date of placement of order.

Voltage transformers & current transformers shall comply with the type tests as stipulated in the latest version of IS: 3156 & IS: 2705 respectively. The reports of all type tests conducted shall be supplied. The 11 kV VCB & associated CTs & PTs shall be subjected to routine tests as specified in the latest version of the relevant ISS in the presence of purchaser's representative, The routine test certificates of bought out components such as relays, switches, indicating instruments & KWH Meter will also be presented to owner's/MECON inspecting officer.

7.0 DRAWINGS:

In addition to any other drawing which the tenderer may like to furnish to explain the merits of his proposal, following drawings shall be submitted with the tender in quadruplicate :

i Principal dimensional details of 11 kV Switchgear.

ii General arrangement of 7 Panel 11kV switchboard including its

foundation details.

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iii Schematic drawings of control, metering & protection circuits in

respect of 11kV incoming VCB, 11kV outgoing VCB alongwith detailed write-up.

iv Drawing showing height of 11 kV bus bars & arrangement of bus

bars v Vacuum interrupter drawing.

Four copies of the descriptive literature in respect of 11 kV switchgear, relays, KWH meters, MFM Meter, voltmeters, ammeters, selector switches etc. proposed to be used shall also be supplied.

The bidder shall submit four sets of final version of all the above drawings for Purchaser's/MECON approval. The supplier shall, if necessary, modify the drawings & resubmit four copies of the modified drawings for purchaser's approval within two weeks from the date of receipt of purchaser's comments. The modified drawings will be approved within 15 days of their receipt by the purchaser. After receipt of purchaser's approval to drawings, a set of reproducibles of approved drawings & five sets of all the approved drawings and operating manuals containing, erection, operation & maintenance instructions per 11 kV switchboard shall be supplied to owner/MECON. However, one set of drawings and operating manual will be despatched alongwith each 11 kV switch board. The 11 kV switchgear will not be fabricated without getting the drawings approved from the purchaser.

8.0 SPECIAL TOOLS:

The tenderer shall supply Erection & Maintenance tolls and list shall be submitted with tender.

9.0 DEVIATION FROM SPECIFICATION:

Should the tenderer wish to deviate from the provisions of the specification either on account of manufacturing practice, or any other reasons, he shall draw attention to the proposed point of deviation in the tender and submit such full information drawing and specification so that merits of his proposal may be fully understood.

10.0 GUARANTEED AND OTHER TECHNICAL PARTICULARS :

These particulars shall be furnished strictly as per Annexure-A. Any deviation from this specification shall be clearly brought out separately.

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ANNEXURE-'A'

SCHEDULE OF GUARANTEED AND OTHER TECHNICAL PARTICULARS 1. Maker's name & country of manufacturer. 2. Type 3. Nominal system voltage 4. Highest system voltage 5. Frequency 6. Normal current ratings

a) As ref. ambient temp. as per relevant standard.

b) At site conditions.

7. Symmetrical breaking capacity. 8. Asymmetrical breaking capacity 9. a) Symmetrical breaking current

b) Short time current rating for 1 sec. 10. Making capacity. 11. 1.2/50 Micro second impulse wave withstand test voltage. 12. One minute power frequency withstand test voltage. 13. No. of poles 14. No. of breaks in circuit per pole. 15. Length of break per phase. 16. Opening time 17. Making time 18. Arc duration 19. a) Type and material and main contacts

b) Material & thickness of plating of contacts. 20. Type of arcing contacts and/or arc control device. 21. a) Whether the circuit breaker is trip free ?

b) Whether it is with lock out preventing closing ?

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22. Nominal voltage of closing mechanism. 23. Power required to close circuit breaker at nominal voltage. 24. Minimum clearance in air

a) Between phases. b) Between the live parts and earth

25. Minimum clearance in vacuum

a) Between phases b) Between live parts & earth

26. Total weight of complete breaker 27 Dimensions and mounting details 28. Standard to which conforms 29. Details of reference drawings attached. B. INSTRUMENT TRANSFORMERS :

i) CURRENT TRANSFORMERS : a) Name of manufacturer.

b) Rated primary current

c) Rated secondary current

d) Rated transformation ratio

e) V.A. output at rated current & accuracy

f) Class of accuracy.

g) Rated over current factor with time in seconds.

h) Type of CTs (whether wound or bar type)

i) One minute power frequency withstand test voltage.

j) 1.2/50 micro second impulse withstand voltage.

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k) Standard to which conform.

ii) VOLTAGE TRANSFORMER : (i) Name of manufacturer. (ii) Rated primary voltage (iii) Rated secondary voltage (iv) Rated burden (v) Class of accuracy (vi) Rated voltage factor and time (vii) One minute power frequency withstand test voltage. (viii) 1.2/50 micro second impulse withstand test voltage. (ix) Standard to which conform. C. RELAYS : (i) Name of manufacturer. (ii) Type & make (iii) Setting range (iv) Other details (v) Standard to which conform D. BUS BAR 1. Material 2. Normal current rating 3. Nominal area per phase 4. Shape. 5. Type of insulation. 6. Short time current rating for 1 sec. E. VACUUM INTERRUPTER BOTTLE

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1. Name of manufacturer. 2. Whether imported or indigenous. 3. Manufacturer's type, normal Amps. &

rupturing capacity for vacuum bottles used on incoming panel.

4. Manufacturer's type, normal Amp. &

rupturing capacity for vacuum bottles used on outgoing panel.

5. Manufacturer's type,. normal Amps.

& rupturing capacity for vacuum bottles used on capacitor control panel.

6. Degree of vacuum inside the vacuum interruptors. 7. Short time rating of vacuum bottles. 8. Number of full short circuit operation,

as per test duty 1 to 5 of IEC-56 which the vacuum bottles offered can safely withstand.

9. Whether the vacuum bottles used on

incoming and outgoing panels are same or different.

10. Whether the operating mechanism is

imported or indigenous.

(SIGNATURE OF SUPPLIER)

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ANNEXURE -'B' SCHEDULE OF REQUIREMENT

1. VACUUM TYPE 9 (1 incoming+8 Outgoing) PANELS, 11 kV SWITCH BOARDS

AND EACH SWITCH BOARD COMPRISING OF THE FOLLOWING:-

-1 No. INCOMING PANEL EQUIPPED AS BELOW: Triple pole 350 MVA, 11 kV 1250A draw out type vacuum circuit breaker

fitted with arc control device, interlocks, auxiliary switches isolating contacts, emergency hand trip device, mechanical `ON' & `Off' indicator and motor operated spring charged mechanism.

-1Set Bus bars 3 phase 1250A. Cable termination arrangement located at the

rear of the unit for receiving 1 sets of 3Cx 185 mm2, 11 kV (UE) three core XLPE insulated, outer PVC sheathed cables. Each cable box shall have vertical entry from below. These cable boxes shall be complete in all respects including cable glands of requisite size. The cable boxes should only be either heat shrinkable or push on type & complete in all respect.

-3 No. CTs of ratio 500/5 A for REF protection. These CTs shall conform to

accuracy class PS of ISS:2705 (Part-IV) and shall have magnetising current as low as possible but in no case exceeding the value corresponding to class 5 P of IS:2705 (Part-III).

-3 No. CTs of 600/5 A of 15 VA output and 5P10 accuracy for over current and

earth fault protection -3 No. CTs of 600/5 A of 15 VA output, accuracy class 1 & ISF less than 5 for

metering instrument.

-1 No. 3 phase star/star connected resin cast voltage transformer of ratio 11000/√3 /110/√3 volts having 15 VA output for phase with accuracy class 1.0 as per IS: 3156 (Part-II) 1965 complete with HT & LT fuses, isolating plugs and sockets for HT & LT copper connectors, current limiting resistances.

-1 set Vermin and dust proof fitments. -1 NO. INSTRUMENT PANEL MOUNTED ON TOP AND EQUIPPED AS

BELOW: -1 No. Ammeter with selector switch as per specification. -1 No. Voltmeter with selector switch as per specification.

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-1 No. KWH meter as per specification. -1 No. PF meter as per specification. -1 Set Triple pole combined over current and earth fault IDMTL relay as per the

specification & SLD. -1 No. Single pole restricted E/F relay as per specification. -1 Set Over voltage relay for incomer panels only. -1 No. Tripping relay with hand reset contacts suitable for 110 V DC auxiliary

supply. -4 No. Indicating lamps with fittings to indicate breaker `open', `close', `auto

trip' & spring charged as per specification. -1 No. Automatic trip circuit supervision scheme as per specification. -1 No. PT fuse alarm scheme as per specification. -1 No. DC fail alarm scheme as per specification. -1 No. Circuit breaker control handle as per specification. -1 No. Alarm equipment for non-trip & trip fault annunciation as per specification. -1 No. Cubicle illumination lamp with door operated ON/OFF switch. -1 No. 15 A power socket with switch. -1 No. Anti-condensation tubular space heater suitable for connection to 240 V

AC supply with a thermostat & a miniature circuit breaker. 1.02 6 N0. OUTGOING FEEDER PANELS EACH COMPRISING OF: -1 No. Triple pole 630 A, 350 MVA 11 kV circuit breaker fitted with Arc control

devices, interlock arrangement, auxiliary switches, isolating contacts, emergency hand trip device, mechanical ON & OFF indicator & motor operated spring charged mechanism operate at 110 V DC.

-1 Set Bus bars 3 phase 630 A.

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-3 No. CTs of ratio 300-150/5-5 A with first core of 15 VA output & 5P10 accuracy for O/C & E/F protection & second core 15 VA output & accuracy class 1.0 for metering.

-1 No. Anti-condensation tubular space heater for connection to 240 V AC supply

with a thermostat & a miniature circuit breaker. -1 Set Vermin proof & dust proof fitments. -1 No. Instrument panel mounted on top & equipped as below. -1 No. Ammeter with selector switch as per specification. -1 No. KWH meter as per specification. -1 set Triple pole combined 2 O/C & 1 E/F IDMTL relay supplemented with triple

pole instantaneous relay (high set element) in the form of 2 O/C & 1 E/F as per clause : 5.14.2 of the specification.

-1 No. Tripping relay with hand reset contacts suitable for 110 V DC auxiliary supply.

-4 No. Indicating lamps with fittings to indicate breaker `open', `close',

`auto-trip' & 'spring charged' as per specification. -1 No. Indicating lamp with fittings & push button switch to indicate trip circuit

healthy in pre-close & post-close conditions as per specification. -1 No. Circuit breaker control handle as per specification. -1 No. Cubicle illumination lamp with door operated ON/OFF switch. -1 No. 15 A power socket with switch. -1 No. Anti-condensation tubular heater suitable for connection to 240 V AC

supply with a thermostat & a miniature circuit breaker.

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TECHNICAL SPECIFICATION

FOR

11 kV VCB (630A) PANEL

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CONTENTS


01.00 General 3

02.00 General Requirements 4-11

03.00 Auxiliary Wiring & Terminals 12

04.00 Control & Indication 13

05.00 Earthing Connection 13

06.00 Space Heaters 14

07.00 Name Plate 14

08.00 Painting 14

09.00 Drawings 15

10.00 Tests & Acceptance 15

11.00 Packing & Transport 16

12.00 Design Criteria 17-19

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11 kV VCB PANEL

This Specification details specification for Medium Voltage, 11 kV VCB Panel for Terminal of HPCL.

11 kV VCB panel shall receive incoming power from overhead 11 kV line from Tamil Nadu Electricity Board through a cable from double pole structure having 200A GOS with earthing switch and shall feed power to 11/0.433kVdistribution transformer. Panel shall be suitable for 11 kV (UE) XLPE cable termination at the incoming and outgoing side.

Adequate space shall be provided in the panel for incoming and outgoing cable termination.

The HT VCB Panel (Indoor type) shall be suitable for installation and satisfactory operation in a tropical, humid and corrosive atmosphere. The VCB Panel shall be designed to operate under site conditions as specified.

The VCB Panel shall be supplied in accordance with the single line diagram. All equipment shall be rated for continuous operation, unless otherwise specified. The rating (voltage, current, frequency, fault current etc.) shall be as specified in the design criteria. Short time current rating of HT Panel as well as making and breaking duty of switchgear shall be certified by recognized testing authority

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GENERAL REQUIREMENTS

1) The VCB shall be three-pole with stored energy, spring charged operating mechanism, re-strike free operation suitable for very low value of chopping currents under all duty conditions. Metal oxide gap-less surge arresters shall be provided with pressure relieving vents and mechanical indication for the arrester failure. Parts of the breaker requiring inspection, maintenance or replacement shall be easily accessible. Circuit breakers shall be fully withdrawable type and interrupting medium shall be vacuum. The breaker operating duty shall be O-0.3 sec-CO-3min-CO unless otherwise agreed. VCB shall be fitted in withdrawable trolley, which can be set in the following positions: -

Plugged in.

Withdrawn, in test.

Withdrawn, fully isolated.

In test position, auxiliary circuits are connected, but power contacts are disconnected.

2) VCB shall be motor operated spring charged, manual independent closing and shunt trip mechanism. Breakers shall be trip free and shall have anti-pumping device. The shunt trip coil, closing coil and spring charging motor shall be suitable for DC control supply. A maintenance free battery of suitable rating along with battery charging unit shall be part of the VCB panel. Alternatively, VCB panel shall be provided with a built in adequately rated power pack for the complete DC control supply. Details shall be furnished for MECON approval.

3) The trip coil shall operate satisfactorily at 50% to 110% of rated voltage while closing coil and spring charging motor shall operate between 80% & 110% of rated voltage.

4) Continuous rated current shall be 630A and Short circuit rating, Impulse and 1 min PF withstand voltages shall be as per datasheet.

1.01

5) A readily identifiable mechanical emergency trip device as well as provision for manual charging of springs through cubicle door shall be provided, which shall cut-off the electrical circuit of spring charging motor on insertion of the operating lever.

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6) A visual ON/OFF indication and spring charged indication shall be provided positively coupled to the operating mechanism and visible from front with the cubicle door closed. Spring charged/discharged indications and operation counter also shall be provided.

7) VCB shall have 8 NO + 8 NC auxiliary contacts for purchaser's use. Advance and retard contacts shall be provided if required. All auxiliary contacts shall be wired to the terminal block. Auxiliary contacts and limit switches shall be in dust tight enclosures.

8) Voltage Transformers (PT) and current transformers (CT) shall be part of the VCB panel. Current transformers shall generally conform to IS: 2705. The voltage transformers shall generally conform to IS: 3156.

9) Separate cores shall be used for metering and protection. CT’s shall have 1A secondary, air insulated, plain ring type encapsulated in thermal setting resin with bar primary mounted in a separate chamber. The PT’s shall be 3 phase star/star type fully insulated with neutral points brought out, protected by HRC fuses on H.T. & L.T. side by MCB for isolation.

10) The VCB panel shall be metal clad (2 mm CRCA sheet), self-standing cubicle, dust & vermin proof in IP43 weatherproof enclosure. A lockable-hinged lift-off type front door shall be provided. All control switches, indicating lamps, instruments, protection and auxiliary relays shall be flush-mounted on the wing panel of L.T. compartment on the front side.

11) Compression type brass cable glands with gland plates for HT cables and for control cables, tinned heavy-duty copper lugs shall be envisaged.

12) Protective relays shall be provided as per Single Line Diagram like Inst. Over current, IDMT Over current relay, Inst. Earth fault relay, Restricted Earth fault relay, Relay for transformer fault protection (winding, oil temperature, buch-holz, oil level etc.). Master trip, Trip circuit supervision relay and Auxiliary relays as per circuit requirement shall also be provided. Protection relays shall be clearly labeled and shall not be sensitive to vibration, shocks or transients. Multiple function elements, such as tripping and alarm duties, shall have separate operating contacts for each function and shall be brought out to separate terminals.

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13) CT’s for over current protection shall have appropriate VA rating and accuracy to energize relays, without causing damage to the relays, cover the range of short circuit currents that can arise. Trip circuits shall be automatically broken and CT secondary circuits shorted when a relay is withdrawn from the case.

14) All protective relays shall be back connected, draw out type, suitable for flush mounting and fitted with dust tight covers. Alternatively, ‘plug in’ type of relays will also be acceptable. All protection relays shall be Microprocessor based relays. However make and model shall be subject to approval from the owner/purchaser.

15) All relays shall preferably be mounted in front of the panel unless otherwise specified. Protective relays shall have hand reset facilities and clear operating indication, e.g. flags for mechanical type relays or light emitting diodes for static type relays. Anti-fungus treatment shall be provided for all relays.

16) Numerical relays covering the transformer faults with proper ranges and operational indications can also be considered as an alternative.

17) All relays in tripping circuits shall have mechanically operated flag indicators, which can be reset without opening the relay case. All tripping relays shall be lockout type with hand reset contacts and shall be suitable to operate on the specified D.C. voltage. These relays shall have self-coil cut-off contacts and shall be provided with hand reset operation indicators. Tripping relays will be acceptable in non-draw out cases. The number of contacts shall be as shown on the approved schematic drawings.

18) Indicating instruments shall be 96 x 96mm size, class 1.0 accuracy, taut band type. Integrating meters shall conform to IS 722, class 2.0, cyclometer register and integration period of 15 min. for maximum demand, 5-digit type.

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19) VCB operating Trip-neutral-close switch shall be of pistol grip type, spring return to neutral and lockable in that position. All control switches shall be rotary, back connected type having a cam operated contact mechanism, and phosphor bronze contacts shall be used on the control switches. Unless otherwise stated, circuit breaker control switches shall be 3-position spring return to ‘neutral’ from both ‘ON’ and ‘OFF’ positions.. Ammeter selector switches shall have ‘make before break feature’ on its contacts. The ammeter and voltmeter selector switches shall generally have four positions.

20) Indicating lamps shall be LED type and supplied complete with the necessary current limiting resistor duly tested for its rating. Lamps shall be provided with translucent lamp covers to diffuse light.

21) Space heaters with thermostat control shall be provided.

22) Operating height of all push buttons, switches, lamps, meters, relays etc shall not exceed 1800 mm.

23) An exclusive Emergency Push Button (to be located in the Depot manager’s room & transformer yard) to trip the VCB shall be wired up in the control circuit.

24) Solid-state Alarm annunciator for Transformer faults and trip indicators shall form part of VCB Panel.

25) Auxiliary relays/contactors shall generally be used for interlocking and multiplying contacts. Auxiliary contacts shall be capable of carrying the maximum estimated current.

26) Selection, sizing and suitability of all components shall be the vendor’s responsibility and the vendor shall include all equipment required for safe and satisfactory operation, even if not specifically mentioned.

27) Only major relays, meters and controls are indicated in the datasheet/SLD/scheme drawings. Any auxiliary relays, timers, switches etc. as required while developing the control schematic and required for safe operation, even if these are not specifically included shall be supplied without price implication.

28) All relays, metering and control components shall be mounted on the panel front only.

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29) Components requiring inspection or adjustment shall be accessible from floor level

30) The vendor shall be solely responsible for coordinating the relay characteristics with suppliers for the proper selection of all CT’s.

31) The vendor shall prepare a proposal for the settings of the protection relays. The final setting of the relays shall be agreed between the vendor and the Purchaser.

32) The VCB Panel components viz. Circuit breaker, main horizontal & vertical bus bars, bus bar joints, bus bar supports etc. shall be designed to withstand the maximum expected short circuit level for a minimum time of 3 sec.

33) Vendor shall indicate the space requirement for the VCB Panel along with the bid (required for designing the electrical room layout).

34) All mounted equipment shall have “identification” tags of self - sticking PVC tape at the rear.

35) All terminals shall be shrouded with plastic covers to prevent accidental contact.

36) Thermal design of the bus bars shall be based on installation of the switchgear in poorly ventilated conditions. The cooling air volume shall take in to account only the bus enclosure.

37) Cable supporting facility shall be provided in cable allay for power and control cables.

38) The earth busbar size shall be 50 x 12 mm copper or equivalent.

39) All power and control cables shall be terminated by purchaser through double compression nickel-plated brass cable glands. However, supplier shall supply lugs and cable glands.

40) Test of the complete panel shall be carried out at site in presence of manufacturer’s specialist, once the external cable connections have been completed.

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41) Vendor shall also provide minimum following potential free normally open contacts for remote annunciation.

Tripped on fault.

Under voltage trip

Trip circuit unhealthy

DC control supply failure

PT secondary MCB off.

42) The vendor shall supply appropriate base frames to provide a substantial foundation for the VCB Panel installation, together with necessary holding down bolts, nuts & washers, rails, etc.

43) The VCB Panel shall be totally enclosed and vermin-proof. If necessary, louvered openings with wire mesh shall be provided for natural ventilation. Wire mesh for bus bar compartments shall be such as to protect against objects of 1 mm and above. The enclosure shall have complete protection against live parts and internal moving parts.

44) Suitable neoprene gaskets shall be provided in all openings, covers and doors. Unless otherwise specified, the minimum protection class for the enclosure shall be IP 43.

45) Each unit of the switchgear shall have necessary internal sheet metal barriers to form separate compartments for bus bars, instruments and relays, cable connections, etc. Suitable arc propagation barrier shall be provided in the bus bar compartment at every junction between two adjacent cubicles. Independent pressure release flaps shall be provided for all HV compartments, viz. Bus bar, cable and breaker compartments. Terminal strips for outgoing control cable connection should be accessible to facilitate working and testing of breaker in test/service condition and while the panel is energized.

46) It shall be possible to extend the panels/bus bars at both the ends.

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47) In the VCB Panel, the draw out carriage shall have three positions: “Service”, “Test” and “Draw out”. Automatic safety shutters shall be provided to ensure the inaccessibility of all live parts after the breaker is drawn out. It shall not be possible to draw out the carriage with the circuit breaker closed. The breaker feeder trolley shall remain inside the cubicle even in the “Test” position. There shall be a distinct overall door for the breaker compartment and it should be lockable. Necessary interlocks to prevent faulty operations shall be provided.

48) Switchgear shall be designed and constructed to facilitate inspection, cleaning, repair and maintenance and to ensure absolute safety during operation, inspection and maintenance.

49) Similar parts and components shall be interchangeable, wherever practical.

50) All hardware shall be corrosion resistant. All joints and connections of the panel members shall be made by zinc-passivated, or cadmium-plated, high quality steel bolts, nuts and washers, secured against loosening.

51) Suitable eye bolts/provision for the lifting of the panel shall be provided.

52) Checking and removal of components shall be possible without disturbing adjacent equipment. All equipment shall be easily accessible.

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53) BUSBARS

Bus bars and connections shall be made of electrolytic Aluminium / Copper and shall be sleeved by using heat-shrinkable PVC sleeves of suitable voltage grade.

Bus bars shall be of same cross sectional area throughout the length of the switchgear, and shall be sized to carry continuously the current specified in the single line diagrams/data sheets.

For the phase identification, bus bars shall be marked with Red, Yellow and Blue colour.

Bus bars and connections shall be adequately sized, braced and supported to withstand the mechanical forces and thermal effects resulting from the switchgear rated short circuit current and carry certification from a recognized testing authority.

54) The incoming and outgoing power connection shall be through XLPE cables. Suitable termination arrangement shall be provided for number and size of cables as indicated in the single line diagrams/data sheets. Ample space for connection for these cables shall be provided at the rear of the switchboard. A removable expanded metal barrier shall be provided in the cable compartment, in order to avoid accidental contact in the cable compartment, while carrying out inspection by opening the back cover. Unless otherwise specified, the power cable shall enter the switchboard from the bottom.

55) The switchboard shall be supplied complete with supports for clamping outgoing and incoming cables. The headroom available between cable gland plate and terminal lug shall not be less than 600 mm for switchgear.

56) A set of earthing plugs shall be provided for earthing the bus bars or circuit cables through circuit breaker.

Provision is also made for earthing through circuit breaker truck by means of separate earthing contacts.

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AUXILIARY WIRING AND TERMINALS

1) Inside the cubicles, the wiring for control, signaling, protection and instrument circuits shall be done with coloured PVC insulated conductors. The insulation grade shall be 1.1 kV. The Wiring shall preferably be enclosed in plastic channels or neatly bunched together. Wiring between HV breakers or cable compartments to relay and metering compartments shall be routed through flexible conduits.

2) 10% spare terminals shall be provided on each terminal block. Sufficient terminals shall be provided on each terminal block to ensure that not more than one outgoing wire is connected per terminal.

3) Terminal strips shall preferably be separated from power circuits by metal barriers or enclosures. All spare contacts of auxiliary relays, timers, etc. shall be wired up to the terminals.

4) Each wire shall be identified at both ends by correctly sized PVC ferrules. Shorting links shall be provided for all CT terminals.

5) For CT circuits 2.5 Sqmm copper conductor shall be used. Other control wiring can be with 1.5 mm2 copper conductors. Unused CT secondary terminals shall be short-circuited. All terminals shall be shrouded with plastic covers to prevent accidental contact.

01.02

6) External control cables shall enter the switchgear from the bottom. Tinned-copper cable lugs and requisite cable glands for these cables are also included in the scope of supply of the switchboard. The cable glands shall be of nickel-plated brass, single-compression type and shall be suitable for control cable sizes as mentioned in the data sheets / approved drawings. Supporting facilities shall be provided for clamping of the control cables. All external control cabling will be carried out with 2.5 Sq.mm Cu conductors. The vendor shall provide suitable terminals and cable lugs accordingly in the panel.

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CONTROL AND INDICATION

1) Breaker tripping and closing devices shall be suitable for D.C. voltage as specified. The power supply distribution for a switchboard shall be arranged as follows:

One D.C. feeder shall be provided from battery. (Refer Battery and charger specifications)

One separate 240 V AC supply shall be provided for feeding space heaters, etc.

2) Breaker positions, ON/OFF/Spring charged/Test position/ Service position shall be indicated mechanically. Following indications shall also be provided on the front of panel.

a) Breaker ‘ON’ : Red Lamp

b) Breaker ‘OFF’ : Green Lamp

c) Breaker ‘Auto Trip’ : Amber Lamp

d) Trip circuit healthy : White Lamp

e) DC supply fail : Blue Lamp

01.03

f) Spring fully charged : Amber Lamp

EARTHING CONNECTIONS

1) All metallic non-current carrying parts of the switchgear shall be bonded together and connected to the switchgear earth bus bar.

2) All doors shall be bonded to the main structure by means of a flexible copper connection arranged so that it cannot be trapped as the door is opened or closed.

3) All withdrawable parts shall be effectively earthed until they are completely withdrawn with all power and control connections disconnected.

4) Provision shall be made, adjacent to cable termination, for earthing of the cable screen and Armouring to the earth bus bar.

5) An earthing bus bar suitable for switchboard rating shall be provided along the full length of the switchboard. Provision shall be made to connect earth bus bar to the plant-earthing grid at two ends.

01.04

6) Each earthing point shall be identified with suitable marking.

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01.05 SPACE HEATERS

The cubicle shall be provided with space heaters to prevent moisture condensation. The space heater shall be controlled through a thermostat with an adjustable setting and a manually operated switch.

01.06 NAMEPLATES

A nameplate with the switchgear designation shall be fixed at the top of the panel. Nameplates shall be provided for each equipment (lamps, PB, switches, relays, auxiliary contactors, etc.). All mounted equipment shall have identification tags of self-sticking PVC tapes at the rear also. Special warning plates shall be provided on all removable covers or doors giving access to high voltage cable or bus bars. Engraved nameplates shall preferably be of 3-ply (Black-White-Black) lamicold sheets or anodized aluminum. Black engraved Perspex sheet nameplates will also be acceptable. Nameplates shall be fastened by ‘screws’ and not by adhesives.

PAINTING

1) All metal surfaces shall be thoroughly cleaned and de-greased to removed mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under-surface shall be prepared by applying a coat of phosphate paint, and a coat of yellow zinc chromate primer. The under-surface shall be made free from all imperfections before undertaking the finishing coat.

2) After preparation of the under-surface, the switchboard shall be spray painted with two coats of epoxy-based final paint. The colour shade of final paint shall be shade 631 (Light Grey) as per IS: 5, unless otherwise specified. Spray-painted finished panels shall be dried in stoving ovens in dust-free atmosphere.

01.07

3) All unpainted steel parts shall be cadmium plated suitable treated to prevent rust corrosion. If these parts are moving elements, then these shall be greased.

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DRAWINGS

The following drawings shall be submitted for approval as per agreed schedule.

a) Single-line diagrams

b) general arrangement drawings

c) flooring and mounting detail drawings

d) schematic diagrams

e) bill of material with all component details

f) Wiring diagram

01.08

HPCL/MECON concurrence of schematic drawings is required before the manufacturer proceeds with the cubicle wiring. Review of the manufacturer’s drawings shall not relieve the manufacturer of his responsibility for supplying equipment conforming with the relevant specifications and standards, or for any mistakes, errors or omissions in manufacturer’s drawings.

TESTS AND ACCEPTANCE

1) Tests shall be carried out at manufacturer’s works under his care and expense.

2) The manufacturer shall submit a QAP inline with the format enclosed for approval of MECON. All tests and documents of inspection documents shall be shall be done based on this.

3) All routine tests as specified by the applicable standard code shall be conducted. Type test certificates for the switchgear panel and circuit breaker from a recognized testing organization shall be furnished with the bids. The vendor shall also submit a list of guaranteed technical particulars with the bids.

4) In addition, specific tests shall be conducted to check mechanical and electrical operation/wiring etc. and switchboard wiring conforming to the specification and approved schematic drawings.

01.09

5) All routine tests on breakers shall be conducted as per relevant standards.

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6) Above tests shall be provisionally conducted at manufacturer’s works by providing temporary connection to switchgear units in order to simulate the actual conditions.

7) Tests shall be finally performed at site, in presence of the manufacturer’s specialist, once the external cable connections have been completed.

8) Tests, which will be witnessed by Purchaser/ MECON representatives shall be as follows:

a) A visual check shall be carried out. This shall cover measurement of overall dimensions, locations, number and type of devices, terminal boxes, location and connection of terminals, etc.

b) Manual and electrical operation of switching device/Relays shall be checked under the worst conditions of auxiliary supply voltage.

c) Dry insulation test with power frequency voltage shall be conducted for the main and auxiliary circuits.

d) Insulation resistance of the main and auxiliary circuits shall be checked.

e) Operation check shall be carried out for every control function as per the approved schematic diagrams by manually simulating fault conditions and operation of control switches/relays etc.

f) Relays shall be tested with secondary injection test equipment.

g) For bought out equipment, test reports of tests carried out at the manufacturer’s works shall be submitted. Normally, all routine tests as specified in the relevant standards shall be conducted at his works.

01.10 PACKING AND TRANSPORT

The switchboard shall be shipped to site packed in wooden crates. They shall be wrapped with polythene sheets before being placed in crates to prevent damage to the finish. Crates shall have skid bottoms for handling.

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e) Provision of mechanical emergency trip push button 14. a)

Type of rack-in /rack-out Mechanism for drawout

b)

Provision of key interlock

c)

Provision of door interlock

d)

Definite positions and associated interlock details of draw-oust breaker

15. Electrical operation a)

Rated voltage

b)

Operating voltage range

c)

Spring charging time

d)

Details of under voltage release

i)

Pick-up & drop off voltage range

ii)

Time setting range

16. No. of Auxiliary contacts 17. Control contacts (Plug-in/ sliding) 18. Type test certificates for breakers a)

Breaking capacity

b)

Short time rating

c)

Making capacity

d)

Capacitor switching rating

e)

Temp. rise test at rated current in IP 52 enclosure

19. Type test certificates for cubicle/PMCC a)

Temp. rise

b)

1 Sec. Rating

c)

Dynamic withstand capacity

20. Protection relays Make & Type 1.06.04 Current transformer

a) Make & Type b) Accuracy class

1.06.05 Meters

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a) Make b) Type c) Size d) Accuracy class

1.06.06 Fuse switch unit

a) Make & Type b) Operating mechanism

1.06.07 Indicating lamps

a) Make & Type b) Rated voltage, watts c) Series resistor Ohm / Watts

1.06.08 Contactor

a) Manufacturer’s name b) Rated voltage ‘c) Rated current d) Min. capacitor switching duty e) Coil rated voltage f) Whether mechanical On/OFF indication provided h) No. of auxiliary contacts i) Applicable standards

1.06.09 Fuse switch name

a) Manufacturer’s name b) Manufacturer’s type designation c) Type of break d) Rated voltage e) No. of auxiliary contacts f) Applicable standards

g) Breaking current of switch at L/R equal to 0.5 h) Whether quick make quick break mechanism provided for the

switch 1.06.10 Thermal O/L relays

a) Make b) Type

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CONTENTS


01.00 Power & Motor Control Centre 2-22

01.02 MOV DB/MLDB 22-26

01.03 Drawings 26

01.04 Inspection & Testing 26

01.05 Packing & Despatch 27

01.06 Earthing 27

01.07 Applicable Codes & Standards 27-29

01.08 Quality Assurance, Inspection & Testing 29-33

01.09 Quastionnaire 33-36

01.10 Preffered Makes 37

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01.00 POWER CUM MOTOR CONTROL CENTRE The PMCC shall be as per the single line diagram attached. 01.1.0 Deleted 01.2.1 Ratings

i) The rated insulation voltage of the main circuit

: 1100V AC.

ii) The rated working voltage of the main circuit

: 415VAC,3Ph, 4 wire

iii) The rated voltage of control circuit : 110VAC,1Ph,2 wire iv) Impulse withstand voltage : 4 kV as per IS-

13947(Part-1) 1993 v) Power frequency withstand voltage : 2.5 kV for 1 minute.

01.2.2 Constructional Features

- Single front/ double front design, Non-draw out, free standing, compartmentalized, floor mounting type suitable for both front and rear access. The panel shall be extendable on both sides at site.

- Panel with sheet steel (CRCA) of 2.0mm thickness based on

the rigidity requirements. However for the doors & covers minimum thickness has to be 1.6 mm.

- Shall have an integral base channel. - A transport section shall not exceed 3 vertical panels. - Lifting facility shall be provided for each section. - Dust & vermin proof design. - Degree of protection for enclosure shall be IP 52 as per IS:

13947 – 1993 Part – 1. - All switches, push buttons etc. shall be capable of operating

from the front. - Cutouts in the module door shall have neoprene gaskets

ensuring dust tightness. - Neoprene gaskets shall be used for cable alley doors, busbar

chamber covers to ensure tightness and making it dust proof. - Feeder module doors and cable alley doors shall open in

opposite direction for providing more working area for maintenance purpose.

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- Each feeder module shall have door interlock, defeat interlock

and padlocking facility. - Cable alley shall be adequately designed for use of

copper/aluminium conductor power cables. Cable entry shall be from bottom with undrilled gland plate.

- Base channel of height 75 mm shall be provided. - Max. Height of operating knobs of any device or indicating

meters shall not exceed 1800 mm from floor of room. Minimum height shall not be less than 450 mm.

- Anticondensation heaters of suitable rating with thermostat

cutoff shall be provided in each PMCC.

01.2.3 Busbars & Supports

- Main busbars shall be made of high conductivity aluminium (IS-5082/198l), Control bus electrolytic copper as per IS-1897-1983.

- Three phase and Neutral bus shall have facility for connection

with earth bus. - Shall be heat shrinkable PVC shrouded except at the points of

tap-off. The bus bars shall be colour coded for phase identification

- Busbars shall be housed in totally enclosed compartments

having removable type covers for easy maintenance. - Horizontal power bus bars and control bus bar shall be located

at the top of PMCC. - Power and control bus bars shall be segregated. - Main bus bars shall run throughout the length of transport

section and vertical bus bars throughout the height of PMCC. - Busbar joints shall be of bolted type with suitable spring

washers to ensure tight fittings. Bolts and washer shall be galvanized or cadmium plated.

- Horizontal bus bars shall be extensible on either side of PMCC. - An aluminium earth bus of mm, size 50 x 6 shall be run at the

bottom of PMCC with a provision of a link for connecting to neutral bus bar.

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- Provision shall also be made for terminating the 4th core of incoming & outgoing cables.

- Bus bars shall be sized for the current rating specified (with

temperature derating) to withstand a short circuit of 30kA rms for 1 sec.

- Temperature rise of bus bars shall be limited to 40 Deg. C. - Bus bar supports shall have adequate mechanical strength,

high dielectric strength, and low moisture absorption characteristics.

- Bus bar supports shall be rigidly held to the frame work of

PMCC and shall be so spaced as to ensure rigid support for bus bars.

- Bus bar supports shall be designed to withstand thermal and

dynamic stresses resulting from specified short circuit current. - Min. clearance between live parts shall be 25 mm and live to

earth 19mm. - All core type CTs mounted on bus bars shall be supported

separately and not supported on bus bars. CT secondary-connecting cables shall be properly dressed and clamped such that these do not hang loose / pass directly over bus bars.

01.2.4 Wiring & Terminal Blocks

Suitable provision shall be made to terminate control / power connections near the respective module. The terminals selected shall be suitable for the termination of armoured cables, as per the details of cable required. Adequate space shall be kept for cabling.

PMCC shall be completely factory wired, ready for connecting to equipment. Power circuit wiring shall be with 1100 V grade single core stranded, PVC insulated copper cable of minimum 4 sq. mm.

Control circuit wiring shall be with 1100 V grade multi strand, PVC insulated copper cable of 2.5 sq. mm.

Internal control wiring shall be laid in PVC ducts with detachable snap - on covers and there shall be enough length to avoid the necessity to stretch the cables for door movement/connection, disconnection or changing.

All terminals, as well as terminations, at various control devices inside the compartment shall be provided with interlocking type

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ferrules having engraved numbers. Terminals having connections from other modules shall be marked with red ferrules. - There shall be no joints or tappings between two

terminations. No more Than two connections shall be made to any terminal.

- 20% spare terminals shall be provided in each control

terminal block. - The wiring shall be terminated in the respective terminal

with suitable crimp type sockets. - Interlocking type ferrules for identification shall be

provided. - All spare contacts to be wired to terminal block. - Interpanel wiring shall be through horizontal bus bar

chamber. - All holes or tubes for wiring runs shall be bushed and

shall have room for reasonable additions. - All power cable terminal blocks / boards shall be stud and

nut type with phase barriers. - For higher rated feeders, suitable staggered extension

links shall be provided to permit direct termination of cables.

- Cable supports / clamps shall be provided in cable alley. - Removable cable gland plate shall be provided. - Double compression type GI / brass glands, accessories

including tinned copper lugs to outgoing cable sizes to be supplied loose.

- The color-codes for the wires shall be as follows:

415V, 3phases Red, yellow & blue Neutral Black Earth Green Single phase – line Red 11OV AC - line Brown 24V DC +ve Orange -ve Black

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01.2.5 Control Transformers

Control transformers of adequate rating (3 kVA each) shall be provided for 110 V AC control supply for each PMCC. Higher rating shall be selected based on actual requirement with 50% margin and voltage drop in control transformer shall be less than 3% at peak KVA requirement during coil pickup. MCB & fuse shall be provided for primary side of control transformers. MCB of suitable rating shall be provided on the secondary side. Voltmeter class 1.5 and scale 0-250 V. Control transformer shall be horizontally mounted in one of the bottom compartments with adequate ventilation. The transformer shall be double wound, dry type with class E insulating materials. The control supply for the motor feeders shall be fed through suitable rated MCBs.

Control transformers shall be provided with +/- 5% and +/-10% voltage taps on 415 V side.

The control bus of the PMCC shall be electrolytic grade copper only and will be designed to carry the transformer rated secondary current as well as withstand the available short circuit level.

01.2.6 Inscriptions

Identification labels shall be provided for each PMCC as well as for each compartment, control device and other components.

PMCC designation at the top of central panel with letters of 25 mm (min.) height.

Anodised Al. Plates (Black background and white lettering) for each feeder inscriptions with letters of mm. 6 mm height for each module on door.

Each component shall be identified as per schematics by good quality polyester film stickers on components and by painting in a conspicuous place on the panel body.

Terminal blocks shall be identified as per schematics with stickers / stenciling by black paint.

Danger boards as per IS on front & rear end of PMCC.

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01.2.7 Moulded Case Circuit Breaker ( MCCB)

The MCCB rating shall be as per SLD. Adjustable inverse time overload and / or instantaneous magnetic releases shall be provided suitably. Operating handle, door interlock and padlocking at ON/OFF position shall be provided. Symmetrical breaking capacity shall not be less than the system short circuit level. Atleast 1 NO and 1 NC auxiliary contacts shall be provided.

01.2.8 Air Circuit Breaker (ACB)

The circuit breakers shall be four pole, air break fully drawout, selective type for achieving discrimination .All current carrying contacts of the breaker shall be silver plated. The main contacts shall have ample area and contact pressure for carrying the rated current of the circuit breaker, to avoid excessive temperature and the resultant pitting. The tips of the arcing contacts shall be made out of suitable arc resisting material. Arc chute shall be provide on each pole and so fitted that it can be easily removed for inspection of the main contacts. The contacts shall meet against spring pressure with a self-cleaning action. Interphase barriers of proper design shall also be incorporated.

The connections of main power and auxiliary control circuits

shall be fitted with self-aligning contacts. The fixed portions of the sliding contacts shall be easily accessible for maintenance and checking, If plug and socket are used for auxiliary control circuit connection, mechanical interlock shall be provided to ensure the following

i) Remove the plug before the breaker is withdrawn from

the test position And

ii) Movement of breaker from test to service position shall

be possible only after connecting plug and socket.

The breaker shall have the following three distinct positions:

a) Service position: Normal service position with main and auxiliary control circuits remaining connected.

b) Test position: In this position, main power contacts of the

breaker are fully disconnected while the auxiliary control circuits remain connected.

c) Isolated/maintenance position: In this position the

breaker shall be fully out of the cubicle and both the main power and auxiliary control circuits are disconnected.

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These three positions shall be possible with door closed. An automatic mechanical indicator shall be provided to indicate these positions, visible from outside. It shall be possible to lock the breaker in test and isolated position.

01.2.8.1 The circuit breaker, together with its operating mechanism isolating

and interlocking gears, contacts and wiring, shall be fixed on a withdrawable carriage. Each carriage shall have a dead front panel. Mechanical interlocking Shall be provided on each carriage to prevent maloperation and in particular to Ensure that:

a) The carriage cannot be moved in or out of its cubicle with the

circuit breaker closed. b) The circuit breaker can only be closed when the carriage is in

one of the three positions viz., the service position, test position or fully out of the cubicle in the maintenance position.

c) Inadvertent withdrawal of a circuit breaker carriage too far

beyond its supports shall be prevented by suitable mechanical stopper.

d) Interlocked rigid clamping and anti lifting arrangements shall

be provided for circuit breaker trucks in the service and test positions.

01.2.8.2 The circuit breaker shall be capable of carrying continuously and

interrupting satisfactorily the currents specified without undue heating or wear of the contacts, under the specified site conditions.

01.2.8.3 Automatically operated shutters shall be provided to screen the fixed

portion of the contacts assembly when the breaker is fully withdrawn from the cubicle.

01.2.8.4 Breakers shall be provided with static trip release consisting of 0/C, S/C

and E/F with adjustable time settings for each independently. Under-voltage tripping shall be provided by help of under voltage relays/ timer.

01.2.8.5 In case of direct acting, static releases with combined short circuit and

inverse overload protections, it shall require no auxiliary supply. Power for the operation shall be drawn from fault current and its performance shall be unaffected by magnitude of fault current, Release shall be suitable for the duty applicable to the breaker, The basic requirements of these releases will be as specified for direct acting electromagnetic releases.

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01.2.8.6 Operating mechanism

The incomer breakers shall have motor operated spring charged stored energy closing mechanism. Means shall be provided for manual closing. The spring charging motor and closing coil shall be suitable for operating in the range of 85-110% of rated voltage of 240V AC single phase. The breaker shall also have shunt trip coil rated for 415 V or unless specified otherwise and suitable for operating in the range of 40-110% of rated voltage. All breakers shall be provided with mechanical trip push button, accessible from outside.

The operating mechanism shall be trip free and designed to reduce mechanical shocks to a minimum during operation. The operating mechanism shall operate normally even when the circuit breaker is closed on to fault. All mechanisms shall be designed to give trouble free service over extended periods and shall not with normal usage, require attention more often than every 1000 operations or once a year whichever is earlier. Each breaker shall be equipped with mechanical 'ON', 'OFF', 'SPRING CHARGED, 'TRIPPED' on fault indications visible from the front of the panel. All electrically operated breakers shall have inherent anti-pumping feature.

01.2.8.7 Auxiliary contacts

All contacts shall have adequate capacity to make, carry and interrupt the currents in their circuits. Minimum rating shall be 5A at 415 V AC/2A at 220 V DC. Each circuit breaker shall be provided with 6 NO + 6 NC auxiliary contacts. Out of these, 3 NO + 3 NC shall be spare auxiliary contacts for owner’s exclusive use at site. The design of the contacts shall be such that they can be easily converted from normally open to normally closed type and vice versa. All the auxiliary contacts shall be wired internally up to the terminal blocks in the fixed portion of the breaker cubicle, In case multiplication of contacts are required, the same shall be done using EE make VAJC relay without any extra cost (Latch in type with electrical reset feature).

01.2.9 Contactor

Contactors provided for control of motors / capacitor banks shall be 3 pole air break, electro-magnetically operated, Contactors meant for capacitor switching shall have duty corresponding to 150% of rated capacity of bank at 440V. The contacts shall be made of special silver alloy suitable for higher switching frequency. The contacts shall have minimum bounce, The contactor shall have mechanical ON/OFF indication, 2 NO + 2 NC auxiliary contacts rated at 5A at 440 V. The coil shall be rated at 110 V AC, and operate satisfactorily from 75 to 110% of rated voltage. Incoming and outgoing terminals shall be segregated and terminal capacity shall be suitable for the type of

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termination adopted. 01.2.10 Current transformer Protection and measuring current transformer shall be of cast resin,

bar type primary, with 5A or 1A secondary conforming to IS-2705 - 1992 Part II, III and IV. The minimum burden shall be 15 VA. CT shall be suitable for 415 V +/- 10 %.

Measuring current transformers shall conform to accuracy class 1 of IS-2705 – 1992 and burden of CTs shall be as required by the associated measuring instruments and connecting leads, The CTs shall have saturation factor of 5.

Protection current transformers shall have their accuracy and burden

as required by the protection circuit in which they are used and shall have minimum saturation factor not less than 10.

CTs for restricted earth fault protection shall conform to Class ‘PS’, Part IV of IS—2705. All CTs shall withstand without injury dynamic stability and thermal stability currents specified for PMCC.

The current transformer ratios specified are provisional and are

subject to alteration and confirmation later at the time of approval of manufacturer’s drawings.


In addition to the mechanical indicators on the circuit breaker, each breaker cubicle shall have cluster LED type indication lamps as specified. All indication lamps shall have series resistance for long life maintaining visibility. Lamps shall be replaceable from front of the cubicle without opening the door.

01.2.12 Indicating instruments

All indicating instruments (voltmeters/ammeters) shall be of taut band, square size, flush mounting type, suitable for vertical mounting and back connection and conform to IS 1248. The accuracy class of instruments shall be class 1.5 of IS-1248. All indicating instruments offered shall be of the best make and shall have non-reflecting bezels, clearly divided and indelibly marked scales and sharply outlined pointer. All instruments shall be provided with a zero adjusting device for external operation. Ammeters shall be suitable for operation on CT and scaled to read actual currents flowing in the circuit.

01.2.13 Control switches

Circuit breaker control switches, when provided, shall be of pistol grip, spring return to neutral type. They shall be arranged to close the breaker by being turned clock-wise and to trip it being turned anticlock

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wise. The trip, neutral and close positions shall be clearly located and the switch cannot be operated inadvertently. It shall be mechanically inter locked to trip before close. Lost motion contacts shall be provided in these switches.

01.2.14 Cable termination accessories

Undrilled G.I gland plates and compression type brass cable glands shall be provided for termination of cables. The gland plates shall have gaskets so that the enclosure conforms to IP-52. . Provision for terminating 1/2 core on to earth bus and neutral bus shall be made.

Provision shall be made in the PMCC to terminate aluminium cables matching the feeder rating. The cables are selected based on a derating factor of 0.6. Necessary glands and lugs have to be supplied along with the PMCC.

01.2.15 Earthing

A continuous earth bus shall be provided for the PMCC at the bottom with an earthing bolt at each end. Bolted joints with tooth spring washers shall be provided for good earth continuity. Provision shall be made for connecting 4th core incoming and outgoing cables. The earth bus shall be of aluminium having the same size as that of neutral bus bar at the top. Neutral and earth busbars shall be connected through a link. Electrical equipment shall be interconnected with earth grid using minimum size 40 x 5 GI strip or 8 SWG Gl wire. Earthing shall confirm IS: 3043 - 1987, IE rules and statutory regulations. Internal earthing network shall be connected at two places minimum to the external-earthing network.

01.2.16 AUTOMATIC POWER FACTOR CORRECTION EQUIPMENT The capacitor banks rating shall be selected in such a way so that the

power factor shall be maintained between 0.93 to 0.95 at 415 V at all load conditions.

The actual rating of the capacitor bank shall be finalised during

drawing approval stage and it shall be provided without any price variation. The rating of the capacitor feeding cables shall be 30% higher than the normal rating

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The capacitor bank shall be sheet steel enclosed, free standing, dust

& vermin proof and suitable for indoor service. The banks shall be complete with capacitors, busbars chamber and busbars, suitable discharge resistor and fuse for individual capacitor, arrangement for cable entry and termination, earthing terminal, nameplate etc.

The control panel shall be complete with all relays, contactors,

switches, lamps etc. Both manual and automatic correction shall be provided. The panel shall be sheet steel enclosed, free standing, dust & vermin proof and suitable for indoor service. The panel shall be complete with busbars chamber and busbars and arrangement for cable entry and termination, earthing terminal, nameplate etc.

The minimum voltage rating of capacitors shall be 440V (phase to

phase). CFS unit and contactors shall be suitable for capacitor switching duty. Capacitor shall have higher voltage rating to account for series reactor and 10% system over voltage.

LT capacitors shall be controlled by contactors. The total bank

isolation, from the MCC bus, shall be achieved by suitably rated CFS unit having capacitor switching capability. Current rating of CFS unit shall be 30% higher than the normal rating of capacitor bank. Each capacitor bank shall be of 3 Nos. of units connected in delta & should have external fuses for protection. Each capacitor feeder shall have under voltage and over voltage protection by using relay.

Each capacitor shall have series reactor/ choke inductance to control

the inrush current. The tenderer shall furnish the rating of capacitor bank along with calculations in the offer based on data indicated in SLD.

Necessary CT requirement for automatic power factor correction in

the incomer breaker panel shall be provided for automatic intelligent power factor controller

01.2.16.1 Capacitor units

Each capacitor unit shall be fully enclosed in sheet steel on plastic container of adequate thickness suitable for mounting inside the capacitor cubicle. The unit shall be supplied with necessary accessories for forming bank of specified rating.

Capacitors shall be of polypropylene dielectric with self-healing properties. Each unit shall have built-in discharge resistor, series reactor and unit protection fuses and two terminal bushings. The

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fuses shall not deteriorate or operate due to repeated switching at rated voltage.

The minimum voltage rating of capacitors shall be 440V (phase to phase). Capacitor shall have higher voltage rating to account for series reactor and 10% system over voltage.

The unit shall conform to IS-2834-1981 / IS-13925 and shall be suitable for an ambient of 50 degrees C.

01.2.16.2 Capacitor banks

Each LT switchboard section shall have specified number and rating of capacitor banks. The capacitor banks shall be delta connected using singlephase units rated for 440 V. Where capacitor banks of different ratings are specified, the same shall be built-up from a single standard capacitor unit. The capacitor bank formation inside the cubicle shall be formed considering easy accessibility for each unit and better air clearances. All bus work shall be adequately supported for maximum fault level specified.

Each bank shall be independently controlled. All the banks shall be controlled automatically based on bus power factor. The control scheme shall be such that maximum numberof steps are achieved for smooth control of power factor.

01.2.16.3 Control equipment

Each capacitor bank shall have independent control equipment comprising fuse switch unit, power contactor with auxiliary contacts, line CTs with taut band ammeter and selector switch to read phase currents of capacitor bank feeder, ON/OFF indicating lamps, auto/manual selector switch, auxiliary relays and any other equipment required for satisfactory operation, maintenance and control. Local/remote selector switches where specified shall be provided for switching ON/OFF capacitor banks from remote location. Each bus section shall have a multistage PF relay with associated contactors, bus PF meter for group control of the banks connected to respective bus section.

All switching equipment shall have capacitor switching rating of 150%of rated current of capacitor bank. All equipment shall be suitable for 240 V AC control supply. Necessary protection through HRC fuses shall be provided for control circuits. Control supply shall be drawn preferably through control transformer. Necessary interlock

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shall be provided to ensure switching-on of capacitor banks after it is fully discharged.

01.2.17 Feeder Types

The following types of feeders shall be envisaged in PMCC. Type ‘A’ Incomers

- Draw out design - Air circuit breaker of 800 / 1200 A / 1600 A rating with static

trip release for O/L, S/C, E/F & shunt trip release. - Incomer from transformer or incomers from DG set can be

switched on one at a time - 415V, 3 Ph, 250/400/630 Amps, rated moulded case circuit

breaker with thermal short circuit, undervoltage and shunt releases.

- Power monitor( ENERCON 3360 or equivalent) with fuses . - Current transformers to read phase currents as per PMCC

rating. - Relay as per SLD - Phase (R, Y, B) Indication lamps with fuses. - ON/OFF/Trip indication lamps (LED type). - All lamps shall have series resistors. - Current transformers for APFC relay and protection relay

Type ‘B’ Control Section

- Dry type control transformer, 415 / 110V with + 2.5 and + 5%

tappings on primary, of required rating (minimum 2.5/3.0 kVA).

- MCB on primary side and secondary side of transformer. - Control supply healthy (lamp) indication.

Type ‘C’ Motor feeders

- Shall have kW rated fuse switch (FS) of AC 23 rating, double break design with 1 NO 1 NC auxiliary contacts.

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- FS shall be interlocked with control circuit and padlocking

facility. - Fuses shall be HRC link type, with current limiting

characteristic, rated for 50 kA symmetrical (Min). - Fuse rating shall be co-ordinated with contactor. - Main contactor shall be of AC 3 category, rating as per SLD, or

125% of motor rated current as per component chart. Shall have min. 2 NO + 2 NC auxiliary contacts.

- 3 Element bimetallic thermal overload relay, manual reset

type, ambient temperature compensated with inherent single phase preventor.

- Overload relay to be of heavy-duty type for drives of higher

inertia and high starting time like pumps. - CT operated overload relays for drives of 11kW and above. - Overload relay shall have minimum 1 NO + 1 NC contacts. - Ammeter to read phase currents with CTs and selector switch. - Ammeter shall be selected based on CT secondary current of 5

Amps. - Ammeter of class 1 accuracy, 74 x 74 mm. taut band, linear

scale to read upto rated current and suppressed scale for 600 to 800% of rated current of motors.

- ON, OFF, Trip on overload indication lamps (LED type) on

module door. - 3 Position, 4 way control selector switch (Local / Remote

(Auto) / OFF), overload reset push button. - Control circuit MCB of 16A rating with short circuit release for

each drive. - Auxiliary contactors of 10 A rating for interlocks etc., required

for each drive. - Potential free one NO O/L contacts for remote annunciation

and potential free one NO + one NC contact of main contactor be wired to terminal block for status indication .

- Motors below 30 kW with DOL starter

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- All motor feeders shall have two modes of control - Local and

Remote. The mode of control shall be selected by a 3 position selector switch mounted on Local Control Push button Station (LCS). Remote control shall be effected from PLC through PMCC module with all interlocking features. Local mode shall be effective from LCS mounted near each motor with permissive from PLC through PMCC. Local control shall be for testing and maintenance purpose from push button station mounted near each motor.

Type ‘D’ (Feeder module)

- Heavy duty fuse switch unit of AC 23 duty or MCCB as per

SLD. - Mechanical ON/OFF indication - Door interlock ,defeat interlock and padlocking facility. - Rating 32/63/125/250 A as specified / as per SLD. Type ‘E’ (Spare Feeders) - Each PMCC shall be provided with the feeders as indicated in

the single line diagram with spare feeders as required with minimum of 1 No. in each rating.

Type ‘F’ (Capacitor Feeders)

- Heavy duty fuse switch unit of AC 23 duty - Mechanical ON/OFF indication - Door interlock, defeat interlock and padlocking facility. - Rating 32/63/125/250 A as specified / as per SLD. - APFC relay for PF correction. - Capacitor Bank as per SLD - PF meter with lagging and leading indication

Type ‘G’ (VFD Feeders)

- 415V, 3 Ph, 100/160/250 Amps, rated moulded case circuit

breaker with thermal short circuit, undervoltage and shunt releases.

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- Main contactor shall be of AC 3 category, rating of 30 Amps, or 125% of motor rated current as per component chart. Shall have min. 2 NO + 2 NC auxiliary contacts.

- 3 Element bimetallic thermal overload relay, manual reset

type, ambient temperature compensated with inherent single phase preventor.

- Overload relay to be of heavy-duty type for drives of higher

inertia and high starting time like pumps. - CT operated overload relays for drives of 11kW and above. - Overload relay shall have minimum 1 NO + 1 NC contacts. - Ammeter to read phase currents with CTs and selector switch. - Voltmeter to read phase voltages with selector switch and

MCB. - Ammeter shall be selected based on CT secondary current of 5

Amps. - Ammeter of class 1 accuracy, 74 x 74 mm. taut band, linear

scale to read upto rated current and suppressed scale for 600 to 800% of rated current of motors.

- ON, OFF, Trip on overload indication lamps or module door. - 3 Position, 4 way control selector switch (Local / Remote

(Auto) / OFF), overload reset push button. - Control circuit MCB of 16A rating with short circuit release for

each drive. - Variable frequency drive suitable for motor rating. - DOL bypass circuit with contactor as per SLD.

01.2.18 Component Selection

Ratings of components for drives are based on the chart indicated

below

Motor kW Rating SFU/MCCB Contactor MPR / OLR Cable

75KW 250 200 100-150 A * AYFY (3.1/2 x 120) 45kW 250A 140A 70 – 90 A * AYFY (3.1/2 x 95) 37kW 250A 125A 57 – 70 A * AYFY (3.1/2 x 70) 30kW 160/125A 100/125A 40 – 57 A * AYFY (3.1/2 x 70)

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22kW 125/80A 63A 32 – 50 A * AYFY (4 x 25) 15kW 63/63A 45A 20 – 32 A * AYFY (4 x 25) 11kw 63/50A 30A 16 – 25 A * AYFY (4 x 16) 7.5kW 63/32A 30A 10 – 16 A AYFY (4 x 10) 5.5kW 32/25A 30A 8 – 12.5 A AYFY (4 x 6) 3.7kw 32/20A 16A 5 – 8 A AYFY (4 x 6) 2.2kW 32/16A 16A 3.2 – 5 A AYFY (4 x 6) 1.5kW 32/10A 16A 2.5 – 4 A YRY (4 x2.5) 1.0kW 32/10A 16A 2.5 – 4 A YRY (4 x2.5)

* CT OPERATED 01.2.19 Special tools

A set of special tools required for the normal operation and maintenance shall be supplied with each PMCC. The tenderer shall include, along with each PMCC, one height adjustable circuit breaker trolley for removal and replacement of the withdrawable circuit breaker carriage.

01.2.20 Painting

All sheet metal work shall undergo a process of

- Degreasing - Pickling in acid - Cold rinsing & Phosphating

- Two primer coats of Epoxy based primer suitable for corrosive (seashore) atmosphere.

- Two finish coats of painting of light grey or approved colour shade and quality.

- The interior of panel shall have eggshell white paint.

01.2.21 Tests Tests at works and tests at site shall include the following:

a. 0ne minute PF withstand voltage between phases, phase to earth and between open poles as well as for the auxiliary/control circuit.

b. Insulation resistance test for power, auxiliary and control

circuits. c. Milli volts drop across incoming and outgoing jumper

connections with breaker closed and in service position.

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d. Physical inspection e. Operational tests f. Tests to prove inter changeability of breakers with same

current rating. g. Calibration of meters (if supplier is to commission the

equipment, this can be done at site) h. Check of control circuits i. Test to prove operating voltage range of spring charging

motor, closing coil, trip coil and relays. j. Heat run test on the PMCC, at extra cost if required by the

customer 01.2.22 Drawings

The following drawings shall be submitted for approval as per agreed schedule.

a) Dimensional GA drawing of PMCC indicating busbar

arrangement, foundation details, gland plate location,

b) Front view of PMCC indicating component locations. c) Single line schematic diagram indicating feeder details.

d) Control schemes of feeders.

e) Component specification details.

f) List of inscriptions.

g) Internal wiring diagrams,

h) Terminal plan and external connection diagrams.

i) Cross sectional drawings of cubicle indicating details of busbar

chamber, cable chamber, breaker chamber, LV chamber etc.

j) Operation and maintenance manuals.

k) Catalogues of relays, breakers.

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01.2.23 Design Criteria – PMCC

Switch Board

1.1 Rated voltage and frequency 415V, 3phase, 4wire, 50Hz 1.2 Maximum voltage 500V 2.0 Continuous current rating at design ambient

temperature As per approved SLD at 45ºC with IP 52 enclosure

3.0 Type of enclosure as per IS 2147 IP 52 3.1 Minimum thickness of sheet steel 2 mm 4.0 Applicable standards IS 2147, 8623 5.0 Design ambient temp. 45º C 6.0 One second Short time rating of switch board

with minimum busbars, feeder busbars, kA(RMS)30 kA

7.0 Dynamic through fault current with complete

busbars, kA (Peak)

8.0 Tier formation (Max.) Max 6 9.0 Maximum No. Of cable terminations in each type

of cubicle

9.1 Size and no. As per approved SLD 10.0 Incoming termination of LT switch board Cables/ Busduct 11.0 Incoming termination top/bottom bottom for cable Top for busduct 12.0 Outgoing feeder cable entry top / bottom Bottom 13.0 Minimum Clearances at front and back of board 1.5 m / 1 m 14.0 Dimensions LxBxH 15.0 Maximum Dimensions of shipping sections L x B

x H 2.5 x 1.5 x 2.4 M

16.0 Min. Clearances in air in mm

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16.1 Between phases 25.4 mm 16.2 Between live parts and ground 19.0 mm 17.0 One minute PF withstand voltage 2.5 kV 18.0 Paint shade 631 of IS-5

f)Busbars

1.0 Busbar material & cross section 1.1 Main busbars E91E aluminium' Max. current density 0.6

A / mm² 1.2 Bus connections to circuit breakers 2.0 Continuous rating at design ambient temp. 2.1 Main busbars As per SLD 2.2 Bus connections to circuit breakers As per rated currents of breakers 3.0 Temperature. rise at rated continuous current of

the busbars in the busbar chamber 40 deg.C over 45 deg.C

4.0 Type of busbar insulators Resin cast/fibre glass

Breakers

1.0 Type of breakers As per approved SLD 2.0 Standards applicable IS 13947-2/IEC947- part-II 3.0 Rated service voltage 415V, 3 ph. 50 Hz 3.1 Highest system voltage 500V, 3 ph. 50 Hz 4.0 Rated current at design ambient

for breakers As per Approved SLD

4.1 Rating with breaker in IP 52 enclosure in two tier

formation in the LT switch board As per Approved SLD

5 Symmetrical breaking capacity in kA (RMS)

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-at 415V, 0.25 PF 50 kA RMS -at 440V, 0.25 PF 50 kA RMS 6 Making capacity kA (Peak) 105 kA Peak 7 Capacitor breaking capacity at 440V Incomer: 600A (min.)

Outgoing: 300A (min.) 8 1 sec. Short time rating, kA (RMS) 50kA RMS 8.1 With releases in any setting 50 kA RMS 9 Thermal release setting ranges (temperature

compensated) As per Approved SLD

10.1 Short circuit release range As per Approved SLD 10.2 Short circuit release timer setting range 0.1 to 0.6 sec. mechanical Note (All the releases O/L, S/C and E/F shall be Static/microprocessor based. 01.3 LOCAL CONTROL STATIONS (Deleted)

1.4 MLDB / MOV DB 1.4.1 GENERAL

This specification covers the requirements for factory assembled low voltage distribution boards for use in electrical systems of up to 1000 volts.

1.4.2 STRUCTURAL AND MECHANICAL REQUIREMENTS 1.4.2.1 Distribution boards shall be single/ double front as specified in Bill of

Quantities, non-drawout, floor mounted/surface and arranged to form a single structure with a common busbar assembly. Where appropriate, lifting facilities shall be provided. Overall height shall not exceed 2500 mm and minimum operating height approximately 300 mm above grade/floor level. MOV DBs shall be in double front design.

1.4.2.2 The structure, including doors and panels, shall be capable of

withstanding the internal pressure created by faults within the structure (equal to the maximum fault-current rating) without danger to the operating personnel. Structures shall be self-ventilating.

1.4.2.3 Interlocks, covers, etc. shall be provided to prevent incorrect or

unsafe operation, and to prevent access to live parts. Mechanical

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interlock shall be provided between two incomers and bus coupler switches.

1.4.2.4 Distribution boards shall be designed and constructed to facilitate

inspection, cleaning, repair and maintenance and to ensure absolute safety during operation, inspection and maintenance. Similar parts and components shall be interchangeable.

1.4.2.5 The overall distribution board enclosure shall have a degree of

protection IP52 minimum. 1.4.2.6 Any equipped spares shall be arranged such that they can be

connected without de-energising the complete distribution board. 1.4.2.7 It shall be possible to operated individual circuit switches and replace

fuses (where used) without de-energising the complete distribution board.

1.4.3 SWITCH AND FUSE COMBINATION UNITS 1.4.3.1 Switch and fuse combination units shall have following features :

• Non-drawout (fix) type modules as mentioned in data sheet. • Rating and number of poles for the switch shall be as

mentioned in feeder list/single line diagram. • Padlocking facility in the ‘off’ position. • fault-make, load-break type, unless specified otherwise • Interlocking to prevent the compartment door being opened

unless the isolator is in the open position. • Distribution board shall be provided with HRC fuses.

1.4.3.2 LED type indicating lamps for incoming supply. 1.4.4 MCCB 01.4.4.1 MCCB units shall have following features:

• Non-drawout (fix) type modules as mentioned in data sheet. • Rating and number of poles for the switch shall be as

mentioned in feeder list/single line diagram. • fault-make, load-break type, unless specified otherwise • Interlocking to prevent the compartment door being opened

unless the isolator is in the open position. • Distribution board shall be provided with current transformers ,

earthfault and overcurrent relay ,contactors (mechanically and electrically interlocked, if required) as per SLD. Distribution board incomers shall have power monitoring meter (Enercon 3360 or equivalent) and indication lamps for metering and indication purpose as shown in SLD for MLDB.

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01.4.5 BUSBARS 01.4.5.1 Busbars shall be of the same cross sectional area throughout the

length of the distribution board. 03.4.5.2 Busbars shall be marked to indicate the phase colour, which shall be

red, yellow, blue and neutral bus shall be marked with black colour. 03.4.5.3 An earth busbar shall be provided along the full length of the

distribution board structure with provision for earth cable connections throughout its length

03.4.5.4 Busbars and connections shall be sized, braced and supported to

withstand the mechanical forces and thermal effects resulting from the distribution board rated short circuit current.

01.4.6 EARTHING 01.4.6.1 All metallic non-current carrying parts of the distribution board shall

be bonded together and connected to the internal earth busbar. 01.4.6.2 All doors shall be bonded to the main structure by means of a flexible

copper connection arranged so that it cannot be trapped as the door is opened or closed.

03.4.6.3 Provision shall be made, adjacent to the cable termination, for cable

armour earthing. 03.4.6.4 Distribution boards shall be supplied with an external M10 brass earth

stud complete with nuts, spring and plain washers. This stud is to be internally connected to the earth busbar.

03.4.7 SECONDARY WIRING

03.4.7.1 Secondary wiring shall be copper conductor PVC insulated 660/1000

volts grade. 03.4.7.2 Secondary wiring within the distribution board shall be securely held

in position (either bunched or run in conduit/trunking). 03.4.7.3 Wiring identification shall be by numbered and/or lettered interlocking

sleeve ferrules, of insulating material adjacent to the terminals. They shall be indelibly marked and removal without disconnecting the wire from its terminal shall not be possible.

03.4.7.4 Flexible cables shall be used for connections on door mounted

equipment. Wiring shall be bunched, wrapped in flexible conduit and be firmly clamped at both ends to prevent movement at terminations.

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03.4.7.5 The minimum conductor size shall be 2.5 mm2, cable sheath colour shall be consistent with the phase/neutral/earth circuit to which they are connected.

03.4.7.6 All wiring for external connections shall be brought out to individual

terminals on a easily accessible terminal block. 03.4.7.7 Only one conductor shall be connected to each side of each terminal,

additional linked terminals shall be provided where more connections are required.

01.4.8 CABLE TERMINATIONS

Cable terminating facilities and terminals shall be suitable for the specified cable type and conductor size. Contractor shall take consideration and provision on the equipment design for the use of cable with aluminum conductors.

Terminal blocks shall be arranged and positioned for easy access for carrying out external cable termination, testing, inspection and maintenance. There shall be clear space allowed between the terminal block and the cable entry for the spreading and termination of external conductors.

Terminal blocks shall be mounted in a single tier arrangement. The panel wiring shall be on one side of the terminal block

only. All terminal blocks shall be shrouded or provided with

transparent covers. Terminals for different voltages shall be separated by partition. An undrilled gland-plate or entry panel of sufficient dimensions

to terminate the specified cables shall be provided. Cable entry shall be from bottom unless specified.

Positioning of cable terminations shall avoid obstruction of other cable terminations, removable covers, etc. and sufficient space shall be available for maintenance work and cable termination.

Cable clamping arrangement shall be provided to avoid undue strain on the cable termination.

03.4.8 ANTI-CONDENSATION SPACE HEATERS 03.4.8.1 Thermostatically controlled heaters suitably rated to prevent

condensation shall be provided within the distribution board. 03.4.8.2 The heater shall be supplied with a double pole isolator.

03.4.8.3 The heater terminals shall be clearly marked as to their use. 01.4.10 LABELS 01.4.10.1 A main nameplate shall be affixed in a prominent position on the front

of each distribution board giving the following information:

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• Manufacturers name. • Distribution board Tag Number and name. • System voltage, phase, wires and frequency. • Year of manufacture.

01.4.10.2 Characters shall be of 12 mm height. 01.4.10.3 Labels shall have black characters on a white background and be

made of a non-corrodible material. Warning/Danger labels shall have black lettering on a yellow background.

03.4.10.4 Label shall be affixed by screws or rivets. 03.4.10.5 Each distribution board shall have fitted a circuit directory within a

clear protective cover located on the inside of the outgoing circuit compartment door.

01.3.00 DRAWINGS 01.3.01 The manufacturer shall develop his own general arrangement

drawings and schematics adding necessary auxiliary devices, accessories, components particulars of the supplied equipment etc., which are required for a safe and convenient operation of the distribution board.

01.3.02 The manufacturer shall submit the general arrangement drawings,

flooring and mounting detail, schematic drawings and bill of material with all component details for owner’s review/approval. Owner’s concurrence of all drawings is required before the manufacturer proceeds with the manufacturing.

01.3.03 Owner’s review of the manufacturer’s drawings shall not relieve the

manufacturer of his responsibility for supplying equipment conforming with the relevant specifications and standards, or for any mistakes, errors or omissions in manufacturer’s drawings

01.4.00 INSPECTION AND TESTING Equipment shall be tested and inspected at vendor's works before

dispatch to ensure compliance with the relevant specifications and agreed quality assurance testing plan.

The owner or his representative may visit the works during

manufacture of various equipment to assess the progress of work as well as to ascertain that only quality raw materials are used for the same. Owner shall be given minimum four weeks advance notice for witnessing the final testing. The minimum testing/inspection requirements for all components/equipment shall conform to the requirements stipulated in applicable codes and standards. Test

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certificates including test records and performance curves etc. shall be furnished by the vendor.

Contractor shall provide test certificates for Type and Routine tests

carried out on the distribution boards. Tests shall be as specified in the relevant standards.

01.5.00 PACKING AND DESPATCH 01.5.01 Distribution boards shall be shipped to suit ease of handling for

transportation and installation. Each shipping section shall be provided with location of lifting points clearly marked on shipping containers. Each shipping section shall have its weight clearly marked on the container.

01.5.02 Preparation for shipment shall protect the distribution board, auxiliary

devices, accessories, etc. against corrosion, dampness, breakage or vibration injury during transportation and handling. The packing shall be completely suitable for long duration outdoor storage in areas with heavy rains/high ambient temperature.

01.5.03 Each shipping container shall be identified with the contents, purchase

order number and item number. 01.5.04 Instructions shall be provided for reassemble of sections in the field.

01.06.00 EARTHING

− A continuous earth bus shall be provided for the PMCC/MOVDB / MLDB at the bottom with an earthing bolt at each end.

− Provision shall be made for connecting 4th core of incoming

and outgoing cables.

− The earth bus shall be of electrolytic grade copper (E 91E) having the same size as that of neutral busbar at the top.

− Neutral and earth busbars shall be connected through a link.

− Electrical equipment shall be interconnected with earth grid using minimum size 50 x 6 copper.

01.07.00 APPLICABLE CODES AND STANDARDS

All applicable Indian and lEC codes, regulations and standards shall govern the work. In the event of the requirements of the specification exceed the requirements of the corresponding codes, regulations or standards, the specification shall govern. The applicable standards shall include standards listed below

1. IS 2705 Part I 1992 to Part IV Current transformers,

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general requirements. 2. IS 12021 - 1987 Control Transformers 3. IS 13947 Part 4 - 1993 Contactors 4. IS 13947 Part 3 1993 Specific requirements for the

direct switching of the individual motors, 5. lEC 171 Moulded Case Ckt. Breakers 6. IS 2419 – 1979 Reaffirmed 1991 Dimensions for panel mounted indicating and recording

electrical instruments. 7. IS 8197—1976 Terminal markings— Electrical measuring instruments. 8. IS 8623 Part 2 -1993

Factory built assemblies of switchgear for voltage upto and including 1000V AC and 1200V DC. Particular requirement busbar trunking system.

9. IS 13947 Part 1 - 1993 General requirements for switchgear and controlgear

for voltages not exceeding 1000V AC. 10. IS 10118 - 1982 Code of practice for design installation and

maintenance of switchgear and controlgear. 11. IS 13947 Part 1 - 1993 Degree of protection provided by enclosure for low

voltage switchgear and controlgear. 12. IS 13703 - 1993 HRC cartridge fuse links. 13. IS 1554 Part 1 - 1988 & Part 2 - 1990 PVC insulated (heavy-duty) electric cables 14. IS 3043 - 1987 Earthing 15. IS 5578 - 1984 Guide for marking of insulated conductors. 16. IS 13234 - 1992 Guide for short circuit calculation 17. IS 2551—1982

Danger boards.

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18. IS 3722—1983

Letters and Symbols used in electrical technology. 19. IS 9676—1980 Reference ambient temperature for electrical

equipment. 20. IS 8923 – 1978 Warning symbols for dangerous

voltages. 21. IS 5 - 1994 Colour for ready mixed paints and

enamels.

22. IS 722 Specification for AC Electricity meters.

23. IS 1248 Specifications for direct acting indicating analogue electrical measuring instruments and their accessories.

24. IS 3618 Phosphate treatment of iron and steel for protection against corrosion.

25. IS: 4047 Heavy-duty air break switches and composite units of air break switches and fuses for voltages not exceeding 1000 V.

26. IS: 4064 Air break switches, Air break disconnection, Air break switch disconnectors and fuse units for voltages not exceeding 1000 V AC or 1200 V DC.

27. IS 5082 Specification for wrought aluminium and aluminium alloy bars, rods, tubes and sections for electrical purposes.

28. IS 5578 Guide for marking of insulated conductors.

29. IS 6005 Code of practice for Phosphating of iron and steel.

30. IS 11353 Guide for uniform system marking and identification of conductors and apparatus terminals.

31 IS 13925 Specification for Shunt capacitors for power Systems

1.08.00 QUALITY ASSURANCE, INSPECTION & TESTING 1.08.01 GENERAL REQUIREMENT OF QUALITY ASSURANCE

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All materials, components and equipment covered under the Technical specification for this Project shall be procured, manufactured, tested, erected and commissioned as per a comprehensive Quality Assurance Programme. It shall be the primary responsibility of the contractor to draw up and implement such a programme which shall be duly approved by the Purchaser/Consultant/their authorised Inspection Agency.

The detailed Quality Assurance Plan (QAP) for manufacturing and testing of equipment shall be prepared by the contractor and submitted for approval by the Purchaser/their aurhorised Inspection Agency.

1.08.02 Inspection and Testing

1.8.02.01 The equipment shall be inspected by the Purchaser and / or

their Inspection Agency at the manufacturer’s works prior to despatch. The equipment will be inspected as per the tests pre-identified in the approved QAP to ensure conformity of the same with relevant approved drawings, data sheets, technical specification, National/International Standard.

1.8.02.02 The contractor shall finalise the QAP within the stipulated schedule

mentioned in the Purchase Order and the QAP shall be submitted in four sets (Blank QAP formats enclosed shall be adopted). In case of any sub-contracting, the QAP shall be prepared by the contractor in consultation with his sub-contractor to avoid any lapse in quality and disputes and misunderstanding.

1.8.02.03 The contractor shall provide full and free access of the Inspection

Agency to the manufacturer’s works to carry out any stage inspection to ensure the quality of the equipment being manufactured.

1.8.02.04 Only on readiness of the equipment and approval of all relevant

drawings & QAP, the contractor shall give “Inspection Call” (Blank format enclosed shall be adopted) to the Purchaser & the Inspection Agency with a clear notice of 10 days for inspection. The Inspection Call shall be accompanied by the manufacturer’s internal inspection report, test certificates, purchase order, sub-purchase order, technical specification, approved QAP and approved drawings / data sheets. The Inspection Call without above documents shall be ignored. In case of any approved sub-contracting, only the main contractor shall give the Inspection Call enclosing internal inspection/ test reports of the sub-contractor duly verified by the main contractor. In case the equipment

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offered for inspection is found not ready, all the cost of the visit of the Inspection Agency shall be borne by the contractor.

1.08.02.05 The contractor shall furnish all relevant documents and test

certificates as required by the Inspection Agency during inspection. Materials shall be tested only in recognised Test House/Laboratory.

1.08.02.06 The contractor shall delegate a representative/ coordinator to

coordinate with the Inspection Agency on all inspection matters. 1.08.02.07 No equipment shall be offered for inspection in the painted condition

unless otherwise agreed to the purchaser. 1.08.02.08 The contractor shall ensure that the equipment and materials once

rejected by the Inspection Agency are not reused in the manufacture of plant and equipment. Where parts rejected by the inspection Agency have been rectified as per pre-agreed procedure, such parts shall be segregated for separate inspection and approval before being used in the work.

1.08.02.09 The contractor shall carry out their internal inspection and obtain

clearance from Statutory bodies, like IBR, CCE, TAC, Weights & Measures, Safety, IE Rules, etc., as required for the equipment prior to offering any such equipment for Purchaser’s inspection.

5.02.10 The contractor shall provide all required instruments, tools, necessary

testing and inspection facilities free of cost to carry out the inspection. These instruments and testing machines shall be calibrated by an agency of National/ International recognition and the calibration shall be valid during inspection period.

5.02.11 The inspection Agency shall have the right to demand for re-testing of

any material re-calibration of the instrument and testing machine & the charges for the above will be borne by the contractor.

5.02.12 Performance tests of any particular equipment which cannot be

conducted / demonstrated either partially or wholly at the manufacturer’s works, shall be conducted after erection at site in the presence of Purchaser and their Inspection Agency. In all the cases, prior approval of the Purchaser shall be obtained.

5.02.13 No equipment shall be despatched before inspection and issue of

Inspection Certificate and despatch clearance from the Purchaser / Inspection Agency.

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5.02.14 In case of waiver category items, the same shall be pre-identified in the QAP itself. For such items, the contractor shall furnish necessary certificate, test reports, etc., as agreed upon and indicated in the QAP. For these items also the contractor shall obtain “Inspection Waiver Certificate” and despatch clearance from the purchaser Inspection Agency before effecting despatch of equipment.

5.02.15 The issue of Inspection Certificate / Waiver Certificate for any

equipment or component thereof does not absolve the contractor from his contractual obligations towards subsequent satisfactory performance of the equipment at site. Should any equipment be found defective, In whole or part thereof after receipt at site or during erection/ commissioning and testing shall be made good by the contractor free of cost.

INSPECTION FORMAT PAGE:1 OF 1 REVISION - 1 DATE:

PURCHASER

CONTRACTOR’S ORDER NO. & DATE

PLACE OF INSPECTION WITH ADDRESS PHONE NO. / FAX NO.

NAME & DESIGNATION OF CONTACT PERSON WITH PHONE NO.

QUANTITY (NO./T/M) QAP & DRG NO WITH REVISION

QAP & DRAWING APPR STATUS (A/AAN/INF)

TOTAL ORDERED

TOTAL ACCEPTED

REF NO & DATE DESCRIPTION REFERENCE &

DATE

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(FOR CONTRACTOR / SUB-CONTRACTOR)

1.09.00 QUESTIONNAIRE 1.09.01 PMCC

1. Manufacturer’s name 2. Manufacturer’s type (enclose catalogues) 3. Type of enclosure as per IS 2147 4. Applicable standards 5. Design ambient temperature 6. Rated voltage and frequency 7. Continuous current rating at design ambient temperature 8. One second short time rating of PMCC

with main busbars, feeder busbars kA (RMS)

50 kA/ 1 Sec

9. Dynamic through fault current with complete busbars, kA (pack) 10. Tier formation 11. Provision of a) Segregated busbar chamber b) Breaker chamber c) CT and cable chamber d) LV chamber e) Automatically operated safety shutters f) Door interlock 12. Cubicle size and number 13. Outgoing feeder cable entry top/bottom 14. Incoming termination of LT PMCC (busduct/cable) 15. Incoming termination top/bottom 16. Min. clearance at front and back of PMCC 17. Max. dimensions of shipping sections LXDXH 18. Max. limiting dimensions of the PMCC LXBXH 19. Weight of PMCC 20. Static and dynamic load 21. Min. clearance in air, in mm

Between phases Between line part & ground

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MECON LTD, DELHI


22. One minute p.f withstand voltage 23. Paints shade

1.09.02 BUSBARS

1. Arrangement & location of busbars inside cubicle. 2. Busbar material and cross section a) Main busbars b) Bus connections to circuit breakers 3. Continuous rating at design ambient temperature a) Main busbars b) Bus connections to circuit breakers 4. Temperature rise at rated continuous current of the busbars in the

busbar chamber a) Over design ambient temp. b) Over 45 deg. C ambient temp.

1.09.03 BREAKER & MCCB

1. Manufacturer’s name 2. Type of breakers 3. Standards applicable 4. Rated service voltage a)

Max. voltages for continuous duty

5. Rated current at design ambient for breakers a)

Open air rating

b)

Rating with breaker in IP 52 enclosure.

6. Symmetrical breaking capacity in Ka (RMS) a)

at 415V, 0.25 p.f Min 50 kA

b)

at 440V, 0.25 p.f

7. Asymmetrical breaking capacity at 440V 10. 1 sec. Short time rating kA (RMS a)

Without releases

b)

With releases in any setting

11.a)

Short circuit release setting range

b)

Short circuit release timer setting range

12. If short circuit and thermal release setting independently adjustable 13. Operating mechanism a) Fixed trip/trip free b) Manual dependent / manual independent c) Spring assisted/spring charged stored energy d) Electrical operated-motor/solenoid

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MECON LTD, DELHI


e) Provision of mechanical emergency trip push button 14. a)

Type of rack-in /rack-out Mechanism for drawout

b)

Provision of key interlock

c)

Provision of door interlock

d)

Definite positions and associated interlock details of draw-oust breaker

15. Electrical operation a)

Rated voltage

b)

Operating voltage range

c)

Spring charging time

d)

Details of under voltage release

i)

Pick-up & drop off voltage range

ii)

Time setting range

16. No. of Auxiliary contacts 17. Control contacts (Plug-in/ sliding) 18. Type test certificates for breakers a)

Breaking capacity

b)

Short time rating

c)

Making capacity

d)

Capacitor switching rating

e)

Temp. rise test at rated current in IP 52 enclosure

19. Type test certificates for cubicle/PMCC a)

Temp. rise

b)

1 Sec. Rating

c)

Dynamic withstand capacity

20. Protection relays Make & Type 1.09.04 Current transformer

a) Make & Type b) Accuracy class

1.09.05 Meters

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MECON LTD, DELHI


a) Make b) Type c) Size d) Accuracy class

1.09.06 Fuse switch unit

a) Make & Type b) Operating mechanism


a) Make & Type b) Rated voltage, watts c) Series resistor Ohm / Watts

1.09.08 Contactor

a) Manufacturer’s name b) Rated voltage ‘c) Rated current d) Min. capacitor switching duty e) Coil rated voltage f) Whether mechanical On/OFF indication provided h) No. of auxiliary contacts i) Applicable standards

1.09.09 Fuse switch name

a) Manufacturer’s name b) Manufacturer’s type designation c) Type of break d) Rated voltage e) No. of auxiliary contacts f) Applicable standards

g) Breaking current of switch at L/R equal to 0.5 h) Whether quick make quick break mechanism provided for the

switch 1.09.10 Thermal O/L relays

a) Make b) Type c) Range d) Whether single phase protection

provided Yes

e) Whether Reset PB provided Yes

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MECON LTD, DELHI


1.10.00 PREFERED MAKES LIST OF EQUIPMENTS

PREFFERED MAKES

SFU SIEMENS/ABB/L&T/ GEC ALSTOM ACB SIEMENS/ABB/GEC ALSTOM/ L&T MCCB GEC ALSTOM/CROMPTON

GREAVES/L&T/ SIEMENS CONTROL VOLTAGE TRANSFORMER SIEMENS/SOUTHERN

ELECTRIC/KAPPA/SWAMY TRADERS LT BUS DUCT C&S/ BEST&CROMPTON / STARDRIVE CONTACTORS SIEMENS/TELE-MECHANIQUE BCH/ABB/

L&T OVERLOAD RELAYS WITH SPP SIEMENS/L&T/TELE-MECHANIQUE

BCH/ABB MINIATURE CIRCUIT BREAKERS SIEMENS/MDS/INDO KOPP/ HAVELLS AMMETER AE/IMP/MECO/ RISHAB VOLTMETER AE/IMP/MECO/ RISHAB PUSH BUTTONS, INDICATION LAMPS VAISHNO/CONCORD/SIEMENS/L&T/TTT

EKNIC/SALZER CT’S SIEMENS/AE/INDCOIL/KAPPA/ INTRANS TERMINAL BLOCKS ELMEX/ESSEN/ CONNECT WELL/ WAGO/

PHOENIX CABLES INCAB/RPGCABLES/UNIVERSAL/CCI/NIC

CO/ SPECIAL CABLES / POLYCAB SELECTOR SWITCHES SIEMENS/EE/KAYCEE/SALZER CABLE LUGS DOWELLS FLAMEPROOF EQUIPMENT Baliga/ CEAG/ FCG/ Sudhir / Flamepack PROTECTIVE RELAYS Alstom / ABB / GE Multiline / Easun

Reyrolle / Siemens

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MECON LTD, DELHI


PARTICULAR JOB SPECIFICATION

247 of 288

SPECIFICATION FOR UPS

SPECIFICATION NO. MEC/TS/05/E9/071

(OIL & GAS SBU) MECON LIMITED DELHI 110 092

Rev.: 0

Edition: 1

248 of 288

STANDARD TECHNICAL SPECIFICATION MECON LIMITED REGD. OFF: RANCHI 834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

REVISION : 0 TITLE UPS MEC/TS/05/E9/071

EDITION : 1

C O N T E N T S

SL. NO. DESCRIPTION 1.0 SCOPE 2.0 STANDARDS 3.0 GENERAL REQUIREMENTS 4.0 DRAWING AND DOCUMENTS 5.0 INSPECTION

ANNEXURE -I PURCHASER'S DATA FOR UPS ANNEXURE -II TECHNICAL DATA FROM MANUFACTURER

ANNEXURE -III PREFERRED MAKE ANNEXURE -IV CHECK LIST ANNEXURE -V QAP

ANNEXURE -V BLOCK DIAGRAM

PREPARED BY:

(Saurabh Singh)

CHECKED BY:

(Quasim Ahmed)

APPROVED BY:

(D.K. Pande)

ISSUE DATE :

Sep. 2009 249 of 288




EDITION : 1

AMENDMENT STATUS

Sl. No.

Clause / Paragraph / Annexure / Exhibit / Drawing

Amended

Page No.

Revision Date By (Name)

Verified (Name)

250 of 288




EDITION : 1

1.0 SCOPE The intent of this specification is to define the requirements of uninterrupted

power supply system, Rectifiers, Inverter system and the associated battery sets. Tenderer's scope of work includes design, manufacture, testing, packing and delivery to site and testing & commissioning of the complete UPS system with static by-pass, solid state voltage stabilizer for by-pass supply, distribution boards and battery banks etc. as per this specification, data sheet.

2.0 STANDARDS 2.1 In general the equipment covered by this specification shall, unless otherwise

specified, be in line with the requirement of any of the latest applicable standards of

a) Bureau of Indian Standards b) British Standard Institution c) American Standard Institution d) International Electro Technical Commission 2.2 Wherever the requirements in this specification are in conflict with any of the

above Standards, the requirements under this specification shall be binding. 3.0 GENERAL REQUIREMENTS 3.1 Uninterrupted Power System 3.1.1 Basic Particulars for Design

- Suitable for industrial application. - The rating of the system shall be as per Schedule of Rates at 0.8 p.f.

Lagging at 45°C ambient. - 125% of the rated output for 10 minutes.

- Automatic selection of available phase (out of three phases) incase of outage of power supply of the phase in use for feeding.

incoming power supply to the UPS, if indicated in SOR/DATASHEET. - Single-phase voltage and frequency controlled output. - Suitable protection shall be provided in the control circuit to guard against

instability of phase controlled rectifier due to electrical oscillation, which may be present in input supply as caused by emergency DG set.

- Single/ Dual redundant system with automatic static bypass, common DC battery and solid-state voltage stabilizer as per data sheet and drawing.

- The load shall normally be fed from the inverter. - Battery shall be suitable to maintain the power supply in the event of

mains failure or battery charger failure for time period as indicated in

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EDITION : 1

Schedule of Rates. - Static by pass switch to connect the load to the mains supply through

static voltage stabilizer or hot standby UPS, as per the configuration, without interruption to the load in the event of inverter failure.

- AC Distribution board/ DC Distribution board as per data sheet. - Space heater and panel illumination to be provided. - Noise level at a distance of 1 m. from UPS panels shall not exceed 60

decibel. 3.1.2 Permissible Variations 1) Mains power supply system:- Voltage : ±10%, Frequency : ±5% 2) Output of the uninterrupted power supply system while delivering a load

of its rated capacity:- Voltage : ±1% Frequency : ±1%

3) Accuracy of static type voltage stabilizer for bypass supply shall be within

±2%.

3.1.2 Protective Features

1) Short circuit and overload protection. 2) DC Earth Fault

3.1.3 Transformer (Isolation Transformer for input & output):

1. Rating suitable for the application 2. Dry type, with class 'H' insulation 3. ± 2.5% tapping on primary side.

3.1.4 Rectifier/ Battery Charger 1. Switched ON through a MCCB. 2. Charger size shall be based on the maximum inverter input load current

and recharging current (in maximum time of 10 hours after complete discharge).

The rating of rectifier / charger shall be not less than the value calculated as follows:

For Ni-Cd batteries = Inverter input current + 0.2 Ah (5 hr. rating of battery)

252 of 288




EDITION : 1

For SMF LA/VRLA batteries= Inverter input current+ 0.2 Ah (10 hr. rating of battery) Rated kVA capacity of UPS X load p.f. Where inverter input current = --------------------------------------------------------- Inverter eff. x (No. of cells x End Cell voltage)

3. With transient and surge protection circuit in input circuit to protect UPS from surges and voltage Spikes.

4. With necessary smoothing reactor and filters 5. Automatic boost and float charging control 6. Protective features: - Maximum current limiting - Over temp. trip.

- Boost charging and float charging current limiting with back up protection against over charging.

7. Indications:

- As per manufacturer’s standard. 8. Charger shall simultaneously supply entire power necessary for inverter and to keep the battery of required capacity in fully charged condition. Provision for automatic charging in both float and boost shall be made. 3.1.5 Inverter 1. With input circuit consisting of battery MCCB, battery filter and smoothing

reactor. 2. DC/DC converter for voltage control 3. Control electronics 4. Series reactor and parallel filter 5. Output transformer 6. Protection against the following: - Abnormal output voltage - Abnormal link voltage - Over load trip - Low battery voltage - High transformer temperature - Auxiliary supply failure 7. Meters - For output voltage - For output frequency - Ammeter - Battery current and voltage with indication of status - "in charge" or

"discharge". 8. Static by-pass switch

253 of 288




EDITION : 1

- Static switch automatically switches the load to the reserve power supply or the mains whenever there is failure in inverter supply to the load.

- Retransfer of load from stabilized bypass supply to the inverter in auto as well as in manual mode.

- High-speed fuses shall be provided for protecting the thyristors against accidental overload.

Following indications & alarms shall be provided in the by-pass module. Indications - Load on bypass 3.1.6 Constructional Features 1. Unitized construction 2. Free standing, floor mounted , indoor type and complete with all interconnection. 3. Dust and vermin proof 4. Sheet steel clad - Minimum 2 mm thick for panels - Minimum 1.6 mm thick for doors and side covers 5. Units shall be self contained and serviceable 6. The arrangement and layout shall facilitate easy and convenient supervision of

the unit while running as well as quick detection of disturbances and troubleshooting.

7. Copper earth bus bar shall run through out the length of Panels. All doors & non-current carrying parts shall be suitably earthed.

8. Dimensions of panels shall be such that it can be accommodated in existing room if indicated in MR/ SOR.

9. The maximum and minimum operating height of the switches shall be 1800mm and 300mm respectively.

3.1.7 Enclosure and Ventilation - Enclosure conforming to minimum IP-31 class. - Units shall be provided with cooling fans and louvers. 3.2 Battery unit 3.2.1 Ampere-hour capacity of the battery shall be selected on the following basis:

a) Load power factor of 0.8 b) Aging factor of 0.8 c) Battery state of charge factor of 0.88 d) Temperature correction factor shall be taken as specified in data sheet e) Backup time as specified in data sheet f) Minimum end cell voltage shall be 1.1V per cell for Ni-Cd battery & 1.85 V

per cell for SMF LA/VRLA battery.

g) Inverter rated KVA X Rated load p.f

254 of 288




EDITION : 1

Battery Current = --------------------------------------------------------------------- Inverter Efficiency X End cell voltage X No of cells

For parallel redundant UPS at 50 % load on each inverter.

h) Load break switch fuse unit in sheet steel enclosure shall be provided near the battery bank for isolation.

3.2.2 The type of battery (Ni-Cd/SMF LA/VRLA) shall be as per MR/

SOR/DATASHEET. 3.2.3 Sets of Indoor Stationary batteries of type as per enclosed data sheet complete

with all required accessories as applicable including but not limited to the following shall be supplied with each battery set;

a) Battery stands in multi row/ single tier formation. Stand Material shall be

as per battery manufacturer’s standard. b) Cell testing voltmeter complete with leads- (1 no. Per set). c) Spanner - (1 no. Per set). 3.2.4 Overall dimensions of complete battery set shall be such that it can be

accommodated in existing room if indicated in data sheet. 4.0 DRAWINGS AND DOCUMENTS 4.1 The following documents shall be submitted along with the offer:

a) List of two years operation and maintenance spare. b) Technical data sheet (Annex-II) and check list duly filled.

4.2 The following calculations/ dimensions shall be submitted alongwith offer:

a) Charger sizing calculation.

b) Battery sizing calculation. c) Battery bank/stand size.

c) UPS panel size including solid-state stabilizer panel.

4.3 The following drawings shall be submitted for approval within 3 weeks of award

of contract. a) G.A. of panel, battery stand, ACDB and DCDB. b) Bill of Material. c) Schematic & Wiring diagram for reference. 4.4 Final drawings, operation & maintenance manual and erection

255 of 288




EDITION : 1

Instructions shall be submitted along with despatch of equipments in three sets in

hard copy & two sets in soft copy (CD). 5.0 INSPECTION Inspection and testing of equipment shall be carried out by the owner/

consultant at the works of the contractor on final product to ensure conformity of the same with the acceptable criteria of technical specification, approved drawings and national/ international standards.

5.1 The contractor shall submit Quality Assurance Plan (QAP) for respective

equipments within 3 weeks of award of contract. QAP shall be prepared and furnished by the contractor in MECON Form No.

11.20(4.4) F-10 along with their internal in process quality checks. 5.2 ‘Type test' including 12 hr. heat run test shall be conducted on one UPS System

of each rating and ‘Routine test’ on the remaining. 5.3 Batteries shall be tested for type and `Acceptance Test’/ Routine Test at battery

manufacturer’s works and test reports shall be submitted for review and approval.

5.4 Final acceptance testing along with the batteries shall be done at site. Site

acceptance test procedure shall be submitted by the Contractor along with QAP.

256 of 288

STANDARD TECHNICAL SPECIFICATION MECON LIMITED REGD. OFF: RANCHI 834002 ELECTRICAL SECTION, DELHI

Page 1 of 10

REVISION : 0 TITLE UNINTERRUPTED POWER SUPPLY (UPS)

DATA SHEET NO.

MEC/DS/05/E9/071 EDITION : 1

ANNEXURE - I PURCHASER'S DATA FOR UPS

1.0 INPUT POWER SUPPLY

1.1 Voltage/freq./ phase: 415 V (±) 10 %, TPN, 50 Hz ± 5%

1.2 System fault level 25 kA

2.0 SITE CONDITION

2.1 Design Ambient/ Minimum ambient

Max. & Min. temperature as indicated in design basis.

2.2 Max. Relative humidity 95%

3.0 SYSTEM REQUIREMENTS

3.1 Input Power Supply to System 415 V (±) 10 %, TPN, 50 Hz ± 5%

3.2 Type of inverter Transistorized (IGBT) or Latest proven technology

3.3 Rating (KVA at 0.8 pf.) As per SOR

3.4 Overload capacity 125% for 10 minutes

3.5 Mode of operation Dual/Parallel Redundant with static bypass & Dual Redundant rectifier as specified in SOR/Design basis/Block diagram

3.6 Load p.f. 0.8 (with variation between 0.7 to 1.0)

3.7 Type of Battery As per SOR.

3.8 i) Battery end cell voltageii) Battery stand formation iii) Battery back up time iv) Derating factor

As per specification (clause no. 3.2.1-f) Multi step and single tier with Stand. As per SOR (i) Ageing -- 0.8 (ii) State of Charge -- 0.88 (iii) Temp. Correction -- As per min. site temp. (Ref. 2.1 above)

3.9 Type of enclosure Minimum IP-31

3.10 Cable entry From bottom

257 of 288


Page 2 of 10


DATA SHEET NO.


4.0 Distribution Board Details (1) ACDB 230 V, Single Phase (1 No.) :

Incomer : DP MCB

Outgoing : 8 Nos., DP MCB’s

(2) DCDB : 24 V DC (1 No.)

Incomer : DP MCB

Outgoing : 6 Nos., DP MCB

(3) DCDB – 48 V DC (1 No.)

Incomer : DP MCB,

Outgoing ; 6 Nos., DP MCB

258 of 288


Page 3 of 10


DATA SHEET NO.


ANNEXURE-II (A) TECHNICAL DATA FROM MANUFACTURER (To be filled up by the Tendered)

1.0 INVERTER

1.1 Manufacturer’s Model No. (Enclose catalogue)

1.2 Rating (at specified ambient) / no. Of phases

1.3 Applicable codes/standards

1.4 Steady state output volt/freq (230 V + 1%)

(50 Hz + 1%)

1.5 Input volt. - DC

1.6 Synchronization (inv. phase locked with main) in percentage

1.7 Synchronization manually adjustable in steps of

1.8 Allowable unbalance between phases (for 3 Phases only)

1.9 Harmonics distortion for linear & non-linear loads (not more than 4% and 15% respectively).

1.10 Mode of operation Dual/Parallel Redundant with static bypass as specified in SOR/Design basis/Block diagram

1.11 Dynamic Responses at following conditions a) ± 50% step load (for parallel redundant

UPS) b) ± 100% step load (for hot standby and

single UPS system). c) Power supply interruption and restoration. d) Load Transferred to bypass line e) When one inv. gets faulty and load

transferred to healthy inv. (for parallel redundant UPS)

1.12 Recovery time to reach steady state after above disturbance (not more than 100m Sec)

1.13 Overload capacity (125% for 10 min.)

1.14 Short circuit capacity and duration (in % and m

259 of 288


Page 4 of 10


DATA SHEET NO.


sec.)

1.15

Degree of protection of the panel.

Minimum (IP – 31)

1.16

Noise Level (dB at 1 m)

(Not more than 75 dB)

1.17 Efficiency at 100%/75%/50% loads (not less than 80% at 100% load)

1.18 Type of control circuit (Static PWM)

1.19 Out put voltage & phase angle (for 3 Phase only) a) For 30% unbalance load b) For 40% unbalance load c) For 50% unbalance load d) For 100% unbalance load

1.20 Crest Factors

2.0 STATIC SWITCHES

2.1 Nos. of static switches in each set

2.2 Current rating at specified ambient

2.3 Transfer time (m sec.) a) Synchronized mode (not more than 4msec)

b) Unsynchronized mode (not more than 20msec)

3.0 BATTERY CHARGER

3.1 Rating (Amp.) / MAKE (Enclose back up calculation).

3.2 Type of charger (Basic configuration)

3.3 Output volt under float/boost charging condition

3.4 Volt. Accuracy under specified input (± 1%)

3.5 Max. Ripple content on DC side (% RMS) (not more than 2% without battery)

3.6 Max. Ripple content on AC side (% RMS)

3.7 Efficiency at 100%/75%/50 % of load

3.8 Mode of Change over from float to boost and vice-versa

260 of 288


Page 5 of 10


DATA SHEET NO.


4.0 BATTERY

4.1 Make

4.2 Type (Enclose catalogue)

4.3 AH rating (Enclose back up calculation)

4.4 End cell voltage at specified discharge rate (V/ cell)

4.5 Output (Nominal) volts

4.6 Nos. of battery banks

4.7 Nos. of cells in each banks

4.8 Battery charging requirements (V/ cell) a) Volts/Cell b) Float c) Boost

4.9 Voltage variation from fully charged battery to discharged battery (volts)

4.10 Charging time (Hrs.)

4.11 Max. Permissible ripple content (% RMS)

4.12 Overall dimension (L*W*H)

4.13 Container type

4.14 Accessories for battery as per specification included

Cell testing Voltmeter, Pair of Gloves, Insulated Spanner Glass String Extra, Electrolyte, Hydrometer, Thermometer

5.0 MANUAL TRANSFER DEVICES

5.1 Rating (Amp.) .

5.2 Make/Type

6.0 STEP DOWN BYPASS TRANSFORMER WITH SOLID STATE VOLTAGE STABILISER

6.1 Make/type

6.2 Rating and Voltage ratio

6.3 Accuracy of stabilizer (not more than ± 2%)

6.4 Type of control (Solid state)

261 of 288


Page 6 of 10


DATA SHEET NO.


6.5 Type of cooling Natural

7.0 AC DISTRIBUTION BOARD

7.1 Nos. of feeder/rating

7.2 Cable entry from (Bottom)

7.3 Max. Rating of outgoing feeders possible for fault clearance by UPS with and without supply back up (as percentage of UPS rating) not less than 25% a) With fast acting semi conducting fuses

8.0 Control Microprocessor based

9.0 Indications and Alarm

10.0 METERING

11.0 UPS Dimension (L x W x H) except Battery:

(Including inverter, charger, rectifier, bypass stabilizer, ACDB etc.)

12.0 OVERALL EFFICIENCY OF UPS SYSTEM

12.1

Ratio of output load to input drawn from mains when inverters are on and synchronized with bypass. a) At 100% load (not less than 80% at 0.8 p.f.) b) At 75% load c) At 50% load

13.0

RELIABILITY a) Safety factor used for selecting electronic

components/ other electrical components (not less than 200%/ 125% respectively)

b) MTBF / MTFR c) Availability factor

14.0 DEGREE OF PROTECTION

15.0 Heat loss for total system (W)

16.0 Spare potential free contracts (for duplicating of fault status in remote panel) to be provided.

17.0 Fault status shall be compatible to hook-up with Owner’s PC through RS 232/ RS 485 interface.

262 of 288


Page 7 of 10


DATA SHEET NO.


ANNEXURE- II (B)

TECHNICAL DATA FROM MANUFACTURER

1.0 2x100% RECTIFIER UNITS

1.1

Mains Input

a) Voltage & Frequency 230 V + 10%, 1 phase, 50 HZ + 3% (Rectifier may be fed from UPS output. However it shall also be suitable for these variations if operated independent of UPS).

b) Input harmonics (max.) at full load.

5% RMS (Voltage)

1.2 Out put details

1.2.1 Rectifier a) Voltage / Wattage 24 VDC , ----- W (-) 48 V DC,---- W b) Method of Voltage / Current Control

Static

1.2.2 Load Bus

a) Voltage Regulation from Full load to no load (for mains variation of +10%)

+ 5%

b) Ripple Content (<30 mV) c) Rating of Double pole MCB and

fuses for DCDB

(DP MCB’s with semiconductor fuses and DC bus for 4 outgoing feeders)

1.3 Efficiency of Rectifier (at 50%, 75%, 100% load)

1.4 Power Factor of Rectifier (at all load)

0.6 to 0.7 (lag)

1.5 Annunciator details a) Audio – Visual DC over voltage

Rectifier Failure Load C.B. Trip

b) Push buttons Acknowledge, reset c) Remote One no. potential free common

263 of 288


Page 8 of 10


DATA SHEET NO.


alarm annunciation contact.

1.6 Indication Lamps

AC Power ON, Rectifier ON

1.7 Meters A.C. input ammeter and voltmeter. Output ammeter and voltmeter.

1.8 MTBF (Hrs.)

60,000 Hrs.

1.9

MTTR (Hrs.) 4 Hrs. (Approx.)

1.10 PTRV (Peak Transient reverse voltage) 600 V on AC side 200 V on DC side

1.11 Construction Details

a) Type of Cooling Natural

b) Cable entry Same as UPS Panel

c) Access Same as UPS Panel d) Painting Same as UPS Panel e) Degree of Protection

Same as UPS Panel

1.12 Safety Factor 2

264 of 288


Page 9 of 10


DATA SHEET NO.


ANNEXURE – III

PREFERRED MAKES

UPS System and Inverter 1. EMERSON 2. DB POWER 3. APLAB 4. KELTRON 5. HI-REL

Batteries (Lead Acid) 1. Amco Batteries Ltd. 2. Exide Industries Ltd. 3. HBLNIFE Power System Ltd. 4. Amara Raja Batteries Ltd.

Batteries (Nickel Cadmium) 1. Amco Batteries Ltd. 2. HBLNIFE Power Systems Ltd.

265 of 288


Page 10 of 10


DATA SHEET NO.


ANNEXURE - IV CHECK LIST (To be filled up by tenderer)

Sl. No Description REMARKS

1 Deviation from specification

2 Charger sizing calculation enclosed

3 Battery sizing calculation enclosed

4 Battery catalogue enclosed

5 UPS Panel Catalogue enclosed

6 Confirm compliance to Block diagram

7 Inspection for UPS and battery as per specification.

8 Dimension for UPS Panel, rectifier and Battery Bank enclosed.

9 Break up for two years operation & maintenance spares enclosed for UPS & Rectifier

266 of 288

CONTRACTOR MECON LIMITED CLIENT: PROJECT:

ORDER NO. & DATE PACKAGE NO. SUB-CONTRACTOR ORDER NO. & DATE

QUALITY ASSURANCE PLAN

FOR ELECTRICAL EQUIPMENT

PACKAGE NAME UPS & BATTERY BANK

INSTRUCTIONS FOR FILLING UP : 1. QAP shall be submitted for each of the equipment separately with break up

of assembly/sub-assembly & part/component or for group of equipment having same specification.

2. Use numerical codes as indicated for extent of inspection & tests and submission of test certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant and equipment

3. Separate identification number with quantity for equipment shall be indicated wherever equipment having same specifications belonging to different facilities are grouped together.

4. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may be indicated wherever actual weights are not available.

ABBREVIATIONS USED : CONTR : CONTRACTOR MFR : MANUFACTURER

CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS: Code Description Code Description Code Description DOCUMENTS:

1. Visual 12. Routine test as per relevant IS 23. Short time rating D1. Approved GA drawings 2. Dimensional other standard 24. Operational & functional D2. Approved single line/ 3. Fitment & Alignment 13. Type test as per relevant IS/ check schematic diagram 4. Physical Test (Sample) other standard 25. Over Speed Test D3. Approved 5. Chemical Test (Sample) 14. Impulse Test 26. Flame Proof Test data sheet 6. Ultrasonic Test 15. Partial Discharge Test 27. Clearance and creepage D4. Approved bill of materials 7. Magnetic Particle Test (MPT) 16. Heat run risc test\tempr. Distance D5. Unpriced P.O. copy 8. Radiography Test 17. Enclosure Protection Test 28. Acceptance Test D6. Calibration Certificate 9. Dye Penetration Test 18. Calibration of all measuring 10. Measurement of IR Value 19. Noise & Vibration instruments and gauges a) Before HV Test 20. Test certificates for bought out b) After HV Test components 11. High Voltage test/Dielectric 21. Tank Pressure Test

test 22. Paint shade verification

E Q U I P M E N T D E T A I L S I N S P E C T I O N A N D T E S T S Quantity Raw Material and inprocess stage

inspection Final Inspection/Test by Sl.

No. Description (With equipment

heading, place of use, and Breif Specifications)

Indentificatuin No.

No/M T

Manufacturer’s Name and Address

Expected schedule of Final Inspection

MFR CONTR MECON MFR CONTR MECON

Test Certificates & documents to be submitted to

MECON / ONGC

Acceptance Criteria

Standards /IS/ BS/ASME/ Norms and Documents

REMARKS / SAMPLING

PLAN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 UPS – System Set

1.

1,2,3,4, 24, 27,28

- - 1,2,3,12, 16,22,23 24,27,28

1,2,3,12, 16*, 22, 23,24,27,

28

1,2,3,12, 16*, 22, 23,24,27,

28

D1, D2, D3, D4, D5, D6, 20, 12,13

Tech. Specification,

Approved Drawings & Data Sheets

( * ) 12 hour heat run test

Battery Set Set

2.

1,2,3,4, 24,27

- - 1,2,3,12, 13,28

1,2 - D1, D3, D4, D5, D6, 12,13

Tech. Specification,

Approved Drawings & Data Sheets

Test certificates

12, 13 Document to be

reviewed by MECON

Q.A.P. NO.

For Manufacturer For CONTR For MECON (Stamp & Signature) (Stamp & Signature) (Stamp & Signature) SHEET 1 OF 1

REV. 0

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MECON LTD, DELHI


STANDARD DRAWINGS

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of 1

LIST OF STANDARD DRAWINGS (ELECTRICAL)

Sl. No.

Description of Drawings Drawings No.

1 MARKING OF TRENCHES FOR ELECTRIC CABLES

MEC/SD/05/E9/01/01

2 TYPICAL SECTION OF CABLE TRENCH IN UNPAVED AREAS

MEC/SD/05/E9/01/02

3 EARTH ELECTRODE IN TEST PIT MEC/SD/05/E9/02/01 4 COPPER PLATE ELECTRODE IN TEST PIT MEC/SD/05/E9/02/02 5 TYPICAL EARTH CONNECTION FOR

STREET LIGHT POLE MEC/SD/05/E9/02/03

6 EARTHING OF TANKS AND VESSELS MEC/SD/05/E9/02/04 7 EARTHING METHOD FOR PROCESSING

EQUIPMENT MEC/SD/05/E9/02/05

8 TYPICAL INSTALLATION OF POLE MOUNTED STREET LIGHTING FIXTURE FOR SAFE AREA (WITHOUT RUNGS)

MEC/SD/05/E9/03/01

9 BLOCK DIAGRAM FOR UPS SYSTEM, 3PH. CHARGER AND ACDB

MEC/SD/05/E9/071/01

10 TYPICAL INSTALLATION OF POLE MOUNTED LIGHTING FIXTURE WITH STRAIGHT ARM FOR HAZARDOUS AREA (WITHOUT RUNGS)

MEC/SD/05/E9/77/01

11 TYPICAL INSTALLATION OF FLOOD LIGHTING POLE (WITH RUNGS)

MEC/SD/05/E9/77/02

12 DIV.2 / FLAME PROOF LIGHTING FIXTURE MOUNTING DETAILS

MEC/SD/05/E9/77/03

13 BLOCK DIAGRAM OF SOLAR SYSTEM FOR 24V/48V DC LOADS

MEC/SD/05/E9/078/01

14 BLOCK DIAGRAM OF SOLAR SYSTEM FOR 230V AC LOADS

MEC/SD/05/E9/078/02

15 BLOCK DIAGRAM FOR CATHODIC PROTECTION POWER SUPPLY MODULE(CPPSM) AC - DC

MEC/SD/05/E9/082A/01

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MECON LTD, DELHI


SCHEDULE OF QUANTITY

279 of 288

Sl.No. Description of Items Unit Qty. Supply ErectionUnit Rate Unit Rate

1 Design,manufacture,testing,packing & forwarding,delivery,installation,testing andcommissioning of 4 pole over head structure to receive one incomer and twooutgoing as per SLD no.MEC/23LK/05/E9/E/001/1081 and specificationincluding interconnection with existing 4 pole structure if required.

Set 1

2 Indoor type Emergency Push botton stations (start / stop for VCB trip / close) Nos. 2

3 Design, manufacture, shop testing,inspection, packing,forwarding, delivery,installtion,testing and commissioning of 500 KVA outdoor type distribution transformer complete with all accessories as per specification and data sheet.

Set 1

4 11 KV VCB Panel (HT- 1)Design, engineering, manufacture, shop testing, supply including packing andforwarding, transportation, delivery at site, storage, transportation from storage tosite, installation, testing, commissioning complete with commissioning spares asrequired and supervision of testing and commissioning by main equipment supplierof:

a)

12 KV, 26.3 KA indoor VCB Panel to receive input power from four pole structurewith operating mechanism, all accessories, auxiliaries etc complete in all respectsas specified in technical specification, data sheet & SLD no.MEC/23LK/05/E9/E/001/1081.

Set 1

b)

Recommended spares for 2 years operation & maintenance.( The list ofrecommended spares along with the item wise price shall be enclosed with theprice part . Unpriced list of the recommended spares shall be enclosed with thetechnical part.)

Set 1

5 11 KV VCB Panel Board(HT MCC)Design, engineering, manufacture, shop testing, supply including packing andforwarding, transportation, delivery at site, storage, transportation from storage tosite, installation, testing, commissioning complete with commissioning spares asrequired and supervision of testing and commissioning by main equipment supplierof:

a)

12 KV, 26.3 KA indoor panel board with VCB as incomer to receive input power fromfour pole structure with outgoing feeders (VCB) 12 KV, 26.3 KA with operatingmechanism, all accessories, auxiliaries etc complete in all respects as specified intechnical specification, data sheet & SLD no. MEC/23LK/05/E9/E/001/1081.

Set 1

b)

Recommended spares for 2 years operation & maintenance.( The list ofrecommended spares along with the item wise price shall be enclosed with theprice part . Unpriced list of the recommended spares shall be enclosed with thetechnical part.)

c) Special Tools and Tackles for erection and maintenance. Set 1 NAd) 1250 A VCB Trolley complete with VCB etc. Nos. 1 NA

6 415 V LT Panel (PMCC)

Design, engineering, manufacture, shop testing, supply including packing andforwarding, transportation, delivery at site, storage, transportation from storage tosite, installation, testing, commissioning(with commissioning spares as required)including supervision of testing and commissioning by main equipment supplier of:

(a) 415 V, 30 KA single front type indoor LT Panel to receive input power fromtransformer with operating mechanism, all accessories, auxiliaries etc complete inall respects as specified in technical specification, data sheet & SLD no.MEC/23LK/05/E9/E/001/1081. (PMCC -1 for Bahadurgarh Terminal)

Set 1

(b) 415 V, 30 KA single front type indoor LT Panel to receive input power from Client'sdistribution board with operating mechanism, all accessories, auxiliaries etccomplete in all respects as specified in technical specification, data sheet & SLD no.MEC/23LK/05/E9/E/004/1081. (PMCC -2 for Tikrikalan Terminal)

Set 1

c) Recommended spares for 2 years operation & maintenance.( The list ofrecommended spares along with the item wise price shall be enclosed with theprice part . Unpriced list of the recommended spares shall be enclosed with thetechnical part.)

Set 1

Total Amount

SCHEDULE OF RATES

ELECTRICAL PACKAGE FOR BAHADUEGARH & TIKRIKALAN TERMINALBAHADURGARH TIKRIKALAN OIL PIPELINE PROJECT- HPCL

Sheet 1 of 7

280 of 288


Total Amount

SCHEDULE OF RATES


7 415 V LT MOV Distribution Board (MOV DB)

Design, engineering, manufacture, shop testing, supply including packing andforwarding, transportation, delivery at site, storage, transportation from storage tosite, installation, testing, commissioning(with commissioning spares as required) of:

(a) 415 V, 30 KA double front type indoor LT MOV Distribution Board to receive inputpower from PMCC with operating mechanism, all accessories, auxiliaries etccomplete in all respects as specified in technical specification, data sheet & SLD no.MEC/23LK/05/E9/E/001/1081. (MOV DB -1 for Bahadurgarh Terminal)

Set 1

(b) 415 V, 30 KA double front tyoe indoor LT MOV Distribution Board to receive inputpower from PMCC with operating mechanism, all accessories, auxiliaries etccomplete in all respects as specified in technical specification, data sheet & SLD no.MEC/23LK/05/E9/E/004/1081.(MOV DB -2 for Tikrikalan Terminal)

Set 1

c) Recommended spares for 2 years operation & maintenance.( The list ofrecommended spares along with the item wise price shall be enclosed with theprice part . Unpriced list of the recommended spares shall be enclosed with thetechnical part.)

Set 1

8 UPS SYSTEMDesign, supply, manufacture, shop testing,inspection, packing, forwarding, delivery,testing and commissioning including supervision of testing and commissioning by equipment supplier at site including commissioning spares as required of UPS systems as per specification, block diagram and following rating :

(a) For Bahadurgarh Dispatch Terminal:(i) 30 KVA, 230 V Single Phase, 50HZ, dual redundant industrial type, UPS system suitable for input Power supply voltage of 415 V, TPN, +/-10%, output 230 V +/-1% , AC with solid state voltage stabilizer for bypass supply, ACDB and 2 hrs. battery back-up as per specification and data sheet. (Nickel Cadmium type battery,1.2 V) and Battery capacity shall not be less than 88 KVAH (where KVAH = Battery Ahx1.2Vx No. of cells). Charger rating shall not be less than 65 KW.

Set 1

(ii) Dual redundant Rectifier system and DCDB as per specification and following rating : (i) -48 V DC(3.5 KW)

Set 1

(iii) All interconnecting cables among UPS, Rectifier, battery stand, ACDB/DCDB etc.(50 mtr shall be considered between battery bank and UPS panel.30 mtr cable shall be considered between ACDB/DCDB and UPS panel.)

Set 1

(b) For Tikrikalan Receiving Terminal:(i) 20 KVA, 230 V Single Phase, 50HZ, dual redundant industrial type, UPS system suitable for input Power supply voltage of 415 V, TPN, +/-10%, output 230 V +/-1% , AC with solid state voltage stabilizer for bypass supply, ACDB and 2 hrs. battery back-up as per specification and data sheet. (Nickel Cadmium type battery,1.2 V) and Battery capacity shall not be less than 60 KVAH (where KVAH = Battery Ahx1.2Vx No. of cells). Charger rating shall not be less than 40 KW.

Set 1

(ii) Dual redundant Rectifier system and DCDB as per specification and following rating : (i) -48 V DC(2.5 KW)

Set 1

(iii) All interconnecting cables among UPS, Rectifier, battery stand, ACDB/DCDB etc.(50 mtr shall be considered between battery bank and UPS panel.30 mtr cable shall be considered between ACDB/DCDB and UPS panel.)

Set 1

(c) Recommended spares for 2 years operation & maintenance of UPS & Rectifiersystem.( The list of recommended spares along with the item wise price shall beenclosed with the price part . Unpriced list of the recommended spares shall beenclosed with the technical part.)

Set 1 NA

Sheet 2 of 7

281 of 288


Total Amount

SCHEDULE OF RATES


9 110 V DC Battery Charger & Batteries(a) Supply, Installation, connection, testing, & commissioning of 2 x 100% 110 V DC

battery charger with battery bank (Lead Acid Sealed Maintenance Free of 200 Ahcapacity) for substation equipment with DCDB, transportation to the the errectionsite ,unpacking, installation on foundation aligning, leveling, grouting;includinginterconnecting cables between charger and battery bank ,commissioning spares asrequired etc. including all labour and materials complete as per specification,datasheet and the direction of Engineer-in-charge

Set 1

(b) Recommended spares for 2 years operation & maintenance of Charger system. (The list of recommended spares along with the item wise price shall be enclosedwith the price part . Unpriced list of the recommended spares shall be enclosed withthe technical part.)

Set 1 NA

10 Supply,laying,termination,testing and commissioning of 1.1kV grade PVC LT powerand control cables (conforming to IS:1554 and specification) of following sizes intrenches,excavated under ground trench/trays,pulling through pipes and its propersealing,cutting of paved area,roads etc (making of underground trenches coveredelsewhere).

a) 3.5 X 300 mm2 YFY Mtr. 10b) 3.5 X 240 mm2 YFY Mtr. 660c) 3 X 185 mm2 AYFY Mtr. 350d) 3.5 x 70 mm2 YWY Mtr. 610e) 3.5 x 50 mm2 YWY Mtr. 50f) 3.5 x 16 mm2 YWY Mtr. 10g) 3.5 x 10 mm2 AYFY Mtr. 4000h) 3.5 x 6 mm2 YWY Mtr 1140i) 3.5 x 4 mm2 YWY Mtr. 720j) 14 X 2.5 mm2 YWY Mtr. 100k) 7 X 2.5 mm2 YWY Mtr. 1000l) 5x 2.5mm2 YWY Mtr. 300m) 3x 2.5mm2 YWY Mtr. 10

11 Supply,laying,testing and commissioning of Aluminium Conductor XLPE insulated,PVC sheathed and armoured cables (conforming to IS:7098 and specification) offollowing sizes in trenches,excavated under ground trench/trays,pulling throughpipes and its proper sealing,cutting of paved area,roads etc (making of undergroundtrenches covered elsewhere).

a) 3 X 185 mm2 11 KV(UE) Grade Mtr. 920b) 3 X 120 mm2 3.3 KV(UE) Grade Mtr. 120

12 Indoor/Outdoor type H.T. termination kits (Raychem/ M seal/CCI make) Push ontype for the cable sizes indicated with stress relievieng cones and anti-trackingtapes, copper 'crimping type sockets including termination on Outdoor TypeTransformer,HT panels metering cubicles etc as per specification andSLD no. MEC/23LK/05/E9/E/001/1081.

Set 24

13 Supply and erection of following Hot Dip Galvanized Ladder/Perforated Type cabletrays (as per IS 2629) including bends, tee, crosses,horizontal and vertical splicesetc. as required including supply of all G.I hardwares, all labour and material asrequired as per standard drawings, specification and direction of Engineer-in-charge

a) Ladder type,made from 50mm height and 2.5 mm thick sheet steel & galvanized (86microns) of following sizes.

(i) 600 mm wide Mtrs. 50(ii) 450 mm wide Mtrs. 50(iii) 300 mm wide Mtrs. 50b) Perforated type,made from 50mm height and 2.5 mm thick sheet steel & galvanized

(86 microns) of following sizes.(i) 150mm wide Mtrs. 50(ii) 300mm wide Mtrs. 100(iii) 600mm wide Mtrs. 10

Sheet 3 of 7

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Total Amount

SCHEDULE OF RATES


14 Excavation to required width and depth (in all types of soil including rock cutting,jungle / debris clearing whever required along the cable route) filling with 150 mmsand above and below cables and good quality approved bricks(75 mm thick)covering the cables through out the trench, back filling (after cable laying), andfinally compacting as per tender specification and approved drawings, including onerun of warning tape.

a) 300mm wide x 1000mm depth Mtrs. 100b) 600mm wide x 1000mm depth Mtrs. 300d) 1000mm wide x 1000mm depth Mtrs. 100

15 LIGHTING DISTRIBUTION BOARDSSupply,Installation, connection, testing, and commissioning of 415V/240Vlighting/power panels, Surface/Recess mounting type in weather/flame proof (withhinged cover )sheet steel enclosure of approved make having 4 Pole MCCB/RCCB(MCB + ELCB) as incoming and SP/DP/TP MCB (9 KA type) for out going circuitcomplete with wiring,indication lamp, ammeter etc including all labour and materialsas per specification and the direction of Engineer-in-charge.

a) Surface mounted Main Lighting Panel consisiting of 160 Amp 4 pole MCCB Incoming 63 A TPN MCBs - 10 Nos. Outgoing 20A/16A SP MCB's - 6 Nos. Outgoing

No. 2

b) Surface/Recess mounted Lighting Panel (MCC/Control/Substation Room Lighting Points) Consisting of 63 Amp (100mA sensitivity) 4 Pole RCCB as incomer and 08nos. 6A SP MCBs as out goings complete with indication lamp etc.

Nos. 7

c) Lighting Panel (for DG Shed/car parking shed ) Consisting of 63 Amp (100mAsensitivity) 4 Pole RCCB as incomer and 08 nos. 6A SP MCBs as out goingscomplete with indication lamp.

Nos. 2

d) Flame proof type LDB for Pump House/Booster Pump House/Dosing Shed consistingof 4 Pole 63 Amp RCCB(100mA snsitivity) as incomer and 12 nos. 6A SP MCBs' asoutgoing complete with indication lamp etc.

Nos. 4

e) Surface/Recess mounted LDB (For Building Power Points , AC's etc) consisting of100Amp (300mA sensitivity) 4 Pole RCCB as incomer and 14Nos. 20A/16A SP MCBsas out goings complete with indication lamp etc.

Nos. 4

16 Supply, installation, testing, commissioning of lighting fixtures for sheds (PumpHouse/DG /Car Parking Shed etc.) complete with mounting bracket, flame proof/nonflame proof, control gear box as per the type of fixture, lamps etc. including civilwork with pipe inserts for cables and connecting work, with all material and labouras per specifications, drawings and instruction of Engineer-in-charge. Work to becompleted in all respects.

a) Bracket mounted non integral type flame proof well glass fixture ( 200W MetalHalide lamp,lighting fixture : Type FLPW-1245 of M/s Baliga make or equivalent).

Set 70

b) Same as above except non flame proof well glass fixture (type HPK 225/HPL 250WB of M/s Philips make or equivalent).

Set 10

17 Supply, installation, testing & commissioning of point wiring as per details inconstruction drawing & specification ( includes PVC conduits in ceiling,luminaries,sockets, lamps, industrial type heavy duty exhaust fans, ceiling fans, electronicspeed regulator, switch boxes & switches(ANCHOR ROMA make or equivalent), Multistrand Flexible HR PVC insulated copper conductor wires/cables,LAN cable etc. asmentioned below)

a) Lighting Pointsi) Surface/ recess mounted mirror type CFL fixture (type TLE211 of CG make or

equivalent).Nos. 60

Sheet 4 of 7

283 of 288


Total Amount

SCHEDULE OF RATES


(ii) Fluorescent tube light luminaire with mounting rails & vitreous enamelled reflectorswith lamps (similar to Philips type - TKC 24/236 HPF )suitable for 2 x 36 w lamp Nos. 120

(iii) Water proof tube light fitting with lamp (similar to Philips type TCW 300/236 HF-EBS)

Nos. 16

(iv) 1x SON/SON-T 150W or 250 W luminaire shall have die cast aluminium housing,clear flat, toughned glass at bottom, adjustable lamp holder position to suit differentinstallation parameters including lamp and accessories fully wired up with GI pipebracket suitable for mounting the fittings similar to. Bajaj BGEST 150 SV Nos. 8

b) Fan point ( Energy Efficient, 50 W, 1200mm sweep) Nos. 30

c) Exhaust fan point (Industrial type 300 mm) with louvers Nos. 4

d) Exhaust fan point (Industrial type 450 mm) with louvers Nos. 6

e) Socket outlet (5/15 Amp combination) of ANCHOR ROMA make or equivalent Nos. 20

f) 20 Amp sheet steel enclosed industrial type socket with 20A DP MCB Nos. 12

g) Socket for Telephone(Piano Reed Type) Nos. 10

h) Socket for LAN cabling (Piano Reed Type) No. 10

18 Wiring for main/ submain with 4 x 4/6 sq.mm Multistrand HR PVC flexible insulatedcopper conductor single core cable/ wire in PVC conduit in recess/ trench asrequired.

Mtr. 20

19 Supply and laying of following sizes of class 'B' G.I.Pipe in required length fixed onsteel, concrete or similar sructure, laid in trenches, ready to be buried inconcrete/floor including cutting, threading, bending and similar works, supply ofclamps, small iron structures, spacers and installation of seats, plugs, bushingsetc.Small civil works like cutting of paved area,roads etc, including all labour andmaterials complete as per approved drawings and directions of Engineer-In-Charge.

a) 25 mm NB Mtr. 10b) 40 mm NB Mtr. 10c) 50 mm NB Mtr. 10d) 100 mm NB Mtr. 10e) 200 mm NB Mtr. 10

20 Supply, installation, testing, commissioning of the complete earthing and lightningprotection system, earth electrodes/ pit, earth main ring, earthing of electricalequipments, instrument panels, field instruments, process equipments and pipes/flanges including all associated civil work with all material and labour as perspecification and drawings approved by the company.

a) Earth Pits- GI PIPE Electrode with 6 mm thick chequered plate cover Nos. 30

b) Earth Pits- Copper plate Electrode with 6 mm thick chequered plate cover Nos. 8c) GI Strip (50 x 6) mm Mtr. 400d) GI Strip (40X5) mm Mtr. 50e) GI Strip (25X5) mm Mtr 50f) GI Strip (25X3) mm Mtr 150g) Copper Strip (25X5) mm Mtr 20h) Copper Strip (25X3) mm Mtr 20i) GI Wire, wire rope and all balance earthing material including copper strip (50 mm x

2 mm thick) jumper for flanges etc. as per the specification. Lot 1

j) GI lightning rod 25 mm dia. 1800 mm long including supply of all hardware labouretc. complete as per approved drawings, specifications and directions of Engineer-In-Charge.

Set 4

Sheet 5 of 7

284 of 288


Total Amount

SCHEDULE OF RATES


21 Erection, Testing & commissioning of 3 phase 415V/3.3KV/6.6KV flame proof motors of following ratings no load /full load running of motor ,including all lalour andmaterials complete as per approved drawings , specifications and direction ofEngineer - in - Charge.

a) Upto 5.5 kW. Nos. 100 NAb) Above 5.5 KW and upto 45 KW Nos. 1 NAc) Above 45 KW and upto 200 KW Nos. 4 NAd) Above 200 kW and upto 600 KW at voltage level 3.3KV/6.6KV Nos. 4 NA

22 Supply and installation of the following including the supply of necessary clamp,bolts, rawl plugs etc. breaking and making good of walls, if required , and includingall labour and materials complete as per directions of Engineer-In-Charge, applicablestandards and Indian Electricity rules.

a) Shock hazard charts complete with frame and glass Nos. 4b) First Aid Boxes Nos. 4c) 6.8 Kg capacity CO2 type fire extinguishers Nos. 10d) Caution boards including supply of necessary clamps, bolts and other hardware. Nos. 10

23 Supply and laying of Insulating Mats(as per IS:15652 - 2006) of 1000mm width,required for maintenance of electrical equipment in substation as required includingcutting to required shape in running length and including all labour and materialsetc. complete and as per directions of Engineer-In-Charge as per applicable Indianor International standards and Indian Electricity Rules.

a) 11 KV grade of 2.5 mm thick Mtr. 50

24 Supply, fabrication and errection of MS base frame support for switch gear andbracket for misc.electrical equipment,cable and cable tray support out of roled MSsection,pipes,plates etc including welding, bolting,reveting,supply of necessaryanchor bolts and grouting etc supply of paints applying one coat of anti rust primertwo finish coats of approved synthetic enamel paints including bracking wlls, floorsetc for structure as required including supply of all GI hardware materials includingall labour and materials complete as required and the direction of Engineer-in-charge

Kg 500

25 Supply, testing and commissioning of portable type emergency lighting unit( 7 WCFL Lamp) fed by a self- contained SMF battery 12V, 7 Ah and charger operating on240 V AC supply, including all labour and materials complete as per directions ofEngineer-In-Charge.

Nos. 4

26 Supply installation,testing and commissioning of latest model( 5 stars BEE certified)2 T split AC complete with remote, 5 KVA stablizer, MS Stand for outdoor unit etc.

Nos. 12

27 Supply, erection and commissioning of Flame proof type 63 Amp. Welding socket Nos. 2

28 Supply of Installation/ erection accessories including , cable tags, cable marker,nickle plated lugs, double compressed brass cable glands,brassadaptar/reducers/nipples, fixing of metallic anchor fasteners for supporting of cabletrays and misc. electrical switchgear including all labour and materials complete asrequired and as per directions of Engineer-In-Charge for Bahadurgarh & Tikrikalanterminal

Lot 1

Sheet 6 of 7

285 of 288


Total Amount

SCHEDULE OF RATES


29 Telephone Cable:

a) Supply and wiring for telephone socket,LAN sockets (Piano reed Type) in recess PVCconduit including PVC conduit,telephone socket,cable,accessories etc as required.

Nos. 20

b) supply and laying of 10 pairs,0.61mm,jelly filled/aerial self supporting armouredTelephone Cable, including MDF box , accessories etc as required.

Mtr. 100

30 Installation, testing & commissioning and handing over of following owner suppliedvariable speed drive system including transportation from owner's stores to site,unpacking, installation, testing and commissioning -

a) HT Variable Speed Drive (VSD) Panels for Main Pump (Approx. Size of each panel is3500x1000x2400)

Sets 4 NA

b) 415 V Variable Speed Drive (VSD) Panels for Booster Pump (Approx. size of eachpanel is 2400x1000x2400)

Sets 4 NA

c) Flame proof type LCS in process area. Nos. 12 NA

31 All works relating to statutory approval of the complete electrical including owner supplied equipments and DG set at Bahadurgarh and Tikrikalan installation from competent authority like Chief Electrical Inspectorate ,HSEB etc. including carrying out of all required modifications in design / Manufacturer / Installation to meet the requirement of Indian Electricity rules and other statutory regulations in force, carrying out necessary paper work and liasion with the authorities to obtain all necessary clearances for charging of instllation as per relevant national standards. However the official fees towards the approvals shall be reimbursed by the client.

Lot. 1

32 Addition / deletion of following types of feeders : -Fixed type feeders of following ratings in PMCC/ MCC Panels : -

a) 400 A MCCB No. 1b) 250 A MCCB No. 1c) 160 A MCCB No. 1d) 100 A MCCB No. 1e) 63 A MCCB No. 1f) DOL feeder upto 75 kW No. 1g) Fuse Switch Unit of 63A No. 1h) Fuse Switch Unit of 100 A No. 1i) Fuse Switch Unit of 125 A No. 1j) Fuse Switch Unit of 200 A No. 1k) pole 100 A , MCCB with shunt trip & ELR No. 1l) pole 63 A, MCCB No. 1

Note1) Quantities given above are only estimated quantities. Procurement shall be done as

per actual site condition, approved construction drawings and instruction of engineer incharge.

2) Rates are applicable for both Bahadurgarh & Tikrikalan Terminals.3) Procurement of Air Conditioners shall be after approval of model/make from

Engineer in Charge/HPCL site Incharge4) Any commissioning spares as required , are included in the supply5) Price quoted against item no. 32 of SOR for addition/deletion of various feeders may be necessitated during execution of work.

Sheet 7 of 7

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MECON LTD, DELHI


QUALITY ASSURANCE

PLAN

287 of 288

CONTRACTOR CLIENT: PROJECT:

HINDUSTAN PETROLEUM CORPORATION LIMITED 10”&8” x 15 KM BAHADURGARH TIKRIKALAN OIL PIPELINE

ORDER NO. & DATE PACKAGE NO. SUB-CONTRACTOR ORDER NO. & DATE

QUALITY ASSURANCE PLAN

FOR ELECTRICAL EQUIPMENT

PACKAGE NAME ELECTRICAL WORKS

INSTRUCTIONS FOR FILLING UP: 1. QAP shall be submitted for each of the equipment separately with break up

of assembly/sub-assembly & part/component or for group of equipment having same specification.

2. Use numerical codes as indicated for extent of inspection & tests and submission of test certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant and equipment

3. Separate identification number with quantity for equipment shall be indicated wherever equipment having same specifications belonging to different facilities are grouped together.

4. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may be indicated wherever actual weights are not available.

ABBREVIATIONS USED : CONTR : CONTRACTOR MFR : MANUFACTURER

CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS: Code Description Code Description Code Description DOCUMENTS:

1. Visual 12. Routine test as per relevant IS 23. Short time rating D1. Approved GA drawings 2. Dimensional other standard 24. Operational & functional D2. Approved single line/ 3. Fitment & Alignment 13. Type test as per relevant IS/ check schematic diagram 4. Physical Test (Sample) other standard 25. Over Speed Test D3. Approved 5. Chemical Test (Sample) 14. Impulse Test 26. Flame Proof Test data sheet 6. Ultrasonic Test 15. Partial Discharge Test 27. Clearance and creepage D4. Approved bill of materials 7. Magnetic Particle Test (MPT) 16. Heat run risc test\tempr. Distance D5. Unpriced P.O. copy 8. Radiography Test 17. Enclosure Protection Test 28. Acceptance Test D6. Calibration Certificate 9. Dye Penetration Test 18. Calibration of all measuring 10. Measurement of IR Value 19. Noise & Vibration instruments and gauges a) Before HV Test 20. Test certificates for bought out b) After HV Test components 11. High Voltage test/Dielectric 21. Tank Pressure Test

test 22. Paint shade verification

E Q U I P M E N T D E T A I L S I N S P E C T I O N A N D T E S T S Quantity Raw Material and inprocess stage

inspection Final Inspection/Test by Sl.

No. Description (With equipment

heading, place of use, and Breif Specifications)

Indentificatuin No.

No/M T

Manufacturer’s Name and Address

Expected schedule of Final Inspection

MFR CONTR MECON MFR CONTR MECON

Test Certificates & documents to be submitted to

MECON

Acceptance Criteria

Standards /IS/ BS/ASME/ Norms and Documents

REMARKS / SAMPLING

PLAN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1. HT Switch board Set Approved 1,2,3,4,

24, 27 - - 1,2,3,12,

22 24,27 1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

D1, D2, D3, D4, D5, D6, 20, 12,

13*

I.S., Data Sheet, Specifications & Approved Drgs.

13* for similar rating

2. LT Panel Set Approved 1,2,3,4, 24, 27

- - 1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

D1, D2, D3, D4, D5, D6, 20, 12,

13*



3. LT MOV DB Set Approved 1,2,3,4, 24, 27

- - 1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

D1, D2, D3, D4, D5, D6, 20, 12,

13*



4. Distribution Transformer No. Approved 1,2,3,4, 24, 27

- - 1,10,11, 12, 28

1,10,11, 12, 28

1,10,11, 12,22,

12,13*,28 D3, D5, D6,

I.S., Data Sheet, Specifications & Test Certificate


LT Power and Control Cable

5(a).

(b) HT Power Cable

Mt. Approved 1,10,11, 12,13

- - 1,10,11, 12,13, 28

1,10,11, 12,13, 28

1,10,11, 12, 28

12,13*,28 D3, D5, D6,

I.S., Data Sheet, Specifications & Test Certificate


6. 110 V DC Battery Charger & Battery

No. Approved 1,2,3,4, 24, 27

- - 1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

D1, D2, D3, D4, D5, D6, 20, 12,

13*



7. UPS Nos. Approved 1,2,3,4, 24, 27

- - 1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

1,2,3,12, 22 24,27

D1, D2, D3, D4, D5, D6, 20, 12,

13*



Q.A.P. NO. MEC/05/E9/23LK/001

For MECON (Stamp & Signature) for CONTRACTOR SUB-CONTRACTOR (Stamp & Signature) SHEET 1 OF 1

REV. 0

288 of 288