Bus Duct Technical Specifications

Specifications for Sandwich Bus duct for Power Conditioning System

Technical Specifications for Sandwich Bus Duct for Power Conditioning System

Techno-commercial Bid (Part-I)

Raja Ramanna Centre for Advanced Technology, Indore (M P)


Contents Section A: 1.0 General Description 2.0 Reference Standards 3.0 Environmental conditions 4.0 Scope of work 5.0 Technical specifications 6.0 Inspection 7.0 Packaging and transport 8.0 Installation, testing and commissioning 9.0 Commercial terms and conditions 10.0 Documentation 11.0 Delivery period 12.0 Performance Bank guarantee 13.0 List of Preferred makes

Section B: (Schedule of Prices) •

Schedule of Prices

•

Schedule of Spares

•

Delivery schedule

•

Schedule of deviations

List of Enclosures and Drawings: 1.

Annexure-1: Guaranteed Technical Particulars

2.

Tender Drawing No. (RRCAT/E/0421/R-0)


1.0 General Description: 1.1 Introduction: The specification covers the Design / Engineering, Fabrication, Assembly, Testing at works, Supply at site, Installation, Testing and commissioning of a continuous duty, 50 Hz, 415 V±10%, 3200A, three phase four-wire, EC grade Aluminium Conductor Sandwich Bus Duct having class F insulation and GI/Aluminium enclosure with degree of Ingress Protection IP65. The Proposed outdoor sandwich Bus duct is required for electrical power transfer in between Indus substation and Power Conditioning system (PCS) building. The Bus duct shall be routed from Indus substation transformers (04 numbers) to existing Input electrical panel at PCS building for feeding unconditioned power to PCS. The conditioned power will be fed back again to existing Low Tension Power Control Centres (LT PCCs - 04 numbers) at Indus substation from Output electrical panel of PCS through Bus duct. The total eight (08) lengths of the sandwich bus duct shall be erected in between Indus substation and PCS building with their end terminations. The end terminations on either sides ends shall be from top and through flexible tinned copper links. The existing equipment layout along with tentative layout of proposed Bus duct is shown in Tender drawing (RRCAT/E/0421/R-0). The bidder shall submit the requisite design details, schematic drawings including end terminations etc. for the same in his technocommercial offer (Part-1).

1.2 Eligibility Criteria: The bidder shall comply with the following conditions

1.2.1 The Bidder should be Original Equipment Manufacturer (OEM) / authorised system integrator of OEM and engaged in supply, installation, testing and commissioning of Sandwich Bus duct. The bidder shall have reasonable number of installed base of similar capacity and submit a valid documentary proof for the same in part–I (Technical Bid). In case bidder is authorised system integrator, he should submit the agreement with OEM, showing that he is authorised to quote on their behalf for this tender and they shall support the bidder for all warranty etc. 1.2.2 Bidder / OEM shall have experience of having successfully completed following works during last five years ending 31.03.2009. Bidder / OEM must submit reference reports / completion certificate from existing customers. Three similar works costing not less than Rs. 64.00 Lakhs each or equivalent OR Two similar works costing not less than Rs. 80.00 Lakhs each or equivalent OR One similar work costing not less than Rs. 128.00 Lakhs or equivalent The similar work would mean supply, installation, testing and commissioning of sandwich bus duct /bus trunking system. In this regard, a list of clientele (with address and contact number) having such installation shall also be provided for verification.

2.0

Reference Standards: The Sandwich bus duct and all associated equipment and components shall be manufactured in accordance with following publications of International Electrotechnical Commission (IEC) / Bureau of Indian (BIS) Standards or equivalent standards.


1.

Specification for low voltage switchgears and control gears General rules Specification for Low-voltage switchgear and control gear assemblies - Type tested and partially type-tested assemblies Specification for Low-voltage switchgear and control gear assemblies - Particular requirements for busbar Trunking systems (bus ways) Steel for general Structural purposes - specifications Cold rolled low carbon steel sheet & strips. Code of practice for phosphate coating of iron and steel. Guide for marking of insulated conductors & Guide for uniform system of marking and identification of conductors and apparatus terminals Specifications for Copper strips for electrical purposes.

IEC 60529/IS 13947Part1: 1993 IEC/EN 60439 (part 1) / IS 8623 (part 1) IEC/EN 60439 (part 2) / IS 8623 (part 2)

9.

Wrought aluminium and aluminium alloy bars, rods, tubes and sections, plates and sheets for electrical applications.

IS - 5082

10.

Danger notice plates.

IS - 2551

2. 3.

4. 5. 6. 7.

8.

IS - 2062 IS - 513 IS - 6005 IS-5578 & IS- 11353

IS - 1897

Note: Type test reports for the offered system issued by any IEC/CPRI/Government accredited Lab shall be submitted with the offer.

3.0 Environmental conditions: 3.1 Service Conditions: The Sandwich Bus Duct and all its associated components shall be capable of withstanding any combination of the following environment conditions, and it must operate, without mechanical and electrical damage or degradation of operating characteristics:

1. 2. 3. 4. 5. 6.

Ambient air temperature Maximum ambient air temperature Relative humidity not exceeding Maximum altitude without de-rating Seismic withstand level Ingress protection degree (acc. IEC 60529)

-

40º C 48º C 95 % non-condensing 1000 M As per Zone–III requirements at least IP65

3.2 Heat dissipation: To remove heat from the Sandwich Bus Duct, its metallic enclosure shall have sufficient heat dissipation capability throughout the year without any additional cooling arrangement. 3.3 Adequate clearance between bus ducts shall be ensured. The proposed clearance shall be sufficient from maintenance point of view. This shall not cause any mutual interference also.

4.0 Scope of Work: 4.1 The scope includes the Design / Engineering, Fabrication, Assembly, Testing at works, Supply at site, Installation, Testing and commissioning of a continuous duty, 50 Hz, 415 V±10%, 3200A, three phase four-wire, EC grade Aluminium Conductor Sandwich Bus Duct having class F insulation and GI/Aluminium enclosure with degree


of Ingress Protection IP65. The external Aluminium earthing conductor of minimum size 2 runs 50X8mm running along the bus duct shall be provided and the same shall be connected to the existing earthing network by equivalent capacity GI/Aluminium strip. Required measures shall be taken during jointing and connection for ensuring the earthing conductor resistance as low as possible. The outdoor bus duct shall be provided with canopy made out of CRCA sheet. These canopies shall be duly painted with polyurethane paint of approved shade. 4.2 Supply, installation, testing and commissioning of all required accessories for this Sandwich bus Duct like bends, end termination flanges with flexible tinned copper links on either sides, MS fabrication for mounting/support, adopter boxes and earthing of the bus duct from substation earthing grid are in the scope of Supplier. All required minor civil works like wall cutting, bricks masonry and plaster on wall crossings etc. shall also be under the present scope. 4.3 The scope also includes supply of spares and accessories required for five years trouble free operation. Item wise unpriced list of spares shall be submitted along with part–I of the offer. The prices shall be indicated for individual spare component alongwith part2 (Price bid) of the offer.

5.0 Technical Specification: 5.1 General: The Sandwiched Bus duct shall be of compact design, maintenance free and suitable for outdoor application confirming to IP 65 as per IEC 60529/IS 13947Part1: 1993. A type tested low voltage switchgear and control gear assembly (TTA) as per IEC 60439 (1 & 2) and IS 8623 (1 & 2) shall only be acceptable. The complete assembly shall include rising mains, straight length, bends, joints, expansion joints, offset, flanges, flexible lengths, overlapped jointing arrangement with indication of proper pressure during tightening, thrust pads, spring hangers, flexible tinned copper links at terminations, flexible rubber bellow and adopter box on flange terminations at transformer side, universal fixing brackets, supports etc. in line with the site requirements. Bolted joints shall be provided with suitable bolts, spring washers, lock nuts etc. in line with the type tested design. The bus duct shall be reusable and can be dismantled without any loss and breakdown of material. 5.2 Technical Parameters: The offered system should be suitable to take continuous 100% loading in all positions. The temperature rise of Busbars shall not exceed 55°C over the 40°C ambient. Calculations shall be submitted, demonstrating rating and temperature rise. The minimum rated RMS short circuit withstand current for the Busbars shall be 50 kA for 1 sec. Bare Aluminium earth bus of minimum size 2 runs 50X8mm shall be provided along the length of the bus duct. The Impedance balance shall be ensured among the phases for achieving equal current sharing and voltage balance. The transposition details may please be submitted with the part-I. Supplier shall furnish the values for mutual inductance and voltage drop during the submission of detailed engineering drawings.

Current density Colour coding Support

: In line with Type tested design : Red, Yellow, Blue, & black etc. :Compatible to withstand the stipulated short-circuit/earth fault Current.

The insulating material shall be non-toxic, chemically inert, fire-retardant and stable material.


5.3 Material description and construction features: 5.3.1 Busbars and Joint: The busbars shall be of fully round edge and made of reputed make EC grade Aluminium. Each busbar shall be individually insulated by means of class F or better insulation. If required, the busbars shall be suitably treated at termination ends and bimetallic strips can be used. Neutral conductor shall have the same size as phase conductor. The Sandwich Bus duct system shall be manufactured in convenient lengths to facilitate easy transportation and installation. Each section shall be provided with suitable brackets at convenient intervals for fixing to the wall/roof support. Expansion joints may be provided as per manufacturer’s design and recommendation. Cross-section of the busbar and current density shall be in accordance with the Type tested assembly for the rated capacity. Flexible tinned copper links shall be used for terminations to the transformer/Panel.

5.3.2 Enclosure: 5.3.2.1 Material: The enclosure shall be made up of hot dip GI, however bidder may offer aluminium. 5.3.2.2 Process: After proper metal pre-treatment (7-tank process) the enclosure shall be hot dip galvanised. The same shall be duly coated with epoxy powder paint of approved shade. The minimum thickness of coating shall not be less than 50 micron.

5.3.3 Supports and Canopy The supplier shall use the purpose made fixing brackets/mountings. The supporting structure shall have adequate space and strength for laying additional one run of similar bus duct and stresses under short circuit (50kA for 1 sec.). The supplier is requested to submit the drawings and design details of required supporting structure. The outdoor bus duct shall be provided with canopy made out of CRCA sheet. This CRCA sheet shall be processed under 7-tank metal pre-treatment process before painting. The canopies and supports shall be duly painted with polyurethane paint of approved shade.

6.0 Inspection & Testing: A comprehensive pre-despatch inspection including following Acceptance tests in line with IEC 60439 (1 & 2) and IS 8623 (1 & 2) shall be conducted prior to despatch at manufacturer's works / approved testing laboratory in presence of authorised representative(s) from RRCAT. Typical section-samples with each of the items of complete sandwich busduct system including coupling, straight sections, interconnecting sections, bends etc shall be offered for these tests. (a) Visual Inspection and Physical measurements for conformity to the specifications. (b) Measurement of Insulation Resistance between Busbars and Busbar & earth with 1KV Megger. (c) mV (milli-volt) drop test of one joint. (d) High Voltage withstand test at 5kV; 50 Hz for one minute


(e) Measurement of Average Resistance per conductor, impedance measurement at 50Hz and few kHz etc. (f) Degree of Protection (IP65) testing. (g) Test for Short circuit withstand capacity for one section of Bus duct System. (h) Heat run test for the assembled sample section with each of the items of complete Sandwich bus duct.

7.0 Packing and Transport: 7.1 The Packing and transport is the responsibility of the supplier. The Company shall furnish the list of packing materials containing items within it along with its weight inside. The company shall do packing in prefabricated wooden crates and on arrival at site material shall be opened and inspected by both supplier and RRCAT. 7.2 Equipments shall be packed and protected so as not to suffer deterioration, damage or breakage during shipment, transhipment or storage in a tropical climate. All lifting/handling points shall be clearly marked. 7.3 Each package shall be properly labelled to indicate the type and quantity of material it contains along with the Purchase Order number, dimensions and any other necessary data to identify the equipment and relate it to the Purchase Order. The supplier shall not ship the equipment without prior approval of the purchaser’s representative and subsequent written instructions to do so.

8.0 Installation, testing and commissioning: 8.1 Installation at site: 8.1.1 Sandwich Bus duct system shall be installed as per the recommendation of the manufacturer. The busbar chamber should not have any access left open to prevent entry of insects inside it. The supplier shall depute their specialist at site during the installation, testing and commissioning period for attending the related issues etc. 8.1.2 Starting from activities of transport of the material within the site at RRCAT, supplier shall arrange all the required material, handling equipments and requisite manpower to carry out the installation work at site. 8.1.3 The installation of the Busducts has to be carried out with necessary rising mains, straight length, bends, joints, expansion joints, offset, flanges, flexible lengths, overlapped jointing arrangement with indication of proper pressure during tightening, thrust pads, spring hangers, flexible tinned copper links at terminations, flexible rubber bellow and adopter box on flange terminations at transformer side, universal fixing brackets, supporting system, which are generated from ground/ External wall of the Indus Substation Building considering the factors of ease of maintenance & replacement of particular section etc. The Supporting and either side termination system drawings shall be submitted for the approval of RRCAT before execution. 8.1.4 The building is ready for the subject system. The bidders are advised to visit the site


with prior intimation for appropriate planning. The Storage at site may be appropriately planned.

8.2 Testing and Commissioning: All the routine tests shall be repeated at site after the completion of Installation of Sandwich Busduct System including HV test, Insulation resistance and mill volt – drop as per relevant IEC/IS and a report shall be submitted for approval of RRCAT. The endurance test for 96 hours with available load/rated load shall be considered as part of commissioning. The supplier shall arrange all the required manpower, equipments etc. to carry out the testing and commissioning work at site.

9.0 Commercial Terms & conditions: The supplier shall strictly adhere to the completion schedule for supply, installation & commissioning. The Bus duct shall be guaranteed for a period of minimum 2 (Two) years from the date of acceptance after commissioning.

10.0 Documentation: 10.1 With Bid: (a) Copies of experience certificate for the similar work executed. (b) Copy of OEM authorisation certificate in case bidder is authorised system integrator. (c) Detailed catalogues and drawings for regular and expansion joints. (d) Original Catalogues and literature for offered items. (e) List of installations completed in last five years along with their completion certificate. (f) Type Test reports for offered items, including following tests: (i) Heat run test. (ii) Ingress Protection (IP). (iii) Impulse voltage withstand test. (iv) Short-circuit withstand test. (g) Detailed supporting calculations for offered items for the followings: (i) Heat loss & Temperature rise. (ii) Sizing of busbars and insulation system rated for continuous current and fault current (50kA) for one second.

10.2 Before manufacturing for approval of RRCAT: Detailed bus duct drawings along with end terminations, supporting structure and bill of material. 10.3 On supply of material: Three (03) sets of proposed layout-drawings, test reports, technical catalogues, installation instructions, O&M instructions, guarantee certificate & compliance report etc. 10.4 After completion: (a) 6 sets of instruction bound manuals to be submitted by the supplier containing asbuilt drawings, inspection & test reports, technical catalogues & test certificates, O&M instructions, installation instructions, guarantee certificate & compliance report etc.


(b) One softcopy of the above mentioned (refer (a)) documents.

11.0 Completion Period: The bidder shall quote for minimum completion period. In this regard, a detailed bar chart shall be submitted by the bidder for manufacturing, testing at works, transportation, delivery at site, and installation, testing & commissioning at site. Expected completion schedule for the total work is around 04 (Four) months.

12.0

Performance Bank Guarantee: The supplier shall furnish a bank guarantee towards performance of the equipment valid till the offered guarantee period of 2 years.

13.0 List of Preferred Makes: Item Aluminium Sandwich Bus Duct System

Make Henikwon/ Schneider

Note: 1. Alternate makes shall also be acceptable subject to compliance with tender specifications. 2. The offered system shall be strictly complying with th e tender specifications. 3. Item not covered above, but required for the work shall be of reputed makes subject to approval of RRCAT.


TECHNICAL DATA SHEET 1.

DESIGN PARTICULARS

1.1

Type of Bus Duct

1.2

Type of construction

1.3 1.4 1.5 1.6 1.7 1.8

Ingress protection Supply frequency Type of Cooling Installation Nominal Service Voltage - in Volts Continuous Current Rating of Bus Ducts under Site Conditions - Amps One minute Power Frequency Withstand Voltage Short Time Current Rating for one second - kA (RMS) Maximum Temperature rise of Busbars at Rated Current over and above an ambient of 40°C Busbar Material

1.9 1.10 1.11

1.12 1.13 1.14 2.0 2.1

Busduct Enclosure Material Thickness of epoxy powder coating over enclosure BUS DUCTS TENTATIVE LENGTH Bus Duct - length in mtrs.

2.2 2.3

90° Bend No. of Terminations

3.0

GENERAL

3.1

External Earthing Conductor

3.2 3.3

Canopy material and thickness Canopy and supports protection against corrosion

COMPACT BUSDUCT WITH SANDWICH BUSBARS Sandwich epoxy resin / mica polyester insulated type busduct. IP 65 50 Hz Natural Air Cooled Outdoor 415±10% 3200A 5 kV (rms) 50 o

55 C

EC grade Aluminium GI/Aluminium Minimum 50 micron

Refer Tender drawing RRCAT/E/0421/R-0

2runs of 50X8mm Aluminium CRCA and 2mm thick Polyurethane painted

No.


Section-B 1.0 Schedule of Prices: Note: 1. The bidders may visit the site for final estimation of required length, bends, joints and supports etc. for the bus duct. The prior permission of Chief Engineer, RRCAT (Fax No. 07312488866 or email ID [email protected].) is mandatory for the site visit. 2. Bidders are requested to quote the prices in foreign currency/Indian Rupees (as applicable) with complete details of taxes and duties as applicable. S.No.

1.0

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

Description

Design/ Engineering, fabrication, Assembly, Testing at works, supply, erection, testing and commissioning at site of continuous duty, three phase, four wire, 3200A, 415V; 50Hz; Outdoor type Aluminium Conductor sandwich bus duct having GI/Aluminium enclosure (IP65) and class F insulation along with required MS fabrication/mountings supports and other accessories as per specifications. From transformer No. 01 to PCS Incoming Panel From transformer No. 04 to PCS Incoming Panel From transformer No. 05 to PCS Incoming Panel From transformer No. 07 to PCS Incoming Panel From PCS output Panel to PCC-3 in Indus substation From PCS output Panel to PCC-2 in Indus substation From PCS output Panel to PCC-1 in Indus substation From PCS output Panel to PCC-4 in Indus substation Spares price as per the spares list

Qty.

Supply Rate

Taxes & Duties

Erection, Testing & Commissioning Rate

Taxes & Duties

Amount

PRICES NOT TO 01 set 01 set

BE FILLED

01 set

IN

01 set

PART-1

01 set 01 set 01 set 01 set

Signature & Seal of the Bidder


2.0 Schedule of Spares: The bidder shall submit the spares list as mentioned in scope of work (4.3). S.No.

Description

Qty.

Supply Rate PRICES NOT TO BE FILLED IN PART-1

Amount PRICES NOT TO BE FILLED IN PART-1

The final spares list/quantity shall be on the purchaser discretion.


3.0 Completion Schedule: The bidder shall submit the completion schedule along with the offer. After placement of order, duration required for each activity should be mentioned separately as per the format given below. S.No.

1.0 2.0 3.0 4.0 5.0 6.0

Activity

Duration

Design and Engineering Fabrication Assembly and Testing at Works Supply at site Installation at site Testing and Commissioning



4.0 Schedule of deviations: There are no deviations in the specification of the offered item(s) except for the following. S.No.

Tender Specification Para/Point No.

Deviation detail

Remarks/Justification



Annexure-1 GUARANTEED TECHNICAL PARTICULARS (GTP) The Bidder should compulsorily fill the Guaranteed Technical particulars. (To be furnished with the Part-I Technical offer)

Sandwich Bus duct System: S. No. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Description (Generals): Make & Model Experience of OEM in the model offered Whether the bidder is Authorised System Integrator In case of Authorised System Integrator Authorisation certificate from OEM is enclosed Experience of the bidder Manufacturing certification (ISO9001etc.) Service Conditions: Average ambient air temperature Maximum ambient air temperature Relative humidity not exceeding Maximum altitude without derating Ingress Protection class

1.8

Compliance to Standards

1.9 1.10

Mounting position Rated current

1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 2.0 2.1 2.2

Momentary Current Rating - kA (Peak) Rated Insulation voltage(Ui) Rated Operating voltage(Ue) Standard Impulse (1.2/50µ sec.) voltage(Uimp) withstand capacity Rated frequency Weight of the assembly per metre Short circuit withstand capacity Perm. suspension distances of Trunking units Approximate expansion from no load to full load at maximum ambient temperature. Minimum recommended clearance between bus ducts, wall, floor and others Conductor: No. of active conductors and cross-section area For each phase and neutral. Name of Conductor Material Purity grade Conductivity

2.3

Bare earth conductor material and size

2.4

Any special coating on conductor / at joints

Details

( Yes/No

) years

Yes/No (

) years

( )°C ( )°C ( )% NonCondensing ( )mtrs. IP( ) IEC( ) IS( ) Vertical/Flat ( )A ( ( ( ( ( ( ( ( (

)V )V )kV )Hz )kg. )kA/ for 1sec. )mtr. )mm/m/°C )mm

…….Numbers, 2 …….mm ………………, ..…………..,and …………mho/m ………….., and ………..mm x mm


S. No. 2.5 2.6 2.7 2.8 3.0 3.1 3.2 3.3 3.4 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 6.0 6.1 7.0 7.1 7.2 8.0 8.1 8.2 8.3 8.4 9.0 9.1 9.2 9.3 10.0 10.1 10.2 10.3

Description Average resistance and reactance per conductor at rated current (Amb. Temp. 40° C) Maximum hot spot temperature rise above Maximum ambient temperature of 48oC Maximum Voltage drop per mtr. (At 0.8 p.f.) at rated current. Maximum Voltage drop per joint at rated current. Insulation: Class of insulation Name of Insulating material and its thickness Dielectric Strength Compressive Strength Enclosure: Material thickness Surface treatment process Painting process Joints: Number of bolts per joint Insulating material over bolt and its Insulation strength Lock nut provided for tightening Expansion joint: Recommended interval length for Expansion joint End Flange: Conductors clearance Terminals Length Supports for bus duct: Supporting interval for horizontal run Spring, hangers etc. included for vertical risers MS angle/brackets included Polyurethane coated MS sheet work: Material for canopy and thickness Material for adopter boxes and thickness Polyurethane coated Flexible Tinned copper links: Cross-section of link Current Carrying Capacity Resistivity of material

Details ………Ohm/m, ………Ohm/m. ( )°C (

)mV and (

)mV

, ……....mm. )kV/mm

(

.........,mm

Yes/No (

)mtr.

( (

)mm )mm

(

) mtr. Yes/No Yes/No Yes/No

, ……..mm , ……..mm Yes/No ( ( (

)mm2 )A ) Ohm-m


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Bus Duct Technical Specifications

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