Tech Spec (Switchyard-ntpc)PDF

NTPC Limited (A Government of India Enterprise)

TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4X130 MW)

400 KV SWITCHYARD PACKAGE TECHNICAL SPECIFICATION SECTION - VI (PART- A, B, C, D & F) BIDDING DOCUMENT NO. CS-5505-500-2 CONSULTANT : Central Electricity Authority Sewa Bhawan, R.K. Puram, New Delhi-110066

AUGUST - 2007

CONTENTS

TECHNICAL SPECIFICATION SECTION-VI -----------------------------------------------------------------------------------------------------------------------------------SUB-SECTION DESCRIPTION ------------------------------------------------------------------------------------------------------------------------------------

PART - A SUB-SECTION-I

INTENT OF SPECIFICATION

SUB-SECTION-II

PROJECT INFORMATION

SUB-SECTION-III

SCOPE OF SUPPLY AND SERVICES

SUB-SECTION-IV

TERMINAL POINTS & EXCLUSIONS

SUB-SECTION-V

SPARES

SUB-SECTION-VI

SUB QR

PART-B CHAPTER-E:0

SWITCHYARD ELECTRICAL GENERAL

CHAPTER-E:1

GAS INSULATED SWITCHGEAR

CHAPTER-E:2

ISOLATORS (AIS)

CHAPTER-E:3

INSTRUMENT TRANSFORMERS (AIS)

CHAPTER-E:4

SURGE ARRESTORS (AIS)

CHAPTER-E:5

POST INSULATOR (AIS)

CHAPTER-E:6

WAVE TRAP (AIS)

CHAPTER-E:7

LIGHTING (COMMON)

CHAPTER-E:8

LT SWITCHGEAR & DBs (COMMON)

CHAPTER-E:9

LT POWER AND CONTROL CABLES (COMMON)

CHAPTER-E:10

SUBSTATION AUTOMATION SYSTEM (COMMON)

TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2

TECHNICAL SPECIFICATION SECTION-VI

CONTENTS

PAGE 1 OF 2

CONTENTS -----------------------------------------------------------------------------------------------------------------------------------SUB-SECTION DESCRIPTION ------------------------------------------------------------------------------------------------------------------------------------

CHAPTER-E:11

DC BATTERY AND BATTERY CHARGER (COMMON)

CHAPTER-E:12

REQUIREMENTS OF AUXILIARY ITEMS (AIS)

CHAPTER-E:13

INSTALLATION (COMMON)

CHAPTER-E:14

SITE TESTING AND COMMISSIONING (COMMON)

CHAPTER-C:0

TECHNICAL SPECIFICATION – CIVIL WORKS

PART – C

GENERAL TECHNICAL REQUIREMENTS (GTR)

PART – D

ERECTION CONDITIONS OF CONTRACT

PART – F

MANDATORY SPARES



CONTENTS

PAGE 2 OF 2

PART-A



CONTENTS

TECHNICAL SPECIFICATION PART-A -----------------------------------------------------------------------------------------------------------------------------------SUB-SECTION DESCRIPTION ------------------------------------------------------------------------------------------------------------------------------------

SUB-SECTION-I


SUB-SECTION-II

PROJECT INFORMATION

SUB-SECTION-III


SUB-SECTION-IV


SUB-SECTION-V

SPARES

SUB-SECTION-VI

SUB QR



PART-A

PAGE 1 OF 1

PART-A SUB-SECTION-I INTENT OF SPECIFICATION



CLAUSE NO.


1.00.00


1.01.00

Scope of the proposal This specification intends to cover the following activities, services and works in respect of 400 KV Switchyard consisting of Gas insulated switchgear, Air Insulated Switchgear (Pothead switchyard) of Tapovan Vishnugad HEPP, Detailed scope of work under this package is listed in Sub section-III of Part-A.

Complete design and engineering of all the systems, sub-systems, equipment, materials and services.

Providing engineering data, design calculations ,drawings and Erection & O&M manuals for Employer’s review, approval and records.

Packing and transportation from the manufacturer’s works to the site including insurance, customs clearance & port clearance, port charges, if any.

Receipt, storage, insurance, preservation and conservation of equipment at the site.

All civil works of pothead yard as required.

Fabrication, pre-assembly (if any), erection, testing and putting into satisfactory operation of all the equipment/material including successful commissioning.

Furnishing of spares on FOR site basis.

Reconciliation with customs authorities, in case of foreign supplies.

Satisfactory conclusion of the contract.

1.02.00

The requirements, conditions, appendices etc. given in Technical Specifications (Section-VI, Parts A, B, C, D, E and F) shall apply to and shall be considered as a part of this volume as completely as if bound herewith.

1.03.00

The Contractor shall be responsible for providing all material, equipment and services specified or otherwise which are required to fulfill the intent of ensuring operability, maintainability and the reliability of the complete work covered under this specification.

1.04.00

It is not the intent to specify all aspects of design and construction of equipment mentioned herein. The systems, sub-systems and equipment shall conform in all respect to high standards of engineering, design and workmanship, and shall be capable of performing in continuous commercial operation in a manner acceptable to the Employer, who will interpret the meaning of the specification and drawings and shall have a right to reject or accept any work or material which, in his assessment, is not complete to meet the requirements of this specification and/or applicable to Indian/ International standards mentioned elsewhere in this specification.



PART-A SUB-SECTION-I

PAGE 1 OF 3

CLAUSE NO.


1.05.00

Whenever a material or article is specified or described by the name of a particular brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and quality desired. Products of other manufacturers may also be considered, provided sufficient information is furnished so as to enable the Employer to determine that the products are equivalent to those named.

1.06.00

Contractor is requested to carefully examine and understand the specifications and seek clarifications, if required, to ensure that they have understood the specifications. Such clarifications should be sought within the time period as stipulated in section ITB. Bidder’s offer should not carry any sections like clarifications, interpretations and/or assumptions. The bid should not include any sections like clarifications, interpretations and/or assumptions. If the Contractor feels that, in his opinion, certain features brought out in his offer are superior to what has been specified, these may be highlighted separately.

1.07.00

The Contractor may also make alternative offers provided such offers are superior in his opinion, in which case adequate technical information, operational feed back, etc., shall be submitted with the offer to enable the Employer to assess the superiority and reliability of the alternative offered. For each alternative offer, its implications on the performance, auxiliary power consumption, etc. shall be clearly brought out in the bid for the Employer to make an overall assessment. In any case, the base offer shall necessarily be in line with specifications. Under no circumstances the specified equipment etc., shall be brought out as an alternative.

1.08.00

Any deviation or variation from the scope requirement and/or intent of this specification shall be clearly mentioned under Deviation Schedule of the Bid Proposal Sheets irrespective of the fact that such deviations/variations may be standard practice or a possible interpretation of the specification by the Contractor. Except for the deviations/variations which are accepted by the Employer before the award of the contract, it will be the responsibility of the Contractor to fully meet the intent and the requirements of the specification within the quoted price. No other departure from the specification except for the declared deviation indicated by the Contractor in his proposal shall be considered. The interpretation of the Employer in respect of the scope, details and services to be performed by the Contractor shall be binding, unless specifically clarified otherwise by the Employer in writing before the award of contract.

1.09.00

The drawings enclosed as per list at Part-E to this section and forming a part of the specification shall supplement the requirements specified herein. The scope and terminal points for the equipment to be furnished under this contract are also identified in these drawings and are to be read in conjunction with the text of the specifications. These are preliminary drawings for bidding purpose only and are subject to changes that may be necessary during detailed engineering after award keeping the basic parameters as specified.

1.10.00

Failure of any equipment to meet the specified requirement of test carried out at works or at site shall be sufficient cause for rejection of the equipment. Rejection of any equipment will not be held as a valid reason for delay in the completion of the works as per schedule. Contractor shall be responsible for removing all deficiencies and supplying the equipment that meet the requirement.




PAGE 2 OF 3

CLAUSE NO.

1.11.00

INTENT OF SPECIFICATION LIST OF TENDER DRAWINGS The list of drawings enclosed with these specifications as Part - E is detailed below: Sl No

NTPC Drawing no.

Title

1.

5505-500-PEH-A-001

General Project layout

2.

5505-500-PEH-A-002

Project Location Map and Accessibility

3.

5505-500-PEH-A-003

General Layout plan of Power House

4.

5505-500-PEH-A-004

Power House Cross - Section.

5.

5505-500-PEH-A-005

Power House Layout Plan at EL1289.0m.

6.

5505-500-PEH-A-006

Single Line Diagram of 400 KV GIS/AIS Switchyard.

7.

5505-500-PEH-A-007

400KV Switchyard Protection SLD – Line bay

8.

5505-500-PEH-A-008

400KV Switchyard – Bus Coupler Bay

9.

5505-500-PEH-A-009

400KV Switchyard Protection SLD – GT bay

10.

5505-500-PEH-A-010

400KV Switchyard Relay & protection room layout

11.

5505-500-PEH-A-011

Protection Single line Diagram for Hydro Generator, GT, SAT and UAT

12.

5505-500-PEH-A-012

GIS Layout Plan at EL 1300.00m.

13.

5505-500-PEH-A-013

Pothead Yard Layout Plan & Sections



Protection


SLD

PAGE 3 OF 3

PART-A SUB-SECTION-II PROJECT INFORMATION



CLAUSE NO.

PROJECT INFORMATION

1.00.00

GENERAL FEATURES OF THE PROJECT

1.01.00

General Tapovan Vishnugad HE Power Project is a run of the river scheme on Dhauliganga river in Chamoli district of Uttaranchal state. The project envisages utilizing a design head of 483 M. The scheme involves construction of barrage across the river Dhauliganga, located near Tapovan and Bhangual Village at the suspension bridge leading to Bhangual village, HRT of 5.60 M in diameter and 11.710 KM long , Tail Race Tunnel of 513M long and an underground power house. The installed capacity of the project is 520MW (4x130MW) with annual generation at 90% dependability 2418.21 GWh.

1.02.00

Hydraulic and Civil features The Tapovan Vishnugad Hydro Electric Power Project is located on Dhauliganga river is developed as a run of river scheme by constructing a barrage with 11.710 km long head race tunnel of horse shoe type having a diameter of 5.60 m to carry out a design discharge/velocity of 122.18 cumecs/4.93 m/sec , restricted orifice type surge tank having 13.5M dia with a height of 148.2 M, 2 nos of 3.6 m dia pressure shaft each with a length of about 586.14 m , each of which is near the power house bifurcates into 4 penstocks, each having a diameter of 2.6m and lengths of 46.768 m, 28.172 m, 38.596 m and 46.768 m to feed each unit of 130MW capacity operating at a design head of 483 M, The general layout of the scheme is indicated in the enclosed drawing number 5505-500-PEH-A-001 “ Project Layout” and Project location shown in the drawing number 5505-500-PEH-A-002 “ Titled “ Project location Map and Accessibility”

2.00.00

SYSTEM DETAILS

2.01.00

The synchronous generators are proposed to be connected with isolated phase bus ducts to Single phase Generator Transformer with Voltage ratio of 13.8 KV /420/√3 KV located down stream of power house in a separate cavern. The HV terminals of Generator Transformers shall be connected with the 400KV GIS located on a separate floor above the transformer bay. The connection between 400KV GIS and 400KV pothead yard shall be through 400KV XLPE cables. The outgoing feeders from the pot-head yard shall be further connected to 400KV substation at Kuwari pass substation and power will be transmitted to Muzaffarnagar.

2.02.00

The power supply for unit auxiliaries is proposed to be obtained from dry type transformer with HV side voltage of 13.8 KV/0.415KV, 3 phase, 630 KVA unit auxiliary transformer. The arrangement of black start of the generating units & emergency supply to feed the unit auxiliaries and station auxiliaries is shown in the enclosed drawing Drg.No.5505-500-PEH-A-006 Single line diagram of the project.

3.00.00

CLIMATIC CONDITIONS The barrage of the project is situated at an altitude of about 1803.5 M. The Power House service bay floor is located at EL 1289.00 m & the tail water level is fixed at EL 1268.00m. The climatic conditions are given below:



PART-A SUB-SECTION-II

PAGE 1 OF 3

CLAUSE NO.

4.00.00

PROJECT INFORMATION i)

Maximum temperature of air in summer

:

27o C

ii)

Maximum temperature of air in winter

:

20C

iii)

Minimum temperature of air in winter

:

Sub zero

iv)

Maximum Relative humidity

:

>70 %

v)

Minimum Relative humidity

:

<35 %

vi)

Average rain fall per year

:

1625 mm

vii)

Thunderstorms

:

Throughout the year

viii)

Average Yield

:

3797 M cum

ix)

Maximum/ Minimum yield

:

11196/ 2262 M cum

SEISMIC FORCES The equipment shall be designed to withstand seismic forces. Uttaranchal State comes under Seismic Zones V and IV of Seismic Zoning Map of India, which correspond to Zone Factors of 0.36 and 0.24 (effective peak ground acceleration in terms of g) of seismic intensities VIII and >IX (MSK-64 scale), respectively (IS 1893,2002).

5.00.00

HIGH ALTITUDE CORRECTION FACTOR All equipment shall be suitably designed and treated for normal life & satisfactory operation under high altitude conditions prevalent at the site. All electrical auxiliary equipment shall be specially treated with High altitude correction factor and the materials and method for this treatment shall be got approved in advance. The equipment and each part of it shall be strong enough and sufficiently well connected to resist total operating stresses, including any stresses resulting from an earthquake in any horizontal direction. Electrical clearances adopted due to high attitude need to be justified with supporting calculations and got approved from the Employer.

6.00.00

TRANSPORTATION

6.01.00

Location and Access Tapovan Vishnugad H.E. Project is located on Dhauliganga river in the Chamoli District of Uttaranchal State. The nearest Railway head of the project is Rishikesh. which is around 280 KM away. The nearest Airport is at Dehradun and the approach/access road to project is on National Highway 58/58A. The main project components can be accessed from the right bank through the National highway serving through a road of 12km away from Joshimath from the highway serving Chamoli-Joshimath-Tapovan.




PAGE 2 OF 3

CLAUSE NO.

6.02.00

PROJECT INFORMATION Transport Limitations The weights and dimension of the packages for transportation to site shall be limited to the following:a)

Max. Weight of the package not to exceed 70 M.Tonnes

b)

Max. Size of the package not to exceed Length = 8500 mm, Width= 3000 mm, and Height= 3000 mm.

The above information is tentative and it is the contractor’s responsibility to verify the actual transport limitation. 7.00.00

BIDDER TO INFORM HIMSELF The Bidder shall make independent/their own investigations about the conditions and circumstances affecting his tender estimates and about the possibility of executing the works as described. During the evaluation of tenders, it shall be presumed that the Bidder have inspected and examined the site and its surroundings and to have satisfied themselves about the form and nature of the site, the quantities and materials necessary for the completion of the work and the means of transport and access to site, the requirements of accommodation, general labor position at the site and have quoted their prices after taking into account, the risks, contingencies and other circumstances which may influence or affect the execution of the Contract. Access to the site shall be allowed, to the prospective bidder(s) by prior appointment with the Employer.




PAGE 3 OF 3

PART-A SUB-SECTION-III SCOPE OF SUPPLY AND SERVICES



CLAUSE NO.


1.00.00


1.01.00

The scope of work for 400 KV switchyard at Tapovan Vishnugad HEPP shall comprise but not limited to the design, engineering., manufacture, testing and inspection at manufacture’s works, packing., supply, transportation, insurance, delivery to site, unloading and handling at site, storage and preservation at site store, transportation to place of installations, complete work of site assembly, erection, testing at site and commissioning of 420 KV SF6 Gas Insulated Switchgears (GIS), Air Insulated switchgears (Pothead Switchyard) and equipment erection including associated civil works of pothead yard and structural works. Further it shall include the cabling, lighting, lightning protection, earthing, association of subvendors in the erection, supervision, site testing, inspection and commissioning of 400 KV switchyard. Any other equipment not explicitly mentioned herein or in the Technical specifications and drawings but are necessary for completeness of works specified shall also deemed to be included in the scope. The equipment shall be suitable for climatic conditions as indicated elsewhere in specifications. The supplier shall provide all the materials, labour, supervisory staff, plant, equipment & machinery and services necessary for accomplishing the work.

1.02.00

Scope of supply of the Bidder includes mandatory spares, start-up and commissioning spares and recommended spares. The general requirements of the mandatory spares are detailed in Part - F of Section-VI.

1.03.00

The scope of the bidder includes all shop tests, site tests, routine tests etc., fulfilment of complete quality assurance & inspection requirements and related activities for all the equipment & systems covered under the scope of work of bidder as per the stipulations of Technical Specifications.

1.04.00

Bay Details are as follows: Gas Insulated Switchgear •

Generator Transformer bays

:

4 nos

•

Line bays

:

2 no

•

Bus Coupler bay

:

1 no

:

2 nos

Air Insulated Switchgear • 1.05.00

Line bays

The equipment and materials to be supplied by the Contractor shall form a complete 400 KV switchyard including GIS & AIS. The equipment and services as detailed in all sections of the bidding documents and as shown on the tender drawings shall be within the scope of supply of the Contractor. Any items though not specifically mentioned but which are required to make the switchyard complete in all respects for its safe, efficient, reliable and trouble free



PART-A SUB-SECTION-III

PAGE 1 OF 9

CLAUSE NO.

SCOPE OF SUPPLY AND SERVICES operation shall also be deemed to be included and the same shall be supplied and erected by the Contractor, unless they are specifically excluded in the text of exclusions given in sub section –IV of Part-A. -

400KV GIS equipments: 3 - single phase (isolated), SF6 gas insulated, metal-enclosed busbars, Circuit Breakers, disconnectors, safety Ground Switches, High Speed fault making ground switches, Current transformers, Voltage transformers, surge arresters, Local bay control cabinet, SF6 gas monitoring equipments, maintenance equipments etc.

-

400KV AIS equipments: Disconnectors with earth switches, Current transformers, capacitor voltage transformers, surge arresters, Post insulators and wave traps.

-

Flexible Conductors (Quad moose ACSR conductor with 450mm spacing to be used for pothead switchyard for all connections)

-

10.98 dia G.S. Earthwire

-

Insulators and hardware

-

Clamps, connectors and spacers

-

48V DC Battery & battery charger (40A float cum boost battery chargers. Minimum rating 400AH for Plante type or 200AH for Ni Cd battery type)

-

Bay Marshalling kiosks

-

LT Switchgears

-

Lighting Panels

-

Contractor shall make earth resistivity measurements at pothead yard & GIS site (based on four electrode method) and design the earthing grid as per IEEE: 80 (Latest edition) and connect the earthing grid with power house earthing grid. The earthing mat for the switchyard shall be individually designed before connection with PH earthing grid.

-

Earthing of all equipments (inclusive of supply of 40mm dia MS rod and GI flat).

-

Complete Direct Stroke Lightning Protection .

-

Power & Control cables, cabling (including interpole and interpanel), cable supports, cable trays and accessories etc. necessary for cable erection such as glands, lugs, clamps for cables, ferrules, cable ties, GI pipes etc. Cable route markers for buried cable trench are also included in the scope.

-

AC supply - auxiliary power for GIS, AIS and Protection system. The cables from Station Service Boards in the power house to AC distribution boards are also included in the scope of switchyard Contractor.

-

Power & Control cable schedules & termination schedules shall be prepared by the Contractor and approved by Employer.




PAGE 2 OF 9

CLAUSE NO.

1.06.00

SCOPE OF SUPPLY AND SERVICES -

Substation Automation System, Generator Relay Protection and metering system including disturbance recorders, fault locators, event loggers and GPS Time Synchronisation Equipment.

-

Phase markers, Danger Plates, Bay identification plates

-

The termination of the outgoing lines in pothead yard area on to the takeoff gantry including supply of insulators, strings and hardware on line side shall be done by line contractor. The connection to the line side equipments including supplying clamps, insulator string, connectors are under the scope of the switchyard contractor.

-

Civil works for the pothead switchyard

-

Inserts, embedments etc. as required for the system

SERVICES AND ITEMS The scope also includes but not limited to the following services/items described herein and elsewhere in specification:

1.07.00

-

System design and engineering

-

Supply of equipment and material

-

Civil works

-

Structural works

-

Erection works

-

Project management and site supervision

-

Testing and commissioning

-

Interface coordination

-

Performance testing

-

Clearances from statutory authorities.

System Design and Engineering The Contractor shall be responsible for detailed design and engineering of overall system, sub-systems, elements, system facilities, equipments, auxiliary services, etc. It shall include proper definition and execution of all interfaces with systems, equipment, material and services of Employer for proper and correct design, performance and operation of the system. -

Contractor shall provide complete engineering data, drawings, reports, manuals, etc. for Employer’s review, approval and records.




PAGE 3 OF 9

CLAUSE NO.

1.08.00

SCOPE OF SUPPLY AND SERVICES -

The scope shall also include the design and engineering as per details elaborated elsewhere in this specification.

-

The Contractor shall carry out earth resistivity measurements at switchyard site (based on four electrode method).

-

Relay setting calculations shall be submitted by the Contractor and approved by Employer.

-

For all civil works of pothead yard and structural works, the Contractor shall carry out design calculations, prepare all the detailed construction and fabrication drawings.

-

The details of 400 KV XLPE cable and Generator Transformer shall be intimated to the successful bidder for consideration with GIS/AIS termination during detail Engineering.

the

Civil & Structural Works ( for pothead yard) The scope of civil works shall include design & construction of all Civil works of pothead yard & Structural works including supply of all materials, complete for all equipment and Gantry Structures for the Switchyard package. The nature of work generally involves detailed Geotechnical investigation for various facilities, earthwork in excavation and filling in all types of soils, dressing to the required profile, dewatering till the structures are constructed/erected upto required level or as directed by the engineer, shoring, backfilling around completed structures and plinth filling, disposal of surplus earth, concreting including reinforcement and formwork, fabrication, galvanising, Proto-assembly & erection of Gantry Structure & Equipment supporting structure, fabrication and erection of all structural steel and miscellaneous steel ( i.e., cable tray supports, galvanised foundation bolts etc.), breaking of concrete/ brickwork/ roads and removal of sheet piling, precast covers, RCC cable trenches, cable ducts/duct banks, soil sterlisation/anti - weed treatment, drainage, fencing, gravel filling, final grading and site clearance before handing over and other auxiliary items of work etc. All material including cement, reinforcement steel, structural steel required for completion of the work covered in the Technical specification shall be within the scope of the Contractor. The scope of work described below is general in nature. The Contractor shall provide all structures / facilities required for the effective functioning of switchyard of the power plant, whether or not they are specifically mentioned. The scope of Contractor for Civil & Structural works shall include but not limited to the following : a)

Detailed Geotechnical investigation of soil as required, classification of soil, measurement of soil resistivity for various facilities.

b)

Detailed design criteria including basis of design shall be prepared by the Contractor based on various requirements specified elsewhere in the specifications. All the above documents shall be finalised after Employer’s approval and the same shall form the basis of Detailed Engineering Work.




PAGE 4 OF 9

CLAUSE NO.

1.09.00

SCOPE OF SUPPLY AND SERVICES c)

Civil & structural works associated with switchyard gantry structure etc

d)

Civil & structural works associated with switchyard equipment supporting structure as required.

e)

Civil and structural works associated with Cable trenches from individual bays and to Employer’s terminal point including cable trench for power & control cables upto cable and ventilation tunnel.

f)

Site Preparation, soil sterilisation/antiweed treatment including gravel filling but excluding major levelling.

g)

Complete fencing along with gates for the switchyard.

h)

Any other facility/structure that would be required as per system requirements.

i)

All protection measures to prevent any damage to the adjoining structures / facilities.

j)

Scope of the Contractor shall also include supply and laying of 40mm dia MS Rods alongwith other earthing materials as required to complete the earthing system.

Erection Works The Contractor shall construct, erect and install all equipment and material of switchyard covered under the contract. He shall be responsible for provision of all labour, tools and plant, and supervisory staff for safe, reliable, proper and correct erection of the components. The tools and plant shall include, but not limited to, special hoisting equipment, cranes, stringing equipment, slings, consumables and all other articles and supplies as required. The Contractor shall ensure periodic cleaning of work sites and removal of all waste material, packing material, surplus earth and left-overs and their proper disposal.

1.10.00

Project Management and Site Supervision The Contractor shall be responsible for the overall management and supervision of works. He shall provide experienced, skilled, knowledgeable and competent personnel for all phases of the contract, so as to provide the Employer with a high quality system. The Contractor shall be responsible for adequate training of Employer’s operation and maintenance personnel as to be able to operate & maintain the equipments and its components properly, safely and efficiently over long period of time. The Contractor’s supervisory personnel shall provide operation and maintenance assistance during the warranty period.




PAGE 5 OF 9

CLAUSE NO.

SCOPE OF SUPPLY AND SERVICES A project execution schedule called Master Network (MNW) in the form of PERT chart/network and based on `Work break down structure’ shall be prepared by the Contractor for Employer’s approval. The MNW shall identify milestones of key events for each work/component in the areas of engineering, procurement, manufacture, despatch, erection and commissioning.

1.11.00

Interface Coordination The Contractor shall identify all interface issues with Employer and other agencies, and shall be responsible for such interfacing, coordination and exchange of all necessary information. The Contractor shall submit to the Employer all drawings for review. He shall list the detailed requirements of interface between Contractor’s work and the material and services to be supplied by Employer.

1.12.00

Facilities to be provided by the Employer and the Contractor Please refer clause no 14.00.00 and 15.00.00 of Part-D, Erection Conditions of Contract

1.13.00

ARRANGEMENT BY THE CONTRACTOR Contractor shall make his own necessary arrangements for the following and for those not listed anywhere else: •

Distribution/extension of the construction power supply at all work areas

•

Further distribution of construction water.

•

Construction office and store (open & covered)

•

Construction workshop and material/field testing laboratory

•

Boarding & lodging arrangement for their personnel. i.e contractor’s personnel

•

Fire protection and security arrangements during construction stage

•

Suitable and adequate land/space & power supply for office, storage area, pre-assembly and fabrication areas, labour and staff colony area, toilets etc.

1.14.00

TYPE TESTS

1.14.01

For AIS

1.14.01.01

All equipments to be supplied shall be of type tested quality. The contractor shall submit for Employers approval the reports of all the type tests as listed as per relevant standard and carried out within last five years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a Client.




PAGE 6 OF 9

CLAUSE NO.


1.14.01.02

In case the contractor is not able to submit report of the type test(s) conducted within last five years from the date of bid opening or in case the type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract free of cost to the Employer and submit the reports for approval.

1.14.02

For GIS

1.14.02.01

The Contractor shall carry out the type tests as listed in this specification on the equipment to be supplied under this contract. The Bidder shall indicate the charges for each of these type tests separately in the relevant schedule of BPS and the same shall be considered for the evaluation of bids. The type test charges shall be paid only for the test(s) actually conducted successfully under the contract and upon certification by the Employer's engineer.

1.14.02.02

The type tests shall be carried out in the presence of the Employer's representative, for which minimum 30 days notice shall be given by the Contractor. The Contractor shall obtain the Employer's approval for the type test procedure before conducting the type test. The type test procedure shall clearly specify the test set up, instrument to be used, procedure, acceptance norms, recording of various parameters, interval of recording, precautions to be taken etc. for the type test(s) to be carried out.

1.14.02.03

In case the Contractor has conducted such specified type test(s) according to the relevant standard and/or specification within last five years as on date of bid opening, he may submit the type test reports to the Employer for waival of conductance of such type test(s). These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a Client. The Employer reserves the right to waive conducting of any or all the specified type tests(s) under this contract. In case the type tests are waived, the type test charges shall not be payable to the Contractor.

1.14.03

Common requirements

1.14.03.01

The Employer will have the right of getting any test of reasonable nature carried out on any component or completely assembled equipment at Contractor’s premises or at site or in any other place in addition to the aforesaid type and routine tests, to satisfy that the materials/equipment comply with the specification.

1.14.03.02

1.14.03.03

Failure of any equipment to meet the specified requirements of tests carried out at works or at site shall be sufficient cause for rejection of the equipment. Rejection of any equipment will not be held as a valid reason for delay in the completion of the works as per schedule. Contractor shall be responsible for removing all deficiencies, and supplying the equipment that meet the requirement All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price.




PAGE 7 OF 9

CLAUSE NO.

1.15.00

SCOPE OF SUPPLY AND SERVICES Pre-commissioning and Commissioning Activities The bidder's scope shall include all pre-commissioning and commissioning activities, materials and services as detailed in clause no. 21.00.00 of Part-D of Technical Specifications (Erection Conditions of Contract) including supply of all consumables, temporary equipments and pipings, instruments, labour/skilled manpower etc. The scope includes complete requirement of flushing oils including fresh oil refilling during the pre-commissioning & commissioning activities and subsequent initial operation.

1.16.00

First Fill of Consumables, SF6 / Oils & Lubricants All the first fill and One year's topping requirements of consumable such as SF6 gas, greases, oil, lubricants, servo fluids and essential chemicals etc. which will be required to put the equipments covered under the scope of specifications, into successful commissioning/ initial operation and to establish completion of facilities shall be furnished by the bidder, unless specifically excluded under the Exclusions in these specifications and documents.

1.17.00

Spares The scope of work includes supply of mandatory spares, commissioning spares, consumable spares and others as specified under conditions of contract. The list of mandatory spares is brought out at Part-F, Section-VI.

1.18.00

Special Tools & Tackles and Test/ Measuring Equipments One set of all special tools and tackles including testing, calibrating and measuring instruments required for erection, assembly, disassembly and maintenance of all equipments/ systems covered under the scope of the bidder shall be supplied by the bidder as specified elsewhere in Part-A/Part-B of Technical Specifications. These shall not be used for erection/ commissioning purposes and shall be in an unused and new condition, when they are handed over to the Employer. A list of all such special tools and tackles shall be submitted alongwith the offer.

1.19.00

The scope of the bidder includes complete design and engineering, technical coordination (including participation and arranging technical co-ordination meetings), finalization of drawings/ documents, submission of engineering drawing / documents and processing of their approvals by the Employer.

1.20.00

Further, the scope shall also include submission, in proper shape & format, of all types of manuals, handbooks & documents in requisite numbers to the Employer at different phases of the project as per the requirement of Employer.

1.21.00

Bidder shall furnish all relevant data required by the Employer, at interface points within 45 days of notification of award.




PAGE 8 OF 9

CLAUSE NO.

1.22.00

SCOPE OF SUPPLY AND SERVICES Noise Level The noise level to be maintained by all the equipment and systems, supplied & erected by the bidder, shall be as specified elsewhere in the Technical specification.

1.23.00

Bidder shall provide all necessary training to Employer’s personnel as specified in Part-C, Section-VI and as specified elsewhere in technical specification.

1.24.00

The Project construction works involve works to be carried out by other contractors in addition to the works in the scope of 400 KV switchyard package Contractor. The Contractor shall, through co-ordination with the other Contractors, ensure the continuity and the coherence between his supply and that of the other Contractors.




PAGE 9 OF 9

PART-A SUB-SECTION-IV TERMINAL POINTS & EXCLUSIONS



Clause No.


1.00.00

TERMINAL POINTS

1.01.00

SF6 gas to Oil bushing of Generator Transformer

1.02.00

SF6 gas to XLPE cable sealing end terminal (GIS hall)

1.03.00

XLPE cable sealing end to outdoor ACSR conductor (in pothead switchyard)

1.04.00

Termination at the switchyard line take off gantry for 400KV lines

1.05.00

Termination of earthing connection upto power house groundmat riser in GIS hall

2.00.00

EXCLUSIONS

2.01.00

Illumination, Ventilation, Fire protection and EOT crane in GIS hall

2.02.00

XLPE cables & cable terminations between GIS and pothead yard

2.03.00

Civil works associated with GIS installation. However foundation bolts, anchor, support embedments if any etc. are in the scope of the bidder. (Details of foundation alongwith design basis to be given by the contractor)

2.04.00

Levelling of pothead yard area including approach road.

2.05.00

Civil works for Construction of Relay room in GIS hall

2.06.00

PLCC

2.07.00

220V DC Battery and Battery charger.

2.08.00

All equipments for the future bay



PART-A SUB-SECTION – IV

PAGE 1 OF 1

PART-A SUB-SECTION-V SPARES



CLAUSE NO.

SPARES

SPARES 1.00.00

All spares supplied under this contract shall be strictly interchangeable with the parts for which they are intended for replacement. The spares shall be treated and packed for long term storage in the climatic conditions prevailing at the site. Small items shall be packed in sealed transparent plastic covers with desiccant bags as necessary.

1.01.00

Each spare part shall be clearly marked and labeled on the outside of the packing together with the description when more than one spare part is packed in single case. A general description of the contents shall be shown on outside of the case and detailed list enclosed. All cases, containers and other packages must be suitably marked and numbered for the purpose of identification.

1.02.00

Commissioning spares: The Contractor shall include in his scope of supply all commissioning spares. List of such spares along with the quantities shall be indicated in the bid

1.03.00

The Contractor shall supply spares which he expects to consume during installation testing and commissioning of system. The quantity of these spares shall be decided based on his previous experience, such that site works shall not be hampered due to non-availability of these spares. Contractor shall submit a complete list of such spares along with the bid, the cost of which shall be deemed to have been included in the lumsum proposal price of the package. The unused commissioning spares may be left at the site for use by the Employer, if so agreed at a cost to be negotiated.

1.04.00

No mandatory or recommended spares will be used during the commissioning of the equipment/plant before take over by the Employer.

1.05.00

Mandatory spares and Maintenance Equipment a)

The list of mandatory spares considered essential by the Employer is indicated in Section-VI, Part-F. The contractor shall indicate the prices for each and every item (except for items not applicable to the contractors design) in the ‘Schedule of Mandatory Spares’ whether or not he considers it necessary for the Employer to have such spares. If the contractor fails to comply with the above or fails to quote the price of any spare item, the cost of such spares shall be deemed to be included in the contract price. The contractor shall furnish the population per unit of each item in the Bid Forms & Price Schedules. Whenever the quantity is mentioned in “sets” the contractor has to give the item details and prices of each item.

b)

Whenever the quantity is indicated as a percentage, it shall mean percentage of total population of that item in the station (project), unless specified otherwise, and the fraction will be rounded off to the next higher whole number. Wherever the requirement has been specified as a ‘set’ it will include the total requirement of the item for a unit, module or the station as



PART-A SUB-SECTION-V

PAGE 1 OF 3

CLAUSE NO.

SPARES specified. Where it is not specified, a ‘set’ would mean the requirement for the single equipment / system as the case may be. Also one set for the particular equipment. e.g. ‘set’ of bearings for a pump would include the total number of bearings in a pump. Also the ‘set’ would include all components required to replace the item; for example, a set of bearings shall include all hardware normally required while replacing the bearings.

1.06.00

c)

The Employer reserves the right to buy any or all the mandatory spare parts

d)

The prices of mandatory spares indicated by the Contractor in the Bid Proposal sheets shall be used for bid evaluation purposes

e)

All mandatory spares shall be delivered at site at least two months before scheduled date of initial operation of the first unit. However, spares shall not be dispatched before dispatch of corresponding main equipments

f)

Wherever quantity is specified both as a percentage and a value, the Contractor has to supply the higher quantity until & unless specified otherwise.

Recommended spares a)

b)

In addition to the mandatory spares, the Contractor shall also provide a list of recommended spares giving unit prices and total prices for 3 years of normal operation of equipment in list and total prices in relevant schedule of the Bid Forms & Price Schedules. This list shall take into consideration the specified mandatory spares and should be a separate list. The Employer reserves the right to buy any or all the recommended spares. The recommended spares parts shall be delivered at the site. The list of recommended spares to be furnished by the Contractor should also contain the following: •

Population of each item installed along with reference drawing number.

•

Service life expectancy of each item.

•

Offer validity period

Price of recommended spares will not be used for evaluation of bids. The prices of these spares will remain valid for a period of not less than 120 days after the date on which the validity of main bid expires. Whenever recommended spares are the same as mandatory spares, then the prices of the mandatory spares and such common recommended spares shall be the same. Further, the prices of any recommended spares, which are not common with mandatory spares listed in the volume, shall be subject to review by the Employer and shall be finalised after mutual discussions.




PAGE 2 OF 3

CLAUSE NO.

1.07.00

SPARES Tools & tackles The Contractor shall also supply at site one set of all special tool & tackles, etc. which are required by the Employer’s maintenance staff to maintain the works successfully at no extra cost. The list of such tools and tackles shall be enclosed with the offer.




PAGE 3 OF 3

PART-A SUB-SECTION-VI SUB QR



CLAUSE NO.


1.00.00

ALL THE MAJOR EQUIPMENTS/ SYSTEMS TO BE SUPPLIED/ ERECTED FOR THE PROJECT SHALL MEET THE FOLLOWING REQUIREMENTS:

1.01.00

400 KV INSTRUMENT TRANSFORMERS The 400 KV Instrument Transformers being offered should be from manufacturer who have manufactured and supplied minimum fifteen (15) nos. of single phase Current Transformers and fifteen (15) nos. of single phase Capacitor Voltage Transformer suitable for Air Insulated Substation/Switchyard of 400 KV or above class which must have been in successful operation for a minimum period of two(2) years as on the date of bid opening.

1.02.00

400KV DISCONNECTORS AND SURGE ARRESTORS The 400KV Disconnectors and Surge Arrestors being offered should be from manufacturer(s) who have manufactured and supplied atleast five (5) nos. of three phase Disconnectors and atleast fifteen (15) nos. of single phase Surge Arrestors suitable for Air Insulated Substation/Switchyard of 400KV or above class which must have been in successful operation for a minimum period of two (2) years as on the date of bid opening.

1.03.00

SCADA SYSTEM & PROTECTIVE RELAYS The SCADA (Supervisory Control And Data Acquisition) System offered with distributed architecture (excluding the requirement of communication protocol IEC61850) should have been in successful operation in atleast one(1) Substation/Switchyard of not less than 220 KV class for a minimum period of one(1) year as on date of bid opening. The Generator Protection Relays, the Bay Protection Units including the Busbar protection and the energy metering System offered should be from manufacturer(s) who have manufactured and supplied respective equipment (excluding the requirement of IEC-61850), which must have been in successful operation in a 100 MW or above unit/ 220 KV class or above Substation/Switchyard for a minimum period of one (1) year as on the date of bid opening.

1.04.00

SITE SUPERVISION OF EQUIPMENTS Bidder shall furnish undertaking (as per the enclosed format) from respective equipment manufacturers for the equipments indicated above that erection, testing and commissioning shall be carried out under their supervision.

1.05.00

For other items of supply the Bidder shall supply equipment/accessories from the manufacturer who has designed, manufactured, type tested and supplied similar items and these should have been in successful operation.

1.06.00

The Bidder must enclose the type test reports for the substation equipment and accessories, main protective relays distance to fault locator, disturbance recorder, event logger, time synchronizing equipment and tariff meters along with the offer.



PART-A SUB-SECTION-VI

PAGE 1 OF 2

CLAUSE NO.

1.07.00

SCOPE OF SUPPLY AND SERVICES The Bidder shall clearly and unambiguously identify and name the proposed subVendors for various equipment and enclose detailed documents for each proposed sub-vendor with the bid to establish that such sub-vendors meet the above stipulated requirements. Any vague statements like ‘….make or equivalent’ shall not be accepted. Any Bidder who fails to comply with the above clause Nos. 1.01.00 to 1.07.00 is liable to be disqualified and his bid is liable to be rejected.



PART-A SUB-SECTION-VI

PAGE 2 OF 2

PART-B



CONTENTS

TECHNICAL SPECIFICATION PART - B -----------------------------------------------------------------------------------------------------------------------------------SUB-SECTION DESCRIPTION ------------------------------------------------------------------------------------------------------------------------------------

CHAPTER-E0

SWITCHYARD ELECTRICAL GENERAL

CHAPTER-E1


CHAPTER-E2

ISOLATORS (AIS)

CHAPTER-E3

INSTRUMENT TRANSFORMERS (AIS)

CHAPTER-E4

SURGE ARRESTORS (AIS)

CHAPTER-E5

POST INSULATOR (AIS)

CHAPTER-E6

WAVE TRAPS (AIS)

CHAPTER-E7

LIGHTING (COMMON)

CHAPTER-E8

LT SWITCHGEAR & DBs (COMMON)

CHAPTER-E9

LT POWER AND CONTROL CABLES (COMMON)

CHAPTER-E10

SUBSTATION AUTOMATION SYSTEM (COMMON)

CHAPTER-E11

DC BATTERY AND BATTERY CHARGER (COMMON)

CHAPTER-E12

REQUIREMENTS OF AUXILIARY ITEMS (AIS)

CHAPTER-E13

INSTALLATION (COMMON)

CHAPTER-E14

SITE TESTING AND COMMISSIONING (COMMON)

CHAPTER-C0

TECHNICAL SPECIFICATION – CIVIL WORKS



PART - B

PAGE 1 OF 1

PART-B SUB-SECTION-E0 SWITCHYARD ELECTRICAL GENERAL



CLAUSE NO.

SWITCHYARD ELECTRICAL GENERAL (E0)

1.00.00

SCOPE AND GENERAL INFORMATION

1.01.00

In addition to the detailed scope and other requirements specified in Part-A, the intent of the specifications for various electrical equipments shall also cover the following scope:

1.02.00

Contractor shall be responsible for design and engineering of overall system/station, and all elements, systems, sub-systems, facilities, equipments, material, etc.. The Contractor shall submit design calculations, drawings, codes, codes of practices, construction drawings, etc. for Employer’s approval. The basic design shall include, but not limited to, the following: a)

Development of general arrangement.

b)

Development of detailed layout (plan & section/elevation) drawings.

c)

Development of single line diagram with parameters of equipment and details of protection.

d)

Protection and control philosophy and selection of protection, control and annunciation schemes.

e)

Development of interlocking schemes.

f)

Development of switchyard structure loading details.

g)

Development of earthing system.

h)

Development of direct stroke lightning protection system.

i)

Insulation coordination of the EHV equipment.

j)

Calculation of static and dynamic force load and selection of spacer spans and equipment terminal loading, (for outdoor switchyard)

k)

Development of clearance diagrams.

l)

Lighting design, Lux level calculations and conduit wiring diagram (for out door switchyard).

m)

Development of power & control cable laying and termination schedules.

n)

Relay setting calculations.

o)

Development of erection key diagram with bill of material.

p)

Foundation design and construction drawings.

q)

Development of cable trench layout and sections, and construction drawings.



PART-B CHAPTER-E0

PAGE 1 OF 5

CLAUSE NO.


1.03.00

Contractor shall furnish detailed drawings for the various equipments covered in their scope for Employer’s approval. The equipment shall conform to type tests as per specification and applicable standards and reports of the same shall be furnished for approval.

1.04.00

Contractor shall furnish design calculations and construction drawings for all civil works showing details of pockets to be left in foundations and embedments to be provided in cable trenches.

1.05.00

Contractor shall furnish the schematics, general arrangement drawings, cable schedules, interconnection schedules, panel wiring diagrams etc. for various control and relay panels for Employer’s approval. Contractor shall also furnish the recommended relay settings to be adopted.

1.06.00

The Contractor shall note that the list of standards specified elsewhere in this specification is not complete. Whenever necessary the list of standards shall be considered in conjunction with specification, IS & IEC. In case governing standards for the equipment is different from IS or IEC, the salient points shall be clearly brought out alongwith English language version of the same.

1.07.00

Exposed live parts shall be placed high enough above ground to meet the requirements of Indian Electricity Rules and other statutory codes. All responsibilities regarding co-ordination with Electrical Inspection Agencies and obtaining clearance certificate from them rests with the Contractor.

1.08.00

All equipment shall be supplied with suitable terminal connectors. The terminal connector shall be well coordinated with the type/size of conductor and equipment to be connected. The conductor terminations for equipment shall be either rigid or expansion type suitable for tube or horizontal or vertical take off suitable for quad moose The spacing for quad moose ACSR conductor shall be 450 mm as required. The exact requirement to terminal clamps would be finalised by the Contractor in consultation with Employer based on layout requirement. The terminal pads shall preferably be capable of taking the required conductor span under normal, short circuit and meteorological conditions, without affecting the performance of the equipment.

1.09.00

All equipment shall be supplied with necessary interpole cabling and its cost shall be included in the cost of equipment.

1.10.00

The minimum temperature is expected to reach upto -10 degree Celcius under extreme condition. The equipments shall be designed to withstand such conditions satisfactorily.

1.11.00

All equipment (outdoor) shall be suitable for hot line washing.

1.12.00

The Contractor shall cooperate in all respects and exchange the necessary technical data/ drawings with other agencies and Employer’s other Contractors under intimation to Employer to ensure proper coordination and completion of work in time.



PART-B CHAPTER-E0

PAGE 2 OF 5

CLAUSE NO.


1.13.00

Insulation Co-ordination and Selection of Surge Arrestor

1.13.01

The contractor shall be fully responsible for complete insulation co-ordination of switchyard including GIS. Contractor shall carry out detailed studies and design calculations to evolve the required parameters locations, energy capability etc. of surge arrestors such that adequate protective margin is available between peak impulse, surge and power frequency discharge voltages and BIL of the protected requirement. The locations of surge arrestors shown in single line diagram is indicative only. If the contractors feels that surge arrestors at some more locations are required to be provided, the cost for the same should also be included in the offer.

1.13.02

The contractor shall perform all necessary studies for surge arrestors. The report shall detail the limits of all equipment parameters which could affect the insulation co-ordination. The report shall also detail the characteristics of the surge arrestor and shall demonstrate arrestor’s protective and withstand levels, discharge and coordinating currents and arrestor ratings and comply with the requirement of this specification.

1.13.03

The contractor shall also consider in the studies, the open circuit breaker condition, fast transients generated by slow operation of disconnecting switches and high speed earthswitches etc. The study report and design calculations shall be submitted for Employer’s approval.

2.00.00

LT SWITCHGEAR AC Feeders: The LT AC switchgear shall be designed to cater for all the loads required for bay marshalling kiosks, auxiliary power requirement. For reliability, each equipment and bay marshalling kiosk shall be connected with two independent sources of power supplies. The LT switchgear shall be suitable for power supplies to all Marshalling kiosks, maximum four (4) bay marshalling kiosks can be looped by forming a ring main. The LT switchgear panels shall be equipped with 20% spare feeders. Two feeders of AC supply at 415V shall be available at Station Service Boards for connection to the (two) nos of 415V, 3 phase AC distribution boards with required no. of MCCB modules including 20% spare modules for switchyard requirement. Additional 2 (two) feeders shall also be available from 415V Switchboard installed in pothead switchyard for catering power supply to outdoor switchyard. DC Feeders: The Contractor shall provide suitable DC distribution boards with busbars and all other equipments. For reliability, dual supplies for all loads shall be considered. 20% spare feeders shall be provided. 4 (four) feeders of DC supply shall be available in unitized unit DC distribution boards of the power house for further connection to DC distribution boards for distribution.



PART-B CHAPTER-E0

PAGE 3 OF 5

CLAUSE NO.

3.00.00


CLEARANCES The minimum clearances for 400 KV Outdoor Switchyard shall be as given below: 400KV Phase to earth clearance

3500 mm

Phase to phase clearance

4000 mm

Section clearance

6500 mm

Ground clearance

8000 mm

The above clearances are valid upto altitude 1000M only. Bidder shall provide adequate clearances considering the altitude of the site. The Contractor shall supply the structures suitable to meet the clearances. 4.00.00

SERVICES TO BE PERFORMED BY THE EQUIPMENT BEING SUPPLIED The 400 KV system is being designed to limit the power frequency over voltage of 1.5 p.u. and the switching surge over voltage to 2.5 p.u. In 400 KV system the initial value of temporary over voltage could be 2.0 p.u. for 1-2 cycles. All the equipment/materials covered in this specification shall perform all its functions satisfactorily without undue strain, restrike etc. under such over voltage conditions.

5.00.00

SYSTEM PARAMETERS The system parameters shall be as under: GIS

AIS

a) Highest system voltage

420 KV rms

420 KV rms

b) System Frequency

50Hz

50Hz

Phase to earth & between phases

1425 KV

1425 KV

Across isolating distance

1425(+240) KV

c) Lightning Impulse Voltage

d) Switching Impulse Voltage

e)

Phase to earth

1050KV

1050 KV

Across isolating distance

900(+345) KV

Between phases

1575KV

Power frequency withstand for 1 min (rms) Phase to earth & between phases


650KV


520 KV

PART-B CHAPTER-E0

PAGE 4 OF 5

CLAUSE NO.


Across isolating distances

815KV

f)

PD level of GIS conductor

Less than 5 Less than 10 Pico coulomb Pico coulomb

g)

Corona Extinction voltage

h) Short Circuit current

610 KV

320 KV (rms) 40 kA for 1 40 kA for 1 sec. sec.

The values of insulation level given above are applicable to altitude of 1000 M. Bidder shall appropriately correct the values as per the site altitude.



PART-B CHAPTER-E0

PAGE 5 OF 5

PART-B SUB-SECTION-E1 GAS INSULATED SWITCHGEAR



CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1)

1.00.00

420 KV GAS INSULATED SWITCHGEAR (GIS) EQUIPMENTS

1.01.00

CODES & STANDARDS The switchgear specified herein shall operate satisfactorily in the climatic conditions as specified. The performance, testing and rating of the switchgear shall conform to the latest edition of the following IEC / IS publications: IEC -62271-100

:

High Voltage Alternating Current circuit breaker

IEC- 60376

:

Technical grade Sulphur Hexaflouride(SF6) for use in Electrical equipment

IEC- 68 Part III

:

Environmental Testing

IEC -71

:

Insulation coordination.

IEC-60099-1/4

:

Non linear resistor type gapped surge arresters for AC systems.

IEC -62271-102

:

AC disconnectors and earthing switches

IEC- 60137

:

Insulated Bushings for alternating voltages above 1000 V.

IEC –60044-1

:

Current transformers

IEC –60044-2

:

Inductive Voltage transformers

IEC –267

:

Guide to testing of circuit breakers

IEC –60270

:

High voltage measurements.

IEC- 60480

:

Guidelines for the checking and treatment of SF6 taken from electrical equipment and specification for its re use

IEC- 506

:

Switching impulse test on HV insulators.

IEC-62271-203

:

Gas Insulated metal enclosed switchgear for rated voltage above 52 KV

IEC-60694 /62271-1 :

Common specification for HV switchgear and control gear standards.

IEC- 60859

:

Cable connections for gas insulated metal enclosed switchgear.

IEC –61128

:

Alternating current disconnectors: Bus transfer current switching by disconnector

IEC -61129

:

AC earthing switches: Induced current switching.


test


techniques-Partial

PART-B CHAPTER –E1

discharge

PAGE 1 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) IEC-1259

:

Requirement for switching of bus charging current by disconnectors.

IS –2705

:

Current transformers

IS- 3156

:

Voltage transformers

IEC- 60439

:

Low Voltage Switchgear and Control Gear assemblies

IEEE-80 (2000)

:

IEEE- Guide for safety in AC substation grounding

CIGRE-44

:

Earthing of GIS –an application guide( Elecra no: 151, Dec’93)

IEC-62271-306

:

Cable connection between power transformer & gas insulated metal enclosed switchgear for rated voltages above 52KV

IEC-62271-305

:

Cable connection for gas insulated metal enclosed switchgear for rated voltages above 52KV

1.02.00

The proposed switchgear may conform to the standards of the country of manufacture, provided these standards are based on or equivalent or better to the above referred standards. The contractor proposing any other standards than the above referred standards must specifically indicate the standards to which the switchgear conforms. The deviations, if any, from the above codes & standards that affect performance and rating are required to be clearly indicated by the contractor alongwith the offer. The contractor is required to furnish the English version copy of all the standards alongwith the bid.

1.03.00

Compliance with the provisions of the specifications does not absolve the switchgear contractor from the responsibility of furnishing switchgear and accessories of proper design, electrically and mechanically suited to meet the operating guarantees at the specified service conditions.

1.04.00

If there are, in the opinion of the contractor, any contradictions between the above standards and these specifications, such contradictions shall be brought to the attention of the Employer.

2.00.00

RATINGS

2.01.00

The ratings and general characteristics of the GIS shall be as follows: (The ratings applicable to specific items of equipment are indicated in the applicable sections dealing with the equipment). a)

Type of Switchgear

420 KV Single phase, metal enclosed, SF6 gas insulated switchgear

b)

Location

Indoor




PAGE 2 OF 69

CLAUSE NO.


c)

Frequency

50 + 3% -5% Hz

d)

Rated voltage class, KV rms

420

e)

Highest System voltage, KV rms

420

f)

Number of phases

Three

g)

Rated lightning impulse withstand voltage (KV peak)

h)

i)

Phase to earth

1425

ii)

Across open contacts

1665

Rated Switching impulse withstand voltage (KV peak)

i)

-

Phase to earth

1050

-

Phase to phase

1575

-


1245

Rated one minute power frequency with stand voltage (KV rms) i)

Phase to earth

650

ii)


815

j)

System earthing

k)

Rated normal current (Amps.) i)

Effectively grounded

Generator transformer feeder circuits

2500A

ii)

Out going feeder circuits

2500A

iii)

Bus coupler circuits

2500A

l)

Rated short circuit withstand current at rated maximum voltage for one sec.

Not less than 40 KA rms (symmetrical)

m)

Rated breaking capacity of circuit breaker

40 KA rms




PAGE 3 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) n)

Rated making capacity

100 KA peak

o)

Prospective transient recovery Voltage appearing across the Circuit breaker terminals

As per IEC62271-100

p)

Radio interference voltage at 266 KV(rms)

Less then 1000 micro volts

q)

Partial discharge level at 1.1 Un/√ 3

5 pico coulombs or less

r)

Material of enclosure

s)

Material of bus bar

Aluminium alloy

t)

Insulation medium

SF6 gas

Alluminium alloy

2.02.00

All current carrying components of the equipment specified shall be capable of continuous operation at the specified rated current without exceeding the maximum temperature rise specified in the relevant IEC standards.

2.03.00

Thermal calculations shall be based on the climatic conditions indicated in. Project Features. These calculations shall be submitted for review of the Employer.

3.00.00

GENERAL DESIGN AND SAFETY REQUIREMENT

3.01.00

The GIS assembly shall be of double busbar arrangement and consist of separate modular compartments e.g. Circuit Breaker compartment, Bus bar compartment filled SF6 gas and separated gas tight partitions so as to minimize risk to human life, allow ease of maintenance and limit the effects of gas leaks failures & internal arcs etc. These compartments shall be such that maintenance on one feeder may be performed without de-energising the adjacent feeders. These compartments shall be designed to minimize the risk of damage to adjacent sections and protection of personnel in the event of a failure occurring within the compartments. Stainless steel carbon impregnated or nickel plate rupture diaphragms with suitable deflectors shall be provided to prevent uncontrolled bursting pressures developing within the enclosures under worst operating conditions. The compartments of GIS assemblies shall be supplied filled with SF6 gas at a positive pressure and hermetically sealed to protect the dielectric system during transportation.

3.02.00

The workmanship shall be of the highest quality and shall conform to the latest modern practices for the manufacture of high technology machinery and electrical switchgear.

3.03.00

The switchgear, which shall be of modular design, shall have complete phase isolation. The conductors and the live parts shall be mounted on high graded epoxy resin insulators. These insulators shall be designed to have high structural strength and electrical dielectric properties and shall be shaped so as to provide uniform field distribution and to minimize the effects of particle deposition either from migration of




PAGE 4 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) foreign particles within the enclosures or from the by-products of SF6 breakdown under arcing conditions.

3.04.00

Gas barrier insulators and support insulators shall have the same basis of design. The support insulators shall have holes on both sides for proper flow of gas.

3.05.00

Gas barrier insulators shall be provided so as to divide the GIS into separate compartments. They shall be suitably located in order to minimize disturbance in case of leakage or dismantling. They shall be designed to withstand 1.5 times full rated pressure on one side while vacuum is exerted on the other side. They shall be designed to withstand any internal fault thereby keeping an internal arc inside the faulty compartment. Due to safety requirement for working on the pressurised equipment, whenever the pressure of the adjacent gas compartment is reduced, it should be ensured by the contractor that adjacent compartment would remain in service with reduced pressure. The gas tight barriers shall be clearly marked on the outside of the enclosures.

3.06.00

The material and thickness of the enclosures shall be such as to withstand an internal flash over without burn through for a period of 500ms till the backup relay protection clears the fault. The material shall be such that it has no effect of environment as well as from the by-products of SF6 breakdown under arcing condition.

3.07.00

Sufficient inspection windows/access openings shall be provided at the switchgear to ensure that each switchgear component can be inspected / monitored during installation and future maintenance. Each section shall have plug-in or easily removable connection pieces to allow for easy replacement of any component with the minimum of disturbance to the remainder of the equipment.

3.08.00

The material used for manufacturing the switchgear equipment shall be of the type, composition and have physical properties best suited to their particular purposes and in accordance with the latest engineering practices. All the conductors shall be fabricated of aluminum tubes of cross sectional area suitable to meet the normal and short circuit current rating requirements. The finish of the conductors shall be smooth so as to prevent any electrical discharge. The conductor ends shall be silver plated and fitted into finger contacts or tulip contacts. The contacts shall be of sliding type to allow the conductors to expand or contract axially due to temperature variation without imposing any mechanical stress on supporting insulators.

3.09.00

Each pressure filled enclosure shall be designed and fabricated to comply with the requirements of the applicable pressure vessel codes and based on the design temperature and design pressures as defined in IEC -62271-203 .

3.10.00

The contractor shall guarantee that the pressure loss within each individual gas-filled compartment shall not be more than half percent ( 0.5%) per year.

3.11.00

Each gas-filled compartment shall be equipped with static filters, density switches, filling valve and safety diaphragm. The filters shall be capable of absorbing any water vapour which may penetrate into the enclosures as well as the by-products of SF6 during interruption. Each gas compartment shall be fitted with separate non-




PAGE 5 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) return valve connectors for evacuating & filling the gas and checking the gas pressure etc.

3.12.00

The switchgear line-up when installed and operating under the ambient conditions shall perform satisfactorily and safely under all normal and fault conditions. Even repeated operations upto the permissible servicing intervals under 100% rated & fault conditions shall not diminish the performance or significantly shorten the useful life of the switchgear. Any fault caused by external reasons shall be positively confined to the originating compartment and shall not spread to other parts of the switchgear. Routine maintenance to any of its external components including the protective relays and instrument transformers shall not be required in less than five years intervals. The internal components shall be maintenance free for at least 10 years. Routine replacement of insulating gas shall not be required in intervals of less than ten years.

3.13.00

Bracings shall be provided for all mechanical components against the effects of short circuit currents. The arc faults shall be positively confined to the originating compartment and shall not spread to the other parts of switchgear.

3.14.00

The thermal rating of all current carrying parts shall be minimum for one sec. for the rated symmetrical short-circuits current.

3.15.00

The Switchgear shall be of the free standing, self-supporting with easy accessibility to all the parts during installation & maintenance, dead front design with all highvoltage equipment installed inside gas-insulated metallic and earthed enclosures, suitably sub-divided into individual arc and gas-proof compartments at least for: a)

Busbars

b)

Intermediate compartment

c)

Circuit breakers

d)

Bus / Line disconnections

e)

Gas insulated bus duct section between Generator-Transformer and GIS.

f)

Current Transformers

g)

Voltage Transformers

h)

Surge Arrestors

i)

Gas Insulated bus duct section between GIS and XLPE cable

GIS shall be of isolated phase type and each phase/pole shall be housed in a separate enclosure. The bus enclosure should be sectionalized in a manner that maintenance work on any bus disconnector ( when bus and bus disconnector are enclosed in a single enclosure) can be carried out by isolating and evacuating the small effected section and not the entire bus. 3.16.00

The arrangement of the individual switchgear bays shall be such so as to achieve optimum space-saving, neat and logical arrangement and adequate accessibility to all external components.




PAGE 6 OF 69

CLAUSE NO.


3.17.00

It is required that the three phases of each switchgear bay be arranged side by side. Segregated phase blocks of equipment in which one phase of each switchgear bay is mounted in a separate block are not acceptable. The arrangement of the equipment offered must provide adequate access for operation, testing and maintenance.

3.18.00

The arrangement of gas section or compartments shall be such as to facilitate extension of any make on either end without any drilling, cutting or welding on existing equipments. The GIS shall be designed such that a future bay can be extended with-out any necessity to move or dislocate the existing switchgear bays. It shall be kept in view that very little shutdown time is needed for adding future bay.

3.19.00

The bay control unit shall be placed in the relay room on the downstream side of GIS Hall as shown in drawing no: 5505-500-PEH-A-012 “GIS Layout Plan at 1300.0M”

3.20.00

All the elements shall be accessible without removing support structures for routine inspections and possible repairs. The removal of individual enclosure part or entire breaker bays shall be possible without disturbing the enclosures of neighboring bays.

3.21.00

It should be impossible to unwillingly touch live parts of the switchgear or to perform operations that lead to arcing faults without the use of tools or brute force.

3.22.00

All interlocks that prevent potentially dangerous mal-operations, shall be constructed such that they can not be operated easily, i.e. the operator must use tools or brute force to over-ride them.

3.23.00

The actual position of circuit breakers, disconnections and grounding switches must be positively displayed by mechanical indicators visible from the operating position.

3.24.00

In general the contours of energized metal parts of the GIS and any other accessory shall be such, so as to eliminate areas or points of high electrostatic flux concentrations. The surfaces shall be smooth with no projection or irregularities which may cause visible corona. No corona shall be visible in complete darkness when the equipment is subjected to specified test voltage. There shall be no radio interference from the energized switchgear at rated voltage.

3.25.00

The enclosure shall be of continuous design and shall meet the requirement as specified in clause no: 10 (special consideration for GIS) of IEEE -80 year 2000. The enclosure shall be sized for carrying induced current equal to the rated current of the bus. The conductor and the enclosure shall form the concentric pair with effective shielding of the field internal to the enclosure.

3.26.00

The fabricated metal enclosures shall be of Aluminum alloy and have high resistance to corrosion, low electrical losses and negligible magnetic losses. All .jointed surfaces shall be machined and all castings shall be spot faced for all bolt heads or nuts and washers. All screws, bolts, studs and nuts shall conform to metric system.




PAGE 7 OF 69

CLAUSE NO.


3.27.00

The breaker enclosure shall have provision for easy withdrawal of the interrupter assemblies. The removed interrupter assembly must be easily and safely accessible for inspection and possible repairs.

3.28.00

The enclosures of the same phase shall be electrically interconnected and at proper points they shall be connected to the other phases thus entailing a return current almost equal to the current circulating in the conductors.

3.29.00

The enclosure shall be designed to practically eliminate the external electromagnetic field and thereby electrodynamics stresses even under short circuit conditions.

3.30.00

The elbows, bends, cross and T-sections of interconnections shall include the insulators bearing the conductor when the direction changes take place in order to ensure that live parts remain perfectly centered and the electrical field is not increased at such points.

3.31.00

The Contractor shall furnish the following information regarding the loosely distributed metallic particles within the GIS encapsulation. a)

Calculations of critical field strength for specific particles of defined mass and geometry.

b)

The methodology and the equipments required for electrical partial discharge (PD) detection and/or acoustic detection method.

The switchgear shall have provision for connection with ground mat risers to be provided by the Employer. This provision shall consist of grounding pads to be connected to the ground mat riser in the vicinity of the equipment. The connection between the grounding pads of switchgear and ground mat risers shall be provided by the contractor. The contractor shall furnish the details & drawings for ground mat requirement for GIS. 3.32.00

The ladders and walkways shall be provided wherever necessary for access to the equipment. The suitability of using a portable ladder with adjustable height may be examined by the contractor and if found suitable shall be offered.

3.33.00

Wherever required, the heaters shall be provided for the equipment in order to ensure the proper functioning of the switchgear at specified ambient temperatures. The heaters shall be rated for 240V AC supply and shall be complete with thermostat, control switches and fuses, connected as balanced 3-phase, 4-wire load. The possibility of using heaters without thermostats in order to achieve the higher reliability may be examined by the contractor and accordingly included in the offer but it shall be ensured by the contractor that the temperature rise of different enclosures where heating is provided should be within safe limits as per relevant standards. Detail calculation with a copy of the relevant extract of standard to which the above arrangement conforms to, shall also be furnished alongwith the offer. The heaters shall be so arranged and protected as to create no hazard to adjacent equipment from the heat produced.




PAGE 8 OF 69

CLAUSE NO.


3.34.00

Arrangement shall be provided to visually observe the contact position of disconnecting switches and earth switches.

3.35.00

The enclosure & support structure shall be designed that a mechanic 1780mm in height and 80 Kg in weight shall be able to climb on the equipment.

3.36.00

The sealing provided between flanges of two modules / enclosures shall be such that long term tightness is achieved.

3.37.00

Alarm circuit shall not respond to faults for momentary conditions. The following indications including those required elsewhere in the specifications shall be generally provided in the alarm & indication circuits.

3.37.01

Gas Insulating System

3.37.02

a)

Loss of gas density

b)

Loss of heater power (if required)

c)

Moisture in gas

d)

Low gas pressure

e)

Any other alarm necessary to indicate deterioration of the gas insulating system

Operating System a)

Low operating pressure.

b)

Loss of Heater Power.

c)

Loss of operating power.

d)

Loss of control

e)

Pole-disordance

3.38.00

The common point of the two busbars alongwith the Earthswitch shall be designed and housed in a separate compartment so as to avoid complete shutdown of the system in case of maintenance required in any disconnector.

3.39.00

Adequate number of gas leak detectors shall be installed at various location at the base of the GIS structure to detect presence of gas which may be harmful for human. The detector shall send alarm signal locally as well as at remote stations.

3.40.00

Separate SF6 gas filled enclosure shall be provided with mounting structures for 2 Nos. of 400 KV XLPE spare cables termination at GIS floor level (1300.00m). The enclosure shall be placed in horizontal direction and equipped with pressure gauges etc.

3.41.00

The equipment shall be suitable for operation under the ambient conditions prevailing at project site specified at Part-A, Subsection- Project Information. The prevailing conditions shall be taken into account by the Contractor in the design of the equipment.




PAGE 9 OF 69

CLAUSE NO.

4.00.00

GAS INSULATED SWITCHGEAR (E1) MANDATORY MAINTENANCE EQUIPMENTS The maintenance equipment as per necessary for the operation and maintenance of GIS shall be supplied alongwith GIS. A list of such equipments is enclosed as Annexure-I.

5.00.00

BELLOWS OR COMPENSATING UNITS Adequate provision shall be made to allow for the thermal expansion of the conductors and of differential thermal expansion between the conductors and the enclosures. The metallic bellows (preferably of stainless steel) of following types or other suitable equivalent arrangement shall be provided wherever necessary.

6.00.00

i)

Lateral / vertical mounting units: These shall be inserted, as required, between sections of bus bars, on transformer, and XLPE cable termination. Provision of these shall enable sections of the switchgear to be removed and reinserted without interfering with adjacent parts. Lateral mounting shall be made possible by a sliding section of enclosure and tubular conductors.

ii)

Axial compensators: These shall be provided to accommodate changes in length of bus bars due to temperature variations.

iii)

Parallel compensators: These shall be provided to accommodate large linear expansions and angle tolerances.

iv)

Tolerance compensators: These shall be provided manufacturing, site assembly & foundation tolerances.

v)

Vibration compensators: These bellow compensators shall be provided for absorbing vibrations caused by the transformers when connected to SF6 switchgear by oil / SF6 bushings.

for

taking

up

INDICATION AND VERIFICATION OF SWITCH POSITIONS Indicators shall be provided on all circuit breakers, Disconnectors and earth switches, which shall clearly show whether the switches are open or closed. The indicators shall be mechanically coupled directly to the main contact operating drive rod or linkage and shall be mounted in a position where they are clearly visible through glass windows.

7.00.00

PRESSURE RELIEF Pressure relief devices shall be provided in the gas sections to protect the main gas enclosures from damage or distortion during the occurrence of abnormal pressure increase or shock waves generated by internal electrical fault arcs (preferably in downward direction). Pressure relief shall be achieved either by means of diaphragms or plugs venting directly into the atmosphere in a controlled direction. If the pressure relief devices vent directly into the atmosphere, suitable guards and deflectors shall be provided. Contractor shall submit to the owner the detailed criteria design regarding location of pressure relief devices/rupture diaphragms.




PAGE 10 OF 69

CLAUSE NO.

8.00.00

GAS INSULATED SWITCHGEAR (E1) PRESSURE VESSEL REQUIREMENTS The enclosure shall be designed for the mechanical and thermal loads to which it is subjected in service. The enclosure shall be manufactured and tested according to the pressure vessel code (ASME/CENELEC code for pressure Vessel.) Each enclosure has to be tested as a routine test at time the design pressure for one minute. The bursting strength of Aluminum castings has to be at least 5 times the design type test on each type of enclosures.

9.00.00

EQUIPMENT DETAILS

9.01.00

CIRCUIT BREAKERS

9.01.01

Type & Rating I)

The power from Generating Units is proposed to be stepped to 420 KV by Generator Transformers. The Generator Transformers shall be connected to proposed 420 KV GIS which shall be connected to pothead yard through 400 KV XLPE cables. The power from pothead yard shall be evacuated through 1 No. double circuit transmission lines. . The circuit breakers offered shall be suitable for operation with Generating Units, Generator Transformers, and Transmission Lines.

II)

SF6 gas-insulated circuit breaker shall conform to IEC-62271 and have the following performance characteristics and ratings: i)

Type of breaker

420 KV Single phase, metal enclosed, SF6 gas insulated.

ii)

Rated frequency

iii)

Rated normal current:-

50 Hz

•

Bus coupler breaker

2500A

•

Generator transformer feeder breaker

2500A

•

Out going line breaker

2500A

iv)

Number of poles

3

v)

Installation

Indoor

vi)

Temperature rise

As per IEC 60694

vii)

Rated short time withstand current KA (rms value of ac component)

40 KA for 1 second




PAGE 11 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) viii)

Rated short circuit making current, KA(peak)

100 KA

ix)

Rated out of phase breaking current (rms)

10KA

x)

Rated short circuit breaking current

xi) xii)

- Rated short circuit current

40 KA (rms)

- Percentage of D.C. component

>70%

a)

System Earthing

b)

First-pole-to clear factor

> 1.3

c)

Rated duration of short circuits

1 sec

d)

Closing time

< 100 ms

Rated transient recovery voltage for terminal faults

As per IEC

Rated characteristics for short line faults

-do-

xiii)

Standard values of rated line characteristics for short line faults

xiv)

Rated One minute Power insulation level

xv)

xvi)

Effectively earthed.

-do

i)

Phase to Earth

650 KV (rms)

ii)

Open contact

815 KV (rms)

Rated lightning impulse withstand voltage (KV peak) i)

Phase to earth

1425 KV

ii)


1665 KV

Rated Switching impulse withstand voltage (KV peak) -


Phase to earth


1050 KV


PAGE 12 OF 69

CLAUSE NO.


xvii)

-

Phase to phase

1575 KV

-


1245 KV

Rated operating duty cycle -

Breakers

-

Auto reclosing (line breakers) Single-phase and 3-phase only)

-

Rated insulation level

As specified

-

Rated line charging with voltage factor of 1.4pu

500 A with maximum breaking current permissible switching Over voltage of 2.0 pu

-

Rated inductive current

0-0.3 s-CO-3 min-CO

All the circuit breakers shall be capable of interrupting 100 Amp. inductive current,

xviii)

Control of switching

Switching surge over voltages while surges (Line Breakers) re-energising to be limited to 2.0 p.u.Single step preinsertion resistor of 400 ohms shall be provided in the circuit breaker. Preinsertion time of the resistor shall be minimum 8 ms.

xix)

Operating mechanism

Hydraulic/Spring/Pneumatic

xx)

Radio interference voltage

Not exceeding 1000 micro-volts for freq. between 0.5MHz and 2.0MHz at 266 KV (rms)

a)

Partial discharge level, 5 or less (pico coulombs) at 1.1 Un/√3

b)

Rated supply voltage of closing and opening devices and auxiliary circuit

c)

Number of auxiliary Contacts

12 NO and 12 NC on each pole wired to terminal blocks in control Cabinet

-

2 per pole


Number of trip coils


220 V dc, 240 V ac, 50Hz / 415 V ac, 50 Hz, 3-phase.


PAGE 13 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) d) xxi)

III)

Number of closing coils

SF6 gas characteristics for SF6circuit breaker

2 per pole As per IEC-60376

Rated break time i)

40ms under test duties 2,3 & 4 at rated values

ii)

45ms under test duties 1-5 and short line fault test duties and combined variation trip coil voltage, opening pressure and quenching media pressure.

xxii)

Maximum difference in the instant of closing/opening of contacts

a) 2.5 millisec within a pole b) 3.3 millisec between poles (opening) c) 5.0 milli sec between poles (closing)

xxiii)

Noise level

140dB at 50m distance from the base of circuit breaker

The governing data for the selection of circuit breakers shall not be limited to the above mentioned parameters but shall also take into account various provisions contained in these specifications and relevant standards. The circuit breakers to be supplied must be suitable for the intended services i.e. for no load, full load and fault service conditions.

9.02.00

Duty Requirement

9.02.01

Circuit breakers shall be C2-M1 class as per IEC 62271-100. the circuit breaker shall be totally restrike free under all duty conditions and shall be capable of performing their duties without opening resistor.The circuit breaker shall meet the duty requirement for any type of fault or fault location and also for line charging and dropping when used on 400KV effectively grounded system with transmission lines of adequate length and characteristic specified elsewhere in the specification and perform make and break operation as per the stipulated duty cycles satisfactorily.

9.02.02

The circuit breaker shall be capable for breaking the steady and transient magnetizing current corresponding to 400KV transformer of 1000 MVA rating. It shall be capable of breaking line charging current as per IEC 62271-100 with a voltage factor of 1.4

9.02.03

The circuit breaker shall be reasonably quiet in operation. Noise level in excess of 140dB measured at the base of the breaker would be unacceptable. Contractor shall indicate the noise level of breaker at a distance of 50 to 150m from base of the breaker.

9.02.04

The Contractor may note that total break time of the breaker shall not be exceeded under any duty conditions as specified such as with the combined variation of trip coil voltage(70-110%), pneumatic/hydraulic pressure and SF6 pressure etc. while furnishing the proof of the total break time of complete circuit breaker, the contractor




PAGE 14 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) may specifically bring out the effect of non-simultaneity between same pole and poles and show how it is covered in the guaranteed total break time.

9.02.05

While furnishing particulars regarding the DC components of the circuit breaker, the contractor shall note that IEC-62271-100 requires that this value should correspond to the guaranteed minimum opening time under any condition of operation.

9.02.06

The critical current which gives the longest arc duration at lock out pressure of SF6 and the duration shall be indicated.

9.02.07

All the duty requirements specified above shall be provided with the support of adequate test reports to be furnished with the bid.

9.03.00

Construction & Design a)

SF6 gas insulated metal enclosed circuit breakers shall comply with the latest revision of IEC-62271-100 & other relevant IEC except to the extent explicitly modified in the specification. Circuit breakers shall be of single pressure (puffer type). They shall be designed for installation in SF6 gas insulated metal clad switchgear and shall use SF6 gas for both insulation & arc quenching. Suitable means shall be provided to ensure that all interrupters & secondary auxiliary switches open and close without loss of synchronism & are of adequate dielectric strength under all operating conditions including an open-close-open operation with zero external dead time delay. The interrupting duty shall be distributed uniformly between interrupters. There shall be two trip and two closing coils per pole for each breaker.

b)

The circuit breakers shall be provided with independent and reliable spring charged mechanism or electro hydraulic /pneumatic operating mechanism for each pole. Provision shall be made for simultaneous opening and closing of all the three poles of the circuit breakers. The full details of the spring charged mechanism/hydraulic operating mechanism/pneumatic mechanism and constructional & operational features must be described in the bid. The detailed drawings to illustrate the operational features shall be supplied by the contractor.

c)

Each circuit breaker shall be capable of withstanding without requiring change of any parts, atleast maximum no. of interruptions at rated short circuit current with associated rate of rise of recovery voltage. The contractor shall state this data and the equivalent number of interruptions at rated continuous current or the cumulative electrical endurance which could be safely withstood by the breaker and also submit proof of short circuit rating with transient voltage severity alongwith the offer.

d)

Out-of-Phase Switching The circuit breaker shall be capable of interrupting symmetrical short circuit current under out-of-phase switching conditions.




PAGE 15 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) Short line Faults: Circuit breaker supplied shall be capable of interrupting line faults on overhead transmission line. e)

The circuit breakers shall be designed to withstand the high stresses imposed on them during fault clearing, load rejection, out of phase switching, re-energization of lines with trapped charges and perform make & break operations as per the stipulated duty cycles satisfactorily. The breakers shall also be required to break small inductive currents without causing excessive over-voltages, line charging currents without restrikes, handle evolving faults and meet the requirements regarding partial discharge, radio interference and corona. However, all the breakers shall be capable of breaking inductive current.

f)

The circuit breakers shall be suitable for in-rush and magnetizing current. The circuit breakers offered shall be suitable for single phase generator transformers, bus coupler and out going lines without restriking and without causing excessive switching surges. Occasionally, a power transformer operating under ferro resonant conditions and having non-sinusoidal current and voltage wave-forms with higher than normal peak values may have to be switched. The Contractor shall provide proof test data and comments on breaker for such applications.

g)

Insulation Co-ordination The insulation strength across the open contacts of the circuit breaker for lightning impulse, switching surges and power frequency withstand voltages shall be as per IEC60694/62271-100. i)

The circuit breaker and bus insulation shall be coordinated so that due to lightning impulse, switching surge and power frequency voltage no flashover shall take place. In case flashover takes place, the same shall be confined in the bus rather than in the circuit breakers in either open or closed position.

ii)

The circuit breakers shall be vertical / horizontal mounted depending on contractor's preferred layout for the double bus system considering the space limitations indicated in the layout and taking into account the worst service conditions / forces imposed by the earthquake.

iii)

Each circuit breaker pole shall be equipped with enclosed type mechanical position indicator clearly visible from the breaker front. The remote position indicator on the bay module control cabinet and in the power house control room shall be provided. The details of the inscription and coloring of the mechanical indicator are given as under: Sign

Background

colour

Open position

Open

Green

Closed position

Close

Red




PAGE 16 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) Each pole of the breaker shall be provided with operating counter to record the number of operations performed during service. h)

The breakers shall be provided with pressure gauges and pressure relays for the operating mechanism.

i)

The circuit breakers shall be supplied with thermostatically controlled tank heaters wherever required. Where the heater current rating exceeds one ampere, thermostatically controlled contactors shall be used.

j)

The circuit breakers shall be provided with a rating plate as per the requirements of IEC. The voltage required to operate the tripping coil shall also be indicated.

k)

Circuit breakers except line circuit breakers shall be designed for 3-phase tripping and closing. Only line circuit breakers shall have single-phase and 3phase auto-enclosing capabilities. The line breakers shall be capable of independent pole operation. Each phase shall be completely isolated from the other two phases.

l)

All necessary interposing & interlocking control relays for circuit breaker tripping and closing shall be located in the control cabinets supplied by the Contractor.

m)

The disconnectors shall be interlocked electrically with the associated circuit breakers such that the disconnector cannot be operated unless the associated circuit breaker is opened. The interlocking shall prevent any incorrect switching sequence and enable the breakers to be operated without risks, either from the Bay Module Control Cabinet, Bay Control Unit or from the power house control room. The actuation of the manual operating device shall also be disabled to energise the electrical control circuits. Necessary interlocks shall be provided to prevent from hunting and other dangerous or undesirable operations of the circuit breaker.

n)

The circuit breaker control system shall prevent closing of the circuit breaker when there is insufficient stored energy in the operating mechanism storage system and insufficient SF6 gas density / dielectric strength. It shall lockout the breaker when the SF6 gas density drops below a minimum permissible level. The state of the breaker arc-quenching and insulating gas shall be monitored by a temperature-compensated pressure switch or density switch with two alarm levels. The first stage alarm shall be set well before any dangerous condition is reached; the second stage shall initiate breaker lockout. In addition, the actual gas pressure shall be shown on a local control cubicle.

o)

The circuit breaker shall be able to operate locally or from a remote point. Local operation shall be by means of an open/close control switch located in the bay module control cabinet. Remote control via a remote/local control transfer switch will be from the Relay room & power house control room. The protection devices will remain operational in either remote or local control mode. When in the maintenance mode, all remote trip or close control




PAGE 17 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) signals will be blocked. The breaker controls shall operate from the two independent 220V DC systems with both the trip coils connected. Mechanical indicators coupled to the movable contact system shall be provided to show the true position of the main breaker contacts. Operation counters shall be provided for each breaker pole or otherwise for each breaker. The two numbers of circuit breakers for the 400KV outgoing feeders shall be provided with preinsertion resistors. However, the requirement of preinsertion resistors will be decided at the detailed design stage. p)

Control scheme for the circuit breakers shall be submitted by the Contractor giving full details of operating mechanism and their advantages alongwith relevant drawings.

q)

The circuit breaker shall be provided with duplicate electrical tripping facilities. This shall include but not be limited to the following:a)

Two electrically separate identical trip coils.

b)

Two electrically independent and identical sets of wiring, terminals and protective equipment for connection to two independent control and/or tripping power sources.

r)

The above noted requirement refers only to duplicate electrical tripping facilities and should not be interpreted as requiring the provision of any mechanical or hydraulic components in duplicate form. Duplicate opening control valve would be considered as an advantage over two solenoids on the same valve.

s)

The circuit breaker as well as local control cubicle shall be provided with red and green local indicating lamps which shall be connected through one normally open and one normally closed contact of auxiliary switch for each pole. The circuit breaker shall further be provided with amber lamp to indicate healthy trip conditions. i.e trip circuit supervision

t)

All DC coils (trip, close, auxiliary etc.) shall be equipped with surge suppression devices such as diodes across the coils to provide a discharge path for transient voltage. The provision of such devices shall neither extend the drop out time of coil nor shall interfere with normal operation of the circuit breaker. a)

On failure of auxiliary supply, the operating mechanism shall be capable of performing a complete 0—0.3S—CO—3 Min—CO sequence for all breakers & corresponding sequence for other breakers.

b)

Only line circuit breakers shall be designed for automatic reclosing duty cycles from remote devices as per duty envisaged in these specifications.




PAGE 18 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) c)

Auxiliary Switches for the Circuit Breakers. Apart from any auxiliary switches normally required in the circuit breakers for control or auxiliary functions as detailed herein, each pole of circuit breaker shall be provided with auxiliary switches having twelve(12) normally open `NO' and twelve(12) normally closed `NC' contacts, all electrically independent and readily convertible from normally open to normally closed operation or vice-versa. If non adjustable and non convertible type of auxiliary switches are offered, the contractor is required to furnish the technical details of such switches alongwith their advantages over the adjustable and convertible switches to be derived by the Employer. Six `NO' and six `NC’ contacts shall be adjustable for early make or early break operation. An early make ‘NO’ contact connected in series with an early break `NC' contact shall provide a pulse during circuit breaker closing and tripping. The above twenty four contacts of each pole shall be connected by the Contractor to terminal blocks in the bay module control cabinet. The contacts shall be capable of interrupting as per IEC 694.

d)

Breakers shall have separate operating mechanism for each pole and shall be equipped with an electrical phase disagreement circuit, complete with a time delay relay with adjustable setting. The relay shall provide automatic 3-phase tripping of the circuit breaker or single pole tripping in case of line breaker, and shall have a normally open contact wired to the bay control cabinet terminal block.

e)

The Contractor shall supply all relays, switches and accessories to provide for fail- safe operation of the circuit breaker under conditions of low stored energy. The circuit breaker shall have local storage sufficient for a duty cycle following the loss of supply to the main energy storage system. The recharging time following the restoration of the supply shall be less than 30 minutes. Low stored energy in any pole shall initiate at:-

f)

i)

Level 1:

Low stored energy (pressure) alarm.

ii)

Level 2

Initiate blocking of breaker closing when stored energy is insufficient to perform a close-open duty cycle.

iii)

Level 3

Initiate automatic lockout of circuit breaker tripping and isolation at a point where sufficient stored energy is still available to perform the operation.

The Contractor shall explain the features incorporated in the circuit breaker control mechanism to properly supervise the operation of opening of each pole of the breaker. A pole discordance alarm shall be provided for annunciation.




PAGE 19 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) g)

The means shall be provided to mechanically block the operating mechanism so that adjustments may be made safely.

h)

All auxiliary devices, such as heaters, receptacles, etc. shall be suitable for connection to the Employer's power sources. The details of these sources are given as under: a)

240 V A.C. Single phase- 50Hz

b) 415 V A.C. 3-phase, 4-wire, 50Hz c) 220 V DC from station battery banks for control circuits. 9.04.00

Operating Mechanism General requirements : a)

Circuit breaker shall be operated by pneumatic mechanism or electric spring charged mechanism or electro hydraulic mechanism or a combination of these. The mechanism shall be housed in a dust proof cabinet and shall have IP : 42 degree of protection.

b)

The operating mechanism shall be anti-pumping and trip free (as per IEC definition) electrically and either mechanically or pneumatically under every method of closing. The mechanism of the breaker shall be such that the position of the breaker is maintained even after the leakage of operating media and/or gas

c)

The operating mechanism shall be strong, rigid, not subject to rebound or to critical adjustments at site and shall be readily accessible for maintenance.

d)

The operating mechanism shall be suitable for high speed reclosing and other duties specified. During reclosing the breaker contacts shall close fully and then open. The mechanism shall be antipumping and trip free (as per IEC definition) under every method of closing.

e)

The mechanism shall be such that the failure of any auxiliary spring will not prevent tripping and will not cause trip or closing operation of the power operating devise.

f)

A mechanical indicator shall be provided to show open and close position of the breaker. It shall be located in a position where it will be visible to a man standing on the ground level with the mechanism housing closed. An operating counter shall also be provided in the central control cabinet.

g)

Working parts of the mechanism shall be of corrosion resisting material, bearings which require grease shall be equipped with pressure type grease fittings. Bearing pin, bolts, nuts and other parts shall be adequately pinned or locked to prevent loosening or changing adjustment with repeated operation of the breaker.




PAGE 20 OF 69

CLAUSE NO.

9.05.00

GAS INSULATED SWITCHGEAR (E1) h)

The contractor shall furnish detailed operation and maintenance manual of the mechanism alongwith the operation manual for the circuit breaker.

i)

The close and trip circuits shall be designed to permit use of momentarycontact switches and push buttons.

j)

Each breaker pole shall be provided with two (2) independent tripping circuits, valves, pressure switches, and coils each connected to a different set of protective relays.

k)

The breaker shall normally be operated by remote electrical control. Electrical tripping shall be performed by shunt trip coils. However, provisions shall be made for local electrical control. For this purpose a local/remote selector switch and close and trip control switch/push buttons shall be provided in the breaker central control cabinet.

l)

The trip coil shall be suitable for trip circuit supervision during both open and close position of breaker.

m)

Closing coil and associated circuits shall operate correctly at all values of voltage between 85% and 110% of the rated voltage. Shunt trip and associated circuits shall operate correctly under all operating conditions of the circuit breaker upto the rated breaking capacity of the circuit breaker and at all values of supply voltage between 70% and 110% of rated voltage. If additional elements are introduced in the trip coil circuit their successful operation and reliability for similar applications on circuit breakers shall be clearly brought out in the additional information schedules. In the absence of adequate details the offer is likely to be rejected.

n)

Densimeter contacts and pressure switch contacts shall be suitable for direct use as permissive in closing and tripping circuits. Separate contacts have to be used for each of tripping and closing circuits. If contacts are not suitably rated and multiplying relays are used then fail safe logic/schemes are to be employed. DC supplies for all auxiliary circuit shall be monitored and for remote annunciations and operation lockout in case of dc failures.

o)

The auxiliary switch of the breaker shall be positively driven by the breaker operating rod.

Spring operated Mechanism a)

Spring operated mechanism shall be complete with motor, opening spring & closing spring with limit switch for automatic charging and other necessary accessories to make the mechanism a complete operating unit.

b)

As long as power is available to the motor, a continuous sequence of the closing and opening operations shall be possible. The motor shall have adequate thermal rating for this duty. After failure of power supply to the motor, one close-open operation shall be possible with the energy contained in the operating mechanism.




PAGE 21 OF 69

CLAUSE NO.

9.06.00

GAS INSULATED SWITCHGEAR (E1) c)

Breaker operation shall be independent of the motor which shall be used solely for compressing the closing spring. Facility for manual charging of the closing spring shall also be provided. The motor rating shall be such that it required preferably not more than 30 seconds for full charging of the closing spring.

d)

Closing action of circuit breaker shall compress the opening spring ready for tripping.

e)

When closing springs are discharged after closing a breaker, closing springs shall automatically be charged for the next operation and an indication of this shall be provided in the local and remote control cabinet.

f)

Provisions shall be made to prevent a closing operation of the breaker when the spring is in the partial charged condition.

g)

The spring operating mechanism shall have adequate energy stored in the operating spring to close and latch the circuit breaker against the rated making current and also to provide the required energy for the tripping mechanism in case the tripping energy is derived from the operating mechanism.

Hydraulically Operated Mechanism a)

Hydraulically operated mechanism shall comprise of operating unit with power cylinder, control valves, high and low pressure reservoir, motor etc.

b)

The hydraulic oil used shall be fully compatible for the temperature range to be encountered during operation.

c)

The oil pressure switch controlling the oil pump and pressure in the high pressure reservoir shall have adequate no. of spare contacts, for continuous monitoring of low pressure, high pressure etc. at switchyard control room.

d)

The mechanism shall be suitable for at-least two close open operations after failure of AC supply to the motor starting at pressure equal to the lowest pressure of auto reclose duty plus pressure drop for one close open operation.

e)

The mechanism shall be capable of operating the circuit breaker correctly and performing the duty cycle specified under all conditions with the pressure of hydraulic operated fluid in the operating mechanism at the lowest permissible pressure before make up. The operating time at the lowest pressure for a particular operation shall not exceed the guaranteed operating time within any value of trip coil-supply voltage as specified.

f)

Trip lockout shall be provided to prevent operations of the circuit breaker below the minimum specified hydraulic pressure. Alarm contacts for loss of Nitrogen shall also be provided.




PAGE 22 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) g)

All hydraulic joints shall have no oil leakage under the site conditions and joints shall be tested at factory against oil leakage at a minimum of 1.5 times maximum working pressure.

h)

Hydraulic controls are to be provided and such controls shall be interlocked to prevent the circuit breakers from being tripped under conditions which will not allow a complete and safe trip operation. A close operation shall also be blocked unless a complete close-open or trip-free operation can be safely carried out.

i)

For hydraulic operated mechanism, auxiliary switches must be provided with a separate operating device working on the same mechanism. The operation of both the mechanisms should be simultaneous.

9.07.00

Pneumatically operated mechanism

9.07.01

Contractor shall offer unit compressor with each circuit breaker. The unit compressor are to be located outdoor near the breaker(s).

9.07.02

The breaker local air receivers shall comply with the requirement specified, and shall have sufficient capacity for two ‘CO’ operations of the breaker at the lowest pressure for reclose duty without refilling.

9.07.03

Independently adjustable pressure switches with potential free ungrounded contacts to actuate lockout device shall be provided. This lock out device with provision for remote alarm indication shall be incorporated in the circuit breaker to prevent operation whenever the pressure of the operating medium is below that required for satisfactory operation at the specified rating. The scheme should permit operation of all block and alarm relays as soon as the pressure transient present during the rapid pressure drop has been damped and a reliable pressure measurement can be made. Such facilities shall be provided for following conditions: Trip lockout pressure

- 2 nos.

Close lockout pressure

- 1 no.

Extreme low pressure

- 1 no.

Auto reclose lock out pressure

- 1 no.

9.07.04

The compressed air mechanism shall be capable of operating the circuit breaker under all duty conditions with the air pressure immediately before operation between 85% and 110% of the rated supply pressures. The make/break time at this supply pressure shall not exceed the specified make/ break time within any value of trip coil supply voltage as specified.

9.07.05

Following additional fittings shall be required for pneumatic Circuit Breaker a.

Unit compressed air system




PAGE 23 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) b.

Breaker Local air receiver

c.

Pressure gauge, spring-loaded safety valve and pressure switch with adjustable contacts.

d.

Pressure switch to initiate an alarm if the pressure in auxiliary reservoir falls below a preset level for longer than it is normally necessary to refill the reservoir.

e.

Stop, non-return and other control valves, piping and all accessories upto breaker mechanism housing.

10.00.00

DISCONNECTORS

10.01.00

Type & Rating a)

Disconnectors shall be of the single phase, single-pole, group operated type, installed in the switchgear at the locations as shown in the single-line diagram to provide electrical isolation of the circuit breakers from the generator transformers, double bus and transmission lines. The disconnectors shall conform to IEC-62271-102 and shall have the following ratings and performance characteristics in addition to those specified: i)

Rated Voltage(rms)

420KV

ii)

Rated Frequency

50Hz

iii)

System Earthing

Effectively earthing

iv)

Type

SF6 Insulated

v)


Open contact Phase to Earth

a)

One minute Power frequency withstand voltage across open gap

815 KV (rms) 650 KV (rms)

b)

Lightning Impulse voltage across isolating distance

1665 KVp

1425 KVp

c)

Rated switching impulse withstand voltage across isolating distance

1245 KVp

1050 KVp

vi)

Rated normal current •

Generator transformer module

2500 Amps

•

Line Module

2500 Amps.

•

Bus coupler module

2500 Amps




PAGE 24 OF 69

CLAUSE NO.


b) 10.02.00

vii)

Rated Short time withstand current for Disconnector and earthswitch

40KA(rms) for 1 sec

viii)

Rated dynamic short circuit withstand current of Disconnector and Earth switch

xi)

Temperature rise over ambient temp.

As per IEC

x)

Rated Mechanical terminal Load

As per IEC

xi)

Rated supply voltages of closing and opening devices & auxiliary circuits

220 V DC ungrounded 240 V, 50Hz, single phase & 415 V, 50Hz, three-phase AC.

xii)

Total operating time of disconnector alongwith its operating mechanism

Not to exceed 12 seconds

xiii)

Rated capacitive current make and break capacity

0.5 Amps.

xiv)

Interruption of loop current

1600/20 A/V

xv)

Partial discharge level at 1.1 Un/√3

5 pico coulombs

xvi)

Radio interference voltage

1000 microvolts from frequency between 0.5 MHz and 2.0 MHz at 266 KV (rms)

100KAp

The Contractor shall offer only those disconnectors which are guarded against the effect of VFTs (Very Fast Transients)

Duty Requirement Disconnector and Earthswitch shall be capable of withstanding the dynamic and thermal effects of the maximum possible short circuit of the system in their closed position. They shall be constructed such that they do not open under influence of short circuit current. The earthswitches wherever provided shall be constructional interlocked so that the earth switches can be operated only when the disconnector is open and vise versa.

10.02.01

The earthing switches shall be capable of discharging trapped charges of the associated lines

10.02.02

Disconnector and earthing switches shall be able to bear on the terminal the total forces including electro dynamic forces on the attached conductor without impairing reliability or current carrying capacity.




PAGE 25 OF 69

CLAUSE NO.


10.02.03

The disconnector shall be capable of making/breaking normal currents when no significant change in voltage occurs across the terminals of each pole of the isolator on account of making /breaking operation.

10.03.00

Construction & Design a)

The three pole group operated disconnectors shall be operated by electric motor suitable for use on AC / 220 V DC ungrounded system and shall be equipped with a manual operating mechanism for emergency use. The motor shall be protected against over current & short circuit.

b)

Disconnectors shall be designed as per relevant IEC. These shall be suitable to make and break the capacitive charging currents during their opening and closing. They shall also be able to make & break loop current which appears during transfer between bus bars. The contact shielding shall also be designed to prevent restrikes and high local stresses caused by the transient recovery voltages when these currents are interrupted.

c)

The disconnecting switches shall be arranged in such a way that all the three phases operate simultaneously. All the parts of the operating mechanism shall be able to withstand starting torque of the motor mechanism without damage until the motor overload protection operates.

d)

It shall be possible to operate the disconnecting switches manually by cranks or handwheels. The contacts shall be both mechanically and electrically disconnected during the manual operation.

e)

The operating mechanisms shall be complete with all necessary linkages, clamps, couplings, operating rods, support brackets and grounding devices. All the bearings shall be permanently lubricated or shall be of such a type that no lubrication or maintenance is required.

f)

The opening and closing of the disconnectors shall be achieved by either local or remote control. The local operation shall be by means of a twoposition control switch located in the bay module control cabinet.

g)

Remote control of the disconnectors from the BCU in Relay room & power house control room shall be made through remote / local transfer switch.

h)

The disconnector operations shall be interlocked electrically with the associated circuit breakers in such a way that the disconnector control is inoperative if the circuit breaker is closed.

i)

Each disconnector shall be supplied with auxiliary switch having six normally open and six normally closed contacts for use by others over and above those required for switchgear interlocking purposes. The auxiliary switch contacts are to be continuously adjustable such that, when required, they can be adjusted to make contact before the main switch contacts.

j)

The signaling of the closed position of the disconnector shall not take place unless it is certain that the movable contacts will reach a position in




PAGE 26 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) which the rated normal current, peak withstand current and short-time withstand current can be carried safely. k)

The signaling of the open position of the disconnector shall not take place unless the movable contacts have reached such a position that the clearance between the contacts is at least 80 percent of the rated isolating distance.

l)

All auxiliary switches and auxiliary circuits shall be capable of carrying a current of at least 10 A DC continuously.

m)

The auxiliary switches shall be capable of breaking at least 2 A in a 220V DC circuit with a time constant of not less than 20 milliseconds.

n)

The disconnectors and safety grounding switches shall have a mechanical key (padlocking key) and electrical interlocks to prevent closing of the grounding switches when isolator switches are in the closed position and to prevent closing of the disconnectors when the grounding switch is in the closed position.

o)

The local control of the isolator and high-speed grounding switches from the bay module control panel should be achieved from the individual control switches with the remote/local transfer switch set to local.

p)

All electrical sequence interlocks will apply in both remote and local control modes.

q)

Each disconnector shall have a clearly identifiable local, positively driven mechanical position indicator, together with position indicator on the bay module control cabinet and provisions for taking the signals to the power house control room. The details of the inscriptions & colouring for the indicator are given as under: Sign

Back ground

colour

Open position

Open

Green

Closed position

Closed

Red

r)

All the disconnecting switches shall have endoscopic arrangement allowing easy visual inspection of the travel of the switch contacts in both open and close positions, from the outside of the enclosure.

s)

The disconnecting switches shall be provided with rating plates and shall be accessible for inspection.

t)

The disconnecting switches shall be capable of being padlocked in both the open and closed positions with the operating motor automatically disengaged. The padlocking device shall be suitable for a standard size lock with a 10mm shank. The padlock must be visible and directly lock the final output shaft of the operating mechanism. Integrally mounted lock when




PAGE 27 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) provided shall be equipped with a unique key for such three phase group. Master key is not permitted.

10.04.00

SAFETY GROUNDING SWITCHES a)

Three-pole, group operated, safety grounding switches shall be operated by electric motor for use on AC / 220V DC ungrounded system and shall be equipped with a manual operating mechanism for emergency use. The motor shall be protected against over current and short circuit.

b)

In order to provide test facilities for CTs, transformers, cables etc., certain ground switches may require to be electrically insulated from the enclosures and have easily removable ground connections.

c)

Each safety grounding switch shall be electrically interlocked with its associated disconnector and circuit breaker such that it can only be closed if both the circuit breaker and disconnector are in open position. Safety grounding switch shall however be mechanically key interlocked with its associated disconnector.

d)

Each safety grounding switch shall have clearly identifiable local positive driven mechanical indicator together with position indicator on the bay module control cabinet and provision for taking the signal to Power House Control Room.

e)

The details of the inscription and colouring for the indicator are given as under: Sign

Background

colour

Open position

Open

Green

Closed position

Closed

Red

f)

Interlocks shall be provided so that manual operation of the switches or insertion of the manual operating device will disable the electrical control circuits.

g)

Each ground switch shall be fitted with auxiliary switches having four normally open and four normally closed contacts for use by others over and above those required for local interlocking and position indication purposes.

h)

Provision shall be made for padlocking the ground switches in either the open or closed position.

i)

All portions of the grounding switch and operating mechanism required for grounding shall be connected together utilizing flexible copper conductors having a minimum cross-sectional area of 50 mm2.

j)

The main grounding connections on each grounding switch shall be rated to carry the full short circuit rating of the switch for 1 s and shall be equipped




PAGE 28 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) with a silver-plated terminal connector suitable for steel strap of adequate rating for connection to the grounding grid.

10.05.00

k)

The safety grounding switches shall conform to the requirements of IEC 62271-102

l)

Mechanical position indication shall be provided locally at each switch and remotely at each bay module control cabinet & in the power house control room.

HIGH SPEED GROUNDING SWITCHES a)

Grounding switches located at the beginning of the Feeder bay modules shall be of the high-speed and will be used to discharge the respective charging currents, in addition to their safety grounding function. These grounding switches shall also be capable of interrupting the inductive currents and to withstand the associated TRV.

b)

Single phase switches shall be provided with operating mechanism for each phase suitable for operation from a AC / 220V DC ungrounded supply.

c)

The switches shall be fitted with a stored energy closing system to provide fault making capability.

d)

The short circuit making current rating of each ground switch shall be at least equal to its peak withstand current rating of 100 KA. The switches shall have inductive / capacitive current switching capability as per IEC-62271102.

e)

Each high speed make proof grounding switch shall have clearly identifiable local positive driven mechanical indicator together with position indicator on the bay module control cabinet and provision for taking the signal to Power House Control Room.

f)

The details of the inscription & colouring for the indicator shall be as under: Sign

Background

colour

Open position

Open

Green

Closed position

Closed

Red

g)

High-speed grounding switch operation should be possible locally from the bay module control cabinet, or remotely from the relay room & power house control room in conjunction with opening of the associated disconnector.

h)

These high-speed grounding switches shall be electrically interlocked with their associated circuit breakers and disconnectors so that the grounding switches can not be closed if the circuit breakers and disconnectors are closed.




PAGE 29 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) i)

Interlocks shall be provided so that the insertion of the manual operating devices will disable the electrical control circuits.

j)

Each high speed grounding switch shall be fitted with auxiliary switches having four normally open(NO) and four normally closed (NC) auxiliary contacts for use by others, over and above those required for local interlocking and position indication. All contacts shall be wired to terminal blocks in the local bay control cabinet. Provision shall be made for padlocking the grounding switches in either the open or closed position.

k)

All portion of the grounding switches and operating mechanism required for connection to ground shall be connected together utilizing flexible copper conductor having minimum cross-sectional area of 50 sq mm.

l)

The main carry the equipped adequate

m)

The high speed grounding switches shall conform to the requirements of IEC-62271-102.

grounding connection on each grounding switch shall be rated to peak withstand current rating of the switch for 1 sec and shall be with a silver-plated terminal connector suitable for steel strap of design for connection to the grounding grid.

11.00.00

CURRENT TRANSFORMERS

11.01.00

General

11.01.01

The current transformers and accessories shall conform to IEC-60044-1 and other relevant standards except to the extent explicitly mentioned in the specification.

11.01.02

The particulars of the various cores may likely change within reasonable limits as per the requirements of protection relays. The contractor is required to have these values confirmed from the Employer before proceeding with design of the cores. The other characteristics of CTs shall be as given below:

11.02.00

Type & Rating a)

i)

Rated short time thermal current for 1sec., KA(rms)

40

ii)

Rated dynamic current KA(peak)

100

iii)

Rated insulation levels

As specified

iv)

Power frequency over voltage withstand requirements for secondary windings

As specified

v)

Limits of temperature rise

As per IEC 185




PAGE 30 OF 69

CLAUSE NO.

11.03.00

GAS INSULATED SWITCHGEAR (E1) vi)

Maximum radio interference

Not exceeding 1000 micro voltage at 266 KV (rms)

vii)

Partial discharge level, pC

5 or less at 1.1 Un / √3

viii)

Nos of Cores

ix)

Accuracy class of Current Transformer

As per the details given in Table-I

Measurement CT

0.2

Protection CT

PS

Construction Details a)

The current transformers incorporated into the GIS will be used for protective relaying and metering and shall be of metal-enclosed type. The secondary windings shall be air insulated and mounted inside the metal enclosure. All the current transformers shall have effective electromagnetic shields to protect against high frequency transients.

b)

Each current transformer shall be equipped with a marshalling box with terminals for the secondary circuits, which are connected to the local control cubicle. The star / delta configuration and the inter connection to the line protection panels will be done at the CT terminal block located in the local control cubicle.

c)

Rating and Diagram Plates shall be as specified in the IEC specification incorporating the year of manufacture. The rated extended current rating voltage and rated thermal current shall also be marked on the name plate. The diagram plate shall show the terminal markings and relative physical arrangement of the current transformer cores with respect to the primary terminals(P1 & P2) The position of each primary terminal in the current transformer SF6 gas section shall be clearly marked by two plates fixed to the enclosure at each end of the current transformer.

d)

Current transformers guaranteed burdens and accuracy class are to be intended as simultaneous for all cores.

e)

The current transformers shall be suitable for high speed auto reclosing.

f)

Electro magnetic shields to be provided against high frequency transients typically 1-30 MHz.

g)

The wiring between each CT and bay module control cabinet shall be included in the scope of supply.




PAGE 31 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) h)

Provision shall be made for primary current injection testing of current transformers.

12.00.00

BUS VOLTAGE TRANSFORMERS

12.01.00

General

12.01.01

The voltage transformers and accessories shall conform to IEC-60044-1 and other relevant standards except to the extent explicitly mentioned in the specification.

12.01.02

Voltage transformers shall be of the electro magnetic type with SF6 gas insulation. The earth end of high voltage winding and the ends of secondary winding shall be brought out in the terminal box.

12.01.03

The rating and diagram plate shall be provided complying with the requirement of IEC specification incorporating the year of manufacture and including turns ratio, voltage ratio, burden, connection diagram etc.

12.01.04

The beginning and end of each secondary winding shall be wired to suitable terminals accommodated in a terminal box mounted directly on the voltage transformer section of SF6 switchgear.

12.01.05

All terminals shall be stamped or otherwise marked to correspond with the marking on the diagram plate. Provision shall be made for earthing of the secondary windings inside the terminal box.

12.01.06

The transformer shall be able to sustain full line voltage without saturation of transformer.

12.02.00

Type and Rating Parameter

Winding-I

a)

Rated secondary voltage, V

110/√3

b)

Rated secondary burden, VA

c)

Winding-II 110/√3

Winding-III 110/√3

50

50

Accuracy class

0.2

3P

d)

Utilisation

Metering

e)

Transformation ratio for all windings

400 KV /√3

f)

Temperature

As per IEC

g)

Voltage factor

1.5 for 30 sec.



50 3P

Spare

Protection 110 V /√3


PAGE 32 OF 69

CLAUSE NO.

12.03.00


h)


As specified

i)

One minute power frequency withstand voltage for secondary winding

3KV (rms)

j)

Radio interference voltage at 1.1Un/√3 and frequency range 0.5 to 2 MHz at 266KV (rms)

1000 micro volts

k)

Partial discharge level

5 pico coulombs or less

Constructional Details a)

The voltage transformers shall be located in a separate bay module on the bus and will be connected phase-to ground and shall be used for protection, metering and synchronizing

b)

The voltage transformers shall be of induction type, nonresistant and shall be contained in their own- SF6 compartment, separated from other parts of installation. The voltage transformers shall be effectively shielded against high frequency electromagnetic transients. The voltage transformers shall have three secondary windings.

c)

The voltage transformer secondaries shall be wired by Contractor to their associated secondary circuit breakers in the bay control cabinets.

13.00.00

SF6 BUSHING CONNECTION

13.01.00

SF6 GIS to XLPE Cable Termination a)

The 400KV overhead lines emanating from surface pothead yard are to be connected to underground 420 KV SF6 GIS through 400KV XLPE cables. The SF6 gas filled cable termination compartment suitable for making connection to 2 (two) nos.1Cx800 mm2 XLPE Copper Cable per phase is under the scope of GIS Contractor. The cable termination kit alongwith its insulators and structure shall be within the Employer’s scope. The Contractor shall have to supply all the details for proper co-ordination with the 400KV XLPE cables Contractor. This interface section shall be designed for ease of operation and maintenance.

b)

The inter connecting busduct shall employ capacitive grading and shall be divided into independent gas compartments by a barrier insulator with grading electrodes. The inter connecting GIS compartment shall be filled with SF6 gas. The gas space on the switchgear side of the barrier insulator shall have the same SF6 gas pressure as that of switchgear.

c)

The SF6 GIS to XLPE cable termination shall conform to IEC-62271-305 (latest edition) and shall have the following ratings:




PAGE 33 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) (a)

Rated lightning impulse withstand voltage

1425KV(peak)

(b)

Rated switching impulse withstand voltage

1050KV(peak)

(c)

One minute power frequency withstand voltage

650 KV(rms)

The copies of the type test certificates shall be supplied by the contractor alongwith the offer.

13.02.00

d)

The provision shall be made for a removable link. The gap created when the link is removed should have sufficient electric strength to withstand the switchgear high voltage site tests. The Contractor may suggest alternative arrangements to meet these requirements. The corona rings/stress shields for control of electrical field in the vicinity of the isolation gap shall be provided by the GIS contractor.

e)

All supporting structures for the SF6 bus-duct connections between the XLPE cable sealing ends and the GIS shall be supplied by the GIS Contractor.The contractor shall coordinate with Power House civil package contractor for civil works related to foundation of equipments.

f)

All contact surfaces of external terminals shall be silver-plated using pure silver.

g)

Sufficient interconnecting bus shall be supplied to connect together the various items of equipment. Bus stubs with appropriate caps shall be provided. The provision for return current conductor shall be made at the interface by the contractor.

h)

The openings for access shall be provided in each phase terminal enclosures as necessary to permit removal of connectors to isolate the XLPE cables to allow carrying out of insulation tests. The typical arrangement drawing of interconnecting bus-duct from GIS bay module to XLPE cable termination end shall be submitted alongwith offer.

Interface Between SF6 GIS to Transformer Oil Bushings a)

The enclosure of the SF6-to-oil bushings of the generator transformers shall form a part of the supply by the GIS Contractor and shall provide the transition section between the enclosure of SF6 equipment and the SF6 to-oil bushing of the transformer . The region adjacent to the interface point shall meet the minimum requirement as per IEC-62271-306. The ducts and the casing shall be suitable for the requirements for which it is designed. The Contractor should specify the forces which shall be transmitted to the SF6 bushing of the transformer. GIS equipment offered by the contractor should also withstand the forces from transformer to GIS, as intimated by the transformer Contractor. The Contractor shall have to supply all details for proper co-ordination with the transformer Contractor alongwith the offer. This




PAGE 34 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) interface section shall be designed in a manner which will allow ease of operation and maintenance of generator transformer bushing. This interfacing portion shall be suitably sectionalized alongwith SA. b)

The provision shall be made for a removable link. The gap created when the link is removed should have sufficient di-electric strength to withstand the switchgear high voltage site tests. The corona rings/stress shields for control of electrical field in the vicinity of the isolation gap shall be provided by the GIS contractor.

c)

The SF6 gas pressure within the termination compartment at the junction of the transformer bushing and the SF6 duct shall be 5.3 bar at 200° C to ensure correct environment for the SF6 bushing termination.

d)

Supporting structures for the SF6 duct connections between the transformer and the GIS shall be supplied by the Contractor. The requirements of any of the interface drawing for civil construction works of the foundation and installation of the equipments, shall also be included in the offer.

e)

Effective forces generated during the operation of transformer and those generated in the enclosure and the conductors of the SF6 equipment shall not exceed the allowable limits specified in the relevant IEC standard.

f)

Precise positional alignment of the enclosures is of crucial importance. The location and tolerances for the connection between the transformer and the equipment shall be specified by the transformer pacKAge Contractor. The Contractor is required to make provision for alignment and positional adjustment within the equipment.

g)

Sufficient interconnecting bus shall be supplied to connect together the various items of equipment. Bus stubs with appropriate caps shall be provided.

h)

The connection at transformer shall allow atleast 25mm of movement in any direction. The openings for access shall be provided in each phase terminal enclosures as necessary to permit removal of connectors to isolate the step-up transformer to carry out insulation tests. The typical arrangement drawing of interconnecting bus-duct from GIS bay module to step up transformer bushing housing shall be submitted alongwith offer. The interface equipment shall incorporate following features. i)

Housing to cover the transformer H.V side oil to SF6 bushing. This housing shall be filled with SF6 gas after assembly.

ii)

Porcelain bushing with oil and SF6 gas separating barrier insulator and flexible connections between transformer H.V. terminal & SF6 bus duct conductor are to be housed inside the enclosure.

iii)

The lateral mounting unit shall be suitable to allow axial assembly tolerances and to allow the transformers to be easily connected to or disconnected from the switchgear.




PAGE 35 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) iv) i)

Compensators shall be provided to avoid transfer of the transformer vibrations to the switchgear.

SF6 gas enclosure at the SF6 to oil bushing shall conform to the relevant IEC and meet all the technical requirements as specified.

14.00.00

SURGE ARRESTORS

14.01.00

Each arrestor shall conform to IEC-60099-4 for Gapless Arrester wherever applicable and shall have the following technical performance characteristics and ratings.

15.00.00

DUTY REQUIREMENTS

15.01.00

The surge arrester shall be of heavy duty station class and gapless (metal oxide) type without any series or shut gaps.

15.02.00

The Surge Arresters (SAs) shall be capable of discharging over-voltages occurring due to switching of unloaded transformers and long lines.

15.03.00

The reference current of SAs shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. Values and calculations shall be furnished with offer.

15.04.00

The SAs shall be fully stabilised thermally to give a life expectancy of one hundred (100) years under site conditions and take care of effect of direct solar radiation.

15.05.00

The SAs shall be suitable for circuit breaker duty cycle in the given system.

15.06.00

The SAs shall protect power transformers, circuit breakers, disconnecting switches, instrument transformers, etc with insulation levels specified in this specification.

15.07.00

The SAs shall be capable of withstanding meteorological and short circuit forces under site conditions.

15.08.00

The surge arresters are provided to protect the following equipment whose insulation levels are indicated in the table A given below. The contractor shall carry out the insulation coordination studies for deciding the location of the surge arrestors.




PAGE 36 OF 69

CLAUSE NO.


TABLE – A ----------------------------------------------------------------------------------------------------------------

15.09.00

S.NO. EQUIPMENT TO BE PROTECTED

INSULATION LEVEL LIGHTNING SWITCHING IMPULSE (KVp) SURGE 250/2500 (KVp) FOR 400 KV FOR 400 KV SYSTEM SYSTEM

1.

Power Transformer

± 1300

± 1050

2.

Instrument Transformer

± 1425

± 1050

3.

CB/Isolator - Phase to ground

± 1425

± 1050

- Across open contacts

± 1425

± 900

(± 240)

(± 340)

Surge arrestors shall be capable of discharge on severe re-energisation switching surges on a 400 KV line upto 450 km. length with surge impedance of 300 ohms and capacitance of 11986 nF/km and over voltage factor of 2.3 p.u. Surge arrestor shall be capable of discharging energy equipment to class 3 of IEC for a 420 KV system on two successive operations followed immediately by 50 Hz energisation with a sequential voltage profile as specified below: 705 KVp for 3 peaks 580 KVp for 0.1 second 565 KVp for 1 second 550 KVp for 10 seconds

15.10.00

400 KV line circuit breakers are equipped with closing resistor of 400 ohms with pre insertion time switching over voltage to 2.3 p.u.

15.11.00

Type & Rating i)

Rated system Voltage

420KV

ii)

System neutral earthing

Effectively earthed

iii)

Rated voltage of arrestor KV(rms)

390

iv)

Rated frequency

50Hz




PAGE 37 OF 69

CLAUSE NO.


v)

Class of arrester

Station type, heavy duty, SF6 gas-insulated, non linear zinc oxide gap less

vi)

Maximum continuous operating voltage capability, (L-N), KV rms

vii)

Nominal discharge current

10 KA of 8/20 microsec. wave

viii)

Discharge current at which insulation coord. is done


ix)

Long duration discharge class

3

x)

Low current long duration test value (2000 micro sec.)

1000 A

xi)

Pressure relief class

Class A of Table VII of IS:3070 or equivalent IEC.

xii)

Partial discharge at 1.05 MCOV (Continuous operating voltage)

Not more than 50 p.C.

xiii)

Min. Switching surge residual voltage (1 KA)

730 KVp minimum , 780 KVp maximum

xiv)

Maximum residual voltage at

303

i)

10KA nominal discharge current

900 KVp

ii)


975 KVp

xv)

Steep fronted wave residual voltage at 10KA

1050 KVp

xvi)

Current for pressure relief test

40KA(rms)

xvii)

Symmetrical fault current

xviii)

High current short duration test value(4/10 micro second work)

100KAp

xix)

Maximum switching surge protective level, KV (Peak)

840

xx)

Maximum residual voltage (discharge voltage) at 10 KA (8/20 microsecond current wave), KV (peak).

760



40KA for 1 sec


PAGE 38 OF 69

CLAUSE NO.


xxi)

xxii)

Maximum equivalent front-of wave protective level, KV (peak) (10 KA with voltage wave crest in 0.5 micro-second)

882

One minute dry/wet power frequency withstand voltage of arrestor housing

650 KV (rms)

Lightning impulse withstand voltage of equipment to be protected: -

Transformers, KV(peak)

1300

-

GIS component, KV(peak)

1425

xxiii)

Switching surge withstand voltage of equipment to be protected, KV(peak).

1050

xxiv)

Radio interference voltage at 266 KV(rms)

Not exceeding 1000 micro-volts

xxv)

Partial discharge level at 1.1 Un /√3

5 or less Pico coulombs

xxvi)

Energy level

8 KJ/KV (minimum )

xxvii)

Connection to system

Phase to earth

15.11.01

The contractor may select the technical parameters and characteristics of the surge arrestor so as to obtain a security ratio of atleast 1.30 under all conditions of over voltages and the basic insulation provided for the transformer winding. The contractor shall furnish a report containing the technical justification & calculations in support of the selection of the location and other technical parameters of the surge arrestor alongwith his bid.

15.11.02

This study report should highlight the technical comments on the proposed rated voltage, the line discharge class and the energy handling capacity. The basis for selecting the line discharge class as indicated in the offer may also be furnished alongwith the offer.

15.11.03

The contractor shall perform an insulation co-ordination study after award of contract to verify that protection of switchgear, main transformers against over voltages is adequate. The final surge arrestor characteristics, their numbers and exact locations of surge arrestors shall be decided after this study.




PAGE 39 OF 69

CLAUSE NO.


15.12.00

Construction Details

15.12.01

One SF6 gas insulated, metal enclosed surge arrester of the gapless non linear zinc oxide, heavy duty, station type shall be located on H.V. side of each generator transformer and and one outdoor lightning arrester on each outgoing feeder bay(line side). Bidder to consider the number of LAs as indicated in Single line diagram in Drawing No. 5505-500-PEH-A-006 as minimum quantity. However, additional lightning arresters, if required, based on the insulation coordination/transient analysis studies for switchyard systems, to be carried out by the contractor during detailed engineering, shall be provided by the Contractor.

15.12.02

The arrester enclosure shall be vertically or horizontally mounted to suit the layout of the switchgear as suggested by the contractor and shall be fitted with a discharge counter located in an easily accessible position.

15.12.03

The main grounding connection from the surge arrestor to the earth shall be provided by the Contractor. The size of the connecting conductor shall be such that all the energy is dissipated to the ground without getting overheated.

16.00.00

BUSBARS

16.01.00

The conductors of the bus bars shall be fabricated from aluminum tubular sections of cross- sectional area suitable to meet the current rating requirements. The busbars shall be housed in single phase enclosure The tubular bus section shall be housed in corrosion resistant aluminum enclosures, filled with pressurized SF6 gas. The conductors shall be supported from the enclosures by homogeneous epoxy resin insulators shaped to ensure uniform electrical field distribution and zero corona at rated voltage. Adequate provisions shall be made for absorption of the thermal expansions between the conductors and the enclosures. The metal bellow type compensators for adjusting tension shall be provided where ever required. The enclosures shall be designed to eliminate as much as possible all external effects of the flux created by normal and fault currents. The power losses in the system shall be kept to a minimum. The induced voltages on the enclosures shall not be allowed to exceed reasonable limits of safety for operating personnel.

16.02.00

The bus end connections shall be made with multi-contact connectors to allow for axial thermal expansion of the bus. The enclosure connections shall be flanged and shall be fitted with gaskets or O-ring seals to provide an effective gastight joint between sections.

16.03.00

Main bus bars shall be designed to have future extension bay as indicated in the single line diagram. The bus conductor end connectors and enclosure flanges shall be designed accordingly.

16.04.00

All necessary indoor and outdoor galvanised steel supporting structures for the proper erection, levelling and alignment of the bus bars shall be provided by the Contractor.

16.05.00

The interior of all the enclosures except cast flanges of aluminium / aluminum alloy shall not be painted.




PAGE 40 OF 69

CLAUSE NO.


16.06.00

The SF6 GIS bus-bars shall have continuous current rating of 2500 Amps.

16.07.00

The system employed shall be of the electrically continuous enclosure type, allowing free circulation of induced currents in the enclosures. The enclosures shall be cylindrical in shape and designed for maximum shielding to minimize electromagnetic forces caused by short circuit currents.

16.08.00

Where the interconnecting GIS bus passes through building walls, flooring or other enclosures, the Contractor shall supply the wall plates, flanges and their fixtures.

16.09.00

Wherever necessary, to absorb expansion / contraction, relative movement between the various items of equipment and the earthquake forces, bellows or other means shall be provided. The contractor must submit details of the means deployed alongwith the offer.

16.10.00

The Interface requirements between the equipments shall be in the scope of GIS Contractor.

16.11.00

Each gas compartment barrier shall be easily identifiable from the outside of the switchgear. The means of identification used shall be a black band, approx. 10mm wide, permanently affixed to the barrier insulator on the outer surface of the enclosure at the location of the barrier insulator. In case of leakage of the gas from any compartment, indication of respective compartments should be provided on the annunciator.

17.00.00

CONTROL EQUIPMENT

17.01.00

Circuit Breaker Accessories/Auxiliary Equipment

17.01.01

The accessories and auxiliary equipment to be supplied with the circuit breaker and other components of the same bay module shall include all parts necessary for proper functioning of the circuit breaker as well as the following items to be installed in the breaker control cabinet: a)

Operation counter, electrically operated.

b)

One set of adequately rated thermostatically controlled, anti-condensation heater with provision for monitoring of heater failure, wired to terminal blocks.

c)

Pair of copper grounding terminals to be located near the control cable entrance.

d)

Operating mechanism, pressurising unit, gauges and switches.

e)

All motors shall have individual thermal over-current protection.

f)

Circuit breaker SF6 gas pressure monitoring unit and moisture detection unit.

g)

One vermin-proof sheet steel cabinet of class IP-54 and adequate size shall be provided for housing the operating mechanism, control and auxiliary equipment and for terminating all control, alarm and auxiliary




PAGE 41 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) circuits in suitable terminal blocks. The control cabinet shall be provided with hinged doors with provision for locking and removable cable gland plates for bottom cable entry. The viewing windows shall be provided for observation of the instruments without opening the cabinet. Suitably engraved name plates shall be provided to identify all the equipment in the control cabinet.

17.01.02

All control wiring and terminations from the circuit breaker cubicle to the switchgear bay module control cabinet shall be provided by Contractor.

17.01.03

All control cables shall be PVC insulated, shielded, Fire Retardant, Low Smoke (FRLS) with stranded copper conductors. Cable shields shall be grounded at both ends. Grounding connections shall be as short & direct as possible and shall terminate at the point of entry to cabinets or terminal boxes.

17.01.04

Coaxial type cable glands suitable for use with shielded cables shall be used at each termination.

17.01.05

All control cables termination shall be plug-in type and shall be installed in such a manner as to limit the effects of transient electromagnetic voltage on the control cables to an acceptable level.

17.02.00

Bay Module Control Cabinets

17.02.01

Each switchgear bay module shall be suitable for local control and remote control (Relay panel room in GIS hall as well as power house control room). The contractor shall supply the main control cabinet of the floor standing type alongwith GIS equipments. The cabinet shall have double, full height, hinged, gasketed, lockable doors. One door shall have a safety glass window through which the various switchgear controls can be viewed without opening the doors.

17.02.02

The cabinet will be utilized for the switchgear bay local control module and as the terminating center for all power supply, control annunciation and supervisory wiring interfacing with Employer's systems.

17.02.03

The following equipments shall be mounted on the cabinet door : -

Remote/local control disconnector switches.

transfer switch

for

the

circuit breakers and

-

Normal operation/maintenance control transfer switch for remote electrical controls.

-

Mimic diagram of the switchgear bay complete with semaphore indicators for the switchgear component position indication and local control switches for open / close or close-trip control of the circuit breaker, isolators and grounding switches.

disconnector of

The following equipments shall be mounted internally in the cabinet : -

All bay switchgear interlocking wiring and auxiliary relays.




PAGE 42 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) -

AC and DC power supply circuit breakers.

-

All necessary incoming and outgoing terminal blocks.

-

Space heaters

-

All instruments and devices required for supervision & control of GIS

17.02.04

The bus voltage transformer secondary terminal circuit breaker will be mounted with in the bus VT bay module control cabinet.

17.02.05

The annunciator system shall have sufficient modules and illuminated windows for providing annunciation for low / high gas pressure / density, alarms & trips for circuit breaker operating mechanism and all other abnormal conditions.

17.02.06

Each annunciator module shall have electrically separate changeover contacts for remote alarm indication. Each remote alarm contact shall be wired to terminal blocks. The annunciator panel shall be complete with an audible warning horn, acknowledge/reset for horn silence and lamp test push buttons. The horn shall automatically silence if the acknowledge reset button is not operated within 1 minute of the alarm initiation. However, the illuminated window of the fault point shall continue to flash until the acknowledge signal is given.

17.02.07

The control cabinets shall be suitable for bottom entry of cables.

18.00.00

SUPPORTING STRUCTURES

18.01.00

The Contractor shall design, fabricate and supply the equipment supporting framework including all rails, transverse & longitudinal beams and supporting members with all necessary hardware & embedded parts. General structural designs and structural details shall be subject to the approval of the Employer.

18.02.00

The floor of the switchgear building will be designed to support all the loads imposed by the equipment supporting framework. The Contractor shall make provision in his designs to minimize transfer of forces resulting from thermal expansion or switchgear operation to the walls & floors of the switchgear building. To facilitate the design of floor of switchgear, the Contractor shall supply the details of static and dynamic loads to be supported by the slab alongwith the offer.

18.03.00

Non-corrosive metal or cadmium plated steel shall be used for bolts and nuts throughout the work when either or both are subjected to frequent adjustment or removal.

18.04.00

All steel structure members shall be hot dip galvanised.

18.05.00

All supporting structures shall be designed in such a way so as to allow dismantling for the addition of further switchgear components or maintenance of existing equipment without requiring temporary supports.




PAGE 43 OF 69

CLAUSE NO.


19.00.00

SF6 GAS PROCESSING UNIT

19.01.00

SF6 gas processing unit suitable for evacuating, liquefying, evaporating, filling, drying, storing and purifying SF6 gas during the initial installation, subsequent maintenance and future extension of GIS, shall be provided. The cart shall be equipped with rubber wheels and shall be easily manouverable by two workers on the GIS floor. The unit shall be provided with gas testing kit to measure the moisture contents of the gas and with pressure monitoring system. The instrument for the measurement of acidity shall also be provided alongwith nozzle etc.

19.02.00

The unit shall be self-contained (except for additional gas storage bottles) and fully equipped with at least an electric vacuum pump, gas compressor, gas drier, gas filter, refrigeration unit, evaporator, gas storage tank, full instrumentation for measuring vacuum on vacuum pump, compressor inlet temperature, tank pressure and temperature, valves and piping to perform the following operations as a minimum requirement: i.

Evacuation from a gas filled compartment using the vacuum pump.

ii.

Transfer of SF6 gas from a system at some positive or negative pressure to the storage tank via the gas drier and filter.

iii.

Recirculation of SF6 gas in the storage tank through the drier.

iv.

Recirculation of SF6 gas in any switchgear through the drier and filter.

v.

Evaporating and filling SF6 gas.

vi.

Drawing off and liquefying SF6 gas.

vii.

A combination operation of filling SF6 gas into gas system and evacuating a second gas system using the vacuum pump.

viii.

Pressure monitoring.

ix.

Measurement of moisture content & acidity measurement. Separate portable instruments should be included in the offer

or bus duct compartment

20.00.00

MONITORING

20.01.00

The gas density in each gas compartment shall be monitored by electrically isolated & independently adjustable temperature compensated density switches. The factory set density switches shall also be acceptable. The relative merits, however for such switches in place of adjustable density switches shall be indicated in the offer. Two level density switches shall be provided for each GIS bus compartment to initiate remote devices of level-I alarm and level-II tripping. The setting of level-I alarm and level – II tripping shall be such that the dielectric strengths of SF6 gas are maintained. The necessary indication shall be




PAGE 44 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) provided at the circuit breaker control cabinet identifying the gas compartment from which a level-I alarm is initiated. Two level density switches shall be provided for each circuit breaker compartment to initiate the following: i)

Level-I

Remote alarm and prevent closing of the breaker in case it is open.

ii)

Level-II

Initiation of each circuit breaker 3-pole tripping plus isolation of the circuit breaker through automatic opening of the associated disconnecting switches.

Wiring for automatic circuit breaker tripping and isolation shall be in the scope of Contractor. Wiring between the GIS compartment gas density switches and the terminals in the circuit breaker control cabinet shall be in the scope of the Contractor and the continuous shielded cable shall be used. Additional Monitoring equipments as per Annexure-II shall also be in the scope of the contractor. 20.02.00

Gas pressure monitoring devices shall be fitted with test valves such that field testing of the monitoring device can be performed without draining the main gas system.

20.03.00

Each gas section shall be fitted with a suitable valve for routine gas sampling.

20.04.00

The Contractor shall satisfy the Employer regarding accuracy limits of gas monitoring devices.

20.05.00

The equipment shall have provision to monitor the following parameters periodically to check anomalies and/or wear & tear of equipment. i)

Operation of mechanical components: The parameters to be monitored are:

ii)

-

Fluid pressure(oil) or hydraulic mechanism power reserve

-

The displacement speed of the moving parts

-

The travel of moving parts

-

Friction of moving parts

Wear of circuit breakers interrupting chamber: The parameters to be monitored are: -

Determination of contact closing position

-

Accumulated effect of interrupted currents

-

Decomposition products content in SF6 Gas




PAGE 45 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) iii)

Insulation failure: The parameters to be monitored are:

iv)

-

SF6 gas density monitoring of all the compartments

-

High frequency current detection for partial discharge detection

-

Sonic detection

Safety bursting disc for each SF6 gas compartment.

21.00.00

TECHNICAL REQUIREMENTS

21.01.00

Common Requirements All the SF6 gas insulated circuit breakers, disconnectors, grounding switches and bus bars shall be of single isolated phase type.

21.02.00

Protective Finish All the exterior surfaces shall be cleaned and painted before leaving the factory with one coat of approved primer and two coats of water resistant approved paint on the equipment. The under-side of all painted surfaces bearing upon the concrete foundation shall be given two coats of approved primer. Extra paint for retouching at site shall be made available by the Contractor.

21.03.00

Fire Retardancy a)

All components shall be fire retardant and shall be tested in accordance with IEC 695. Gas emmissivity when the material is heated shall be minimal. PVC material shall not be used.

b)

Control cables in a grouped environment shall not catch fire flame or continue to burn when tested as per IEC 695. The method of test and criteria for success or failure shall be in accordance with the above IEC.

22.00.00

GROUNDING

22.01.00

The grounding system shall be designed and provided as per IEEE-80-2000 and CIGRE-44 to protect operating staff against any hazardous touch voltages and electro-mechanical interferences.

22.02.00

The GIS contractor shall define clearly what constitutes the main grounding bus of the GIS. The GIS contractor must supply the entire material for grounding bus of GIS viz conductor, clamps, joints, bimetallic strips( for connection between different type of earthing materials), operating and safety platforms etc. The GIS contractor is also required to supply all the earthing conductors and associated hardware material for the following:




PAGE 46 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) i)

Connecting all GIS equipment, bus ducts, enclosures, control cabinets, supporting structure etc. to the ground bus of GIS.

ii)

Connecting grounding bus of GIS to the groundmat riser in transformer / GIS cavern to be provided by the Employer.

22.03.00

The enclosure of the GIS shall be grounded at several points so that there shall be grounded cage around all the live parts. A minimum of two nos. of grounding connections should be provided for each of circuit breaker, transformer terminals, cable terminals, surge arrestors, earth switches and at each end of the bus bars. The grounding continuity between each enclosure shall be effectively interconnected with links or straps to bridge the flanges. Subassembly-to-subassembly bonding shall be provided to provide gap & safe voltage gradients between all intentionally grounded parts of the GIS assembly & between those parts and the main grounding bus of the GIS.

22.04.00

The enclosure grounding system shall be designed to minimize circulating currents and to ensure that the potential rise is kept to an acceptable level. Each marshalling box, local control panel, power and control cable sheaths and other non current carrying metallic structures shall be connected to the grounding system of GIS via connections that are separated from GIS enclosures.

22.05.00

The grounding connector shall be of sufficient mechanical strength to withstand electromagnetic forces as well as capable of carrying the anticipated maximum fault current without overheating. At least two grounding paths shall be provided to connect each point to the main grounding bus. Necessary precautions should be undertaken to prevent excessive currents from being induced into adjacent frames, structures of reinforcing steel and to avoid establishment of current loops via other station equipment. Care should be taken to prevent discontinuities in enclosure grounding path at the transformer connections to GIS to prevent circulating currents in the circuit breaker and transformer tank made of steel.

22.06.00

All flexible bonding leads shall be of tinned copper. All connectors, for attaching flexible bonding leads to grounding conductors and grounding conductors to support structures shall be tinned bronze with stainless steel or tinned bronze hardware.

22.07.00

The contractor shall provide suitable measure to mitigate transient enclosure voltage caused by high frequency currents caused by lightning strikes, operation of surge arrester, phase/earth fault and discharges between contracts during switching operation. The grounding system shall ensure safe touch & step voltages in all the enclosures. The contractor shall provide suitable barrier of non-liner resistor/counter discontinued SF6/Transformer and SF6/ HV cable bushing etc. to mitigate transient enclosure voltage.

23.00.00

HIGH VOLTAGE TRANSIENTS High voltage transients from switching operations and internal faults are coupled to the external enclosure of the GIS. Since the effects of these transients on people are not known, the operating personnel are required to avoid contact with the enclosure during switching operations. Such a restriction is considered




PAGE 47 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) undesirable. The Contractor is therefore required to furnish the details of the devices and techniques to be deployed by him for reducing transients to an acceptable level along with his offer.

24.00.00

BURN THROUGH PREVENTION

24.01.00

The Contractor shall furnish the details regarding the design features of their equipment which are intended to prevent burn through when an internal arc occurs. Internal arcing test reports for aluminum enclosures of a similar configuration and wall thickness of the equipment should be included in the offer. The worst case of fault with an arc adjacent to a spacer should be considered and discussed in the offer. The effect of pressure rise and time to burn through should also be discussed for an internal arc. The latest and most efficient technique of burn through shall be incorporated by the Contractor and the details of the same shall be furnished by the Contractor alongwith the offer.

24.02.00

The Contractor is required to furnish the details regarding techniques to be used by him to reduce or eliminate the probability of burn through.

25.00.00

BOLTING REQUIREMENTS

25.01.00

The details of bolt sizes and threading shall be shown on the appropriate drawings.

25.02.00

Where self locking type of nuts are used , they shall be of the reusable type. The pressed type of nuts are not acceptable.

25.03.00

The Contractor shall arrange all the foundation bolts, embedments and insertions as required well in advance in order to enable the Employer to make provision for these embedments in the slab as required.

26.00.00

HEATERS

26.01.00

All the heaters shall be suitable for connection to a 240V AC, single phase, 50 Hz supply. The heater in the mechanism housing shall be connected inside the housing to this supply and shall be thermostatically controlled. The leads to the tank heaters shall be enclosed in a conduit.

26.02.00

All the thermostats and the temperature indicating devices shall be calibrated in metric units.

27.00.00

SERVICE LIFE

27.01.00

SF6 circuit breakers, disconnecting switches and grounding switches will be subjected to frequent and occasionally repetitive, no load / full load operations and switching off short circuit currents , capacitive and inductive currents within their ratings. In order to minimize maintenance and component replacement, the Contractor shall submit proof that all offered SF6 GIS equipments has withstood a life of 10,000 mechanical operations. The maintenance free period for any of its external components shall not be less than 5 years intervals & internal components including refilling of gas shall not be




PAGE 48 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) less than 10 years. The Contractor shall propose the recommended period for scheduled maintenance.

28.00.00

WELDING

28.01.00

Pressure Vessel and Pressure Pipe Welding

28.02.00

The pressure vessel and pressure piping shall be designed and built according to the requirements of International standards for construction & inspection of boilers and pressure vessels.

28.03.00

All welding and brazing must Indian/International standards.

28.04.00

In addition to the requirements of the specifications, the following requirements shall also be fulfilled:

28.05.00

satisfy

the

requirements

of

the

relevant

a)

All welding procedures to be used in the fabrication of pressure vessels and pipings shall be submitted to Employer for approval. These procedures must be in consistence with the International Standards.

b)

All butt welds shall be full penetration welds

c)

All the welding works shall be performed by the qualified welders and the test certificates of welder qualification duly approved by reputed test house shall be submitted to the Employer.

Non-Destructive Examination Procedure (NDE) NDE procedures to be adopted by the fabricator shall be submitted to the Employer for approval. As a minimum requirement, butt welds on pressure vessels and pressure piping shall be subjected to radiography inspection.

29.00.00

INSPECTION AND TESTING

29.01.00

General

29.01.01

All the equipment, apparatus, materials and supplies provided by the contractor under this contract shall be subjected to tests in the shop and at the field in the presence of Employer for conformity with the requirements of the specifications. The method and procedure of the tests shall be as specified for the particular item or shall be in conformity with the applicable recognized standards for making such test. The details of the test procedures and test equipment to be used should be intimated to the Employer well in advance i.e. not less than 30 days before these tests are conducted. Unless otherwise specified, the contractor shall perform all shop and field tests.

29.01.02

The Contractor shall submit a detailed quality assurance plan within 30 days after the commencement date intimating the testing program to the Employer for approval. The testing of the related equipment shall be coordinated so that




PAGE 49 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) testing may proceed with minimum delay. The performance tests shall start, proceed, stop and be resumed in accordance with the approved schedule.

29.01.03

The Contractor shall, at its own expense, promptly make good all defects evident by testing or made apparent in any other ways. After defects in the equipment have been rectified, the equipment will be subjected to such retesting as may be necessary until the equipment is proved to be in satisfactory operation.

29.01.04

Within 30 days of completion of each and every specified test, including commissioning tests, the Contractor shall submit six signed copies of the test reports to the Employer.

29.01.05

The test reports shall indicate the tests performed, the results obtained, instruments used, names of personnel carrying out the tests and provisions for signatures of witnesses. They shall also show the number and date. The format of these reports shall be submitted alongwith testing procedure for the Employer's approval well in advance.

29.01.06

The test report shall include, but not necessarily be limited to the following. -

A description of the test equipment with diagram showing arrangement of the test instruments and devices.

-

Sample computations, wherever necessary or desirable to show the test values employed in the equations.

-

Curves showing relation of tested quantities.

-

Data in tabulated form

-

The comparison of the test results with the guaranteed requirements of the specification and explanation of deviations, if any.

29.02.00

Shop Tests

29.02.01

All major parts of the equipment, especially those necessitating sub-division of parts for transport and subsequent reassembly at site, shall be match assembled in the factory and carefully match marked before dismantling. The dowel holes shall be provided with dowels to assist in reassembly. The accuracy of fitting has to be assured at site at all stages of assembly.

29.02.02

Each transport section of switchgear shall be shop tested.

29.02.03

Switchgear components forming part of GIS namely circuit breakers, disconnectors, grounding switches, current transformers, Voltage transformers, surge arrestors & SF6 interface bushing, the routine tests of which have been covered under other relevant IEC standards and which do not form the part of tests specified below shall have these tests performed before being assembled into the switchgear. However, for electronic modules, equipment and individual components burn-in tests, temperature & voltage stress tests shall also be performed. Routine tests shall be conducted by automatic processes, wherever practicable particularly during




PAGE 50 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) testing of wiring. An example of the other tests referred to above would be as follows: a)

Verification of terminal markings and accuracy & composite for current and potential transformers.

b)

Routine and standard acceptance tests for surge arrestors specified in IEC60099-4 relevant to metal oxide type arrestors without gaps.

c)

Routine tests (on transport section) : i)

error tests

Dry Power frequency voltage withstand tests on the main circuit.

ii)

Dielectric tests on auxiliary and control circuit.

iii)

Tests to verify the resistance of the main circuit

iv)

Partial discharge tests

v)

Pressure test on enclosures

vi)

Gas tightness test.

vii) Mechanical operation tests. viii) Tests of auxiliary, electrical and hydraulic devices. ix)

Check of wiring.

x)

Power frequency voltage dry tests

xi) Voltage tests on auxiliary and control circuits xii) Fluid leakage tests (where applicable) The applicable standards for the above tests shall be IEC 62271-203 , IEC 62271100 and IEC 60694/ 62271-1. In addition, corrosion protection tests at random on all equipment shall be performed. 29.03.00

Mechanical Tests Mechanical tests shall be carried out as per respective IEC and also include the following.




PAGE 51 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) (a)

(b)

(c)

Mechanical operation of Circuit Breaker -

25 open and close operations at rated voltage & rated pressure.

-

5 open and close operations at minimum voltage & minimum pressure.

-

5 open and close operations at maximum voltage & maximum pressure.

-

5 close - open cycles at rated voltage and rated pressure.

-

5 open-close-open cycles at rated voltage and rated pressure.

-

5 close open operating cycles with the tripping mechanism energised by the closing of the main contacts.

-

5 open-close sequences 0-0.3 sec-CO-3 min-CO for line breakers.

The operating times are to be recorded as follows: -

Opening time measured at rated supply voltage for each pole.

-

Closing time measured at rated supply voltage for each pole.

-

Recording of time travel diagram.

-

Measure hydraulic mechanism recharging time after one opening and closing.

Mechanical operation of Disconnector and Ground Switches -

5 open/close cycles at rated voltage.

-

5 open/close cycles at minimum voltage.

-

5 open/close cycles at maximum voltage.

-

Ensure operation of interlocks in proper sequence.

(d)

Gas tightness leak test on single pole assembly of switchgear module.

(e)

Design and visual checks as per respective IEC.

29.04.00

Electrical Tests/Routine Tests

29.04.01

The electrical tests to be performed on the specified factory assemblies shall be as per respective IEC and shall include the following: -

Main circuit resistance measurement for each pole.




PAGE 52 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) -

Measurement of resistance of circuit breaker close and trip coils.

-

Measurement of power consumption of motor operated mechanism at rated supply voltage.

-

Ensure operation of electrical interlocks in proper sequence.

(a)

Control cubicle

-

Operation or functional checks of all circuits at rated supply voltage.

-

Dielectric test of auxiliary circuits at 2000 V at 50 Hz for one minute.

-

Operation test of all pressure density monitoring switches.

-

Dielectric tests (in the following order) :

-

Power frequency withstand test

-

Partial discharge test

(b)

Current transformers (As perIS-2705 / IEC 185) i)

Verification of terminal marking & polarity.

ii)

Power frequency dry withstand tests on primary windings

iii)

Power frequency dry withstand tests on secondary windings

iv)

Over voltage inter-turn test.

v)

Determination of errors or other characteristics.

vi)

Partial Discharge tests (as per IS: 11322)

For the protective current transformers the following additional tests shall be performed : i)

Knee point voltage test

ii)

Exciting current test




PAGE 53 OF 69

CLAUSE NO.


Secondary winding resistance tests

iv)

Turns ratio test

v)

For the protective current transformers (other than class PS type the following additional tests should be performed :

c)

vi)

Current error & phase displacement

vii)

Composite error test

Surge arresters (As per IEC-60099-4). i)

Measurement of reference voltage.

ii)

Residual voltage test.

iii)

Satisfactory absence from partial discharges & contact noise to be checked on each unit by any sensitive method adopted by contractor.

iv)

A leakage check may be made on each unit by any sensitive method adopted by contractor in case of arrester unit with sealed housing.

v) d)

Current distribution test for multi-column arrester.

Disconnectors & grounding switches (As per IEC-62271-102) i)

Power frequency voltage withstand dry tests of the main circuit and auxiliary circuits.

ii)

Voltage withstand tests on auxiliary and control circuits.

iii)

Measurement of the resistance of the main circuit.

iv)

Mechanical operating tests.

v)

Tests to prove as per IS:1818




PAGE 54 OF 69

CLAUSE NO.


e)

Voltage transformers (As per IEC 60044-2/IS 3156) i)

Verification of terminal marking.and polarity

ii)

Power

frequency dry withstand tests on primary

and secondary

windings.

f)

iii)

Determination of errors or other characteristics

iv)

Partial discharge measurement as per IS:11322

Routine tests for circuit-breakers (as per IEC 62271-100) : i)

Power frequency voltage withstand of dry tests on the main circuit

ii)

Voltage withstand tests on control and auxiliary circuits

iii)

Measurement of the resistance of the main circuit

iv)

Mechanical operating tests

v)

Design and visual checks

29.05.00

Any assembly which fails to meet the requirements of these tests shall not be shipped, without the specific approval of the Employer.

29.06.00

In addition to the above tests, all the enclosures shall be pressure tested after manufacture in accordance with the latest requirements of IEC 62271-203.

29.07.00

The routine tests for bus bars shall be as per the relevant IEC standard and shall include the tests as specified.




PAGE 55 OF 69

CLAUSE NO.


PERCENTAGE CHECKS TO BE APPLIED FOR VARIOUS

SL. NO.

1

NAME OF THE TEST

SUPPORT GAS INSULATOR BARRIER

2

3

4

100%

100%

ENCLOSURE

CONDUCTOR

5

6

100%

100%

TESTS

ACCESSORIES

7

i)

Dimension

ii)

Gas Tightness

--

100%

100%

--

iii)

Pressure Test

--

100%

20%

--

--

iv)

Welding (X-ray) --

--

10%

--

--

v)

Electric resistance

--

--

--

100%

vi)

50Hz voltage withstand

100%

100%

--

--

--

vii)

Partial discharges

100% **

100%

--

--

--

viii)

Section shall be RIV free at 2 times rms line to ground

100%

100%

100%

100%

--

ix)

Weld shall be leak tested with SF6 leak detector

--

--

100%

--

--

x)

Contact resistance measurement at plug in contact

--

--

--

100%

--

xi)

Cleanliness aspect

100%

100%

100%

100%

100%

xii)

Silvering

--

--

--

*

--

xiii)

Packing

*

*

*

*

*



100% 100%


--

PAGE 56 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) *

: Sample tests or control

--

: Not required

**

: Sample tests on insulators alone and 100% for insulators in assemblies

sub-

29.08.00

Type Tests

29.08.01

The following type tests shall be conducted on a complete single pole assembly of one typical switchgear bay module as per IEC 62271-203 . The components forming parts of the GIS which are covered by other standards shall comply with and shall be type tested according to those standards. i)

Lightning impulse voltage dry tests.

ii)

Switching impulse voltage dry tests.

iii)

Power frequency voltage dry tests.

iv)

Partial discharge tests.

v)

Radio interference voltage tests.

vi)

Test to prove the temperature rise of any part of the equipment and measurement of the resistance of the main circuit.

vii)

Test to prove the ability of the main circuit and earthing circuit to carry the rated peak and the rated short time withstand current.

viii)

Test to verify the making and breaking capacity of the included switching devices.

ix)

Test to satisfactory operation of the of the included switching devices.

x)

Test to prove the strength of enclosures.

xi)

Gas tightness test

xii)

Electromagnetic compatibility test

xiii)

Test on partitions

xiv)

Internal arc tests.

xv)

Mechanical operation tests.

xvi)

Test to prove the satisfactory operation at limit temperature.

xvii)

Verification of degree of protection of auxiliary and control circuits.




PAGE 57 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) xviii)

Test to prove performance under thermal cycling and gas tightness test on insulators

xix)

Earthquake withstand test.

29.09.00

In case the contractor has not type tested a similar module for earthquake withstand test he shall supply supporting design calculations of simulated parameters of this test.

29.10.00

Following type tests on one piece each of related component parts of a single pole assembly of one typical switchgear bay module shall be conducted. a)

Circuit breakers (In accordance with IEC 62271-100 ) i)

Dielectric test.

ii)

Radio Interference Voltage tests.

iii)

Temperature rise-tests.

iv)

Measurement of Resistance of Main Circuit.

v)

Short time withstand current & peak withstand current tests.

vi)

Mechanical operation test at ambient temperature .

vii)

Miscellaneous Provisions for making & breaking test.

viii)

Short circuit current making & breaking tests.

ix)

Verification of degree of protection

x)

EMC test .

xi)

Critical current tests.

xii)

Single Phase short circuit tests.

xiii)

Short line fault tests.

xiv)

Out of phase making & breaking tests. i. Capacitive current switching tests. ii. Tightnes test




PAGE 58 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) b)

c)

d)

Surge arresters (In accordance with IEC60099-4) i)

Insulation withstand tests.

ii)

Residual voltage tests.

iii)

Long duration current impulse withstand test

iv)

Operating duty tests.

v)

Pressure relief test.

vi)

Tests of arrestor disconnectors.

vii)

Artificial pollution test.

viii)

Partial discharge test.

ix)

Seal leakage test.

x)

Current distribution test for multi column arrestor.

Disconnectors & Earth switches (In accordance with IEC 62271-102 ) i)

Dielectric tests

ii)

Radio interference voltage (r.i.v.) tests

iii)

Temperature – rise tests

iv)

Measurement of the resistance of the main circuit (for isolators)

v)

Short-time and peak withstand current test

vi)

Tests to prove the short-circuit making performance of earthing switches

vii)

Operating & mechanical endurance tests

viii)

Operation at the temperature limits

CTs (As per IEC 60044-1) i)

Short time current tests.

ii)

Temperature rise test.




PAGE 59 OF 69

CLAUSE NO.


Lightning impulse test for current transformers for service in electrically exposed installation

iv)

Switching impulse voltage tests for CTs for 420 KV and above

v)

Determination of errors or other characteristics

Special tests (optional) i) e)

Chopped lightning impulse test

Potential transformers (as per IEC 60044-2) I.

Temperature rise tests.

II

radio interference voltage (r.i.v)

III.

Lightning Impulse test.

IV.

Switching Impulse test.

V.

Determination of errors.

VI.

Short circuit withstand capability test.

Special tests (optional ) i) 29.11.00

Chopped lightning impulse test as a type test

Pressure vessel test Test according to used pressure vessel code shall be performed on the enclosures.

29.12.00

Shop Test Reports The Contractor shall furnish to the Employer six bound certified copies of a report describing the complete shop tests. This report shall include, but not necessarily be limited to the following: -

A description of the test equipment with diagram showing arrangement of the test instruments and devices.

-

Sample calculations, wherever necessary or desirable, to show the test values employed in the equations.

-

Curves showing relation of tested quantities.

-

Data in tabulated form

-

Comparison of the test results with the guaranteed requirements of the specifications and justification of deviations, if any.




PAGE 60 OF 69

CLAUSE NO.

29.13.00


Performance Tests Performance tests will be required to prove that equipment meets the requirements of the specifications and the guarantees. All the tests shall be conducted by the contractor subject to Employer's approval. The contractor shall supply all labour, consumables, materials, equipment, meters, gauges etc. necessary for the performance of all the tests and recording the results of the tests. The contractor shall assume full responsibility for the operation and safety of the equipment during all tests. The reports of all the tests shall be prepared by the contractor and incorporated in the final test report. The performance tests shall comprise of:

29.14.00

a)

Field stage tests, to be carried out during erection, to demonstrate that the equipment or any component or subassembly has been properly erected and functions correctly.

b)

Commissioning tests, precedent to the acceptance of work, in respect of the equipment or any section of the equipment, to demonstrate proper operation.

c)

Final acceptance tests, precedent to issue of a Final Acceptance Certificate, to prove compliance with performance guarantees.

Field Stage Tests From time to time at various stages of erection, tests of sub-assemblies of the equipment shall be carried out as instructed by the Employer. The contractor shall make records of all measurements and shall make corrections or adjustments as required. A record of all stage tests shall be embodied in a report. These tests shall include, but not be limited to the following: (a)

Continuous testing of the properties of SF6 gas through the entire filling period.

(b)

Test to check the continuity of wiring and correct operation of electrical systems.

(c)

Testing of all current carrying & ground connections to all conductors and terminal pads, to determine that the surfaces & all the bolted connections are tightly secured with lock washers; testing of all the flexible connections to ensure that sufficient slack is available for expansion.

(d)

Individual inspection of pressure relief devices, pressure gauges, moisture detectors and all other auxiliary devices to examine their condition.

(e)

Checking of cabling between apparatus by the contractor, prior to acceptance tests. Written evidence shall be produced on these tests. Random checks shall be made in the presence of the Engineer.

(f)

Measurement of the insulation resistance of the various measuring and control circuits, including cables, instruments and apparatus wherever practical and feasible.




PAGE 61 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) (g)

Operation checks of operating mechanism, all control, signaling, measuring, metering, recording and interlocking equipment to confirm complete conformity with designed data. Prior to commencement of these tests, the contractor shall submit a detailed programme to Employer’s for approval. Detailed records, including all the details of tests performed and the results obtained shall be prepared by the contractor and furnished to the Employer.

29.15.00

Commissioning Tests On completion of the erection and installation, the contractor shall give the Employer a written certificate stating that the equipment has been erected and installed in accordance with the specifications and approved drawings, thus giving notice of readiness to be carried out before the equipment is placed into regular service. The contractor shall demonstrate that all specification have been met and in addition, that the entire equipment, including all auxiliary equipments & accessories, are properly erected, installed and correctly adjusted. The following commissioning tests shall be performed as per IEC 62271-203, CIGRE working Group 23.03, 1975Electra No.42, 7-29: (a)

One minute power frequency withstand tests for the main circuits. As per IEC 62271-203 high voltage tests at site with lightning impulse and switching impulse voltages are also acceptable as alternative. The Contractor may carry out either of the above tests but relative merits of particular type of test over the other tests to be carried out by the contractor should be indicated in the offer.

(b)

Partial discharge measurement tests.

(c)

Voltage tests for the main circuits

(d)

Voltage tests for the auxiliary and control circuits.

(e)

Tests to verify the resistance of the main circuits.

(f)

Operation tests for various components.

(g)

Gas leakage tests.

(h)

Calibration of SF6 gas pressure/density switches. Measurement of moisture. After erection, a test shall be made to prove the absence of the dangerous voltages in the enclosure and other metal parts such as pipes and framework. If the tests prove the existence of any fault or faults in the equipment, or any failure to meet the requirements of the specifications the Employer may direct Contractor to rectify the defects or repair, reconstruct or replace faulty work and Contractor shall without delay, carry out the instructions of the Employer in this respect.




PAGE 62 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) Except as otherwise provided hereunder, responsibility for apparatus & test equipment and the control thereof shall be exercised by contractor subject to the over riding control of the Employer. Commissioning tests shall be as per the IEC standard and shall not be restricted to the tests stated above. The Contractor shall also recommend any additional commissioning tests.

29.16.00

Final Acceptance Tests After commissioning tests have been satisfactorily completed, the contractor, in cooperation with and under the supervision of Employer shall conduct the final acceptance tests listed below to determine whether all the requirements of these specifications have been fulfilled: a)

SF6 GIS complete with all appurtenances, shall be operated at continuous rating and at such part loading as may be directed by the Employer, continuously for 30 calendar days.

b)

All shop tests included in the test report as specified shall be deemed to be a part of the final acceptance tests. Routine tests may be repeated at the site, if, in the opinion of the Employer, these are necessary to establish the conformity of the equipment with the specifications.

c)

A record of all performance tests shall be embodied in a test report. Successful completion of the final acceptance tests shall be a condition precedent to a final acceptance certificate for the equipment.

29.17.00

Test Reports The contractor shall record all the relevant facts and the quantities on the basis of which a final test report shall be prepared. Such reports will be prepared in a form approved by the Employer and reproduced at the expense of the contractor in six copies for submission to the Employer.




PAGE 63 OF 69

CLAUSE NO.


TABLE -1 PARAMETERS OF THE CT IN GIS Sl. No.

Application

Current ratio

Output burden (VA)

Accuracy

Min Knee Point voltage (volts)

Max CT seconda ry res.(oh ms)

Max. exciting current (mA) at knee point voltage

1

Bus bar protection

2000-1000500/1A

• PS

20001000-500

10/5/2.5

30//60/120

2

Bus bar protection

2000-1000500/1A

• PS

20001000-500

10/5/2.5

30//60/120

3

Metering

2000-1000500/1A

4

Differential protection

2000-1000500/1A

• PS

20001000-500

10/5/2.5

30//60/120

5

Differential protection

2000-1000500/1A

• PS

20001000-500

10/5/2.5

30//60/120

20

0.20

20001000-500

Note: The rated continuous thermal current of all CTs shall be 125 % of 2000 A for all bays.

TABLE –2 PARAMETERS OF VOLTAGE TRANSFORMERS OF GIS BUS Sl No

Particulars

Secondary-I

Secondary-II

SecondaryIII

1

Rated Secondary Voltage

110/√3

110/√3

110/√3

2

Application

Protection

Protection

Metering

3

Accuracy

3P

3P

0.2

4

Output Burden( Minimum)

50VA

50VA

50VA




PAGE 64 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) Annexure-I

1.00.00

MANDATORY MAINTENANCE EQUIPMENT

1.01.00

SF6 Gas Handling Plants:a)

SF6 gas filling and evacuating equipment (Portable)- 1 No.: The capacity of this plant shall be such that it shall not take appreciable time for filling or evacuating of a GIS bay including all equipments compartment. The required vacuum for complete evacuation shall be attained with the help of this plant.

b)

1.02.00

1.03.00

SF6 gas filtering, drying, storage and recycling plant- 1 No.: -

This shall include all the necessary devices for measurement of purity, moisture content, decomposition products etc. of SF6 gas mixing with air/oil/moisture during above process should be proved to be Nil during testing.

-

The plant shall be complete with accessories and fittings so that SF6 gas from the breaker can be directly filled in the plant storage reservoir.

-

In case purging of the equipment before filling with SF6 gas is desirable, then the required equipment for dry gases etc. shall be furnished as a part of the plant.

-

For heavy items within the plant, the lifting hooks shall be provided for lifting and moving with the overhead cranes.

-

The capacity of the plant shall be such as to handle and store 300 kg of SF6 gas.

i)

These SF6 gas handling plants shall be complete with all the necessary pipes, couplings, flexible tubes and valves for coupling to the equipment.

ii)

The design and construction of the plant, valves, couplings, connections shall be such that leakage of SF6 gas shall be minimum. Similarly valves, couplings and pipe work shall be so arranged that accidental loss of gas to the atmosphere shall be minimum.

SF6 gas analyzing equipment and instruments should have capacity for performing the following functions: a)

The moisture content measurement or alternatively dew point measurement.

b)

The SF6 gas content measurement.

c)

Sensitivity should not be affected by dust, humidity, heat & wind etc.




PAGE 65 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) d)

Acidic product detection

NOTE: The equipments should have in-built calibration facility. The calibration/sensitivity check shall be demonstrated at contractor’s supplier’s works. 1.04.00

SF6 Gas leak detector - 2 nos.: The SF6 gas leak detector shall meet the following requirements:

1.05.00

a)

The detector shall be free from induced voltage effects.

b)

The sensing probe shall be such that it can reach all the points on the GIS where leakage is to be sensed.

c)

The accuracy of the equipment shall be atleast 10 ppm.

Operational analyser and Signature analysis equipment- 1no.: The operational analyser shall meet the following requirements: a)

Operational analyser shall be one complete system, which once installed should record all the parameters, as laid down in subsequent clauses.

b)

It shall have facility to record the breaker contact movement during opening, closing, auto reclosing and make-break operation, the speed of contacts at various stages of operation, travel of contacts, opening time, closing time and make break time ,etc.

c)

The analyser shall have provisions for recording atleast 12 different functions of the circuit breaker. All necessary transducers (i.e three nos. for complete 3 phase speed and travel record of breaker), cables, pickups, attachments required for the breaker shall be supplied with the analyser. The cables supplied shall be sufficient enough for recordings at site on a completely assembled and erected breaker.

d)

The analyser shall be suitable for operation outdoor and shall be suitably shielded against induced charges.

e)

The output of the analyser shall be on a plain paper or any paper having infinite shelf life and the output thus obtained shall have a long life and shall not require any special storage facility. Photographic paper is not acceptable.

f)

All the necessary catalogues, write up for operation and maintenance of the analyser shall be furnished alongwith each analyser and peripheral system.

g)

Demonstration at manufacturer’s premises for functional/operational check and compatibility with breaker.

The necessary equipments for monitoring various parameters of circuit breaker termed as signature analysing shall be supplied along with all softwares, laptop




PAGE 66 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) computer, devices etc. with the breaker. The same shall be demonstrated at site on a fully assembled breaker.

1.06.00

Nitrogen filling device (Applicable for Hydraulically operated breaker): a)

The device shall be suitable for operation outdoor and shall be suitably shielded against induced charges.

b)

The capacity of the plant shall be such that the N2 filling in one pole can be carried out in shortest time.

c)

The plant shall be driven by 1 ph./3ph. AC supply.

d)

The plant shall be complete (with N2 cylinder) and with all accessories required for charging of N2 at site.

e)

Demonstration at manufacturer’s premises/site for functional/ operational check shall be carried out.

f)

All catalogues, write up etc. shall be supplied with device.




PAGE 67 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) Annexure-II

1,00.00

DEW POINT METER

1.01.00

The meter shall be capable of measuring the due point of SF6 Gas of the Circuit Breaker/GIS equipment It should be portable and adequately protected for outdoor use. The meter shall be provided with due point hygrometer with digital indication to display the due point temperature in degree C. or PPM. It should be capable of measuring the corresponding pressure at which due point is being measured.

1.02.00

The measurement and use of the instrument must be simple, direct without the use of any other material/chemical like dry ice/acetone etc. It should be battery operated with rechargeable batteries.

1.03.00

The equipments should have the following parameters a.

Measuring range: Upto -100 degree C Dew Point

b.

Accuracy:

c.

Display: 4 digit LCD, inch. High

+ 2 degreeC.

2.00.00

PORTABLE PD MONITORING SYSTEM FOR GAS INSULATED SWITCHGEAR

2.01.00

GENERAL The equipment shall be used for detecting different types of defects in Gas Insulated Stations (GIS) such as Particles, Loose shields and Partial Discharges as well as for detection of Partial discharges in other types of equipment such as Cable Joints, CTs and PTs.

2.02.00

It shall be capable for measuring PD in charged GIS environment as EHV which shall have bandwith in order of 10 KHz – 500 KHz with possibility to select a wide range of intermediate bandwidths for best measurement results. The principal of operation shall be on acoustic technique and the method of measurement shall be non-intrusive. The instrument is able to detect partial discharges in cable joints, terminations, CTs and VTs etc., with the hot sticks.

2.03.00

Detection and measurement of PD and bouncing particles shall be displayed on built in large LCD display and the measurement shall be stored in the instrument and further downloadable to a PC for further analysis to locate actual source of PD such as free conducting particles, floating components, voids in spacers, particle on spacer surfaces etc.

2.04.00

The equipments should have the following parameters: a.

Measurement shall be possible in noisy environment.

b.

Stable reading shall be possible in presence of vibrations within complex GIS assemblies, which can produce signals similar to PD.




PAGE 68 OF 69

CLAUSE NO.

GAS INSULATED SWITCHGEAR (E1) c.

Environment should have necessary synchronizing circuits to obtain PD correlation with power cycle and power frequency.

d.

The equipment shall be battery operated with built-in battery charger. It shall also be suitable for 230V AVC/50 Hz input.

e.

Measurement shall be possible in the charged switchyard in the presence of EMI/EMC. Supplier should have supplied similar detector for GIS application to other utilities. Performance certificate and the list of users shall be supplied alongwith the offer.

f.

Instrument shall be supplied with standard accessories i.e., re-locatable sensors with mounting arrangements, connecting cables (duly screened) to sensors, Lap-top PC, diagnostic software, carrying case, rechargeable battery pack with charger suitable for 230V AC, 50 Hz supply connecting cables (duly screened) to view in storage.

g.

The function of software shall be covering the following : -

Data recording, storage and retrival in computer

-

Data base analysis

-

Template analysis for easy location of fault inside the GIS

-

Evaluation of PD Synchronisation etc.

-

Evaluation of bouncing/loose particles with flight time and estimation on size of particle.

-

Report generation

measurement

i.e.,

Amplitude,

Phase

h.

To prove the suitable in charged switchyard condition, practical demonstration shall be conducted before acceptance.

i.

Supplier shall have “Adequate after sales service” facility in India

j.

Necessary training may be accorded to personnel to make use of the kit for locating PD sources inside the GIS.

k.

Instrument shall be robust and conform to relevant standard.




PAGE 69 OF 69

PART-B SUB-SECTION-E2 ISOLATORS (AIS)



CLAUSE NO.

ISOLATORS (E2)

1.00.00

GENERAL

1.01.00

The isolators and accessories shall conform in general to IEC 62271-102 except to the extent explicitly modified in specification.

1.02.00

Earth switches shall be provided on isolators wherever called for.

1.03.00

The isolators and earth switches shall be motor operated.

1.04.00

Complete isolator with all the necessary items for successful operation shall be supplied.

1.05.00

Isolators shall be horizontal centre break type and Tandem type..

2.00.00

DUTY REQUIREMENTS

2.01.00

Isolators and earth switches shall be capable of withstanding the dynamic and thermal effects of the maximum possible short circuit current of the system in their closed position. They shall be constructed such that they do not open under influence of short circuit current and wind pressure together. The earth switches wherever provided shall be constructional interlocked so that the earth switches can be operated only when the isolator is open and vice-versa.

2.02.00

In addition to the constructional interlock, isolator and earth switches shall have provision to prevent their electrical and manual operation unless the associated and other interlocking conditions are met. All these interlocks shall be of fail safe type.

2.03.00

Suitable individual interlocking coil arrangements shall be provided. The interlocking coil shall be suitable for continuous operation from DC supply and within a variation range as stipulated in relevent section . The interlock coil shall be provided with adequate contacts for facilitating permissive logic for ‘DC’ control scheme of the isolator as well as for AC circuit of the motor to prevent opening or closing of isolators when the interlocking coil is not energised.

2.04.00

The earthing switches shall be capable of discharging trapped charges of the associated lines. Isolator and earth switches shall be able to bear on the terminals the total forces including wind loading and electrodynamic forces on the attached conductor without impairing reliability or current carrying capacity.

2.05.00

The isolator shall be capable for making / breaking normal currents when no significant change in voltage occurs across the terminals of each pole of the isolator on account of making / breaking operation.

3.00.00

CONSTRUCTIONAL FEATURES

3.01.00

The isolators shall be provided with high pressure current carrying contacts on the hinge/ jaw ends and all contact surfaces shall be silver plated. The thickness of silver plating should not be less than 25 microns. The contacts shall be accurately machined and self aligned.

TAPOVAN VISHNUGAD HYDRO E LECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2


PART-B CHAPTER – E2

PAGE 1 OF 5

CLAUSE NO.

ISOLATORS (E2)

3.02.00

The isolator shall be provided with a galvanised steel base provided with holes and designed for mounting on a lattice/pipe support structure. The base shall be rigid and self supporting. The position of movable contact system (main blades) of each of the isolator and earthing switch shall be indicated by a mechanical indicator at the lower end of the vertical rod of shaft for the isolator and earthing switch. The indicator shall be of metal and shall be visible from operating level.

3.03.00

All metal parts shall be of non-rusting and non-corroding metal. Current carrying parts shall be from high conductivity electrolytic copper/aluminium. Bolts, screws and pins shall be provided with lock washers. Keys or equivalent locking facilities, if provided on current carrying parts, shall be made of copper silicon alloy or equivalent. The live parts shall be designed to eliminate sharp joints, edges and other corona producing surfaces.

3.04.00

The isolators shall be so constructed that the switch blade will not fall to the closed position if the operating shaft gets disconnected. Isolators and earthing switches including their operating parts shall be such that they cannot be dislodged from their open or closed positions by gravity, wind pressure, vibrations shocks or accidental touching of the connecting rods of the operating mechanism. The switch shall be designed such that no lubrication of any part is required except at very infrequent intervals.

3.05.00

The insulator of the isolator shall conform to the requirements stipulated under Chapter-E12 and shall have a min. cantilever strength of 800 kg. Pressure due to the contact shall not be transferred to the insulators after the main blades full close. The insulators shall be so arranged that leakage current will pass to earth and not between terminals of the same pole or between phases.

3.06.00

The terminal connectors shall conform to requirements stipulated under Chapters-E0 and E12.

4.00.00

EARTHING SWITCHES Where earthing switches are specified these shall include the complete operating mechanism and auxiliary contacts. The earthing switches shall form an integral part of the isolator and shall be mounted on the base frame of the isolator. Earthing switches shall be suitable for local operation only. The earthing switches shall be constructional interlocked with the isolator so that the earthing switches can be operated only when isolator is open and vice versa.

5.00.00

OPERATING MECHANISM AND CONTROL

5.01.00

The Contractor shall offer, motor operated switches having padlock arrangement on both ‘ON’ and ‘OFF’ positions.

5.02.00

Limit switches for control shall be fitted on the isolator/ earth switch shaft, within the cabinet to sense the open and close positions of the isolators and earth switches.




PAGE 2 OF 5

CLAUSE NO.

ISOLATORS (E2) 5.03.00

It shall not be possible, after final adjustment has been made for any part of the mechanism to be displaced at any point in the travel sufficient enough to allow improper functioning of the isolator when the isolator is opened or closed at any speed.

5.04.00

Control cabinet/operating mechanism. box shall conform to requirements stipulated in Chapter-E12 and IS:5039/IS:8623/IEC: 439 as applicable.

6.00.00

OPERATION

6.01.00

Isolator shall be gang operated for main blades and earth switches. The operation of the three poles shall be well synchronised and interlocked.

6.02.00

The design shall be such as to provide maximum reliability under all service conditions. All operating linkages carrying mechanical loads shall be designed for negligible deflection. The length of inter insulator and interpole operating rods shall be capable of adjustments.

6.03.00

The design of linkages and gears be such so as to allow one man to operate the handle with ease for isolator and earth switch.

7.00.00

TESTS

7.01.00

In continuation to the requirements stipulated under Part-A the isolator alongwith operating mechanism shall conform to the type tests and shall be subjected to routine tests and acceptance tests in accordance with IEC 62271-102. Minimum 50 nos. mechanical operations will be carried out on 1 (one) isolator assembled completely with all accessories as acceptance test. During final testing of isolator sequential closing/ opening of earth switch shall also be checked only after isolator is fully open/close. Acceptance test shall be carried out with operating box.

7.02.00

The insulator shall conform to all the type tests as per IEC 168. In addition to all type, routine and acceptance tests, as per IEC-168, the following additional routine/ acceptance tests shall also be carried out: (a)

Bending load test in four directions at 50% min. bending load guaranteed in all insulators.

(b)

Bending load test in four directions at 100% min. bending load guaranteed on sample insulators in a lot.

(c)

Torsional test on sample insulator of a lot.

8.00.00

PARAMETERS

8.01.00

General (a)

Type of isolator

Outdoor type

(b)

Rated frequency

50 Hz




PAGE 3 OF 5

CLAUSE NO.

ISOLATORS (E2)

(c)

Number of poles

Three (3)

(d)

Operating time

Not more than 12 sec.

(e)

Rated short time withstand current of isolator and earthswitch

40 KA rms for One (1) second

(f)

Rated dynamic short circuit withstand current of isolator and earthswitch

100 KAp

(g)

Control voltage

220V DC

(h)

Auxiliary contacts on Isolator

As required plus 8NO and 8NC contacts per pole/isolator as spare. The contacts shall have continuous rating of 10A and breaking capacity of 2A with circuit time constant of minimum 20 millisecond at 220V DC. Additionally MBB contacts as required shall also be provided.

(i)

Auxiliary contacts on earth switch

Total 6NO and 6NC

(j)

Rated mechanical terminal load

As per Table III of IEC 60129

(k)

Temperature rise over ambient

As per IEC:60129

(l)

Minimum creepage distance

As indicated in Section – E0

(m)

Rated ambient temperature

40 degree C

(n)


Effectively earthed

(o)

Seismic acceleration

0.36 g horizontal

(p)

Support structure height

Adequate so that lowest part of support insulator of equipment is minimum 2550 mm from ground or plinth level.

(q)

Rated mechanical terminal Load

As per Table III of IEC 60129

(r)

Operating mechanism of Isolator and Earth Switch

Motor operated

(s)

Temperature rise

As per Table V of IEC 694 for an ambient of 50 deg. C.




PAGE 4 OF 5

CLAUSE NO.

ISOLATORS (E2) 8.02.00

400KV Class Disconnectors (a)

Rated voltage

420 KVrms

(b)

Rated continuous current

Minimum 2500 A at rated ambient temperature

(c)

Rated Insulation levels

i.

ii.

iii.

Rated one minute power

i)

520 KV rms between live terminals and earth.

Frequency withstand voltage ii)

610 KV rms across isolating distance.

Rated Lightning Impulse withstand voltage

i)

±1425 KVp between live terminals and earth.

ii)

± 1425 KVp impulse on one terminal and 240 KVp power freq. Voltage of opposite polarity on other terminal (across isolating distance).

i)

± 1050 KVp between live terminals and earth.

ii)

± 900 KVp impulse on one terminal and 345 KVp power freq. voltage of opposite polarity on other terminal (across isolating distance).

Rated switching impulse withstand voltage

(d)

Max. Radio interference voltage

1000 micro volts for freq. between 0.5 MHz and 2.0 MHz at voltage 266 KVrms.

(e)

Corona extinction voltage

Not less than 320 KV rms

(f)

Phase to phase spacing

7000 mm




PAGE 5 OF 5

PART-B SUB-SECTION-E3 INSTRUMENT TRANSFORMERS (AIS)



CLAUSE NO.

1.00.00

INSTRUMENT TRANSFORMERS (E3)

CODES AND STANDARDS Current transformers

IEC 60044, BS:3938, IS: 2705

Voltage transformers

IEC 60186, IEC 186A, IEC 358, IS:3156

Insulating oil

IS:335

2.00.00

GENERAL REQUIREMENTS

2.01.00

The instrument transformers i.e. current and voltage transformers shall be single phase transformer units and shall be supplied with a common marshaling box for a set of three single phase units.

2.02.00

The tank as well as top metallics shall be hot dip galvanised or painted Grey color RAL 9002

2.03.00

The instrument transformers shall be hermetically sealed units. The instrument transformers shall be provided with filling and drain plugs.

2.04.00

Polarity marks shall indelibly be marked on each instrument transformer and at the lead terminals at the associated terminal block.

2.05.00

The insulators shall have a cantilever strength of more than 500 kg.

3.00.00

CURRENT TRANSFORMERS (CTs)

3.01.00

The CTs shall have single primary of either ring type or hair pin type or bar type.

3.02.00

In case of “Bar Primary” inverted type CTs, the following requirements shall be met:

3.03.00

The secondaries shall be totally encased in metallic shielding providing a uniform equipotential surface for even electric field distribution.

3.04.00

The lowest part of insulation assembly shall be properly secured to avoid any risk of damage due to transportation stresses.

3.05.00

The upper part of insulation assembly sealing on primary bar shall be properly secured to avoid any damage during transportation due to relative movement between insulation assembly and top dome.

3.06.00

The insulator shall be one piece without any metallic flange joint.

3.07.00

The CT shall be provided with oil sight glass.

3.08.00

The core lamination shall be of cold rolled grain oriented silicon steel or other equivalent alloys. The cores shall produce undistorted secondary current under transient conditions at all ratios with specified parameters.


TECHNICAL SPECIFICATION SECTION- VI

PART-B CHAPTER-E3

PAGE 1 OF 7

CLAUSE NO.


3.09.00

Different ratios shall be achieved by secondary taps only, and primary reconnections shall not be accepted.

3.10.00

The guaranteed burdens and accuracy class are to be intended as simultaneous for all cores.

3.11.00

The instrument security factor at all ratios shall be less than five (5) for metering core. If any auxiliary CT/reactor is used, then all parameters specified shall be met treating auxiliary CTs/reactors as integral part of CT. The auxiliary CT/reactor shall preferably be in-built construction of the CT. In case it is separate, it shall be mounted in secondary terminal box.

3.12.00

The physical disposition of protection secondary cores shall be in the same order as given under CT requirement table(s) given below.

3.13.00

The CTs shall be suitable for high speed auto-reclosing.

3.14.00

The secondary terminals shall be terminated on stud type suitable nondisconnecting terminal blocks inside the terminal box of degree of protection IP:55 at the bottom of CT.

3.15.00

The CTs shall be suitable for horizontal transportation.

3.16.00

The CTs shall have provision for taking oil samples from bottom of CT without exposure to atmosphere to carry out dissolved gas analysis periodically. Contractor shall give his recommendations for such analysis, i.e. frequency of test, norms of acceptance, quantity of oil to be withdrawn, and treatment of CT.

4.00.00

VOLTAGE TRANSFORMERS (CVTs)

4.01.00

Voltage transformers shall be of capacitor voltage divider type with electromagnetic unit.

4.02.00

The CVTs shall be thermally and dielectrically safe when the secondary terminals are loaded with guaranteed thermal burdens.

4.03.00

The electro-magnetic unit (EMU) shall comprise of compensating reactor, intermediate transformer, and protective and damping devices. The oil level indicator of EMU with danger level marking shall be clearly visible to maintenance personnel standing on ground.

4.04.00

The secondaries shall be protected by HRC cartridge type fuses for all windings In addition fuses shall also be provided for protection and metering windings for connection to fuse monitoring scheme. The secondary terminals shall be terminated on stud type non-disconnecting terminal blocks via the fuse inside the terminal box of degree of protection IP: 55. The access to secondary terminals shall be without the danger of access to high voltage circuit.

4.05.00

The damping device shall be permanently connected to one of the secondary winding and shall be capable of suppressing ferro-resonance oscillations.



PART-B CHAPTER-E3

PAGE 2 OF 7

CLAUSE NO.


4.06.00

CVTs shall be suitable for high frequency (HF) coupling for power line carrier communication. Carrier signals must be prevented from flowing into potential transformer (EMU) metering circuit by means of RF choke/reactor suitable for effective blocking the carrier signals over the entire frequency range of 40 to 500 kHz. HF terminal shall be brought out through a suitable bushing and shall be easily accessible for connection to the coupling filters of the carrier communication equipment. The HF terminal shall be provided with earthing link with fastener.

4.07.00

A protective surge arrester/spark gap shall preferably be provided to prevent break down of insulation by incoming surges and to limit abnormal rise of terminal voltage of shunt capacitor, tuning reactor, RF choke, etc. due to short circuit in transformer secondary. The details of this arrangement (or alternative arrangement) shall be furnished by Contractor for Employer’s review.

4.08.00

The protection cores shall not saturate at about 1.5 times the rated voltage for a min. duration of 30 secs.

4.09.00

The accuracy of metering core shall be maintained through the entire burden range upto 75 VA on all three windings without any adjustments during operations.

5.00.00

MARSHALLING BOX

5.01.00

Marshaling box shall conform to all requirements as given in Section E12. The wiring diagram for the interconnection of three phases instrument transformer shall be pasted inside the box in such a manner so that it is visible and it does not deteriorate with time. Terminal blocks in the marshaling box shall have facility for star/delta formation, short circuiting and grounding of secondary terminals. The box shall have enough terminals to wire all control circuits plus 20 spare terminals.

6.00.00

PARAMETERS FOR CURRENT TRANSFORMERS

6.01.00

400 KV Current Transformers (a)

Rated dynamic current

100 KA (peak)

(b)

One minute power frequency withstand voltage between secondary terminal and earth

5 KV

(c)


10 pico Coulombs max.

(d)

Temperature rise

As per IEC 60044

(e)

Type of insulation

Class A

(f)

Number of cores

Five (5): Details are given in Table- I below.

(g)

Rated frequency

50 Hz



PART-B CHAPTER-E3

PAGE 3 OF 7

CLAUSE NO.

INSTRUMENT TRANSFORMERS (E3) (h)


Effectively earthed

(i)

Installation

Outdoor (up right)

(j)


0.36 g horizontal

(k)

Rated short time thermal current

40 KA for 1 sec.

(l)

Number of terminals in marshalling All terminals of control circuits wired box upto marshalling box plus 20 terminals spare.

(m)

Rated extended primary current

125% of rated primary current of 2000A

(n)

Rated system voltage (Um)

420 KV (rms)

(o)

Corona extinction voltage (min)

320 KV (rms)

(p)

Radio Interference Voltage at 266 KV at frequency range 0.5 to 2 MHz (rms)

1000 micro volts

(q)

Rated insulation levels i.

1.2/50 micro-sec. impulse

1425 KVp

ii.

250/2500 micro-sec. switching surge withstand voltage (dry & wet)

1050 KVp

iii.

One minute power frequency withstand voltage

630 KV rms

7.00.00

PARAMETERS FOR VOLTAGE TRANSFORMERS

7.01.00

400 KV CVTs (a)

Rated frequency

50 Hz

(b)


Effective earthed

(c)

Installation

Outdoor

(d)


0.36 g horizontal

(e)

System fault level

40 KA for 1 sec.



PART-B CHAPTER-E3

PAGE 4 OF 7

CLAUSE NO.

INSTRUMENT TRANSFORMERS (E3) (f)

Standard reference range of frequencies for which the accuracies are valid

96% to 102% for protection and 99% to 101% for measurement.

(g)

High frequency capacitance for carrier frequency range

Within 80% to 150% of rated entire capacitance

(h)

Equivalent resistance over entire carrier frequency range

Less than 40 ohms

(i)

Stray capacitance and stray conductance of LV terminal over entire carrier frequency range

As per IEC:358

(j)

One minute power frequency withstand voltage a)

between LV (HF) terminal and earth

10KV rms for exposed terminals or 4 KV rms for terminals enclosed in a weather proof box.

b)

For secondary winding

2 KV rms

(k)

Temp. rise over an ambient temp. of 40 deg. C

As per IEC 60186

(l)

Number of terminals in control Cabinet

All terminals of control circuits wired upto marshalling box plus 10 terminals spare.

(m)

Rated total thermal burden

750 VA

(n)


10 pico Coulombs max.

(o)

Number of cores

As per details given in Table-II below.

(p)

Rated system voltage

420 KV (rms)

(q)

Rated insulation levels

(r)

i)

1.2 micro sec. impulse

1425 KV (peak)

ii)

250/2500 micro sec. switching surge withstand voltage (dry & wet)

1050 KV (peak)

Radio Interference voltage at 266 KV at frequency range 0.5 to 2 MHz(rms)


1000 micro volts (max.)


PART-B CHAPTER-E3

PAGE 5 OF 7

CLAUSE NO.

INSTRUMENT TRANSFORMERS (E3) (s)

Corona extinction voltage (min.)

(t)

HF Capacitance a)

320 KV (rms)

3 Nos. of CVT with 4400 pF capacitance

b) 3 Nos. of CVT with 8800 pF capacitance Bidder shall quote the unit prices for the above items in the relevant Bid proposal sheets for price adjustment based on actual quantities required during detailed engineering. 8.00.00

TESTS

8.01.00

The current and voltage transformers shall confirm to type tests and shall be subjected to routine tests in accordance with the relevant IS/IEC and shall also conform to the following additional type tests : i)

Radio Interference test - As per IS:8263

ii)

Switching impulse withstand test.

iii)

Thermal withstand test i.e. application of rated voltage and rated current simultaneously by synthetic test circuit.

iv)

Seismic withstand test alongwith structure.

v)

Thermal co-efficient test i.e. measurement of Tan-Delta as function of temperature (at ambient and between 80 deg. C and 90 deg. C) and voltage (at 0.3, 0.7, 1.0 and 1.1 Um).

vi)

Fast transient test.

vii)

Each CT shall be subjected to capacitance and Tan delta test at site

viii)

CTs’ shall be subjected to Instrument security factor(ISF) test

8.02.00

Each CT shall be subjected to Capacitance and Tan Delta test at site.

8.03.00

CT’s shall be subjected to Instrument Security Factor test (ISF).

8.04.00

In addition to routine tests as per IEC/IS, measurement of partial discharge in continuation with power frequency withstand test required for 400 KV current transformer.



PART-B CHAPTER-E3

PAGE 6 OF 7

CLAUSE NO.

INSTRUMENT TRANSFORMERS (E3) TABLE -1 PARAMETERS OF THE CT IN AIS Sl. No

1

Application

•

Differential

Current ratio

Output burden (VA)

Accuracy

Min Knee Point voltage (volts)

Max CT secondary res. (ohm)

Max. exciting current(m) at knee point voltage

2000-1000500/1A

• PS

20001000-500

10/5/2.5

30//60/120

• PS

20001000-500

10/5/2.5

30//60/120

Protection 2

•

Differential Protection

2000-1000500/1A

3

•

Metering

2000-1000500/1A

20

0.20

20001000-500

4

Line Differential protection

2000-1000500/1A

• PS

40002000-1000

10/5/2.5

30//60/120

5

Line Differential protection

2000-1000500/1A

• PS

40002000-1000

10/5/2.5

30//60/120

Note: The rated continuous thermal current of all CTs shall be 125% of 2000 A for all bays.

TABLE –2 PARAMETERS OF CAPACITIVE VOLTAGE TRANSFORMERS OF AIS BUS Sl No

Particulars

Secondary-I

Secondary-II

Secondary-III

1

Rated Secondary Voltage

110/√3

110/√3

110/√3

2

Application

Protection

Protection

Metering

3

Accuracy

3P

3P

0.2

4

Output Burden( Minimum)

50VA

50VA

50VA



PART-B CHAPTER-E3

PAGE 7 OF 7

PART-B SUB-SECTION-E4 SURGE ARRESTORS (AIS)



CLAUSE NO.

SURGE ARRESTERS (E4) 1.00.00

GENERAL

1.01.00

The Surge Arresters shall conform in general to IEC-60099-4 and IS:3070 except to the extent modified in the specification and shall be in accordance with requirements under Part-A.

1.02.00

Arresters shall be hermetically sealed units, self supporting construction, suitable for mounting on lattice type support structures.

2.00.00

DUTY REQUIREMENTS

2.01.00

The Surge Arresters (SAs) shall be capable of discharging over-voltages occurring due to switching of unloaded transformers and long lines.

2.02.00

The reference current of SAs shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. Values and calculations shall be furnished with offer.

2.03.00

The SAs shall be fully stabilised thermally to give a life expectancy of one hundred (100) years under site conditions and take care of effect of direct solar radiation.

2.04.00

The SAs shall be suitable for circuit breaker duty cycle in the given system.

2.05.00

The SAs shall protect power transformers, circuit breakers, disconnecting switches, instrument transformers etc with insulation levels specified in this specification. The Contractor shall carry out the insulation coordination studies for deciding the exact location and quantity of the SAs.

2.06.00

The SAs shall be capable of withstanding meteorological and short circuit forces under site conditions.

3.00.00


3.01.00

Each Surge Arrester (SA) shall be hermetically sealed single phase unit.

3.02.00

The non linear blocks shall be sintered metal oxide material. The SA construction shall be robust with excellent mechanical and electrical properties.

3.03.00

SAs shall have pressure relief devices and arc diverting ports suitable for preventing shattering of porcelain housing and to provide path for flow of rated fault currents in the event of SA failure.

3.04.00

The SA shall not fail due to porcelain contamination.

3.05.00

Seals shall be effectively maintained even when SA discharges rated lightning current.

3.06.00

Porcelain shall be so coordinated that external flashover will not occur due to application of any impulse or switching surge voltage upto maximum design value for SA. The cantilever strength of the insulator shall be minimum 500kg.

TAPOVAN VASHNUGAD HYDRO ELECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2

TECHNICAL SPECIFICATION PART-VI

PART-B CHAPTER - E4

PAGE 1 OF 5

CLAUSE NO.


The end fittings shall be non-magnetic and of corrosion proof material.

3.08.00

The Contractor shall furnish the following: a)

The heat treatment cycle details with necessary quality checks used for individual blocks alongwith insulation layer formed across each block.

b)

Metalizing coating thickness for reduced resistance between adjacent discs alongwith procedure for checking the same.

c)

Details of thermal stability test for uniform distribution of current on individual discs.

d)

Detailed energy calculations to prove thermal capability of discs.

4.00.00

FITTINGS AND ACCESSORIES

4.01.00

Each SA shall be complete with insulating base for mounting on structure.

4.02.00

SAs shall be provided with grading and/or corona rings as required.

4.03.00

Self contained discharge counters, suitably enclosed for outdoor use (IP:55 degree of protection) and requiring no auxiliary or battery supply shall be fitted with each SA alongwith necessary connections to SA and earth. Suitable leaKAge current meters shall also be supplied in the same enclosure. The reading of milliammeter and counter shall be visible through an inspection glass panel to a man standing on ground. A pressure relief vent/suitable provision shall be made to prevent pressure build up.

4.04.00

The Contractor shall also supply micro-processor based portable maintenance equipment for monitoring resistive current of SA. This equipment shall be suitable for measurement in GIS also.

5.00.00

PARAMETERS

5.01.00

General (a)


Effectively earthed

(b)

Installation

Outdoor

(c)

i)

Nominal discharge current


ii)

Discharge current at which insulation coord. is done


(d)

Rated frequency

50 Hz

(e)

Long duration discharge class

3



PART-B CHAPTER - E4

PAGE 2 OF 5

CLAUSE NO.

SURGE ARRESTERS (E4)

5.02.00

(f)

Current for pressure relief test

40 KA rms

(g)

Prospective symmetrical fault current

40 KA rms for 1 second

(h)

Low current long duration test value (2000 micro sec.)

1000 A

(i)


Class A of Table VII of IS:3070 or equivalent IEC.

(j)

Partial discharge at 1.05 MCOV (Continuous operating voltage)

Not more than 50 p.C.

(k)

Siesmic acceleration

0.36 g horizontal

(l)

Reference ambient temp.

40 deg. C

400 KV class Surge Arrester (a)


420 KV

(b)

Rated arrestor voltage

390 KV

(c)

Minimum discharge capability

8 kJ/KV or corresponding to minimum discharge characteristics given in clause n) below whichever is higher.

(d)

Continuous operating voltage (COV) at 50 deg. C

303 KV rms

(e)

Min. Switching surge residual voltage (1 KA)

730 KVp minimum, 780 KVp maximum

(f)

Maximum residual voltage at i)


900 KVp

ii)


975 KVp

(g)

Steep fronted wave residual voltage at 10KA

1050 KVp

(h)

High current short duration test value (4/10 microsec. wave)

100 KAp

(i)

Min. Total creepage distance

10500 mm

(j)

One minute dry/wet power frequency withstand voltage of arrestor housing

630 KV (rms)



PART-B CHAPTER - E4

PAGE 3 OF 5

CLAUSE NO.

SURGE ARRESTERS (E4) (k)

Impulse withstand voltage of arrestor Housing with 1.2/50 micro sec. wave.

1425 KVp

(l)

RIV at 266 KV (rms)

Less than 1000 micro volts

(m)

The surge arrestors are provided to protect the following equipment whose insulation levels are indicated in the table A given below. The contractor shall carry out the insulation coordination studies for deciding the location of the surge arrestors.

TABLE – A -------------------------------------------------------------------------------------------------------------SNO. EQUIPMENT TO BE INSULATION LEVEL PROTECTED _________________________________________________________________ LIGHTNING IMPULSE (KVp) FOR 400 KV SYSTEM

SWITCHING SURGE 250/2500 (KVp) FOR 400 KV SYSTEM

1.

Power Transformer

± 1300

± 1050

2.

Instrument Transformer

± 1425

± 1050

3.

CB/Isolator ± 1425

± 1050

- Phase to ground

- Across open ± 1425 ± 900 contacts (± 240) (± 340) --------------------------------------------------------------------------------------------------------------(n)

Surge arrester shall be capable of discharging energy equipment to class 3 of IEC for a 420 KV system on two successive operations followed immediately by 50 Hz energisation with a sequential voltage profile as specified below: 705 KVp for 3 peaks 580 KVp for 0.1 second 565 KVp for 1 second 550 KVp for 10 seconds

(o)

400 KV line circuit breakers are equipped with closing resistor of 400 ohms with pre insertion time switching over voltage to 2.3 p.u.



PART-B CHAPTER - E4

PAGE 4 OF 5

CLAUSE NO.


Surge Arresters shall conform to all type tests as per IEC and shall be subjected to routine and acceptance tests in accordance with IEC-60099-4. The resistive current drawn by the arrestor for at rated voltage shall be indicated in the routine test report.



PART-B CHAPTER - E4

PAGE 5 OF 5

PART-B SUB-SECTION-E5 POST INSULATOR (AIS)



CLAUSE NO.

POST INSULATOR (E5) 1.00.00

GENERAL

1.01.00

The post insulators shall conform in general to latest IS:2544 and IEC - 815.

2.00.00


2.01.00

Post type insulators shall consist of a porcelain part permanently secured in a metal base to be mounted on the supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand any shocks to which they may be subjected to by the operation of the associated equipment. Only solid core insulators shall be accepted. Height of post insulator shall be preferably as given in Clause No. 4.00.00 of this section.

2.02.00

The other requirements of insulator as given in Section – E12 shall also be applicable.

3.00.00

TESTS

3.01.00

In accordance with the stipulations under part-A the post insulators shall conform to type tests and acceptance, sample and routine tests as per IS:2544, IEC-168 shall be carried out.

3.02.00

In addition to acceptance/sample/routine tests as per IS:2544, IEC-168, the following tests shall also be carried out.

3.03.00

(a)

Ultrasonic tests on all cutshells as routine check.

(b)

Visual examination and magnaflux test on all flanges prior to fixing.

(c)

Check for uniformity of thickness and weight of zinc coating as a sample test from each lot of flanges prior to fixing.

(d)

Bending load test shall be carried out at 50% minimum failing load in four directions as a routine test.

(e)

Bending load in four directions at 100% minimum bending load guaranteed on samples as per clause-2.3 of IEC. Subsequently this post insulator shall not be used.

(f)

Tests for deflection measurement at 20, 50, 70% of specified minimum failing load on sample.

The post insulator shall conform to following type tests as applicable according to voltage class: (a)

Switching Impulse withstand test (dry & wet)

(b)

Lightning Impulse withstand test (dry)

(c)

Power frequency withstand test (dry & wet)



PART-B CHAPTER - E5

PAGE 1 OF 3

CLAUSE NO.

POST INSULATOR (E5)

4.00.00

(d)

Measurement of RIV

(e)

Corona extinction voltage test

(f)

Test for deflection under load.

(g)

Test for mechanical strength,

PARAMETERS I.

400 KV class Bus Post Insulator (a)

Type

Solid core type

(b)

Voltage class (KV)

400

(c)

Dry and wet one minute power frequency withstand voltage (KV)

680

(d)

Dry impulse withstand positive and negative (KVp)

1550

(e)

Wet switching surge withstand voltage (KVp)

1175 (As per IEC)

(f)

Max. radio interference voltage (μV) for any frequency between 0.5 MHz to 2 MHz at voltage of 266 KV (rms) between phase to ground.

1000

(g)

Corona extinction voltage (KV rms)

320

(h)

Total min. cantilever strength (Kg)

800

(i)

Min. torsional moment (Kg m)

600

(j)

Total height of insulator (mm)

3650

i)

Top PCD. (mm)

127

ii)

Bottom PCD (mm)

300

(k)

No. of bolts : Top Bottom

(l)

4 8

Diameter of bolt holes (mm) Top

M16

Bottom

dia 18

(m)

Pollution level as per IEC – 815

Class III, Heavy

(n)

Min. total creepage distance (mm)

10500



PART-B CHAPTER - E5

PAGE 2 OF 3

CLAUSE NO.

POST INSULATOR (E5)

Note: If corona extinction voltage is to be achieved with the help of corona ring or any other similar device, the same shall be deemed to be included in the scope of the bidder without any price implication to NTPC.



PART-B CHAPTER - E5

PAGE 3 OF 3

PART-B SUB-SECTION-E6 WAVE TRAPS (AIS)



CLAUSE NO.

WAVE TRAPS (E6) 1.00.00

GENERAL The Wave Trap covered under the package shall conform to IEC 353 or IS:8792, IS:8793 and relevant IEC/IS Specifications except to the extent modified by the specification.

2.00.00

LOCATION OF EQUIPMENT

2.01.00

Wave Traps as specified under this section shall be installed at the respective transmission line bays as indicated in the single line diagram.

3.00.00

TECHNICAL REQUIREMENTS

3.01.00

Wave Trap shall be inserted into high voltage transmission line to prevent undue loss of carrier signal for all power system conditions. Its impedance shall be negligible at power frequency (50 Hz) so as not to disturb power transmission but shall be relatively high over the frequency band appropriate to carrier transmission.

3.02.00

Wave trap shall consist of a main coil designed to carry continuously the rated current without exceeding the limit of temperature rise. It shall be supplemented with a protective device and tuning device.

3.03.00

Wave trap shall be Broad Band tuned for its entire carrier frequency range. Resistive component of impedance of the Wave trap within its carrier frequency blocking range shall not be less than 570 ohms.

3.04.00

Wave trap shall be provided with a protective device in the form of lightning arrestor which shall be designed and arranged such that neither significant alternation in its protective function nor physical damage shall result from either temperature rise or the magnetic field of the main coil at continuous rated current or rated short time current. The protective device shall neither enter into operation nor remain in operation, following transient actuation by the power frequency voltage developed across the line trap by the rated short time current. The protective device shall be shunt connected to the main coil and tuning device. The lightning arrestor shall be of gapless/gap type. Its rated discharge current shall be 10 KA. Coordination, however, shall be done by taking 20 KA discharge current into account.

3.05.00

The lightning arrestor provided with the Wave trap of each rating shall fully comply with the requirements of IS-3070-Part-I (1974)/IEC-60099-4. It shall conform to type tests as applicable and type test certificate for the same shall be submitted by the Bidder.

3.06.00

The lightning arrester provided with the Wave trap shall be subject to routine and acceptance tests as per IEC – 60099.

3.07.00

The Wave trap on 400 KV lines shall show no visual corona at extinction voltage of 320 KV rms. Suitable corona rings shall be incorporated in the line trap for 400 KV.



PART-B CHAPTER-E6

PAGE 1 OF 3

CLAUSE NO.

WAVE TRAPS (E6) 3.08.00

Wave trap shall be equipped with bird barriers.

3.09.00

Wave trap shall be spray painted with light admiralty Grey paint RAL-9002

3.10.00

Wave trap shall conform to IEC 353 (latest) fulfilling the following technical particulars. a)

Rated power frequency

50 Hz

b)


400 KV

c)

Highest system voltage

420 KV

d)

Rated continuous current at 40 degree C ambient

2500 Amps .

e)

Rated short time current for 1sec.

40 KA

f)

i) Nominal discharge current


ii) Discharge current at which insulation coord. is done


g)

Type of tuning

Broad Band

h)

Rated Blocking band-width

To be indicated by the contractor

i)

Inductance a) 2 Nos. with 1.0mH inductance b) 2 Nos. with 0.5mH inductance Bidder shall quote the unit price for the above items in the relevant Bid proposal sheets for price adjustment based on actual quantities required during detailed engineering

j)

Radio Inteference voltage level at 266 KV

not more than 500 micro volts/N.A.

k)

Corona extinction voltage level

320 KV rms (min)/N.A.

3.11.00

The Bidder shall indicate continuous current rating of the Wave trap at 45 deg.C ambient.

3.12.00

In accordance with the requirements stipulated under Part-A, the Wave Trap shall confirm to following type tests and shall be subjected to routine and acceptance tests as per IEC-353. a)

Measurement of inductance of the main coil



PART-B CHAPTER-E6

PAGE 2 OF 3

CLAUSE NO.

WAVE TRAPS (E6) b)

Measurement of temperature rise

c)

Insulation tests

d)

Short time current tests

e)

Corona Extinction Voltage Measurement

f)

Radio Interference Voltage measurement

4.00.00

WAVE TRAP MOUNTING

4.01.00

The Wave Trap for 400 KV shall be suitable for outdoor pedestal mounting and shall be mechanically strong enough to withstand the stresses due to maximum wind pressure of 195 kg/square metre.

4.02.00

For pedestal mounting, each Wave trap shall be mounted on a tripod structure formed by three solid core type insulators shall be of non-magnetic material. The Support structures and insulator stacks are also covered in the scope of supply.

5.00.00

TERMINAL CONNECTOR

5.01.00

The Wave traps for 400 KV shall be suitable for connecting to ACSR twin bundle conductor.

5.02.00

Terminal Connectors shall conform to IS-5561 and shall be in accordance with requirements stipulated in Section E12.

5.03.00

Terminal Connectors for conductor(s) shall be suitable for either horizontal or vertical take-off of the conductor(s).

5.04.00

Clamps/connectors shall conform to type test and shall be subject to routine tests as per IS: 5561. In case of 400 KV, test reports shall be also submitted for following additional type tests.

5.05.00

a)

Visual Corona Extinction Test

b)

Radio Interference Voltage Measurement

Bidders are required to submit alongwith their bid typical drawings clearly indicating the above mentioned features of the Wave traps, Wave trap mounting arrangement and terminal connectors.



PART-B CHAPTER-E6

PAGE 3 OF 3

PART-B SUB-SECTION-E7 LIGHTING (COMMON)



CLAUSE NO.

LIGHTING (E7)

1.00.00

GENERAL

1.01.00

The lighting system and its accessories shall conform in general to the relevant standards except to the extent explicitly modified in the specification and shall be in accordance with the requirement specified elsewhere. The switchyard lighting shall be carried out by fixtures mounted on the switchyard structures/masts to be provided at appropriate locations.

1.02.00

Supply, storage and installation of various lighting fixtures complete with lamps and accessories on the gantries and switchyard structures shall be carried out by the contractor.

1.03.00

Supply, storage and installation of lighting panels, including their cable terminations, from switchyard LT switchboard/ Lighting distribution boards shall be carried out by the contractor.

1.04.00

Supply, storage and installation of fixture supports, complete with all accessories including junction boxes shall be carried out by the contractor.

1.05.00

All the civil works like fixing of anchor bolts, erection of lighting panels etc. shall be carried out by the contractor. Hardwares for fixing of fixtures etc. are also included in the erection component of the items.

1.06.00

Laying and termination of 415 V Aluminium conductor PVC armoured power cables of 2Cx6 mm2 from lighting panel to the junction box at the bottom of the gantry/ structures for the lighting fixture and looping from one gantry/structures to the other shall be carried out by the contractor.

1.07.00

Laying and termination of 415 V Aluminium conductor PVC armoured power cables of 3 ½ Cx 35 mm2 (or of required size whichever is higher) from switchyard LT switchboard/ Lighting distribution boards to lighting panels shall be carried out by the contractor.

1.08.00

Power supply shall be fed from 415/240V normal AC power supply through suitable number of conveniently located lighting panels (LPs).

1.09.00

Lighting panels, fixtures, masts, distribution boards, switchboxes, conduits, junction boxes, etc. shall be properly installed and earthed as per relevant IE rules.

1.10.00

All outdoor fixtures shall be weather proof type (IP 55 as per IS 2147). Fluorescent fixtures shall be provided with electronic ballasts.

1.11.00

All luminaries and their accessories and components shall be of the type readily replaceable by the available Indian makes. All fixtures and accessories shall of reputed make and non-corrosive type. Acrylic covers/louvers shall be of nonyellowing type.

1.12.00

The constructional features of lighting distribution boards shall be similar to AC/DC distribution boards described elsewhere. Outgoing circuits in LPs shall be provided with MCBs of adequate ratings.

1.13.00

Wiring shall be by multi-stranded PVC insulated colour coded copper wires laid in GI conduits. Minimum size of the wire shall not be less than 1.5 sq.mm. copper or 4 sq.mm. aluminium. Wires shall conform to IS:694 and wiring installation shall be as per IS:732.



PART-B CHAPTER - E7

PAGE 1 OF 3

CLAUSE NO.

LIGHTING (E7)

1.14.00

Conduits shall be of heavy duty type, hot dip galvanised steel conforming to IS:9537. In corrosive areas, conduits shall have additional suitable epoxy coating.

1.15.00

All outdoor lighting systems shall be automatically controlled by synchronous timer or photocell. Arrangement shall be provided in the panel to bypass the timer/photocell for manual control.

2.00.00

LIGHTING FIXTURES AND ACCESSORIES

2.01.00

General

2.01.01

All lighting fixtures and accessories shall be designed for continuos operation under atmospheric conditions existing at site, without reduction in the life or without deterioration of materials and wiring etc.

2.01.02

Lighting fixtures shall be as given below: 1x400W weather proof miniature flood lighting with aluminium housing polished inside and stove enameled grey outside suitable to Bajaj type BHEF 21-S or Crompton type FBD-14 or Philips type SVF -12. All the fixtures shall be supplied with matching lamps.

2.02.00

Lighting fixtures

2.02.01

The lighting fixtures and accessories shall be designed to operate at 240V AC 50Hz with supply voltage variation of ± 10%, frequency variation of ± 5%and combined voltage and frequency variation of ± 10%.

2.02.02

All fixtures shall be complete with accessories like ballasts, igniters, power factor improvement capacitors etc. These shall be mounted inside the fixtures as far as possible. If these cannot be accommodated inside, then a separate metal enclosed weather proof box shall be included to accommodate these. The starting time of these lamps to attain full light output shall be minimum. Each fixture shall have terminals suitable for 2.5 sq.mm stranded flexible copper conductor.

2.02.03

The mounting facility and conduit knockouts for the fixtures shall be as required and shall be suitable for cable/conduit entry.

2.02.04

On completion of the manufacture, all surfaces of the fixtures shall be thoroughly cleaned and degreased. The fixtures shall be free from scale, rust, sharp edges and burns.

2.02.05

All enamel finishing shall have a minimum thickness of 2 mils for outside surface and 1.5 mils for inside surface. The finish shall be non porous and free from blemishes, blisters and fading.

2.02.06

The housing shall be stove enamelled or vitreous enamelled or anodised aluminium as relevant for the type of fixtures.

2.03.00

Lamps

2.03.01

Sodium vapour lamps shall be colour corrected type with screw caps.



PART-B CHAPTER - E7

PAGE 2 OF 3

CLAUSE NO.

LIGHTING (E7)

2.03.02

The contractor shall furnish typical wiring diagram for HPSV fitting including all accessories. The diagram shall include all technical details of accessories i.e. starters, chokes, capacitors and igniters etc.

3.00.00

LIGHTING PANELS

3.01.00

Each panel shall be provided with one incoming triple pole switchfuse unit with neutral link and outgoing MCB’s as specified.

3.02.00

The panel shall have degree of protection of IP55 as per IS 2147. The panel shall be single front construction, front hinged and front connected, suitable for floor mounting.

3.03.00

The panel shall be provided with a circuit directory plate (of anodised aluminium with the inscriptions indelibly etched on the plate) which is fitted on the inside of the door.

3.04.00

Each panel shall be provided with one no. ON indicating lamp for each phase.

3.05.00

The main busbars of the panel shall be of aluminium alloy with adequate cross section to carry rated and short circuit currents. The maximum temperature of the busbars shall not exceed 85 degree C. The busbars shall be able to withstand a fault level of 9KA for 1 sec.

3.06.00

Switches shall be hand operated air break type, heavy duty confirming to IS 4064. The fuses shall be of class 3 type (9KA prospective breaking current).

3.07.00

The MCB’s shall in general conform to IS 8828. The rating shall be well coordinated with the corresponding circuits and shall be ‘Morarjee Dorman’ or ‘Standard’ make or its equivalent.

3.08.00

The contactors shall be of full voltage, direct on line air break, single throw, electromagnetic type. They shall be provided with atleast 2 NO and 2 NC type auxiliary contacts.

3.09.00

The panels shall be provided with proper identification labels for the panel, incoming and outgoing circuits etc.

4.00.00

ILLUMINATION LEVELS AND TYPE OF FIXTURES AND LUMINAIRES Location

Average Illumination level (lux)

Type of Fixture

Switchyard

20 (general)

HPSV flood light, weather proof

50 (on strategic equipment)

HPSV flood light, weather proof



PART-B CHAPTER - E7

PAGE 3 OF 3

PART-B SUB-SECTION-E8 LT SWITCHGEAR & DBs (COMMON)



LT SWITCHGEAR & DBs (E8)

CLAUSE NO

1.00.00

CODES AND STANDARDS

1.01.00

All equipments shall, generally, comply with the updated issues of : I)

IEC-947, IS-13947

II)

Indian Electricity Act

III)

Indian Electricity Rules

1.02.00

Equipment complying with any other authoritative / internationally recognised standards such as IEC, British, U.S.A., German, etc. will also be considered if it ensures performance equivalent or superior to indian Standards . In such cases the bidder shall clearly indicate the standard adopted and furnish the copy of latest English version of the same alongwith the bid and bring out the salient features for comparison.

2.00.00


2.01.00

This section covers supply, installation, testing and commissioning of all the 415V Switchgears, AC Distribution Boards (ACDBs), Lighting Distribution Boards (LDBs) and 220V & 48V DC Distribution Boards (DCDBs), complete with all components and accessories for commissioning these boards.

2.01.00

To derive 415V AC power from two feeders available in Station Service Boards installed inside the power house through cable connection is included in the scope of Contractor.

2.02.00

To provide auxiliary AC power supply to various station equipments, 415 V AC switchboards are to be supplied and installed by the Contractor.

2.03.00

The Bidder shall meet the requirement of feeders under his scope of works. The contractor shall supply all equipments and devices required for satisfactory operation..

2.04.00

The AC switchgear Boards shall comprise of suitable incoming breaker for each board and bus coupler breaker with proper interlocking mechanism. Each distribution board shall consist of adequate nos of of 63A modules type E complete with base frame anchoring bolts, fuses, cable glands etc. The lighting distribution board shall comprise of adequate nos. of MCCBs of 63A rating including support channel, installation of base frame etc. 220V DC distribution Board shall have sufficient nos of feeders to extend DC supply to all required equipments covered under the package. 48 V DC distribution Board shall be consist of adequate nos of 32A feeders with MCCB.

3.00.00

CONSRUCTIONAL DETAILS OF SWITCHBOARDS

3.01.00

All Switchboards. i.e., 415V Switchgears, AC Distribution Boards (ACDBs), Lighting Distribution Boards (LDBs) and 220V/48V DC Distribution Boards (DCDBs) shall be of metal enclosed, indoor, floor-mounted, free-standing type.



PART-B CHAPTER - E8

PAGE 1 OF 21


CLAUSE NO

3.02.00

All switchboard frames and load bearing members shall be fabricated using suitable mild steel structural sections or pressed and shaped cold-rolled sheet steel of thickness not less than 2.0 mm. Frames shall be enclosed in cold-rolled sheet steel of thickness not less than 1.6 mm. Doors and covers shall also be of cold rolled sheet steel of thickness not less than 1.6 mm. Stiffners shall be provided wherever necessary. The gland plates thickness shall be 3.0 mm (minimum) for hot / coldrolled sheet steel and 4.0 mm (minimum) for non-magnetic material.

3.03.00

All panel edges and cover / door edges shall be reinforced against distortion by rolling, bending or by the addition of welded reinforcement members. The top covers of the panels should be designed such that they do not permanently bulge/ bend by the weight of maintenance personnel working on it.

3.04.00

The complete structures shall be rigid, self-supporting, free from flaws, twists and bends. All cutouts shall be true in shape and devoid of sharp edges.

3.05.00

All switchboards shall be of dust-proof and vermin-proof construction and shall be provided with a degree of protection of IP : 52 as per IS:13947. Provision shall be made in all compartments for providing IP : 52 degree of protection, when circuit breaker or module trolley has been removed. All cutouts shall be provided with synthetic rubber gaskets. The switchboards which are meant for outdoor duty shall be provided with degree of protection of IP : 54 as per IS : 13947.

3.06.00

Provision of louvers on switchboards would not be preferred.

3.07.00

All switchboards shall be of uniform height not exceeding 2450 mm.

3.08.00

Switchboards shall be easily extendable on both sides by the addition of vertical sections after removing the end covers.

3.09.00

Switchboards shall be supplied with base frames made of structural steel sections, alongwith all necessary mounting hardware required for welding down the base frame to the foundation / steel insert plates. The base frame height shall be such that floor finishing (50 mm thick) to be done by Employer after erection of the switchboards does not obstruct the movement of doors, covers, with drawable modules etc.

3.10.00

All switchboards shall be divided into distinct vertical sections (panels), each comprising of the following compartments: a.

BUSBAR COMPARTMENT A completely enclosed bus bar compartment shall be provided for the horizontal and vertical busbars. Bolted covers shall be provided for access to horizontal and vertical busbars and all joints for repair and maintenance which shall be feasible without disturbing any feeder compartment. Auxiliary and power busbars shall be in separate compartments.

b.

SWITCHGEAR / FEEDER COMPARTMENT All equipments associated with an incomer or outgoing feeder shall be housed in a separate compartment of the vertical section. The compartment



PART-B CHAPTER - E8

PAGE 2 OF 21


CLAUSE NO

shall be sheet steel enclosed on all sides with the withdrawable units in position or removed. Insulating sheet at rear of the compartment is also acceptable. The front of the compartment shall be provided with the hinged single leaf door with captive screws for positive closure. c.

CABLE COMPARTMENT OR CABLE ALLEY A full-height vertical cable alley of minimum 175 mm width shall be provided for power and control cables. Cable alley shall have no exposed live parts and shall have no communication with busbar compartment. Cable terminations located in cable alley shall be suitably shrouded to prevent accidental contact by falling of tools etc. For distribution boards, the partition between the feeder compartment and cable alley made of FRP sheet may also be offered. It shall be of such construction as to allow cable cores with lugs to be easily inserted in the feeder compartment for termination. Wherever. cable alleys are not provided for distribution boards, segregated cable boxes with complete shrouding for individual feeders shall be provided at the rear for direct termination of cables in each individual feeder. For circuit breaker external cable connections, a separately enclosed cable compartment shall also be acceptable. The contractor shall furnish suitable plugs to cover the cable openings in the partition between feeder compartment and cable alley. Cable alley door shall be hinged.

d.

CONTROL COMPARTMENT A separate compartment shall be provided for relays and other control devices associated with a circuit breaker.

3.11.00

Sheet steel barriers shall be provided between two adjacent vertical panels running to the full height of the switchboard, except for the horizontal busbar compartment. Synthetic rubber gasket shall be provided between the panel sections to avoid ingress of dust into panels. Each shipping section shall have full metal sheets at both ends for transport and storage.

3.12.00

After isolation of power and control circuit connections it shall be possible to safely carryout maintenance in a compartment with the busbar and adjacent circuit live. Necessary shrouding arrangement shall be provided for this purpose. Wherever two breaker compartments are provided in the same vertical section insulating barriers and shrouds shall be provided in the rear cable compartment to avoid accidental touch with the live parts of one circuit when working on the other circuit.

3.13.00

All 415 V switchgear (circuit-breaker) panels shall be of single -front type. MCCs and DBs shall be of single -front construction. All single-front switchboards shall be provided with single-leaf, hinged or bolted covers at the rear. The bolts shall be of captive type. The covers shall be provided with “DANGER” labels. All panel doors shall open by 90 deg. or more.

3.14.00

All ACDBs, Lighting DBs and DCDBs shall be of fixed module type. All 415 V circuitbreaker modules and MCC modules shall be of fully drawout type having distinct ‘Service’ and ‘Test’ positions. The equipments pertaining to a drawout type incomer or feeder module shall be mounted on a fully withdrawable chassis which can be



PART-B CHAPTER - E8

PAGE 3 OF 21


CLAUSE NO

drawn out without having to unscrew any wire or cable connection. Suitable arrangement with cradle/ rollers and guides shall be provided for smooth movement of the chassis. For modules of size more than half the panel height, double guides shall be provided for smooth removal or insertion of module. All identical module chasis of same size shall be fully interchangeable without having to carryout any modifications. 3.15.00

All disconnecting contacts for power and control circuits of drawout moduels shall be of robust and proven design, fully self aligning and spring -loaded. Both fixed and moving contacts shall be silver - plated and replaceable. The spring- loaded power and control drawout contacts shall be on withdrawable chassis and same on fixed portion shall not be accepted. Detachable plug and socket type control terminals shall also be acceptable.

3.16.00

Individual opening in the vertical bus enclosure shall permit the entry of moving contacts from the drawout modules into vertical droppers.

3.17.00

All equipment and components shall be neatly arranged and shall be easily accessible for operation and maintenance. The internal layout of all modules shall be subject to Employer’s approval. The Contractor shall submit dimensional drawings showing complete internal details of busbars and module components, for each type and rating for approval of Employer.

3.18.00

The power and control cable entries shall be from the bottom.

3.19.00

Each switchboard shall be provided with undrilled, removable type gland plate which shall cover the entire cable alley. Bidder shall ensure that sufficient cable glanding space is available for all the cables coming in a particular section through gland plate. For all single core cables, gland plate shall be of non-magnetic material. The gland plate shall preferably be provided in two distinct parts for the easy of terminating addition cables in future. The gland plate shall be provided with gasket to ensure enclosure protection. Recommended drilling chart of gland plates for all power and control cables in the vertical panels shall be indicated by the Contractor in the respective G.A. drawings of the boards.

3.20.00

The Bidder shall consider layout of panels in a switchbaord consisting of various feeder modules required for the system in a straight line, unless specified otherwise. The actual composition and disposition of various modules in a switchboard shall be finalised during detailed engineering.

3.21.00

Clearances The minimum clearance in air between phases and between phases and earth for the entire run of horizontal and vertical busbars and bus-link connections at circuitbreaker shall be 25 mm. For all other components, the clearance between “two live parts”, “a live part and an earthed part”, shall be atleast ten (10) mm throughout. Wherever it is not possible to maintain these clearances, insulation shall be provided by sleeving or barriers. However, for horizontal and vertical busbars the clearances specified above should be maintained even when the busbars are sleeved or insulated. All connections from the busbars upto switch / fuses shall be fully shrouded / insulated and securely bolted to minimise the risk of phase to phase and phase to earth short circuits.



PART-B CHAPTER - E8

PAGE 4 OF 21

CLAUSE NO

4.00.00


POWER BUSBARS AND INSULATORS

4.01.00

All 415 V Switchboards and ACDBs shall be provided with three phase and neutral busbars.. DCDBs shall be provided with two (2) busbars . Entire busbar system of DCDBs shall be insulated.

4.02.00

All busbars and jumper connections shall be of high conductivity aluminium alloy / copper of adequate size.

4.03.00

The cross-section of the busbars shall be uniform throughout the length of switchboard and shall be adequately supported and braced to withstand the stresses due to the specified short circuit currents. Neutral busbar short circuit strength shall be same as main busbars.

4.04.00

All busbars shall be adequately supported by non-hygroscopic, non-combustible, track-resistant and high strength sheet moulded compound or equivalent type polyester fibre glass moulded insulator. Separate supports shall be provided, for each phase and neutral busbar. If a common support is provided, anti-tracking barriers shall be provided between the supports. Insulator and barriers of inflammable material such as Hylam, shall not be accepted. The busbar insulators shall be supported on the main structure.

4.05.00

All busbar joints shall be provided with high tensile steel bolts, Belleville/ spring washers and nuts, so as to ensure good contacts at the joints. Non-silver plated busbar joints shall be thoroughly cleaned at the jointed locations and a suitable contact grease shall be applied just before making a joint. All bolts shall be tightened by torque spanner to the recommended value. The overlap of the busbars at each joint surface shall be such that the length of overlap shall be equal to or greater than the width of the busbar.

4.06.00

All copper to aluminim joints shall be provided with suitable bimetallic washers.

4.07.0

All busbars shall be colour coded as per IS : 375. Wherever the busbars are painted with black matt paint, the same should be suitable for temperature encountered in the switchboard under normal operating conditions.

4.08.00

The Bidder shall furnish calculations establishing the adequacy of busbar sizes for specified current ratings.

4.09.00

All busbars shall have PVC sleeves (not taped) wherever called for in the Specification.

5.00.00

AUXILIARY BUSBARS AND CONTROL TRANSFORMERS.

5.01.00

AC CONTROL SUPPLY BUSBAR Each bus-section of all Switchgears shall be provided with two(2) nos. 415V / 110V control transformers. The 110V AC control supply from the control transformers shall be run through the MCC by means of two sets of control supply busbars of electrolytic copper. In case of one transformer failure, whole bus section can be fed



PART-B CHAPTER - E8

PAGE 5 OF 21

CLAUSE NO


through single transformer. The control supply to different modules shall be tapped individually from the control supply busbars. 5.02.00

DC CONTROL SUPPLY BUSBARS Electrically controlled circuit breaker boards shall be provided with DC control supply busbars. The manually controlled breakers shall also be provided with such busbars in case relays are provided.. The Contractor shall provide suitable terminals, switchfuse etc. to receive the DC supply and distribute the same through above mentioned control busbars to the required modules of the respective section. The DC control supply bus of one section shall be coupled to the control supply of other section through a switch located in the buscoupler breaker panel. The DC supply to the buscoupler breaker may be given from any of the control buses.

5.03.00

SPACE HEATER BUSBARS Panel and motor space heaters shall be fed from separate AC auxiliary busbars running throughout the switchboard. The supply for these busbars shall be tapped from incomer, before the isolating switch/ circuit breaker.

5.04.00

CONTROL TRANSFORMERS The control transformers shall be 415 V/110 V with neutral point-earthed, of insulation class ‘B’ or better. The sizing of Control transformers shall be carried out by Bidder considering the actual load of power contactors, auxiliary contactors, indicating lamps and other equipments in the module circuit. An additional load of 15 watts should also be considered for each module, for remote auxiliary relays and lamps to be connected in the control circuit of modules. Bidder shall also ensure that control transformers are adequately designed for meeting the momentary loading requirements & the voltage drop during this condition shall not be more than 5%.

6.00.00

EARTH BUS AND EARTHING

6.01.00

A galvanised steel earth bus shall be provided at the bottom of each panel and shall extend throughout the length of each switchboard. It shall be welded / bolted to the framework of each panel and breaker earthing contact bar. Vertical earth bus shall be provided in each vertical section which shall in turn be bolted / welded to main horizontal earth bus.

6.02.00

The earth bus shall have sufficient cross section to carry the momentary short circuit and short time fault current to earth, as indicated in “Technical Parameters”, without exceeding the allowable temperature rise.

6.03.00

Suitable arrangements shall be provided at each end of the horizontal earth bus for bolting to Employer’s earthing conductors. The horizontal earth bus shall project out of the switchboard ends and shall have predrilled holes for this connection. All joint splices to earth bus shall be made through atleast two bolts, and taps by proper lug and bolt connection.

6.04.00

All non-current carrying metal work of the switchboard shall be effectively bonded to the earth bus. Electrical conductivity of the whole switchgear enclosure framework and truck shall be maintained even after painting.



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6.05.00

The carriage and breaker frame shall get earthed while being inserted in the panel and positive earthing of the breaker frame shall be maintained in all positions, i.e. SERVICE & ISOLATED, as well as throughout the intermediate travel.

6.06.00

Each module frame shall get engaged to the vertical earth bus before the disconnecting contacts on the module are engaged to the vertical busbars.

6.07.00

All metallic cases of relays, instruments and other panel-mounted equipments shall be connected to earth by independent stranded copper wires of size not less than 2.5 sq. mm. All the equipment mounted on the door shall be earthed through flexible wire/braids. Insulation colour code of earthing wires shall be green. Earthing wires shall be connected to terminals with suitable clamp connectors, soldering is not acceptable. Looping of earth connections which would result in loss of earth connections to other devices, when a device is removed, is not acceptable. However, looping of earth connections between equipments to provide alternative paths to earth bus is acceptable.

6.08.00

VT and CT secondary neutral point earthing shall be at one place only, i.e. on the terminal block. Such earthing shall be made through links so that earthing of one secondary circuit shall be removed without disturbing the earthing of other circuit.

6.09.00

All hinged doors having potential carrying equipment mounted on it shall be earthed by flexible wire/ braid. For doors not having potential carrying equipment mounted on it, earth continuity through scraping hinges/ hinge pins of proven design may also acceptable. The Contractor shall establish earth continuity at site also.

7.00.00

CIRCUIT BREAKERS

7.01.00

Circuit breakrers shall be three pole, air break, horizontal drawout type , and shall have fault making and breaking capacities as specified. The circuit breakers which meet specified parameters of continuous current rating and fault making / breaking capacity only after provision of cooling fans or special device shall not be acceptable.

7.02.00

Circuit breakers alongwith its operating mechanism shall be provided with suitable arrangement for easy withdrawal. Suitable guides shall be provided to minimise misalignment of the breaker.

7.03.00

There shall be “SERVICE”, “TEST” and “FULLY WITHDRAWN” positions for the breakers. In “Test” positon the circuit breaker shall be capable of being tested for operation without energising the power circuits i.e. the power contacts shall be disconnected, while the control circuits shall remain undisturbed. Locking facilities shall be provided so as to prevent movement of the circuit breaker from the “SERVICE”, “TEST” or “ FULLLY WITHDRAWN” position. It shall be possible to close the door in “Test” position.

7.04.00

All circuit breakers shall have short circuit releases and shunt trip coil irrespective of the type of operating mechanism.

7.05.00

All circuit breakers shall be provided with “4 NO” and “ 4NC” potential free auxiliary contacts. These contacts shall be in addition to those required, for internal



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mechanism of the breaker and should be directly operated from breaker operating machanism. In case the manufacturer does not have a proven arrangement for providing the required number of circuit breaker auxiliary contacts on the fixed portion of the cubicle, necessary electrically reset latched relays similar to Alshtom make type VAJC11 relays shall be provided complete with all wiring in series with service position limit switch contacts, for multiplying the circuit breaker mounted auxiliary contacts and provide 4 NO and 4 NC contacts . Separate limit switches, each having required numbers of contacts shall be provided in both “SERVICE “ and “TEST” position of the breaker. All contacts shall be rated for making, continuously carrying and breaking 10 Amp at 240 V AC and 1 Amp (Inductive) at 220 V DC respectively. 7.06.00

Suitable mechanical indications shall be provided on all circuit breakers to show “OPEN”, “CLOSE”, “SERVICE “, “TEST” AND “SPRING CHARGED” positions.

7.07.00

Main poles of the circuit breakers shall operate simultaneously in such a way that the maximum difference between the instants of contacts touching during closing shall not exceed half a cycle of rated frequency.

7.08.00

All circuit breakers shall be provided with the following interlocks : i)

Movement of a circuit breaker between “SERVICE” and “TEST” position shall not be possible unless it is in open position. Attempted withdrawal of a closed circuit breaker shall preferably not trip the circuit breaker. In cases the offered circuit breaker trips on attempted withdrawal as a standard interlock, it shall be ensured that sufficient contact exist between the fixed and drawout contact at the time of breaker trip so that no arcing takes place even with the breaker carrying it’s full rated current.

ii)

Closing of a circuit breaker shall not be possible unless it is in “SERVICE” position, “TEST” position or in “FULLY WITHDRAWN” position.

iii)

Circuit-breaker cubicles shall be provided with safety shutters operated automatically by the movement of the circuit breaker carriage, to cover the stationary isolated contacts when the breaker is withdrawn. It shall however be possible to open the shutters intentionally against pressure for testing purposes.

iv)

Circuit breakers shall be provided with coded key / electrical interlocking devices.

7.09.00

Circuit breaker shall be provided with electrical anti-pumping and trip free feature, even if mechanical anti-pumping feature is provided.

7.10.00

Mechanical tripping shall be possible by means of front mounted Red “trip” pushbutton. In case of electrically operated breakers these push buttons shall be shrouded to prevent accidental operation.

7.11.00

Means shall be provided to slowly close the circuit breaker in “withdrawn position”, if required, for inspection and setting of contacts. In “service position” slow closing shall not be possible.



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7.12.00

Complete shrouding/ segregation shall be provided between incoming and outgoing bus links of breakers. In case of bus coupler breaker panels the busbar connection to and from the breaker terminals shall be segregated such that each connection can be approached and maintained independently with the other bus section live. Dummy panels if required to achieve the above feature shall be included in the Bidder’s scope of supply.

8.00.00

OPERATING MECHANISM : Circuit breaker shall be provided with either of the following mechanisms.

8.01.00

8.02.00

Manually operated Mechanism i)

Manually operated mechanism shall be of manual spring charging, stored energy type.

ii)

The circuit breaker shall have a spring charging handle and push-button for closing the breaker mechanically after the spring has been charged. However, closing by spring charging handle after the spring has been fully charged shall also be acceptable, provided the movement of contacts does not take place with the movement of handle and the contacts operate only when the spring stored energy is released. Overcharging of spring shall not be possible.

iii)

The closing action of the circuit breaker shall charge the tripping spring, thus making it ready for tripping.

iv)

The circuit breaker shall be provided with the interlocks so that it shall not close unless the spring is fully charged.

POWER OPERATED MECHANISM i)

Power operated mechanism shall be provided with a universal motor suitable for operation on 220 V DC/240 AC Control supply, with voltage variation from 90% to 110% rated voltage. Motor insulation shall be class “E” or better.

ii)

The motor shall be such that it requires

iii)

Not more than 30 seconds for fully charging the closing spring at minimum available control voltage.

iv)

Once the closing springs are discharged, after one closing operation of circuit breaker, it shall automatically initiate recharging of the spring.

v)

The mechanism shall be such that as long as power is available to the motor, a continuous sequence of closing and opening operations shall be possible. After failure of power supply at least one open-close-open operation shall be possible.

vi)

Provision shall be made for emergency manual charging and as soon as this manual charging handle is coupled, the motor shall automatically get mechanically decoupled.



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8.03.00

vii)

All circuit breakers shall be provided with closing and trip coils. The closing coil shall operate correctly at all values of voltage between 85% to 110% of rated control voltage. The trip coil shall operate satisfactorily at all values of voltage between 70% to 110% of rated control voltage.

vii)

Provision for mechanical closing of the breaker only in “Test” and “WITHDRAWN” positions shall be made. Alternately, the mechanical closing facility shall be normally made inaccessible; accessibility being rendered only after deliberate removal of shrouds.

TELESCOPIC TROLLY Telescopic trolly or suitable arrangement shall be provided for maintenance of circuit-breaker module in a cubicle. The trolly shall be such that the top most breaker module can be withdrawn on the trolly and can be lowered for maintenance purpose. The telescopic trolly shall be such that all type, size and rating of breaker can be withdrawn /inserted of a particular switchgear.

9.00.00

AIR BREAK SWITCHES

9.01.00

Air break switches shall be of heavy duty, single throw, group operated, load break, fault make type when associated with fuses. All switches for motor circuits shall be of utilisation category AC-23 with 1NO +1NC auxiliary contact which shall be wired to the control circuit All switches for other outgoing feeders shall be of utilization category AC-22. All switches for DC circuits shall be suitable for 220 V DC and shall be of DC-22 utilisation category .

9.02.00

Continuous current rating of the switches shall be selected by the contractor as required for the system.”.

9.03.00

The combination of switch-fuse unit would be preferred. However, if separate switch and fuses are provided, switch shall be located before fuses.

9.04.00

The main switches shall be operable from outside the module door. The switch handle shall clearly indicate the position of switch. Switch operating handles shall be provided with padlocking facilities. However, incomer switches of switchboards shall be provided with padlocking facility in both ‘ON’ and ‘OFF’ positions.

9.05.00

Interlocks shall be provided such that the cubicle door will not open when the switch is in closed position and the switch will close only when the door is closed. However, suitable means shall be provided to intentionally defeat these interlocks.

9.06.00

Switches and fuses for AC/DC control supply and heater supply wherever required, shall be mounted inside the cubicles. Toggle switch is not acceptable.

10.00.00

CONTROL AND SELECTOR SWITCHES

10.01.00

Control and Selector switches shall be of rotary type, with escutcheon plates clearly marked to show the function and positions. The switches shall be of sturdy construction suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts against dust ingress shall be preferred.



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10.02.00

Circuit breaker control switches shall have three positions and shall be spring return to “NEUTRAL” from “CLOSE” and “TRIP” positions and shall have pistol grip handles. The control switch shall have adequate number of contacts in each position and shall have at least two (2) contacts closing in “Close” position, and two (2) contacts closing in ‘Trip’ position unless specified otherwise.

10.03.00

Circuit breaker selector switches for motor feeders ( M- type) shall have two stay put position marked ‘Switchgear’, ‘Normal’ respectively. They shall have at least three contacts for each of the two positions and shall have black spade handles. Circuit breaker selector switches for other feeders shall have two stay put positions marked ‘Switchgear’ and ‘Normal’ with two contacts for each of the two positions.

10.04.00

Ammeter and voltmeter selector switches shall have four stay put positions with adequate number of contacts for 3-phase 4-wire system. These shall have oval handles. Ammeter selector switches shall have make before break type contacts to prevent open circuiting of CT secondaries.

10.05.00

Contacts of the switches shall be spring assisted and shall be of suitable material to give a long trouble free service.

10.06.00

The contact ratings shall be at least the following : i.

Make and carry, continuously, 10 A at 220 V DC and 110 V AC

ii.

Breaking current at 220 V DC, 1 A (inductive).

iii.

Breaking current at 110 V AC, 5A and 0.3 lagging p.f

11.00.00

CONTACTORS

11.01.00

Motor starter contactors shall be of air break, electromagnetic type rated for uninterrupted duty as per IS : 13947 Part-4 Section- 1.

11.02.00

Contactors shall be double-break, non-gravity type and their main contacts shall be silver faced.

11.03.00

Direct-on-line contactors shall be of utilisation category AC3. Reversing starters shall comprise of forward and Reverse contactors mechanically and electrically interlocked with each other. These contactors shall be of utilisation category AC4. DC contactors shall be of DC-3 utilisation category.

11.04.00

The number of normally open (NO) and normally closed (NC) auxiliary contacts of a contactor shall be as per requirement. It shall, however, be not less than 2NO+2NC.

11.05.00

Operating coil of contactors shall be of 110 V AC unless otherwise specified elsewhere. The contactor shall operate satisfactorily between 85% to 110% of the rated voltage. The contactor shall not drop out at 70% of the rated voltage but shall definitely drop out at 20% of the rated voltage.



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11.06.00

Contactors for DC drives shall have a coil voltage of 220 V DC. DC operated contactor coil shall have an economy resistor and shall be suitable for satisfactory continuous operation at 85% to 110% of the rated voltage.

12.00.00

FUSES

12.01.00

All fuses shall be of HRC cartridge fuse link type. Screw type fuses shall not be accepted. Fuses for AC circuits shall be rated for 80 kA rms. (prospective) breaking capacity at 415 V AC and for DC circuits 20 kA rms. breaking capacity at 220 V DC.

12.02.00

Fuse shall have visible operation indicators. Insulating barriers shall be provided between individual power fuses.

12.03.00

Fuse shall be mounted on insulated fuse carriers, which are mounted on fuse bases. Wherever it is not possible to mount fuses on carriers, fuses shall be directly mounted on plug-in type of bases. In such cases one set of insulated fuse pulling handles shall be supplied with each switchboard.

12.04.00

Suitable Fuse ratings shall be selected by the Bidder to achieve coordination. Switch rating shall in no case be less than the fuse rating.

12.05.00

The Neutral links shall be mounted on fuse carriers, which shall be mounted on fuse bases.

13.00.00

INSTRUMENT TRANSFORMERS

13.01.00

All current and voltage transformers shall be completely encapsulated, cast resin insulated type suitable for continuous operation at the temperature prevailing inside the switchgear enclosure, when the switchboard is operating at its rated condition and the specified ambient temperature. The class of insulation shall be ‘E’ or better.

13.02.00

All instrument transformers shall be able to withstand the thermal and mechanical stresses resulting from the maximum r.m.s. short circuit breaking and peak making current ratings of the associated switchgear.

13.03.00

All instrument transformers shall have clear indelible polarity markings. All secondary terminals shall be wired to separate terminals on an accessible terminal block where star point formation and earthing shall be done.

13.04.00

Current transformers may be multi or single-core type. All voltage transformers shall be single phase type . However separate set of CT shall be provided for differential protection purpose.

13.05.00

The bus VTs shall be housed in a separate compartment. All VTs shall have readily accessible HRC current limiting fuses on both primary and secondary sides.

13.06.00

All CTs shall be provided with supports independent of busbar/busbar supports.

13.07.00

The CTs shall be located in such a way that they can be easily approached for maintenance without necessitating shut down of adjacent feeders.



PART-B CHAPTER - E8

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14.00.00

RELAYS & TIMERS

14.01.00

All relays and timers in protective circuits shall be flush mounted on panel front with connections from the inside. They shall have transparent, dust tight covers removable from the front. All protective relays shall have a drawout construction for easy replacement from the front. They shall either have built-in test facilities, or shall be provided with necessary test blocks and test switches located immediately below each relay. The auxiliary relays and timers may be furnished in non-drawout cases.

14.02.00

All AC relays shall be suitable for operation of 50 Hz with 110 Volt VT secondary and 1A or 5A CT secondary.

14.03.00

DC auxiliary relays shall be designed for 220 V DC unless otherwise specified and shall operate satisfactorily between 75% and 110% of the rated voltage. Relays shall have adequate thermal capacity for continuous operation in circuit in which they are used.

14.04.00

Protective relays, auxiliary relays and timers shall be provided with hand reset operation indicators for analysing the cause of operation.

14.05.00

All relays shall withstand a test voltage of 2.5KV AC rms for one second or 2 KV AC rms for one minute.

14.06.00

All fuse protected contactor controlled motor and actuator starters shall be provided with three element, ambient temperature compensated, time lagged, hand reset type thermal overload relays with single phasing protection using differential movement and bimetallic strips. The single phasing protection shall operate even with 100% of the set current flowing in two of the phases and no current in the third phase. The setting ranges shall be properly selected to suit the motor ratings and shall be adjustable type. These relays shall have a separate black coloured hand reset push button mounted on compartment door and shall have atleast one NO + one NC contact.

14.07.00

All releases in circuit breakers shall conform to IS ; 13974 Part-2. The releases shall be instantaneous or time delayed as per the requirement mentioned in module description. The releases shall have an operation indicator. A contact denoting “release operated” should be available for connecting to relay 86 circuit. . The instantaneous release used for motor feeders shall be co-ordinated such that it does not operate with motor starting current.

15.00.00

INDICATING INSTRUMENTS

15.01.00

All indicating and integrating meters shall be flush mounted on panel front. The instruments shall be of at least 96 mm. square size with 90 degree linear scale and shall have an accuracy class of 2.0 or better. The covers and cases of instruments and meters shall provide a dust and vermin proof construction.

15.02.00

All instruments shall be compensated for temperature errors and factory calibrated to directly read the primary quantities means shall be provided for zero adjustment without removing or dismantling the instruments.



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15.03.00

All instruments shall have white dials with black numerals & lettering. Black knife edge pointer shall be provided for meters.

15.04.00

Ammeters shall have a compressed scale at the upper current region to cover the starting current upto 6.0 times the CT primary current.

16.00.00

PUSH BUTTONS

16.01.00

Push-buttons shall be of spring return, push to actuate type,. Their contacts shall be rated to make, continuously carry and break 10 A at 110 V AC and 1 A (inductive) at 220 V DC.

16.02.00

All push -buttons shall have two (2) normally open and two(2) normally closed contact, unless specified otherwise. The contact faces shall be of silver alloy.

16.03.00

All push-buttons shall be provided with integral escutcheon plates marked with its function.

16.04.00

The colour of the button shall as follows : Green for motor START, breaker CLOSE. Red: for motor trip, breaker open. Black: for all annunciation functions, overload reset and miscellaneous commands.

16.05.00

All push buttons on panels shall be located in such a way that Red push button shall always be to the left of Green push buttons.

16.06.00

All emergency push buttons shall have mushroom knobs.

17.00.00

INDICATING LAMPS

17.01.00

Indicating lamps shall be of the panel mounting, filament type and low watt consumption. Lamps shall be provided with non-hygroscopic series resistors, preferably built-in the lamp assembly. The lamps shall have escutcheon plates marked with its function, wherever necessary.

17.02.00

Lamps shall have translucent lamp-covers of the following colours, as warranted by the application : Red for motor ON, breaker CLOSE. Green for motor OFF , breaker OPEN. White for motor AUTO TRIP. Blue for all healthy conditions (e.g. control supply, and also for ‘SPRING CHARGED”). Amber for all Alarm Conditions (e.g. overload). Also for “SERVICE” and “TEST” position indications.



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17.03.00

Bulbs and lamp covers shall be easily replaceable from the front of the cubicle. The method of mounting indicating lamp fittings on panels shall prevent their rotation under the action of lamp removal or replacements, reliance upon the tightness of ring nut for the purpose is not sufficient.

17.04.00

Indicating lamps should be located just above the associated push-button / control switches. Red lamps shall invariably be located to the right of green lamps. In case a white lamp is also provided, it shall be placed between the red and green lamps along the centre line of control switch / push button pair. Blue and Amber should normally be located above the Red and Green lamps.

17.05.00

When associated with push-buttons, red lamps shall be directly above the green push-button and green lamp shall be directly above the red push button.

17.06.00

All indicating lamps shall be suitable for continuous operation at 90% to 110% of their rated voltage.

18.00.00

SPACE HEATER

18.01.00

Space heaters shall be provided in the switchboards wherever the manufacturer considers them necessary and recommends their provision for preventing harmful moisture condensation.

18.02.00

The space heaters shall be suitable for continuous operation on 240 V AC , 50 Hz., single phase supply, and shall be automatically controlled by thermostats. Necessary switches and fuses shall be provided.

18.03.00

The circuit for each panel and motor space heater should have an isolating switch, HRC fuse and isolating link. in addition, the space heater circuit of each panel shall also have a thermostat of suitable rating.

19.00.00

INTERNAL WIRING

19.01.00

All switchboards shall be supplied completely wired internally upto the terminals, ready to receive external cables.

19.02.00

All intercubicle and interpanel wiring and connections between panels of same switchboard including all bus wiring for AC and DC supplies shall be provided by the Bidder.

19.03.00

All auxiliary wiring shall be carried out with 650 V grade, single core stranded copper conductor, colour coded, PVC insulated wires. Conductor size shall be 1.5 mm2 (min.) for control circuit wiring and 2.5 mm2 (min) for CT and space heater circuits.

19.04.00

Extra flexible wires shall be used for wiring to devices mounted on moving parts such as hinged doors. The wire bunches from the panel inside to the doors shall be properly sleeved or taped.

19.05.00

All wiring shall be properly supported, neatly arranged, readily accessible and securely connected to equipment terminals and terminal blocks.



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19.06.00

All internal wiring terminations shall be made with solderless crimping type tinned copper lugs which shall firmly grip the conductor or an equally secure method. Similar lugs shall also be provided at both ends of component to component wiring. Insulating sleeves shall be provided over the exposed parts of lugs to the extent possible. Wago type terminal shall also be provided with lugs.

19.07.00

Engraved core identification ferrules marked to correspond with panel wiring diagram shall be fitted at both ends of each wire. The ferrule shall be of selflocking type of ‘Novoflex’ or equivalent make. The wire identification marking shall be in accordance with IS : 375. Red Ferrules should be provided on trip circuit wiring.

19.08.00

All connections from vertical busbars for individual modules above 100 A shall be by Copper / Aluminium links only. The cable connections for modules less than 100 A shall be selected in such a way that there will not be any melting / shorting in case of a short circuit inside the module and the cable shall have current rating to carry the let through energy of the corresponding fuses in case of a fault. The insulation of the cable and its cross section shall be decided considering the high ambient temperature within the module. For all modules where use of cable is envisaged by the Contractor specific approval from the Employer regarding cable details are to be taken. For power wiring colour coded wire insulation / tapes shall be provided.

20.00.00

CONTROL TERMINAL BLOCKS

20.01.00

Control terminal blocks shall be of 650 Volts grade, rated for 10 Amps and in one piece moulding. It shall be complete with insulating barriers, clipon type terminals and identification strips. Marking on terminal strip shall correspond to the terminal numbering on wiring diagrams. It shall be ‘Klippon’ type RSF-1 (‘Elmex’ type CSLT1) with insulating material of Melamine conforming to ESI standard 12.1 or equivalent. Terminal blocks may alternatively be of CAGE clamp spring type.

20.02.00

Terminal blocks for CT & VT secondary leads shall be provided with test links & isolating facilities. CT secondary leads shall be provided with short-circuiting & earthing facilities. It shall be similar to ‘Elmex’ CATD type. The terminals for remote ammeter connection etc. shall also be disconnecting type only.

20.03.00

In all circuit breaker panels MCC modules at least 10% spare terminals for external connections shall be provided and these spare terminals shall be uniformly distributed on all terminal blocks.

20.04.00

All terminal blocks shall be suitable for terminating on each side two (2) nos. stranded copper conductors of size upto 2.5 mm2 each.

20.05.00

All terminals shall be numbered for identification and grouped according to the function. Engraved white-in- black lables shall be provided on the terminal blocks.

20.06.00

Wherever duplication of a terminal block is necessary it shall be achieved by solid bonding links.

20.07.00

Terminal blocks shall be arranged with atleast 100 mm clearance between two sets of terminal blocks. The minimum clearance between the first row of terminal blocks and the associated cable gland plate shall be 250 mm.



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21.00.00

POWER CABLE TERMINATION

21.01.00

Cable termination compartment and arrangement for power cables shall be suitable for heavy duty, 1.1 kV grade, stranded aluminium conductor, PVC/ XLPE insulated, armoured / unarmoured and PVC sheathed cables. The size and type of cable for individual modules shall be selected by bidder and get approved from Employer. All necessary cable terminating accessories such as supporting clamps and brackets, hardware etc shall be provided by the contractor.

21.02.00

All power cable terminals shall be of stud type and the power cable lugs shall be of tinned copper solderless crimping ring type conforming to IS : 8309. All lugs shall be insulated/ sleeved.

22.00.00

NAME PLATES AND LABELS

22.01.00

All Switchgears, Distribution Boards, , all feeders, shall be provided with prominent, engraved identification plates. The module identification plate shall clearly give the feeder number and feeder designation. For single front switchboards, similar panel and board identification labels shall be provided at the rear switchgear also.

22.02.00

All name plates shall be of non-rusting metal or 3-ply Lamicoid, with white engraved letterings on black background. Inscription & lettering sizes shall be subject to Employer’s approval.

22.03.00

Suitable stencilled paint mark shall be provided inside the panel/module for identification of all equipments in addition to the plastic sticker labels, if provided. These labels shall be positioned so as to be clearly visible and shall have the device number, as mentioned in the module wiring drawings.

22.04.00

Caution name plate “Caution Live Terminals” shall be provided at all points where the terminals are likely to remain live and isolation is possible only at remote end.

23.00.00

LIGHTING TRANSFORMERS Each Lighting Distribution Board (LDB) shall be fed from A 415 V / 415V, 50 KVA isolating transformer which is, in turn, fed from switchgear. The lighting transformer may, preferably be located inside LDB panel itself. Otherwise, the side of respective LDB shall locate the same. Lighting transformers shall be dry type, natural air cooled with class B insulation or better. Impedance of lighting transformer shall be so selected that the fault level of lighting system shall be reduced to 3 to 5 KA. Lighting transformers shall be tested as per IS : 2026. Off-circuit tap changer with ± 2.5% and ± 5% tapping shall be provided. In case the transformers are not mounted inside the LDB panels, the same shall be housed in a separate 2 mm thick CR sheet steel enclosure with IP-42 degree of protection as per IS : 13947. However, the transformer terminal box shall have IP-52 degree of protection.

24.00.00

PAINTING All sheet steel work shall be pretreated, in tanks, in accordance with IS : 6005. Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline hot water and dried. The phosphate coating



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shall be “Class-C “ as specified in IS : 6005. The phosphated surfaces shall be rinsed and passivated prior to application of stoved lead oxide primer coating. After primer application, two coats of finishing synthetic enamel paint on panels shall be applied. Electrostatic painting shall also be acceptable. Finishing paint on panels shall be Grey RAL 9002. The inside of the panels shall be glossy white. Each coat of finishing shall be properly stoved. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peelable compound by spraying method to protect the finished surfaces from scratches, grease, dirt and oil spots during testing, transportation, handling and erection. All hardwares shall be nickel chromium plated / zinc passivated. The pad locking plate shall be suitably painted to avoid rusting. 25.00.00

GASKETS The gaskets, wherever specified, shall be of good quality synthetic rubber with good ageing, compression and oil resistance characteristics suitable for panel applications.

26.00.00

TEMPERATURE RISE The temperature rise of the horizontal and vertical busbars and main bus links including all power drawout contacts when carrying 90% of the rated current along the full run shall in no case exceed 65 deg C with silver plated joints and 50 deg C with all other types of joints over an outside ambient temperature of 40 deg C. Temeprature rise for the busbars shall be carried out at 90% of the rated current and no diversity factor shall be used for temperature rise test.

27.00.00

DERATING OF EQUIPMENTS

27.01.00

The Bidder shall, ensure that the equipments offered will carry the required load current at site ambient conditions specified and perform the operating duties without exceeding the permissible temperature as per Indian Standards / Specification. Continuous current rating at 40 deg C ambient in no case shall be less than 90% of the normal rating specified.

27.02.00

The Bidder shall indicate clearly the derating factors if any employed for each component and furnish the basis for arriving at these derating factors duly considering the specified current ratings and ambient temperature of 40 deg C.

28.00.00

PROTECTION CO-ORDINATION It shall be the responsibility of the Contractor to fully coordinate the overload and short circuit tripping of the circuit breakers fuses to provide satisfactory discrimination. Further the various equipment supplied shall meet the requirements of Type II class of Co-ordination as per IS : 8544.

29.00.00

TESTS AND TEST REPORTS

29.01.00

The following type test certificates on each type & rating of L.T. Switchgear, and distribution boards shall be submitted.



PART-B CHAPTER - E8

PAGE 18 OF 21


CLAUSE NO

(a)

Short time withstand test with circuit breaker mounted inside the switchgear panel

(b)


(c)

Type II-Short circuit co-ordination test for any three rating of MCC module as selected by the Employer.

(d)

Test sequence-1 & combined test sequence shall be carried out on each rating of circuit breaker mounted inside the panel.

(e)

Degree of protection tests.

29.02.00

Routine tests shall be carried out on all switchboards and associated equipments, as per relevant standards and approved QP at Contractor’s cost.

29.03.00

Routine checking to observe compliance to degree of protection, first numeral , on switchboard enclosures and busbar chambers shall be as under : a)

IP -4 X It shall not be possible to insert a one mm dia. steel wire into the enclosure from any direction, without using force.

b)

IP-5X It shall not be possible to insert a thin sheet of paper under gaskets and through enclosure joints.

30.00.00

COMMISSIONING CHECK TESTS

30.01.00

After installation of panels, power and control wiring and connections, Contractor shall perform operational tests on all switchboards, to verify proper operation of switchboards / panels and correctness of all equipment in each and every respect.

30.02.00

The Contractor shall carry out the following commissioning checks, in addition to other checks and tests recommended by the manufacturers.

30.03.00

General

30.04.00

i.

Check name plate details according to the approved drawings.

ii.

Check for physical damage.

iii.

Check tightness of all bolted connections, by torque wrench.

iv.

Check earth connections.

v.

Check cleanliness.

vi.

Check all moving parts for proper lubrication.

CIRCUIT BREAKERS i.

Check alignment of breaker truck for free movement.



PART-B CHAPTER - E8

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CLAUSE NO

30.05.00

30.06.00

30.07.00

ii.

Check correct operation of shutters .

iii.

Check control wiring for correctness of connections, continuity and IR values.

iv.

Manual operation of breakers completely assembled.

v.

Closing /opening operation, manually and electrically.

vi.

Trip free and anti-pumping operation.

vii.

I.R. values of contacts.

viii.

Contact resistance.

ix.

Check on spring charging motor, correct operation of limit switches and time for charging.

x.

All functional checks

xi.

Breaker closing and tripping time, if required.

CURRENT TRANSFORMERS i.

Visual inspection.

ii.

IR value

iii.

Ratio check.

iv.

Magnetising current.

v.

Wiring connection.,

vi.

spare CT cores, if any, to be shorted and earthed.

VOLTAGE TRANSFORMERS i.

Visual inspection.

ii.

IR Value

iii.

Ratio check

iv.

Magnetising current

v.

Line connection as per connection diagram.

CUBICLE WIRING i.

Check all switch developments



PART-B CHAPTER - E8

PAGE 20 OF 21


CLAUSE NO

30.08.00

30.09.00

30.00.00

ii.

Each wire shall be traced by continuity tests and it shall be ensured that the wiring is as per relevant drawing. All inter-connections between panels / equipment shall be similarly checked.

iii.

All the wires shall be meggered to earth.

iv.

Functional checking of all control circuit e.g., closing, tripping, control, interlock, supervision and alarm circuit.

RELAYS i.

Check connections and wiring.

ii

a)

Megger all terminals to body.

b)

Megger AC to DC terminals.

iii.

Check operating characteristics by secondary injection.

iv.

Check minimum pick up voltage of DC coils.

v.

Check operation of electrical / mechanical targets.

vi.

Relay settings.

vii.

Check CT and VT connections with particular reference to their polarities.

METERS i.

Visual inspection.

ii.

Megger all insulated partitions.

iii.

Check CT and VT connections with particular reference to their polarities for power type meters.

iv.

Calibration.

COMPLETNESS OF EQUIPMENT All the fittings and accessories that might not have been mentioned specifically in the specification but are necessary for equipment's of the plant, shall be deemed to be included in the specification and shall be supplied and furnished by the Contractor without any extra cost/charge.



PART-B CHAPTER - E8

PAGE 21 OF 21

PART-B SUB-SECTION-E9 LT POWER AND CONTROL CABLES (COMMON)



L T POWER AND CONTROL CABLES (E9)

CLAUSE NO

1.00.00

CODES AND STANDARDS

1.01.00

Cables IS:1554, IS:7098, IS:502, IS:6380, IS:9968

2.00.00


2.01.00

All cables shall be suitable for high ambient, high humid tropical Indian climatic conditions. All cables shall be Flame Retardant Low Smoke (FRLS) type designed to withstand the mechanical, electrical and thermal stresses under the foreseen steady state and transient/fault conditions, and shall be suitable for the proposed method of installation.

2.02.00

The aluminium/copper wires used for manufacturing the cables shall be true circular in shape before stranding and shall be of uniformly good quality, free from defects. All aluminium used in the cables shall be of H2 grade.

2.03.00

The fillers and inner sheath shall be of non hygroscopic, fire retarding material, softer than insulation and outer sheath shall be suitable for the temperature of the cable.

2.04.00

For cables having more than five (5) cores, each core shall be identified by number marking. However, for cables upto five (5) cores, the same shall be by colour.

2.05.00

The normal current rating of all the PVC insulated cables shall be as per IS 3961.

2.06.00

All the cables used in the switchyard shall be armoured.

2.07.00

Other parameters of the cables are as follows: Particulars

Power cables XLPE PVC

Control cables

i) Material

Stranded Aluminium

Stranded plain annealed copper

ii) Size

As required Min. 6 sq.mm size

As required, but min. 1.5 sq.mm. size

iii) Shape

Circular / sector shaped

Circular / sector shaped

Conductor

Main Insulation i) Material


XLPE

PVC


PVC

PART-B CHAPTER - E9

PAGE 1 OF 1

PART-B SUB-SECTION-E10 SUBSTATION AUTOMATION SYSTEM (COMMON)



CLAUSE NO

SUBSTATION AUTOMATION SYSTEM (COMMON) (E10)

PREAMBLE This specification is based on the understanding that a complete integrated Substation Automation System (SAS)/SCADA including GRP is required for the 400 kV SWYD that provides a central station from where the complete 400 kV substation can be monitored and controlled. The status of the generator plant must also be available to the substation operator. The SAS/SCADA offered shall fulfill the criteria given in Clause No. 1.03.00 of Sub-Section-VI of Part-A. Provision is made for remote monitoring and control of the substation from two control rooms, i.e. a local (Switchyard Protection Room as well as Main Plant Control Room) and remote control center (possibly future). Provision is made for extension of SAS to the Generation control room to enable the operators in the power station to Control as well as Monitor the 400 kV substation network. 1.00.00


1.01.00

The Bidder’s scope of work shall include the supply, delivery, installation, testing and commissioning of the following:

1.01.01

The Substation Automation System (SAS) for the 400 kV network, including Substation Controllers, Bay Controllers, Workstations, MIMIC display, rear projection display, metering, protection, Control Room furniture and all other equipment required for the SAS for the 400 kV network as defined in this specification. Control & Monitoring of complete Switchyard from Main Plant Control room through two nos OWS and one no. LVS (which shall be supplied loose by the Employer). The installation, networking ,testing , commissioning, etc shall be in the bidder’s scope.

1.01.02

The integration with Employer’s OPC-compliant DCS of the main plant shall be in bidders scope. The integration of status and analog signals such as MW, MVAR, Generation Voltage from the Main Plant DCS into the switchyard SAS and GRP Relay Status information, switchyard status, etc from the switchyard SAS into the Main Plant DCS network shall be possible. To facilitate above ,two nos OPC compliant gateways shall be provided by the bidder.

1.01.03

Communication Gateways shall be provided by the bidder at CCR to facilitate control & Monitoring of complete switchyard from remote control centre,

1.01.04

Communication Gateways ( alongwith Modems) shall be provided by the bidder for communicating switchyard information to RLDC and NTPC OS control Room.

1.01.05

The architecture for the SAS is enclosed as Drg Title “Substation Automation System Architecture”. The Bidder shall provide full details of the offered system Architecture with the Bid.

1.01.06

The point-to-point testing of all signals for the 400 kV network at the plant end and protection equipment end and the terminal end (Substation Controller and Operator Workstations) at the substation shall be the responsibility of the bidder.



PART-B CHAPTER-E10

PAGE 1 OF 59

CLAUSE NO


1.01.07

The point-to-point testing of all signals of the Main Plant DCS gateway shall be the responsibility of the Employer. The bidder shall be responsible for all the works on switchyard SAS.

1.02.00

The SAS shall be suitable for full protection, control, metering, monitoring and communication functions of all the bays in the bidder’s scope.

1.03.00

The SAS shall be a computer-based system that shall integrate independently operating subsystems, such as Bay Control Units, Bay Protection Units including GRP, Metering, and alarm annunciation, into a unified data acquisition, monitoring, protection and control system in the substation. The Substation Controllers, Bay Control Units, Bay Protection Units, disturbance recorders, time synchronizing equipment, the Energy Metering System and relay test kit offered should meet the proven-ness criteria specified elsewhere. The bidder shall state any limitations in this regard during Bidding, and provide details of any similar systems (previous generation) supplied by the contractor that are in successful operation.

1.04.00

All the systems comprising the SAS shall be state-of-the-art, based on industry standards, suitable for operation under electrical conditions present in the EHV substations, follow the latest engineering practice, ensure long term compatibility requirements and continuity of equipment supply and safety of the operating staff.

1.05.00

The SAS architecture shall be flexible to allow future extensions in switchyard. Only IEC 61850 protocols shall be used for inter-device communication, with the exception of the engineering bus.

1.06.00

The SAS at substation level and the communication network(s) shall be designed in a dual redundancy configuration. No single failure of any component / module of the SAS, including the communication links, shall cause loss of functionality of the SAS of more than a single bay.

1.07.00

Each component / module of SAS, including all the communication links, shall be provided with built-in supervision and self-diagnostic features and any failures shall be alarmed to the operator.

1.08.00

The SAS shall be designed such that no periodic testing and maintenance is required for various subsystems comprising SAS. On-line testing routines for various subsystems of SAS shall be provided.

1.09.00

SAS shall be designed such that maintenance, modification or extension of its components / modules shall not cause shutdown of the complete SAS.

1.10.00

The SAS and all its components shall be synchronized from a GPS time referenced clock receiver. The Time Synchronization Equipment shall also be in Bidder’s scope of supply. A timing accuracy of better than 1 ms shall be achieved for all the devices within the SAS.

1.11.00

The Bidder shall provide all the documentation required during project implementation and during the life cycle of SAS for operation and maintenance. A list of such documentation shall be reviewed and approved by the Employer during detailed engineering.



PART-B CHAPTER-E10

PAGE 2 OF 59

CLAUSE NO


1.12.00

The SAS shall be suitable for inter-operation with future Intelligent Electronic Devices (IED) like Bay Control Units and Bay Protection Units from various suppliers operating on IEC61850, in order to facilitate a more efficient and cost-effective monitoring, control and protection of complete substation.

1.13.00

Employer intends to ensure interoperability of any third party IEC61850 compatible IEDs to be incorporated in future with the offered SAS. Bidder to provide all necessary data information in this regard.

1.14.00

The SAS shall be designed so that a skilled operator (without any background in microprocessor-based technology) shall be able to operate it easily after he has been provided with some basic training.

1.15.00

The SAS supplied as per this specification shall be designed and constructed to meet all specification requirements for 15 years. Further, the Bidder should guarantee for hardware and software support for 15 (fifteen) years to guard against obsolescence. SAS equipment or components that can not meet this life expectancy or specified design and operational requirements or likely to become obsolete during the entire service life shall be identified and their expected failure rate / obsolescence period with corrective action shall be indicated by the bidder in his proposal. When no such information is furnished, the SAS shall be deemed to be suitable for above service life and requirements. All requirements / devices of the SAS that are not listed under recommended spares shall have a normal life expectancy exceeding the specified expected life of the SAS.

2.00.00

SAS RELIABILITY REQUIREMENTS

2.01.00

Each component and equipment offered by the Bidder shall be of established reliability. The minimum target reliability of each piece of equipment like each electronic module/card, power supply, peripheral etc. shall be established by the Bidder considering its failure rates/meantime between failures (MTBF), meantime to repair (MTTR), such that the availability of the complete system is assured. The guaranteed annual system availability shall not be less than 99.9%.

2.02.00

The Bidder shall submit reliability and maintainability values including detailed calculation for the projected overall system availability along with all assumptions supported by relevant standard for each device/equipment/system module which, with the help of a schematic of various systems connected in series or in parallel as the case may be, and Mean Time Between Failures (MTBF) & Mean Time to Repair (MTTR) values for the various equipment shall show that availability calculation is as specified in IEEE standard-P-1046 or equivalent. This shall be submitted by the Bidder along with his bid.

2.03.00

To ensure availability, adequate redundancy in system design shall be provided at hardware and software level to satisfy the availability criteria indicated above.

2.04.00

The bidder shall furnish in the bid a composite list of bought out items (i.e. items not from his own manufacturing range) which the Bidder has included in his proposal along with the name of proposed sub-vendors, as a part of his proposal. However, the make and model of all bought out items supplied by the Bidder shall be as approved by the Employer during the detailed engineering stage.



PART-B CHAPTER-E10

PAGE 3 OF 59


CLAUSE NO

3.00.00

SAS PERFORMANCE REQUIREMENTS

3.01.00

It shall be the responsibility of the Bidder to predict and indicate in the bid, the worst case loading conditions and design the system accordingly to meet the same. The worst case loading conditions shall include the following tasks as a minimum:

3.01.01

All analog inputs scanning and processing is in progress and all the data is being transmitted over the system bus every one second.

3.01.02

Four operator comments for information from any Operator Workstation with in a base period of one minute.

3.01.03

A burst of 100 alarms is generated over a period of 10 s.

3.01.04

One operator control is generated every 10 s.

3.01.05

Data collection for logs/reports is in progress.

3.01.06

Data collection for historical storage and trend function in progress.

3.01.07

Data collection of fault records is in progress.

3.01.08

All health monitoring functions/diagnostics in progress.

3.01.09

All output devices are in operation with rated performance/speed.

3.01.10

All data are transferred to the Operator Workstations.

3.02.00

Duty Cycle Time The Substation Controller processor spare duty cycle (free time) Under the worst case loading conditions, each processor shall have:

3.03.00

a)

40% free time when measured over any two second period

b)

60% free time when measured over any one minute period

Interbay Bus and Substation Network Spare Duty (free time) The Interbay Bus and Substation Network shall have minimum 50% free time during the worst case loading conditions measured over any two-second period. The Bidder shall furnish all necessary data to fully satisfy the Employer that the processor spare duty cycle figures quoted by the bidder are realistic and based on configuration and computational capability of the offered system and these shall be actually implemented system as commissioned at project site.



PART-B CHAPTER-E10

PAGE 4 OF 59

CLAUSE NO

3.04.00


Display Response Time The display response time under worst case conditions for all displays shall not be worse than 1.5secs for HMI displays. The display response time is defined as the time interval between the pressing of the last key demanding a display and completion of the requested display on CRT with full foreground and background information, and/or the updating of status indications according to plant changes, and/or the updating of event / alarm register according to alarm conditions.

4.00.00

SOFTWARE LICENSE AND UPGRADES

4.01.00

The bidder shall provide all software licenses for all the software being used in SAS system. The license shall be provided on a site license basis and shall be valid for the plant / equipment life cycle. The license shall not be hardware / machine specific i.e. if any hardware / machine is changed / upgraded, the same software license shall be valid and the Employer shall not have to seek fresh license or renewal of license. In the case of anti-virus software, the license shall include regular updates untill the end of warranty and one year AMC period. The Bidder shall guarantee that all software are defect free and meet the system specifications, and undertake to fix any defects which may arise during the life of the system at no cost to the Employer.

4.02.00

All software versions in components of the SAS shall be the latest official releases as on the date of shipment from works and shall include all software updates etc. released till that date. A certificate to this effect shall be furnished by the bidder at the time of pre-dispatch inspection for each software package. All new software revisions and/or patch updates that are released before the end of the warranty period which addresses system defects shall be implemented on site and the system re-tested to validate system integrity by the bidder at no cost to the Employer (This excludes new revisions which provides additional functionality). The bidder shall periodically inform the designated officer of the Employer about software updates / new releases that would be taking place after the system is commissioned.

5.00.00

DESIGN AND OPERATING REQUIREMENTS OF SAS

5.01.00

Appendix-A to the Chapter E-10 gives the main functional components / subsystems of SAS. This list serves as a guide to the bidder to offer correct quantities and does not relieve the bidder of any requirement specified elsewhere in the specification. The SAS specification has priority over this list of quantities. Appendix-A is enclosed.

5.02.00

The control hierarchy and control levels of the SAS shall be based on the logical structure of the SAS, which is as follows:



PART-B CHAPTER-E10

PAGE 5 OF 59


CLAUSE NO

Control Level 3

Remote Control Center

Control Level 2

Substation Level (HMI)

Control Level 1

Bay Control Units

Control Level 0

Switchgear Equipment

5.03.00

The data exchange between Control Level 3 and Control Level 2 shall take place via the communication links provided by the Employer for remote telemetry and control of the substation using the IEC60870-5-101/104/OPC protocol. However, protocol may subject to change and shall be finalized during detailed engg.

5.04.00

The data exchange between Control Level 2 and Control Level 1 shall take place via the inter-bay / station communication bus using the IEC61850 protocol. The interbay communication bus shall support peer-to-peer communications capability.

5.05.00

The data exchange between Control Level 1 and Control Level 0 shall be by means of hard-wired status / control signals between Switchgear Equipment and Bay Control / Protection Units and analog signals from CTs / CVTs.

6.00.00

SUBSTATION LEVEL FUNCTIONALITY

6.01.00

Control Functions i)

The SAS shall perform control functions on various switchyard equipment based on the status, analog and logical inputs acquired by SAS from various bay control units.

ii)

It shall be possible to monitor and control all the switchyard bays in the Bidder’s scope, and monitor the status of the Generator plant (status and analog signals such as MW, MVAR, Generation Voltage, GRP Relay Status, information etc)from any of the Operator Workstations at Control Level 2 i.e either from switchyard Control Room or Main Plant control Room. However, in the case of maintenance, failure or emergency, it shall be possible to control the individual bays from the Bay Control Units at Control Level 1.

iii)

Clear control priorities shall ensure that operation of a particular bay equipment (Circuit Breaker or Isolator) cannot be initiated simultaneously from more than one of the control levels. The priority shall always be on the



PART-B CHAPTER-E10

PAGE 6 OF 59


CLAUSE NO

lowest enabled control level. The selected control level shall be indicated at all the levels so that the operator is aware of his control capabilities.

6.02.00

6.03.00

iv)

The SAS shall have provision of Device Tagging for all the substation devices. This function is to block the control of any substation device in such a manner that its command is prevented from Operator’s Workstations.

v)

Interlocking shall be implemented and shall ensure that no illegal switch operation can be performed by any control initiated from Control Level 3, Control Level 2 or Control Level 1. Interlocking shall be implemented on bay level as specified in relevant section of this specification.

Sequence of Events and Alarm Management i)

The SAS shall be capable of reporting on both Operator Workstation and printers, the time sequenced record of events occurring in the substation. Separate logs shall be created for alarms and events and both the logs shall be time-tagged. Suitable filters, based on date and time, bay number, device number, function etc. shall be provided for both alarm as well as event logs for ease of viewing.

ii)

The SAS shall record in non-volatile memory all changes of alarms and plant statuses of switchyard equipment, including the alarms generated by Bay Control and Bay Protection units. It shall be possible to print historic events and real-time (unacknowledged and non-cleared) alarms after a system failure or reset with no loss of information.

iii)

All the alarms and events shall be time tagged at the Bay Controller or Bay Protection unit with a time resolution of 1 ms.

iv)

The SAS shall include all the alarms and changes of plant statuses of the 400 kV networks.

v)

The SAS shall acquire the alarm signals from Bay Control Units and Bay Protection Units with preset priorities and on receipt of an alarm, shall generate an audible signal and report it either upon request or automatically to the respective printer.

vi)

The Employer shall approve the list of alarms and plant statuses to be wired for Sequence of Events log and Alarm Management, during detailed engineering stage.

Historical Data Management and Trending i)

The SAS shall maintain historical data in bulk non-volatile memory. The historical data shall be available for review and editing by authorized user.

ii)

The SAS shall monitor specified incoming information for historical data base, perform calculations on some of the incoming data and store incoming and calculated data in the non-volatile memory as historical data.



PART-B CHAPTER-E10

PAGE 7 OF 59


CLAUSE NO

6.04.00

iii)

The historical data shall include Digital Fault Records and Sequence of Event logs received from bay protection units and bay control units.

iv)

It shall be possible to trend any measurement signal or summation of signals available in real time or data available in the historical database, in the shape of trend curves.

Operations Log It shall be possible to create a daily operations log, in a user-defined format, about the substation operations as well as any failures / tripping therein. It shall also be possible to include on daily basis all the information required to keep a historical record of equipment behavior.

6.05.00

Reports The SAS should be capable of generating different types of reports, which can be presented in the operator interface screens upon request or programmed for automatic presentation in printers. It shall be possible to generate reports with information from both historical data base and real time information.

6.06.00

Mass Storage Back up Either an industry standard DVD writer or tape streamer shall be provided to permit mass storage of all information existing in the computers hard disks such as application programs, database configuration, historical data, operations log etc.

6.07.00

System Security i)

Security features shall be provided at each level for safeguarding against unauthorized access. An alarm message will be displayed at the Control Centre and recorded in the logs for any unauthorized access attempts. The bidder shall provide software locks and passwords to the Employer’s engineers at site for all operating and application software at all levels.

ii)

The system shall maintain a SYSTEM CHANGE log, recording all system changes made along with the identification of the person making the change, date, time and area of the system modified. The format and details of this log shall be finalized during detailed engineering.

iii)

No single failure either of equipment or power source shall result in rendering any part / subsystem of SAS inoperative, except that the information related to failed part / component is not available.

iv)

To ensure system security, the complete functionality of SAS shall be divided into various system security levels, to be decided by Employer during detailed engineering. Each security level shall offer certain functionality of the SAS to users e.g. Security Level 0 – Display only of Graphics, Real Time data and Historical Data



PART-B CHAPTER-E10

PAGE 8 OF 59


CLAUSE NO

Security Level 1 – Normal Control Operations, Access to acknowledge alarm logs Security Level 2 – Restricted Control Operations; access to edit / defeat bay interlocks Security Level 3 – Complete access, engineering and maintenance of configurations and databases. v)

The users shall be grouped into various user-groups with each user having a user name and password. The level of accessibility to each user group shall be pre-defined.

vi)

The system administrator group shall have complete access to SAS and shall be able to add / remove users and redefine access rights.

vii)

The various system security levels and various user groups shall be defined by the Employer during detailed engineering.

6.08.00

GATEWAYS: Remote Interface with RLDC, OS control Room & Remote Control Centre

6.08.01

The SAS shall have provision for interfacing with remote RLDC through suitable gateways with adequate number of ports alongwith modems at Substation Level as shown in the tender drawing. The modems, to be supplied by the bidder, shall be suitable for use with PLCC, being provided for 400kV lines and to be used for communication between the switchyard and RLDC using communication protocol IEC 60870-5-101. Each port shall allow for remote telemetry and control of the 400kV networks in the substation using IEC 60870-5-101. The interface ports for communication with RLDC shall use V.24/V.28 communication standard (CCITT Std.) for interfacing with modems. The interoperability requirements for above shall be furnished during detailed engineering. One (1) number of suitable modem shall also be supplied as loose item for each of the above serial ports for the remote end.

6.08.02

Only selected information such as bus voltage, frequency, active / reactive power through various feeders, open / close status of circuit breakers, isolators etc is required to be shared with RLDC. However, actual list of information to be shared with RLDCs shall be finalized during detailed engineering. The bidder shall have to demonstrate the availability of desired information at the output of modem at site.

6.08.03

Provision for interfacing with owners remote control station (OS Control Room) through gateways with adequate number of ports shall be provided at Substation Level as shown in the tender drawing. The communication protocol for this port shall be OPC and the gateway shall be OPC version 2.0a compliant and implement a OPC – DA 2.0a server and OPC – HAD 2.0a server as per the specification of OPC foundation. All data like MW, MVAR, CB status etc. shall be through this OPC Server.

6.08.04

The SAS shall have provision for two ports/Gateways at Substation Level in Main Plant Control Room (CCR) to interface the SAS with remote Control centre. The



PART-B CHAPTER-E10

PAGE 9 OF 59


CLAUSE NO

actual communication protocol for these ports/Gateway shall be finalized during detailed engineering. 6.08.05

Tender Drg Titled “ Substation Automation System Architecture” may be referred for the above.

6.09.00

DCS Interface Suitable hardware and software, including adequate number of LAN switches / gateways, shall be provided, to interface the switchyard SAS with Employer’s OPCcompliant DCS as shown in the relevant NTPC tender drawing. This is to enable data exchange between switchyard SAS and Employer’s DCS. The exact signals shall be finalized during detailed engineering.

7.00.00

SUBSTATION CONTROLLERS AND OPERATOR WORKSTATIONS a)

Redundant Controllers and Operator Workstations shall be provided and shall be based on the latest state of the art workstations and servers and technology suitable for industrial applications and switchyard environments. The minimum specifications indicated in the Appendix-B to Chapter E-10 shall be provided. Appendix-B is enclosed herewith.

b)

The main memory shall be sized sufficient to meet the functional and parametric requirements as specified. The bulk memory shall be sized at 1.5 times the capacity required sufficient to meet the functional and parametric requirements. However, both the main and the bulk memory shall be subject to minimum hardware specification. The exact system configuration and sizing shall be approved by the Employer during detailed engineering.

c)

Graphic Mimic display for entire switchyard shall be provided in each OWS.

d)

All operator’s functions shall be possible from any of the OWS at any point of time regardless of which controller is active. Each OWS shall be able to access all the substation information related data under all operating conditions.

e)

No single failure in Controller shall lead to non-availability of more than one OWS. In such an event, i.e. single failure leading to non-availability of any OWS, it shall be possible to monitor the entire switchyard from the other available OWS.

f)

The Workstation shall be based on industry standard hardware and software which will ensure easy connectivity and portability of all the software being provided for various IEDs under this contract.

g)

Power Fail Auto Restart (PFAR) facility, with automatic time synchronization to GPS time shall be provided. The only operation required will be the login of operators.

h)

All AC powered Workstations, Communication and/or other SAS devices shall be powered from 2X100% Inverter Supply connected to the station



PART-B CHAPTER-E10

PAGE 10 OF 59


CLAUSE NO

batteries or Un-interruptible Power Source (UPS) providing a standby time equal to the specified station battery standby time.

7.01.00

i)

Employer will provide Two Workstations and One Rear Projection Mimic Display (LVS) loose in the Power Station Control room. Bidder shall configure the OWS & LVS, to enable the operators in the Power station to monitor and control the 400kV substation network and alarms. A fibre-optic extension of the Substation Network LAN is to be provided in the Power Station control rooms for this purpose.

j)

The workstations shall include a color wall mounted rear projection MIMIC display, on which a dynamic substation overview display screen is projected. The MIMIC shall be flat. The rear projection MIMIC display shall be on a single screen LVS having minimum 80 inch diagonal. The MIMIC shall be suitable for continuous operation in a substation control room environment, and shall be clearly visible during all hours from the operator positions at the control desk. The Bidder shall include consumables for 1 year operation of the unit according to specification. Details of the MIMIC offered shall be provided during Biding, with an indication of the maintenance required and typical operating cost of the unit.

Functional Requirements of the HMI Software i)

The HMI shall have an intuitive graphical design to ensure effective use of the SAS with minimal confusion. The amount of keyboard typing needed for using the SAS shall be minimized.

ii)

The HMI shall be strictly divided into various levels depending on the system security levels.

iii)

The complete Single Line Diagram of the 400kV network, including the status of the plant equipment, shall be displayed on one or more graphical displays. A high-level overview display shall be provided, with the ability to zoom to more detailed displays. Different colors shall be used to differentiate voltage levels, earthed network components, selected object on screen, selected object for command, blocked / tagged equipment etc. on the graphical displays. A library of standard symbols shall be used to represent switchyard equipment on the graphical displays. The same symbols and colors used on the 400 kV network SAS shall be used . The graphic displays shall be subject to Employer’s approval.

iv)

The process status of the switchyard in terms of actual values of currents, voltages, frequency, active and reactive powers ,summated MW/MVAR of all GT bays, as well as the positions of the circuit breakers, isolators and earth switches, tap positions, winding temperature, monitoring of GIS etc, shall be displayed on the station single line diagram.

v)

All the Substation Level Functionality described in Clause No. 6.00.00 shall be possible through HMI.



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vi)

Highest degree of security shall be provided to prevent unwanted operation of any equipment through SAS. Simultaneous switching of more than one device from the same or different Control Levels shall not be possible. The security features to achieve these requirements shall be clearly brought out in appropriate project-specific documentation of SAS, which shall be approved by Employer. Once a device is “Selected” for operation, the operator shall be able to recognize the “Selected” device on all the graphical and other displays. All other devices shall be blocked as long as a device is selected for operation. The “execution” of a command shall be possible only if the device is not blocked and no interlocking condition is being violated. The interlocking scheme, implemented at the Bay Level, shall be checked before releasing the “execute” command. The operator shall receive suitable feedback about the successful or unsuccessful execution of the command. In case of unsuccessful execution, the reason for non-execution of command shall be indicated to the operator, which shall include details of the blocking condition in the interlocking logic. In case of successful execution, the operator shall receive confirmation about the new switching position of the equipment depending on the command. The ability to override the interlocking shall also be available, subject to the security access (see section 6.07.00).

vii)

The following functionality shall be available at the Engineer and Fault Recording Workstation.

viii)

-

Formulation and Implementation of interlocking logic for various bay equipment into Bay Control Units

-

Downloading or altering the protection relay settings in the Bay Protection Units.

-

Automatically upload, archive, review and analyze graphically the Digital Fault Data available from the BCU and Bay Protection Units.

-

Ability to export fault records in COMTRADE format.

All workstations shall work on the same Operating system, preferably Windows XP or Windows ( latest version ). The Bidder shall state any other recommendations during Biding. Latest anti-virus software shall be supplied on all workstations.

8.00.00

COMMUNICATION NETWORK BUS

8.01.00

General i)

The technology employed must be applicable to substation environment, incorporating substation noise immunity and isolation.

ii)

The data communication network (substation / interbay bus) shall provide a redundant bus configuration, either ring or dual star topology. The redundant buses shall be physically separate and shall be routed separately. The



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bidder shall submit details regarding the communication system like communication protocol, bus utilization calculations etc.

8.02.00

8.03.00

iii)

Built-in diagnostics shall be provided for easy fault detection and to alarm any single bus failures. The design and installation of the main communication bus shall take care of the environmental conditions and hazardous area classification as applicable to similar services.

iv)

The system architecture shall allow a number of application protocols to coexist on the application layer of the LAN stack.

Substation Network Bus i)

The substation network LAN configuration / protocol shall be as per the tender drawing. The substation network LAN shall be an Ethernet LAN based on IEEE802.3 Ethernet standard using the IP protocol. It shall allow interoperability with LANs from other vendors or with IEDs (Intelligent Electronic Devices) from other vendors in future, supporting IEC 61850.

ii)

CAT 5 shielded UTP cables or fibre optic cables shall be employed for all Ethernet data communication bus. Fibre optic cables shall be used wherever the Ethernet connection is in excess of 50m, or where the connection extends between rooms or buildings. The Bidder shall ensure that structured cabling philosophy and good engineering practices as per internationally accepted standards are followed, for ease of maintenance and traceability, and that fibre-optic cables are adequately protected. Armoured Fibre Optic cables shall be used in all cable routes containing other armoured electrical cables.

iii)

The LAN shall have a data communication speed of minimum 100MBPS. It shall be sufficient to meet the responses of the system in terms of displays, monitoring and control commands according to the design.

iv)

Suitable hardware and software interface shall be provided to link main plant DCS station bus.

400 kV Interbay Network Bus i)

An Interbay Communication bus shall be provided for the 400 kV network , which shall support peer-to-peer communication, and communication to the Substation Controller.

ii)

The communication protocol used for all devices including Bay Control Units and Bay Protection Units shall be the IEC61850 protocol. No hardwiring of alarms shall be permitted between Bay Protection Units and Bay Control Units. As a minimum, all Bay Controller Units and primary relays i.e, Distance, Differential, BUS BAR PROTECTION and multi-functional Over current and Earth fault protection relays offered shall support the IEC61850 protocol. Bidders may use the IEC60870-5-103 protocol only to extract events / alarms and analogues from secondary protection relay that does not support the IEC61850 protocol.



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iii)

Fibre optic cables shall be used for Interbay Communication Bus. Bidder shall ensure that structured cabling philosophy and good engineering practices as per internationally accepted standards are followed, for ease of maintenance and traceability. Electrical data connections may only be used within a cubicle of the same bay.

8.04.00

For the requirements for Generator Circuit LAN, tender drawing “ Substation Automation System Architecture “ may be referred.

9.00.00

BAY LEVEL FUNCTIONALITY i)

All the Bay Level Functionality shall be built into Bay Control Units (BCUs) and Bay Protection Units (BPUs).

ii)

Dedicated Bay Control Units and Bay Protection Units shall be provided for each bay in the Bidder’s scope of work. Controls shall be provided as specified elsewhere in this specification.

iii)

BCUs and Bay Protection Units shall be provided at Control Level 1 i.e. Bay Level of Logical Architecture, to facilitate control, monitoring and protection of switchyard equipment. One Bay Control Unit shall provide complete functionality for one 400kV bay. Each set of BCUs shall have sufficient analog and digital inputs to acquire the status of each and every circuit breaker, isolator, earth switch, GIS gas pressure, temperature monitoring etc. of all the bays in Bidder’s scope. A minimum of 64 Digital Inputs and 32 Digital Outputs per bay shall be provided in associated Bay Control Units. A minimum number of 16 Analogue input channels (for Current, Voltage) and minimum of 4 Analogue input channels (4-20mA) per feeder shall also be provided in the associated BCU.

iv)

All the Bay Control Units and Bay Protection Units shall be installed in the SWYD control room. The protection relays for Generators (GRP) shall be located in respective power station control rooms.

v)

All BCUs and Bay Protection Units shall be provided with self-diagnosis and supervision functions to ensure maximum availability. BCUs shall require no periodic routine maintenance and testing. An alarm contact shall be provided for hardware failures, failures of internal and external auxiliary supplies etc. Special algorithms shall be provided to check the microprocessor’s memories. A watchdog function shall supervise the execution of program by the microprocessor.

9.01.00

Bay Control Units (BCU)

9.01.01

Control and Protection Features of BCUs The Bay Control Units shall have following built-in functions: i)

Mimic control panel to display graphically the bay configuration, status of the plant, analogue measurands, alarms, and offer bay level control.



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ii)

Switching of Switchyard Bay Equipment depending on conditions such as interlocking, synchro-check, control mode, or external status condition. Adequate safety features like prevention of double operation, command supervision, block/deblock, over-riding the interlocking etc. shall be provided. This shall include 2 pole control for closing of circuit breakers, 1 pole control for tripping of circuit breakers, and 1½ pole control for all other devices. All such security features shall be finalized and approved by Employer during detailed engineering.

iii)

Status Supervision of switchyard equipment

iv)

Interlocking Function to prevent unsafe operation of switchyard equipment such as circuit breakers, isolators, earth switches etc. Interlocking shall be implemented on bay level, by user-friendly, menu-driven configuration software within the BCU, Interlocking shall operate independent from the Substation Controller. Signaling of statuses between bays shall be performed by inter-bay communication (peer-to-peer) i.e., Goose messaging. The auxiliary contacts of each of the equipments shall be wired to the BCU for this purpose. However for those equipments, which are required for interlock of other bay equipment, two sets of their contacts shall be wired to BCUs of two different bays. Such interlocks involving more than one bay equipment shall be realized through goose messaging. An over-riding / bypass function for bay-level interlocking shall be provided at appropriate security level for maintenance or during emergency conditions. Failure of any one BCU shall not affect the interlocking at any other bay, only the bay with failed BCU shall not be able to operate. This shall be achieved by providing a backup mechanism in case of failure of one BCU which affects the interlocking in another BCU (e.g. a backup mechanism for monitoring the status of the busbar earths), to allow the remainder BCUs to function with full interlocking. The bidder shall provide details of their design during Biding. The interlocking logic shall be defined during the details engineering phase to prevent illegal operation. The following minimum criteria will be considered: z

Isolators: If the corresponding earth switch is closed, isolator cannot be closed, and vice versa. If the corresponding circuit breaker is closed, the isolator cannot be opened. The isolator can not be closed if any of the earth switches in series till the nearest Isolator is closed. The earth switch can not be closed if the immediate isolator on either side is closed.

z

Busbar isolators: If the earth switch connected to the busbar is closed, none of the busbar isolator cannot be closed, and vice versa.

z

Busbar earths: All busbar isolators connected to the busbar must be open and no voltage present before the earths can be closed.

z

If voltage is present on the feeders, the earthing switches on the feeders cannot be closed.

z

The earthing switches on the transformer can only be closed when no voltage is present.



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v)

Analog Measurements for bay voltage (per phase), current (per phase), frequency, MW and MVAR, tap position and winding temperature of ICT, shunt reactor. These measurements shall not require the use of any intermediate transducers. The accuracy of measurement shall be 0.5% for voltage, current and frequency, and 1.0% for MW and MVAR. The measured and computed values shall be displayed locally on BCU and on operator’s workstation located in central control room.

vi)

Event and Alarm Handling: BCUs shall acquire all the bay level alarms and events from field inputs with a resolution and time tagging of 1 ms and shall transfer these to operator’s workstation over substation LAN.

vii)

Synchronization Check Feature: Synchronization Check feature shall determine the difference between the amplitudes, phase angles and frequencies of two voltage vectors. Checks shall be provided to detect a dead line or bus bar. The voltage difference and phase angle difference settings shall be adjustable. A common hand held synchroscope with a compatible synchronizing socket in each BCU shall also be provided.

9.02.00

Bay Protection Units

9.02.01

General

9.02.02

i)

Each Bay Protection Unit shall comprise two or more numerical relays to meet the protection requirements specified for each type of feeder.

ii)

Bay Protection Units for all Switchyard Bays shall interact with BCUs over switchyard Interbay Network Bus to share information related to Bay Level Interlocking, fault data, alarms / events etc. However, the trip commands from Bay Protection Units shall be hard-wired directly to appropriate switchyard equipment. Also, critical interlocking data between Bay Protection Units and Bay Control Units, including the substation level interlocks such as bus earth switch, busbar protection trip etc., shall also be hard-wired to ensure complete bay level functionality even in case of failure of substation LAN. The interlocking information to be hard-wired between Bay Protection Units and Bay Control Units shall be decided by Employer during detailed engineering stage.

iii)

Bay Protection Units for Main Generator Circuits shall be wired as described in clause 9.02.03.

iv)

The interface of Bay Protection Unit for 400kV lines with PLCC panels shall be in bidder’s scope.

General Requirements of Numerical Relays and Auxiliary Relays i)

All numerical relays, auxiliary relays and devices comprising the Bay Protection Units shall be of types, proven for the application, satisfying the requirements specified elsewhere and shall be subject to the Employer’s approval. Numerical Relays shall have appropriate setting ranges, accuracy,



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resetting ratio, transient overreach and other characteristics to provide the required sensitivity to the satisfaction of the Employer. ii)

Equipment shall be designed for a working life of at least fifteen years in the specified environment and application. Components, component ratings and all other factors determining equipment life shall take this into account. Normal routine and breakdown maintenance shall be assumed and it is accepted that certain consumable components and modules may need periodic replacement or adjustment. However, the Bidder shall state in his bid, the expected frequency of such replacement or adjustment and life expectancy.

iii)

Numerical relays shall be suitable for efficient and reliable operation of the protection scheme. The necessary auxiliary relays, trip relays, etc. required for complete scheme, interlocking, alarm, logging, etc. shall be provided. No control relay, which shall trip the circuit breaker when the relay is deenergized, shall be employed in the circuits.

iv)

Relays shall be provided with self-reset contacts except for the trip lockout, which shall have contacts with a manual reset feature. Manual resetting shall be possible from Control Level 2 as well as Control Level 1 with suitable authorization.

v)

Suitable measures shall be provided to ensure that transients present in CT & VT connections due to extraneous sources in the EHV system do not cause damage to the numerical and other relays. CT saturation shall not cause mal-operation of numerical relays.

vi)

Only DC/DC converters shall be provided in the solid state devices / numerical relays wherever necessary to provide a stable auxiliary supply for relay operation.

vii)

DC batteries in protective relays necessary for relay operation shall not be acceptable. Equipment shall be protected against voltage spikes in the auxiliary DC supply.

viii)

The numerical relays shall have continuous self-monitoring & cyclical test facilities. The internal clock of the system shall be synchronized through the GPS Time Synchronizing System to be supplied under this contract.

ix)

Each numerical relay shall have a serial interface on the front for local communication to a Personal Computer and Printer. Facilities shall be provided to access each discrete protection function including modification in relay settings and monitoring of the relay from a HMI or a separate Protection / Disturbance Recorder Station provided at the Substation Level and permanently wired to all the numerical relays comprising various Bay Protection Units, as shown in NTPC tender drawing . A print out of all settings, scheme logic, event records etc. shall be accessible through the HMI. The display of various measured parameters during normal as well as fault conditions on a segregated phase basis shall be provided. LEDs and a backlit LCD screen shall be provided for visual indication and display of



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messages related to major trips / alarms. Necessary multilevel password protection shall be provided.

9.02.03

x)

The sampling rate of analog inputs, the processing speed and processing cycle of digital values shall be selected so as to achieve the operating times of various protection functions specified. In case the Bidder does not have all the protection functions specified as a part of the standard numerical relay, separate discrete numerical relays can be provided for such protection. The reasons for providing such discrete relays shall be clearly outlined in the bid.

xi)

The Bay Protection Units shall be arranged to provide two independent, high performance and reliable systems with separate DC supplies, separate CT/VT cores, separate cables and trip relays to obtain 100% redundancy. Associated trip relays of the two systems shall be separate, having a sufficient number of contacts for all the functions.

xii)

The numerical relays shall be provided with built-in disturbance recording functionality. The data from DR function shall be available in IEEE/COMTRADE format and shall be compatible with the dynamic relay test system being supplied under this contract.

xiii)

The manufacturer of the numerical protection system offered shall carry out the complete engineering, testing and commissioning on site of the offered protection equipment including the associated relays and protection panels. The testing and commissioning protocols for the numerical protection systems offered shall be approved by the Employer before commissioning on site.

xiv)

The numerical relays offered shall have self-diagnostic features to reduce the down time of the relay and to provide useful diagnostic information upon detection of an internal fault so as to speed up the maintenance. The necessary support documentation explaining in detail the self-diagnostic features of the numerical relays shall be furnished for the Employer’s use.

xv)

Pick up range of the Binary inputs shall be minimum 70 V DC / AC.

Protection for Main Generator Circuit a)

For protection purpose, each Main Generator Circuit comprises the Generator, associated Generator Transformer and the Unit Transformer. Dedicated Bay Protection Units (BPUs), comprising numerical relays for various protection functions listed in following clauses, shall be provided for each Main Generator Circuit to achieve comprehensive protection for all types of faults and abnormal operating conditions. Numerical relays constituting the BPUs shall meet the requirements of clause 9.02.02 above.

b)

The BPU for each Generator Circuit shall be mounted in Generator Relay Panels (GRP) to be located in Central Control Room for respective Generator Circuit. The numerical relays constituting the BPU for all the Generator Circuits of 4x150MW plant., shall be wired to form a Generator



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Circuit LAN and connected to Main Plant Engineering and Fault Recording Stations, as shown in NTPC drawing. The Main Plant Engineering and Fault Recording Station shall be located in Central Control Room . The Main Plant Engineering and Fault Recording Stations shall be connected to the Substation Level LAN operating on IEC 61850. The preferred configuration for Generator Circuit LAN is shown in drawing “ Substation Automation System Architecture “. c)

9.02.03.01

The Main Plant Engineering Stations shall allow following functionality related to Numerical Relays for all the Generator Circuits: -

Extract all the alarms, events and fault data captured by numerical relays.

-

Change / upload Relay Settings for various numerical relays.

-

Share the data as above with switchyard SAS through Substation Level LAN.

d)

The communication protocol for Generator Circuit LAN shall preferably be IEC61850.

e)

The numerical relays constituting the BPU for each Main Generator Circuit, shall be configured into two independent Numerical Protection Systems, each fed from a separate DC supply, such that one numerical protection system shall be always available to detect and operate for any type of fault in the Generator Circuit, under condition of failure of the other numerical protection system AND/OR on failure of the associated DC supply systems of other numerical protection system. The individual protection systems shall be connected to independent set of hand re-set trip relays. Trip circuit supervision shall be provided for continuous monitoring of trip relays, trip circuit and associated trip coils and the discontinuity shall be annunciated in Unit / Switchyard Control Room as applicable. Further the system shall have facilities to accept digital input signals of various alarms and trip conditions of the Generator transformer and unit transformer with complete galvanic separation. All interface and coordination requirements with the control, interlock and protection schemes provided for the switchyard shall be achieved.

f)

The alarm/status of each individual protection function and trip operation shall be communicated to SCADA. The numerical system shall have built-in features/hardware interface to provide such inputs to SCADA for analog/digital values.

Following protection functions shall be provided for each Generator Circuit: a.

Duplicated Generator differential protection, 3 pole (87 G1 & 87G2) having operating time of 25 millisec. or lower at five times the current rating. (Preferably, One of high impedance type and other bias differential type) 87G2 is applicable only for schemes with GCB.



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b.

Stator Earth Fault Protection covering 100% of winding (64G1), operating on low frequency signal injection principle suitable for continuous monitoring of stator insulation even during machine shut down.

c.

Stator Standby Earth Fault Protection covering 95% of winding (trip) (64 G2) with adjustable time delay

d.

Inter-turn Fault Protection through comparison of zero sequence voltage on generator phase and neutral side or through current differential in case Generator parallel windings are taken out separately for each phase.

e.

Duplicated loss of field protection (40G1 & 40G2).

f.

Back up Impedance Protection, 3 pole (21G) along with suitable timer for co ordination with line protections.

g.

Negative Sequence Current Protection, alarm and I22t element for trip (46G) matching with the machine characteristics.

h.

Duplicated Low-Forward Power and duplicated reverse power Interlock for turbine generator (37 G1 & 37G2), each having two stages, short time delayed interlocked with turbine trip and long time delayed independent of turbine trip. Suitable interlocks shall be provided for operation during synchronous condenser mode.

i.

Two Stage Rotor Earth Fault Protection (alarm & trip) operating on principle of continuously monitoring rotor insulation value even during machine shut down period (64F). Setting range of rotor earth fault protection (Alarm / trip ) shall be 1 kohm to 20 kohm.

j.

Generator circuit breaker failure protection (50ZG), if applicable.

k.

Definite Time Delayed Over-Voltage Protection (59G) for alarm and trip.

l.

Over fluxing protection (99G & 99T) for generator and generator transformer having inverse time characteristics suitable for generator / generator transformer over fluxing capability. Separate relays on either side of generator circuit breaker to be provided for units having generator circuit breakers..

m.

Overall Differential Protection (87GT).

n.

Overhead Line Connection Differential Protection (87HV), including generator transformer HV winding.

o.

Backup Earth Fault Protection on Generator Transformer HV neutral (51NGT).

p.

Generator Under Frequency Protection with alarm and stage trippings (81G) and with df/dt elements.



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q.

Generator Pole Slipping Protection (98G).

r.

Accidental Back Energisation closure/flashover of

protection

(50GDM)

for

accidental

GCB/EHV breaker or EHV disconnecting switch. 50 GDM protection based on the following two separate principles shall be provided: 1.

checking of under voltage and over current at generator terminal

2.

Checking of over current and open position of generator breakers.

s.

Duplicated Excitation transformer instantaneous and time delayed over current protection on HV side of excitation transformer, if applicable.

t.

Generator Transformer Differential Protection (87T) for individual / three phase(as applicable) bias type having instantaneous high set over current elements.

u.

Aux. bus bar Over-current protection(50B): For protection of bus bar between GT, SAT & UAT when GCB is open

v.

Earth fault protection for GT LV winding/UT HV winding and connections (64GT1 & 64GT2) for units having GCB.

w.

Individual alarm and trip inputs given by the Generator Transformer , SAT and UAT for all operating conditions including the following: i)

Winding temperature protection

ii)

Oil temperature protection

iii)

Buchholtz protection

iv)

OLTC Buchholtz protection

v)

OLTC oil surge protection

vi)

PRV protection

vii)

Power supply fail

viii)

Cooler fail

ix)

Tap changer trouble

x.

VT fuse failure protection having alarms and for blocking the VT fed protection

y.

Trip Circuit, trip relay and DC supply supervision relays for each EHV breaker and generator protection circuits.



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CLAUSE NO

9.02.03.02

z.

Relays with flags/LED’s for EHV breakers for indication and logging.

aa.

Duplicated hand reset Trip Relays.

bb.

Station Aux Transformer (SAT) Differential Protection, 3 pole (87SAT)

cc.

SAT HV back-up Overcurrent protection (50SAT, 51SAT), wherever applicable

dd.

SAT LV REF protection(64RSAT), wherever applicable

ee.

SAT back-up earth fault protection (51NSAT), wherever applicable

ff.

Unit Aux Transformer (UAT) Differential Protection, 3 pole (87UAT)

gg.

UAT HV back-up Overcurrent protection (50UAT, 51UAT)

hh.

UAT LV REF protection(64RUAT)

ii.

UAT back-up earth fault protection (51NUAT)

jj.

Any other protection proposed by the bidder.

Generator Disturbance Recorder a.

One Disturbance / Fault Recorder generator.

(DFR) shall be provided for each

b.

Offered DFR shall be Microprocessor based used to record the graphic form of instantaneous values of voltage and current in all three phases and neutral, open and closed positions of relay contacts and breaker during disturbances.

c.

It shall have the facility of fast scan as well as slow scan to record transient as well as dynamic performance of the system.

d.

The DFR for each generator circuit shall have 8 analog/16 digital inputs in both slow scan and fast scan.

e.

Slow Scan Feature -

The input for slow scan rate shall at least be MW, MVAR, field voltage, frequency and generator terminal voltage. Any transducers, if required, shall be supplied.

-

Shall be suitable to record the frequency excursions and response of generator field and governor control on system fluctuations.

-

Shall have the scan rate in the range of 2.0 to 50.0 Hz.

-

The Non-volatile memory in the DR shall be suitable for recording for a minimum of 15 minute at scan rate corresponding to 2.0 Hz with



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possibility to dedicate 10% of the memory space in pre-fault zone of recording. f.

The frequency response of analog signals shall be 25 Hz or better.

Fast Scan Feature The fast scan feature of generator DFR shall meet the requirements specified elsewhere for the Digital Fault Recording for EHV Lines in clause 9.02.07.

g.

9.02.03.03

All the DFRs provided for various generator circuits of 4X150MW shall be wired together to a Engineering and Fault Recording Station to be located in Central Control Room as shown in the relevant NTPC drawing . It shall be possible to extract the DFR records from any of the DFRs from this Engineering and Fault Recording Station for review and analysis. In addition, a laptop shall also be supplied to facilitate downloading of DFR records locally. Suitable communication port shall be provided for this in each of the DFRs. The configuration of the laptop shall be finalized during detailed engineering.

Relays / transducers for Employer’s use a.

Seven (7) interposing relays shall be provided for each generator circuit in respective Generator relay panels for Employer’s use (closing and tripping of the 400 kV generator breakers and GCB from Unit Control Room).

b.

Following transducers ( with Dual output) shall be provided in each of the generator relay panel for Employer’s use: (i)

400 kV Bus 1 voltage

4-20mA

0-500kV

(ii)

400 kV Bus 2 voltage

4-20mA

0-500kV

(iii)

400kV Bus 1 frequency

4-20 mA

45-55Hz

(iv)

400kV Bus2 frequency

4-20 mA

45-55Hz

(v)

Generator Current

R phase

4-20 mA

0-10kA

(vi)

Generator Current

Y phase

4-20 mA

0-10kA

(vii)

Generator Current

B phase

4-20 mA

0-10kA

(viii)

Generator voltage (R-Y)

4-20mA

0-20kV

(ix)

Generator voltage (Y-B)

4-20mA

0-20kV

(x)

Generator voltage (B-R)

4-20mA

0-20Kv

(xi)

Generator frequency



4-20 mA

PART-B CHAPTER-E10

45-55Hz

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CLAUSE NO

9.02.03.04

(xii)

Generator power factor

4-20 mA

0.5 lead –0.5 lag

(xiii)

Generator Active Power

4-20 mA

0-200 MW

(xiv)

Generator Reactive Power

4-20 mA

100 lead-200 lag

METERING for Generator circuit. The following integrating meters shall be provided in the generator circuit.:

9.02.04

9.02.05

a)

Generator Main and Check MWh meter.

b)

Generator Main MVARh meter.

c)

MWH meter for each Unit Auxiliary transformer(UAT) and Station Auxiliary Transformer(SAT)

d)

Meters shall be static type. MWH meters shall be of accuracy class of 0.2 or better. MVARH meters shall have accuracy class of 0.5 or better. These meters shall have provision for downloading of data through an optical port and /or through RS 232 / 485 port. These meters will be located in Generator Relay Panel.

Protection for EHV System (400 kV) i)

The general protection requirements for the 400 kV system are indicated in the tender drawing for switchyard protection SLD.

ii)

The total critical fault clearing time, including the circuit breaker operating time, from fault initiation in any part of the system under all conditions shall not be more than 80 ms for faults within zone-I reach (i.e. up to 80% of line length) and 100 ms for end zone faults including carrier transmission time of 20ms.

iii)

The SIR values to be considered for the operating time of relays for the swyd feeders shall be between 4 and 15. The rated break time for the EHV circuitbreaker, as offered, shall be considered for the purpose of circuit-breaker operating time. The Bidder shall furnish the operating time curves at various SIR values for all types of faults.

EHV Line Protection Each 400 kV line shall be provided with the following protection: i)

Main-I : Numerical Distance protection scheme suitable for carrier aided protection.

ii)

Main-II : Numerical Distance protection scheme suitable for carrier aided protection and with a hardware platform different from that of the Main-I Protection.



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The Main-I and Main-II distance protection shall be of equal performance capability. The Main-I and Main–II distance protection relays shall be connected to two different protection groups to meet the requirements of clause 9.02.02 (xi) above.

9.02.06

iii)

Local Overvoltage Function: The overvoltage function shall have adjustable voltage and time settings. It shall monitor all phases and be tuned to power system frequency. The overvoltage function shall have two independent voltage and time stages. It is also acceptable for the local overvoltage function to be a built-in feature of the Main-I and Main-II Distance Protection relays.

iv)

Back-up IDMT Earthfault Function: A back-up IDMT earthfault protection function shall be provided in each Main protection system. The function shall measure zero sequence current and have a current setting range of 0,2 In to 0,8 In with a time multiplier range of 0,1 to 1.

v)

Open Jumper Protection: The open jumper protection function shall operate upon detecting negative sequence current and shall provide an alarm. The open jumper protection function, as a built-in feature of the MainI and Main-II protection is also acceptable.

vi)

The protective relays shall be suitable for use with capacitor voltage transformers (CVTs) having non-electronic damping and transient response as per IEC.

Numerical Distance Protection Scheme i)

The numerical distance relays shall be the latest version meeting the inservice criteria specified elsewhere.

ii)

The distance protection schemes shall be such as to facilitate compatibility with the protection at the remote ends of the 400 kV transmission lines.

iii)

The reaches of relay for zones 1, 2 & 3 should be able to cover line lengths associated with this contract.

iv)

The distance protection shall be of the non-switched type with separate measurements for all phase-to-phase and phase-to-ground fault types.

v)

The protection shall have two, independent, continuously variable, time settings each with a range of 0 to 5 s for zone-2 and zone-3.

vi)

The characteristics shall have adjustable characteristic angle setting ranges of 45° to 85°.

vii)

Tripping characteristics shall be polygonal and / or mho circle with adjustable offset and with independently adjustable reactive and resistive reaches (for polygonal characteristics) separately settable for each zone. The type of tripping characteristics shall be user selectable.



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viii)

The protection shall operate correctly for close-up three-phase faults and other adverse conditions. It shall operate instantaneously when the circuitbreaker is closed onto a zero-volt 3-phase fault.

ix)

The protection shall provide Phase segregated tripping i.e. single phase as well as three-phase tripping.

x)

The protection shall have a maximum resetting time of 60 milliseconds.

xi)

Zone 3 shall have a reverse offset capability adjustable to 10 to 20% of zone3 setting, or alternatively, an independent reverse zone 4 shall be provided..

xii)

The earth fault measurements shall have zero sequence compensation variable from 0,5 to 5 (scalar Z0/Z1).

xiii)

The setting / reach should not be affected by mutual coupling effects

xiv)

It shall have a continuous current rating of 2 times rated current. The relay shall also be capable of carrying a high short time current of 100 times the rated current without damage for a period of 1.0 s. The voltage circuit shall be capable of continuously withstanding 1.2 times the rated voltage and 1.7 times for 3 s.

xv)

The protection shall include Power Swing Blocking protection. The power swing blocking feature shall:

xvi)

xvii)

-

be of three pole type

-

block/unblock tripping during power swing conditions, separately for each zone.

-

have a continuously adjustable time delay on pick up of 0 to 5s.

-

be in service during the dead time of a single pole reclosing cycle.

-

have user configurable unblocking criteria in the case of fault detection during a power swing.

Shall include Fuse Failure Protection, which shall a)

Monitor all the three fuses of the CVT and associated cabling against open circuit

b)

Inhibit trip circuits on operation and initiate annunciation

c)

Have an operating time of less than 7.0 ms

d)

Remain inoperative for system earth faults

It shall have user configurable scheme logic such as permissive under-reach (PUTT), Permissive over-reach (POTT), Direct Transfer Trip, Blocking scheme etc. using communication channels. The scheme shall be complete so that the user can select any option on site without any modification. Non-



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carrier aided schemes such as Zone-1 extension, Loss of Load etc. shall be provided to ensure high-speed clearance during channel failure.

9.02.07

xviii)

The protection shall be able to distinguish between short circuit and heavy load conditions.

xix)

It shall have supplementary over current and earth fault protection functions.

xx)

The dead line charging feature shall have adjustable minimum and maximum voltages.

xxi)

The protection shall have a multiple settings group feature. It shall be possible to switch between the various available setting groups when the relay is in service without compromising the protection during the switchover.

xxii)

The protection shall include the following additional functions: -

Weak-infeed tripping

-

Echo function

-

Current reversal guard

-

Switch onto fault logic

-

It shall be suitable for series compensated lines.

Digital Fault Recording A Digital Fault Recorder shall be provided for each 400kV line. The Digital Fault Recorder shall meet the following requirements: a)

Shall be used to record the graphic form of the instantaneous values of analog inputs such as voltages and currents in all the three phases, open delta voltage and neutral current in the primary circuits in the case of a short circuit (fault) and a disturbance in the Power System, as per the required technical parameters.

b)

Shall be provided with a self-monitoring facility.

c)

Fault / disturbance logs shall be clearly identified by Fault ID, Fault date and time (hour, minutes, seconds and ms). Time stampings on fault records shall be synchronized with a GPS clock.

d)

The disturbance recorder shall comprise distributed individual acquisition units, one for each feeder and an evaluation unit which is common for the entire substation. The acquisition units shall acquire the disturbance data for the pre-fault, fault and post-fault periods and transfer them to the evaluation unit automatically for storage on a mass storage device. The acquisition unit shall be suitable for inputs from current transformers with 1 A rated



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secondaries and capacitive voltage transformers with 63.5 V (phase-toneutral voltage) rated secondaries. e)

Shall have Scan rate of 1000 Hz or better for sampling each of the analog channels having a fundamental frequency of 50 HZ. The frequency response for these channels shall be DC on the lower side to 500 HZ or better on the upper side. Any interposing devices provided with the DFR system shall not compromise this frequency response.

f)

Shall be provided with sensors based on threshold values of voltage, current and frequency and rate of change of system frequency. External signals if required can also be used for triggering the DR. The starting sensors of the DFR, and pick-up, shall preserve the disturbance/fault data on the nonvolatile solid state memory of the acquisition unit. The setting of the starting sensors shall be flexible, and shall have reasonable range/steps. The settings of the starting sensors shall be field programmable.

g)

The fault data from the Digital Fault Recording feature shall be available in IEEE / COMTRADE format. The data format shall be compatible for dynamic protection relay testing with the relay test kit to be supplied by the Bidder. The necessary equipment for interfacing and transfer of data shall also be supplied by the Bidder.

h)

All the fault records shall be transferred to the Protection / DR Station at the Substation Level automatically or on request for further detailed analysis. The software for analyzing the fault data shall be available at the Substation Level. The software shall be capable of the complete analysis of fault data, including the display of RMS/Peak envelop of any voltage / current, fundamental power frequency deviation, display of instantaneous values of Real Power (computed value), Reactive Power (computed value), power factor angle etc. A facility to edit the fault data shall also be provided.

i)

Following analog values shall be recorded – Currents (R-phase, Y-phase, B-phase and Neutral), Voltages (VRY, VYB, VRB, Open Delta). The pre-fault recording time shall be at least 200 ms and the post-fault recording time shall be at least 5.0secs. 8 Analogue channels (IR,IY,IB,IN,VRY,VYB,VBR AND OPEN DELTA) 16 Nos Digital Channels Amplitude Resolution of Analogue channels(minimum) : 16 bit Event Resolution of Digital Channel (minimum) : 1 ms Aux.voltage : 220VDC (+10%,-20%)



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DFR system offered shall also have a built-in Distance-to-Fault Locator Function. This function shall be an on-line function and shall be suitable for circuit-breaker operating times of 2 cycles. The computed distance-to-fault shall be available as a percentage of line length or kilometers without requiring any further calculations. It shall have a provision for mutual zero sequence compensation. It shall have an accuracy of 3% or better for all types of faults and fault levels. This accuracy shall not be impaired under following conditions: -

Presence of remote end in-feed

-

Predominant DC component in fault current

-

High fault arc resistance

-

Severe CVT transients

-

Mutual zero sequence coupling between adjacent lines

The Digital Fault recorder can be provided as a standalone device or as a built in feature of numerical relays if it meets all the above requirements 9.02.08

Sequence-of-Event Recording Sequence of event functionality pertaining to the main protection applications shall be provided as a part of the individual protection devices. Sequence of event recording pertaining to the monitoring of non-protection device status information, such as switchyard open and close states which are not catered for by the main protection relays, shall be recorded by the bay controller. The sequence of event recording shall: (a)

have a time resolution of 1 millisecond or better.

(b)

be able to cope with up to 40 changes in any one 10 millisecond interval.

(c)

the date and time should be printed to the nearest 1 millisecond followed by a tag describing the point which has operated.

(d)

events that occur while another event is in the process of being printed are to be stored for subsequent printing. Over 100 such events must be stored.

The event printouts shall contain at least the station identification, date and time (in hour, minutes, seconds and milliseconds), event number and event description (at least 40 characters).



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9.02.09

Auto-Reclose and Synchronizing Check Auto-reclose (AR) and Synchronizing Check (SC) functionality shall be provided in a separate device. The interfacing between BCUs and Bay Protection Units for achieving the AR function logic shall be achieved at Bay Level using communication LAN as well as standby hard-wired logic between BCU and Bay Protection Units. The intent of providing the hard-wired logic as a back-up to the software logic is to ensure that in the event of failure of Substation LAN, the bay level functionality is not hampered. The AR function shall meet the following criteria: -

Be of single shot type

-

Have single-phase and/or three phase reclosing facilities. It shall have a user-selectable option of single phase, three phase, single & three phase reclosing or non-auto reclosure mode.

-

Incorporate a normal/delayed auto reclosure option with a time range of 1 to 60 s.

-

Have a continuously variable three-phase and single-phase dead time of 0,1 to 5 s.

-

Have a continuously variable reclaim time of 5 to 300 s.

-

Be properly configured for the breaker-and-a-half arrangement, permitting sequential closing of breakers.

-

Incorporate the necessary auxiliary relays and timers to provide a comprehensive reclosing and synchronizing scheme.

-

Have facilities for selecting check synchronizing or dead line charging features. The user shall have an option to change the required feature.

The built-in Synchronization Check feature shall determine the difference between the amplitudes, phase angles and frequencies of two voltage vectors. Checks shall be provided to detect a dead line or bus bar. The voltage difference, phase angle difference and slip frequency settings shall be adjustable. 9.02.10

Transformer Protection i)

The following protections shall be provided for each SAT/UAT -

Differential Protection (87T)

-

Restricted E/F Protection for HV ( if applicable) and LV windings (64RHV,64RLV)

-

Back up over current protection on HV (50/51)

-

LV Back-up neutral E/F protection (51N)



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ii) 9.02.10.01

Buchholtz/WTI/OTI/Pressure Relief Device / Sudden Pressure Relay Alarm / Trip

Differential and REF protection shall be configured in separate relays.

Transformer differential protection shall: (a)

be of numerical type and shall have continuous self-monitoring and diagnostic features;

(b)

be three-pole type, with faulty phase identification/indication. The operating time of the relay shall not be greater than 30ms at 5 times the setting.

(c)

be stable for magnetizing inrush currents and shall be stable under normal over-fluxing conditions. Magnetising inrush stability shall not be achieved through the use of an intentional time delay;

(d)

have an internal feature in the relay to take care of the angle and ratio correction;

(e)

have a disturbance recording feature to record the analogue form of instantaneous values of the current in all three windings (i.e. nine analog channels) during faults and disturbances for the pre-fault and post-fault periods. The disturbance recorder shall have the facility to record the following external digital channel signals in addition to the digital signals pertaining to the differential relay itself: .

HV breaker (main and tie) status

.

LV breaker status

.

Buchholtz/On-load tap-changer Buchholtz alarm/trip

.

Winding temperature/Oil temperature/Pressure relief alarm/trip of transformer

The necessary hardware and software for downloading the data captured by the disturbance recording function to a personal computer available in the substation shall be included in the scope. (f)

9.02.10.02

be acceptable with built-in features of definite time overload protection (alarm) relay provided the technical requirements of these relays specified under the relevant clauses are met.

Restricted Earth Fault Protection shall: (a)

be single-pole type;

(b)

be of current/voltage operated high impedance type;

(c)

have a suitable non-linear resistor to limit the peak voltage



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9.02.10.03

Back-up Directional Over current and Earth Fault Protection with High-set Function, if applicable (a)

Shall have three over current and one earth fault element(s) which shall be either independent or composite unit(s) and shall have built-in timer with suitable range;

(b)

shall be of numerical type;

(c)

the scheme shall include the necessary VT fuse failure relays for alarm purposes;

(d)

the over current function shall:

(e)

9.02.10.04

have a low transient, overreach high-set instantaneous unit;

-

include hand-reset indication.

the earth fault function shall: -

have a low transient, over-reach high set instantaneous unit;

-

include hand reset indication;

-

include the necessary separate interposing voltage transformers or have an internal feature in the relay for open delta voltage to the relay.

Transformer Over fluxing Protection(99T) shall a)

Operate on the principle of voltage to frequency ratio

b)

Have inverse time characteristics compatible to transformer over fluxing withstand capability and also a separate high set feature.

c)

Provide an independent alarm with continuously adjustable time delay.

d)

Tripping time shall be governed by V/ F vs time characteristic of the relay

e)

Have a set of characteristics for various multiplier settings.

f) 9.02.10.05

-

Have a resetting ratio of 98% or better.

Transformer Backup Over current Protection (50/51) shall 1)

Be triple pole type

2)

Be of definite time over current type

3)

Have an adjustable setting range of 20-80%, or 150-600% of rated current (as applicable) and 0.3 to 3.0 sec time delay



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4) 9.02.10.06

Be provided with operation indicator

Transformer Backup Earth Fault Protection (51N) shall 1)

Be single pole type

2)

Be of definite time over current type

3)

Have an adjustable setting range of 20-80% of rated current as applicable and 0.3 to 3.0 sec. Time delay

4) 9.02.11

Be provided with operation indicator

400KV Cable Protection Duplicated differential Protection shall be provided

9.02.11.01

9.02.12

Differential Protection shall: (a)

be of numerical type and shall have continuous self-monitoring and diagnostic features;

(b)

be three-pole type, with faulty phase identification/indication. The operating time of differential function shall not be greater than 30ms at 5 times the setting;

EHV Circuit-breaker Protection Each circuit breaker in the 400 kV switchyard shall be provided with following protection functions: i)

Local Breaker Back up Protection Function: Duplicated LBB protection function shall be provided for each circuit breaker in the 400 switchyard. The LBB protection function for each circuit-breaker shall be interfaced with the Bus bar protection at the Bay Level over the communication LAN as well as by hard-wired signals between the Bay Protection Unit and the Busbar protection panels. The intent of providing the hard-wired logic as a back up to the software logic is to ensure that in the event of failure of Substation LAN, the bay level functionality is not hampered. The LBB function as a built-in function of BCUs or Bay Protection Unit is acceptable provided it meets all the requirements specified for the LBB function. In addition, the LBB protection function shall meet following criteria: -

Be three pole type having three single phase units

-

Shall operate for stuck breaker conditions

-

Have an operating/resetting time each of less than 15 ms.

-

The LBB function shall be initiated by external trip contacts from the Bay Protection Units and after a set time delay shall energize the trip bus in the busbar protection scheme on which the stuck breaker is



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connected for tripping of all breakers connected to the particular bus. In addition, for all 400 kV breakers (except Lines), an instantaneous repeat trip command from LBB shall be given to the primary breaker through a separate trip relay. The interlocking between the BCU and Bay Protection Units to achieve the LBB functionality shall be achieved at the Bay Level using the communication LAN as well as standby hard-wired logic between the BCU and Bay Protection Units.

ii)

-

Have a setting range of 5 to 80% of rated current

-

Have a continuous thermal withstand of 2 times rated current irrespective of the setting.

-

Have time delay feature with a continuously adjustable setting range of 0,1 to 1 s.

-

Shall be an individual phase comprehensive scheme.

-

Shall not operate during the single-phase auto-reclosing period.

-

Shall provide end-fault protection that initiates a direct transfer trip to the remote end upon the detection of a loss of SF6

Trip Coil Supervision: A Trip Coil supervision function shall be provided for each lockout trip relay and each of the circuit-breaker trip coils. It shall incorporate both the pre-close and post-close supervision of trip coils and associated trip circuits. An audible alarm shall be given in the event of operation of trip coil supervision function. It shall have a time delay on dropoff of not less than 200ms. Trip coil supervision function as a built-in feature of the BCUs / Bay Protection Units is also acceptable, provided it meets all other requirements specified here, including loss of DC supply.

9.02.13

Bus bar Protection

9.02.13. 01

Each 400 kV bus bar shall be covered with a duplicated high-speed bus bar protection scheme connected to two different CT cores. Bus bar protection of each 400 kV bus shall operate in a two-out-of-two mode so as to achieve better security.

9.02.13.02

Each bus bar protection scheme shall: -

Be numerical having modular construction and three pole type.

-

Have a maximum operating time for all types of faults of 20ms at five times the setting value.

-

Operate selectively for each busbar.

-

Give 100% security up to a 40kA fault level.

-

Incorporate continuous supervision for the CT secondary against any possible open circuit and if it occurs, shall render the relevant zone of protection in-operative. The zone protection contact shall be bypassed



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automatically and the affected zone shall be protected by the appropriate healthy zone only. -

Not give any false operation during normal load flow in busbars.

-

Shall not mal-operate for an out-of-zone fault, particularly with current transformer saturation under maximum through fault current with maximum DC offset

-

Shall provide independent zones of protection and incorporate clear zone indication.

-

Include individual high speed tripping relays for each feeder, including future ones, as identified in single line diagram.

-

Be transient free in operation.

-

Incorporate protection „In-Out“ switches for each zone.

-

Be a biased differential type, have operate and restraint characteristics and self monitoring facilities.

-

Shall be of phase segregated type with three-pole tripping

-

Shall include individual high speed hand reset tripping relays for each bay

-

Shall include continuous DC supply supervision

9.02.13.03

The Bus bar protection relay shall be connected to the Interbay communication bus. Use of external CT-switching relays and CT ratio correction relays is not acceptable. The busbar relay settings and analysis of busbar fault data shall be possible from the Substation Level.

9.03.00

Islanding Scheme

9.03.01

Islanding scheme shall be provided for the entire 400kV switchyard (BUSES I&II) as below

9.03.02

An under frequency with df/dt based islanding scheme for the whole generating station shall be provided and shall be located in the switchyard.

9.03.03

Shall employ two out of three channels of U/F and df / dt for high reliability for each side of the bus section.

9.03.04

Each of the three channels of under frequency islanding scheme shall be independent from each other, starting from the VT measuring core, control cables, dc supplies, under frequency or df / dt measuring relay, etc. till the islanding trip relay of the breaker.

9.03.05

Shall be a multi-step scheme and each step shall have setting range of + 5% to - 8% with timers of required setting.



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9.03.06

Shall have a separate dedicated islanding trip relay for each of the EHV breaker including all 400kV bays and future bays as per switchyard SLD

9.03.07

Separately fused 220V DC supplies shall be employed.

10.00.00

ENERGY METERS

10.01.00

The following energy meters shall be for the 400 kV bays specified below: A single class 0.2 accuracy energy meter suitable for ABT requirement as specified below in clause 10.02.00, on each 400 kV Line feeder and on each generator transformer bay on the positions as indicated on the Protection Single Line Diagrams.

10.02.00

Technical Requirements of Energy Meters for ABT Requirement Bidder shall supply energy meters along with metering station , MRI( Meter Reading Instrument) or lap top (as applicable) as per the technical specification given below: a)

Shall be microprocessor-based conforming to IEC 60687 /IEC 62052-11/IEC 62053-22 / IS 14697

b)

Shall carry out measurement of active energy (both import and export ) and reactive energy (both import and export ) by 3 phase, 4 wire principle suitable for balanced/ unbalanced 3 phase load.

c)

Shall have an accuracy of energy measurement of at least Class 0.2 for active energy and at least Class 0.5 for reactive energy according to IEC 60687, and shall be connected to Class 0.2 CT cores and Class 0.2 VT windings.

d)

The active and reactive energy shall be directly computed in CT & VT primary ratings.

e)

The reactive energy shall be recorded for each metering interval in four different registers as MVARh (lag) when active export, MVARh (Lag) when active import, MVARh (lead) when active export, MVARh (Lead) when active import.

f)

Two separate registers shall be provided to record MVARH when system voltage is >103% and when system voltage is < 97%.

g)

Shall compute the net MWh and MVARh during each successive 15-minute block metering interval along with a plus/minus sign, instantaneous net MWh, instantaneous net MVARh, average frequency of each 15 minutes, net active energy at midnight, , net reactive energy for voltage low and high conditions at each midnight.

h)

Each energy meter shall have a display unit with a seven digit display unit. It shall display the net MWh and MVARh with a plus/minus sign and average frequency during the previous metering interval; peak MWh demand since the last demand reset; accumulated total (instantaneous) MWh and MVARh



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CLAUSE NO

with a plus/minus sign, date and time; and instantaneous current and voltage on each phases. i)

All the registers shall be stored in a non-volatile memory. Meter registers for each metering interval, as well as accumulated totals, shall be downloadable. All the net active/reactive energy values displayed or stored shall be with a plus /minus sign for export/import. At least the following data shall be stored before being over-written for the following parameters. Parameters

details

Min No of days

1.

Net MWH

15 min block

40 days in meter

2.

Aver Freq

15 min block

40days in meter

3.

Net MVARH for V > 103%

15min block

40days in meter

4.

Net MVARH for V < 97%

15min block

40days in met

5.

Cumulative Net MWH at every midnight

10 days in meter/ 40 days in PC

6.

Cumulative Net MVARH for V> 103% at every midnight

10 days in Meter/ 40 days in PC

7.

Cumulative Net MVARH for V < 97% At every midnight

10 days in Meter / 40 days in PC

8.

Date and time blocks of VT failure on any phase.

j)

Shall have a built in clock and calendar with an accuracy of less than 15 seconds per month drift without assistance of external time synchronizing pulse.

k)

Date/time shall be displayed on demand. The clock shall be synchronized by GPS time synchronization equipment being supplied by the bidder.

l)

The voltage monitoring of all the three voltages shall be provided and alarm contacts provided to signal failures to the Substation Automation System, as well as alarm contact to indicate meter healthy status. The meter shall be suitable to operate with power drawn from the VT supplies. The burden of the meters shall be less than 2 VA.

m)

The power supply to the meter shall be healthy even with a single-phase VT supply. An automatic backup, in the event of non-availability of voltage in all the phases, shall be provided by a built in long life battery and shall not need replacement for at least 10 years with a continuous VT interruption of at least 2 years. Date and time of VT interruption and restoration shall be automatically stored in a non-volatile memory.



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11.00.00

n)

Shall have an optical port on the front of the meter for data collection from either a hand held meter reading instrument (MRI) having a display for energy readings or from a notebook computer with suitable software . The bidder shall supply the MRI and/or notebook complete with all optical interface unit required.

o)

A dedicated Metering Master Station (MMS), hardwired to all the energy meters in bidder’s scope shall be provided. The MMS shall be complete to offer the following functionality: -

To automatically downloaded the meter data from each meter point at scheduled daily intervals

-

To create calculated metering points by addition, subtraction, and applying multiplication factors to meter points

-

To present the demand of each meter point and calculated meter points in graphical format over specified intervals.

-

To calculated the total energy exchanged on meter points or calculated meter points for different time-of-use periods over specified intervals.

-

To export meter data to Excel format for external analysis.

-

To calculate the Unscheduled interchanges (UI) and the corresponding commercial parameters to suit the ABT requirements. The exact requirements shall be worked out during detail engineering stage, in coordination with site.

p)

The meter shall have means to test MWh and MVARh accuracy and calibration at site in-situ and test terminal blocks shall be provided for the same.

q)

Each meter shall have an unique identification code provided by the Employer and shall e permanently marked on the front of the meter and stored in the non volatile memory of the meter.

r)

The MMS shall be connected to substation LAN so as to facilitate display of Energy data at other locations of the LAN. However, this may be treated as optional.

TIME SYNCHRONIZATION EQUIPMENT i)

Two Time Synchronization equipment shall be provided and shall be located one each in the switchyard Control Room and the main control room. It shall receive Coordinated Universal Time (UTC) transmitted through Geo Positioning Satellite (GPS) for time synchronization of all components of the SAS/ generator relay panel.

ii)

Shall be complete in all respects including antenna, all cables, processing equipment, etc.



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CLAUSE NO

12.00.00

iii)

All auxiliary systems and special cables required for synchronization of the equipment shall be supplied and commissioned by the Contractor.

iv)

Shall work from DC supplies only and the Bidder to clarify if any built-in battery back up is provided, in which case, same shall be of long life lithium batteries.

v)

Shall be immune to hostile electrical environment. Suitable protections are to be provided against lightning surges and over-voltages in power supply systems and antenna feeders.

vi)

The system shall be fully tested to the relevant international standards such as IEC: 801 and IEC: 255. One copy of all the test reports shall be enclosed with the bid.

vii)

All components of the 400 kV SAS, including Substation Controllers, Workstations, Bay Control Units (BCU) and Bay Protection units (BPU) and all numeric protection relays shall be synchronized with an accuracy of 1ms.

viii)

The system should be able to track more than 1 satellite at a time to ensure no interruptions of synchronization signals.

ix)

The system shall have the following minimum output signals: ·

NTP (network time protocol) 10/100Mbits Ethernet port

·

IRIG-B00x (TTL, pulse width modulated signal)

·

2 x Pulse per half-hour / Pulse per minute / Pulse per second outputs via potential free contacts

·

Any other output port as may be required for the offered system.

·

Alarm status contact indicating healthy status of system

x)

These output ports shall be compatible with the requirement of the equipment to be synchronized i.e. BCUs and BPUs. The master clock in control room shall also be synchronized with the time synchronization system.

xi)

The equipment should have a periodic time correction facility of one-sec. periodicity. The equipment shall also have real time display in hour, minute, second (24 hour mode) and have a separate time display unit to be mounted on top of the MIMIC panel, having display size of approx. 144mm height.

RELAY TEST EQUIPMENT i)

The required relay test equipment shall comprise the following: -

One dynamic portable relay test system based on type Multi-Amp PULSAR Cat. 10 E3T3N or Omicron make type CMC256 or equivalent for allowing dynamic and steady state testing.



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CLAUSE NO

-

Any other auxiliary items like phantom loads, etc. required for testing all the protection relays supplied under this contract.

ii)

It shall have the capability to replay the Disturbance / Fault records acquired by the numerical relays / stand-alone DR in IEEE / COMTRADE format or EMTP simulations, to facilitate dynamic testing of all the numerical relays supplied under this contract. The required software for steady state/dynamic testing of all the numerical protection relays, energy meters and transducers, along with a laptop PC, shall also be supplied.

iii)

All commissioning tests on protection relays, energy meters and transducers shall be carried out with this relay test equipment being supplied under this contract and test reports shall be maintained as per the agreed protocols.

13.00.00

INTERFACE WITH OTHER AUTOMATION SYSTEM (SAS)

13.01.00

A fibre-optic extension of the Substation Network LAN from switchyard to the Main Plant is to be provided by the bidder along with all associated hardware.

13.02.00

A separate OPC complaint DCS for Main Plant located in Main Plant Control Room, will be provided by Employer. Bidder shall interface the requisite status and analog signals such as MW, MVAR, Generation Voltage, information, etc from the Main Plant DCS into the SWYD SAS (Note: The I/O list for above shall be made available to the Bidder during detailed engineering).

13.03.00

The bidder shall provide the necessary gateway so that necessary data such as Status of 400KV Circuit Breaker, associated Isolator & Earth switch, 400KV Bus Voltage /frequency, GRP Status, alarms, events etc can be provided to the Main Plant .The master-slave configuration and the configuration of the gateway computer for this interface shall be decided during detailed engineering. (Note: The I/O list for above shall be made available to the Bidder during detailed engineering)

13.04.00

The HMI software at Substation Level shall be so designed that it will require insignificant changes during interface with third party devices in future. In any case, such an interface would not impair the working of existing SAS in anyway. Further, no shutdown of the SAS shall be required to achieve this integration.

13.05.00

The cable and associated hardware required for connecting SAS gateway to the main plant SCADA terminal and those required between SWYD SAS bus (located in the main plant Control Room) and the main plant SCADA terminal shall also be provided by the bidder.

13.06.00

Necessary hardware/software to ensure provision for Remote Interface with RLDC, OS control Room & remote control centre in line with Cl 6.08.00

14.00.00

PANELS

14.01.00

All panels shall be free standing, floor mounting type and completely metal enclosed. Cable entries shall be from the bottom. Panels shall be of IP 31 class or better.


THIRD


PARTY

DEVICES/SUBSTATION

PART-B CHAPTER-E10

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14.02.00

Panels shall have removable gland plates with glands made of brass and shall be suitable for armoured cables.

14.03.00

Panels shall be painted. The colour of paint for exterior of the panel shall be as follows: a)

Ends: Colour-Blue, Shade-RAL5012

b)

Front and Rear:

Colour-Grey, Shade-RAL9002

14.04.00

Panels shall have a lockable front Plexiglas door and a swing frame. Panels shall facilitate direct access to any component mounted inside and shall have at least 20% free space for future expansion.

14.05.00

For installation of PGCIL Energy meter alongwith TTB, TBs, etc for GT bays & Line bays provision of sufficient space, terminal blocks, and associated wiring shall be made by the bidder.

14.06.00

Earthing a)

The panels shall be equipped with an earth bus of at least 50x6mm2 galvanized steel flat bar or equivalent copper.

b)

Earth bus of adjoining panels shall be connected for continuity. The continuous earth bus so formed shall be connected to the main earth grid at one end only.

c)

All metallic cases of the mounted equipment shall be separately connected to the earth bus by 2.5mm2 copper wire. No loops in the earth wiring shall be permitted.

d)

CT/VT neutral secondary shall only be earthed at the terminal block of the panel through links, such that the earthing of one group may be removed without disturbing others.

e)

An independent Electronic Earth System shall be provided as per bidder’s standard. The electronic earth shall be connected to the substation earth mat through a dedicated riser.

14.07.00

Panels shall, in general, meet the requirements as specified elsewhere in the specification.

15.00.00

CONTROL CABLING PHILOSOPHY IN SWITCHYARD a)

Each secondary core of each phase CT/CVT shall be brought to the equipment marshalling box through independent cables.

b)

Each three phase secondary core of each CT/CVT shall be brought to the associated control/relay panel from the equipment marshalling box through independent cables.



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c)

Duplicated cores with at least 4mm2 equivalent core cross-sectional area per connection shall be used for connection of all CT/CVT circuits.

d)

VT leads used for tariff metering shall have an equivalent core crosssectional area of at least 10 mm2 per phase/neutral connection.

e)

Duplicate channels of protection shall have independent cables for tripping, DC supply, etc.

f)

For the following applications multiple cores with at least 4mm2 equivalent core cross - sectional area per connection shall be used:

g)

h)

i)

DC supply to Bay Marshalling box

ii)

DC supply to circuit-breaker cubicle

iii)

DC looping for closing and tripping circuits of circuit-breaker

Spare cores shall be provided as per following norms: Up to 3-core cable

-

Nil

5 Core Cable

-

Min. 1 core

7 to 14 core cables

-

Min. 2 cores

More than 14 core

-

Min. 3 cores

All the interconnections ( both AC / DC ) within the switchyard and between switchyard and other systems required for the successful implementation of the control , interlocks and protection schemes under present package shall be in the scope of the bidder. Such interconnections between Switchyard and other system shall include but not limited to the following: i)

CT connections from Owner’s 11 kV/6.6 KV/415V Switchgear / transformer MB to SWYD Control room for transformer protections as per relevant protection SLD

ii)

CT connections from SWYD to GRP for overall differential protection and overhang differential protection in line with GRP protection SLD.

iii)

Extension of switchyard bus voltages to respective GRPs for transducer circuit and Generator synchronizing circuit.

iv)

Extension of manual closing and tripping commands coupling relays in GRP to EHV generator breakers.

v)

Necessary cabling from SWYD CR to GRP for protection interfacing, Generator EHV breaker closing interlock and signal exchange between switchyard and GRP.



PART-B CHAPTER-E10

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vi)

Any special cables ( other than 1.5 sq.mm unarmored required for the implementation of the protections being provided by the bidder.(eg: 100% stator E/F, Rotor E/F etc)

vii)

Necessary interconnections for the Inter tripping / closing, interlocking between upstream and down stream systems for Station transformer/ miscellaneous transformer/ unit transformer/Excitation System..

viii)

Necessary interconnections from transformer MB to RTCC (located in SWYD control room) and RTCC to BCU for OLTC control & Monitoring.

ix)

Necessary interconnections for signal exchange between SWYD/ SWYD CR to interfacing panels of RLDC where ever applicable.

x)

Necessary interconnection for signal exchange for DGA of GT shall be made.

xi)

Necessary interfacing between Transformer/Reactor MB and Switchyard Control Room, Hydrant System and Switchyard Control Room for transformer monitoring and fire protection system.

16.00.00

FACTORY ACCEPTANCE TESTS (FAT)

16.01.00

All equipment furnished under this specification shall be subject to test by authorized quality assurance personnel of the bidder and Employer’s representatives during manufacture, erection and on completion. The approval of the Employer or passing such inspections or tests will not, however, prejudice the right of the Employer to reject the equipment if it does not comply with the specifications when erected or fails to give complete satisfaction in service. The detailed requirement of operational and pre-FAT tests as well as FAT test (Integrated Test) is given in this Section.

16.01.01

The FAT shall be mutually agreed upon and approved by Employer during detailed engineering.

16.02.00

Operational and Pre-FAT Tests a)

The authorized quality assurance personnel of the bidder shall conduct all tests as per the requirements of this clause 16.02.00 and clause 16.03.00 and fully satisfy themselves regarding completeness of hardware, software and full compliance with specification requirements by all equipment/subsystems and the system as a whole before sending notification for FAT to the Employer. Bidder shall maintain accurate records for all pre-FAT tests which shall be properly documented and duly certified documents shall be furnished to Employer at least two weeks prior to FAT tests, while giving inspection call.

b)

Each individual item of equipment/ sub-system/ software package furnished by the Bidder as well as the complete system as per this specification shall be inspected and tested by the Bidder in his works for full compliance with



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specification requirements, completeness, proper assembly, operation, cleanliness and state of physical condition as applicable.

16.03.00

proper

c)

The Bidder shall conduct a point by point wiring continuity check to every input and output and verify that the wiring connections agree with the documentation.

d)

Bidder shall conduct all tests as per requirements of clause 16.04.00 (Factory Acceptance Tests) to fully satisfy himself regarding completeness of the system and full compliance with specification requirements for SAS as a whole as well as for individual components/ software module. This test will be done for 100% samples, even if the FAT requires tests for only some smaller percentages.

e)

The pre-FAT report shall be in the format of FAT procedure as approved by the Employer. It shall be accompanied by a very detailed report, in a log form, of the performance of all pre-FAT Tests. These records shall list not only the successfully completed tests, but shall detail all system, test and component failures.

Notification for FAT a)

Bidder shall send notification regarding readiness for FAT and indicate the proposed date for commencement of FAT to enable the Employer to depute representatives for participating in these tests. The notification shall be sent to the Employer not less than one month prior to commencement of the FAT along with the copies of documents covering pre-FAT results as per clause 16.02.00.

b)

The Bidder shall ensure that all hardware and software required for fully implementing the system as per requirements of this specification is available and the adequacy of hardware, software, system configuration, etc., is fully established during the pre-FAT Tests conducted by the Bidder. In case any deficiencies in hardware and/or software are noticed by the Bidder during the pre-FAT Tests, the Bidder shall make good all such deficiencies and reconduct the required tests to fully satisfy himself regarding completeness of the system and full compliance with specification requirements before sending notification to the Employer regarding FAT Tests.

16.04.00

Factory Acceptance Tests (FAT)

16.04.01

Factory Acceptance Tests (FAT) shall include all tests required to fully demonstrate to Employer’s satisfaction that each equipment/sub-system/system as well as software modules furnished as per this specification as well as SAS as a whole, fully meets the functional, parametric and other requirements of this specification and Employer’s approved drawings/documents under all operating regimes. The testing shall be conducted with the all the SAS components fully interconnected as per the final system configuration, including BCU, BPU and other protection relays. The Employer shall witness all FAT tests.



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16.04.02

The Factory Acceptance Tests (FAT) shall include all reasonable exercises which the combination of equipment and software can be expected to perform. These tests shall be divided into, as a minimum, but not limited to the following categories: a)

Pre power on checks

b)

Power on checks

c)

Hardware tests

d)

Functional tests

e)

Parametric tests

f)

Specific tests on electronic hardware

g)

Power failure auto-restart tests

h)

Testing of interlocking

16.04.03

The Bidder shall submit a detailed FAT procedure for Employer’s approval during detailed engineering stage based on the above guidelines. The FAT procedure to be submitted by the Bidder shall be detailed and exhaustive enough such that Employer is satisfied that all the SAS System specification requirements and features are being tested and the system meets these requirements. The test results obtained shall be properly documented by the Bidder and furnished in the Employer approved format as decided during detailed engineering and submitted in the requisite number of copies with all annexes irrespective of the fact that Employer‘s representative was present during the tests.

16.04.04

For integrated testing of the total SAS system, the Bidder shall provide an I/O generator/simulator, which will be connected, to the BCUs simulating the plant status and plant operation. This will help in generating desired rate and sequence of I/O to test various BCU and HMI functionality under worst case loading conditions. With the I/O generator/simulator, all possible interlocking conditions shall be simulated and controls tested.

16.04.05

Following the tests, if in the opinion of the Employer, the system has not been adequately manufactured, programmed, tested or debugged the Bidder shall make good all deficiencies including system parametric specifications of display response time, processor duty cycle, SOE resolution, etc., and re-run the test to fully satisfy the Employer regarding full compliance with specification requirements and requisite quality standards. The Bidder shall be responsible for all travel and accommodation costs of the Employer related to re-visits and/or re-testing required.

16.04.06

The system shall not be shipped without approval of Employer in writing. Upon successful completion of FAT, the Employer will provide the Bidder with a written authorization for shipment of the system equipment to the project site.

16.04.07

Bidder shall note that no payments towards dispatch of equipment and subsequent activities shall be due and payable to the Bidder till the Bidder is able to successfully



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demonstrate to Employer’s satisfaction that the SAS and parts thereof fully meet the FAT requirements. 16.04.08

The tests shall include the verification of all I/O functions at all Control Levels. The interface to the control center(s), interface to the 400 kV SAS and interface to the Power Generation SAS/SCADA system shall be tested with the use of a protocol simulator.

17.00.00

SITE / COMMISSIONING TESTS

17.01.00

Site tests shall include all tests to be carried out at site upon receipt of equipment. It shall include but not be limited to testing calibration, configurations and precommissioning trials, start up tests, trial operation and performance and guarantee tests. The Bidder shall be responsible for all site / commissioning tests.

17.02.00

The Bidder shall maintain all tests, calibration records in Employer approved formats, and these shall be countersigned by authorized quality assurance personnel of the Bidder supervising these works.

17.03.00

The Bidder shall maintain master checklists to ensure that all tests and calibration for all equipment/devices furnished under these specifications are satisfactorily completed under the supervision of the authorized quality assurance personnel of the Bidder.

17.04.00

The site / commissioning tests shall be categorized under following categories: a)

Start up tests

b)

Calibration and configuration checks

c)

Pre-commissioning tests

d)

Trial Operation

e)

Availability Tests

17.05.00

Point-to-point testing of all the I/O signals in the 400KV network shall be done by the Bidder at the plant and protection equipment end and the terminal end (Substation Controller and Operator Workstations) at the substation. The Employer shall be responsible to test the signals at the Control Centre(s) side.

17.06.00

Point-to-point testing of all the I/O signals in the Generation plant shall be done by the Bidder at the terminal end (400kV Substation Controller and Operator Workstations) at the substation. The Employer shall be responsible to test the signals at the plant and protection equipment end in the Generation plant.

17.07.00

Point-to-point testing shall include:

17.07.01

Verification of all status indications by operating the plant

17.07.02

Verification of event / alarm indications by simulating alarm conditions



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17.07.03

Verification of all analogue indications by injection testing

17.07.04

Verification of all controls by operating the plant

17.08.00

Availability Tests a)

The Bidder shall guarantee 99.9 percent availability for a continuous period of 180 days. Availability guarantee test shall be conducted to assure this level of availability. If the accrued down time exceeds 0.1% of 180 days, during availability test run, a new 180 days test run shall start at the time when the system becomes available again. Loss of availability (unavailable system) shall be defined as the loss of the systems guaranteed accuracy and repeatability or of any system function, except however, that the loss of a function for not more than five percent of the points shall not be considered loss of availability. Loss of function for not more than 5% of the points shall be treated as partial unavailability and the corresponding outage time shall be weighted with respect to the function and the percentage of the points for which the function is unavailable. Loss of each function shall have one weighing factor and unavailability of each equipment, peripherals device or process I/O card etc. shall have another weighing factor. The guaranteed accuracy and repeatability and system parametric requirements specified in clauses on system parametric requirements shall be maintained for the entire 180 days run without any manual re-calibration or any other changes made to the SAS.

b)

Downtime shall start upon loss of a system function and shall end upon full restoration of the affected system function. A minimum of one hour’s down time shall be charged for each loss of availability in determining system availability.

c)

The Bidder shall submit the Availability Test Procedure for Employer’s approval. The details regarding outage time, weighing factors for various systems functions equipment to calculate the down time shall be discussed and finalized during detailed engineering.

d)

The availability test shall start at a date, which will occur, between the commissioning date and 5 months after commissioning. The bidder will be notified the date during PG test.

e)

The availability test shall be expressed as percentage, which shall be calculated as (100% x (test duration time – Accumulated test outage time/Test duration time).

f)

System outage time will be accumulated over test duration and calculated as outage time x weighing factor. The bidder shall submit a list of weighing factors for all system components along with the bid and the same will be mutually finalized before contract award. Outage time shall be weighted by each function’s weighing factor.



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17.09.00

Conditions for Availability Tests a)

Down time shall start with the notification to bidder about any loss of function. Downtime shall be exclusive of travel time required by the Bidder, but not in excess of 8 hours.

b)

The bidder shall furnish in his bid recommended spare parts inventory, along with unit price, to be maintained at site during availability test run. If the spare parts required for maintenance as recommended by bidder are not available with Employer for fault repair the outage time necessary for obtaining spare will not be counted. If the required spare are not recommended by the Bidder and are required for repairs, then the time required to obtain the part by the Bidder shall be multiplied by weighting factor or 0.05 and counted as a accumulated outage time. The spare parts, which are used by the Bidder and not replaced by the bidder, shall accumulate outage time at the rate of time required to obtain the spare parts multiplied by the weighing factor of 0.05 if the part is required on a subsequent outage.

c)

The bidder shall be responsible for replacing any of the Employer’s spare parts which are used in the availability run free of cost to the Employer.

d)

Failure of peripheral output devices shall be counted as outage time if failure of the device affects any for part of the system function.

e)

Any degradation of function shall accrue outage time regardless of processor configuration.

f)

During a period of system outage, the Employer shall use operable functions of the system provided that such use does not interfere with maintenance of the inoperable functions or hardware as determined by the Bidder.

g)

Should the bidder determine that partial use of the system by the Employer will interfere with the bidder’s maintenance procedures, system outage time shall accumulate with a weighing factor of 1.0 since no functions are available to the Employer. This shall include offline servicing.

h)

Outage time for each function shall stop at the time the bidder returns each of the functions in full service and relinquishes full use of the system to the Employer.

17.09.01

The bidder shall prepare a detailed site / commissioning tests procedure based on the guidelines given here and submit to Employer for approval during detailed engineering stage.

17.10.00

System Hand-over and Final Acceptance

17.10.01

The system will be handed-over to the Employer for commercial operation after the site / commissioning tests have been completed to the satisfaction of the Employer. A hand-over certificate will be issued by the Employer. The Bidder will still be responsible for the Availability Tests.



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17.10.02

Final acceptance of the system by the Employer will take place after the Availability Tests have been done to the satisfaction of the Employer.

18.00.00

TYPE TEST REQUIREMENTS

18.01.00

Test reports for following type tests shall be submitted for all BCUs / BPUs/DR / Energy Meter as per Subsection –III ,Part-A, Section – VI of Technical Specification.

18.01.01

BCU/BPU A. Insulation Tests: Sl. No. 1.

Description Dielectric Withstand Tests

IEC 60255-5 2kV rms for 1 minute between all case terminals connected together and the case earth. 2kV rms for 1 minute between all terminals of independent circuits with terminals on each independent circuit connected together. ANSI/IEEE C37.90-1989 1kV rms for 1 minute across the open contacts of the watchdog relays. 1kV rms for 1 minute across open contacts of changeover output relays. 1.5kV rms for 1 minute across open contacts of normally open output relays.

2.

High Voltage Impulse Test, class III

IEC 60255-5 5 kV peak; 1.2/50 μsec; 0.5 J; 3 positive and 3 negative shots at intervals of 5 sec



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B. Electrical Environment Tests: 1.

DC Supply Interruption

IEC 60255-11 The unit will withstand a 20ms interruption in the auxiliary supply, in its quiescent state, Without de-energizing.

2.

AC Ripple on DC supply

IEC 60255-11 The unit will withstand a 12% ac ripple on the dc supply.

3.

4.

AC voltage dips and short

IEC 61000-4-11

Interruptions

20ms interruptions/dips.

High Frequency Disturbance

IEC 60255–22–1, class III At 1MHz, for 2s with 200 ohms source impedance: 2.5 kV peak; 1 MHz; T = 15 μsec; 400 shots/sec; duration 2 sec between independent circuits and independent circuits and case earth. 1.0kV peak across terminals of the same circuit.

5.

Fast Transient Disturbance

IEC 60255-22-4, class IV 4kV, 2.5kHz applied directly to auxiliary supply 4kV, 2.5kHz inputs.

6.

Surge Withstand Capability

applied

to

all

IEEE/ANSI C37.90.1 (1989) 4kV fast transient and 2.5kV oscillatory applied directly across each output contact, optically isolated input and power supply circuit.



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7.

Radiated Immunity

C37.90.2: 1995 25MHz to 1000MHz, zero and 100% square wave modulated. Field strength of 35V/m.

8.

Electrostatic Discharge

IEC 60255-22-2 Class 4 15kV discharge in air to user interface, display and exposed metal work. IEC 60255-22-2 Class 3 8kV discharge in air to all communication ports. 6kV point contact discharge to any part of the front of the product.

9.

Surge Immunity

IEC 61000-4-5: 1995 Level 4 4kV peak, 1.2/50ms between all groups and case earth. 2kV peak, 1.2/50ms between terminals of each group.

10.

Capacitor Discharge

No change of state or any operation shall occur when a capacitor of capacitance shown below, charged to 1,5 × Vn volts, is connected between any combination of terminals and any combination of terminals and ground. Master trip circuits - 10 μF Other protection circuits - 2 μF

&

control

Carrier/channel interface - 0,2 μF



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C. EMC Tests: Sl. No. 1.

2.

Description Radio-Frequency Electromagnetic Modulated

IEC 60255–22–2, class III Field,

Non-

10 V/m; 27 MHz to 500 MHz

ENV 50140, class III Radio-Frequency Electromagnetic Field, Amplitude 10 V/m; 80 MHz to 1000 MHz; Modulated 80% AM; 1 kHz

3.

4.

Radio-Frequency Electromagnetic Modulated

ENV 50140/ENV 50204 Field,

Pulse

10 V/m; 900 MHz; repetition frequency 200 Hz; duty cycle 50 %

Disturbances Induced by Radio ENV 50141, class III Frequency fields, Amplitude 30 A/m continuous; 300 A/m for Modulated 3 sec; 50 Hz

5.

Power Frequency Magnetic Field

EN 61000-4-8, class IV 30 A/m continuous; 300 A/m for 3 sec; 50 Hz

6.

7.

Interference Voltage

Voltage,

Aux. EN 50081-*

Interference Field Strength

150 kHz to 30 MHz EN 50081-* 30 MHz to 1000 MHz



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D. Atmospheric Environment Tests: Sl. No. 1.

Description IEC 60255-6Operating –25 0C to +55 0C

Temperature

Storage and transit –25 0C to +70 0C IEC 60068-2-1 for Cold IEC 60068-2-2 for Dry heat 2.

Humidity

IEC 60068-2-3 56 days at 93% RH and +40 C

E. Mechanical Stress Tests: Sl. No. 1.

Description Vibration (during Operation and IEC 255-21-1; IEC 68-2-6 Transportation) Response Class 2 Endurance Class 2

2.

Shock (during Operation and IEC 255-21-2, class 1, IEC 68-227 Transportation) Shock response Class 2 Shock withstand Class 1 Bump Class 1

18.01.02

3.

Seismic Vibration Operation)

(during IEC 60255-21-3 Class 2

4.

Continuous Shock Transportation)

(during IEC 255-21-2, class 1, IEC 68-227

ENERGY METER All type test reports as per IEC 2052-11/IEC 62053-22



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18.01.03

DISTURBANCE RECORDER. Type test reports for the following tests shall be submitted

18.02.00

i)

High Voltage Impulse Test, class III as per IEC 60255 - 3

ii)

High Frequency Disturbance as per IEC 60255 – 22 – 1, class III

iii)

Fast Transient Disturbance as per IEC 60255 – 22 – 4 , class IV

Functional Tests All the numerical relays shall be tested for the functions specified in NTPC technical specifications. In case of Numerical Distance Relays, test reports for dynamic tests clearly indicating the operating time under different system / fault conditions shall be submitted.

19.00.00

SETTINGS Fault levels will be provided to the Contractor by the Employer. The Contractor shall, based on this information, compile a complete and detailed report for the setting of the protection elements on all the protection equipment, to the approval of the Employer. Any additional information required to complete this exercise shall be timeously requested by the Contractor. The bidder shall provide the Employer with a philosophy document clearly setting out the philosophy the bidder will use in determining setting levels. Each setting will have a brief description of the specific function or element. The setting calculation and formula will also be shown on the document. All relevant system parameters, line data, transformer data additionally used for calculating the setting will appear in the setting document. The bidder will conduct system studies in determining fault levels on different locations. These study results will also form part of the setting document. Any additional information required to complete this exercise shall be timeously requested by the Bidder. The setting document will be presented and discussed with the Employer prior to final issue of the document. The final accepted setting document should be made available to the Employer in PDF format. It is the Bidder’s responsibility to configure each protection relay to provide the protection and control facilities required. A full set of relay configuration and setting files shall be included in the design and documentation submissions. The bidder will issue three sets of setting documents once accepted by the client and consultant.

20.00.00

FURNITURE The minimum furniture requirement as specified in Appendix-A to Chapter E-10 shall be supplied.



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APPENDIX-A TO CHAPTER E10: SUBSTATION AUTOMATION SYSTEM (SAS) SL. NO.

DESCRIPTION OF ITEM

I

400KV Switchyard

1.

Panel Mounted Bay Control Units (BCUs) for:

2

2.

QTY

a)

400 kV Generator Transformer Bays (GT#1,GT#2 , GT #3 & GT#4)

Nos.

4

b)

400 kV Line Bays (Line#1 & 2)

Nos.

2

c)

400KV Bus Coupler Bay

Nos

1

Panel Mounted Bay Protection Units (BPUs) for: a.

400 kV Lines (One set for each line; No. of lines being 2) (Each set shall contain duplicated distance protection scheme, duplicated LBB, Disturbance Recorder, 400KV cable protection, Auto-Reclose Breakers, Trip circuit supervision, etc)

Sets

2

b.

400KV GT Bays (one set for each GT bay, one set shall contain duplicated LBB,Trip circuit supervision, etc)

Sets

4

c.

400KV Bus coupler bay( one set shall contain duplicated LBB, Bus coupler protection scheme, trip circuit supervision, etc)

Set

1

Set

1

Bus Bar Protection 400 kV Bus#1 & #2 with Duplicated Bus Bar Protections for each bus.

3.

UNIT

Energy Metering System a

Energy Meters (ABT Meters) for:

i.

400 kV Lines

Sets

2

ii

400 kV Generator-Transformers

Sets

4

b.

Networking for Energy Meters, Relays, Disturbance recorders for 400KV system including all hardware/ software required e.g. licensed copies of Relay, Energy meter & DR softwares, networking fiber optic cable, Desktop PC (above software loaded), printer.

Set

1



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4.

Islanding Scheme Islanding scheme for the project based on bus under frequency relays with two out of three logic including independent trip relays for each bay, including future bays.

Set

1

(one for GRP and one for 400KV Switchyard)

Nos.

2

6.

Dynamic Relay Test Kit including a Laptop PC (Latest version)

No.

1

II.

GENERATOR RELAY PANEL (GRP)

5.

Time Synchronizing Equipment

1.

GRP for Unit# 1&4 containing Generator, GT,SAT( Gen-V/11.5KV) & UAT (11KV /0.433KV) protection ( one set per generator)

Sets

2

2.

GRP for Unit# 2 & 3 containing Generator, GT & UAT protection( one set per generator)

Sets

2

3.

Disturbance Recorder ( Slow as well as fast scan) for each Generator ( one set per generator)

Sets

4

4.

Energymeters (0.2 class, Non-ABT type) for each Generator, SAT, UAT ( Two sets for unit # 1& 4, with each set containing Main & check energymeters for Generator, one for SAT & one for UAT. Two sets for unit# 2& 3, with each set containing Main & check energymeters for Generator & one for UAT)

Sets

4

5.

Networking for GRP Relays, Disturbance recorder, energy meters including all hardware/software required e.g. licensed copies of energymeter, relay & DR software, networking fiber optic cable, Desktop PC (above software loaded), printer, furniture etc

III.

SAS Accessories

a.

Operator’s Workstations with Printer for Bay equipment control, (Two sets for SCR)

Sets

2

i.

400KV Network Controller

Sets

2

ii.

Engineering Workstation with Printer.

Set

1

iii.

Portable engineering workstation (Laptop) (loaded with software for Energy meter, DR and Relay also)

Set

1



PART-B CHAPTER-E10

PAGE 56 OF 59


CLAUSE NO

iv.

Gateways(IEC 60870-5-101/104 compliant) alongwith two modems each per set for interface with RLDC and OS control Room.

Set

2

v.

Gateways (OPC compliant) for interface with Main Plant SCADA.

Set

2

Vi

Gateways (IEC 60870-5-101/104 compliant) for interface with Remote Control Station.

Set

2

vii

400KV Network Controller

Sets

2

b.

Communication cables (other than fiber optic) including any other software/hardware items necessary for interconnecting BCUs, BPUs, GRP, Gateways, Main Plant control room to Switchyard Protection room etc.

As per requirement of the systems

c.

Multi-mode Fiber Optic cables required in the SCADA for various interconnections including that between Main Plant Control room to Switchyard Control Room


1.

Control Cables Control cables required for interconnecting analog/status/ control signals between BCUs/BPUs and field equipment

2.


Furniture a.

Desk suitable for one workstation/PC and printer

Nos.

6

b.

Revolving Chair

Nos.

6

Note: This list serves as a guide to the bidder to offer the correct quantities, and does not relieve the bidder of any requirement specified elsewhere.. Any other item required as per specification but not mentioned in the list shall be also be deemed to be included in the scope of the Bidder.



PART-B CHAPTER-E10

PAGE 57 OF 59


CLAUSE NO

APPENDIX B TO CHAPTER E10: SUBSTATION AUTOMATION SYSTEM (SAS) Minimum Hardware Requirements Note: This list serves as a guide to the bidder to offer the correct quantities, and does not relieve the bidder of any requirement specified elsewhere. The SAS specficiation in Chapter 10 has priority over this list of quantities.

Portable Engineering Workstation

Engineering and Fault Recording Station

Item Description

Operator Workstations

Processor

64 bit Pentium of latest model 512 MB upgradeable to 1GB

64 bit Pentium of latest model

Hard Disk

2 x 40GB

Monitor

Substat ion Control ler

Metering Master Station

64 bit Pentium of latest model 512 MB upgradeable to 1GB

64 bit Pentium of latest model

2 x 80GB

1 x 40GB

1 x 40GB

Colour 19"; Flat LCD type Screen; Resolution 1600x1280

Colour 19"; Flat LCD type Screen; Resolution 1600x1280

Colour 14"; LCD screen; Active display

128 bit with 8MB graphic memory 230 VAC from UPS


128 bit with 8MB graphic memory 230 VAC with built-in battery for 2 hours operation

Floppy Drive CD-ROM read/write drive DVD read/write drive

1 x 3.5" (1.44 MB) 40x

1 x 3.5" (1.44 MB) 40x

1 x 3.5" (1.44 MB) 40x

24x

24x

NA

NA

Operating System

Windows 2000 or XP

Windows 2000 or XP

Windows 2000 or XP

Windows 2000 or XP

Memory

Graphic Accelerator card

512 MB upgradeable to 1GB

Power Supplies



512 MB upgradeable to 1GB

Colour 19"; Flat LCD type Screen; Resolution 1600x1280 To meet system specific ations and design architec ture


1 x 3.5" (1.44 MB) 40x

PART-B CHAPTER-E10

PAGE 59 OF 59

CLAUSE NO


Printers Item Description

Colour Laser printer A3

B&W Laser printer A4

Paper size

A4 & A3

A4

Printing speed

6ppm (colour), 24 ppm (B&W)

24 ppm (B&W)

Type

Heavy Duty (50,000 pages per month)

Heavy Duty (50,000 pages per month)

Resolution

600 dpi

600 dpi

Memory

128 MB 500 sheets A4 & A3

128 MB 500 sheets A4

Ethernet port (network ready) & USB port

Ethernet port (network ready) & USB port

Paper input capacity Communication Port

Paper (1ream=500sheets) Cartridges

20 reams of A3; 20 reams of A4 4 sets B&W for each printer; each printer.


4 sets colour for


4 sets B&W for each printer; printer.

PART-B CHAPTER-E10

4 sets colour for each

PAGE 59 OF 59

RLDC MODEM

MODEM

400KV SWYD Control Room

TO OS CONTROL ROOM COMMUNICATION DEVICE

TSE

Printer (A4-color laser)

Printer(A3color laser)

Rear Projection MIMIC Display (LVS)

SWYD Network Main Controller

Engg & DFR Station

SWYD Network Standby Controller

Operator Workstat ion

Metring Master Station (MMS)

To Energy meters MODEM

MODEM

Gateway for RLDC/ OS Control Room

(Heartbeat)

Hi-end Dot Matrix Printer for SOE printing

Gateway for RLDC/ OS Control Room Communication: IEC61850 protocol

To Sheet 2 /2 Inter-bay / Station Bus A

Communication: IEC61850 protocol

To Sheet 2/2 Inter-bay / Station Bus B

Engineering Bus (optional)

To DFR workstation

IEC60870-5-103

BCU

BPU

BPU

IEC60870-5-103

BCU

BCU Engineering Workstation (portable)

Bay 1 Option 1

BPU SEC

BPU PRIM

BPU

BPU

BCU

Bay n

Stand alone DFR (optional)

Option 1 Bay n

BPU PRIM

BPU SEC

Bay 1 Option 2

LEGEND: BCU BPU DFR TSE PRIM SEC

Option 2

Bay Control Unit Bay Protection unit DISTURBANCE and Fault Recorder Time Synchronizing Equipment Primary Relays (as per spec) Secondary Relays (as per spec)

Notes: 1. The switchyard network controllers and operator workstations are fully redundant 2. The SWYD Interbay bus shall be a ring or dual redundant star topology, fiber optic bus. 3. All network connections between rooms or buildings shall be via fiberoptic. 4 . The BCU includes Graphic mimic display, analogue and status indications, alarm annunciation, local control, and inter-bay communication for control with interlocking 5. All BCU, BPU, Controllers, Workstations shall be synchronized to GPS reference time. 6. In case BCU/BPU are provided with only single ethernet port , suitable ethernet switch shall be provided in each BPU/BCU panel to provide dual connection to Inter-bay bus. 7. Each gateway shown to be treated as physically separate Device. 8. Gateway Communication protocol: RLDC->IEC60870-5-101; OS control room-> OPC 9. Connectivity of Energy Metering Master Station to Station Bus LAN is optional. 10. The minimum hard disk capacity of each of the controllers shall be 2 x 80 GB and that of the OWS/EWS/MMS shall be minimum 80 GB.

FOR TENDER PURPOSE ONLY

TAPOVAN VISHNUGAD HEPP 400KV SWITCHYARD TITLE - SUBSTATION AUTOMATION SYSTEM ARCHITECTURE DRN

DGN

CHKD

APPD

DATE

DRG. NO.

1246-001-POE-A-001 SH 1/2

REV. 0

U#1

Gateway for Remote Control Centre (IEC 60870-5101/104)

Gateway for Remote Control Centre (IEC 60870-5101/104)

**Rear Projection MIMIC Display (LVS)

U#n Gateway for Connectivity to Owner’s OPC-compliant DCS

TO MAIN PLANT SCADA

Gateway for Connectivity to Owner’s OPC-compliant DCS

Main Plant Engineering cum DFR Station

**Operator’s Workstation

**Operator’s Workstation

Printer (A3color laser)

CCR (Power House Control Room)

TSE

TSE


FROM SH 1/2


IEC 61850 protocol converter

IEC 61850 protocol converter

ENGINEERING BUS FOR RELAYS FOR DFR

Engg & DFR Station

IEC61850 compliant numerical relays

NonIEC61850 compliant numerical relays

DFR FOR GEN-1

Engig & DFR Station

IEC61850 compliant numerical relays

Printer (A4- Color Laser)

BPUs FOR GEN-1

Engineering Workstation (portable)

NonIEC61850 compliant numerical relays

DFR FOR GEN-n

Printer (A4- Color Laser)

BPUs FOR GEN-n

Machine Hall at EL 1289.00m (Near Unit#1)”

Machine Hall at EL 1289.00m (Near Unit#n)”

Notes: contd.

FOR TENDER PURPOSE ONLY

11. IEC61850 GOOSE compliant Ethernet switches shall be provided for realizing the above system. 12. Engg Bus wherever not required on account of IEC61850 compliance may be treated as optional. 13. IEC61850 compliance for BPUs of Generator Protection is optional. 14. In case it is not possible to accommodate RLDC and OS control Room interfacing gateways in one PC , the same may provided in separate PCs i.e RLDC gateway: 2 PCs, OS control Room gateway: 2 PCs. ** : To be Supplied loose by EM Package Contractor.

TAPOVAN VISHNUGAD HEPP 400KV SWITCHYARD TITLE - SUBSTATION AUTOMATION

SYSTEM ARCHITECTURE DRN

DGN

CHKD

APPD

DATE

DRG. NO.

1246-001-POE-A-001 SH 2/2

REV. 0

PART-B SUB-SECTION-E11 DC BATTERY AND BATTERY CHARGER (COMMON)



DC BATTERY AND BATTERY CHARGER (E11)

CLAUSE NO

The bidder has to offer either Nickel Cadmium Battery or Lead-Acid Plante Battery. The Battery Chargers shall be accordingly suitable for the type of battery offered. 1.00.00

PART-A:

NICKEL-CADMIUM BATTERY

1.01.00

CODES AND STANDARDS All standards, specifications and codes of practice referred to herein, shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. All works shall be carried out as per the following standards and codes: IS : 10918

Specification for vented type Nickel Cadmium Batteries.

IS : 1069

Quality tolerances for water for storage batteries Indian Electricity Rules Indian Electricity Acts.

1.02.00

Equipment complying with other internationally accepted standards such as IEC., BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison.In case of conflict between this specification and those (IS codes, Standards etc.) referred to herein, the former shall prevail

2.00.00

GENERAL TECHNICAL REQUIREMENT

2.01.00

Equipments a)

DC Batteries shall be stationary Nickel Cadmium Pocket plate type (KPH) conforming to IS:10918. The batteries shall be high discharge performance type as specified.

b)

DC batteries shall be suitable for standby duty. The batteries shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency conditions when AC supplies are lost. Batteries shall be suitable for a long life under continuous float operations and occasional discharges. The batteries shall be boost charged at about 1.54 to 1.7 volts per cell maximum and float charged at about 1.42 V/cell.

c)

The number of cells for the 48 Volts shall be 37

d)

Batteries should be suitable for continuous operation for the maximum ambient temperature as defined in technical parameters.



PART-B CHAPTER - E11

PAGE 1 OF 23


CLAUSE NO

2.02.00

Construction Features

2.02.01

Containers Containers shall be made of polypropylene plastic material. Containers shall be robust, heat resistance, leak proof, non absorbent, alkali resistant, non-bulging type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be marked on container in case of transflucent containers.

2.02.02

Vent Plugs Vent plugs shall be provided in each cells. They shall be antisplash type, having more than one exit hole shall allow the gases to escape freely but shall prevent alkali from coming out. The design shall be such that the water loss due to evaporation is kept to minimum. In addition the ventilator shall be easily removed for topping up the cells and of such dimensions that the syringe type hydrometer can be inserted into the vent to take electrolyte samples.

2.02.03

Plates The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuations of load. The construction of plates shall conform to latest revisions of IS:10918. The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. Separators should be suitable for continuous immersion in the electrolyte without distortion. The positive and negative terminal posts shall be clearly marked.

2.02.04

Sediment Space Sufficient sediment space shall be provided so that cells will not have to be cleaned during normal life and prevent shorts within the cells.

2.02.05

Cell Insulator Each cell shall be separately supported on PVC/porcelain/hard rubber insulators fixed on to the racks with adequate clearance between adjacent cells. Minimum distance between the adjacent cells shall be more than the bulge allowed for two cells in accordance with IS:1146.

2.02.06

Electrolyte The electrolyte shall be prepared from battery grade potassium hydroxide conforming to BS:1069. The cells shall be shipped in charged condition.




PAGE 2 OF 23


CLAUSE NO

Necessary electrolyte for make-up shall be supplied separately. 2.02.07

Connectors and Fasteners Nickel coated copper connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be effectively Nickel coated to prevent corrosion. The thickness of Nickel coating of connectors should be not less than 0.02 mm. All the terminals and cells inter-connectors shall be fully insulated or have insulation shrouds. End take off connections from positive and negative poles of batteries shall be made by single core cables having stranded aluminium conductors and XLPE insulation. Necessary supports and lugs for termination of these cables on batteries shall also be supplied by the contractor. All connectors and lugs shall be capable of continuously carrying the 30 minutes discharge current of the respective batteries and through fault short circuit current which the battery can produce and withstand for the period declared. Contractor shall furnish necessary sizing calculations to prove compliance to the same. Suitable number of Inter-rack connectors shall be supplied by the Bidder to suit the battery room layout during detailed engineering.

2.02.08

Battery racks Mild steel racks for all the batteries shall be provided. They shall be free standing type mounted on procelain/hard rubber/PVC pads insulators. Batteries shall preferably be located in the single tier arrangement. However, batteries having a complete cell weight of lower than 50 Kg could be located in the double tier arrangement. The batteries racks and supports for cable termination shall be coated with three (3) coats of anti-alkali paint of approved shade. Name plates, resistant to alkali, for each cell shall be attached on to the necessary racks. The bottom tier of the stand shall not be less than 150 mm above the floor. Wherever racks are transported in dismantled conditions, match markings shall be provided to facilitate easy assembly.

2.02.09

Manufacturer’s Identification System The following information shall be indelibly marked on outside of each cell. i)

Manufacturers’ name and trade marks

ii)

Country and year of manufacture.

iii)

Manufacturer type designation.

iv)

AH capacity at 5 hour discharge rate.

v)

Serial number

The following information shall be given on the instruction cards supplied with the battery: TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2



PAGE 3 OF 23


CLAUSE NO

3.00.00

a)

Manufacturer's instructions for filling and initial charging of the battery together with starting and finishing charging rate.

b)

Maintenance instructions.

c)

Designation of cell in accordance with IS:10918.

d)

Storing conditions of electrolyte.

TESTS All routine, type and acceptance test shall be carried out as per latest issue of IS: 10918. Tests shall have to be carried out in the presence of Employer’s representative, if desired by the Employer.

3.01.00

Routine Tests All the routine tests listed below shall be carried out on cells containers, hardware being supplied:

3.02.00

a)

Physical Examination

b)

Dimension, Mass & layout

c)

Marking

d)

Polarity and absence of short circuit.

Type Tests All type tests reports listed below shall be submitted for Employer’s approval on cells containers, hardwares of each type being supplied: a)


b)

Dimension, Mass & layout

c)

Marking

d)

Polarity & absence of short circuit

e)

Insulation resistance

f)

Dielectric test

g)

Life cycle test




PAGE 4 OF 23


CLAUSE NO

h)

In addition to above the following type tests reports ( carried out in the sequence) shall also be submitted: i)

Air pressure test

ii)

Tests for capacities for 5 hr and 1/2 hr. discharge rates and test for voltage during discharge.

iii)

Ampere hours and watt-hour efficiency test.

iv)

Tests for retention of charge.

v)

Endurance tests.

vi)

Discharge performance at low temperature.

Type tests shall be carried out on four cells selected at randomly. Two cells shall undergo all tests except capacity and endurance tests while the others would undergo only capacity and endurance test. 3.03.00

Acceptance Tests All acceptance tests as listed below shall be carried out on sample cell selected at random by the employer before despatch and at site after completion of installation. a)


b)

DImensions, Mass & layout

c)

Marking

d)

Polarity and absence of short circuit.

e)

Air pressure test

f)

Ampere - hour capacity

g)

Retention of charge

h)

Insulation resistance

The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments. If a Battery fails to meet the guaranteed requirements the Employer shall have the option of asking the Contractor to replace the same.




PAGE 5 OF 23


CLAUSE NO

1.00.00

PART-B:

LEAD-ACID PLANTE BATTERY

1.01.00

CODES & STANDARDS All standards, specification and codes of practice, referred to herein, shall be the latest edition including all applicable official amendments and revisions as on date of opening of bid.

1.02.00

All works shall be carried out as per the following standards and codes : IS : 266

Specification for sulphuric acid

IS : 1069

Specification for water for storage batteries

IS : 1146

Specification for rubber & plastic containers for lead acid storage batteries.

IS : 1652

Specification for stationary cells and batteries, lead acid type (with plant positive plates).

IS : 3116

Specification for sealing compound for lead acid batteries.

IS : 8320

General requirements and methods of tests for lead acid storage batteries. Indian Electricity Rules Indian Electricity Acts

IS : 6071

Specification for synthetic separators for lead acid batteries.

1.03.00

Equipment complying with other internationally accepted standards such as IEC, BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. In case of conflict between this specification and those (IS Codes Standards etc.) referred to herein, the former shall prevail

2.00.00

GENERAL TECHNICAL REQUIREMENTS

2.01.00

Equipments

2.01.01

DC Batteries shall be stationary lead acid Plante positive plate type conforming to IS:1652. The battery shall be high discharge performance type.




PAGE 6 OF 23


CLAUSE NO

2.01.02

DC Batteries shall be suitable for standby duty. The Batteries shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency conditions when AC supplies are lost. Batteries shall be suitable for a long life under continuous float operations and occasional discharges. The batteries shall be boost charged at about 2.7 volts per cell maximum and float charged at about 2.2 V/cell:

2.01.03

The number of cells for the 48 Volts shall be 24.

2.01.03

Batteries should be suitable for continuous operation for the maximum ambient temperature as defined in technical parameters.

2.02.00

Construction Features

2.02.01

Containers Containers shall be made of transparent glass, hard rubber, suitable robust, heat resistance, leak proof, non absorbent, acid resistant, non-bulging type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be marked on container in case of transparent containers. Float type level indicator shall be provided in case of opaque containers. The stem portion of the float should be long enough to prevent falling of the float inside the container even if there is no electrolyte in the container. The marking for the electrolyte level should be for the upper and lower limits. The material of level indicator shall be acid proof and oxidation proof. Container shall be closed/sealed lid type. Lid and sealing compound shall be non-cracking type. The container made of hard rubber and plastics shall be type tested as per IS : 1146. All type tests shall be carried out for sealing compound as per IS:3116. The pole sealing arrangement should be such that no acid particle get entrapped due to acid creep as a result of capillary action and it should be possible to remove and refix the sealing to carry out the maintenance.

2.03.00

Vent Plugs Vent plugs shall be provided in each cells. They shall be antisplash type, having more than one exit hole shall allow the gases to escape freely but shall prevent acid from coming out. The design shall be such that the water loss due to evaporation is kept to minimum. In addition the ventilator shall be easily removed for topping up the cells and of such dimensions that the syringe type hydrometer can be inserted into the vent to take electrolyte sample.

2.04.00

Plates The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuations of load. The construction of plates shall conform to latest revisions of IS : 1652 as applicable.




PAGE 7 OF 23


CLAUSE NO

The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. Separators should be suitable for continuous immersion in the electrolyte without distortion. The positive and negative post shall be clearly marked. 2.05.00

Sediment Space Sufficient sediment space shall be provided so that cells will not have to be cleaned during normal life and prevent shorts within the cells.

2.06.00

Cell Insulator Each cell shall be separately supported on PVC/porcelain/hard rubber insulators fixed on the racks with adequate clearance between adjacent cells. Minimum distance between adjacent cells shall be more than the bulge allowed for two cells in accordance with IS:1146.

2.07.00

Electrolyte The electrolyte shall be prepared from battery grade sulphuric acid conforming to IS:266 and distilled water conforming to IS:1069. The cells shall be shipped dry uncharged. The electrolyte shall be supplied separately.

2.08.00

Connectors and Fasteners Lead or Lead coated copper connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be effectively lead coated to prevent corrosion. The thickness of lead-coating of connectors should not be less than 0.025 mm. The lead coating thickness shall be measured in accordance with APPENDIX F of IS:6848 (latest edition). All the terminals and cells inter-connectors shall be fully insulated or have insulation shrouds. End take off connections from positive and negative poles of batteries shall be made by single core cables having stranded aluminum conductors and XLPE insulation. Necessary supports and lugs for termination of these cables on batteries shall also be supplied by the contractor. All connectors and lugs shall be capable of continuously carrying the 30 minutes discharge current of the respective Batteries and through fault short circuit current which the battery can produce and withstand for the period declared. Contractor shall furnish necessary sizing calculations to prove compliance to the same.

2.09.00

Battery racks Wooden racks for all the batteries shall be provided. These racks shall be made of good quality first class seasoned teak wood in line with CPWD specification. They shall be free standing type mounted on procelain/hard rubber/PVC pads insulators. Batteries shall preferably be located in the single tier arrangement. However, batteries having a complete cell weight of lower than 50 Kg could be located in the double tier arrangement. The batteries rack and wooden support for cable




PAGE 8 OF 23


CLAUSE NO

termination shall be coated with three (3) coats of anti-acid paint of approved shade. Numbering tags, resistant to acid, for each cell shall be attached on to the necessary racks. The bottom tier of the stand shall not be less than 150 mm above the floor. Wherever racks are transported in dismantled condition, suitable match markings shall be provided to facilitate easy assembly. 2.10.00

Manufacturer’s Identification Systems The following information shall be indelibly marked on outside of each cell.

3.00.00

i)

Manufacturer's name and trade marks

ii)

Country and year of manufacture.

iii)

Manufacturer type designation.

iv)

AH capacity at 10 hour discharge rate.

v)

Serial number

TESTS All routine, type and acceptance tests shall be carried out as per relevant Indian standards. Tests shall have to be carried out in the presence of Employer’s representative, if desired by the Employer.

3.01.00

Routine Tests All the routine tests listed below shall be carried out on cells containers hardware being supplied as per the latest issue of IS:1146 and IS:1652. A)

Container i)

Verification of constructional requirements.

ii)

Verification of marking and packing.

iii) B)

High voltage tests.

Cells and Batteries i)

Verification of constructional requirements.

ii)

Verification of markings

iii)

Verification of dimensions.

iv)

Checking of polarity and absence of short circuit.




PAGE 9 OF 23


CLAUSE NO

3.02.00

Type Tests All type tests listed below shall be carried out on cells containers, hardware of each type being supplied, as per the latest issue of IS:1146 or IS:1652. A)

C)

Container (Rubber and Plastic containers) i)

High voltage test

ii)

Drop Ball test

iii)

Plastic Yield Test

iv)

Acid resistance test

v)

Hydraulic thrust endurance test.

Cells and Batteries The following tests shall be carried out in the sequence given below : i)

Tests for capacities for 10 hr and 30 minutes discharge rates and test for voltage during discharge.

ii)

Ampere hours and watt-hour efficiency test.

iii)

Tests for retention of charge.

iv)

Endurance tests.

Type tests shall be carried out on three cells selected randomly. Two cells shall undergo all tests except capacity and endurance tests while the other would undergo only capacity and endurance test. 3.03.00

Acceptance Tests All acceptance tests as listed below shall be carried out on sample cell selected at random by the employer before despatch and at site after completion of installation. i)

Verification of markings.

ii)

Verification of dimensions.

iii)

Test for capacities for 10 hrs discharge rate alongwith the test for voltage during discharge.

The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments. If a battery fails to meet the guaranteed requirements, the Employer shall have the option of asking the Contractor to replace the same.




PAGE 10 OF 23


CLAUSE NO

BATTERY CHARGER 1.00.00

CODES AND STANDARDS

1.01.00

All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards and codes. ANSI-C 37.90a

Guide for surge withstand capability tests.

IS:5

Colours for ready mix paints.

IS : 694

PVC Insulated Cable for working voltages upto and including 1100 V.

IS : 1248

Specification for Direct acting indicating analogue electrical measuring instruments.

IS : 2147

Degree of protection provided by enclosures for low voltage switch gear and control gear.

IS : 13947

Specification for low voltage switch gear and control gear.

IS : 3231

Electrical relays for power system protection.

IS : 3842

Application guide for Electrical relays for AC System

IS : 3895

Mono-crystalline semi-conductor Rectifier Cells and Stacks.

IS : 4540

Mono crystalline semi-conductor Rectifier assemblies and equipment.

IS:6005

Code of practice for phosphating of Iron and Steel.

IS:6619

Safety Code for Semi-conductor Rectifier Equipment.

IS:6875

Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto 1000 V AC or 1200 V DC.

IS : 9000

Basic environmental testing procedures for electronic and electrical items.

IS:13703

Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC.




PAGE 11 OF 23


CLAUSE NO

EEUA-45D

Performance requirements for electrical Alarm Annunciation System. Indian Electricity Rules Indian Electricity Act.

1.02.00

Equipment complying with other internationally accepted standards such as IEC, BS, VDE. etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison.

2.00.00

EQUIPMENT DESCRIPTION

2.01.00

PART-I

BATTERY CHARGER FOR LEAD ACID PLANTE TYPE BATTERY

a)

The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC lead-acid Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 2.15 to 2.25 Volts per cell. All chargers shall also be capable of Boost Charging the associated D.C. Battery at 2.0 to 2.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 40°C.

b)

Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging.

c)

All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice-versa under normal operating condition.

d)

Soft start feature shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall neither damage the Charger nor shall it cause blowing of any of the changer fuses. The Charger shall not trip on overload or external short circuit. After clearance of




PAGE 12 OF 23


CLAUSE NO

fault, the Charger voltage shall build up automatically when working in automatic mode. e)

When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/-1% of the set value for AC input voltage variation of +/-10%, frequency variation of +3/-5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode.

f)

During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type.

g)

Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits in clause 2.01.00 (e), shall be less than fifteen seconds.

h)

Momentary output voltage of the Charger, with the Battery connected shall be within 94% to 106% of the voltage setting during sudden load Change from 100% to 20% of full load or vice-versa. Output voltage shall return to, and remain, within the limits specified in clause 2.01.00 (e) in less than 2 seconds after the above mentioned change.

i)

The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the trickle charging mode is also used as Boost charging current setting device.

j)

Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery.




PAGE 13 OF 23


CLAUSE NO

k)

2.02.00

The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the contractor in the DC distribution board for remote annunciation.

PART-II

BATTERY CHARGER FOR NICKEL-CADMIUM TYPE BATTERY

a)

The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC Nickel-Cadmium Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 1.4 to 1.42 Volts per cell. All chargers shall be capable of Boost Charging the associated D.C. Battery at 1.53 to 1.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 40°C.

b)

Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging.

c)

All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice-versa under normal operating condition.

d)

Soft start features shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall not damage the Charger, nor shall it cause blowing of any of the charger fuses. The Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode.

e)

When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/-1% of the set value for AC input voltage variation of +/-10%, frequency variation of +3 to -5%, a combined voltage and frequency (absolute sum) varation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode.




PAGE 14 OF 23


CLAUSE NO

2.03.00

f)

During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type.

g)

Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits in clause 2.02.00 (e), shall be less than fifteen seconds.

h)

Momentary output voltage of the Charger, with the Battery connected shall be within 94% to 106% of the voltage setting during sudden load change from 100% to 20% of full load or vice-versa. Output voltage shall return to, and remain, within the limits specified in clause 2.02.00 (e) in less than 2 seconds after the above mentioned change.

i)

The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the trickle charging mode is also used as Boost charging current setting device.

j)

Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery.

k)

The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the contractor in the DC distribution board for remote annunciation.

Printed Circuits Boards (PCBs) PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with 99.8% pure copper foil, free of wrinkles, blisters, scratches and pinholes. The contact surface of the edge connectors of the PCBs shall be plated with hard gold to a minimum thickness of 5 microns. Component identification shall be printed on PCB by silk screen method. All PCBs shall be tropicalised and masked.

2.04.00

Contactors All Battery Chargers shall have an AC contactor on the input side. It shall be of air break type and suitable for continuous duty. The operating coil shall be rated for 415 Volts AC.




PAGE 15 OF 23


CLAUSE NO

2.05.00

Thermal Overload Relay A thermal overload relay incorporating a distinct single phasing protection (using differential movement of bimetal strips) shall also be provided for the AC input. The relay shall trip the above contactor.

2.06.00

Rectifier-Transformers and Chokes The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating of the rectifier-transformers and chokes shall correspond to the rating of the associated rectifier assembly. The rectifier-transformers and chokes shall have class-B insulation with temperature rise limited to class-A insulation value.

2.07.00

Rectifier Assembly The rectifier assembly shall be full wave bridge type and designed to meet the duty as required by the respective Charger. The rectifier cells shall be provided with their own heat dissipation arrangement with natural air cooling. The rectifier shall utilise diodes/thyristors and heat sinks rated to carry 200% of the load current continuously and the temperature of the heat sink shall not be permitted to exceed 85°C absolute duly considering the maximum charger panel inside temperature. The Contractor shall submit calculations to show what maximum junction temperature will be and what the heat sink temperature will be when operating at 200% and 100% load current continuously duly considering the maximum surrounding air temperature for these devices inside the charger panel assuming air ambient temperature of 27°C outside the panel. Necessary surge protection devices and rectifier type fast acting fuses shall be provided in each arm of the rectifier connections.

2.08.00

Instruments D.C. voltmeter, D.C. ammeter and A.C. voltmeter in 96 mm square shall be provided for all Chargers. The instruments shall be flush mounted type, dust proof and moisture resistant. The instruments shall have easily accessible means for zero adjustments. The instruments shall be of 1.5 accuracy class.

2.09.00

Air Break Switches All Chargers shall have AC input and DC output switches of air break, single throw, load break and fault make type. The contacts of the switches shall open and close with a snap action. Switches shall be rated for 120% of the maximum continuous load. ‘ON’ & ‘OFF’ position of the switch shall be clearly indicated.

2.10.00

Control and Selector Switches Control and selector switches shall be of rotary stayput type with escutcheon plates showing the functions and positions. The switches shall be of sturdy construction and suitable for mounting on panel front. Switches with shrouding of live parts and




PAGE 16 OF 23


CLAUSE NO

sealing of contacts against dust ingress shall be preferred. The contact ratings shall be atleast the following :

2.11.00

i)

Make and carry continuously – 10 Amps.

ii)

Breaking current at 220 V DC – 0.5 Amp. (inductive)

iii)

Breaking current at 240 V AC – 5 Amp. At 0.3 p.f.

Fuses Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers which are mounted on fuse bases. Wherever it is not possible to mount fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In such cases one insulated fuse pulling handle shall be supplied for each charger. Kick-off fuses (trip fuses) with alarm contacts shall be provided for all D.C. fuses.

2.12.00

Indicating Lamps Three (3) indicating lamps shall be provided to indicate A.C. supply availability. The indicating lamp shall be of panel mounting, filament type low wattage or LEDs and capable of clear status indication under the normal room illumination. The lamps shall be provided with series resistors (non-hygroscopic) preferably built in the lamp assembly and replaceable from front. The lamp covers shall be preferably screwed type, unbreakable and moulded from heat resistant material.

2.13.00

Blocking Diode Blocking diode shall be provided in the output circuit of each Charger to prevent current flow from the D.C. Battery into the Charger.

2.14.00

Annunciation System Visual indications through indicating lamps/LEDs or annunciation facia as per EEUA-45D shall be provided in all Chargers for the following: i)

A.C. supply failure

ii)

Rectifier fuse failure

iii)

Surge circuit fuse failure

iv)

Filter fuse failure

v)

Load limiter operated

vi)

Charger trip

vii)

Battery on Boost




PAGE 17 OF 23


CLAUSE NO

Potential free NO contacts of all above conditions shall be provided for following remote alarms in the Employer’s Unit Control Board:

2.15.00

a)

Battery on boost

b)

Charger trouble (this being a group alarm initiated by any of the faults other than ‘Battery on Boost’)

Name Plates and Marking The name plates shall be made of non-rusting metal/3 ply Lamicoid and shall have black back-ground with white engraved letters and secured by screws. These shall be provided near top edge on the front as well as on rear side of Charger. Name plates with full and clear inscriptions shall also be provided on and inside the panels for identification of the various equipments.

3.00.00

CONSTRUCTION

3.01.00

The Chargers shall be indoor, floor mounted, self supporting sheet metal enclosed cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The Charger shall be fabricated using cold rolled sheet steel shall not less than 1.6 mm and shall have folded type of construction. The panel frame shall be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm. Removable undrilled gland plates of at least 3.0 mm sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for cables shall be made of electrolytic copper with tin coat. Cable sizes shall be determined by the Contractor and get approved from the Employer. The Charger shall be tropicalised and vermin proof. Ventilation louvers shall be backed with fine brass wire mesh. All doors and covers shall be fitted with synthetic rubber gaskets. The Chargers shall have hinged double leaf doors provided on front and/or backside for adequate access to the Charger internals. All the Charger cubicle doors shall be properly earthed. The degree of protection of Charger enclosure shall be atleast IP-42.

3.02.00

All indicating instruments, control & selector switches and indicating lamps shall be mounted on the front side of the Charger. Design of panels shall be based on the following dimensions. a)

Overall height

-

Maximum 2350 mm

b)

Operating handles (highest and lowest positions reached by operator’s hands), protective mechanical indicators

-

Maximum 1800 mm Minimum 350 mm

c)

Doors and panel handles and locks

-

Maximum 1800 mm Minimum 300 mm




PAGE 18 OF 23


CLAUSE NO

3.03.00

Electronic equipments shall be of modular design consisting of plug in modules in standard 19 inches metallic racks with metallic card guides. The cards should be provided with proper handles. Card to card wiring should be preferably through a mother board. Unplanned jumpering and track modifications are not permitted. Mechanical interlocks to prevent wrong insertion of cards should be provided. Each card shall have its junction and test points identified. Maintenance aids such as extension printed wiring boards and jumper leads shall be provided.

3.04.00

The layout of Charger components shall be such that their heat losses do not give rise to excessive temperature within the Charger panel surface. Location of the electronic modules will be such that temperature rise of the location, in no case, will exceed 10°C over ambient air temperature outside the Charger.

3.05.00

Each Charger panel shall be provided with an illuminating lamp and one 5 Amp. Socket. Switches and fuses shall be provided separately for each of the above.

3.06.00

Locking facilities shall be provided as following: a)

For locking Trickle/Boost selector switch in the trickle position only. This would be used for having key mechanical interlock between Trickle/Boost selector switch and isolator in D.C. distribution board.

b)

The Charger enclosure door locking requirements shall be met by the application of padlocks. Padlocking arrangement shall allow ready insertion of the padlock shackle but shall not permit excessive movement of the locked parts with the padlock in position.

3.07.00

Wiring

3.07.01

Each Charger shall be furnished completely wired upto power cable lugs and terminal blocks ready for external connection. The power wiring shall be carried out with 1.1 KV grade PVC insulated cables conforming to IS:1554 (Part-I). The control wiring shall be of 1.1KV grade PVC insulated stranded copper conductors of 2.5 sq.mm. conforming to IS:694. Control wiring terminating at electronic cards shall not be less than 1.0 sq. mm. Control terminal shall be suitable for connecting two wires with 2.5 sq.mm. stranded copper conductors. All terminals shall be numbered for ease of connections and identification. At least 20% spare terminals shall be provided for circuits.

3.07.02

Power and control wiring within panels shall be kept separate. Any terminal or metal work which remains alive at greater than 415 V, when panel door is opened, shall be fully protected by shrouding.

3.07.03

An air clearance of at least ten (10) mm shall be maintained throughout all circuits, except low voltage electronic circuits, right upto the terminal lugs. Whenever this clearance is not available, the live parts should be insulated or shrouded.




PAGE 19 OF 23


CLAUSE NO

3.08.00

Painting Treatment as per IS:6005. Two coats of lead oxide primer followed by powder painting with final shade of RAL 9002.

4.00.00

TESTS

4.01.00

The type and routine test shall be carried out on Battery Chargers as per relevant latest Indian Standards. The Employer reserves the right to witness any or all the tests.

4.02.00

Type Tests Following type tests shall be carried out on each rating and type of Battery Charger: a)

Complete physical examination.

b)

i)

Temperature rise test at full load.

ii)

Temperature rise test of rectifier assembly at 200% of full load.

c)

Insulation resistance test.

d)

High voltage (power frequency) test on power and control circuits except low voltage electronic circuits.

e)

Ripple content test at

f)

i)

No load

ii)

Half load

iii)

Full load

Automatic voltage regulator operation test at specified A.C. supply variations at i)

No load

ii)

Half load

iii)

Full load

g)

Load limiter operation test

h)

Efficiency and power factor measurement.




PAGE 20 OF 23


CLAUSE NO

i)

Input and output surge withstand capability test. Surge Voltage as per ANSIC37.90a shall be applied for period not less than 2 sec. At the following points of the Charger operating at 40 deg. C at full load : i)

Across each A.C. input phase

ii)

Across AC input line to ground.

iii)

Across D.C. output terminals.

iv)

Across each D.C. output terminal to ground

The Charger shall not exhibit any component damage and there shall be no change in performance as per clause 4.02.00 (f) and (g). j)

Environmental Tests Steady state performance tests (clause 4.02.00 (f) and (g) ) shall be carried out before and after each of the following tests. i)

Soak Test The electronic modules shall be subjected to continuous operation for a minimum period of 72 hours. During last 48 hours, the ambient temperature shall be maintained at 50 deg. C. The 48 hour test period shall be divided into four equal 12 hour segments. The input voltage during each 12 hours shall be nominal voltage for 11 hours followed by 110% of nominal voltage for 30 minutes, followed by 90% of nominal voltage for 30 minutes.

ii) 4.03.00

Degree of protection test.

Routine Tests Following routine tests shall be carried out on all Rectifier transformers.

4.04.00

a)


b)


c)

High voltage (power frequency) test.

Following routine tests shall be carried out on all Battery Chargers: a)


b)


c)





PAGE 21 OF 23


CLAUSE NO

d)

High voltage (power frequency) test.

e)

Ripple content test at

f)

i)

No load

ii)

Half load

iii)

Full load

Automatic voltage regulator operation test at specified A.C. supply variations at i)

No load

ii)

Half load

iii)

Full load

g)

Load limiter operation test

h)

Checking of proper operation of annunciation system.

i)

Dynamic response test Overshoot/Undershoot in out put voltage of the charger as a result of sudden change in load from 100% to 20 % and 20% to 100% shall be measured.

4.05.00

j)

Burn in Test - shall be carried out on all electrical modules as panels with module as routine test. During the test panel/ module shall be subjected to temperature of 50 deg. C for 48 hours in energised condition. The temperature rise inside the cubicle shall not exceed 10 deg. during the temperature rise test.

k)

Degree of protection test - the charger shall be checked for gasketing arrangement as per drawing.

Following routine tests shall be carried out on annunciation system a)

Annunciation Assembly & module shall be functionally tested as per EEUA45D.

b)

Burn in test shall be carried out as per Cl. 4.04.00 (j). The Contractor shall furnish for inspection, the type and routine tests certificates for the following components whenever required by the Employer. Makes of these components (not restricted to) shall be subject to Employer’s approval.




PAGE 22 OF 23


CLAUSE NO

4.06.00

i)

Relays

ii)

Instruments

iii)

SCR

iv)

Diodes

v)

Chokes and transformer.

vi)

Annunciator.

Commissioning The contractor shall carryout the following commissioning tests and checks after installation of the equipment at site: a)


b)

Checking of proper operation of annunciation system.

c)


d)


e)

Automatic voltage regulator operation.

f)

Load limiter operation.

g)

Dynamic response test.

Overshoot/Undershoot in output voltage of the Charger as a result of sudden change in load from 100% to 20% and 20% to 100% shall be measured with the Batteries connected/disconnected. Output voltage of the Charger connected with Battery shall be within 94% to 106% of the voltage setting in above conditions and shall return to, and remain, within the limits specified in clause 2.01.00 (e) or 2.02.00 (e) in less than 2 seconds (as applicable).




PAGE 23 OF 23

PART-B SUB-SECTION-E12 REQUIREMENTS OF AUXILIARY ITEMS (AIS)



CLAUSE NO.

REQUIREMENTS OF AUXILIARY ITEMS (E12) 1.00.00

ACSR CONDUCTOR (a)

Code and standard

IS 398

(b)

Name

MOOSE ACSR

(c)

Overall diameter

31.77 mm

(d)

Weight

2004 kg/km

(e)

Ultimate tensile strength

161.2 KN minimum

(f)

Strands and wire diameter of -

Aluminium

54 / 3.53 mm

-

Steel

7 / 3.53 mm

2.00.00

CLAMPS AND CONNECTORS

2.01.00

The material of clamps and connectors shall be Aluminium alloy casting conforming to designation A6 of IS:617 for connecting to equipment terminals and conductors of aluminium. In case the terminals are of copper, the same clamps/connectors shall be used with 2mm thick bimetallic liner.

2.02.00

The material of clamps and connectors shall be Galvanised mild steel for connecting to shield wire.

2.03.00

Bolts, nuts and plain washers shall be hot dip galvanised mild steel for sizes M12 and above. For sizes below M12, they shall be electro-galvanised mild steel. The spring washers shall be electro-galvanised mild steel.

2.04.00

All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be rounded off to meet specified corona and radio interference requirements.

2.05.00

They shall have same current rating as that of the connected equipment. All current carrying parts shall be at least 10 mm thick. The connectors shall be manufactured to have minimum contact resistance.

2.06.00

Flexible connectors, copper/aluminium.

2.07.00

Current rating and size of terminal/conductor for which connector is suitable shall be embossed/punched on each component.


braids

or

laminated


strips

shall

be


made

up

of

PAGE 1 OF 11

CLAUSE NO.


INSULATOR STRING HARDWARE

3.01.00

The insulator hardware shall be of bolted type and shall be of forged steel except for insulator cap, which can be of malleable cast iron. It shall also generally meet the requirements of clamps and connectors as specified above.

3.02.00

In one span, Tension string assembly at one end shall be supplied with suitable turn buckle.

3.03.00

Disc Insulator The disc insulator shall meet the following parameters:

3.04.00

4.00.00

A

Type

Antifog type insulator

b.

Size of insulator

255x145

c.

Electro mechanical strength

120KN

d.

Leakage distance (mm)

430mm minimum or as required to meet the total creepage.

e.

Power frequency withstand voltage 85 KV (dry), 50KV (wet)

Insulator Strings Assembly 1.

No of disc

25

2.

Electro magnetic strength

120KN/string

3.

Creepage distance

10500 mm

4.

Power frequency withstand voltage

680 KV rms

5.

Lightning Impulse withstand voltage

1550 KV rms

6.

Switching impulse withstand voltage

1175 KV rms

SPACERS

4.01.00

Spacers shall conform to IS:10162. They shall be of non-magnetic material except nuts and bolts, which shall be of hot dip galvanised mild steel.

4.02.00

Spacers shall generally meet the requirements of clamps and connectors as specified above. Its design shall take care of fixing and removing during installation and maintenance.

4.03.00

In addition to the type tests as per IS:10162, clamp slip test should have been conducted. In this test the sample shall be installed on test span of twin/quad bundle string at a tension of 44.2 KN (4500 kg). One of the clamps when subjected to a




PAGE 2 OF 11

CLAUSE NO.

REQUIREMENTS OF AUXILIARY ITEMS (E12) longitudinal pull of 2.5 KN (250 kg) parallel to the axis of conductor shall not slip, i.e. permanent displacement between conductor and clamp after the test shall not exceed 1.0 mm. This test should have been performed on all other clamps of the sample. 5.00.00

EARTHING CONDUCTOR

5.01.00

The main conductor buried in earth shall be 40mm dia rod for main and auxiliary mat. The earthing conductors over the ground shall be of 75x12 mm GS flat. The earthing leads for columns, auxiliary structures and cable trenches shall be of 75x12 mm GS flat. The earthing of the lighting fixtures shall be carried out by 16 SWG wire.

5.02.00

All conductors above the ground level shall be of galvanised steel.

6.00.00

EARTHWIRE FOR LIGHTNING PROTECTION (a)

Number of strands

7 of steel

(b)

Strand diameter

3.66 mm

(c)

Overall diameter

10.98 mm

(d)

Weight

583 kg/km approx.

(e)


68.4 KN minimum

(f)

Total cross-sectional area

73.65 sq.mm.

(g)

Calculated d.c. resistance

2.5 ohms/km at 20 deg.C.

(h)

Direction of lay of outer layer

Right hand

(i)

Protective coating for storage

Boiled linseed oil to avoid wet storage stains (white rust)

7.00.00

CABLE SUPPORTS AND CABLE TRAY MOUNTING ARRANGEMENTS

7.01.00

Cable Support Structures & Accessories a.

Cable trenches are normally provided with embedded steel inserts on concrete floors/walls. The Contractor shall secure supports by welding to these inserts or available building steel structures.

b.

The cable supports shall conform to the requirements indicated elsewhere in the specification.

c.

Insert plates will be provided at an interval of 600 mm wherever cables are to be supported without the use of cable trays, while at all other places these will be at an interval of 2000mm.




PAGE 3 OF 11

CLAUSE NO.

REQUIREMENTS OF AUXILIARY ITEMS (E12)

d.

The cabling in the switchyard shall be carried out through RCC trenches with covers. The cable shall be supported on GI angles bolted to the insert plates in RCC trenches. The RCC trenches shall be provided for the main runs which would cater to one bay on either side. The spacing of the angle support shall be 600 mm. The power and control cables shall be supported on separate tiers. The cabling between the main trench and the equipments shall be carried out through GI pipes with 40% fill criteria. The interpole cabling shall also be carried out through GI pipes of suitable sizes.

7.01.02

Cable trays and supports shall be painted after installation. The painting shall be in conformity with stipulated in Part-C. All welding works inclusive of the consumables required for fabrication and installation shall be in the scope of the Contractor.

7.02.00

Cable Trays

7.02.01

Hot dip galvanised ladder type cable trays of adequate width are to be provided for cables.

7.02.02

Aux. power cables are to be laid on the top tray and AC and DC control cables at bottom trays. Cable trays shall be designed to carry cables load without bending and proper tray supports shall be provided at every 1 m interval.

7.02.03

Cable trays having power and control cable are spaced at 300 mm and between control cable trays, the spacing is 225 mm. For tray lengths more than 2.5 m coupler plates are to be used for joining the two standard tray lengths. All accessories for cable trays and supports including hardware etc. are included under the scope of this contract.

7.02.04

Cable trays shall be made of 2 mm thick sheet steel having a slotted rung spacing of 250 mm. Height of cable tray channel shall be 75 mm and the standard length of trays shall be 2.5 m.

7.02.05

All nuts, bolts, washers etc. to be supplied by the Contractor shall be hot dip galvanised after fabrication.

7.02.06

The Contractor shall perform all tests and inspection to ensure that material and workmanship are according to the relevant standards.

8.00.00

BUSHINGS, HOLLOW COLUMN INSULATORS, SUPPORT INSULATORS, AND DISC INSULATORS

8.01.00

Bushings shall be manufactured and tested in accordance with IS:2099 & IEC:137 while hollow column insulators shall be manufactured and tested in accordance with IEC 233/IS 5284. The support insulators shall be manufactured and tested as per IS:2544 / IEC 168/IEC 273. The insulators shall also conform to IEC 815 as applicable.




PAGE 4 OF 11

CLAUSE NO.


Support insulators/ bushings/ hollow column insulators shall be designed to have ample insulation, mechanical strength and rigidity for the conditions under which they will be used.

8.03.00

Porcelain used shall be homogenous, free from laminations, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. Hollow porcelain should be in one integral piece in green & fired stage.

8.04.00

Glazing of the porcelain shall be uniform brown in colour, free form blisters, burns and other similar defects.

8.05.00

When operating at normal rated voltage there shall be no electric discharge between conductor and insulators which would cause corrosion or injury to conductors or when operating at normal rated voltage.

8.06.00

The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall be lead to deterioration. All ferrous parts shall be hot dip galvanised.

8.07.00

Contractor shall make available data on all the essential features of design including the method of assembly of shells and metal parts, number of shells per insulator, the manner in which mechanical stresses are transmitted through shells to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions.

8.08.00

Post type insulators shall consist of a porcelain part permanently secured in metal base to be mounted on supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand all shocks to which they may be subjected to during operation of the associated equipment.

8.09.00

Bushing porcelain shall be robust and capable of withstanding the internal pressures likely to occur in service. The design and location of clamps, the shape and the strength of the porcelain flange securing the bushing to the tank shall be such that there is no risk of fracture. All portions of the assembled porcelain enclosures and supports other than gaskets, which may in any way be exposed to the atmosphere shall be composed of completely non hygroscopic material such as metal or glazed porcelain.

8.10.00

All iron parts shall be hot dip galvanised and all joints shall be air tight. Surface of joints shall be trued, porcelain parts by grinding and metal parts by machining. Insulator/ bushing design shall be such as to ensure a uniform compressive pressure on the joints.

8.11.00

In accordance with the requirements stipulated under Part-A, bushings, hollow column insulators and support insulators shall conform to type tests and shall be subjected to routine tests and acceptance test/ sample test in accordance with relevant standards.




PAGE 5 OF 11

CLAUSE NO.


The parameters of bushings/ Hollow column insulators/ support insulators shall conform to the parameters given in section E0. Insulator shall also meet requirement of IEC - 815 as applicable, having alternate long & short sheds.

9.00.00

CABINETS, BOXES, KIOSKS, PANELS, ETC.

9.01.00

All types of control cabinets, junction boxes, marshalling boxes, lighting panels, terminal boxes, operating mechanism boxes, etc. shall generally conform to IS:5039, IS:8623 and IEC:439 as applicable.

9.02.00

They shall be of painted sheet steel or aluminium. The thickness of sheet steel shall be 2mm cold rolled or 2.5mm hot rolled. The thickness of aluminium shall be 3mm and shall provide rigidity. Top of the boxes shall be sloped towards rear of the box. The paint shall be of grey RAL 9002 on the outside and glossy white inside. However, the junction and switch boxes shall be of hot dip galvanised sheet steel of 1.6mm thickness.

9.03.00

The cabinets/boxes/kiosks/panels shall be free standing or wall mounting or pedestal mounting type. They shall have hinged doors with padlocking arrangement. All doors, removable covers and plates shall be gasketed all around with neoprene gaskets.

9.04.00

The degree of protection of of all the outdoor boxes shall not be less than IP 55 as per IS 2147.

9.05.00

The cable entry shall be from bottom, for which removable gasketed cable gland plates shall be provided.

9.06.00

Suitable 240V, single phase, 50Hz AC heaters with thermostats controlled by switch and fuse shall be provided to maintain inside temperature 10deg. above the ambient.

9.07.00

The size of enclosure and the layout of equipment inside shall provide generous clearances. Each cabinet/box/kiosk/panel shall be provided with a 15A, 240V AC, 2 pole, 3 pin industrial grade receptacle with switch. For incoming supply, MCB of suitable rating shall be provided. Illumination of each compartment shall be with door operated incandescent lamp. All control switches shall be of rotary switch type.

9.08.00

Each cabinet/box/kiosk/panel shall be provided with two earthing pads to receive 75mmx12mm GS flat. The connection shall be bolted type with two bolts per pad. The hinged door shall be connected to body using flexible wire. The cabinets/boxes/kiosks/panels shall also be provided with danger plate, and internal wiring diagram pasted on inside of the door. The front label shall be on a 3mm thick plastic plate with white letters engraved on black background.

10.00.00

BAY MARSHALLING BOX

10.01.00

Each bay of the switchyard shall be provided with a Bay Marshaling Box located at a convenient location to receive and distribute cables within the bay. It shall meet all the requirements as specified for cabinets/boxes above.




PAGE 6 OF 11

CLAUSE NO.


It shall have three separate distinct compartments for following purposes: -

To receive two incoming 415V, three phase, AC supplies controlled by 100A four pole MCBs with auto changeover provision, and to distribute five (5) three phase ac supplies controlled by 32A four pole MCBs. It shall also be provided with 63A, 3 phase 4 pin industrial grade receptacle with rotary switch.

-

To receive three phase incoming from first compartment and to distribute ten (10) single phase ac supplies controlled by 16A two pole MCBs.

-

120 nos. terminal blocks in vertical formation for interlocking facility.

11.00.00

TERMINAL BLOCKS

11.01.00

They shall be non-disconnecting stud type of extensible design equivalent to Elmex type CAT-M4.

11.02.00

The terminal blocks shall be of 1100V grade, and rated to continuously carry maximum expected current. The conducting part shall be tinned or silver plated.

11.03.00

They shall be of moulded, non-inflammable thermosetting plastic. The material shall not deteriorate with varied conditions of temperature and humidity. The terminal blocks shall be fully enclosed with removable covers of transparent, nondeteriorating plastic material. Insulating barriers shall be provided between the terminal blocks so that the barriers do not hinder the wiring operation without removing the barriers.

11.04.00

The terminals shall be provided with marking tags for wiring identification.

11.05.00

Unless otherwise required (expected current rating) or specified, terminal blocks shall be suitable for connecting the following conductors on each side: All CT & VT circuits

-

Min. four 2.5 sq.mm. copper flexible conductor

AC & DC power supply Circuits

-

Two 16 sq.mm. aluminium conductor

Other control circuits

-

Min. two 2.5 sq.mm. copper flexible conductor

11.06.00

The terminal blocks for CT and VT secondary leads shall be provided with test links and isolating facilities. CT secondary leads shall also be provided with short circuiting and earthing facilities.

12.00.00

WIRING

12.01.00

All wiring shall be carried out with 1100 V grade stranded copper wires. The minimum size of the stranded conductor used for internal wiring shall be as follows : (a)

All circuits except CT circuits 2.5 sq.mm

(b)

CT circuits 4 sq. mm (minimum number of strands shall be 3 per conductor).




PAGE 7 OF 11

CLAUSE NO.


All internal wiring shall be securely supported, neatly arranged readily accessible and connected to equipment terminals and terminal blocks.

12.03.00

Wire terminations shall be made with solderless crimping type of tinned copper lugs which firmly grip the conductor and insulation. Insulated sleeves shall be provided at all the wire terminations. Engraved core identification plastic ferrules marked to correspond with the wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wires shall not fall off when the wires is disconnected from terminal blocks.

12.04.00

All wires directly connected to trip circuit breaker shall be distinguished by the addition of a red coloured unlettered ferrule. Number 6 & 9 shall not be included for ferrules purposes.

12.05.00

All terminals including spare terminals of auxiliary equipment shall be wired upto terminal blocks. Each equipment shall have its own central control cabinet in which all contacts including spare contacts from all poles shall be wired out. Interpole cabling for all equipment’s shall be carried out by the Contractor.

13.00.00

CABLE GLANDS AND LUGS

13.01.00

Cable glands shall be Double compression type, tinned/Nickel plated (coating thickness not less than 20 microns in case of tin and 10 to 15 microns in case of nickel) brass cable glands for all power and control cables. They shall provide dust and weather proof terminations. They shall comprise of heavy duty brass casting, machine finished and tinned to avoid corrosion and oxidation. Rubber components used in cable glands shall be neoprene and of tested quality. Required number of packing glands to close unused openings in gland plates shall also be provided.

13.02.00

The cable glands shall be tested as per BS:6121. The cable glands shall also be duly tested for dust proof and weather proof termination.

13.03.00

Cables lugs shall be tinned copper solder less crimping type conforming to IS:8309 and 8394 suitable for aluminum or copper conductor (as applicable). The cable lugs shall suit the type of terminals provided. The cable lugs shall be of Dowell make or equivalent.

14.00.00

CONDUITS, PIPES AND ACCESSORIES

14.01.00

The Contractor shall supply and install all rigid conduits, mild steel pipes, flexible conduits, hume pipes, etc. including all necessary sundry materials, such as tees, elbows, check nuts, bushing reduces, enlargers, wooden plugs, coupling caps, nipples, gland sealing fittings, pull boxes, etc.

14.02.00

Rigid conduits shall be heavy duty type, hot dip galvanized conforming to IS:9537 Part-I & II and shall be suitable for heavy mechanical stresses, threaded on both sides and threaded length shall be protected by zinc rich paint. All rigid conduits/ pipes shall be of reputed make.




PAGE 8 OF 11

CLAUSE NO.


Flexible conduits shall be heat-resistant lead coated steel, water-leak, fire and rust proof and shall be of reputed make.

15.00.00

MOTOR CONTROL CENTRE

15.01.00

The 415 Volt motor control centres (if provided separately) shall conform to the requirements for boxes/cabinets/kiosks. They shall be fixed type, shall be fully sectionalised and shall be equipped with load break switches. Motor feeders shall be provided with isolating switch fuse unit and Contractor with thermal overload relay and single phase protection. The motor Contractor shall have one normally open auxiliary contact for alarm purposes. The motor control circuit shall be independent from all other control circuits.

15.02.00

Isolating Switches The incoming power supply isolating switch operation handle shall be interlocked with the control cabinet door as to prevent opening of door when main switch is closed. Device for by passing the door interlock shall also be provided. Switch handle shall have provision for locking in both fully open and fully closed positions.

15.03.00

Fuses All fuses shall be of the HRC cartridge type, conforming to IS:2208 and suitable to mount on plugin type of fuse bases. Fuses shall be provided with visible operation indicators to show that they have operated. All accessible live connections shall be adequately shrouded, and it shall be possible to change fuses with the circuit alive, without danger of contact with live conductor. Insulated fuse pulling handle shall be supplied with each control cabinet.

16.00.00

MOTORS

16.01.00

Motors shall be “Squirrel Cage” three phase induction motors of sufficient size capable of satisfactory operation for the application and duty as required for the driven equipment and shall conform to type tests and shall be subjected to routine tests as per applicable standards.

16.02.00

Enclosures (a)

For motors to be installed outdoor, the motor enclosure shall have degree of protection IP:55. For motors to be installed indoor, i.e. inside a box, the motor enclosure shall be dust proof equivalent to IP:44.

(b)

Two independent earthing points shall be provided on opposite sides of the motor for bolted connection of earthing conductor.

(c)

Motors shall have drain plugs so located that they will drain water resulting condensation or other causes from all pockets in the motor casing.

(d)

Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means or facility for lifting.




PAGE 9 OF 11

CLAUSE NO.


16.04.00

Operational Features : (a)

Continuous motor ratings (name plate rating) shall be at least suitable for the driven equipment at design duty operating point of driven equipment that will arise in service.

(b)

Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously in the given system.

Starting Requirements (a)

All induction motors shall be suitable for full voltage direct on-line starting. These shall be capable of starting and accelerating to the rated speed alongwith the driven equipment without exceeding the acceptable winding temperature even when the supply voltage drops.

(b)

Motors shall be capable of withstanding the electrodynamic stresses and heating imposed if it is started at a voltage of 110% of the rated value.

(c)

The locked rotor current shall not exceed six(6) times the rated full load current for all motors subject to tolerance given in IS:325.

(d)

Motors when started with driven equipment imposing full staring torque and supply voltage conditions specified shall be capable of withstanding at least two successive starts from cold condition at room temperature and one start from hot condition without injurious heating of winding. The motors shall also be suitable for three equally spread starts per hour under the above referred supply condition.

(e)

The locked rotor withstand time under hot condition at 110% of rated voltage shall be more than starting time with the driven equipment of minimum permissible voltage by a least two seconds or 15% of the accelerating time whichever is greater. In case it is not possible to meet the above requirement, the Contractor shall offer centrifugal type speed switch mounted on the motor shaft which shall remain closed for speeds lower than 20% and open for speeds above 20% of the rated. The speed switch shall be capable of withstanding 120% of the rated speed in either directions of rotation.

16.05.00

The maximum permissible temperature rise over the ambient temperature shall be within the limits specified in IS:325 (for 3 phase induction motors) after adjustment due to increased ambient temperature specified.

16.06.00

The double amplitude of motor vibration shall be within the limits specified in IS:729. Vibration shall also be within the limits specified by the relevant standard for the driven equipment when measured at the motor bearings.

16.07.00

All the induction motors shall be capable of running at 80% of rated voltage for a period of 5 minutes.




PAGE 10 OF 11

CLAUSE NO.


AUXILIARY SWITCH The auxiliary switch shall conform of following type tests:

18.00.00

(a)

Electrical endurance test - A minimum of 1000 operations for 2A. D.C. with a time constant greater than or equal to 20 milliseconds with a subsequent examination of mV drop/ visual defects/ temperature rise test.

(b)

Mechanical endurance test - A minimum of 5000 operations with a subsequent checking of contact pressure test/ visual examination

(c)

Heat run test on contacts

(d)

IR/HV test, etc.

TYPE TESTS All equipment with their terminal connectors, control cabinets, main protective relays, etc. as well as insulators, insulator strings with hardwares, clamps and connectors, marshalling boxes, etc., shall conform to type tests and shall be subjected to routine and acceptance tests in accordance with the requirements stipulated under respective equipment sections.




PAGE 11 OF 11

PART-B SUB-SECTION-E13 INSTALLATION (COMMON)



CLAUSE NO.

INSTALLATION (E13) 1.00.00

EARTHING The earthing shall be done in accordance with requirements given in Annexure-I of this section and drawing enclosed with the specifications. Earthing of panels shall be done in line with the requirements given in respective equipment section of this specification.

2.00.00

CIVIL WORKS The civil works shall be done in accordance with requirements stipulated under Part-B, Section C-0 of this specification.

3.00.00

STRUCTURAL STEEL WORKS The structural steel works shall be done in accordance with requirements stipulated under Part-B, Section-C-0 of this specification.

4.00.00

BAY EQUIPMENT

4.01.00

The disposition of equipment to be supplied are shown in enclosed single line diagrams and layout drawings.

4.02.00

The Contractor shall prepare layout drawings and submit the same for approval of the Employer. The approval of drawing shall not absolve Contractor from his responsibility regarding designing & engineering of switchyard and Contractor shall be fully responsible for all works covered in the scope of this specification.

5.00.00

LIGHTNING PROTECTION

5.01.00

Direct stroke lightning protection (DSLP) shall be provided in the switchyard by shield wires.

5.02.00

Lightning protection System down conductors shall not be connected to other conductors above ground level. Also no intermediate earthing connection shall be made to Surge arrester and Voltage Transformer, earthing leads for which shall be directly connected to rod electrode.

5.03.00

Every down conductor shall be provided with a test joint at about 150mm above ground level. The test joint shall be directly connected to the earthing system.

5.04.00

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

6.00.00

EQUIPMENT ERECTION NOTES (a)

All support insulators, circuit breaker interrupters and other fragile equipment shall be handled with cranes with suitable booms and handling capacity.

(b)

Where, assemblies are supplied in more than one section, Contractor shall make all necessary mechanical and electrical connections between sections




PAGE 1 OF 15

CLAUSE NO.

INSTALLATION (E13) including the connection between buses. Contractor shall also do necessary adjustments/alignments necessary for proper operation of circuit breakers, isolators and their operating mechanisms. All components shall be protected against damage during unloading, transportation, storage, installation, testing and commissioning. Any equipment damaged due to negligence or carelessness or otherwise shall be replaced by the Contractor at his own expense. The contractor shall strictly follow manufacturer’s recommendations for handling and erection of equipment.

7.00.00

(c)

The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing, scratching by sling ropes etc. Handling equipment, sling ropes etc. should be tested before erection and periodically thereafter for strength.

(d)

Bending of piping should be done by a bending machine and through cold bending only. Bending shall be such that inner diameter of pipe is not reduced. The pipes shall be thoroughly cleaned before installation.

(e)

Cutting of the pipes wherever required shall be such as to avoid flaring of the ends. Hence only a proper pipe cutting tool shall be used. Hack saw shall not be used.

(f)

For cleaning the inside and outside of hollow insulators only Muslin or leather cloth shall be used.

STORAGE OF EQUIPMENT Contractor is responsible for the proper storage and maintenance of all materials/equipment entrusted to him. The Contractor shall provide & construct adequate storage shed for proper storage of equipment. Sensitive equipment shall be stored indoors. All equipment during storage shall be protected against damage due to acts of nature or accidents. Contractor shall take all required steps to carryout subsequent inspection of materials/equipment stored as well as erected until the same is taken over by the Employer. The storage instructions of the equipment manufacturers/Engineer-in-Charge shall be strictly adhered to.

8.00.00

JUNCTION BOXES Contractor shall supply and install junction boxes complete with terminals as required. The brackets, bolts, nuts and screws required for the erection are included in the scope of Contractor. The junction boxes shall conform to the requirements of Section E-12.

9.00.00

CABLE TAGS AND MARKERS

9.01.00

Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedule.

9.02.00

The tag shall be of aluminium with the number punched on it and securely attached to the cable conduit by not less than two turns of 20 SWG GI wire conforming to IS:




PAGE 2 OF 15

CLAUSE NO.

INSTALLATION (E13) 280. Cable tags shall be of rectangular shape for power cables and of circular shape for control cables. 9.03.00

Location of cables laid directly underground shall be clearly indicated with cable marker made of galvanised iron plate.

9.04.00

Location of underground cable joints shall be indicated with cable marker with an additional inscription “Cable joint”.

9.05.00

The marker shall project 150mm above ground and shall be spaced at an interval 30 meters and at every change in direction. They shall be located on both sides of road and drain crossings.

9.06.00

Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry. Cable tags shall be provided inside the switchgear, motor control centres, control and relay panels etc., wherever required for cable identification, such as where a number of cables enter together through a gland plate.

9.07.00

The cable tags and markers are included in the scope of the Contractor.

9.08.00

Specific requirements for cabling, wiring ferrules as covered in respective equipment section shall also be complied with.

10.00.00

STORAGE AND HANDLING OF CABLE DRUMS Cable drums shall be unloaded, handled and stored in an approved manner and rolling of drums shall be avoided as far as practicable. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In absence of any indication the drums may be rolled in the same direction it was rolled during taking up the cables.

11.00.00

CABLE TERMINATIONS AND CONNECTIONS

11.01.00

The termination and connection of cables shall be done strictly in accordance with cable and termination kit manufacturer’s instructions, drawing and/or as directed by the Employer.

11.02.00

The work shall include all clamping, fittings, fixing, plumbing, soldering, drilling, cutting, taping, heat shrinking(where applicable), connecting to cable terminal, shorting and grounding as required to complete the job.

11.03.00

All consumable materials are included in the scope of the Contractor.

11.04.00

The equipment will be generally provided with undrilled gland plates for cables/conduit entry. The Contractor shall be responsible for drilling of gland plates, painting and touching up. Holes shall not be made by gas cutting.

11.05.00

The contractor shall tag/ferrule the control cable cores at all terminations, as instructed by the Employer. In panels where a large number of cables are to be




PAGE 3 OF 15

CLAUSE NO.

INSTALLATION (E13) terminated and cable identification may be difficult, each core ferrule may include the complete cable number as well. 11.06.00

Spare cores shall be similarly tagged with cable numbers and coiled up.

11.07.00

Control cables shall have stranded copper conductor. Bare portion of the solid conductors shall be tinned after removing the insulation and shall be terminated directly without using cable lugs.

11.08.00

All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively closed.

11.09.00

If the cable end box or terminal enclosure provided on the equipment is found unsuitable and requires modification, the same shall be carried out by the Contractor as directed by the Employer.

11.10.00

Directly Buried Cables

11.10.01

The Contractor shall construct the cable trenches required for directly buried cables. The scope of work for construction of cable trenches for cables shall include excavation, preparation of sand bedding, soil cover, supply and installation of brick or concrete protective covers, back filling and reaming, supply and installation of route markers and joint markers.

11.10.02

Laying the cable and providing protective covering shall be as per approved drawing.

11.11.00

Installation of Cables

11.11.01

Power and control cables shall be laid in separate trays/tiers. The order of laying of various cables shall be as follows, for cables other than directly buried: (a)

Power cables on top trays/tiers.

(b)

Control, instrumentation and other service cables in bottom trays/tiers.

11.11.02

Single core cables in trefoil formation shall be laid with a distance of three times the diameter of cable between trefoil centre lines. All power cables shall be laid with a minimum centre to centre distance equal to twice the diameter of the cable.

11.11.03

Power and control cables shall be securely fixed to the trays/supports. Trefoil clamps for single core cables shall be pressure die-cast aluminium (LM-6), Nylon-6 or fibre glass and shall include necessary fixing GI nuts, bolts, washer, etc. These are required at every 2 metre of cable runs. Vertical and inclined cable runs shall be secured with 25mm wide and 2mm thick aluminium strip clamps at every 2m. Horizontal runs in cable trays and trenches shall be secured using 4mm nylon cord at every 2m.

11.11.04

Cables shall not be bent below the minimum permissible limit. The permissible limits are as follows :




PAGE 4 OF 15

CLAUSE NO.

INSTALLATION (E13)

(a)

Type of cable & voltage grade

Minimum bending radius

(b)

Power cable

12 D

(c)

Control cables

10 D

Where D is overall diameter of cable. 11.11.05

Where cables cross roads, drains and rail tracks, the cables shall be laid in reinforced spun concrete or steel pipes, burried at not less than one metre depth.

11.11.06

In each cable run some extra length shall be kept at a suitable point to enable one (for LT Cables ) or two (for H.T cables) straight through joints to be made, should the cable develop fault at a later date.

11.11.07

Selection of cable drums for each run shall be so planned as to avoid using straight through joints. In case joints are necessary the same shall be supplied by the Contractor. Cable splices will not be permitted except where called for by the drawings, unavoidable or where permitted by the Employer.

11.11.08

Control cable terminations inside equipment enclosures shall have sufficient lengths so that switching of termination in terminal blocks can be done without requiring any splicing.

11.11.09

Metal screen and armour of the cable shall be bonded to the earthing system of the station, wherever required.

11.11.10

Rollers shall be used at intervals of about 2.0 metres, while pulling cables.

11.11.11

All due care shall be taken during unreeling, laying and termination of cable to avoid damage due to twist, kink, sharp bends etc.

11.11.12

Cable ends shall be kept sealed to prevent damage.

11.11.13

Inspection on receipt, unloading and handling of cables shall generally be in accordance with IS: 1255 and other Indian Standard Codes of practices.

11.11.14

Wherever cables pass through floor or through wall openings or other partitions, wall sleeves with bushes having a smooth curved internal surface so as not to damage the cables, shall be supplied, installed and properly sealed by the Contractor at no extra charges.

11.11.15

The erection work shall be carried out in a neat workmanlike manner and the areas of work shall be cleaned of all scrap materials, etc. after the completion of work in each area every day. Contractor shall remove the RCC/steel bench covers before taking up the work and shall replace all the trench covers after the erection work in that particular area is completed or when further work is not likely to be taken up for some time.




PAGE 5 OF 15

CLAUSE NO.


Contractor shall furnish three copies of the report on work carried out in a particular week, such as cable numbers and a date on which laid, actual length and route, testing carried out, alongwith the marked up copy of the cable schedule and interconnection drawing wherever any modifications are made.

11.11.17

Contractor shall paint the tray identification number on each run of trays at an interval of 10m.

11.11.18

In case any part of a cable is damaged, the same shall be replaced by a healthy cable, at no extra cost.

11.11.19

All cable terminations shall be appropriately tightened to ensure secure and reliable connections. The Contractor shall cover the exposed part of all cable lugs whether supplied by him or not with insulating tape, sleeve or paint.

11.12.00

Conduits, Pipes and Duct Installation

11.12.01

Contractor shall supply all conduits, pipes and ducts as specified and to be shown in detailed engineering drawing. Flexible conduit shall be used between junction box and equipment terminal boxes or as per requirement. Where vibration is anticipated, the flexible conduit shall be as per the relevant IS.

11.12.02

Contractor shall have his own facility for bending, cutting and threading the conduits at site. Cold bending should be used. All cuts & threaded ends shall be made smooth without leaving any sharp edges. Anti corrosive paint shall be applied at all field threaded portions. The Contractor shall supply and apply this protective material.

11.12.03

All conduit/pipes shall be extended on both sides of wall/floor/openings. Exposed conduits/pipes shall be adequately clamped at an interval of about 2m. The fabrication and installation of supports and the clamping shall be included in the scope of work by Contractor.

11.12.04

When two lengths of conduits are joined together through a coupling, running threads equal to twice the length of coupling shall be provided on any length to facilitate easy dismantling of two conduits.

11.12.05

Conduit installation shall be permanently connected to earth by means of special approved type of earthing clamps. G.I. Pull wire of adequate size shall be laid in all conduits before installation.

11.12.06

Each conduit run shall be painted with its designation as indicated on the drawings, such that it can be identified at each end.

11.12.07

Embedded conduits shall have a minimum concrete cover of 50mm. Positioning and ensuring proper alignment during concrete by other agencies shall be the responsibility of the Contractor.

11.12.08

Conduit runs sleeves shall be provided with the bushings at each end.




PAGE 6 OF 15

CLAUSE NO.


Metallic conduit runs at termination shall have two locknuts and a bushing for connection. Flexible conduits shall also be suitably clamped at each end. Bushings shall have rounded edges so as not to damage the cables.

11.12.10

Where embedded conduits turn upwards from a slab or fill, the termination dimensions shown on the drawings, if any, shall be taken to represent the position of the straight extension of the conduit external to and immediately following the bend. At least one half the arc length of the bend shall be embedded.

11.12.11

For underground runs, Contractor shall excavate and back fill as necessary.




PAGE 7 OF 15

CLAUSE NO.

INSTALLATION (E13)

ANNEXURE-I Page 1 of 4 EARTHING NOTES 1.00.00

GENERAL

1.01.00

The quantity of Earthing conductor shall be determined by the contractor. Exact location of earthing connections shall be designed to suit the site conditions.

1.02.00

Neutral points of systems of different voltages, metallic enclosures and frame works associated with all current carrying equipments and extraneous metal works associated with electric system shall be connected to a single earthing system unless stipulated otherwise.

1.03.00

Earthing system installation shall be in strict accordance with the latest editions of Indian Electricity Rules, relevant Indian Standards and Codes of practice and Regulations existing in the locality where the system is installed.

1.04.00

Bolts and nuts required for earthing all main equipment structures and for connecting with earthing system as explained above shall be in the scope of the Contractor.

2.00.00

DETAILS OF EARTHING SYSTEM Item

Size

Material

Main Earthing conductor

40mm dia rod

Mild steel rod

Conductor above ground & earthing leads (for equipment)

75 x 12mm or 50 x 6mm

Galvanized steel flat

Rod Electrode

40mm dia, 3000mm long

Mild steel rod

G.I. Earthwire

7/8 SWG

GI

3.00.00

EARTHING CONDUCTOR LAYOUT

3.01.00

Earthing conductors in outdoor areas shall be burried atleast 600mm below finished grade level unless stated otherwise.

3.02.00

Minimum 6000mm spacing between rod electrodes shall be provided unless stipulated otherwise.

3.03.00

Wherever earthing conductors cross cable trenches, underground service ducts, pipes, tunnels, railway tracks etc., it shall be laid atleast 300mm below them and shall be re-routed in case it fouls with equipment/structure foundations.




PAGE 8 OF 15

CLAUSE NO.

INSTALLATION (E13) ANNEXURE-I Page 2 of 4 3.04.00

Tap connections from the earthing grid to the equipment/structure to be earthed, shall be terminated on the earthing terminals of the equipment/structure, if the equipment is available at the time of laying the grid. Otherwise, “earth insert” with temporary wooden cover or “earth riser” shall be provided near the equipment foundation/pedestal for future connections to the equipment earthing terminals.

3.05.00

Earthing conductor along their run on cable trenches, trays, ladders, columns, beams, walls, etc. shall be supported by suitable welding/cleating at intervals of 750mm. Earthing conductors along cable trenches shall be on the wall nearer to the equipment. Wherever it passes through walls, floors etc. galvanized iron sleeves shall be provided for the passage of the conductor. Both ends of the sleeves shall be sealed to prevent the passage of water through the sleeves.

3.06.00

Earthing conductor around the building shall be buried in earth at a minimum distance of 1500mm from the outer boundary of the building. In case high temperature is encountered at some location, the earthing conductor shall be laid minimum 1500mm away from such location.

3.07.00

In outdoor areas, tap connections shall be brought 300mm above ground level for making connections in future, in case equipment is not available at the time of grid installations.

3.08.00

Earthing conductors crossing the road shall be either installed in hume pipes or laid at greater depth to suit the site conditions.

3.09.00

Earthing conductors embedded in the concrete fibre shall have approximately 50mm concrete cover.

4.00.00

EQUIPMENT AND STRUCTURE EARTHING

4.01.00

The connection between earthing pads and the earthing grid shall be made by short and direct earthing leads free from kinks and splices. In case earthing pads are not provided on the item to be earthed, same shall be provided in consultation with engineer.

4.02.00

Metallic pipes, conduits and cable tray sections for cable installation shall be bonded to ensure electrical continuity and connected to earthing conductors at regular interval. Apart from intermediate connections, beginning points shall also be connected to earthing system.

4.03.00

Metallic conduits shall not be used as earth continuity conductor.

4.04.00

A separate earthing conductor shall be provided for earthing lighting fixtures, lighting poles, receptacles, switches, junction boxes, lighting conduits, etc.




PAGE 9 OF 15

CLAUSE NO.


Wherever earthing conductor crosses or runs along metallic structures such as gas, water, steam, conduits, etc. and steel reinforcement in concrete it shall be bonded to the same.

4.06.00

Cable and cable boxes/glands, lockout switches etc. shall be connected to the earthing conductor running alongwith the supply cable which, in turn, shall be connected to earthing grid conductor at minimum two points, whether specifically shown or not.

4.07.00

Railway tracks within switchyard area shall be bonded across fish plates and connected to earthing grid at several locations.

4.08.00

Earthing conductor shall be burried 2000mm outside the switchyard fence. Every post of the fence and gates shall be connected to earthing loop by one lead.

4.09.00

Flexible earthing connectors shall be provided where flexible conduits are connected to rigid conduits to ensure continuity.

4.10.00

Equipment earthing (Riser & welding of two conductors) shall be done as per enclosed sketch. ( Drg. No. 5505-500-POE-A-11)

5.00.00

JOINTING

5.01.00

Earthing connections with equipment earthing pads shall be of bolted type. Contact surfaces shall be free from scales, paint, enamel, grease, rust or dirt. Two bolts shall be provided for making each connection. Equipment bolted connections, after being checked and tested, shall be painted with anti-corrosive paint/compound.

5.02.00

Connection between equipment earthing lead and between main earthing conductors shall be welded/brazed type. For rust protections, the welds should be treated with red lead oxide and afterwards thickly coated with bitumen compound to prevent corrosion.

5.03.00

Steel to copper connections shall be brazed type and shall be treated to prevent moisture ingression.

5.04.00

Resistance of the joint shall not be more than the resistance of the equivalent length of the conductor.

5.05.00

All ground connections shall be made by electric arc welding. All welded joints shall be allowed to cool down gradually to atmospheric temperature before putting any load on it. Artificial cooling shall not be allowed.

5.06.00

Bending of large diameter rod/thick conductor shall be done preferably by gas heating.




PAGE 10 OF 15

CLAUSE NO.


All arc welding with large diameter conductors shall be done with low hydrogen content electrodes.

6.00.00

POWER CABLE EARTHING Metallic sheaths and armour of all multi core power cables shall be earthed at both equipment and switchgear end. Sheath and armour of single core power cables shall be earthed at switchgear end only.

7.00.00

SPECIFIC REQUIREMENT FOR EARTHING SYSTEMS

7.01.00

Earthing terminal of each surge arrester, capacitor voltage transformer and lightning down conductors shall be directly connected to rod electrode which in turn, shall be connected to Main earthing grid.

7.02.00

Earthing mat comprising of closely spaced (300mm x 300mm) conductors shall be provided below the operating handles of the isolators.

7.03.00

For specific requirements for earthing at panel refer to Section- E-10,Statioin Automation System of this specification.

8.00.00

SPECIFIC REQUIREMENTS FOR LIGHTNING PROTECTION SYSTEM

8.01.00

Conductors of the lightning protection system shall not be connected with the conductors of the safety earthing system above ground level.

8.02.00

Down conductors shall be cleated on the structures at 2000mm interval.

8.03.00

Connection between each down conductor and rod electrodes shall be made via test joint located approximately 150mm above ground level.

8.04.00

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

8.05.00

Lightning protection system installation shall be in strict accordance with the latest editions of Indian Electricity Rules, Indian Standards and Codes of practice and Regulations existing in the locality where the system is installed.




PAGE 11 OF 15

CLAUSE NO.

INSTALLATION (E13) PROCEDURE FOR NON DESTRUCTIVE TESTING A.

LIQUID PENETRANT EXAMINATION OF WELDED JOINTS (a)

Evaluation of indications: Relevant indications are those which result from mechanical discontinuities. Rounded indications or indications which are circular or elliptical with the length less than three times the width. Linear indications are those indications in which the length is more than three times the width. Any questionable or doubtful indications, shall be retested to verify whether or not actual defects are present. Localised surface imperfections, such as may occur from machining marks, surface conditions, may procedure similar indications which are not relevant to the detection of unacceptable discontinuities.

(b)

Acceptance standards All surfaces to be examined shall be free of linear indications. Four or more rounded defects with any dimensions more than 1.6mm in a line separated by 1.16 inch (1.6mm) or less (edge to edge).

(c)

Defect removal and repair Unacceptable imperfections shall be removed and re-examination made to assure the complete removal. Whenever a defect is removed and subsequent repair by welding is not required, the excavated area shall be blended into the surrounding surface so as to avoid sharp notches, crevices or corners. Where welding is required after removal of a defect, the area shall be cleaned and welding performed in accordance with a qualified welding procedure. Completed repairs shall be re-examined by the method originally used for detection of the defect.

(d)

Treatment of imperfections believed non-relevant Any indication of an imperfection which is believed to be non-relevant shall be regarded as a defect unless, on re-evaluation, it is shown by re-examination by the same method or by the use of other nondestructive methods and/or by surface conditioning that no unacceptable defect is present.




PAGE 12 OF 15

CLAUSE NO.

INSTALLATION (E13) (e)

Examination of areas from which defects have been removed After a defect is thought to have been removed and prior to making weld repairs, the area shall be examined by suitable methods to ensure the defect has been eliminated.

(f)

Re-examination of repaired area After repairs are made, the repaired areas shall be blended.

B.

RADIOAGRAPHIC EXAMINATION OF WELDED JOINTS Radiographic examination shall cover minimum 10% of weld seam and acceptance standard for visual examination and Radiography shall be as follows: Any of the following imperfections shall not be acceptable: (i)

Cracks

(ii)

Zone of incomplete fusion or penetration, which exceed 10% of the weld length of the joint. In longitudinal or transverse butt weld, where full penetration is intended by the weld procedure, some lack of penetration is acceptable. The total length of weld with lack of penetration shall not exceed 10% of the overall weld length. At no place, shall weld penetration be less than 90% of the thickness of the material. Continuous occurrence of lack of penetration is permitted, but shall not exceed 50mm in any 500mm length of weld.

(iii)

Inadequate weld dimensions, Root Cavity (shrinkage) and incompletely filled groove greater than 10% effective throat thickness.

(iv)

Excess penetration shall be permitted provided it does not exceed 25% of the wall thickness or 4mm whichever is smaller.

(v)

Weld reinforcement: Build up in excess of 25% of the effective throat thickness shall be dressed. Any reinforcement shall be substantially symmetrical about the centreline of the weld and shall be of smooth contour blending smoothly at the toes with the parent material.

(vi)

Undercutting and overlapping greater than 10% effective throat thickness.

(vii)

Elongated cavities and/or worm holes exceeding 3mm dia or equivalent area in length provided the limitations on porosity are met with.




PAGE 13 OF 15

CLAUSE NO.

INSTALLATION (E13) (viii)

Copper, tungsten or oxide inclusions greater than t/4 or 3mm dia or its equivalent area, whichever is smaller.

(ix)

Crater pipes exceeding 25% effective throat thickness or 3mm whichever is smaller.

(x)

Porosity: Scattered porosity not exceeding 0.5% by volume is acceptable. In general, the size of the pores shall not exceed 0.8mm dia, but occasional 1.6mm dia pores may be acceptable, provided the following limits are not exceeded: Where pore size is 0.4mm or less, upto 150t pores may be permitted in 1000mm sq. area or radiograph. Where pore size is 0.8 mm dia or less, upto 19t pores may be permitted in 1000mm sq. area or radiograph. Where pore sizes are generally 0.8mm dia or less, but occasional 1.6mm dia pores are present, upto 9t of 0.8mm dia may be permitted in 1000mm sq. area of radiograph, provided the number of pores upto 1.6mm in dia does not exceed it. However, visible surface porosity > 1mm dia is not acceptable. Note: In all cases, t = thickness of the thinnest section of the weld under examination. Unacceptable weld defects shall be repaired in accordance with the original welding procedure. All repairs shall be 100% inspected in accordance with original testing procedure.

Erection Drawings to be submitted by the Contractor 1.

Single line diagram

2.

Switchyard layout (Plan & Section)

3.

Equipment & Foundation Cable trench layout

4.

Structural Arrangement Drawing

5.

Earthmat Layout

6.

Composite G.A. Drawing

7.

Clearance Diagram




PAGE 14 OF 15

CLAUSE NO.

INSTALLATION (E13)

8.

Cable Trench Sections

9.

Equipment Earthing details

10.

Welding Details

11.

All Design Calculations

12.

G.A. of Clamps and Connectors Drawings

13.

G.A. and Part Drawing of Insulator String and Hardware

14.

G.A. and Schematics of all Marshalling Kiosks and cabinets

15.

Data Sheets and Drawings of all Other Miscellaneous Items




PAGE 15 OF 15

PART-B SUB-SECTION-E14 SITE TESTING AND COMMISSIONING (COMMON)



SITE TESTING AND COMMISSIONING (E14)

CLAUSE NO

1.00.00

INTRODUCTION An indicative list of tests is given below. Contractor shall perform any additional test based on specialities of the items as per the field QP/ instructions of the equipment supplier or Employer without any extra cost to the Employer. The Contractor shall arrange all instruments required for conducting these tests alongwith calibration certificates and shall furnish the list of instruments to the Employer for approval.

2.00.00

3.00.00

GENERAL CHECKS (a)

Check for physical damage.

(b)

Visual examination of zinc coating/ plating

(c)

Check from name plate that all items are as per order/ specification.

(d)

Check tightness of all bolts, clamps and connecting terminals using toque wrenches.

(e)

For oil filled equipment check for oil leakage, if any. Also check oil level and top up.

(f)

Check ground connections for quality of weld and application of zinc rich paint over weld joint of galvanized surfaces.

(g)

Check cleanliness of insulator and bushings.

(h)

All checks and tests specified by the manufactures in their drawings and manuals as well as all tests specified in the relevant code of erection.

(i)

Check for surface finish of grading rings (corona control ring.)

(j)

Pressure test on all pneumatic lines at 1.5 times the rated pressure shall be conducted.

ISOLATORS (a)

Insulation resistance of each pole

(b)

Manual and electrical operation on interlocks

(c)

Insulation resistance of control circuits and motors.

(d)

Ground connections

(e)

Contact resistance

(f)

Proper alignment to minimise the vibration to the extreme possible during operation.

(g)

Measurement of operating torque for disconnector and Earth switch

(h)

Resistance of operating and interlocking coils.




PAGE 1 OF 3


CLAUSE NO

4.00.00

5.00.00

6.00.00

7.00.00

8.00.00

CURRENT TRANSFORMERS (a)

Insulation Resistance Test

(b)

Polarity test.

(c)

Ratio identification test-checking of all ratios on all cores by primary injection of current.

(d)

Magnetising characteristics test.

VOLTAGE TRANSFORMERS (a)

Insulation resistance test

(b)

Polarity test

(c)

Ratio test

SURGE ARRESTER (a)

Grading leakage current

(b)

Resistance of ground connection.

WAVE TRAP (a)


(b)

Visual check.

SUBSTATION AUTOMATION SYSTEM The tests as listed under chapter E10 shall be carried out.

9.00.00

10.00.00

STATION EARTHING (a)

Check soil resistivity

(b)

Check continuity of grid wires

(c)

Check earth resistance of the entire grid as well as various sections of the same.

(d)

Check for weld joint and application of zinc rich paint on galvanised surface.

(e)

Dip test on earth conductor prior to use.

CONDUCTOR STRINGING AND POWER CONNECTORS (a)

Physical check for finish




PAGE 2 OF 3


CLAUSE NO

11.00.00

(b)

Electrical clearance check

(c)

Testing of torque by torque by torque wrenches on all bus power connectors and other accessories.

(d)

Milli volt drop test on all power connectors.

(e)

Sag and tension check on conductors.

INSULATORS Visual examination for finish damage, creepage distance, etc.

12.00.00

CHECKS AFTER COMMISSIONING (a)

Thermal scan of all connections.

(b)

Night vision corona check.




PAGE 3 OF 3

PART-B SUB-SECTION-C0 TECHNICAL SPECIFICATION CIVIL WORKS



CLAUSE NO.

TECHNICAL SPECIFICATION (CIVIL WORKS)

TECHNICAL SPECIFICATION - CIVIL WORKS 1.00.00


1.01.00

This chapter includes the technical requirements for 400 KV Switchyard at Tapovan Vishnugad HEPP, including associated design and preparation of all civil & structural drawings and execution of all associated civil works. This Chapter deals mainly with technical specifications for the design, supervision and construction of complete civil & structural works complete under the scope of this contract.

1.02.00

The specifications are intended for general description of work, quality and workmanship. The specifications are not however exhaustive to cover minute details and the work shall be executed according to relevant latest Indian Standards / IRC or IRS Specifications. In the absence of the above, the work shall be executed according to the best prevailing practices in the trade, recommendations of relevant American or British Standards or to the instructions of Project Manager. The IS standards / IRC or IRS specifications to be followed are mentioned in the technical specifications attached hereto. They shall be latest edition / version of the same issued 15 days prior to the date of opening of this tender. The Bidder is expected to get himself clarified on any doubts about the specifications etc. before bidding, and the discussions recorded in writing with the Employer in respect of interpretation of any portion of this document. The contractor shall take all necessary precautions to protect all the existing equipments, structures, facilities & buildings etc. from damage. In case any damage occurs due to the activities of the Contractor on account of negligence, ignorance, accidental or any other reason whatsoever, the damage shall be made good by the Contractor at his own cost to the satisfaction of the Project Manager. The Contractor shall also take all necessary safety measures, at his own cost, to avoid any harm / injury to his workers and staff from the equipment & facilities of the power station. During the progress of work, the Project Manager will exercise supervision of the work to ensure that the technical provisions of the contract are being followed and the work is being executed accurately and properly. However, such supervision shall in no way relieve the Contractor of the responsibility for executing the work in accordance with the specifications. Before submitting the bid, the Bidder shall inspect and examine the site and its surroundings and shall satisfy himself as to the nature of the ground and subsoil, the availability of materials necessary for completion of the work, means of access to site and in general shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his offer. No extra claim consequent on any misunderstanding or otherwise shall be allowed.

2.00.00

LAYOUT AND LEVELS The layout and levels of all structures etc. shall be made by the Contractor at his own cost from the general grid of the plot and bench marks given by the Project Manager. The Contractor shall give all help in instruments, material and men to the

TAPOVAN VISHNU HYDRO ELECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2


PART-B C-0

PAGE 1 OF 42

CLAUSE NO.


Project Manager, at no extra cost, for checking the detailed layout & correctness of the layout and levels. However the Contractor shall be solely responsible for their correctness. 3.00.00

CODES AND STANDARDS

3.01.00

All standards, specifications, acts and code of practice referred to herein shall be the latest editions including all applicable official amendments and revisions.

3.02.00

In case of conflict between this specification and those ( IS standards, codes etc. ) referred to here - in, the former shall prevail.

3.03.00

Some of the relevant Indian standards, Acts and Codes are referred to here below : (a.) EXCAVATION AND FILLING IS : 2720 (Part – II, IV TO VIII, XIV, XXI, XXIII, XXIV, XXVII TO XXIX, XL) Methods of test for soils - determination for water content etc. IS : 4701

Code of practice for earth work on canals.

IS : 9758

Guide lines for Dewatering during construction

IS : 10379

Code of practice for field control of moisture and compaction of soils for embankment and sub - grade.

(b.) PROPERTIES, STORAGE AND HANDLING OF COMMON BUILDING MATERIALS IS : 280

Specification for mild steel wire for general engineering purposes.

IS : 456

Code of practice for plain and reinforced concrete.

IS : 457

Code of practice for general construction of plain & reinforced concrete for dams & other massive structures.

IS : 516

Method of test for strength of concrete.

IS : 650

Specification for standard sand for testing of cement.

IS : 1199

Methods of sampling and analysis of concrete.

IS : 1791

General requirements for batch type concrete mixers.

IS : 1838 (Part - I)

Specification for preformed fillers for expansion joints in concrete pavements and structures (non - extruding and resilient type).

IS : 2438

Specification for roller pan mixer.



PART-B C-0

PAGE 2 OF 42

CLAUSE NO.


IS : 2502

Code of practice for bending and fixing of bars for concrete reinforcement.

IS : 2505

General requirements for concrete vibrators, immersion type.

IS : 2506

General requirements for concrete vibrators, screed board type.

IS : 2514

Specification for concrete vibrating tables.

IS : 2645

Specification for Integral cement water proofing compounds.

IS : 2722

Specification for portable swing weigh batches for concrete. (single and double bucket type)

IS : 2750

Specification for Steel scaffolding.

IS : 2751

Code of practice for welding of mild steel plain and deformed bars for reinforced concrete construction.

IS : 3025

Methods of sampling and test waste water.

IS : 3366

Specification for Pan vibrators.

IS : 3370 (Part I to IV)

Code of practice for concrete structures for the storage of liquids.

IS : 3414

Code of practice for design and installation of joints in buildings.

IS : 3550

Methods of test for routine control for water used in industry.

IS : 3558

Code of practice for use of immersion vibrators for consolidating concrete.

IS : 4014 (Parts I & II)

Code of practice for steel tubular scaffolding.

IS : 4326

Code of practice for earthquake resistant design and construction of buildings.

IS : 4656

Specification for form vibrators for concrete.

IS : 4925

Specification for batching and mixing plant.

IS : 4990

Specification for plywood for concrete shuttering work.

IS : 5256

Code or practice for sealing joints in concrete lining on canals.



PART-B C-0

PAGE 3 OF 42

CLAUSE NO.


IS : 5525

Recommendations for detailing reinforced concrete work.

of

reinforcement

in

IS : 5624

Specification for foundation bolts.

IS : 6461

Glossary of terms relating to cement concrete.

IS : 6494

Code of practice for water proofing of underground water reservoirs and swimming pools.

IS : 6509

Code of practice for installation of joints in concrete pavements.

IS : 7861

Code of practice for extreme weather concreting. (Parts I & II)

IS : 9012

Recommended practice for shot concreting.

IS : 9103

Specification for admixtures for concrete.

IS : 9417

Recommendations for welding cold worked steel bars for reinforced concrete construction.

IS : 10262

Recommended guidelines for concrete mix design.

IS : 11384

Code of practice for composite construction in structural steel and concrete.

IS : 12118

Specification for two - parts poly sulphide.

IS : 12200

Code of practice for provision of water stops at transverse contraction joints in masonry and concrete dams.

IS : 13311

Method of non - destructive testing of concrete.

Part – 1

Ultrasonic pulse velocity.

Part – 2

Rebound hammer.

SP : 23

Handbook of concrete mixes

SP : 24

Explanatory Handbook on IS : 456 - 1978

SP : 34

Handbook on concrete reinforcement and detailing.

(c.) CAST - IN - SITU CONCRETE AND ALLIED WORKS IS : 280

Specification for mild steel wire for general engineering purposes.

IS : 456

Code of practice for plain and reinforced concrete.



PART-B C-0

PAGE 4 OF 42

CLAUSE NO.


IS : 457

Code of practice for general construction of plain & reinforced concrete for dams & other massive structures.

IS : 516

Method of test for strength of concrete.

IS : 650

Specification for standard sand for testing of cement.

IS : 1199

Methods of sampling and analysis of concrete.

IS : 1791

General requirements for batch type concrete mixers.

IS : 1838 (Part - I)

Specification for preformed fillers for expansion joints in concrete pavements and structures (non - extruding and resilient type ).

IS : 2438

Specification for roller pan mixer.

IS : 2502

Code of practice for bending and fixing of bars for concrete reinforcement.

IS : 2505

General requirements for concrete vibrators, immersion type.

IS : 2506

General requirements for concrete vibrators, screed board type.

IS : 2514

Specification for concrete vibrating tables.

IS : 2645

Specification for Integral cement water proofing compounds.

IS : 2722

Specification for portable swing weigh batches for concrete. (single and double bucket type)

IS : 2750

Specification for Steel scaffolding.

IS : 2751

Code of practice for welding of mild steel plain and deformed bars for reinforced concrete construction.

IS : 3025

Methods of sampling and test waste water.

IS : 3366

Specification for Pan vibrators.

IS : 3370 (Part I Code of practice for concrete structures for the storage of to IV) liquids. IS : 3414

Code of practice for design and installation of joints in buildings.

IS : 3550

Methods of test for routine control for water used in industry.

IS : 3558

Code of practice for consolidating concrete.



use

of

immersion

PART-B C-0

vibrators

for

PAGE 5 OF 42

CLAUSE NO.


IS : 4014 (Parts I Code of practice for steel tubular scaffolding. & II) IS : 4326

Code of practice for earthquake construction of buildings.

IS : 4656

Specification for form vibrators for concrete.

IS : 4925

Specification for batching and mixing plant.

IS : 4990

Specification for plywood for concrete shuttering work.

IS : 5256

Code or practice for sealing joints in concrete lining on canals.

IS : 5525

Recommendations for detailing of reinforcement in reinforced concrete work.

IS : 5624

Specification for foundation bolts.

IS : 6461

Glossary of terms relating to cement concrete.

IS : 6494

Code of practice for water proofing of underground water reservoirs and swimming pools.

IS : 6509

Code of practice for installation of joints in concrete pavements.

IS : 7861

Code of practice for extreme weather concreting. (Parts I & II)

IS : 9012

Recommended practice for shot concreting.

IS : 9103

Specification for admixtures for concrete.

IS : 9417

Recommendations for welding cold worked steel bars for reinforced concrete construction.

IS : 10262

Recommended guidelines for concrete mix design.

IS : 11384

Code of practice for composite construction in structural steel and concrete.

IS : 12118

Specification for two - parts poly sulphide.

IS : 12200

Code of practice for provision of water stops at transverse contraction joints in masonry and concrete dams.

IS : 13311

Method of non - destructive testing of concrete.

Part – 1

Ultrasonic pulse velocity.

Part – 2

Rebound hammer.



resistant

PART-B C-0

design and

PAGE 6 OF 42

CLAUSE NO.


SP : 23

Handbook of concrete mixes

SP : 24

Explanatory Handbook on IS : 456 – 1978

SP : 34

Handbook on concrete reinforcement and detailing.

(d.) PRECAST CONCRETE WORKS SP : 7 (PartVI / Sec.7)

National Building Code - Structural design of prefabrication and systems building.

IS : 10297

Code of practice for design and construction of floors and roofs using precast reinforced / prestressed concrete ribbed or cored slab units.

IS : 10505

Code of practice for construction of floors and roofs using pre – cast reinforced concrete units.

(e.) MASONRY AND ALLIED WORKS IS : 1905

Code of Practice for Structural Safety of Buildings - Masonry walls.

IS : 2212

Code of Practice for Brickwork.

IS : 2250

Code of Practice for Preparation and use of Masonry Mortar.

SP : 20

Explanatory hand book on masonry code.

(f.)

SHEETING WORKS

IS : 277

Galvanised steel sheets (plain or corrugated).

IS : 459

Unreinforced corrugated and semi - corrugated asbestos cement sheets.

IS : 513

Cold - rolled carbon steel sheets.

IS : 730

Specification for fixing accessories for corrugated sheet roofing.

IS : 1626

Specification for Asbestos cement building pipes and pipe fittings, gutters and gutter fittings and roofing fittings.

IS : 2527

Code of practice for fixing rain water gutters and down pipe for roof drainage.

IS : 3007

Code of practice for laying of asbestos cement sheets.

IS : 5913

Methods of test for asbestos cement products.

IS : 7178

Technical supply conditions for tapping screw.



PART-B C-0

PAGE 7 OF 42

CLAUSE NO.


IS : 8183

Bonded mineral wool.

IS : 8869

Washers for corrugated sheet roofing.

IS : 12093

Code of practice for laying and fixing of sloped roof covering using plain and corrugated galvanised steel sheets.

IS : 12866

Plastic translucent sheets made from thermosetting polyester resin (glass fibre reinforced).

IS : 14246

Specification for continuously pre - painted galvanised steel sheets and coils.

(g.) FABRICATION AND ERECTION OF STRUCTURAL STEEL WORK IS : 2016

Specification for plain washers.

IS : 814

Specification for covered Electrodes for Metal Arc Welding for weld steel.

IS : 1852

Specification for Rolling and Cutting Tolerances for Hot rolled steel products.

IS : 3502

Specifications for chequered plate.

IS : 6911

Specification for stainless steel plate, sheet and strip.

IS : 3757

Specification for high strength structural bolts

IS : 6623

Specification for high strength structural nuts.

IS : 6649

High Tensile friction grip washers.

IS : 800

Code of practice for use of structural steel in general building construction.

IS : 816

Code of practice for use of Metal Arc Welding for General Construction.

IS : 4000

Code of practice for assembly of structural joints using high tensile friction grip fasteners.

IS : 9595

Code of procedure of Manual Metal Arc Welding of Mild Steel.

IS : 817

Code of practice for Training and Testing of Metal Arc Welders.

IS : 1811

Qualifying tests for Metal Arc Welders (engaged in welding structures other than pipes).

IS : 7215

Tolerances for fabrication steel structures.



PART-B C-0

PAGE 8 OF 42

CLAUSE NO.


IS : 12843

Tolerance for erection of structural steel.

IS : 4353

Recommendations for submerged arc welding of mild steel and low alloy steels.

SP:6 (Part 1 to 7)

ISI Hand book for structural Engineers.

IS : 1608

Method of Tensile Testing of Steel products other than sheets, strip, wire and tube.

IS : 1599

Method of Bend Tests for Steel products other than sheet, strip, wire and tube

IS : 802 (1977)

Code of practice for use of Structural Steel inOver head Transmission Line Towers.

IS : 228

Methods of chemical Analysis of pig iron, cast iron and plain carbon and low alloy steel.

IS : 2595

Code of Practice for Radio graphic testing.

IS : 1182

Recommended practice for Radiographic Examination of fusion welded butt joints in steel plates.

IS : 3664

Code of practice for Ultra sonic Testing by pulse echo method.

IS : 3613

Acceptance tests for wire flux combination for submerged Arc Welding.

IS : 3658

Code of practice for Liquid penetrant Flaw Detection.

IS : 5334

Code of practice for Magnetic Particle Flaw Detection of Welds.

(h.) PLASTERING AND ALLIED WORKS IS : 1635

Code of practice for field slaking of Building lime and preparation of putty.

IS : 1661

Application of cement and cement lime plaster finishes.

IS : 2333

Plaster - of - paris.

IS : 2402

Code of practice for external rendered finishes.

IS : 2547

Gypsum building plaster.

IS : 3150

Hexagonal wire netting for general purpose.

(i.)

WATER SUPPLY, DRAINAGE AND SANITATION

IS : 458 TAPOVAN VISHNU HYDRO ELECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2

Specification for concrete pipes. TECHNICAL SPECIFICATION SECTION-VI

PART-B C-0

PAGE 9 OF 42

CLAUSE NO.


IS : 554

Dimensions for pipe threads, where pressure tight joints are made on thread.

IS : 651

Specification for salt glazed stoneware pipes.

IS : 774

Flushing cisterns for water closets and urinals.

IS : 775

Cast iron brackets and supports for wash basins and sinks.

IS : 778

Copper alloy gate, globe and check valves for water works purposes.

IS : 781

Cast copper alloy screw down bib taps and stop valves for water services.

IS : 782

Caulking lead.

IS : 783

Code of practice for laying of concrete pipes.

IS : 1172

Basic requirements for water supply, drainage and sanitation.

IS : 1230

Cast iron rain water pipes and fittings.

IS : 1239

Mild steel tubes, tubulars and other wrought steel fittings.

IS : 1536

Centrifugally cast (Spun) iron pressure pipes for water, gas and sewage.

IS : 1537

Vertically cast iron pressure pipes for water, gas and sewage.

IS : 1538

Cast iron fittings for pressure pipe for water, gas and sewage.

IS : 1703

Ball valves (horizontal plunger type) including float for water supply purposes.

IS : 1726

Cast iron manhole covers and frames.

IS : 1729

Sand cast iron spigot and socket, soil, water and ventilating pipes, fittings and accessories.

IS : 1742

Code of practice for building drainage.

IS : 1795

Pillar taps for water supply purposes.

IS : 1879

Malleable cast iron pipe fittings.

IS : 2064

Code of practice for selection, installation and maintenance of sanitary appliances.

IS : 2065

Code of practice for water supply in building.



PART-B C-0

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CLAUSE NO.


IS : 2326

Automatic flushing cisterns for urinals.

IS : 2470 (Part - I Code of practice for installation of septic tanks. & II) IS : 2501

Copper tubes for general engineering purposes.

IS : 2548

Plastic seat and cover for water - closets.

IS : 2556 (Part 1 Vitreous sanitary appliances (vitreous china). to 15) IS : 2963

Non - ferrous waste fittings for wash basins and sinks.

IS : 3114

Code of practice for laying of cast iron pipes.

IS : 3311

Waste plug and its accessories for sinks and wash basins.

IS : 3438

Silvered glass mirrors for general purposes.

IS : 3486

Cast iron spigot and socket drain pipes.

IS : 3589

Electrically welded steel pipes for water, gas and sewage (200mm to 2000mm nominal diameter).

IS : 3989

Centrifugally cast (Spun) iron spigot and socket soil, waste and ventilating pipes, fittings and accessories.

IS : 4111 (Part I Code of practice for ancillary structure in sewerage system. to IV) IS : 4127

Code of practice for laying of glazed stone - ware pipes.

IS : 4764

Tolerance limits for sewage effluents discharged into inland surface waters.

IS : 4827

Electro plated coating of nickel and chromium on copper and copper alloys.

IS : 5329

Code of practice for sanitary pipe work above ground for buildings.

IS : 5382

Rubber sealing rings for gas mains, water mains and sewers.

IS : 5822

Code of practice for laying of welded steel pipes for water supply.

IS : 5961

Cast iron grating for drainage purpose.

IS : 7740

Code of practice for road gullies.



PART-B C-0

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IS : 8931

Cast copper alloy fancy bib taps and stop valves for water services.

IS : 8934

Cast copper alloy fancy pillar taps for water services.

IS : 9762

Polyethylene floats for ball valves.

IS : 10446

Glossary of terms for water supply and sanitation.

IS : 10592

Industrial emergency showers, eye and face fountains and combination units.

IS : 12592

Specification for precast concrete manhole covers and frames.

IS : 12701

Rotational moulded polyethylene water storage tanks.

SP : 35

Hand book on water supply and drainage.

-

Manual on Sewerage and sewage treatment (Published by CPH & EEO) As updated.

(j.)

Loading

IS : 875 (Pt. I to Code of practice for design loads other than earthquake for V) buildings and structures. IS : 1893

Criteria for earthquake resistant design of structures.

IS : 4091

Code of Practice for design and construction of foundation for transmission line towers & poles.

IRC : 6

Standard specifications & code of practice for road bridges, Section - II Loads and stresses.

M.O.T.

Deptt. of railways Bridge Rules.

(k.) SAFETY IS : 3696 (Part I & Safety code for scaffolds and ladders. II) IS : 3764

Safety code for excavation work.

IS : 4081

Safety code for blasting and related drilling operations.

IS : 4130

Safety code for demolition of buildings.

IS : 5121

Safety code for piling and other deep foundations.

IS : 5916

Safety code for construction involving use of hot bituminous materials.



PART-B C-0

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CLAUSE NO.


IS : 7205

Safety code for erection on structural steelwork.

IS : 7293

Safety code for working with construction machinery.

IS : 7969

Safety code for handling and storage of building materials

IS : 11769

Guidelines for safe use of products containing asbestos.

Indian Explosives Act. 1940 as updated. 4.00.00

SUBMISSIONS The following documents shall be submitted by the Bidder for approval of the Employer, prior to commencement of fabrication and erection / construction. This list is not exhaustive but indicative only : 1.

G A drawing showing facilities.

2.

Drawing showing underground facilities with co-ordinates of all facilities such as Gantry foundation, equipment foundation, R.C.C cable trench, cable ducts, drains, sumps, pits, culverts, other foundations etc.

3.

Proposed erection / construction scheme for various structural and civil works envisaged as per design requirement.

4.

Foundation design & drawing for Gantry structure & LM.

5.

Foundation design &drawing for equipment supports, their control cubicles, bus post supports and bay marshalling kiosks

6.

Details of RCC cable and pipe trenches with necessary precast RCC removable covers with lifting facility, sump pits, back-filling, cable trays and supports,

7.

Site preparation, soil sterilization / antiweed treatment including gravel filling, but excluding major leveling.

8.

Complete fencing along with gate for the switchyard

9.

Structural steel fabrication drawings and Reinforcement bar bending schedules for reference.

10.

Electronic soft copy of all the approved drawings/calculations in Cat-II / Cat-I.


co-ordinates of various Gantry


PART-B C-0

structures and

PAGE 13 OF 42

CLAUSE NO.

5.00.00


DESIGN PARAMETERS Gantry structure, which consist of open web towers connected by girders. These shall be made of structural steel conforming to IS: 2062 Grade and duly galvanized conforming to IS: 2629. All joints shall be bolted connections. All bolts shall be 16mm dia conforming to IS:12427:1988 of property class 5.6 conforming to IS:1367(Part 6):1980. Nuts shall conform to I.S 1363(Part 3):1992 of property class 5 .Butt splice is used for splicing the main members and splice shall be located away from the node point. IS: 802 - 1977 “Code of practice for use of structural steel in overhead transmission line towers” shall be followed for design of structural supports, Height & type of towers shall be established based on electrical requirements. A provision of ± 30-degree angle of deviation of line in horizontal plane and ± 20 degree deviation in vertical plane is considered and the resulting worst combination of forces shall be considered for design. For all outgoing and in coming feeders, the conductor span shall be 200 m. LOADING CONDITIONS Towers and girders shall be designed for the following loading conditions : a)

Transverse load due to wind.

b)

Longitudinal load due to unbalanced tension in conductor.

c)

Transverse load due to deviation of conductor.

d)

Torsion load due to unbalanced vertical and horizontal forces.

e)

Short circuit forces including ‘snatch’ in case of bundled conductor.

f)

A construction load of 150 Kg shall be allowed on any member whose horizontal axis is 45 degree or less with the horizontal during erection of structure.

g)

Temperature stress.

h)

Earthquake forces as per IS:1893.

i)

Ice loading

The occurrence of earthquake and maximum wind pressure is unlikely to take place at the same time. The structure shall be designed for either of the two. However, temperature stresses can be ignored, as these towers are freestanding structure in open space. Load Combinations and Factor of Safety Simultaneous application of following loads shall be considered for the design of switchyard structure : a)

Normal condition



PART-B C-0

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CLAUSE NO.


b)

1.

Wind load on bus bars, shield wires, insulator strings, electrical equipment, structural members etc.

2.

Unbalanced load due to conductor/wire tension.

3.

Dead load of wires/conductors, insulator, electrical equipment and structural members.

4.

Load due to angle of deviation of the approach span.

5.

Torsion loads due to unbalanced vertical & horizontal forces.

Abnormal conditions 1.

short-circuit forces

2.

seismic forces

Note :

6.00.00

1)

Earthquake forces shall not be combined with wind forces.

2)

Direction of wind shall be assumed such as to produce maximum stresses in any member for the combination of wind load with conductor tensions. The wind acting perpendicular and parallel to bus conductor and shield wire shall be considered separately.

3)

The conductor tension shall be assumed as acting on only one side of the gantry for the analysis and design of switchyard gantries.

FACTOR OF SAFETY The factor of safety for the design of members for switchyard structures shall be considered as 2.0 for normal conditions & 1.5 for Abnormal Conditions

7.00.00

MINIMUM THICKNESS OF MEMBERS & GALVANIZING THICKNESS All steel work used in construction of gantry structure should be galvanized and minimum section thickness should not be less than 4 mm. Weight of zinc coating shall be at least 0.610 kg/m2 & foundation bolts shall have heavier zinc coating at least 0.80 kg/m2

8.00.00

SPECIAL DESIGN CONSIDERATION FOR LIGHTNING MASTS Diagonal wind condition shall be considered for lightning masts. Provision of IS: 875(Part-III) - 1987 shall apply for inclined wind condition. Lightning mast shall be provided with minimum two nos. of platforms are at 12.5 m & other at 25.0 m an internal ladder for climbing purpose upto platform at top level. Top of platform shall have grating, railing and two guard plates.



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CLAUSE NO.

9.00.00


DESIGN CONSIDERATION FOR EQUIPMENT SUPPORT The supporting structure for P.I., LA, CVT, Isolator, CT & Wave Trap equipment shall be comprised of lattice structural steel conforming to IS 2026 and shall be designed as per IS: 802

10.00.00

SWITCHYARD SURFACING Entire area of switchyard shall be provided with broken stone filling which shall consist of 75mm thick stone metal filling of 40 mm stone aggregate on the top and 75mm thick filling of 20 mm stone aggregate below. Each layer shall be compacted by using half ton roller with 4-5 passes and suitable water sprinkling. Before laying the broken stone fill, the top layer of the soil shall be treated for anti-weed considering the type of weeds found in the vicinity. The antiweed - soil sterilisation details such as manufacturer's name, their specification, test certificate, etc. shall be furnished for Owner's approval. Any modification if required in the proposed antiweed treatment chemical shall have to be done by the contractor at no extra cost to the Owner. The contractor shall be required to furnish a performance guarantee of three years for the antiweed treatment. This guarantee shall be commenced from the date of completion of work or date of handing over, whichever is later.

11.00.00

SWITCHYARD TRENCHES Cable trenches shall be provided for routing of cables to equipments through a common marshalling box for each bay. Each cable trench shall cater to two bays on either side. The cable trench shall be of adequate size. The trenches located within switchyard shall project at least 300 mm above the finished formation level so that no storm water shall enter into the trench. The bottom of trench shall be provided with a longitudinal slope of 1:500. The downstream end of cable trenches shall be connected through pipe drains to the nearby RCC manholes (to convey water from trenches) of storm water drainage system. The precast covers shall not be more than 300mm in width and shall not be more than 65 kg. Lifting hooks shall be provided in the precast coveres. Trenches shall be given a slope of 1:50 in the direction perpendicular to the run of the trenches. PVC water stop shall be provided at all expansion joints of all trenches. Angle of size 50x50x6 mm (minimum) with lugs shall be provided in the edges of RCC cable trenches supporting cover, edges of manhole supporting, supporting edges of precast RCC cover and any other place where breakage of corners of concrete is expected.

12.00.00

DESIGN CONSIDERATION FOR FOUNDATION Detail design of foundation shall be as per IS: 4091 “code of practice for design and construction for transmission line tower and poles”. The F.O.S. for foundation shall be 10% more than factor of safety for supporting structure i.e. 2.2 for normal condition and 1.65 for abnormal condition



PART-B C-0

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CLAUSE NO.

12.01.00


Seismic Loads All structures shall be designed for seismic forces adopting the site specific seismic information is placed at Annexure – I to this chapter and using the other provisions in accordance with IS : 1893.

12.02.00

Wind Load All structures shall be designed for wind forces in accordance with the IS : 875 ( Part - 3 ) and as specified in this document. Site specific wind parameters is placed at Annexure - II to this chapter.

12.03.00

Increase in permissible stresses The increase in permissible stress of materials and soil bearing pressure for different load combinations under wind, seismic and temperature loads shall be as per relevant IS Codes.

12.04.00

STRUCTURAL DESIGN CRITERIA

12.04.01

CHAIN LINK FENCING The fence shall comprise of PVC coated G.I. chain link fencing of minimum 8G (including PVC coating) of mesh size 75 mm and of height 2.4 m above toe wall with a 600 mm high galvanised concertina at the top, such that total fence height of 3.0m above toe wall is achieved. The diameter of the steel wire for chain link fence (excluding PVC coating ) shall not be less than 12G. The PVC coated chain link will be stretched by the clips at 0.5m intervals to three strands of galvanised high tensile spring steel wire ( HTSSW ) of 12G interwoven chain link wire mesh and kept under tension which in turn are attached to the fence post with security nuts and bolts. On every fourth post a clamping strip will be threaded through the links of chain link and bolted to the fence post with the help of security nuts and bolts. Above the chain link a 600 mm high tensile serrated galvanised wire (HTSW) concertina will be stretched to 6m and attached to two strands of galvanised HTSSW by means of clips at 1 m intervals. These two HTSSW strands will be attached to the fence posts with 1 / 2" security fasteners. All nuts, bolts, fasteners, clamping strips, clamps, clips, etc. shall be hot dip galvanised. Weight of zinc coating shall be at least 900 gm / Sq. M. All fence posts shall be 65x65x6 MS angles spaced at 2.5mC/C. All straining posts shall be 65x65x6 ms angles. All corner posts will have two stay posts and every



PART-B C-0

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CLAUSE NO.


tenth post will have transverse stay post suitable RCC foundations for the post and stays shall be provided based on the prevailing soil conditions. Toe walls either of brick masonry with bricks of class designation 50 with minimum crushing strength 50 Kg / M2 or of hollow concrete block masonry shall be provided between the fence posts all along the run of the fence with suitable foundation. Toe wall shall be minimum 200 mm above the formation level with 50 thick PCC coping (1 : 2 : 4) and shall extend minimum 300 below formation level. Toe wall shall be plastered with cement sand mortar (1 : 6) on both sides and shall be painted with coats of texture cement paint (Sand tex matt or equivalent) of approved colour & make. Toe wall shall be provided with weep holes at appropriate spacings. 12.04.02

M. S. GATE M. S. Gate of 3.0 M wide x 2.6 M height shall be provided to provide access through the fencing to the switchyard. It shall be made in two leaf, with locking arrangements. The gate shall be made with outer frame of 50 NB (Medium) M. S. Pipe, vertical & horizontal runners with 40x6 M. S. flat and weld mesh of opening size 50 x 25 mm and nominal size of mesh 4 mm dia. Hinges, al-drops and other accessories shall be provided for effective working of the gate.

13.00.00

MATERIALS AND GRADE OF CONCRETE

13.01.00

Concrete

13.01.01

Minimum grade of structural concrete shall be M25 conforming to IS : 456.

13.01.02

Blinding concrete below foundations, cable trenches, shall be PCC of minimum grade M-7.5,

13.01.03

Blinding concrete under brick foundations shall be minimum 150mm thick in PCC of minimum grade M-10.

13.02.00

Cement Cement shall be ordinary Portland cement conforming to IS : 269, Portland slag cement conforming to IS : 455, Fly ash based pozzolona cement conforming to IS 1489 (Part - I), or Portland pozzolona cement conforming to IS 1489 (Part - II).For miscellaneous concrete works, Fly ash based Portland pozzolona cement or Blast slag cement may be used as per the specifications if directed by the Project Manager. Ordinary portland cement conforming to IS 269 shall be used for all structures requiring grade of concrete M - 25 or above. Supply of all types of cement shall be in Bidder’s scope. Further the Contractor shall meet the following requirement: The contractor shall use the aggregate available locally conforming to IS 383.



PART-B C-0

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CLAUSE NO.


The Contractor shall use lower cement content in the concrete while designing the concrete mix. Contractor shall procure cement having alkali content as low as possible but limited to maximum 0.9%. 13.03.00

Reinforcement Steel HYSD bars (Fe 415) conforming to IS : 1786 shall be used for all structures. Supply of reinforcement steel shall be in bidder’s scope.

13.04.00

Structural Steel Structural steel shall be of tested quality and shall be of mildsteel of Grade ‘A’ up to 20 mm thickness and of Grade ‘B’ with normalised steel for thickness above 20 mm and shall conform to IS : 2062. Chequered plates shall conform to IS : 3502 and MS pipes for handrail shall conform to medium grade of IS : 1161. All gratings shall be electroforged type. Minimum thickness of the grating shall be 40mm. The opening size shall not be more than 30mm x 100mm.The minimum thickness of the main bearing bar shall be 3mm. All gratings located inside the building shall be sand blasted and provided with two coats of suitable primer and two coats of finish paint (black colour) as per approved painting system. All gratings located outside the building shall be hot double dip galvanised at the rate of 610 gms / Sq. M.. Supply of all structural steel shall be in Bidder’s scope.

13.05.00

Materials (1)

Masonry units shall be stones, bricks or concrete block units. The Contractor shall submit samples of bricks and blocks to the Project Manager for approval.

(2)

Cement, sand and water shall be as specified in the relevant section of "Concrete".

(3)

Masonry units shall have a moisture content (expressed as a percentage of total absorption) of not more than 30% at time of delivery. Units made from cinder aggregate shall not be used.

(4)

All stones, bricks and blocks shall be adapted to the wall thickness and approved by the Engineer-in-Charge.

(5)

All bricks shall be uniform in size and shape, deep red in colour and well burnt. They shall be clean and free from flaws, cracks and underburnt lumps or defects of any kind. The bricks may be local product available in the vicinity of the Site, but the quality shall conform to a standard acceptable to the Engineer-in-Charge.



PART-B C-0

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CLAUSE NO.


(6)

All concrete blocks shall be of the nominal face dimension 200x400 mm and shall be uniform in size. They shall be clean and free from flaws and cracks.

(7)

The mortar shall be thoroughly mixed until uniform in colour and shall be used before it has taken initial set. Mortar which has partially set shall not be used, nor shall more water be added to it. The mortars shall be composed as follows : a)

Cement-lime mortar: 150 kg cement + 250 kg hydrated lime + 1 m3 sand + water

b)

Cement mortar: 300 kg cement + 1 m3 sand + water

14.00.00

GEOTECHNICAL INVESTIGATION & FOUNDATION SYSTEM

14.01.00

Details pertaining to Geo-Technical Investigation and Foundation system are specified at ANNEXURE-III to this chapter.

15.00.00

TESTS FOR MATERIAL / WORKMANSHIP All tests required for various bought out items, materials, quality of workmanship or any other tests as desired by Project Manager and as specified in technical specification shall be carried out by the Contractor at his own cost in the presence of the authorised representative of the Engineer. The quality assurance check lists are given at the end of respective chapters / sections of this specifications. The Contractor shall submit comprehensive Quality Assurance plan for all materials, equipment, workmanship, services etc. and get it approved from the Project Manager. This shall include setting up a test laboratory at site. However, such check list shall in no way limit the liability and responsibility of the Contractor in regard to quality of workmanship as detailed out in the specifications.

16.00.00

ALTERATION IN SPECIFICATION AND DESIGN The Project Manager shall have the power to make any alteration and omissions from, additions to or substitution for, the original specifications, drawings, designs and instructions that may appear to him to be necessary during the progress of the work, and the Contractor shall carry out the work in accordance with any instruction which may be given to him in writing signed by the Project Manager and such alterations, omissions, additions or substitutions shall not invalidate the contract and any altered, added or substituted work which the Contractor may be directed to do in the manner above specified as part of the work shall be carried out by the Contractor on the same conditions in all respects on which the Contractor agreed to do the original contract work. The time for completion of work shall be altered in the proportion that the altered, added or substituted work bears to the original contract work, and the certificate of the Project Manager shall be conclusive as to such proportion.



PART-B C-0

PAGE 20 OF 42

CLAUSE NO.


The rates for the altered items of work shall be worked out on the following basis and necessary alternations in the total amount shall be made on that basis: (a.)

The rates to be reimbursed or recovered shall be taken as same as those given in CPWD – State PWD (latest) for those items for which the rates are available in CPWD - State PWD (latest). However, the premium as officially declared by CPWD’s official circulars, at the time of carrying out these works, the same shall also be applicable.

(b.)

Rates for the items not covered under CPWD - State PWD (latest) shall be derived from the rates of similar items of CPWD schedule of rates. However, the premium as officially declared by CPWD on the above State PWD rates if existing or prevalent through CPWD’s official circulars, at the time of carrying out these works, the same shall be applicable.

(c.)

In the event there is no similar class of work specified in the CPWD - State PWD (latest) the Contractor shall work on a rate for such an item on the basis of the prevalent market rates for materials / men / machines and submit the same together with the detailed analysis to the Project Manager within 7 days. The Project Manager shall thereafter review the correctness and then conduct necessary negotiations with the Contractor to arrive at a mutually agreeable rate. Engineer’s decision in regard to rates of such items shall be final and binding on the Contractor.

In case of conflict between this chapter and other Chapters of Technical Specifications, provisions given in this chapter shall govern in the case of civil & structural works



PART-B C-0

PAGE 21 OF 42

CLAUSE NO.


SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES

The various site specific seismic parameters for the project site shall be as follows: 1)

Peak ground horizontal acceleration

2)

Multiplying factor to be applied to the site specific horizontal acceleration spectral coefficients (in units of gravity cceleration ‘g’) to obtain the design acceleration spectra

for *MCE for **DBE

= =

: :

0.38g 0.19g

a)

For moment resisting steel frames designed and detailed as per IS:800 and moment resisting RC frames designed and detailed as per IS:456

:

0.14

b)

For braced steel frames designed and detailed as per IS:800

:

0.11

c)

For moment resisting RC frames designed and detailed as per IS:456 and IS:13920

:

0.083

:

0.14

d)

For design of structures not covered under 2 (a) to 2 (c) above and under 3 below

3)

Multiplying factor to be applied to the site specific horizontal acceleration spectral coefficients (in units of gravity acceleration ‘g’) for design of equipment and structures where inelastic action is not relevant or not permitted

:

0.20

Note: g = Acceleration due to gravity The horizontal seismic acceleration spectral coefficients are furnished in subsequent pages.

* MCE = Maximum Considered Earthquake. ** DBE = Design Based Earthquake.



PART-B C-0

PAGE 22 OF 42

CLAUSE NO.


Time (T) (s)

Damping (D) 1%

2%

5%

7%

10%

0

1

1

1

1

1

0.015

1

1

1

1

1

0.03

1

1

1

1

1

0.045

1.519589

1.417224

1.276977

1.231218

1.186136

0.06

2.044857

1.815038

1.518872

1.427015

1.338855

0.075

2.574389

2.199016

1.737632

1.600086

1.470729

0.09

3.107343

2.572316

1.939564

1.756965

1.588064

0.105

3.64316

2.936963

2.128497

1.901546

1.694543

0.12

4.18144

3.294364

2.306971

2.03637

1.792533

0.135

4.721884

3.645548

2.476778

2.163207

1.88366

0.15

5.026

3.991298

2.63924

2.283345

1.969094

0.165

5.026

4.007

2.743

2.356

2.004

0.18

5.026

4.007

2.743

2.356

2.004

0.195

5.026

4.007

2.743

2.356

2.004

0.21

5.026

4.007

2.743

2.356

2.004

0.225

5.026

4.007

2.743

2.356

2.004

0.24

5.026

4.007

2.743

2.356

2.004

0.255

5.026

4.007

2.743

2.356

2.004

0.27

5.026

4.007

2.743

2.356

2.004

0.285

5.026

4.007

2.743

2.356

2.004

0.3

5.026

4.007

2.743

2.356

2.004

0.315

5.026

4.007

2.743

2.356

2.004

0.33

5.026

4.007

2.743

2.356

2.004

0.345

5.026

4.007

2.743

2.356

2.004

0.36

5.026

4.007

2.743

2.356

2.004

0.375

5.026

4.007

2.743

2.356

2.004

0.39

5.026

4.007

2.743

2.356

2.004

0.405

5.026

4.007

2.743

2.356

2.004

0.42

5.026

4.007

2.743

2.356

2.004

0.435

5.026

4.007

2.743

2.356

2.004



PART-B C-0

PAGE 23 OF 42

CLAUSE NO.


0.45

5.026

4.007

2.743

2.356

2.004

0.465

5.026

4.007

2.743

2.356

2.004

0.48

5.026

4.007

2.743

2.356

2.004

0.495

5.026

4.007

2.743

2.356

2.004

0.51

5.026

4.007

2.743

2.356

2.004

0.525

5.026

4.007

2.743

2.356

2.004

0.54

5.026

4.007

2.743

2.356

2.004

0.555

5.026

4.007

2.743

2.356

2.004

0.57

5.026

4.007

2.743

2.356

2.004

0.585

5.026

4.007

2.743

2.356

2.004

0.6

5.026

4.007

2.743

2.356

2.004

0.615

5.026

4.007

2.743

2.356

2.004

0.63

5.026

4.007

2.743

2.356

2.004

0.645

5.026

4.007

2.743

2.356

2.004

0.66

5.026

4.007

2.743

2.356

2.004

0.675

5.026

4.007

2.743

2.356

2.004

0.69

5.026

4.007

2.743

2.356

2.004

0.705

5.026

4.007

2.743

2.356

2.004

0.72

5.006944

4.007

2.743

2.356

2.004

0.735

4.904762

4.007

2.743

2.356

2.004

0.75

4.806667

4.007

2.743

2.356

2.004

0.765

4.712418

3.950327

2.743

2.356

2.004

0.78

4.621795

3.874359

2.743

2.356

2.004

0.795

4.534591

3.801258

2.743

2.356

1.973585

0.81

4.450617

3.730864

2.706173

2.319753

1.937037

0.825

4.369697

3.66303

2.65697

2.277576

1.901818

0.84

4.291667

3.597619

2.609524

2.236905

1.867857

0.855

4.216374

3.534503

2.563743

2.197661

1.835088

0.87

4.143678

3.473563

2.51954

2.15977

1.803448

0.885

4.073446

3.414689

2.476836

2.123164

1.772881

0.9

4.005556

3.357778

2.435556

2.087778

1.743333

0.915

3.939891

3.302732

2.395628

2.053552

1.714754



PART-B C-0

PAGE 24 OF 42

CLAUSE NO.


0.93

3.876344

3.249462

2.356989

2.02043

1.687097

0.945

3.814815

3.197884

2.319577

1.98836

1.660317

0.96

3.755208

3.147917

2.283333

1.957292

1.634375

0.975

3.697436

3.099487

2.248205

1.927179

1.609231

0.99

3.641414

3.052525

2.214141

1.89798

1.584848

1.005

3.587065

3.006965

2.181095

1.869652

1.561194

1.02

3.534314

2.962745

2.14902

1.842157

1.538235

1.035

3.483092

2.919807

2.117874

1.815459

1.515942

1.05

3.433333

2.878095

2.087619

1.789524

1.494286

1.065

3.384977

2.837559

2.058216

1.764319

1.473239

1.08

3.337963

2.798148

2.02963

1.739815

1.452778

1.095

3.292237

2.759817

2.001826

1.715982

1.432877

1.11

3.247748

2.722523

1.974775

1.692793

1.413514

1.125

3.204444

2.686222

1.948444

1.670222

1.394667

1.14

3.162281

2.650877

1.922807

1.648246

1.376316

1.155

3.121212

2.61645

1.897835

1.62684

1.358442

1.17

3.081197

2.582906

1.873504

1.605983

1.341026

1.185

3.042194

2.550211

1.849789

1.585654

1.324051

1.2

3.004167

2.518333

1.826667

1.565833

1.3075

1.215

2.967078

2.487243

1.804115

1.546502

1.291358

1.23

2.930894

2.456911

1.782114

1.527642

1.27561

1.245

2.895582

2.427309

1.760643

1.509237

1.260241

1.26

2.861111

2.398413

1.739683

1.49127

1.245238

1.275

2.827451

2.370196

1.719216

1.473725

1.230588

1.29

2.794574

2.342636

1.699225

1.456589

1.216279

1.305

2.762452

2.315709

1.679693

1.439847

1.202299

1.32

2.731061

2.289394

1.660606

1.423485

1.188636

1.335

2.700375

2.26367

1.641948

1.407491

1.175281

1.35

2.67037

2.238519

1.623704

1.391852

1.162222

1.365

2.641026

2.213919

1.605861

1.376557

1.149451

1.38

2.612319

2.189855

1.588406

1.361594

1.136957

1.395

2.584229

2.166308

1.571326

1.346953

1.124731



PART-B C-0

PAGE 25 OF 42

CLAUSE NO.


1.41

2.556738

2.143262

1.55461

1.332624

1.112766

1.425

2.529825

2.120702

1.538246

1.318596

1.101053

1.44

2.503472

2.098611

1.522222

1.304861

1.089583

1.455

2.477663

2.076976

1.506529

1.291409

1.078351

1.47

2.452381

2.055782

1.491156

1.278231

1.067347

1.485

2.427609

2.035017

1.476094

1.26532

1.056566

1.5

2.403333

2.014667

1.461333

1.252667

1.046

1.515

2.379538

1.994719

1.446865

1.240264

1.035644

1.53

2.356209

1.975163

1.43268

1.228105

1.02549

1.545

2.333333

1.955987

1.41877

1.216181

1.015534

1.56

2.310897

1.937179

1.405128

1.204487

1.005769

1.575

2.288889

1.91873

1.391746

1.193016

0.99619

1.59

2.267296

1.900629

1.378616

1.181761

0.986792

1.605

2.246106

1.882866

1.365732

1.170717

0.97757

1.62

2.225309

1.865432

1.353086

1.159877

0.968519

1.635

2.204893

1.848318

1.340673

1.149235

0.959633

1.65

2.184848

1.831515

1.328485

1.138788

0.950909

1.665

2.165165

1.815015

1.316517

1.128529

0.942342

1.68

2.145833

1.79881

1.304762

1.118452

0.933929

1.695

2.126844

1.782891

1.293215

1.108555

0.925664

1.71

2.108187

1.767251

1.281871

1.09883

0.917544

1.725

2.089855

1.751884

1.270725

1.089275

0.909565

1.74

2.071839

1.736782

1.25977

1.079885

0.901724

1.755

2.054131

1.721937

1.249003

1.070655

0.894017

1.77

2.036723

1.707345

1.238418

1.061582

0.886441

1.785

2.019608

1.692997

1.228011

1.052661

0.878992

1.8

2.002778

1.678889

1.217778

1.043889

0.871667

1.815

1.986226

1.665014

1.207713

1.035262

0.864463

1.83

1.969945

1.651366

1.197814

1.026776

0.857377

1.845

1.95393

1.63794

1.188076

1.018428

0.850407

1.86

1.938172

1.624731

1.178495

1.010215

0.843548

1.875

1.922667

1.611733

1.169067

1.002133

0.8368



PART-B C-0

PAGE 26 OF 42

CLAUSE NO.


1.89

1.907407

1.598942

1.159788

0.99418

0.830159

1.905

1.892388

1.586352

1.150656

0.986352

0.823622

1.92

1.877604

1.573958

1.141667

0.978646

0.817188

1.935

1.863049

1.561757

1.132817

0.971059

0.810853

1.95

1.848718

1.549744

1.124103

0.96359

0.804615

1.965

1.834606

1.537913

1.115522

0.956234

0.798473

1.98

1.820707

1.526263

1.107071

0.94899

0.792424

1.995

1.807018

1.514787

1.098747

0.941855

0.786466

2.01

1.793532

1.503483

1.090547

0.934826

0.780597

2.025

1.780247

1.492346

1.082469

0.927901

0.774815

2.04

1.767157

1.481373

1.07451

0.921078

0.769118

2.055

1.754258

1.47056

1.066667

0.914355

0.763504

2.07

1.741546

1.459903

1.058937

0.907729

0.757971

2.085

1.729017

1.4494

1.051319

0.901199

0.752518

2.1

1.716667

1.439048

1.04381

0.894762

0.747143

2.115

1.704492

1.428842

1.036407

0.888416

0.741844

2.13

1.692488

1.418779

1.029108

0.88216

0.73662

2.145

1.680653

1.408858

1.021911

0.875991

0.731469

2.16

1.668981

1.399074

1.014815

0.869907

0.726389

2.175

1.657471

1.389425

1.007816

0.863908

0.721379

2.19

1.646119

1.379909

1.000913

0.857991

0.716438

2.205

1.634921

1.370522

0.994104

0.852154

0.711565

2.22

1.623874

1.361261

0.987387

0.846396

0.706757

2.235

1.612975

1.352125

0.980761

0.840716

0.702013

2.25

1.602222

1.343111

0.974222

0.835111

0.697333

2.265

1.591611

1.334216

0.96777

0.829581

0.692715

2.28

1.58114

1.325439

0.961404

0.824123

0.688158

2.295

1.570806

1.316776

0.95512

0.818736

0.68366

2.31

1.560606

1.308225

0.948918

0.81342

0.679221

2.325

1.550538

1.299785

0.942796

0.808172

0.674839

2.34

1.540598

1.291453

0.936752

0.802991

0.670513

2.355

1.530786

1.283227

0.930786

0.797877

0.666242



PART-B C-0

PAGE 27 OF 42

CLAUSE NO.


2.37

1.521097

1.275105

0.924895

0.792827

0.662025

2.385

1.51153

1.267086

0.919078

0.787841

0.657862

2.4

1.502083

1.259167

0.913333

0.782917

0.65375

2.415

1.492754

1.251346

0.90766

0.778054

0.649689

2.43

1.483539

1.243621

0.902058

0.773251

0.645679

2.445

1.474438

1.235992

0.896524

0.768507

0.641718

2.46

1.465447

1.228455

0.891057

0.763821

0.637805

2.475

1.456566

1.22101

0.885657

0.759192

0.633939

2.49

1.447791

1.213655

0.880321

0.754618

0.63012

2.505

1.439122

1.206387

0.87505

0.7501

0.626347

2.52

1.430556

1.199206

0.869841

0.745635

0.622619

2.535

1.422091

1.19211

0.864694

0.741223

0.618935

2.55

1.413725

1.185098

0.859608

0.736863

0.615294

2.565

1.405458

1.178168

0.854581

0.732554

0.611696

2.58

1.397287

1.171318

0.849612

0.728295

0.60814

2.595

1.38921

1.164547

0.844701

0.724085

0.604624

2.61

1.381226

1.157854

0.839847

0.719923

0.601149

2.625

1.373333

1.151238

0.835048

0.71581

0.597714

2.64

1.36553

1.144697

0.830303

0.711742

0.594318

2.655

1.357815

1.13823

0.825612

0.707721

0.59096

2.67

1.350187

1.131835

0.820974

0.703745

0.58764

2.685

1.342644

1.125512

0.816387

0.699814

0.584358

2.7

1.335185

1.119259

0.811852

0.695926

0.581111

2.715

1.327808

1.113076

0.807366

0.692081

0.577901

2.73

1.320513

1.10696

0.80293

0.688278

0.574725

2.745

1.313297

1.100911

0.798543

0.684517

0.571585

2.76

1.306159

1.094928

0.794203

0.680797

0.568478

2.775

1.299099

1.089009

0.78991

0.677117

0.565405

2.79

1.292115

1.083154

0.785663

0.673477

0.562366

2.805

1.285205

1.077362

0.781462

0.669875

0.559358

2.82

1.278369

1.071631

0.777305

0.666312

0.556383

2.835

1.271605

1.065961

0.773192

0.662787

0.553439



PART-B C-0

PAGE 28 OF 42

CLAUSE NO.


2.85

1.264912

1.060351

0.769123

0.659298

0.550526

2.865

1.25829

1.054799

0.765096

0.655846

0.547644

2.88

1.251736

1.049306

0.761111

0.652431

0.544792

2.895

1.24525

1.043869

0.757168

0.64905

0.541969

2.91

1.238832

1.038488

0.753265

0.645704

0.539175

2.925

1.232479

1.033162

0.749402

0.642393

0.53641

2.94

1.22619

1.027891

0.745578

0.639116

0.533673

2.955

1.219966

1.022673

0.741794

0.635871

0.530964

2.97

1.213805

1.017508

0.738047

0.63266

0.528283

2.985

1.207705

1.012395

0.734338

0.629481

0.525628

3

1.201667

1.007333

0.730667

0.626333

0.523

3.015

1.195688

1.002322

0.727032

0.623217

0.520398

3.03

1.189769

0.99736

0.723432

0.620132

0.517822

3.045

1.183908

0.992447

0.719869

0.617077

0.515271

3.06

1.178105

0.987582

0.71634

0.614052

0.512745

3.075

1.172358

0.982764

0.712846

0.611057

0.510244

3.09

1.166667

0.977994

0.709385

0.608091

0.507767

3.105

1.161031

0.973269

0.705958

0.605153

0.505314

3.12

1.155449

0.96859

0.702564

0.602244

0.502885

3.135

1.14992

0.963955

0.699203

0.599362

0.500478

3.15

1.144444

0.959365

0.695873

0.596508

0.498095

3.165

1.139021

0.954818

0.692575

0.593681

0.495735

3.18

1.133648

0.950314

0.689308

0.590881

0.493396

3.195

1.128326

0.945853

0.686072

0.588106

0.49108

3.21

1.123053

0.941433

0.682866

0.585358

0.488785

3.225

1.117829

0.937054

0.67969

0.582636

0.486512

3.24

1.112654

0.932716

0.676543

0.579938

0.484259

3.255

1.107527

0.928418

0.673425

0.577266

0.482028

3.27

1.102446

0.924159

0.670336

0.574618

0.479817

3.285

1.097412

0.919939

0.667275

0.571994

0.477626

3.3

1.092424

0.915758

0.664242

0.569394

0.475455

3.315

1.087481

0.911614

0.661237

0.566817

0.473303



PART-B C-0

PAGE 29 OF 42

CLAUSE NO.


3.33

1.082583

0.907508

0.658258

0.564264

0.471171

3.345

1.077728

0.903438

0.655306

0.561734

0.469058

3.36

1.072917

0.899405

0.652381

0.559226

0.466964

3.375

1.068148

0.895407

0.649481

0.556741

0.464889

3.39

1.063422

0.891445

0.646608

0.554277

0.462832

3.405

1.058737

0.887518

0.643759

0.551836

0.460793

3.42

1.054094

0.883626

0.640936

0.549415

0.458772

3.435

1.049491

0.879767

0.638137

0.547016

0.456769

3.45

1.044928

0.875942

0.635362

0.544638

0.454783

3.465

1.040404

0.87215

0.632612

0.54228

0.452814

3.48

1.03592

0.868391

0.629885

0.539943

0.450862

3.495

1.031474

0.864664

0.627182

0.537625

0.448927

3.51

1.027066

0.860969

0.624501

0.535328

0.447009

3.525

1.022695

0.857305

0.621844

0.53305

0.445106

3.54

1.018362

0.853672

0.619209

0.530791

0.44322

3.555

1.014065

0.85007

0.616596

0.528551

0.44135

3.57

1.009804

0.846499

0.614006

0.526331

0.439496

3.585

1.005579

0.842957

0.611437

0.524128

0.437657

3.6

1.001389

0.839444

0.608889

0.521944

0.435833

3.615

0.997234

0.835961

0.606362

0.519779

0.434025

3.63

0.993113

0.832507

0.603857

0.517631

0.432231

3.645

0.989026

0.829081

0.601372

0.515501

0.430453

3.66

0.984973

0.825683

0.598907

0.513388

0.428689

3.675

0

0.822313

0.596463

0.511293

0.426939

3.69

0

0.81897

0.594038

0.509214

0.425203

3.705

0

0.815655

0.591633

0.507152

0.423482

3.72

0

0.812366

0.589247

0.505108

0.421774

3.735

0

0.809103

0.586881

0.503079

0.42008

3.75

0

0.805867

0.584533

0.501067

0.4184

3.765

0

0.802656

0.582205

0.49907

0.416733

3.78

0

0.799471

0.579894

0.49709

0.415079

3.795

0

0.796311

0.577602

0.495125

0.413439



PART-B C-0

PAGE 30 OF 42

CLAUSE NO.


3.81

0

0.793176

0.575328

0.493176

0.411811

3.825

0

0.790065

0.573072

0.491242

0.410196

3.84

0

0.786979

0.570833

0.489323

0.408594

3.855

0

0

0.568612

0.487419

0.407004

3.87

0

0

0.566408

0.48553

0.405426

3.885

0

0

0.564221

0.483655

0.403861

3.9

0

0

0.562051

0.481795

0.402308

3.915

0

0

0.559898

0.479949

0.400766

3.93

0

0

0.557761

0.478117

0.399237

3.945

0

0

0.55564

0.476299

0.397719

3.96

0

0

0.553535

0.474495

0.396212

3.975

0

0

0.551447

0.472704

0.394717

3.99

0

0

0.549373

0.470927

0.393233

4.005

0

0

0.547316

0.469164

0.39176

4.02

0

0

0.545274

0.467413

0.390299

4.035

0

0

0.543247

0.465675

0.388848

4.05

0

0

0.541235

0.463951

0.387407

4.065

0

0

0.539237

0.462239

0.385978

4.08

0

0

0.537255

0.460539

0.384559

4.095

0

0

0.535287

0.458852

0.38315

4.11

0

0

0.533333

0.457178

0.381752

4.125

0

0

0.531394

0.455515

0.380364

4.14

0

0

0.529469

0.453865

0.378986

4.155

0

0

0.527557

0.452226

0.377617

4.17

0

0

0.525659

0.4506

0.376259

4.185

0

0

0.523775

0.448984

0.37491

4.2

0

0

0.521905

0.447381

0.373571

4.215

0

0

0.520047

0.445789

0.372242

4.23

0

0

0.518203

0.444208

0.370922

4.245

0

0

0.516372

0.442638

0.369611

4.26

0

0

0.514554

0.44108

0.36831

4.275

0

0

0.512749

0.439532

0.367018



PART-B C-0

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CLAUSE NO.


4.29

0

0

0.510956

0.437995

0.365734

4.305

0

0

0.509175

0.436469

0.36446

4.32

0

0

0.507407

0.434954

0.363194

4.335

0

0

0.505652

0.433449

0.361938

4.35

0

0

0.503908

0.431954

0.36069

4.365

0

0

0.502176

0.43047

0.35945

4.38

0

0

0

0.428995

0.358219

4.395

0

0

0

0.427531

0.356997

4.41

0

0

0

0.426077

0.355782

4.425

0

0

0

0.424633

0.354576

4.44

0

0

0

0.423198

0.353378

4.455

0

0

0

0.421773

0.352189

4.47

0

0

0

0.420358

0.351007

4.485

0

0

0

0.418952

0.349833

4.5

0

0

0

0.417556

0.348667

4.515

0

0

0

0.416168

0.347508

4.53

0

0

0

0.41479

0.346358

4.545

0

0

0

0.413421

0.345215

4.56

0

0

0

0.412061

0.344079

4.575

0

0

0

0.41071

0.342951

4.59

0

0

0

0.409368

0.34183

4.605

0

0

0

0.408035

0.340717

4.62

0

0

0

0.40671

0.33961

4.635

0

0

0

0.405394

0.338511

4.65

0

0

0

0.404086

0.337419

4.665

0

0

0

0.402787

0.336334

4.68

0

0

0

0.401496

0.335256

4.695

0

0

0

0.400213

0.334185

4.71

0

0

0

0

0.333121

4.725

0

0

0

0

0.332063

4.74

0

0

0

0

0.331013

4.755

0

0

0

0

0.329968



PART-B C-0

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CLAUSE NO.


4.77

0

0

0

0

0.328931

4.785

0

0

0

0

0.3279

4.8

0

0

0

0

0.326875

4.815

0

0

0

0

0.325857

4.83

0

0

0

0

0.324845

4.845

0

0

0

0

0.323839

4.86

0

0

0

0

0.32284

4.875

0

0

0

0

0.321846

4.89

0

0

0

0

0.320859

4.905

0

0

0

0

0.319878

4.92

0

0

0

0

0.318902

4.935

0

0

0

0

0.317933

4.95

0

0

0

0

0.31697

4.965

0

0

0

0

0.316012

4.98

0

0

0

0

0.31506

4.995

0

0

0

0

0.314114



PART-B C-0

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CLAUSE NO.


ANNEXURE-I CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT All structures shall be designed for seismic forces adopting the site specific seismic information provided in this document and using the other provisions in accordance with IS:1893 (Part 1):2002. Pending finalisation of Parts 2 to 5 of IS:1893, provisions of part 1 shall be read along with the relevant clauses of IS:1893:1984, for structures other than the buildings. A site specific seismic study has been conducted for the project site. The peak ground horizontal acceleration for the project site, the site specific acceleration spectral coefficients (in units of gravity acceleration ‘g’) in the horizontal direction for the various damping values and the multiplying factor (to be used over the spectral coefficients) for evaluating the design acceleration spectra are as given at the end of this Annexure. Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding horizontal values. The site specific design acceleration spectra shall be used in place of the response acceleration spectra, given at figure-2 in IS:1893 (Part 1). The site specific acceleration spectra along with multiplying factors specified in Annexure-I includes the effect of the seismic environment of the site, the importance factor related to the structures and the response reduction factor. Hence, the design spectra do not require any further consideration of the zone factor (Z), the importance factor (I) and response reduction factor (R) as used in the IS:1893 (Part 1). Damping in Structures The damping factor (as a percentage of critical damping) to be adopted shall not be more than as indicated below for: a)

Steel structures

:

2%

b)

Concrete structures and brick structures in cement mortar

:

5%

c)

Concrete Stacks / ND Cooling Towers

:

2%

d)

Steel stacks

:

As per IS:6533 & CICIND Model Code, whichever is more critical.



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CLAUSE NO.


Method of Analysis Since most structures in a power plant are irregular in shape and have irregular distribution of mass and stiffness, dynamic analysis for obtaining the design seismic forces shall be carried out using the response spectrum method. The number of vibration modes used in the analysis should be such that the sum total of modal masses of all modes considered is at least 90 percent of the total seismic mass and shall also meet requirements of IS:1893 (Part 1). Modal combination of the peak response quantities shall be performed as per Complete Quadratic Combination (CQC) method or by an acceptable alternative as per IS:1893 (Part 1). If the design base shear (VB) , obtained from modal combination, is less than the base shear (‘VB), computed using the approximate fundamental period (Ta) given in IS:1893:Part 1 and using site specific acceleration spectra with appropriate multiplying factor, the response quantities (e.g. member forces, displacements, storey forces, storey shears and base reactions) shall be enhanced in the ratio of ‘VB/ VB. However, no reduction is permitted if ‘VB is less than VB. For building less than 12m in height, design seismic base shear and its distribution to different floor levels along the height of the building may be carried out as specified under clause 7.5, 7.6 & 7.7 of IS:1893 (Part 1) and using site specific design acceleration spectra. The design horizontal acceleration spectrum value (Ah) shall be computed for the fundamental natural period as per clause 7.6 of IS:1893 (Part 1) using site specific spectral acceleration coefficients with appropriate multiplying factor given in Annexure-I. Further, the spectral acceleration coefficient shall get restricted to the peak spectral value if the fundamental natural period of the structure falls to the left of the peak in the spectral acceleration curve. Design/Detailing for Ductility The site specific design acceleration spectra is a reduced spectra and has an in-built allowance for ductility. Structures shall be engineered and detailed in accordance with relevant Indian/International standards to achieve ductility.



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CLAUSE NO.


ANNEXURE-II CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT All structures shall be designed for wind forces in accordance with IS:875 (Part-3) and as specified in this document. Site specific information is given at the end of this Annexure. Along wind forces shall generally be computed by the Peak (i.e. 3 second gust) Wind Speed method as defined in the standard. Along wind forces on slender and wind sensitive structures and structural elements shall also be computed, for dynamic effects, using the Gust Factor or Gust Effectiveness Factor Method as defined in the standard. The structures shall be designed for the higher of the forces obtained from Gust Factor method and the Peak Wind Speed method. Analysis for dynamic effects of wind must be undertaken for any structure which has a height to minimum lateral dimension ratio greater than “5” and/or if the fundamental frequency of the structure is less than 1 Hz. Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc. should be examined and designed/detailed accordingly following the recommendations of IS:875 (Part-3) and other relevant Indian standards. It should be estimated if size and relative position of other structures are likely to enhance the wind loading on the structure under consideration. Enhancement factor, if necessary, shall suitably be estimated and applied to the wind loading to account for the interference effects. Damping in Structures The damping factor (as a percentage of critical damping) to be adopted shall not be more than as indicated below for: a)

Welded steel structures

:

1.0%

b)

Bolted steel structures

:

2.0%

c)

Reinforced concrete structures

:

1.6%

d)

Steel stacks

:

As per IS:6533 & CICIND Model Code whichever is more critical.



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CLAUSE NO.


SITE SPECIFIC DESIGN PARAMETERS The various design parameters, as defined in IS: 875 (Part-3), to be adopted for the project site shall be as follows: a)

The basic wind speed “V ” at ten b metres above the mean ground level

: 39 metres/second

b)

The risk coefficient “K ” 1

: 1.06

c)

Category of terrain

: Category-1

Note:

Notwithstanding the values of the above mentioned parameters, the design wind pressure so computed at any point shall not be taken less than 195 Kg/m2 based as IS:802 (1977) for design of Switchyard Gravity & equipment supporting structure.



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CLAUSE NO.


ANNEXURE-III

FOUNDATION SYSTEM AND GEOTECHNICAL DATA 1.00.00

SOIL DATA AND FOUNDATION SYSTEM Recommended bearing capacity for design of foundations and Bore-log data is given at Annexure to this chapter. The requirements for the foundation systems to be adopted are as given in the following clauses.

1.01.00

Soil Data

1.01.01

Employer has carried out detailed GEOTECHNICAL INVESTIGATION in the areas pertaining to this package. The detailed geotechnical investigation report comprising of boreholes, Laboratory tests, Chemical analysis, etc. in respect of the sub-strata prevailing at site will be made available for the Bidder’s study at the Employer’s office, if required. The onus of correct assessment / interpretation and understanding of the existing subsoil condition / data is on the Bidder.

1.02.00

Foundation System The requirements for the foundation system to be adopted are as given in subsequent clauses.

1.02.01

General Requirements (a)

All structures/equipment shall be supported either on suitable open foundations (isolated, combined, raft) or on pile foundations as required.

(b)

The roads, ground floor slabs, trenches, channels/drains and other lightly loaded structures (such as staircase foundation with foundation loading intensity less than 5 T / M2) may be supported on open / shallow foundations resting on virgin / controlled compacted filled up soil.

(c)

All foundations shall be designed in accordance with relevant parts of the latest revisions of Indian Standards. The water table for design purpose shall be considered at Finished Ground Level.

(d)

No other foundation shall rest on the filled up ground / soil.

(e)

A combination of open and pile foundations shall not be permitted under the same equipment / structure / building.

(f)

It shall be ensured that all foundations of a particular equipment / structure / building shall rest on one bearing stratum.

(g)

For identifying the sub strata for founding purposes, the Contractor shall depute / post an experienced geotechnical Engineer / Geologist at site to verify and ensure that the foundations rest in the specified strata.



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CLAUSE NO.

1.02.02


Open Foundations In case open foundations are adopted, following shall be adhered to. (a)

The minimum width of foundation shall be 1.0 m.

(b)

The minimum depth of foundation shall be 1.0 m below natural ground level.

(c)

Minimum founding level, bearing capacity and permissible settlements shall be as given in the Annexure - 1 to this specification. The bearing capacities higher than those mentioned in the Annexure - 1 shall not be permitted. At intermediate founding levels, the bearing capacity shall be considered same as the net allowable bearing pressure corresponding to the immediate shallow level.

(d)

GWT shall be considered at F.G.L for design of Foundation.

Incase pile foundations are to be adopted the requirements under para “pile foundations” shall be adhered to. 1.03.00

Special Requirements

1.03.01

Details of treatment for foundations / underground structures required to counteract soil / water chemical environment, cement type, grade of concrete, type of reinforcement, cover to reinforcement and protective coating to foundations, etc. shall be as mentioned in Annexure-1 of this specification.

1.04.00

Excavation and Filling

1.04.01

For excavation works, comprehensive dewatering arrangement wherever required shall be adopted.

1.04.02

Excavation for shallow foundations shall be covered with PCC immediately after reaching the founding level. In case of any local loosening of soil or pockets are encountered at founding level during excavation the same shall be removed and compensated by PCC M 7.5. The foundation pits shall be maintained dry during construction period.

1.04.03

The final layer of about 300 mm thickness above the founding level shall be excavated by suitable means, so as to avoid disturbance to founding stratum.

1.04.04

Backfilling around foundations, pipes, trenches, sumps, pits, plinths, etc. shall be carried out with approved material in layers not exceeding 300 mm thick when compacted and each layer shall be compacted to 90% of standard proctor density for cohesive soils and to 75% of relative density for non cohesive soils.

1.04.05

The founding level for trenches/channels shall be decided as per functional requirement. The bottom of excavation shall be properly compacted prior to casting of bottom slab of trenches / channels.



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CLAUSE NO.


1.04.06

CBR tests for pavement design shall be carried out by the Contractor after earth filling (if applicable) has been completed upto the formation level.

1.04.07

Following details shall be submitted by the Bidder before start of work at site. (a)

Scheme for initial pile load tests in vertical, lateral and uplift modes along with supporting design calculations and methodology for installation of working piles and the complete piles installation data for individual pile including the pile test result for all piles (for reference only).

(b)

Analysis of proportioning of major footings to minimise differential settlement.

(c)

Scheme of dewatering, sheet piling, etc. to the Engineer at site for his reference.

For open foundations, the total permissible settlement and differential settlement shall be governed by IS:1904 / IS:13063 and from functional requirements, whichever is more stringent. However, total settlement shall not exceed the values given in Annexure - 1 of this specification.



PART-B C-0

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CLAUSE NO.


SOIL DATA AND FOUNDATION SYSTEM a)

Logs of representative boreholes from this area are enclosed with this Annexure.

b)

Foundation system to be adopted for various structures shall be as given in Table - 1 below.

Table – 1 : Foundation System for Switchyard Structures ---------------------------------------------------------------------------------------------------------------Switchyard Structure TYPE OF FOUNDATION TO BE ADOPTED --------------------------------------------------------------------------------------------------------------Tower foundations

Raft Foundation

Equipment foundations

Open Foundation

Cable trenches etc.

Open Foundation

---------------------------------------------------------------------------------------------------------------c)

For Isolator, combined foundation shell be provided for each pole.

d)

The minimum founding level and the corresponding net allowable bearing pressure shall be as given in Table – 2 below.

Table – 2: Net Allowable Bearing Pressure ---------------------------------------------------------------------------------------------------------------Structure Founding Width/ Net Remarks Level Diameter of Allowable Foundation Bearing (m) Pressure t/m2 --------------------------------------------------------------------------------------------------------------Structures in 1.5 m below 1 to 6 Finished Switchyard NGL > 6 (Rafts) 10 Ground Level (FGL) is 3.54.0 m above Natural Ground Level (NGL) 3.0m 1 to 6 10 below NGL > 6 (Rafts) -------------------------------------------------------------------------------------------------------------The net allowable bearing pressure higher than above mentioned values shall not be permitted. At intermediate levels the bearing capacity shall be same as the net allowable bearing pressure corresponding to the immediate shallower level mentioned above. The test for the safe bearing capacity shall be carried out by the Contractor at no extra cost to NTPC for detailed TAPOVAN VISHNU HYDRO ELECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2


PART-B C-0

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CLAUSE NO.


designing purposes. In case the actual value is different from the above value, actual value shall be taken for the detailed design. e)

Excavations for foundations shall be covered with PCC immediately after reaching the founding level. In case of any local loosening of soil or if loose pockets are encountered, at the founding level during excavation, the same shall be removed and compensated by PCC (1:3:6). The foundation pits shall be maintained dry during the complete construction period.

f)

Permissible Settlement of Foundations: For open foundations, the total permissible settlement and differential settlement shall be governed by IS: 1904 / IS: 13063 and from functional requirements whichever is more stringent. However, total settlement shall be restricted to the following: Isolated Foundations

40 mm

Raft (widths greater than 6 m)

75 mm

In case the total permissible settlement is to be restricted to less than as above specified from functional requirements, then the net allowable bearing pressure shall be reduced / reviewed accordingly in consultation with Employer. g)

For roads, ground floor slabs, trenches and other lightly loaded structures, the safe bearing capacity shall be limited to 5 t/m2 resting at 1.0 m depth in virgin / controlled compacted filled up soil.



PART-B C-0

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PART - C



TECHNICAL SPECIFICATION SECTION-VI PART-C

TABLE OF CONTENTS PART - C GENERAL TECHNICAL REQUIREMENTS

-----------------------------------------------------------------------------------------------------------------------------------CLAUSE NO. DESCRIPTION PAGE NO. -----------------------------------------------------------------------------------------------------------------------------------1.00.00

General Technical Requirements

1

1.01.00

General Requirements

1

1.02.00

Limit of Contract

3

1.03.00

Standards

3

1.04.00

Name Plate

4

1.05.00

Galvanising

4

1.06.00

Painting

5

1.07.00

Quality Assurance Programme

5

1.08.00

General Requirements – Quality Assurance

7

1.09.00

Burn in and Elevated Temperature - Test Requirement for Electronics Solid State Equipment

10

1.10.00

Quality Assurance Documents

11

1.11.00

Transmission of Quality Documents

12

1.12.00

Engineer’s Supervision

13

1.13.00

Inspection, Testing and Inspection Certificates

13

1.14.00

Associated Document

15

1.15.00

Quality Assurance Programme for Civil Work

15

1.16.00

Associated Document for Quality Programme

21

1.17.00

Training of Employer’s Personnel

21

1.18.00

Packing, Transportation and Storage

23

1.19.00

Engineering Coordination Procedure

25

1.20.00

Reference Drawings

28

1.21.00

Taking Over

29


TECHNICAL SPECIFICATION SECTION-VI PART-C

CLAUSE NO.

1.00.00

GENERAL TECHNICAL REQUIREMENTS GENERAL TECHNICAL REQUIREMENTS In addition to the technical requirements stipulated elsewhere in the specification, the following requirements shall also be applicable.

1.01.00

General Requirements

1.01.01

The equipment must be new, of highest grade, best quality of their kind, to best engineering practice and latest state of art, and in accordance with purpose for which they are intended and to ensure satisfactory performance throughout the service life.

1.01.02

The Contractor shall note that the equipment offered by him in the bid only shall be accepted for supply, with the minimum modifications as agreed/accepted.

1.01.03

The auxiliary power shall be of the following parameters: ---------------------------------------------------------------------------------------------------------------Nominal Variations Frequency Phase Neutral connection Voltage in voltage (Hz) ---------------------------------------------------------------------------------------------------------------415V

+ 10%

50 + 5%

3

Solidly earthed

240V + 10% 50 + 5% 4 Solidly earthed ---------------------------------------------------------------------------------------------------------------Combined variation of voltage and frequency shall be + 10%. Fault level of 415V system shall not be less than 45kA. 1.01.04

All equipment/systems shall be designed for ambient temperature of 40 deg.C.

1.01.05

The equipment and systems shall conform in all aspects to high standards of engineering, design and workmanship and shall be capable of continuous commercial operation in the specified manner and shall also be in line with the current practice for reliable and efficient functioning of system. The Employer will interpret the meaning of the specifications, data, drawings, etc., and shall have a right to reject or accept any work or material which in his assessment does not meet the requirement of this specification and /or applicable national and international standards, codes, rules, etc.

1.01.06

In the event of a conflict between requirements of any two clauses of the specification, documents or requirements of different codes/standards specified, interpretation of the Employer shall apply, unless confirmed otherwise by the Employer in writing based on a written request from the Contractor.

1.01.07

In addition the Employer shall have the right to reject any materials or equipment which is not of type proven in service in similar applications or which is not supplied by a manufacturer with the applicable experience. Whenever a material or equipment is specified by reference to a particular brand name, manufacturer or

TAPOVAN VISHNUGAD HYDRO LECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2


PART-C

PAGE 1 OF 100

CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS vendor, the Contractor may supply another manufacturer’s equivalent product if sufficient information is furnished so as to enable the Employer to determine, without the need for any additional clarification/data, that the products proposed are proved and equivalent or superior to those named.

1.01.08

In accordance with the specific instructions as shown on manufacturer’s drawings or as directed by the Employer or his representative, the Contractor shall unload, store, erect, install, wire, test and place into commercial use all electrical equipment included in the contract. Equipment shall be installed in a neat and workman like manner so that it is level, plumb square and properly aligned and oriented. Commercial use of switchgear equipment shall mean completion of all site tests specified and energisation at rated voltage.

1.01.09

The Contractor shall be responsible for obtaining statutory clearance from the concerned authorities for commissioning the equipment and the switchyard .

1.01.10

Manufacturer’s drawings, instructions and recommendations shall be correctly followed in handling, setting, testing and commissioning of all equipment and structures. Care shall be exercised in handling to avoid distortion to stationary structures, damage to the finish, damage to delicate instruments or other electrical parts. Adjustment shall be made wherever necessary to the stationary structures for plumb and level, for the sake of appearance or to avoid twisting of frames or bending of hinged members.

1.01.11

During erection, the equipment furnished with finish coats of paint shall be touched up by the Contractor if their surface is spoiled or marred while handling.

1.01.12

The Contractor shall supply the normal consumables, adhesives, filling compounds, touch up paints, soldering/brazing materials, wherever required.

1.01.13

The Contractor shall also supply the requisite name plates, number plates, phase plates, colour plates, labels, etc.

1.01.14

The Contractor’s responsibility under the contract shall also generally include: (a)

The adherence to the dimensions of parts, specifications and locations thereof as shown on the drawings/documents except for deviations or variations specifically reviewed and authorized by the Employer/Engineer.

(b)

To ensure the strength of all parts, materials and equipment to withstand all stresses including electrical, mechanical, seismic and other forces which may be experienced or expected during long term operations as well as those stresses caused by faults, switching operations and abnormal system conditions.

(c)

The correct application, and the satisfactory and proper performance of all material, equipment, structures, systems and auxiliary services under all specified operating conditions without signs of undue strain and without breakdown, damage or deterioration of any of the equipment due to faulty or



PART-C

PAGE 2 OF 100

CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS unsuitable material, equipment, workmanship, design, erection, construction, installation and commissioning. (d)

The correct, safe and proper installation of all equipment at the site.

(e)

The transportation of all temporary and permanent materials, equipment and apparatus from the places of manufacture to the site, and the subsequent removal of temporary materials, equipment and structures.

(f)

The supply of complete documentation including drawings, specifications, reports, quality control documents, operating/maintenance/commissioning procedures and manuals for all works equipment.

(g)

To replace/modify/correct any faulty equipment/systems found at any time up to the completion of the guaranteed period.

1.01.15

The Contractor shall take utmost care while working so that no damage is done to existing equipment. The Contractor shall be liable to pay for the damage done by making good the loss.

1.01.16

The Contractor shall cooperate in all aspects and exchange the necessary technical data /drawings with the other agencies and Employer’s consultants/contractors to ensure proper coordination and completion of work in time.

1.02.00

Limit of Contract All the equipment, materials and services furnished by the Contractor shall be complete in every respect with all mountings, fitting, fixtures and standard accessories normally provided with such equipment, and needed for erection, completion and safe operation of the equipment as required by applicable codes though they may not have been specifically detailed in technical specification and unless included in the list of exclusions. The Contractor shall supply at no extra cost to Employer any additional material/service not covered specifically but which are found to be required for fulfillment of the scope of work under specification.

1.03.00

Standards

1.03.01

The Contractor is required to follow local statutory regulations stipulated in the latest amended Electricity Supply Act 1948 and Indian Electricity Rules 1956, and other local rules and regulations.

1.03.02

The equipment to be furnished under this specification shall conform to latest issue with all amendments of standards and/or codes specified under respective section heads. The standards mentioned in the specification are not mutually exclusive or complete in themselves, but intended to compliment each other. The Contractor shall also note that list of standards presented in this specification is not complete. Whenever necessary the list of standards shall be considered in conjunction with specific IS/IEC. When the specified requirements stipulated in the specifications exceed or differ than those required by the applicable standards, the stipulation of the specification shall take precedence.



PART-C

PAGE 3 OF 100

CLAUSE NO.


1.03.03

Other internationally accepted standards which ensure equivalent or better performance that specified in the standards referred under section shall also be acceptable.

1.03.04

In case governing standards for the equipment is different from IS or IEC, the salient points of difference shall be clearly brought out in additional information schedule alongwith English language version of standard of relevant extract of the same. The equipment conforming to standards other than IS/IEC shall be subject to Employer’s approval.

1.03.05

The list of standards for the various equipment is given in the Annexure-V of this section.

1.03.06

The full names of the codes and standards mentioned in abbreviations under various equipment heads are as follows: BS

British Standards

IEC/CISPR

International Electro-technical Commission

IS

Bureau of Indian Standards

ISO

International Organisation for Standards

NEMA

National Electric Manufacturers Association

1.04.00

Name plate

1.04.01

The equipment nameplate should preferably be of stainless steel. In case of aluminium, it should be at least 2mm thick.. The inscription on the name plate shall be engraved and no punching shall be accepted except for equipment serial number and year of manufacture. These nameplates shall be black with white engraved lettering.

1.04.02

The rated current, extended current rating and rated thermal current shall be clearly indicated in the name plate in case of current transformer.

1.04.03

Rated voltage, voltage factor and intermediate voltage shall be clearly indicated on the nameplate in case of capacitor voltage transformer.

1.04.04

Name plates of cubicles and panels may be made of non-rusting metal or 3 ply lamicoid.

1.04.05

Each switch shall have a clear inscription identifying its function. Switches shall also have a clear inscription of each position indication.

1.05.00

Galvanising

1.05.01

The galvanised surface shall consist of a continuous film adhering to the steel. The finished surface shall be clean and smooth, and shall be free from defects like



PART-C

PAGE 4 OF 100

CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS dissolved patches, base, spot, unevenness of coating, spelter which is loosely attached to the steel globules, spiky deposits, blistered surfaces, flaking or peeling off, etc. The presence of any of these defects shall render the material liable to rejection.

1.05.02

All exposed ferrous parts shall be hot dip galvanised as per IS:2629 & IS:2633, Galvanising shall be uniform, smooth continuous and free from acid spots. Should the galvanising of the sample be found defective, the entire batch of steel shall have to be re-galvanised at Contractor’s cost. The amount of zinc deposit shall be not less than 610 gms. per sq.m. of surface area and in addition, the thickness of zinc at any spot shall not be less than 85 microns. The Employer reserves the right to measure the thickness of zinc deposit by Elkometer or any other instrument acceptable to Employer and reject any component which shows thickness of zinc at any location less than 85 microns. The testing on the galvanised materials shall be carried out as per IS:2633.

1.05.03

The amount of zinc deposit over threaded portion of the bolts, nuts and screws shall not be less than 300 gms. per sq. meter of surface area. The amount of zinc deposit on washers shall not be less than 340 gms. per sq. meter of surface area. The threads having extra deposit of zinc shall be removed by die cutting after the completion of galvanising. The removal of extra zinc shall be carefully done so that threads shall have minimum deposits of zinc on them as specified.

1.06.00

Painting The sheet steel to be painted shall be pretreated in tanks in accordance with IS:6005. Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline hot water and dried. The phosphate coating shall be “class-C” as specified in IS:6005. The phosphated surfaces shall be rinsed and passivated prior to application of stoved lead oxide primer coating. After primer application, two coats of finishing synthetic enamel paint on panels shall be applied. Electrostatic painting shall also be acceptable. Finishing paint on outside of the panels shall be as required otherwise by the Employer. The inside of the panels shall be glossy white. Each coat of finishing shall be properly stoved. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peelable compound by spraying method to protect the finished surfaces from scratches, grease, dirt and oil spots during testing, transportation, handling and erection.

1.07.00

Quality Assurance Programme

1.07.01

The Contractor shall adopt suitable quality assurance programme to ensure that the equipment and services under the scope of contract whether manufactured or performed within the Contractor’s works or at his sub-contractor’s premises or at the Employer’s site or at any other place of work are in accordance with the specifications. Such programmes shall be outlined by the Contractor and shall be finally accepted by the Employer/authorised representative after discussions before the award of the contract. The QA programme shall be generally in line with



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GENERAL TECHNICAL REQUIREMENTS ISO-9001/IS-14001. A quality assurance programme of the contractor shall generally cover the following: (i)

His organisation structure for the management and implementation of the proposed quality assurance programme

(ii)

Quality System Manual

(iii)

Design Control System

(iv)

Documentation Data Control System

(v)

Qualification data for Bidder’s key Personnel.

(vi)

The procedure for purchase of materials, parts, components and selection of sub-contractor’s services including vendor analysis, source inspection, incoming raw-material inspection, verification of materials purchased etc.

(vii)

System for shop manufacturing and site erection controls including process, fabrication and assembly.

(viii)

Control of non-conforming items and system for corrective actions and resolution of deviations.

(ix)

Inspection and test procedure both for manufacture and field activities.

(x)

Control of calibration and testing of measuring testing equipments.

(xi)

System for Quality Audits.

(xii)

System for identification and appraisal of inspection status.

(xiii)

System for authorising release of manufactured product to the Employer.

(xiv)

System for handling storage and delivery.

(xv)

System for maintenance of records, and

(xvi)

Furnishing quality plans for manufacturing and field activities detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component as per enclosed formats No.: QS-01-QAI-P-09/F1 and QS-01-QAI-P-09/F2 respectively. (2)

(xvii)

Furnishing Monthly Progress reports on sub-contractor (vendor) approvals identified in “DR” cateogory during pre-award discussions and MQP / FQP submission/ approval on enclosed format No.: QS-01-QAI-P-02/F1 and QS01-QAI-P-02/F2 respectively.



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GENERAL TECHNICAL REQUIREMENTS (xviii) Furnishing Monthly status of final placement of purchase order on identified sub-contractors.

1.08.00

General Requirements - Quality Assurance

1.08.01

All materials, components and equipment covered under this specification shall be procured, manufactured, erected, commissioned and tested at all the stages, as per a comprehensive Quality Assurance Programme. An indicative programme of inspection/tests to be carried out by the contractor for some of the major items is given in the respective technical specification. This is, however, not intended to form a comprehensive programme as it is the contractor’s responsibility to draw up and implement such programme duly approved by the Employer. The detailed Quality Plans for manufacturing and field activities should be drawn up by the Bidder and will be submitted to Employer for approval. Schedule of finalisation of such quality plans will be finalised before award.

1.08.02

Manufacturing Quality Plan will detail out for all the components and equipment, various tests/inspection, to be carried out as per the requirements of this specification and standards mentioned therein and quality practices and procedures followed by Contractor’s/ Sub-contractor”s/ sub-supplier’s Quality Control Organisation, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of materials procurement, manufacture, assembly and final testing/performance testing. The Quality Plan shall be submitted on electronic media e.g. CD or E-mail in addition to hard copy, for review. Once the same is finalised, hard copies shall be submitted for approval. After approval the same shall be submitted in compiled form on CD ROM.

1.08.03

Field Quality Plans will detail out for all the equipment, the quality practices and procedures etc. to be followed by the Contractor’s site Quality Control Organisation, during various stages of site activities starting from receipt of materials/equipment at site.

1.08.04

The Bidder shall also furnish copies of the reference documents/plant standards/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans alongwith Quality Plans. These Quality Plans and reference documents/standards etc. will be subject to Employer’s approval without which manufacturer shall not proceed.

1.08.05

These approved documents shall form a part of the contract. In these approved Quality Plans, Employer shall identify customer hold points (CHP), i.e. test/checks which shall be carried out in presence of the Employer’s Project Manager or his authorised representative and beyond which the work will not proceed without consent of Employer/Authorised representative in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to Employer alongwith technical justification for approval and dispositioning.

1.08.06

The contractor shall submit to the Employer Field Welding Schedule for field welding activities in the enclosed format No.: QS-01-QAI-P-02/F3. The field welding schedule shall be submitted to the Employer alongwith all supporting procedures,



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1.08.07

GENERAL TECHNICAL REQUIREMENTS like welding procedures, heat treatment procedures, NDT procedures etc. atleast ninety days before schedule start of erection work at site. (2) No material shall be despatched from the manufacturer’s works before the same is accepted subsequent to predespatch final inspection including verification of records of all previous tests/inspections by Employer’s Project Manager/Authorised representative and duly authorised for despatch by issuance of MDCC.

1.08.08

All material used for equipment manufacture including casting and forging etc. shall be of tested quality as per relevant codes/standards. Details of results of the tests conducted to determine the mechanical properties, chemical analysis and details of heat treatment procedure recommended and actually followed shall be recorded on certificates and time temperature chart. Tests shall be carried out as per applicable material standards and/or agreed details.

1.08.09

All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirements of ASME Section IX/BS-4870 or other International equivalent standard acceptable to the Employer.

1.08.10

All welding/brazing procedures shall be submitted to the Employer or its authorised representative for approval prior to carrying out the welding/brazing.

1.08.11

All brazers, welders and welding operators employed on any part of the contract either in Contractor’s/his sub-contractor’s works or at site or elsewhere shall be qualified as per ASME Section-IX or BS-4871 or other equivalent International Standards acceptable to the Employer.

1.08.12

Test results or qualification tests and specimen testing shall be furnished to the Employer for approval. However, where required by the Employer, tests shall be conducted in presence of Employer/authorised representative.

1.08.13

For all pressure parts and high pressure piping welding, the latest applicable requirements of the IBR (Indian Boiler Regulations) shall also be essentially complied with. Similarly, any other statutory requirements for the equipments/systems shall also be complied with.

1.08.14

All the heat treatment results shall be recorded on time temperature charts and verified with recommended regimes.

1.08.15

No welding shall be carried out on cast iron components for repair.

1.08.16

Unless otherwise proven and specifically agreed with the Employer, welding of dissimilar materials and high alloy materials shall be carried out at shop only.

1.08.17

All non-destructive examination shall be performed in accordance with written procedures as per International Standards, The NDT operator shall be qualified as per SNT-TC-IA (of the American Society of non-destructive examination). NDT shall be recorded in a report which includes details of methods and equipment used, result/evaluation, job data and identification of personnel employed and details of corelation of the test report with the job.



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1.08.18

1.08.19

GENERAL TECHNICAL REQUIREMENTS The Contractor shall list out all major items/ equipments/ components to be manufactured in house as well as procured from sub-contractors ( BOI). All the subvendors proposed by the Contractor for procurement of major bought out items including castings, forging, semi-finished and finished components/equipment, list of which shall be drawn up by the Contractor and finalised with the Employer, shall be subject to Employer’s approval. The contractor’s proposal shall include vendor’s facilities established at the respective works, the process capability, process stabilization, QC systems followed, experience list, etc. alongwith his own technical evaluation for identified sub-contractors enclosed and shall be submitted to the Employer for approval within the period agreed at the time of pre-awards discussion and prior to any procurement. Such vendor approval shall not relieve the contractor from any obligation, duty or responsibility under the contract. (3) For components/equipment procured by the contractors for the purpose of the contract, after obtaining the written approval of the Employer, the contractor’s purchase specifications and inquiries shall call for quality plans to be submitted by the suppliers. The quality plans called for from the sub-contractor shall set out, during the various stages of manufacture and installation, the quality practices and procedures followed by the vendor’s quality control organisation, the relevant reference documents/standards used, acceptance level, inspection of documentation raised, etc. Such quality plans of the successful vendors shall be finalised with the Employer and such approved Quality Plans shall form a part of the purchase order/contract between the Contractor and sub-contractor. Within three weeks of the release of the purchase orders/contracts for such bought out items/components, a copy of the same without price details but together with the detailed purchase specifications, quality plans and delivery conditions shall be furnished to the Employer on the monthly basis by the Contractor.

1.08.20

Employer reserves the right to carry out quality audit and quality surveillance of the systems and procedures of the Contractor’s or their subvendor’s quality management and control activities. The contractor shall provide all necessary assistance to enable the Employer carry out such audit and surveillance.

1.08.21

The contractor shall carry out an inspection and testing programme during manufacture in his work and that of his sub-contractor’s and at site to ensure the mechanical accuracy of components, compliance with drawings, conformance to functional and performance requirements, identity and acceptability of all materials parts and equipment. Contractor shall carry out all tests/inspection required to establish that the items/equipments conform to requirements of the specification and the relevant codes/standards specified in the specification, in addition to carrying out tests as per the approved quality plan.

1.08.22

Quality audit/surveillance/approval of the results of the tests and inspection will not, however, prejudice the right of the Employer to reject the equipment if it does not comply with the specification when erected or does not give complete satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring complete conformance of the materials/equipment supplied to relevant specification, standard, data sheets, drawings, etc.



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1.08.23

For all spares and replacement items, the quality requirements as agreed for the main equipment supply shall be applicable.

1.08.24

Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Employer/ authorised representative.

1.09.00

Burn in and Elevated Temperature Test Requirement for Electronics Solid State Equipment (a)

All solid state electronic systems/equipment shall be tested as a complete system/equipment with all devices connected for a minimum of 168 hours (7 Days) continuously under energized conditions prior to shipment from Manufacturing works, as per the following cycle.

(b)

Elevated Temperature Test Cycle During the elevated temperature test which shall be for 48 hours of the total 168 hours of testing, the ambient temperature shall be maintained at 40 deg.C. The equipment shall be interconnected with devices which will cause it to repeatedly perform all operations it is expected to perform in actual service with load on various components being equal to those which will be experienced in actual service. During the elevated temperature test the cubicle doors shall be closed (or shall be in the position same as they are supposed to be in the field) and inside temperature in the zone of highest heat dissipating components/modules shall be monitored. The temperature rise inside the cubicle should not exceed 10 deg.C above the ambient temp. at 40 deg.C.

(c)

Burn in Test Cycle The 48 hours elevated temperature test shall be followed by 120 hours of burn in test as above except that the temperature shall be reduced to the ambient temperature prevalent at that time. During the above tests, the process I/O and other load on the system shall be simulated by simulated inputs and in the case of control systems, the process which is to be controlled shall also be simulated. Testing of individual components or modules shall not be acceptable. In case the Contractor/ sub-contractor is having any alternate established procedure of eliminating infant mortile components, the detail procedures followed by the Contractor/ sub- contractor alongwith the statistical figures to validate the alternate procedure to be forwarded. The Contractor/Sub-contractor shall carry out routine test on 100% item at contractor/sub-contractor’s works. The quantum of check/test for routine & acceptance test by employer shall be generally as per criteria/sampling plan defined in referred standards. Wherever



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CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS standards have not been mentioned quantum of check/test for routine / acceptance test shall be as agreed during detailed engineering stage.

1.10.00

Quality Assurance Documents The Contractor shall be required to submit within three weeks after despatch of the equipment, two hard copies and two sets on CDROM of the following Quality Assurance Documents as identified in respective quality plan with tick ( √ ) mark .

1.10.01

Typical contents of Quality Assurance Document is as below:i)

Quality Plan,

ii)

Material mill test reports on components as specified by the specification and approved Quality Plans.

iii)

Factory test reports/results for testing required as per applicable codes and standard referred in the specification and approved Quality Plans.

iv)

Type test report (wherever applicable).

v)

Non-destructive examination interpretation reports.

results

/reports

including

Sketches/drawings used for indicating the method of radiographs to the location on the equipment.

radiography

traceability of

the

vi)

Heat Treatment Certificate/Record (Time- temperature Chart)

vii)

All the accepted Non-conformance Reports (Major/Minor) / deviation, including complete technical details / repair procedure)Verification sketches, if used and methods used to verify that the inspection and testing points in Quality Plan were performed satisfactorily.

viii)

CHP / Inspection reports duly signed by the Inspector of the Employer and Contractor for the agreed Customer Hold Points.

ix)

Certificate of Conformance (COC) wherever applicable.

x)

MDCC

1.10.02

Similarly, the contractor shall be required to submit two hard copies and two sets on CD ROM of Quality Assurance Documents (in line with above) pertaining to field activities as per Approved Field Quality Plans and other agreed manuals/ procedures, prior to commissioning of individual system.

1.10.03

Due to the large variety of equipment items, it is always possible to adapt the content of the quality document to better match the particularities of any equipment. This shall be done in agreement with the Supplier and the Inspector.



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1.10.04

The Quality Document file shall be progressively completed by the Supplier’s subsupplier to allow regular reviews by all parties during the manufacturing.

1.10.05

Each quality document shall have a project specific Cover Sheet bearing name & identification number of equipment and including an index of its contents with page control on each document.

1.10.06

Before shipping any equipment, the Supplier shall make sure that the corresponding quality document or in the case of protracted phased deliveries, the applicable section of the quality document file is completed. The supplier will then notify the Inspector regarding the readiness of the quality document (or applicable section) for review. i)

If the result of the review carried out by the Inspector of the Quality document (or applicable section) is satisfactory. The Inspector shall stamp, the quality document (or applicable section) for release.

ii)

If the quality document is unsatisfactory, the Supplier shall endeavor to correct the incompleteness, thus allowing to finalize the quality document (or applicable section) by time compatible with the requirements as per contract documents. When it is done, the quality document (or applicable section) is stamped by the Inspector.

iii)

If a decision is made to ship equipment, whereas all outstanding actions cannot be readily cleared for the release of the quality document by the time as per contract documents (or finalization of the applicable section of the quality document within one month as per corresponding shipment date). The supplier shall immediately, upon shipment of the equipment, send a copy of the quality document Review Status (signed by the Supplier Representative) to the Inspector and notify of the committed date for the completion of all outstanding actions & submission.The Inspector shall stamp the quality document for applicable section when it is effectively completed. The final quality document will be compiled and issued at the final assembly place of equipment before shipment.

1.11.00

Transmission of Quality Documents As a general rule,two hard copies of the quality document and Two CD ROMs shall be issued to the Employer not later than 1 month after the delivery date for the corresponding equipment . One set of quality document shall be forwarded to Corporate Quality Assurance Department and other set to respective Site . For the particular case of phased deliveries, the complete quality document to the Employer shall be issued not later than 1 month after the date of the last delivery similarly as stated above.



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CLAUSE NO.


1.12.00

Engineer’s Supervision

1.12.01

To eliminate delays and avoid disputes and litigation, it is agreed between the parties to the Contract that all matters and questions shall be referred to the Project Manager and without prejudice to the provisions of ‘Arbitration’ clause in Section GCC of Bidding documents, the Contractor shall proceed to comply with the Project Manager’s decision.

1.12.02

The work shall be performed under the supervision of the Project Manager. The scope of the duties of the Project Manager pursuant to the Contract, will include but not be limited to the following: i)

Interpretation of all the terms and conditions of these documents and specifications:

ii)

Review and interpretation of all the Contractor’s drawing, engineering data, etc:

iii)

Witness or his authorised representative to witness tests and trials either at the manufacturer’s works or at site, or at any place where work is performed under the contract :

iv)

Inspect, accept or reject any equipment, material and work under the contract :

v)

Issue certificate of acceptance and/or progressive payment and final payment certificates

vi)

Review and suggest modifications and improvement in completion schedules from time to time, and

vii)

Supervise Quality Assurance Programme implementation at all stages of the works.

1.13.00

Inspection, Testing And Inspection Certificates

1.13.01

The word ‘Inspector’ shall mean the Project Manager and/or his authorised representative and/or an outside inspection agency acting on behalf of the Employer to inspect and examine the materials and workmanship of the works during its manufacture or erection.

1.13.02

The Project Manager or his duly authorised representative and/or an outside inspection agency acting on behalf of the Employer shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection and if part of the works is being manufactured or assembled on other premises or works, the Contractor shall obtain for the Project Manager and for his duly authorised representative permission to inspect as if the works were manufactured or assembled on the Contractor’s own premises or works.



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CLAUSE NO.


1.13.03

The Contractor shall give the Project Manager/Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Contractor’s account except for the expenses of the Inspector’s. The Project Manager/Inspector, unless the witnessing of the tests is virtually waived, will attend such tests within fifteen (15) days of the date on which the equipment is noticed as being ready for test/inspection failing which the contractor may proceed with test which shall be deemed to have been made in the inspector’s presence and he shall forthwith forward to the inspector duly certified copies of test reports in two (2) copies.

1.13.04

The Project Manager or Inspector shall within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Contractor, or any objection to any drawings and all or any equipment and workmanship which is in his opinion not in accordance with the contract. The Contractor shall give due consideration to such objections and shall either make modifications that may be necessary to meet the said objections or shall inform in writing to the Project Manager/Inspector giving reasons therein, that no modifications are necessary to comply with the contract.

1.13.05

When the factory tests have been completed at the Contractor’s or sub-contractor’s works, the Project Manager /Inspector shall issue a certificate to this effect fifteen (15) days after completion of tests but if the tests are not witnessed by the Project Manager /Inspectors, the certificate shall be issued within fifteen (15) days of the receipt of the Contractor’s test certificate by the Project Manager /Inspector. Project Manager /Inspector to issue such a certificate shall not prevent the Contractor from proceeding with the works. The completion of these tests, or the issue of the certificates shall not bind the Employer to accept the equipment should it, on further tests after erection be found not to comply with the contract.

1.13.06

In all cases where the contract provides for tests whether at the premises or works of the Contractor or any sub-contractor, the Contractor, except where otherwise specified shall provide free of charge such items as labour, material, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Project Manager /Inspector or his authorised representatives to carry out effectively such tests on the equipment in accordance with the Contractor and shall give facilities to the Project Manager/Inspector or to his authorised representative to accomplish testing.

1.13.07

The inspection by Project Manager / Inspector and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed Quality Assurance Programme forming a part of the contract.

1.13.08

To facilitate advance planning of inspection in addition to giving inspection notice as per Clause 1.13.03, the Contractor shall furnish quarterly inspection programme indicating schedule dates of inspection at Customer Hold Point and final inspection stages. Updated quarterly inspection plans will be made for each three consecutive months and shall be furnished before beginning of each calendar month.

1.13.09

All inspection, measuring and test equipments used by contractor shall be calibrated periodically depending on its use and criticality of the test/measurement to be done. The Contractor shall maintain all the relevant records of periodic calibration and instrument identification, and shall produce the same for inspection by NTPC.



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PAGE 14 OF 100

CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS Wherever asked specifically, the contractor shall re-calibrate the measuring/test equipments in the presence of Project Manager / Inspector.

1.14.00

Associated Document:-

1.14.01

Subcontractor approval Schedule Status/ Exception Format No.:QS-01-QAI-P02/F1-R2

1.14.02

Quality Plan Schedule Status/ Exception Format No.: QS-01-QAI-P-02/F2-R2

1.14.03

Field Welding Schedule Format No.: QS-01-QAI-P-02/F3-R1

1.14.04

Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R1

1.14.05

Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1

1.15.00

QUALITY ASSURANCE PROGRAMME FOR CIVIL WORKS GENERAL REQUIREMENTS - QUALITY ASSURANCE AND QUALITY CONTROL (QA&QC)- CIVIL WORKS

1.15.01

This part covers the QA&QC requirements pertaining to this package with respect to the Technical Specifications, as per comprehensive QAP. The detailed Quality Plans for fabrication/ manufacturing/ erection/ construction/ commissioning and testing shall be drawn up by the Contractor and shall be submitted to NTPC for approval. Schedule of submission of such quality plans will be finalized before award of work.

1.15.02

The Contractor shall take every precaution to ensure that the requirements of all items of works / services in the contract are covered in the Quality Plans.

1.15.03

The Contractor shall submit a The Field Quality Plan, which shall detail out for all the works, equipments, services, quality practices and procedures etc in line with the requirement of the technical specifications/ CPWD specification (as applicable) to be followed by the Contractor’s site QA&QC organization, during various stages of site activities starting from receipt of construction materials/equipment at site. The Field Quality Plan (FQP) submission shall be furnished on the format No. QS-01-QAI-P09/F2-R1 for NTPC approval. The FQP for DSR items shall be based on the CPWD Specification and the FQP for non-DSR items shall be based on the requirements of technical specifications. An Indicative Field Quality Plan is enclosed at Annexure – IV.

1.15.04

All materials / components and equipment covered under the scope of work, shall be procured by the Contractor for the purpose of the contract, after obtaining the written approval of the NTPC, which are to be manufactured at shop/ factory of the vendor/sub vendor shall be covered under a comprehensive quality assurance programme. The Contractor’s purchase specifications and inquiries shall call for Manufacturing Quality Plans (MQP) to be submitted by the sub-contractor/ subsupplier/ sub-vendor. The MQPs called for from the sub-contractor shall detail out for



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CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS all the components and equipment-various tests/inspection, to be carried out as per the requirements of this specification and standards mentioned therein, quality practices and procedures followed by contractor’s/ sub-contractor’s/ sub-supplier's Quality Control Organization, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of materials procurement, manufacture, assembly and final testing/performance testing. Such quality plans of the vendors shall be submitted to the NTPC for approval in the prescribed format No. QS-01-QAI-P-09/F1-R1 for Manufacturing Quality Plan and such approved Quality Plans shall form a part of the purchase order/contract between the Contractor and sub-contractor. The Quality Plans shall be submitted on electronic form e.g. CD or E-mail in addition to hard copy, for review and approval of NTPC. After approval the same shall be submitted in compiled form on CD in addition to hard copy.

1.15.05

The Contractor shall furnish copies of the reference documents/plant standards /acceptance norms/tests and inspection procedure etc., as referred in Quality Plans. These Quality Plans and reference documents/standards etc. will be subject to NTPC approval without which manufacturer shall not proceed. These approved documents shall form a part of the contract. In these approved Quality Plans, NTPC shall identify customer hold points (CHP), i.e. test/checks which shall be carried out in presence of the NTPC Engineer or his authorized representative and beyond which the work shall not proceed without consent of NTPC in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to NTPC along with technical justification for approval and dispositioning.

1.15.06

Within three weeks of the release of the purchase orders /contracts for such bought out items /components, a copy of the same without price details but together with the detailed purchase specifications, quality plans and delivery conditions shall be furnished to the NTPC for reference/record by the Contractor along with a report of the Purchase Orders placed so far for the contract.

1.15.07

Monthly progress reports on MQP/FQP submission/approval shall be furnished by the Contractor on the format No. QS-01-QAI-P-02/F1-R0. List of items requiring Quality Plans and Sub-supplier approval shall be finalized with the Contractor on the format No. QS-01-QAI-P-01/F3-R1 during the post bid discussions.

1.15.08

The FQA laboratory set-up shall be constructed by the Contractor at his own cost at site in line with the indicative field QA&QC laboratory set-up enclosed at Annexure-I. The Laboratory building shall be constructed and installed with the adequate facilities to meet the requirement of envisaged test setup. Temperature and humidity controls shall be available wherever necessary during testing of samples. The Quality Plan shall identify the testing equipments/ instrument, which the Contractor shall deploy and equip the Field quality Laboratory for meeting the Field Quality Plan requirements. The Contractor shall furnish a comprehensive list of testing equipments/ instrument required to meet the planned/scheduled tests for the execution of works for NTPC acceptance/ approval. The contractor shall mobilize the requisite laboratory equipment and QA&QC manpower at least 15 days prior to the planned test activity as per the schedule of tests.



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PAGE 16 OF 100

CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS If any facility for testing or the trained personnel for conducting any special test is not available with the Contractor then the Contractor may get the test done from reputed/ approved laboratory or out source the personnel as approved by NTPC. All equipments and instruments shall be calibrated before the commencement of tests and then at regular intervals, as per the manufacturer’s recommendation and as directed by the NTPC. Contractor shall arrange for having the instruments/ equipments tested for their calibration at an NABL/NPL accredited agency and the test report shall be submitted to the NTPC.

1.15.09

Based on agreed L-2 network, the Contractor shall submit the schedule of various tests require to be performed on monthly/quarterly basis for the quantum of work identified. The tests required is to be carried out well in advance, for the works anticipated to start during currency of contract and shall be accordingly planned before the schedule date of start of activities as per L-2 network. The test schedule and the status of the tests carried out shall be maintained on a PC connected to the network of NTPC (if available) for day to day monitoring and planning of tests to be carried out.

1.15.10

Based on approved fabrication/ manufacturing/ erection/ construction/ commissioning methodology, the Contractor shall also prepare and submit to the NTPC a checklist indicating the sequence of work and protocols in line with the requirement of the technical specification, which shall be signed and maintained. The Contractor shall update/ revise this checklist as and when the sequence of work is affected due to modifications in fabrication/ manufacturing/ erection/ construction/ commissioning methodology or any other unavoidable circumstances.

1.15.11

Before execution of any civil work the Contractor shall conduct full-scale suitability tests on various construction and building material such as fine and coarse aggregates, Cement, Reinforcement, construction chemicals, supplementary cementitious Materials and Construction water to check their suitability for use from reputed institutes such as NCB-Ballabhgarh, CSMRS-Delhi, IIT’s. A full-scale test on aggregate shall be carried out including Alkali aggregate reactivity and Petrography examination. Three copies of all test reports shall be submitted to the NTPC in triplicate, within seven (07) days after completion of any test for review, acceptance and records.

1.15.12

The Contractor shall appoint a dedicated, experienced and competent QA&QC incharge at site, preferably directly reporting to the Project Manager, supported as necessary by experienced personnel, to ensure the effective implementation of the approved QAP. An indicative structure of Contractors QA&QC manpower required to be deployed at site is enclosed at Annexure-II. Based on the finalized L-2 network and the approved Field Quality plan the Contractor shall finalize and submit a deployment schedule of QA&QC personnel along with their details to NTPC for approval/ acceptance and further shall ensure their availability well before the start of the concern activity. The QA&QC in-charge shall have the organizational freedom and authority to implement the requirements of these quality assurance arrangements, free from



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GENERAL TECHNICAL REQUIREMENTS commercial and programme restraints. The QA&QC setup of the Contractor shall consist of qualified and experienced Civil Engineers, Electrical Engineers and Laboratory assistants with their supporting staff both at their works and site.

1.15.13

The Contractor shall enclose a comprehensive list of bought out items (BOIs) envisaged in the contract for carrying out fabrication/ manufacturing/ erection/ construction/ commissioning activities, procurement of forged, cast, semi-finished and finished components/equipment etc and shall indicate the names of reputed manufacturers for each of them in their bid proposal. The items envisaged by the Contractor to be procured from these manufacturers shall meet the specification requirement. Some of these major bought out items (not exhaustive) is enclosed at Annexure- III for which the Contractor shall submit the requisite details / lists of manufacturer’s in their bid proposal.

1.15.14

The list of manufacturers / sub-vendors of each of the BOIs identified / indicated by the Contractor shall be discussed / reviewed by the NTPC during post bid discussions and the list of proposed manufacturers / sub-vendors for each of the BOI shall be agreed/ approved. The list of manufacturers for all the BOIs envisaged in contract shall be included in the bid proposal and the same shall be discussed for finalization during the post bid discussions before placement of award. Where the manufacturers are placed in “DR” (Details required) category, the details of the manufacturers / sub-vendors placed in the “DR” category shall be submitted to the NTPC for approval within the period agreed at the time of post bid discussions. The Contractor’s proposal shall include vendor’s site facilities, expertise, facilities established at the respective works, the process capability, process stabilization, QC systems followed, experience list, etc. along with his own technical evaluation for identified sub-Contractors proposed. The formats for furnishing above details shall be given to the Contractor at post bid discussion stage. Monthly progress reports on sub-Contractor detail submission / approval shall be furnished on format no. QS-01QAI-P-02/F1. The NTPC shall furnish other relevant formats for information/ clarification for manufacturers / sub-vendors approval to the Contractor at the time of post bid discussions (Main supplier’s evaluation report Format No: QA-01-QAI-P04/F1-R0 and Sub supplier questionnaire Format no: QA-01-QAI-P-04/F2-R0). Such manufacturers / sub-vendors approval shall not relieve the Contractor from any obligation, duty or responsibility under the contract.

1.15.15

No material shall be dispatched from the manufacturer’s works before the same is accepted, subsequent to pre-dispatch final inspection including verification of records of all previous tests/inspections by NTPC’s Engineer/Authorized representative and duly authorized for dispatch by issuance of Material Dispatch Clearance Certificate (MDCC).

1.15.16

All material used for equipment manufacture including casting and forging etc. shall be of tested quality as per relevant codes/standards. Details of results of the tests conducted to determine the mechanical/engineering properties; chemical analysis and details of heat treatment procedure recommended and actually followed shall be recorded on certificates and time temperature chart. Tests shall be carried out as per applicable material standards and/or agreed details.



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1.15.17

GENERAL TECHNICAL REQUIREMENTS The Contractor shall submit to the NTPC Field Welding Schedule for field welding activities in the format No.: QS-01-CQA-W11/F1, this format shall be furnished to the Contractor at pre-award stage. The field-welding schedule shall be submitted to the NTPC along with all supporting documents, like welding procedures, heat treatment procedures, NDT procedures etc. at least ninety days before schedule start of erection work at site. The Contractor shall submit Welding Procedure Specification (WPS) in the format No: QS-01-QAI-W-06/F1 for NTPC approval/ acceptance, this format shall be furnished to the Contractor during post bid discussion stage. All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirements of ASME Section IX/BS-4870 or other International equivalent standard acceptable to the NTPC. All welding/brazing procedures shall be submitted to the NTPC or its authorized representative for approval prior to carrying out the welding/brazing. All brazers, welders and welding operators employed on any part of the contract either in the Contractor’s/ sub-Contractor’s works or at site or elsewhere shall be qualified as per AWSD1.1/ASME Section-IX or BS-4871 or other equivalent International Standards acceptable to the NTPC. Welding procedure qualification and Welder qualification test results shall be furnished to the NTPC for approval. However, where required by the NTPC, tests shall be conducted in presence of NTPC/authorized representative. No welding shall be carried out on cast iron components for repair. All the heat treatment results shall be recorded on time temperature charts and verified with recommended regimes. All Non-destructive examination shall be performed in accordance with written procedures as per International Standards and as mentioned elsewhere in the technical specification; The NDT operator shall be qualified as per SNT-TC-IA (of the American Society of non-destructive examination). NDT shall be recorded in a report, which includes details of methods and equipment used, result/evaluation, job data and identification of personnel employed and details of co-relation of the test report with the job. The records of RT (Films) and UT (inspection records or printed reports if possible) shall be documented and produced to NTPC.

1.15.18

NTPC reserves the right to carry out quality audit and quality surveillance of the systems and procedures of the Contractor’s or their sub-Contractor’s quality management and control activities. The Contractor shall provide all necessary assistance to enable the NTPC carry out such audit and surveillance. The Contractor shall carry out an inspection and testing programme during manufacture in his work and that of his sub-Contractor’s and at site to ensure the mechanical accuracy of components, compliance with drawings, conformance to functional and performance requirements, identity and acceptability of all materials parts and equipment. The Contractor shall carry out all tests/inspection required to establish that the items/equipment conform to



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GENERAL TECHNICAL REQUIREMENTS requirements of the specification and the relevant codes/standards specified in the specification, in addition to carrying out tests as per the approved quality plan. Quality audit/surveillance/approval of the results of the tests and inspection will not, however, prejudice the right of the NTPC to reject the equipment/ facilities if it does not comply with the specification when erected or does not give complete satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring complete conformance of the materials/equipment supplied to relevant specification, standard, data sheets, drawings, etc.

1.15.19

For all spares and replacement items, the quality requirements as agreed for the main equipment supply shall be applicable.

1.15.20

Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the NTPC/ authorized representative.

1.15.21

The Contractor shall associate themselves with the reputed specialized blasting agency such as CMRI, NIRM for all type of blasting operations at site. The blasting operation shall remain in charge of a responsible, competent, authorized and experienced supervisor (Man-In-Charge) and thoroughly acquainted workmen. All blasting work shall be done as per approved blasting scheme / design in line with the technical specification requirements and all statutory laws, rules, regulations, relevant standards pertaining to the acquisition, transport, storage, handling along with use of explosives shall be strictly followed by the Contractor. The Contractor shall install and operate equipments for continuous monitoring and control of blast induced vibrations, noise level/ air pressure, dust, silica and noxious gases during all blasting operations in line with the Technical Specification requirements.

1.15.22

Apart from other details in approved QAP, the Contractor shall submit the following to Owne:; •

Scheme /Calculation of blasting plan including the scheme for Pre-splitting the rock along the excavation boundaries prepared by specialist organization such as CMRI, NIRM for the trial blast to establish blasting methodology while undertaking rock excavations to avoid the possibility of over breaks.

•

Before execution of any civil work, full-scale suitability tests on various construction material (e.g. for Concrete, the material like cement, coarse aggregates, fine aggregates, reinforcement, water, construction chemicals, supplementary Cementitious Materials etc.) shall be carried out by the Contractor. The Contractor shall submit all the test results to the Owner in triplicate, within seven (07) days after completion of any test for review and records.



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GENERAL TECHNICAL REQUIREMENTS •

Details such as type of grout and methodology/equipment proposed to be used for grouting to meet the specification requirement. Also the methodology for test (permeability test for grout) shall be specified by the Contractor.

1.16.00

ASSOCIATED DOCUMENT FOR QUALITY ASSURANCE PROGRAMME:

1.16.01

Indicative list of Field Quality Laboratory and Survey equipment list (Annexure-I)

1.16.02

Indicative QA&QC Manpower requirements (Annexure-II)

1.16.03

Indicative list of Bought Out Items for Civil Works (Annexure – III)

1.16.04

Indicative Field Quality Plan for Civil Works (Annexure-IV)

1.17.00

TRAINING OF EMPLOYER'S PERSONNEL

1.17.01

General The Contractor shall provide suitable instructors, training material and facilities (instruments, apparatus, simulators, documents, drawings, protective clothing, rooms, office supplies, etc.) for the Personnel made available by the Employer for training. One month before the training start, the Employer will send the list of the trainees and any comments on the training program proposed by the Contractor. This program shall be adapted to the design and nature of the Works, and the needs of trainees. Trainees shall be suitably trained in the various aspects of design, manufacture, installation/erection, operation and maintenance, relevant to the training , of works similar to the Works The Contractor shall supervise and provide direction to, and be liable for the acts or omissions, other than negligent or wilful misconduct of such personnel, of the Employer’s trainees. The Contractor shall provide the training described hereafter in accordance with any further specific requirements stated in the Employer’s Requirements. The Contractor shall assist the Employer in obtaining any visas and other formalities for entering or leaving the territory on which the training is being provided. The Contractor shall bear responsibility for ensuring the safety of the trainees during their stay in the country of the training. On their part, the trainees shall comply with the laws, regulations and customs of the country in which training is being held. In the event of illness or accident, the Contractor shall take all steps to provide the trainees with the appropriate medical care.

.



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1.17.02

GENERAL TECHNICAL REQUIREMENTS Training of Employer’s Personnel The Bidder shall provide training to Employer’s personnel to meet operational and maintenance requirements of various Systems/equipments supplied under this package. This shall include training in the areas as given below. The scope of service under training of Employer’s engineers shall include a training module covering the following : a)

Training During Engineering/ Manufacturing Phase This shall cover all disciplines viz, GIS & Station Automation Systems etc. and shall include all the related areas like Design familiarisation, training on product design features and product design software of major equipment and systems, engineering, manufacturing, erection, commissioning, training on operating features of equipment, quality assurance and testing, plant visits and visits to manufacturer’s works, exposure to various kinds of problems which may be encountered in fabrication, manufacturing, erection, welding etc. The training in areas of Operation and Maintenance shall take place preferably during end of manufacture/ tests.

b)

Training During the Erection / Installation / Site Work Independently from the supervision and inspection functions of the Employer's Representative, the Contractor shall authorise the Employer’s Personnel to follow the erection / installation / site work at his site. The Employer’s Start-up Personnel shall take no part in the equipment erection and/or installation operations, which shall be exclusively carried out by the Contractor and under his entire responsibility. This on site training shall cover each phase of erection / installation / site work and shall be of sufficient duration. The Contractor shall supply the information or measurements concerning the erection requested by the Employer's Representative or/and by the Employer’s personnel.

c)

Training during the Tests on Completion phase, Operation & Maintenance The scope of service under training of Customer's engineers shall necessarily include, training of upto five (5) Employer's personnel in the areas of GIS and Station Automation Systems. The Contractor shall provide on the-job training in the operation and maintenance of the Works to the Employer’s Operating Personnel. Such training shall start at least 30 days prior to commencement of Tests on Completion and continue until Taking Over. Its scope and quality shall be such so that the operation and maintenance phase of the equipments can be carried out to ensure sustained performance of the equal availability of the units as offered. The



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GENERAL TECHNICAL REQUIREMENTS training should provide the trainees with comprehensive understanding of all operational and maintenance aspects of the Works. Such training shall also include safety and environmental protection aspects applicable to the Works.

1.17.03

Exact details, extent of training and the training schedule shall be finalised based on the Bidder’s proposal. In all the above cases, whenever the training of Employer’s personnel is arranged at the works of the manufacturers, it shall be noted that the lodging and boarding of the Employer’s personnel shall be Bidder’s scope. The Bidder shall make all necessary arrangements towards the same.

DETAILS OF TRAINING AREA Sl

Description of Training

Training Duration

Place of Training

Number of Trainees from Employer

5 days

Manufact urers works

6

5 days

Site

6

No. (Days) 1 a)

GIS GIS equipments including system description, Specific Design and engineering & Quality Assurance concepts for the offered equipments.

b)

Erection Testing and commissioning of the GIS

2

Sub station automation System

a)

Detail design, implementation, relay configuration, control, control configuration and setting calculations.

5 days

Manufact urers works

4

b)

Testing,Commissioning , operation

5 days

Site

4

and maintenance of the system 1.18.00

Packing, Transportation And Storage

1.18.01

Packing, Marking and shipping (a)

The packing and shipping shall be carried out in accordance with the standard practice of Contractor and with the following additional requirements:

(b)

The equipment shall be prepared in such a manner as to protect the equipment from damage or deterioration during shipping or storage. The shipments can be exposed to heavy rains, hot sun, high humidity and sudden extreme changes of temperature. The equipment shall be packed and



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CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS shipped so as to protect it from all such conditions and any other abnormal conditions, generally expected during shipping & storage.

1.18.02

1.18.03

(c)

The metallic containers, if any, shall be considered as the property of the Contractor and he will be allowed to remove them from site once the contents are unpacked, inspected, documented and placed in temporary storage or in final position.

(d)

The equipment shall be shipped in such a manner as to facilitate unloading, handling and storage enroute and at the site. The Contractor shall provide lifting lugs and special lifting devices for proper handling and erection.

(e)

The Contractor shall be liable for any damage or loss resulting due to careless, improper, poor or insufficient packing and handling.

(f)

Spare parts and spare equipment shall be packed separately in containers adequate for long term storage, plainly marked “Spare Parts Only”. They shall be crated individually or in kits to be used in one single renewal or overhaul operation. Other spare part kits shall not be disturbed when using one set or kit.

(g)

The Contractor shall at all times protect and preserve from damage, loss, corrosion and all other forms of damage, all parts of the works.

Transportation (a)

The Contractor shall make a careful examination of access rail/roadways to the site in order to confirm the practical maximum transport weight and dimensions as well as a careful examination of the ports of disembarkation particularly with respect to the capacity of the cranes installed and access roads.

(b)

All instruments and computer/microprocessor based equipment imported into India from overseas for the purpose of this contract shall be air freighted to the nearest possible point and further by rail/road taking due precautions as per manufacturer’s recommendations. Employer shall have the right to decide the items that should be air freighted and Employer’s decision shall be binding on Contractor.

Insurance (a)

The Contractor shall insure all shipments and works at his own expense for not less than the full replacement cost plus any additional cost for accelerated manufacturing of the replacement parts.

(b)

Loss or the damage to equipment during shipping or transportation to the site(s) or otherwise shall not constitute groups for claims for extension in time or for extra payment.



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1.18.04

GENERAL TECHNICAL REQUIREMENTS Storage of Equipment (a)

The Contractor shall provide and construct adequate storage sheds for proper storage of equipment. Sensitive equipments shall be stored indoors. All equipment during storage shall be protected against damage due to act of nature or accidents. The storage instructions of the equipment manufacturers shall be strictly adhered to.

(b)

The necessary transport packing shall be removed as soon as possible after receipt of equipment at the work site(s)

1.19.00

Engineering Coordination Procedure

1.19.01

Identification of Principal Engineering Coordinators The following principal engineering coordinators will be identified by respective organisations at the time of award of contract. All engineering correspondence shall be in the name of designated coordinators on behalf of the respective organisations:

1.19.02

(a)

Engineering coordinator

(b)

Contracts coordinator

(c)

Site coordinator

(d)

QA&I coordinator

(e)

Project Engineering Management coordinator

Vendor Document Submission and Approval Procedure The following procedure for submission and review/approval of the drawings, data, reports, information, etc. shall be followed by Contractor: (a)

All data/information furnished by Vendor in the form of drawings, documents, catalogues or in any other form for NTPC’s information/interface and/or review and approval are referred by the general term “drawings”.

(b)

The ‘Master drawings list’ shall be submitted for review and approval of Employer before award of contract. The Contractor shall have to prepare and submit any other drawings and reference documents in addition to the drawings contained in the list, if so required during engineering stage as felt necessary by the Employer. Number of copies of the list for the distribution shall be as mutually agreed between Contractor and Employer.

(c)

All drawings (including those of subvendors’) shall bear at the right hand bottom corner the ‘title block’ with all relevant information duly filled in. The format of title block shall approved by Employer within thirty (30) days after the Notification of award. The Contractor shall give this format to his



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CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS subvendor along with his purchase order for subvendor’s compliance. The size of title block basic format and its contents shall not be changed. All drawings shall be in English language. All dimensions shall be in metric units. (d)

Contractor shall submit all the drawings in five (5) copies for review of Employer. Employer shall forward their comments within four (4) weeks of receipt of drawings.

(e)

Upon review of each drawings, depending on the correctness and completeness of the drawings, the same will be categorised and approval accorded in one of the following categories: CATEGORY I

Approved

CATEGORY II

Approved subject to incorporation of comments/ modification as noted. Resubmit revised drawing incorporating the comments.

CATEGORY III

Not approved. Resubmit revised drawings for Approval after incorporating comments/ modifications as noted

CATEGORY IV

For information and records.

(f)

Contractor shall resubmit the drawings approved under Category II and III within three (3) weeks of receipt of comments on the drawings, incorporating all comments. Every revision of the drawing shall bear a revision index wherein such revisions shall be highlighted in the form of description or marked up in the drawing identifying the same with relevant revision number enclosed in a triangle (e.g 1.2.3. etc.)

(g)

In case Contractor does not agree with any specific comment, he shall furnish the explanation for the same to Employer consideration. In all such cases Contractor shall necessarily enclose explanations along with the revised drawing (taking care of balance comments) to avoid any delay and/or duplication in review work.

(h)

It is the responsibility of the Contractor to get all the drawings approved in the Category I or IV (as the case may be) and complete engineering activities within the agreed schedule. Any delay arising out of submission and modification of drawings shall not alter the contract completion schedule.

(i)

Contractor shall not make any changes in the portion of the drawing other than those commented. If changes are required to be made in the portions already approved, the Contractor shall resubmit the drawings identifying the changes (alongwith reasons for changes) for Employer’s review and approval.

(j)

Approval of drawings will not in any way relieve the Contractor of his obligations of furnishing the equipment in accordance with the specification



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GENERAL TECHNICAL REQUIREMENTS and shall not prevent subsequent rejection if such equipment is later found to be defective. (k)

1.19.03

1.19.04

The drawing approval progress report shall be submitted in at least three (3) copies within one (1) week from the last date of the every month

Erection Drawings. (a)

Contractor shall furnish erection drawings for the guidance or commencement of erection or the first shipment, whichever is earlier. These shall generally comprise of fabrication/assembly drawings, various component/part details drawing, assembly, clearance data requirements, etc. The drawings shall contain details of components/ equipment with identification number, match marks, bill of materials, assembly procedures etc.

(b)

For all major equipment apart from above details, assembly sequence and instructions with check-lists shall be furnished in the form of erection manuals.

Technical Coordination Meetings To resolve and sort out various technical matters and outstanding issues, technical coordination meeting (TCM) shall be held periodically at venue to be decided by the Employer.

1.19.05

Instruction Manual (a)

The Contractor shall submit to the Employer preliminary instruction manuals for all the equipments for review. The final instructions manuals incorporating Employer’s comments and complete in all respect shall be submitted at least thirty (60) days before the first shipment of the equipment. The instruction manuals shall contain full details and drawings of all the equipments, the transportation, storage, installation, testing, operation and maintenance procedures, etc. separately for each component/equipment alongwith log record format. These instruction manuals shall be submitted in five (5) copies for approval.

(b)

If after commissioning and initial operation of the plant, the instruction manuals require any modifications/additions/changes, the same shall be incorporated and the updated final instruction manuals shall be submitted.

(c)

The operating and maintenance instructions together with drawings (other than shop drawings) of the equipment, as completed, shall have sufficient details to enable the Employer to maintain, dismantle, reassemble and adjust all parts of the equipment. They shall give a step by step procedure for all operations likely to be carried out during the life of the plant/equipment, including erection, testing, commissioning, operation, maintenance dismantling and repair. Each manual shall also include a complete set of approved drawings together with performance/rating curves of the equipment



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CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS and test certificates, wherever applicable. The contract shall not be considered completed for purpose of taking over until such instructions and drawings have been supplied to the Employer. (d)

1.19.06

A separate section of the manual shall be for each size/type of equipment and shall contain a detailed description of construction and operation, together will all relevant pamphlets, drawings and list of parts with procedures for ordering spares. Maintenance instructions shall include charts showing lubrication, checking, testing and replacement procedure to be carried out daily, weekly, monthly and at longer intervals to ensure trouble free operation. Where applicable, fault location charts shall be included to facilitate finding the cause of mal-operation or breakdown. A collection of the manufacturer’’ standard leaflets will not accepted to be taken as a compliance of this clause. The manual shall be specifically compiled for the concerned project.

Final submission of Drawings and Documents The Contractor shall furnish the following after approval of all drawings/documents and test reports:

1.19.07

(a)

List of drawings bearing the Employer’s and Contractor’s drawing number.

(b)

Eight (8) bound sets alongwith 3 CD-ROMs of all drawing.

(c)

All documents/designs in four (4) copies as noted above.

(d)

Contractor shall also furnish eight (8) bound sets of all as-built drawings including the list of all as-built drawings bearing drawing numbers. The Contractor shall also furnish three (3) sets of film reproducibles or CD-ROMs of all as-built drawings as decided by the Employer.

(e)

The Contractor shall also furnish ten (10) copies of instruction manuals (after approval) for all the equipments.

Test Reports Four (4) copies of all test reports shall be supplied for approval before shipment of equipment. The report shall indicate clearly the standard value specified for each test to facilitate checking of the reports. After final approval six bound copies of all type and routine test reports shall be submitted to Employer.

1.20.00

Reference Drawings

1. 20.01

The drawings enclosed with the specification are for information and for purpose of tendering only. They give the basic scheme of the works and associated services including the scope of work. In case of any discrepancy between drawings and text of specification, the requirement of text shall prevail.



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1. 20.02

1. 21.00

GENERAL TECHNICAL REQUIREMENTS The dimensions shown on the drawings between center line of various equipment are tentative and are for guidance only. Contractor while preparing the final drawings shall: (a)

Co-ordinate with various suppliers for the actual dimensions of the equipment.

(b)

Maintain the overall dimensions of the switchyard, bay length and bay width, phase-to-phase clearance between buses, etc. but may alter the locations of equipment to obtain the statutory electrical clearances required for the switchyard. In this process he must follow all rules and satisfy all conditions of: i)

BS:162 - Specification for electrical power switchgear and associated apparatus.

ii)

Indian Electricity Rules.

iii)

Fire Protection Manuals issued by Tariff Advisory Committee of India.

iv)

National Electricity Safety Code published by Institute of Electrical and Electronics Engineers, New York.

Taking Over Upon successful completion of all the tests to be performed at site on equipments furnished and erected by the Contractor, the Engineer shall issue to the Contractor, a taking over certificate as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably be with-held nor will the Engineer delay the issuance thereof on account of minor omissions or defects which do not affect the commercial operation and/or cause any serious risk to the equipments which otherwise survive, by the terms and conditions of the contract after issuance of such certificate.



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Annexure – I INDICATIVE FIELD QA&QC LABORATORY SET-UP S. No 1. 2. 3.

Equipment Standard sieve analysis setup along with the sieve G.I. frame , Motorized sieve shaker , Pans and Covers etc. Slump Testing Equipment - Slump test mould, temping rod, Compression test for concrete cubes and bricks - Cube moulds, compression testing machine, cylinders, temping rods, laboratory concrete mixer Viacat apparatus, balance, standard weights, gauging trowel Rebound Hammer for NDT testing of concrete Thermostatically controlled laboratory Electric ovens. Physical balance and Electronic balance Micro Meter, Vernier Calipers Mhos scale for hardness test Digital Elco-meter for paint thickness Standard Proctor test set-up and Core cutter for in-situ density test set-up Glass Jar, sedimentation pipette, Measuring Cylinders, Containers, Evaporating dish, steam bath, desiccators, muffle furnace, chemicals etc. Thermometer, Steel rules, Measuring wedge for bricks etc

4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Nos 1 Set 2 Set 1 Set 1 Set 1 Set 1 Set 1 Set each 1 Set 1 Set 1 Set 1 Set each As required As required

NOTE: 1. The above laboratory equipment list is indicative and not exhaustive. The CC shall mobilize all the laboratory equipments in good working conditions preferably not more than 3 years old to carry out all the tests required to meet the specification requirements. 2. The CC may indicate the tests proposed to be outsourced, if any, to be conducted at NTPC approved third party laboratories such as NCB, CSMRS, IIT’s etc. 3. All laboratory / measurement / survey equipments to be used at site shall be calibrated by NABL/NPL accredited laboratory / agency.

TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2


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Annexure – II INDICATIVE QA&QC MANPOWER STRUCTURE PROJECT MANAGER

QA & QC MANAGER

• • • • •

QUALITY ASSURANCE DOCUMENTATION- QAP, FQP, MQP, MONTHLY/ QUARTERLY REPORTS ETC. CO-ORDINATION AND INTERACTION WITH NTPC AND SUB-CONTRACTORS TEST ON BOUGHT OUT ITEMS THIRD PARTY LABORATORY TESTING

QC ENGINEER-IN-CHARGE

QA&QC LABORATORY IN-CHARGE

EXCAVATION, FILLLING - GEOTECHNICAL ENGINEERS

CONCRETE & BUILDING MATERIALS EVALUATION/ TESTING, CONCRETE MIX DESIGN AND PRODUCTION STRUCTURAL STEEEL WORKS, ROAD, BUILDING AND ARCHITECHTURAL WORKS - CIVIL ENGINEERS

SUPPROTING FIELD/ NDT AND LABORATORY STAFF

SUPPROTING STAFF

NOTE: The Contractor shall submit the details/ bio-data of QA&QC manpower along with their deployment schedule for approval/ acceptance. The CC shall mobilize additional manpower, if required to meet the construction schedule. The deployment of this manpower shall be based on the agreed/ approved manpower deployment schedule linked to L-2 Network. All the areas/ activities shown above shall headed by experienced and qualified engineers supported by sufficient nos of supervisors and supporting staff. The bidder shall indicate the number of engineers and supervisors in their bid, which shall be discussed and finalized before award of the package. TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2


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Annexure – III Indicative List of Bought Out Items for Civil Works Sr. No.

Bought Out Item

Proposed Make

1.

Cement, if procured by Contractor

2.

Structural and Reinforcement Steel, if procured by Contractor

3.

Construction Chemicals- admixtures, waterproofing, accelerators, Epoxy Resin, grouts etc.

4.

Bitumen, Bitumen Impregnated Fiber Board Joint Filler, Joint Sealing Compound, Bituminous Compound, Joint Sealant

5.

Paint and Painting System

6.

PVC water stops, hydrophilic strips

7. 8.

PVC Pipes and accessories Any other specific high value and critical bought out item required, meeting the specification requirements

Proposed list of Manufacturers

Note: The Bidders are required to indicate the list of proposed manufacturers/ sub-vendors for each of the BOI in their Bid proposal, which shall be discussed for finalization at post bid stage.



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SUPPLIERS NAME AND ADDRESS: LO GO

Sl. No

1

A

B

C

D

E

F

Activity and operation

INDICATIVE FIELD QUALITY PLAN- CIVIL WORKS ITEM : CIVIL WORKS INCLUDING QP NO. : 1 STRUCTURAL STEEL WORK, PILING, BUILDING REV. NO .: 0 DATE : SUB-SYSTEM : PAGE : Characteristics / instruments Class Type of Quantum Of check # of Check check

2 GENERAL REQUIREMENTS Setting up of Field QA&QC laboratory

Availability of requisite laboratory set up and equipment in good working condition well before commencement of concerned activity Submission of QA & QC manpower deployment schedule based on agreed L-2 network . Availability of QA& QC manpower based on deployment schedule . Sampling for testing of building materials, concrete mix design etc. Submission of schedule of tests to be done monthly / quarterly and maintenance of the same on a computer connected to LAN of NTPC for monitoring


3

ANNEXURE- IV PROJECT: PACKAGE:

LOHARINAG PALA HEPP (4 × 150 MW) 400KV SWITCHYARD PACKAGE

CONTRACT NO. MAIN CONTRACTOR Reference Document

CS-5506-500-2-XXX

Acceptance Norms

Format of Record

9

D *

As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology

SR

√

Once prior to start of work and thereof monthly


SR

√

Physical

Once prior to start of work


A

Physical



SR

√

A

Physical

Once per each source


SR/TR

√

A

Physical



SR

√

4

5

6

A

Physical

Once prior to start of work

A

Physical

-

A

-

As agreed / required

7

8

Remarks

10

Functioning of laboratory equipment in proper working condition to be verified on monthly basis


As agreed / required -


PART- C

√

Test report along with the recommendations from specialist agency to be submitted to NTPC.

PAGE 33 OF 100

1 1.1 i

ii iii

GEOTECHNICAL INVESTIGATION Borehole Drilling/ Core Drilling Submission of Detailed description of Geotechnical Investigation and testing equipments to be deployed, methodology for core drilling Check for drilling location layout Submission of daily copy of the borehole Journal

-

B

Prior to start of work


SR

B

Review and Approval/ acceptanc e Review

-

Prior to start of work

SR

-

B

Review

Daily During the work

As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology

Latest within 15 days after completion of borehole Latest within 1 month after completing all works

iv

Submission of Borehole Section document

-

B

Review

v

Submission of Geotechnical Investigation Summarizing Report for all tests as described in Technical Specifications

-

B

Review


B

Physical


B


1.2

1.3

1.4

1.5

1.6

2

2.1

2.2

Sampling of Material for Laboratory Testing Execution of Geotechnical Investigation by Insitu Testing Execution of Ground Investigations by Destructive Drilling Execution of Ground Investigation by Geophysical Method Reinstatement of work site EXCAVATION AND FILLING IN FOUNDATION WORKS ExcavationsCheck for the Nature, type of soil/rock before and during excavations Check for the Initial ground level before start of excavations


SR


SR


SR

100%


SR

Physical

100%


SR

B

Physical

100%


SR


B

Physical

100%


SR


B

Physical

Each location after completion


B

Visual

Random in eah shift


SR

B

Measurem ent

100%


SR

As agreed / required As agreed / required


PART- C

This shall include SPT, Collection of disturbed and undisturbed soil/ rock core sample, water sample etc -do-

Interpretation of results, Photograph of the core samples, trial pit and trenches walls, location co-ordinates etc. (3 hard copies and 1 CD)

PAGE 34 OF 100

2.3

2.4 2.5 2.6 i

ii iii 2.7

2.8 i

ii

iii

Check for the final shape and Dimensions of excavations. Check for the Final excavation levels Check for the Side slope of final excavation Excavation in Hard Rock. Receipt, Storage, accountability of Explosive Execution of Blasting Operation Submission of Blasting report to EIC Excavation in Hard Rock (Blasting Prohibited) Fill/ Backfill Suitability of borrow fill material Grain size analysis

Liquid & plastic limit

Shrinkage limit

iv

Free Swell Index

v a

Chemical Analysis Organic Matter

b

Calcium carbonate

c

pH value

d

Total soluble sulphate

As agreed / required As agreed / required As agreed / required

B

Measurem ent

100%


SR

B

Measueme nt Measurem ent

100%


SR

Indian Explosive Act 1940/all statutory norms, Tech Specs and Const. Drawings IS:4081, Tech Specs and Const. Drawings As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology

SR

√

SR

√

B

B

Physical

Random in each week

B

Physical

Random in eah shift

C

Physical

Each blast

B

Physical

100%

Set of Seives, Hydrometer etc. As per IS 2720

B

Physical

-do-

B

One in every 2000 cum for each type and source of fill materials subject to a min. of 2 samples One in every 2000 cum for each type and source of fill materials subject to a min. of 2 samples One in every 5000 cum for each type and source of fill materials subject to a min. of 2 samples One in every 5000 cum for each type and source of fill materials

As agreed / required As agreed / required As agreed / required As agreed / required

Measuring cylinders, etc. As agreed / required As agreed / required As agreed / required

B

Physical

Physical

B

Physical

B

Physical

B

Physical

B

Physical

B

Physical



Random in eah shift


One in every 5000 cum for each type and source of fill materials One in every 5000 cum for each type and source of fill materials One in every 5000 cum for each type and source of fill materials One in every 5000 cum for each type and source of fill materials

SR

√ SR

√

SR/TR

√

SR/TR

√

SR/TR

√

SR/TR

√

SR/TR

√

SR/TR

√

SR/TR

√

SR/TR

√

NTPC approved specialist blasting agency such as CMRI, NIRM shall be deployed at site for trial blasts, design blasts, blast vibration monitoring etc. Seismographs shall be deployed at site for monitoring of blast operation vibrations.

IS:2720 (Pt.IV), Tech Specs and Const. Drawings

IS:2720 (Pt.IV) , Tech Specs and Const. Drawings

IS:2720 (Pt.IV), Tech Specs and Const. Drawings IS:2720 (Pt.XI), Tech Specs and Const. Drawings

IS:2720 Pt.XXII, Tech Specs and Const. Drawings Part XXIII of IS-2720, Tech Specs and Const. Drawings Part XXVI of IS-2720, Tech Specs and Const. Drawings Part XXVII of IS-2720, Tech Specs and Const. Drawings

PART- C

PAGE 35 OF 100

2.9

Standard proctor Test

2.10

Moisture content

2.9

Degree Of Compaction Of Fill / Backfill Dry density by core cutter method

i

Optimum moisture content and max. dry density before fill Moisture content of fill before compaction

Dry density in place by sand displacement method Relative density (Density Index) Dry Density by proctor needle penetration

iii

3.0


A

Physical

A

Physical

A

Physical


---- OR----

ii



A

Physical

B

Physical

One in every 2000 cum for each type and source of fill materials One in every 2000 cum for each type and source of fill materials i) For foundation fill/ backfill one for every 10 foundations for each compacted layer. ii) For area filling, one every 1000 SQM area for each compacted layer. ----do----- (i) & (ii) above Random checks to be carried out for each compacted layer

IS 2720 (Pt.VII), Tech Specs and Const. Drawings IS 2720 (Pt.II), Tech Specs and Const. Drawings

SR/TR

√

SR/TR

√

SR/TR

√

SR/TR

√

SR/TR

√

SR/TR

√

IS 2720 (Pt. XXIX), Tech Specs and Const. Drawings IS 2720 (Pt. XXVIII), Tech Specs and Const. Drawings IS 2720 (Pt. XIV), Tech Specs and Const. Drawings Tech Specs and Const. Drawings

CAST-IN-SITU CONCRETE MATERIALS CEMENT

3.1 i

Ensure that cement is stored in weather tight covered storage on raised platform. If cement is stored more than 60 days in godown of contractor same shall be retested for comp. Strength & setting time.

ii

3.2

B

Visual

100% covered storage


SR/LB Tech Specs and Const. Drawings

A

Physical

At Random


Test Report

Tech Specs and Const. Drawings

√

Each consignment of cement shall be duly correlated with Manufacturers TC. In case the cement is supplied by the contractor random sample from each lot of delivery shall be tested for Setting time and Compressive strength. Acceptance norms shall be as per relevant IS code

Coarse Aggregate i

Moisture content

B

Physical


ii

Specific gravity, density, voids, absorption,


bulk water

B As agreed / required

Physical

Once for each stack of 100 Cum. or part there of Except during monsoon when this has to be done every day before start of concreting Once for each source & for every change of source


SR/LB

Accordingly water content of the concrete will be adjusted

SR/LB / Test Report

These tests will be carried out white establishing design mix and the results to be intimated to NTPC.

IS:2386 Part-III, IS : 456, IS : 383/Tech Spec, Tech Specs and Const. Drawings

IS:2386 Part-III, IS : 456, IS : 383/Tech Spec, Tech Specs and Const. Drawings

PART- C

PAGE 36 OF 100

iii

Particle, size & Shape(Sieve analysis, determination of material finer than 75 micron, flakiness index, elongation index, angularity number)

iv

v

Deleterious materials & organic impurities (determination of clay lumps, fine silt, fine dust , light weight pieces , soft particle & estimation of organic impurities.) Soundness

vi

Alkali aggregate reactivity

vii

Petrographic examination

viii

Crushing value abrasion value and impact value

3.3

B

Physical

One per 100 cum., or part thereof/change of source whichever is earlier


B

Physical

SR/LB IS:2386 Part-I, IS : 456, IS : 383/Tech Spec, Tech Specs and Const. Drawings

Once per source/ on every change of source IS:2386 Part-II, IS : 456, IS : 383/Tech Spec, Tech Specs and Const. Drawings



B

Physical

Once per source/ on every change of source

B

Physical


B

Physical


B

Physical


B

Physical

To be done every day before start of work

-do-

IS: 2386 Part-V, IS:383 , Tech Specs and Const. Drawings IS: 2386 (Part-VII), IS:383 , Tech Specs and Const. Drawings IS: 2386 Part-VIII, IS:383 , Tech Specs and Const. Drawings IS:383, IS-2386 Part IV/, Tech Specs and Const. Drawings

SR/LB / Test Report

SR/LB / Test Report SR/LB / Test Report SR/LB / Test Report SR/LB / Test Report

√ √ -do-

Fine Aggregate i

Bulkage/ moisture content

ii

Mortar making properties

iii

Silt, Clay content and organic impurities All other tests similar to coarse aggregates as mentioned above.

iv

3.4

balance oven etc

,


B

Physical

B

Physical

B

As above

Buret, conical flask, pipette etc

B

Testing

Once per each source thereof quarterly.

As agreed / required pH meter

B

Physical

B

Testing

Once per each source thereof quarterly. Once per each source thereof quarterly.


Once per source& for on every change of source Once per source& for on every change of source Refer above

IS: 2386 Part-III IS:383 , Tech Specs and Const. Drawings IS: 2386, IS:383, Tech Specs and Const. Drawings IS: 2386 Part-II, IS:383 , Tech Specs and Const. Drawings IS-2386, IS-383, Tech Specs and Const. Drawings

SR/LB / TR

SR/LB / TR SR/LB / TR SR/LB / TR

Volume of sand and weight of water shall be adjusted as per bulkage & moisture content.

Acceptance limit as per relevant IS code Except for flakiness, elongation, crushing value and abrasion value

Water i

Test for chlorides

ii

Tests for ascertaining limit of solids Tests for pH Value

iii

sulphates


and


IS:3025 part 22 and 23 (for test procedure ), IS:456(for acceptance criteria ) , Tech Specs and Const. Drawings IS:3025 part 18 (organic),IS:456 , Tech Specs and Const. Drawings IS:3025, IS:456, Tech Specs and Const. Drawings

PART- C

SR/LB / TR

SR/LB / TR SR/LB / TR

PAGE 37 OF 100

iv

Check for initial set time for used water and distilled water

vicat appratus

A

Physical

See Remarks

See Remar ks

√

Initial set time with used water should not be less than that with distilled water. This check is to be carried out only if the results of the tests mentioned at sl. no. 2.01.04 i),ii)& iii) mentioned above

See Remar ks

√

This check is to be carried out only if the results of the tests mentioned at sl. no. 2.01.04 i),ii)& iii) mentioned above

SR/LB / Test Report

√

SR/LB / Test Report

√

For trial mix min. of 6 cubes for each mix, 3 specimen shall be tested at 7 days remaining 3 shall be for 28 days comp. Strength. Mix design shall carried out at agency finalised during pre award ) Min. of 6 cubes for each mix, 3 specimen shall be tested at 7 days remaining 3 shall be for 28 days comp. Strength.

See Remarks, Tech Specs and Const. Drawings

v

3.5

Check for Concrete compressive strength with used water and distilled water

standard sand and compression testing machine

A

Physical

See Remarks


See Remarks, Tech Specs and Const. Drawings

CONCRETE i

ii

Check for the proportions of materials for nominal mix concrete as per Table-9 of IS 456 Trial mix (Cubes compressive strength) as per Mix Design

B

Physical

Random in each shift


IS:456, Tech Specs and Const. Drawings A

Physical

Min. 4 Trial Mixes with admixtures and Without admixtures With fly ash.


iii

Crushing strength Tests cubes)

(works

iv

Workability - slump test

v

Cement content

vi

Admixtures for Concrete from approved sources

vii

Water Tightness Test for Water Retaining Structures

viii

Dimensions and visual examination of finished structure


IS: 516 & IS:456, IS:10262, Tech Specs and Const. Drawings

A

Physical

As agreed / required As agreed / required As agreed / required As agreed / required As agreed / required

SR/LB / Test Report

One set of 6 cubes per 100 M3 or part thereof for each grade of concrete per shift whichever is earlier. One sample every 2 hrs. from every mixing plant At random at the time of batching. Random in each shift

B

Physical

B

Physical

A

Review of MTC

B

Physical

100%

B

Physical/ visual

100%



IS:516, IS:456, Tech Specs and Const. Drawings IS:456, Tech Specs and Const. Drawings IS:1199 , Tech Specs and Const. Drawings IS:456 , Tech Specs and Const. Drawings IS:3370 (Tanks and Revision) , Tech Specs and Const. Drawings

SR/LB /TR SR/LB Test Report Inspec tion Report SR

√

Admixture of appd. Brand and tested quality shall be used.

√

As per Tech. Specification./Appd. Drg./IS-456

PART- C

PAGE 38 OF 100

3.6 i

ii

CONCRETE CONVEYING, PLACING& COMPACTION Mixing of concrete mixing of concrete shall be done in a approved mixer such as to produce a homogenous mix Calibration of Batching Plant

iii

Handling and Transportation of concrete

iv

Placement of concrete

v

Check for compaction and Curing

vi

Cleanliness, provision of chute and arrangement for transportation & placement of concrete. check for segregation

x 3.7 i

ii

iii 3.8

TEST/CHECK ON RCC STRUCTURE IN HARDENDED CONDITIONS Core Test

Dimensional check finished structures Dimensional tolerances Rebound Hammer test

batcher should comply with requirement of IS 457

A

buckets,chut es,belts,conv eyer etc Visual

B

Physical


B

Physical


B

Physical


C

Visual

100%


Physical


Visual

100%

A

Physical

As required by NTPC Engineer.

B

Measurem ent

Approved Drawing


A

physical

As required by the NTPC engineer

As required/ agreed

A

Review of MTC

Each batch of delivery


B

Measurem ent Visual



time of mixing will be as given in IS 457

Review of calibration chart/ Certificate, IS 457, Tech Specs and Const. Drawings TR Review of calibration chart/ Certificate, Tech Specs and Const. Drawings

IS:456, Tech Specs and Const. Drawings IS:456, Tech Specs and Const. Drawings Check for period of curing as per IS 456 , Tech Specs and Const. Drawings

√

Cement consumption at batching plant shall also be obtained through comp. Output. Provision of online printer is mandatory

SR

SR SR

SR IS:456, Tech Specs and Const. Drawings

C

As agreed / required on &

To be calibrated at the time of starting and subsequently once in three months, and shall confirm to IS:4925 To be calibrated at the time of starting and subsequently once in three months, and shall confirm to IS:4925

IS:456, Tech Specs and Const. Drawings

As per IS:456, IS 516, Tech Specs and Const. Drawings As per IS:456, Tech Specs and Const. Drawings , Tech Specs and Const. Drawings

SR/LB / Test Report SR/LB

SR/LB

√

√

REINFORCEMENT STEEL i

ii iii 3.9 I

Physical and Chemical Properties for each lot as per relevant IS codes Cutting tolerance Freedom form cracks surface flaws, Lamination. PLACEMENT OF REINFORCEMENT STEEL Check for bar bending schedule with necessary laps. Spacers & Chairs TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2


B

B

Visual & Measurem ent




IS : 1786, IS:432, IS:1566, Tech Specs and Const. Drawings IS : 1852, IS: 432, IS:1786, Tech Specs and Const. Drawings IS: 1852, IS:432, IS:1786, Tech Specs and Const. Drawings Approved Drawings, Tech Specs and Const. Drawings

PART- C

MTC

SR/LB

√

Applicable if steel is procured by Contractor Tolerance as per specifications

SR/LB

SR

PAGE 39 OF 100

ii

Check for cover, spacing of bars

iii

Check for bending of bars

iv

Check for spacers and chairs after the reinforcement cage is put inside the formwork Acceptance of placement od reinforcement before start of concreting

v

3.10 i

Materials and accessories Soundness of staging, shuttering and scaffolding

iii

Acceptance of formwork before start concreting EMBEDDED PART(INCLUDING LAYING OF RAILS & ANCHOR FASTENERS) Position and levels of embedded parts

i

ii

Position depth and size of bolt hole

iii

Location verticality of pipe sleeve/opening of bolt hold

iv

Laying of rails under supervision of NTPCs specilised agency. Welding / tying of embedment to reinforcement

v

3.12 i

ii


B

B

B As agreed / required As agreed / required

Visual & Measurem ent Visual & Measurem ent Visual & Measurem ent



Approved Drawings, Tech Specs and Const. Drawings Approved Drawings, Tech Specs and Const. Drawings


SR

SR

SR Approved Drawings, Tech Specs and Const. Drawings

B


beofre start of each concreting

IS : 456/ Drawings & approved bar bending, Tech Specs and Const. Drawings schedule

SR

B

Visual

Once before start of work

SR

B

Visual

Once before start of work

B

Physical / visual

before start of each concreting

As per relevant IS, Tech Specs and Const. Drawings As per manufacturer's spec. and as per 3696,4014, 4990, Tech Specs and Const. Drawings As per provisions and tolerances, Tech Specs and Const. Drawings

B

Physical/ measurem ent Physical/ measurem ent Physical/ measurem ent Physical/ measurem ent Physical/ measurem ent

100%

STAGING AND FORMS

ii

3.11




B

B

B

B





As per drawing, Tech Specs and Const. Drawings As per drawing, Tech Specs and Const. Drawings As per drawing, Tech Specs and Const. Drawings As per drawing, Tech Specs and Const. Drawings As per drawing, Tech Specs and Const. Drawings

SR

SR

SR

SR

SR

SR

SR

PRE-CAST CONCRETE Crushing strength

iii

Workmanship free from visual defects Dimension of finish structure

iv

Workability


compression strength testing machine Visual As agreed / required slump test apparatus

A

Physical

one sample of six cubes per 50 cum or part thereof

B

Physical

100%

B

Measurem ent Physical

100%

B

one sample every two hrs from mixing plant


SR/LB IS:516&IS; 456, Tech Specs and Const. Drawings As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per IS:456, Tech Specs and Const. Drawings IS:1199 &IS:456, Tech Specs and Const. Drawings

PART- C

√

a minimum of three specimen shall be tested for 28 days comp. strength

SR SR SR/LB

According to the mix design

PAGE 40 OF 100

v vi

Water cement ratio Cement content

vii

Load Test


B

Physical

B

Physical

A

Physical

At random at the time of batching At random at the time of batching 5% or as desired by EIC

ii

i ii 3.15 i

Acceptance of installation of materials for Joints in concrete DAMP PROOF COURSE Check for the material - Hot bitumen and water proffing materials etc Acceptance of damp proof course GROUTING Check for the material Check for the type of mix fluid mix, plastic mix, stiff mix etc. Check for the mixing, placement, application and grout pressure Check for the compressive strength Acceptance of the grouts

ii

iii iv

4.00 4.1 i

ii

SR SR √

According to the mix design According to the mix design These tests shall also be carried out, in case of doubt regarding grade of concrete and poor quality.

JOINTS IN CONCRETE Check for the joint material - bitumen impregnated fibre board, PVC water stops, Sealing compound, Expanded polystyrene board, Hydrophillic strip, Acrylic polymer etc.

3.14

SR/LB

IS:456/ As decided by NTPC Site Engr. In charge., Tech Specs and Const. Drawings

As agreed / required 3.13 i

IS:1199 , Tech Specs and Const. Drawings IS:1199 /tech spec, Tech Specs and Const. Drawings

As per manufacture r Standards


A

B

Review of MTC


Acceptanc e

Each installation randomly

Tech Specs and Const. Drawings, IS 1838, IS 1834, IS12200

MTC √

Tech Specs and Const. Drawings Tech Specs and Const. Drawings


A

Review of MTC

Each batch of delivery at site


B

Acceptanc e

100%


A B

Review of MTC Physical


Tech Specs and Const. Drawings, IS 702

SR


SR


SR

√

√

Check for chemical, epoxy, resin grouts etc

Prior to start of work Tech Specs and Const. Drawings

B

Physical


A

Physical


B

Physical

Each grout section

A

Measurem ent/ Physical Test Measurem ent/ Physical Test

As per relevant IS Code/ One Sample for 30,000 Nos. or part thereof


SR


SR


SR

IS: 1077, Tech Specs and Const. Drawings

Inspec tion Report

√

BRICK MASONARY Test on Bricks Check for Dimensions , shape

compressive strength, water absorption, warpage efflorescence.


As agreed / required Balance Oven compression testing machine etc.

B


As per relevant IS Code/ One Sample for 30,000 Nos. or part thereof

IS: 1077, IS:3495 part I ( Compressive Strength) Part II ( Water Absorbtion) Part III( Efflorescence) Part IV ( War page), Tech Specs and Const. Drawings

PART- C

√

√

Efflorescence shall be checked at each source.

Preconditioning of brick shall be done as per IS. For comperssive strength, warpage and water absorbtion

PAGE 41 OF 100

4.2

Test on Mortar

4.3

Masonry construction

5.00 5.1 i

Compressive strength, consistency and water retentivity for each portion of walls, plasters and ceilings. Acceptance Workmanship, and alignment

of verticality

FINISHING AND ALLIED WORKS MATERIALS- FINE SAND, SAND FOR PLASTERING Deleterious Material

ii

Grading

iii

Galvanized hexagonal wire netting for lath plastering Check for the thickness and finishing of plaster

iv

5.2

B

At random


LB

Cement used in mortar shall confirm to either IS 269: 1976 or IS 4551976 sand shall confirm to IS 2116 -1980

IS 2250-1981, Tech Specs and Const. Drawings B


Visual/ Physical

100%

SR/LB IS 2212, IS 1905 , Tech Specs and Const. Drawings .


B

Physical

Once per source

B

Physical

50 Cum./or part thereof

B

Review of MTC Visual/ Measurem ent


Visual/ Physical


B


IS : 2386 (Part-I &II) & IS :2116, Tech Specs and Const. Drawings IS:3150,1542& Apprd. drgs, Tech Specs and Const. Drawings , Tech Specs and Const. Drawings As per IS 1661 , Tech Specs and Const. Drawings

SR SR

Table –I of IS:2116

SR SR/LB

PLASTERING i

ii iii 5.4

Check for defects and the remedial measure for bond filler , blistering , cracking and crazing , efflorescence and irregularity of surface texture Truness of plastering system Acceptance of Grooves and finishing WATER PROOFING SYSTEM

B As agreed / required


ii 6.00 6.1

SR Tech Specs and Const. Drawings, IS: 1661

B B

i

6.2

Test

Visual/ Physical Acceptanc e

Random in each shift 100%


SR SR

Check for the material


A

Physical and Review of MTC

Each lot of delivery

Tech Specs and Const. Drawings,

SR/ MTC

Acceptance of water proofing system Application, fixing, laying


B

Physical

100%


SR

A

Review of MTC


PAINTING SYSTEM - All surfaces Check for the White wash, Distemper and Materials and all types of Primer and accessories Paints - Check for Shade, type from brand and manufacturer as approved by NTPC EIC Check for Surface prepration TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2



Physical /visual



Water pounding test shall be done

SR/MT C √


B

√


PART- C

Mfr.’s T.C. shall be correlated with the consignment received.

SR

PAGE 42 OF 100

6.3

Check for DFT of painted surfaces Acceptance of painted surfaces

6.4

7.00 7.1

ii)

7.3

8.00

Review of MTC/ make / Physical checks, tests ( if MTC is not available)


PVC coated chain link fencing (IS 2720), Welded wire mesh (IS 1566), Reinforced barbed tape galvanised (IS 2629) etc.


Check for alignments, erection painting, DFT etc. Acceptance of the installation and working Galvanised Chicken Wire Mesh

8.2

i

ii

B

Physical

Each surface at random

A

Review of MTC for each delivery

For each batch of delivery

Tech Specs and Const. Drawings Tech Specs and Const. Drawings

SR SR


SR

√

As agreed / required Check for Guage and Dimensions from NTPC approved Source


B

B

Review of MTC


Physical / measurem ents Physical / measurem ents

Each installation

Each installation

B

Acceptanc e


A

Physical and Review of MTC for each delivery

one sample for each section for each lot of delivery


B

Physical

100%

As required / agreed

B

Physical

Each location

Random for each delivery


SR/MT C

√

As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology SR

Erection shall be as per NTPC Tech. Specs.

SR

Erection shall be as per NTPC Tech. Specs.



SR

WATER PROOFING

8.1

9.1


A


Check for water proofing compoud, Blown/ residual bitumen, PVC sheet, PVC water stops, Geotextiles, Poly-scrim cloth, elastomeric membrane, from NTPC approved sources Acceptance of water proofing work

9.00

Physical

Fencing and Gates Check for Materials for fencing and gates

ii)

B

GENERAL STEEL WORK Check for Material

7.2 i)


As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology SR


FOUNDATION SYSTEM SHALLOW FOUNDATIONS Check for the foundation excavation - Location, Layout, size, depth etc Check for the foundation casting - Layout, Shape, dimensitions, Reinforcement, concreting, curing etc TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2



SR

As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology B

Physical


Each foundation

SR

PART- C

√

lines and levels to be checked lines and levels to be checked. Concrete Grade to be checked as per Mix Design

PAGE 43 OF 100

10.0 i

Earthing Mat (Grounding System) Check for the earthing mat material

iii

D P test

DP test Kit

A

Physical and MTC Review Visual/ Measurem ent Physical

iv

Earth test

Earthing test kit

A

Physical

100%

A

Physical

One in every 2000 cum for each type and source of fill materials

B

Physical


A

Physical

One in every 500 SQM area for each compacted layer.

ii

11.0 11.1 i

ii

iii

11.2 i

Weld sizes & length

ROAD WORKS Construction of Sub-Grade and earthen/hard shoulders Standard proctor Test to determine optimum moisture content and max. dry density Moisture content of fill before compaction

Dry density by core cutter method ---OR---Dry density in place by sand displacement method Water Bound Macadam (Non-Bituminous) for base course and sub-base course Aggregate Impact value

ii

Grading

iii

Flakiness index and elongation index Atterberg Limits of binding material Atterberg Limits of portion of agreggate passing 425 micron sieve Standard proctor Test to determine optimum moisture content and max. dry density Moisture content of fill before compaction

iv v

vi

vii

viii

Dry density by core cutter TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2

As agreed / required Visual/Tape

A

B

10% at random


A

Physical

One test per 200 cum of Test aggregate One test per 100 cum of aggregate One test per 200cun of agregate One test per 25 cum of binding material One test per 100cum of aggregate

B

Physical

B

Physical

A

Physical

A

Physical

A

Physical


B

Physical

A

Physical

One in every 2000 cum for each type and source of fill materials For area filling, one every

As agreed / required As agreed / required As agreed /

SR/MT C

√ Low hydrogen electrode as per NTPC approval shall be used.




As per relevant IS and Tech. Specs / Manufacturer's TC, IS 3043

100%





Free from defect , Tech Specs and Const. Drawings Tech Specs and Const. Drawings, Relevant IS 3043

IS 2720 (Pt.VII), Tech Specs and Const. Drawings,Section 900 of MORTH specification IS 2720 (Pt.II), Tech Specs and Const. Drawings, Section 900 of MORTH specification

TR

√

SR

√

Earthing required as per IS 3043

SR/TR

√

In cutting or existing levelled ground quantum of check shall be one per 1000 SQM In cutting or existing levelled ground quantum of check shall be one per 1000 SQM Both for embankment and cut formation quantum of check - One in every 1000 SQM area for each compacted layer.

SR/TR

SR/TR

√

SR

√

IS 2720 (Pt. XXIX)/ IS 2720 (Pt. XXVIII),Tech Specs and Const. Drawings, Section 900 of MORTH specification

Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings IS 2720 (Pt.VII), Tech Specs and Const. Drawings,Section 900 of MORTH specification IS 2720 (Pt.II), Tech Specs and Const. Drawings, Section 900 of MORTH specification IS 2720 (Pt. XXIX)/ IS 2720 (Pt.

PART- C

SR SR SR

√

SR

√

SR

√

SR

SR

√

PAGE 44 OF 100

11.3 i

method ---OR---Dry density in place by sand displacement method Bituminous Macadam for base and binder course Quality of binder

ii

Aggregate Impact Value / Los angeles abrasion value

iii

Flakiness Index and elongation index of aggregates Stripping value of aggregate (Immersion tray test)

iv

v

required


Physical

B

Physical

One test per 50 cum of aggregate

B

Physical

Initialy one set of 3 representative specimen per source, and on every change of source. Initialy one set of 3 representative specimen per source, and on every change of source. Two test per day per plant both on individual constituents and mixed aggregate from drier Initially one set of 3 representative specimen per source, and on every change of source. Once per source by each method and on every change of source When gravel is used one test per 50cum of aggregates Periodic, subject to a min of two tests per day per plant At regular close intervals

Physical

B

Physical

As agreed / required vii

viii

Water absorption aggregate

of As agreed / required

Soundness ( Magnesium and Sodium Sulphate)

ix

Percentage faces

x

Binder content aggregate grading

xi

Control of Temperature of binder and aggregate for mixing and of the mix at the time of laying and rolling Rate of spread of mixed materials Density of compacted Layer

xii xiii 11.4 i

of

fractured

Bituminous Surfacing - Open graded premix carpet and Seal coat Quality of binder TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2

and


IS 73,Tech Specs and Const. Drawings, Section 900 of MORTH specification Section 900 of MORTH specification, Tech Specs and Const. Drawings

A

A

Grading of aggregates

No. of samples per Lot & tests as per IS:73, IS:217, IS:8887 as applicable One test per 50 cum of aggregate

Physical

As agreed / required vi

XXVIII),Tech Specs and Const. Drawings, Section 900 of MORTH specification

A


Water sensitivity of mix

1000 SQM area for each compacted layer.

A

Physical

B

Physical

A

Physical

B

Physical


As agreed /

Section 900 of MORTH specification, Tech Specs and Const. Drawings

SR

√

SR

√

SR

SR Section 900 of MORTH specification, Tech Specs and Const. Drawings SR

√

Section 900 of MORTH specification, Tech Specs and Const. Drawings SR Section 900 of MORTH specification, Tech Specs and Const. Drawings SR Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings

SR

√

SR

SR

√

SR Section 900 of MORTH specification, Tech Specs and Const. Drawings

B

Physical

A

Physical

A

Physical

Regular control through checks of layer thickness One test per 250 sqm of area

Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings

No. of samples per Lot &

IS 73,Tech Specs and Const.


PART- C

SR SR

√

SR

√

PAGE 45 OF 100

required ii

Aggregate Impact Value / Los angeles abrasion value Flakiness Index and elongation indexof aggregates Stripping value of aggregate (Immersion tray test)

iii

iv

v


A

Physical

B

Physical


B

Physical


A


B

Physical

A

Physical


B

Physical

Initialy one set of 3 representative specimen per source, and on every change of source. Initialy one set of 3 representative specimen per source, and on every change of source. Initialy one set of 3 representative specimen per source, and on every change of source. One test per 25 cum of aggregates Once per source by each method and on every change of source As required

B

Physical

At regular close intervals

A

Physical

One test per 500 cum& not less than two tests per day One test per 500 cum and not less than 2 tests per day When gravel is used one test per 50cum of aggregates

Water absorption test

vi

Water sensitivity of mix

vii

Grading of aggregates

viii

Soundness ( Magnesium and Sodium Sulphate)

A

Physical

Physical

ix

Polished stone value

x xi

Temperature of binder at application Binder content

xii

Rate of spread of materials


B

Physical

xiii

Percentage faces


A

Physical

A

Physical

B

Physical

B

Physical

-

-

11.5 i

fractured

Tack Coat/ Prime coat/ fog coat Quality of binder

ii

Temperature of binder at application Rate of spread of binder

iii

11.6

of

RCC Pavements

Concrete - Material, Mix design, Trial Mixes, Production, Transportation, Placement, Compaction,


tests as per IS:73, IS:217, IS:8887 as applicable One test per 50 cum of aggregate One test per 50 cum of aggregate

As agreed / required As agreed / required As required / agreed

No. of samples per Lot & tests as per IS:73, IS:217, IS:8887 as applicable At regular close intervals



One test per 500 cum and not less than 2 tests per day Refer FQP for concrete Works

Drawings, Section 900 of MORTH specification Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings

SR

√

SR

SR Section 900 of MORTH specification, Tech Specs and Const. Drawings SR

√

SR

√


Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings IS 73,Tech Specs and Const. Drawings, Section 900 of MORTH specification Section 900 of MORTH specification, Tech Specs and Const. Drawings Section 900 of MORTH specification, Tech Specs and Const. Drawings Refer FQP for concrete Works, , Tech Specs and Const. Drawings, IRC & MOST

PART- C

SR SR

√

SR SR SR

√

SR

SR

√

SR

√

SR SR

-

−

FQP for Concrete Works shall be application for all concrete works

PAGE 46 OF 100

11.7

12.0

Curing, Test on green concrete, Test on hardened concrete etc. Alignment, Level, Surface regularity and rectification Horizontal alignment, Surface levels and Surface regularity Rectification

B

Physical

As per section 900 of MORTH specification

B

Physical

Each rectification


SR

A



SR

B

Physical and MTC Review Physical

Random check for each treatment


SR

B

visual

100%


Visual Examination of raw material

B

Visual

100%


Marking and Cutting

B


100%


SR

B

Visual &

100%

As per Tech. Specs, Const. Drgs and

SR

Check for the Anti-weed treatment materials

12.2

Execution of treatment

13.1 i


STRUCTURAL STEEL WORK - FABRICATION & ERECTION MATERIAL FOR FABRICATION & ERECTION Material- Identification and marking

ii

13.2 i



SR

√

Tested steel is supplied by NTPC, and painted for identification by the contractor . Any rest piece / offcuts shall be similarly marked with red colour for steels conforming to IS:8500 for identification at a later date . Unpainted steel pieces shall be treated as those confirming to IS:2062 NTPC to ensure steel confirms to specification requirement before issue to Contractor

FIT-UP


ii

√

ANTI WEED TREATMENT

12.1

13.0


Ensure Proper fit up before TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2

As agreed /


PART- C

In case the material is supplied byContractor, correlated MTC shall be verified. In the event of non submission of MTC, sample shall be collected and tested for physical and metallurgical properties. Proper identification

PAGE 47 OF 100

welding

13.3 i

ii

iii

iv v

vi

vii

13.4 i

required

Measurem ent

Approved/ accepted Methodology

mark to be put. If laminations are found during cutting of the material same shall not be used.

WELDING REQUIREMENTS Check for the qualification of welders and qualification of Welding procedures to be used for all welding. Ensure that the welding consumables used are as per procedure (WPS) approved by NTPC.

Check for proper edge preparation wherever applicable Check for proper sequence of welding Check that the temporary attachment welding are removed and ground Check & ensure that the overlap/excess weld metal is removed by grinding and painting Check the measurement of parts/structures after welding for the correctness of dimensions & and matching, absence of distortion & alignment. NON DESTRUCTIVE AND DESTRUCTIVE TESTING Fillet Welds i). Check for size and visual examination ii). Microetch Examination on production test coupons

iii). Dye Penetration Test Crane Girder iv). Dye Penetration Test Except Crane Girder, for all TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2

A

Physical

100%

As agreed / required A

Physical

100%

Approved WPS/WPS AWSD1.1/ASME-IX, Tech Specs and Const. Drawings

Test Report

Approved WPS/latest NTPC Rationalized list of Electrodes.

SR



√

√

C

100%


SR

B

Physical/ Measurem ent Visual

100%

SR

B

Visual

100%


B

Visual

100%


SR

B

Measurem ent

100%

Tech Specs and Const. Drawings, IS-7215/Approved Drg.

SR

B

Visual/ Measurem ent Physical

100%


SR

Main fillet weld with min one joint per built up beam, columns and crane girders 25% weld length of tension member of crane girder 5% of Weld length with min. 300mm at each


SR


SR


SR


WPS to be submitted for NTPC approval and low hydrogen electrodes to be used for welding of high/medium tensile steel

SR


As required/ agreed

B As required/ agreed As required/ agreed As required/ agreed

B

Physical

B

Physical


PART- C

As per requirement of NTPC Engineer

√

PAGE 48 OF 100

other Fillet Welds ii

loaction

Butt Welds i) Visual examination ii) DPT iii) Mechanical testing on production test coupons

As required/ agreed As required/ agreed As required/ agreed

iv) Radiography Test

B

Visual


B

Physical

B

Physical

A

Physical

On all butt welds DPT after back gouging. Min. one joint per built up beams, columns and crane girder. 100% radiography test on butt welds of tension flange (bottom flange) of crane girder. All other butt welds shall be subjected to 10% weld length of each welder.

As required/ agreed

iii

Full Penetration Welds (Other than butt welds) i) Ultrasonic Testing

A

Physical

i) 100% UT on the web to flange joint of crane girder

As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology

SR


IR

IR IR

√


IR

As required/ agreed

ii) Ultrasonic Testing 13.5 i

Check for the paining Materials and accessories Check for Surface preparation (Sa 2½) Check for DFT of paint

iii iv

Acceptance of painted surfaces Ensure the markings are done a) Assembly designation b) Part number c) Weight d) Any other important identifications.

v

ii

iii

√

A

Physical

ii) 10% UT on other full penetration joints

As per technical specifications and construction drawings

IR

√

A

Review of MTC



SR/MT C

√

B

Random in each shift Each surface at random

B

Physical


C

Visual/ Physical

100%

As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology

SR

B

Physical /visual Physical

C

Visual

100%

B

Physical/ Measurem ent Visual

100%

Wherever RT is not feasible UT to be carried out.

In case of failure of any welds in SPOT/RT or UT the % of retesting shall be doubled at that particular loaction. Acceptance criteria of NDT on welds shall be as per AWS D1.1.

PAINTING SYSTEM

ii

13.6 i

As required/ agreed

√

As per requirement of NTPC Engineer All butt welds to be back gouged before DPT Test on production test coupons



SR SR SR

FOUNDATION CHECKS Ensure that availability of permanent Bench Mark Ensure the foundation are cast as per requirements Check the orientation of the TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2

As agreed / required As agreed / required As agreed /

C


100%

As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and

PART- C

SR SR

SR

PAGE 49 OF 100

foundation Check the top level of foundation pedestal with respect of the permanent bench mark. Check the center to centre distance of column foundation pedestals with respect to the reference axis.

iv

v

vi

Check the diagonals between columns

vii

Check the pitch distance of foundation bolts on both axis & diagonal.

13.7 i

ii

iii

iv

PERMANENT BOLTS AND NUTS AND WASHERS Check for the Material Permanent mild steel Bolts, mild steel Nuts, Mild steel Washers, High strength structural Bolts, GI Bolts, Washers Check for the prepared contact surfaces before bolting Visual inspection of the assembeled bolts - for physical defects Inspection for tensioning procedure and tensioning

v

Acceptance of installation of bolts

required B

100%

Physical/ Measurem ent

100%

Physical/ Measurem ent Physical/ Measurem ent

100%


SR

100%


SR

Physical and MTC Review

Once for each lot of delivery


SR/MT C

B

Physical

Random before asembly for bolting

B

Physical

Randomly in each shift for assembeled bolts

B

Physical

B

Physical

Randomly during snug tight test and after full tensinoning Each bolt

As agreed / required B As agreed / required


B

B

A As agreed / required


Approved/ accepted Methodology As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology

Physical/ Measurem ent


Main-supplier

Signature

Tech Specs and Const. Drawings,and Approved/ accepted Methodology, IS 4000 Tech Specs and Const. Drawings,and Approved/ accepted Methodology, IS 4001 Tech Specs and Const. Drawings,and Approved/ accepted Methodology, IS 4002 As per Tech. Specs, Const. Drgs and Approved/ accepted Methodology

√ √

Check dimensions, properties, storage along with MTC

SR

SR

SR

√

SR

DOC. NO.: CS - Project Code - 323-9-QVC-G-002 REV: 0

For NTPC USE

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings


SR

√

Categorization Witnessing & Accepting (As per NTPC QA&I System) Category ‘A’ FQA Engineer in association with Executing Engineer, Category ‘B’ Executing Engineer, Category ‘C’ Executing Engineer ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate


√

√

LEGEND: D * Records, indentified with “Tick” (√) shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB Sub sup plier

SR

REVIEWED BY

PART- C

APPROVE D BY

APPROVAL SEAL

PAGE 50 OF 100

CLAUSE NO.


ANNEXURE-V LIST OF STANDARDS

1.

Gas Insulated metal enclosed switchgear for rated voltage above 52 KV

IEC-62271-203

2.

New Sulpher Hexaflouride

IEC- 60376

3.

Environmental Testing

IEC- 68 Part III

4.

Insulation coordination.

IEC -71

5

Non linear resistor type arresters for AC systems.

IEC-60099-1/4

6.

Insulated Bushing foralternatingvoltages above1000 V.

IEC- 60137

7.

Guide to testing of circuit breakers

IEC –267

8.

High voltage test techniques-Partial discharge measurements.

IEC –60270

9.

Specification & acceptance of new SF6 gas. IEC- Rec. 376

10.

Report on synthetic testing of high voltage AC circuit breaker.

IEC- 60427

11.

Guide to the checking of SF6 taken from electrical equipments.

IEC- 60480

12.

Switching impulse test on HV insulators.

IEC- 506

13.

Common specification for HV switchgear and control gear standards.

IEC-60694 /62271-1

14.

Cable connections for gas insulated metal enclosed switchgear.

IEC- 60859

15.

Alternating current disconnectors. Bus transfer current switching by disconnector

IEC –61128

16.

AC earthing switches. Induced current switching.

IEC -61129

17.

Requirement for switching of bus charging IEC-1259 current by disconnectors.



PART-C

PAGE 51 OF 100

CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS 18.

Factory built assembly of New Voltage Switchgear and Control Gear

IEC- 60439

19.

IEEE- Guide for safety in AC substation grounding

IEEE-80 (2000)

20.

Earthing of GIS –an application guide (Elecra no: 151, Dec’93)

CIGRE-44

21.

Cable connection between power transformer & gas insulated metal enclosed switchgear for rated voltage above 52KV

IEC-62271-306

22.

Cable connection for gas insulated metal enclosed switchgear for rated voltage above 52KV

IEC-62271-305

23.

Circuit Breaker

IEC:62271-100, IS:13118, IEC:427

24.

Isolator

IEC:62271-102

25.

Current Transformer

IEC:60044 or IS:2705, BS:3938

26.

Capacitor Voltage Transformer

IEC:186, IEC:186A&186B IEC:358, IS:3156

27.

Surge Arrestor

IEC:99-4 and IS:3070

28.

Common clauses for switchgear

IEC:694

29.

Post Insulator

IEC:168 or IS:2544

30.

Gas Cylinders

IS:4379, IS:7285

31.

SF6 gas

IEC:376A & 376B

32.

Piping material for fire protection

IS:3589, IS:1239

33.

Degree of Protection

IS:3589, IS:1239

34.

Specification for zinc

IS:209

35.

Methods of Chemical Analysis

IS:406

36.

Procelain insulators for Overhead IS:731, BS:137(Part-I&II) power lines with a nominal voltage greater IEC:274, IEC:385 than 1000 volts



PART-C

PAGE 52 OF 100

CLAUSE NO.


37

Methods of high voltage testing

38.

Specification for conductor and earthwire IS:2821 (Part-I) accessories for overhead power line armour rods, binding wires, and tapes for conductor

39.

Specification for Insulators fittings for Overhead Power lines with a nominal Voltage greater than 1000V

IS:2486

- General Requirements and

IS:2486 PartI, BS:3288

- Dimensional Requirement

IS:2486 PartII, IEC-120

- Locking Devices

IS:2486 PartIII, IEC-372

40.

Recommended practice for hot dip galvanisation of iron and steel

IS:2629

41.

Testing of uniformity of zinc coated articles IS:2633

42.

Hexagonal Bolts and Nuts

IS:3138, ISO:R947 & ISO:R272

43.

Characteristics of string insulator units

IS:3188, IEC:304

44.

ISO Metric Screw Threads SR-26, R-262, R-965

IS:4218, ISO:R68,

45.

Determination of weight of coating on zinc coated iron & steel articles

IS:6745

46.

Methods of RIV test on HV insulators

IEC:437

47.

Methods for Switching Impulse test on HV insulators.

IEC:506

48.

Thermal Mechanical Performance test on string insulators units.

IEC:575

49.

Radio Interference Voltage of high voltage IS:8263/NEMA publication Appratus Method of measurements No.107/1964,CISPR

50.

Electrical relays for power system protections

IS:3231, IEC-255 Pt I to III, BS:142

51.

Indicating Intruments

BS-89, IS:1248, IEC:5, IS:2419



IS:2071

PART-C

PAGE 53 OF 100

CLAUSE NO.


Recorders

BS-90, IS:6236, IEC258

53.

Energy meters

BS-5585,IS:722,IEC:521 IEC:687

54.

General requirements for switchgear and IS:4237 control gear for voltage not exceeding 1kV.

55.

Marking and arrangements for switchgear busbars, main connection and auxiliary

IS:375

56.

Specification for static protection relay

IS:8686

57.

Cross link polythelene PVC cable for working voltage upto and including 1100 volts.

7096 (Part-I)

58.

Conductors for insulated electrical cables and flexible cords.

IS:8130

59.

Recommended current rating for cables

IS:3961

60

Specification for copper and copper alloy tubes

BS:2871

61.

PVC insulation and sheath of electrical cables

IS:5831

62.

Mild steel wires,strips and tapes for armouring of cables

IS:3975

63.

PVC insulated electric cables for voltages upto and including 1100 volts

IS:1554 (Part-I), IS:894

64.

Cables

IEEE:383,ASTMD 2893

65.

Glands

BS 6121

66.

Rigid steel conduits for electrical wiring

IS:9537 (Part 2)

67.

Flexible steel conduits for electrical wiring

IS:3480

68.

Fitting for rigid steel conduits for elect. wiring

IS:2667

69.

Accessories for rigid steel conduits for electrical wiring

IS:3837



PART-C

PAGE 54 OF 100

CLAUSE NO.


Mild steel tube

IS:1239.

71.

Specification for concrete pipes

IS:458

72

Guide for safety procedures and practices in practices in electrical works

IS:5216

73.

MS wire for general engineering purpose

IS:280

74.

Compression type tubular terminal end for aluminium conductors insulated cables.

IS:8309

75.

Soldering and welded type terminal end for IS:8394 conductors of insulated cables

76.

Cold rolled carbon sheet steel

77.

Indian Electricity Act.

78.

Indian Electricity Rules.

79.

National Electricity Safety code

EEE 80

80.

Installation & Maintenance of cables

IS:1255

81.

Colours for ready mixed paints & enamels

IS:5

82.

Code of practice for earthing.

IS:3043

83.

Code of practice for protection of building and allied structure against lightning.

IS:2309

84.

Specification for hollow column insulators

IS:5621, IEC233

85.

Specification for bushings.

IS:2099, IEC 137

86.

Requirements for profile of insulators

IEC 815

87.

Requirements for boxes, cabinets

IS:5133, IEC 439

88.

Degree of protection provided by enclosures for motors

IS:4691

89.

Test on motors

IS:325, IS:12075

90.

Ferrules

IS:10942.

91.

Specifications for fuses

IS:9224, IS:8724



IS:513

PART-C

PAGE 55 OF 100

CLAUSE NO.


Requirements for electric power connectors

IS:5561

93.

GLS lamps

IS:418

94.

Water tight electric fitting

IS:3553

95.

Adopters for flexible steel conduits

IS:4649

96.

Specification for structural steel standard quality

IS:226

97.

Method of chemical analysis of pig. iron, cast iron, plain carbon and low alloy steel

IS:228

98.

Code of practice for use of structural steel in overhead trans. line towers. Part I - Loads and permissible stress. Part II - Fabrication, galvanising. Inspection & packing

IS:802(1977)

99.

Code of practice for use of steel tubes in general building construction

IS:806

100.

Specification for single coil rectangular IS:3063 section washers for bolts, nuts and screws

101.

Code of practice for Ultrasonic testing by pulse Echo method

IS:3664

102.

Specification for hot dip coating on structural steel and other allied products

IS:4759

103.

Specification for hot dip galvanised coatings on fasteners

IS:1367

104.

Specification for hexagon bolts for steel structure

IS:6639

105.

Specification for Rolled Steel

IS:808

106.

Specification for covered electrodes for metal arc welding of structural steel

IS:814

107.

Code of practice for manual metal arc welding for general construction in mild steel.

IS:816



PART-C

PAGE 56 OF 100

CLAUSE NO.


Code of practice for manual metal arc welding of mild steel.

IS:9595

109.

Specification for steel tubes for structural purposes.

IS:1161

110.

Recommended practice for Radiographic examination of fusion welded butt joints in steel plates.

IS:1182

111.

Specification for hexagonal bolts, screws nuts and lock nuts grade C

IS:1363

112.

Specification for bolts, screws, nuts and lock nuts (Grade A&B)

IS:1364

113.

Technical supply conditions for threaded steel fasteners.

IS:1367

114.

Code for practice for finishing of Ferrous IS:1477 metal in building (painting and allied finishes)

115.

Method of Tensile Testing of steel products IS:1599 other than sheet, wire and Tube.

116.

Method of Tensile Testing of steel products IS:1608 other than strip, wire and tube.

117.

Specification for Line Pipe.

IS:1978

118.

Specification for structural steel Fusion welding quality.

IS:2062

119.

Code of practice for Radiographic Testing

IS:2595

120.

Plugs and sockets.

IS:1293

121.

Switches for domestic and similar purposes. IS:3854.

122.

Code of practice for elect. wiring installation IS:732

123.

Guide of practice for general construction for hazardous areas

124.

Code of practice for general construction in IS:800 steel

125.

Code of practice for phosphating of iron & steel



IS:5571

IS:6005

PART-C

PAGE 57 OF 100

CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS 126

Water proof electric lighting fittings

IS:3526

127.

Dust proof electric lighting fitting

IS4012

128

Dust tight electric lighting fittings

IS:4013

129.

Industrial luminaire with metal reflectors

IS:1777

130.

Industrial lighting fitting with plastic reflectors

IS:3287

131.

Specification for flood light

IS:10322

132.

Specification for decorative lighting outfits

IS:5077

133.

Specification for new insulating oils.

IS:335

134.

Specification for wrought aluminium and aluminium alloys drawn tube.

IS:2678

135.

Dimensions for wrought aluminium and aluminium alloys, extruded round tube

IS:2673

136.

Wrought aluminium and Aluminium alloy IS:5082 bars, rods, tubes and sections for electrical purposes

137.

Ready mixed paint, air drying, red oxide, zinc chrome priming

IS:2074

138.

Spacers and spacer dampers for twin horizontal bundle conductors

IS:10162

139.

Method of measurement of building and civil engineering works Part-I earthwork

IS:1200

140.

Safety code for excavation work.

IS:3764.

141.

Code for practice for earthwork on canals.

IS:4701

142.

Specification for paving Bitumen

IS:73

143.

Specification for low density polythene films

IS:2508

144.

Methods fo test for polythene moulding materials and polytheylene compounds.

IS:2530

145.

Ordinary and low heat portland cement

IS:269



PART-C

PAGE 58 OF 100

CLAUSE NO.


Coarse and fine aggregates from natural sources for concrete.

IS:383

147.

Cpde of practice for plain and reinforced concrete.

IS:456

148.

Methods of test for strength of concrete

IS:516

149.

Methods of sampling and analysis of concrete

IS:1199

150.

Pre-formed fillers for expansion joints in concrete non-extruding and resilient type (bitumen impregnated filler)

IS:1838

151.

Specific Gravity, density, voids absorption and bulking.

IS:2386 (Part-III)

152.

General requirements for concrete vibrators immersion type.

IS:2505

153.

Screed board concrete vibrators.

IS:2506

154.

Concrete vibrating tables.

IS:2514

155.

Methods of sampling and test (physical and chemical) for water used in industry)

IS:3025

156.

Code of practice for concrete structures for the storage of liquids.

IS:3370

157.

Methods of tests for routine control for water used in industry.

IS:3342

158.

Form vibrators for concrete

IS:4656

159.

Admixture of concrete

IS:9103

160.

Cold worked steel high strength deformed bars to concrete reinforcement.

IS:1786

161

Code of practice for bending and fixing of bars for concrete reinforcement

IS:2502

162.

Integral cement water proofing compound

IS:2645

163.

Line traps.

IEC:353, IS:8792, IS:8793

164.

Planning of (single side band) power line carrier system

IEC:663



PART-C

PAGE 59 OF 100

CLAUSE NO.


Coupling device for power line carrier system

IEC 481

166.

Recommended value for characteristic input and single side band power line carrier terminals

IEC 495

167.

Installation of line traps.

IS 9859

168.

Specification for static protective relays

IEC-255 (Part-5 & 6), IS-8686

169.

Surge withstand capability & dielectric strength

ANSI, IEEE-C37.90

170.

Control switches (LV switching devices for IEC:337 control and auxiliary circuits)

171.

Transducers

IEC-688-1

Lighting Fixtures and Accessories 1.

Tungsten filament general service electric lamps.

IS:418

2.

Bayonet lamp holders.

IS:1258

3.

Ballast for fluorescent lamps.

IS:1534

4.

Capacitors for use in tubular fluorescent, high pressure mercury vapour and low pressure sodium vapour discharge lamp circuit.

IS:1569

5.

Industrial luminaire with metal reflectors.

IS:1777

6.

General and safety requirements for luminairies.

IS:1913

7.

Flame proof enclosures of electrical apparatus.

IS:2148

8.

Starters for fluorescent lamps.

IS:2215

9.

Tubular fluorescent lamps for general lighting services.

IS:2418

10.

Bi-pin lamp holders for tubular fluorescent lamps.

IS:3323



PART-C

PAGE 60 OF 100

CLAUSE NO.


Holders for starters for tubular fluorescent lamps.

IS:3324

12.

Code of practice for interior illumination.

IS:3646

13.

Dust-tight electric lighting fittings.

IS:4013

14.

Ballasts for high pressure mercury vapour lamps.

IS:6616

15.

Electric Lighting fittings for Division 2 areas. IS:8224

16.

High-pressure mercury vapour lamps.

IS:9900

17.

High pressure Sodium vapour lamps.

IS:9974

18.

Edison screw lamp holders.

IS:10276

19.

Luminaires.

IS:10322

20.

AC Supplied Electronic Ballasts for tubular IS:13021 fluorescent lamps.

Lighting Panels, Switch-boxes, Receptacles and Junction Boxes 1.

Plugs & socket outlets of rated voltage upto and Including 250 volts & rated current upto and including 16 Amps.

IS:1293

2.

Degree of protection provided by enclosures for low-voltage switchgear and control gear.

IS:2147

3.

Danger notice plates.

IS:2551

4.

Low voltage switchgear and control gear

IS:13947

5.

Switches for domestic and similar purposes. IS:3854

6.

Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto and including 1000 V AC and 1200 V DC.

7.

Low voltage fuses for voltages not exceeding IS:13703 1000V AC or 1500 V DC.



IS:6875

PART-C

PAGE 61 OF 100

CLAUSE NO.

GENERAL TECHNICAL REQUIREMENTS Conduits, Pipes and Accessories 1.

Fittings for rigid steel conduit for electrical wiring.

IS:2667

2.

Accessories for rigid steel conduits for electrical wiring.

IS:3837

3.

Conduits for electrical installations.

IS:9537

Lighting Wires/Cables 1.

PVC insulated cables for working voltages IS:694 upto and including 1100 V

2.

Recommended current ratings for cables. (PVC Insulated and PVC sheathed heavy duty cables and light duty cables).

IS:3961

3.

Conductors for insulated electric cables and flexible cords.

IS:8130

4.

Methods of tests for cables.

IS:10810

Electrical Installation Practices & Miscellaneous 1.

Colour for ready mixed paints & enamels.

IS:5

2.

Mild steel wires for general engineering purposes.

IS:280

3.

Electric ceiling type fans & regulators.

IS:374

4.

Code of practice for electrical wiring installations.

IS:732

5.

Code of practice for use of structural IS:802 steel in overhead transmission line towers-Fabrication Galvanising, inspection & packing.

6.

Code of practice for installation and maintenance of power cables Upto and including 33KV rating.

IS:1255

7.

Code of practice for lighting of public thorough fare.

IS:1944

8.

Steel for general structural purposes.

IS:2062



PART-C

PAGE 62 OF 100

CLAUSE NO.


Recommended practice for hot-dip galvanising of iron and steel.

IS:2629

10.

Methods for testing uniformity of coating of zinc coated articles.

IS:2633

11.

Tubular steel poles for overhead power lines.

IS:2713

12.


IS:3043

13.

Code of practice for interior illumination.

IS:3646

14.

Guide for safety procedures and practices in electrical work.

IS:5216

15.

Guide for selection of electrical equipments IS:5571 for hazardous areas.

16.

Classification of Hazardous areas (other than Mines)having flammable gases and Vapours for electrical installation.

IS:5572

17.

Code of practice for industrial lighting.

IS:6665

National Electrical Code. Indian Electricity Rules. Indian Electricity Act. 18.

Mechanical cable glands.

BS:6121

19.

Colours for ready-mixed paints and enamels.

IS : 5

20.

PVC insulated cables for working voltages upto and including 1100V.

IS: 694

21.

A.C. Electricity Meters

IS : 722

22.

Electrical Indicating instruments

IS : 1248

23.

Degree of protection provided by enclosures for low Part –1 voltage Switchgear and Control gear

IS : 13947



PART-C

PAGE 63 OF 100

CLAUSE NO.


A.C. circuit Breakers PART-2 IEC-947-2

IS : 13947

25.

Danger Notice Plates

IS : 2551

26.

Hot dip galvanising

IS : 2629

27.

Current Transformers

IS : 2705

28.

Contactors and motors starter for voltages

IS : 13947

29.

Part 4 not exceeding 1000 V AC or 1200 V DC Sec-1 (IEC-947-4-1)

30.


IS : 3043

31.

Code of practice for installation and maintenance of Switchgear

IS : 3072

32.

Voltage Transformers

IS : 3156

33.

Code of practice for climate proofing of electrical equipment.

IS : 3202

34.

Electrical relays for power system protection.

IS : 3231

35.

Air-Break Switches, air break disconnectors, air break PART-3 disconnector and fuse combination units for voltages not exceeding 1000V AC or 1200 V DC.

IS : 13947

36.

General Requirements for Switchgear and Control gear

IS : 13947

37.

Part – I for voltages not exceeding 1000 V.

IEC -947-I

38.

Wrought Aluminium and Aluminium alloys for electrical

IS : 5082 purposes.

39.

Code of practice of phosphating of iron and steel.

IS : 6005

40.

LV switchgear and Control gear Control current devices

IS : 13947



PART-C

PAGE 64 OF 100

CLAUSE NO.


Part-5 Sec1 and switching element.

IEC-947-5-1

42.

Specification for factory built assemblies of Switchgear (3 parts) & Control gear for voltages upto and including 1000 V

IS : 8623

43.

AC & 1200 V DC .

IEC 439-1 439-2 439-3

44.

Static Relays

IS : 8686

45.

HRC Cartridge fuses

IS : 13703 / IEC-269

46.

Code of practice for selection, installation and (4 parts) main tenance of switchgear and control gear.

IS : 10118

47.

Specification for dry type transformers.

IS : 11171

48.

Guide for uniform system of marking and identification of conductors and apparatus terminals.

IS : 11353

49.

Specification of control transformers for switchgear and Control gear for voltage not exceeding 1000V AC.

IS : 12021



PART-C

PAGE 65 OF 100

CLAUSE NO

QUALITY ASSURANCE AND INSPECTION

GENERATOR CIRCUIT BREAKER

SQE_11 Mechanical properties, Pressure Test, Chemical Composition

Attributes / Characteristics

Routine Test

Approval of WPS and PQR

NDT/UT/ DPT

Items/Components Sub Systems Aluminum Casting Insulator (EN 10204-3.1 B / CENELEC/ EN 50089) SF6 Gas (IEC 600376) Circuit Breaker Components (IEC : 60056 / 600129 / 60298 / 60694 / ANSI / IEEE / EN 10204-3.1) :a) Retainign Ring b) Contact Pin

Y Y Y

Y Y Y Y Y Y

c) Tulip Contact d) Arcing Ring e) Heater Split Ring f) Contact finger Pole Frame (DIN EN 25817 / 50976 ) Enclsorue (DIN EN 13920 / 25817) Welding Surge Capacitor (IEC 60358) Control Cubilce (IEC 60056 / 60129 / 60298) WPS / PQR Complete Assembly (IEC 60056 / 60129 / 60298 / 60694 /ANSI / IEEE) Notes :

Y

Y Y Y Y Y Y Y

1) This is an indicative list of tests/checks. The manufacturer to furnish a detailed Quality Plan indicating their practice & procedure along with relevant supporting documents during QP finalisation for all items. 2)


All major Bought Out Items will be subject to NTPC approval.


PART-B CHAPTER-QA

PAGE 66 OF 100

CLAUSE NO


SWITCHYARD Attributes / Characteristics

SQE_20 Make, model, Type & Rating, Test Certificate

Routine & Acceptance Test as per IS / IEC

Functional requirements as per NTPC Specification

Y

Y

Y

Y

Y

Y

Y Y

Y Y

Y Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y

Y Y

Y Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y Y Y Y Y Y Y Y Y Y



Items/Components Sub Systems Circuit Breaker (IEC:56) Interruptor & hollow insulator (IEC:233/ IS:5284) Isolator (IEC:129 / IEC:694) Current Transformer (IEC:185) Capacitor Voltage Tramsformer (IEC:186 / 358) Bus Post Insualtor (IEC:168 / 273 / IS:2544) Disc,Pin & String Insualtor (IEC:383 / IS:731) Long Rod Insualtor (IEC:433) Surge Arrestor (IEC:99-4) Hardware fittings for Insulator (IS:2486 / BS:3288) Spacer Clamps & Connector (IS:10162 / 5561) Aluminium Tube (IS:5082 / 2673 / 2678) Wave Trap (IEC:353 / IS:8792 / 8793) Conductor (IS:398-P-II)(V) Galvanised Steel Structures (IS:2062/2629/4759/6745) Vibration Damper (IS:9708) Sag Compensating Spring DIN:2089/2096 IS:3195 / 7906 Control & Relay Panel SF6 Gas filling & evacuating plant SF6 Gas Leak Detector Leakage Current Analyser Nitrogen Gas Filling Device Protection Relays Event Logger Operation Analyser Disturbance Recorder Tariff Metering System Synchronising Trolly TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2


PART-B CHAPTER-QA

PAGE 67 OF 100

CLAUSE NO


Make, Type Rating,and Model, Test Certificates

Routine & Acceptance Test as per relevant IS/IEC


Y

Y

Y

Y

Y

Y

Battery IS:1652

Y

Y

Y

Lighting Panels

Y

Y

Y

Surge Monitor

Y

Y

Y


Items/Components Sub Systems Relay Test Kit LT Switchgear /LT Panels (IEC:947 / IS:13947)

Notes : 1)

2)


This is an indicative list of test/checks. The manufacture is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents during QP finalisation for all items. All major Bought Out Items will be subject to NTPC approval.


PART-B CHAPTER-QA

PAGE 68 OF 100

CLAUSE NO


DC SYSTEM

SQE_19

Y

Y

Y

Y

Y

Y

Test for Capacities for 10 hrs. discharge rate along with the test for voltage during discharge ( Acceptance Test)

Sealing Compound

Checking of Polarity & absence of short circuit (Routine & Acceptance Test)

Y

Marking ( Routine & Acceptance Test)

Y

Constructional requirements as per NTPC Spec Insulation Resistance

Vent Plugs

Shade,

Y

Paint Process checks, Paint Thickness, Adhesion & Finish

Y

Conformance to CPWD Spec. for Teak

Container & Lids (IS : 1146)

ITEMS, COMPONENTS, SUB SYSTEM ASSEMBLY

Lead Coating Thickness (min. 25 microns, IS: 6848 App.F) & Adhesion Check

Conformance to relevant part drg. & Manufacturer’s standards

/

Dimensions & Finish

ATTRIBUTES CHARACTERISTICS

Chemical composition

LEAD ACID BATTERY

Y

Y

Y

(IS : 3116) Positive & Negative Plates Separators (IS : 6071)

Y

Electrolyte

Y Y

Y

(Water / Sulphuric Acid) (IS : 1069 / 266) Inter-cell Connectors Fasteners

&

Y

Y

Battery Stand

Y

Y

Cell Insulators

Y

Y

Stack Assembly

Y

Y

Lead Acid Battery

Y

Y

Y

Y

(IS : 1652) Note: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.



PART-B CHAPTER-QA

PAGE 69 OF 100

CLAUSE NO


Y

Dimensions & Finish Active Material for Positive & Negative Plates Separators

Y

Y

Electrolyte

Y

Y

Y

Battery Stand

Y

Cell Insulators

Y

Y

Stack Assembly

Y

Y

Ni-Cd Battery

Y

Y

Y

Y Y

Y

Y

Inter-cell Connectors & Fasteners

Polarity & absence of short circuit (Routine & Acceptance Test)

Y

Insulation Resistance (Acceptance Test)

Y

Perforated Steel Strips

AH Test (Acceptance Test)

Y

Retention of Charge Test ( Acceptance Test)

Y

Air Pressure Test (Acceptance Test)

Y

Vent Plugs

Marking & Mass (Routine & Acceptance Test)

Y

Y

Air Pressure Test after heat sealing

Resistance to Alkali

Y

Container & Lids

Paint Shade, Thickness, Adhesion & Finish

Conformance to relevant part drg. & Manufacturer’s standards

Y

ITEMS, COMPONENTS, SUB SYSTEM ASSEMBLY

Nickel Plating thickness

Impact Strength

ATTRIBUTES / CHARACTERISTICS

Chemical composition

Ni- Cd BATTERY

Y Y Y

Y Y

Y

Y

Y Y

Y

Y

Y Y

Y

(IS : 10918) Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2.

Makes of all major Bought Out Items will be subject to NTPC approval.



PART-B CHAPTER-QA

PAGE 70 OF 100

Items / Components / Sub- assembly

(IS : 6875)

Indicating (IS : 1248)

(IS : 13703)

Control Blocks

Verification of Routine test reports as per relevant IS

Attributes Characteristics

Make, Model, Type, Rating & Finish

Rectifier Transformer and Reactors IS : 4540, 2026) Y Y

Electronic Components including Potentiometer (Vernier Type) Y Y

Electronic Cards Y Y

PCB & racks for electronic cards Y

Control & Selector Switches Y Y Y

Meters Y Y Y

Indicating Lamps (IS: 13947)

Y

Y

Y

Air Break Switches / Fuses

Y

Y

Y

Y

Y

13947

TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE

BID DOC NO: CS-5505-500-2

/

Terminal

SECTION-VI

Y

TECHNICAL SPECIFICATION

Test,

CHAPTER-QA

PART-B

Load

Y

Limiter

&

AVR

Degree of Protection Test as per NTCP Spec.

Alternating current measurement test

Burn-In Test at 50^C for 48 hrs in energised

HV & IR Test

Operational & Functional Checks

Dynamic Response Test

Ripple Content Operation Test

Complete physical examination for constructional features as per NTPC approved drgs & f Temperature Rise Test on one unit of each rating if Type testing is waived off

Dimensional check and Paint shade, thickness, adhesion & Finish checks

Conform to relevant Standard & NTPC spec

Sheet Steel Pretreatment & Painting process

CLAUSE NO QUALITY ASSURANCE AND INSPECTION

BATTERY CHARGER

Y

Y

Y

Y

/

(IS : 13947)

PAGE 71 OF 100

CLAUSE NO


Control Transformer

Y

Y

Y

Push Buttons (IS : 4794)

Y

Y

Y

MCB (IS : 8828)

Y

Y

Y

PVC insulated Copper control wires (IS : 694)

Y

Y

Sheet Steel (IS : 513)

Y

Synthetic Gaskets

Y

(IS : 12021)

Rubber

Annunciator

Y

Battery Charger

Y

Y

Y Y Y Y

Y

Y

Y

Y

Y

Y Y

Y

Y

Y

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Makes of all major Bought Out Items will be subject to NTPC approval.



PART-B CHAPTER-QA

PAGE 72 OF 100

CLAUSE NO


Page 1 of 3

Y

Y

Y Y Y Y Y Y

Anti ternite treatment on wooden drums

Thermal Stability of insulation and outer sheath *

& after Tensile strength, elongation before ageing of insulation & outer sheath

Sequential marking/surface finish /cable length

Lay length / Sequence

Y

Y

Y Y

Y Y

Y

Y

Y

FRLS Test

Y Y Y

Hot set test (XLPE)

Spark Test

Y

Electrical Properties

Y Y Y

Routine and acceptance test as per Relevant Standard and NTPC specification

Y

Chemical Composition

Y

Constructional / requirement as per NTPC Spec.

Insulated Core Laid up core PVC Inner sheath Armouring Outer sheath Finish cable (IS-1554 & 7098 – Part-1) ASTM-D-2843/ IS 10810 (Part- - 58) IEC-754 Part-I Swedish Chimney SS 4241475 for (F3 category) Flammability test IEC-332 Part –3 Cat-B Wooden drum (IS-10418) / Steel drum

Y Y Y

Mechanical Properties

Aluminum (IS-8130) PVC Compound (IS-5831) XLPE Compound(IS-7098 Part-I) FRLS PVC Compound (IS5831) ASTM-D-2843/ ASTM-D2863 IEC-754 Part-I Armour wire/strip (IS-3975)

Dimension/surface finish

Item / Components / Sub System Assembly

Make, Rating, Type & TC


Armour coverage, Cross over, looseness, Gap between two armour wire/strip

LT POWER CABLES (1.1 KV PVC & XLPE CABLES)

Y

Y Y

Y

Y Y Y Y

Y Y

Y Y

Y

Y Y

Y

Note: 1. This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice and procedure along with relevant supporting documents. ∗

2. Not applicable for XLPE insulation



PART-B CHAPTER-QA

PAGE 73 OF 100

CLAUSE NO


ROUTINE TESTS Routine tests shall be carried out on each drum of finished cables for all types & sizes. Following shall constitute routine tests: 1)

Conductor Resistance test

2)

High voltage test at room temperature ACCEPTANCE TESTS Following Acceptance tests shall be carried out for each type and size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 1554 Part 1 & IS 7098 Part-I

A)

For Conductor

1)

Annealing test

2)

Tensile test

For aluminium conductor only

3)

Wrapping test

For aluminium conductor only

4)

Resistance test

B)

For Armour Wires / Formed Wires ( If applicable )

1)

Measurement of Dimensions

2)

Tensile Tests

3)

Elongation Test

4)

Torsion Test

5)

Wrapping Test

6)

Resistance Test

7)

Mass of Zinc coating test

8)

Uniformity of Zinc coating

9)

Adhesion test

10)

Freedom from defects

C)

For PVC / XLPE insulation & PVC Sheath

1)

Test for thickness

2)

Hot set test

3)

Tensile strength & Elongation before ageing


For copper conductor only

For Round wires only

For G S wires / Formed wires only For G S wires / Formed wires only For G S wires / Formed wires only

For XLPE insulation only


PART-B CHAPTER-QA

PAGE 74 OF 100

CLAUSE NO


D)

For completed cables

1)

Insulation resistance test (Volume resistivity method)

2)

High voltage test at room temperature

E)

Following tests shall be carried out and only one sample shall be taken from each offered lot of all sizes for these tests:-

1)

Tensile strength & elongation after ageing on PVC / XLPE insulation and PVC outer sheath

2)

Thermal stability test on PVC insulation and outer sheath

3)

Oxygen index test on outer sheath

4)

Smoke density rating test on outer sheath as per ASTM –D 2843

5)

Acid gas generation test on outer sheath as per IEC – 754 (Part 1)

6)

Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed cable

7)

Fire resistance test as per SS 4241475 (F3 Category ) on completed cable

F)

Following tests shall be carried on one length of each size of offered lot:

1)

Surface finish, length measurement, sequence of cores, armour coverage, Gap between two consecutive armour wires / formed wires



PART-B CHAPTER-QA

PAGE 75 OF 100


Y

Insulating Material

Y

CRGO Lamination & Built Core

Y

Bushing (IS:2544 / 5621)

Y

Y

Y

Gasket

Y

Y

Y

Off-Circuit Tap Changer

Y

Y

Core Coil Assembly

Y

Marshalling Box

Y

WTI, Thermister, Terminal Connector

Y

/Insulator

Routine Test

Y

WPS & PQR

Copper Conductor

NDT / DP / MPI

Y

Chemical Properties

Y

Thermal Properties

Mechanical properties

Enclosure door, H.V. & L.V. Cable Box / Flange Throat

Items/Components Sub Systems

Electrical strength

Visual & Dimensional check


Table: QE-5 Voltage Ratio, Vector Gorup & Polarity Make / Type / Rating / Model /TC / General Physical Inspection

LT INDOOR TRANSFORMER

Routine Test as per relevant standard Measurement of capacitance & tan delta between winding

CLAUSE NO

Y Y

Y Y

Y

Y Y Y

Welding

Y

Complete Transformer (IS:11171 / IEC 60076)

Y

Y

Y

Notes: 1) This is an indicative List of test/checks. The manufacturer is to furnish a detailed Quality Plan indicating his practice and procedure along with relevant supporting documents during QP finalisation for all item. 2) All major Bought Out Items will be subject to NTPC approval.



PART-B CHAPTER-QA

PAGE 76 OF 100

CLAUSE NO


SQE _10


Y

Y

Y

Y

Y

Y

Y

Y Y

Y Y

Y

Y

Y

Functional Checks

Milli-volt drop Test

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y

Y Y

Y

Y Y

Y Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y


Item

to

Y

Y Y

Y

Degree of Protection Routine test as per NTPC spec

Y

IR – HV – IR Test

Y

Paint Shade, Adhesion, Thickness

Y

conform

Y

Electrical properties

Y

Pretreatment as per IS 6005

Y

relevant

Y

to

Y

Functional & Operational Features as per NTPC Spec.

Y

Chemical properties

Y


Aluminum Bus bar Material (IS : 5082) Copper Bus bar Material (IS : 613) Support Insulator Air Circuit Breaker (IS: 1394) Energy Meters (IS : 13010, 13779) Power & Aux. Contactors (IS : 13947) Protection & Aux. Relays (IS : 3231) Control & Selector Switches (IS : 13947) CT’s & PT’s (IS 2705 / 3156) MCCB (IS : 13947) Indicating Meters (IS : 1248) Indicating Lamps (IS : 13947) Air Break Switches (IS : 13947) Control Terminal Blocks

Dimensions & Finish

ITEMS/ COMPONENTS/ SUB SYSTEM ASSEMBLIY Sheet Steel (IS : 513)

Make, Model, Type, Rating & TC

( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR STARTERS) ATTRIBUTES / CHARACTERIS-TICS

All Routine tests as per NTPC spec.

LT SWITCHGEAR

Y Y

Y

Y

PART-B CHAPTER-QA

Y

PAGE 77 OF 100

CLAUSE NO


LT SWITCHGEAR

Y

Y

Y

Push Buttons (IS : 4794)

Y

Y

Y

Y

Y

Transducer (IEC : 60688)

Y

Y

Y

Y

Y

MCB (IS : 8828)

Y

Y

Y

Y

Y

Breaker Handling Trolley

Y

Y

Y

Synthetic Rubber Gasket

Y

Y

Y

Y

Functional Checks

All Routine tests as per NTPC spec. & IS

Y

Degree of Protection Routine test as per NTPC spec

Y


Control Transformer

Milli-volt drop Test

Y

Paint Shade, Adhesion, Thickness & Finish

Item to conform to relevant Standards

Y

Pretreatment as per IS 6005

Functional & Operational Features as per NTPC Spec.

Y

Chemical properties

Y


Dimensions & Finish

Fuse (IS 13703)

Electrical properties

ITEMS/ COMPONENTS/ SUB SYSTEM ASSEMBLIY

Make, Model, Type, Rating & TC

( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR STARTERS) ATTRIBUTES / CHARACTERIS-TICS

Y

(IS : 12021)

Y

Y

Y

Y

Y

Y

Y

Y

Y

(IS : 11149) LT SWITCHGEAR

Y

Y

Y

Y

Y

Y

Y

(IS : 8623) Notes: 1.

This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.

2.

Makes of all major Bought Out Items will be subject to NTPC approval.



PART-B CHAPTER-QA

PAGE 78 OF 100

CLAUSE NO


CRCA Flats / ISMC (IS 2062)

Y

Y

Y

Y

Y

Neoprene / Synthetic Rubber Gaskets (IS 11149 / 3400)

Y

Y

Y

Y

Rubber Bellows (IS : 3400)

Y

Y

Y

Y

Support Insulator (BS : 2782,

Y

Y

Y

Y

Degree of Protection routine test as per NTPC spec.

Y

Phase Sequence Check

Weld Quality Check ( DP test

Y


WPS Approval, Welder Qualification

Y

Galvanizing Test as per IS 2629/ 2633/

Item to conform to relevant IS

Y

Electrical Clearances

Chemical Properties

Y

Tightness by Torque measurement

x-ray Mechanical Properties

&

Make, Type, Rating & TC Y

Aluminum Sheets / Plates / Strips / Flexibles / tubes


Dimension & Surface Finish Y

ITEM, COMPONENTS, SUB SYSTEM ASSEMBLY

Paint Shade, Thickness, Adhesion & Finish

LT BUSDUCT ATTRIBUTES , CHARACTERISTICS

Y

Y

(IS : 5082 / 737)

Y

Y

IEC : 660, IS : 10912) Galvanized Structure & GI Earthing Flat

Y

Y

(IS : 2629 / 2633 / 4749) Space Heater Thermostat

&

LT Busduct (IS : 8623 PART 2)

Y Y

Y

Y

Y Y

Y

Y

Y

Y

Y

Y

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Makes of all major Bought Out Items will be subject to NTPC approval.



PART-B CHAPTER-QA

PAGE 79 OF 100

CLAUSE NO


MAIN SUPPLIES’S EVALUATION REPORT (For Proposed Sub-Supplier)

MAIN SUPPLIER M/S.

:

PACKAGE & PROJECT

:

EQUIPMENT / ITEM

:

GENERAL INFORMATION

1.

PROPOSED SUB-SUPPLIER’S NAME & WORKS ADDRESS

:

2.

CONTACT PERSON TELEPHONE (LAND LINE/MOB.) FAX E-MAIL

: : : :

3.

BRIEF SPEC. OF EQUIPMENT ITEM/MODEL/TYPE /RANGE / CAPACITY

:

4.

REFERENCE LIST (EXTENSIVE EXPERIENCE IN THE PARTICULAR TYPE OF EQUIPMENT / ITEM)



PART-B CHAPTER-QA

PAGE 80 OF 100

CLAUSE NO


CUSTOMER/ LOCATION WITH ADDRESS AND CONTACT PERSON

5.

TYPE , RATING & CAPACITY

DATE OF COMMISS -IONING.

NO. OF YRS. IN OPERATION

PERFORMANCE FEEDBACK

RECOMMENDATIONS :

NAME_____________________DESIGN____________________SIGN.:_______________ List of Encl.

Date :________________



PART-B CHAPTER-QA

Item to conform to relevant standard

Acceptance Test as per relevant std and spec

Routine Test as per relevant std aad spec

Constructional Feature as per NTPC spec.

Functional Check as per spec.

HV & IR

Bought Out Items/ Bill of Material

IP Test

Galvanise Test

Paint Shade Thickness Adhesion & Finish

Pre-Treatment of sheat

Dimension

Attributes Characteristics

SQE_17

Make, Type , Rating/ TC

STATION LIGHTING Item Components Sub System Assembly

PAGE 81 OF 100

CLAUSE NO


Luminaries (IS-10322 Part-5 Sec.1)

Y

Electronic Ballast

Y

Y

Y

Y

Y

Lighting Wire (IS-694)

Y

Y

Fans (IS-374)

Y

Y

Pole (IS-2713) Lamps (IS-9800, IS9974) Lighting Mast (with raise & lower lantern type) Wall Mounted Lighting Panel (IS-513, IS-5) Switch Box/ Junction Box/Receptacles/ Local Push Button Station,Lighting Panel (IS-513, 2629, 2633, 4759, 6745) Cable Gland (BS-6121)

Y Y

Cable Lug (IS-8309) Flexible Conduit Lighting Transformer (IS-1117) Epoxy & Galvanised Conduit (IS-9537, 2629, 2633, 4759, 6745)

Y

Y

Y

Y

Y

Y Y

Y Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y Y

Y

Y Y Y

Y

Y

Y

Y

Y Y

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2.

Make of all major Bought Out Items will be subject to NTPC approval.



PART-B CHAPTER-QA

PAGE 82 OF 100


FRLS Test

Routine & Acceptance test as per relevant standard & page 2 & 3 of this table

Constructional feature as per NTPC Spec.

Anti termite treatment on wooden drums

Tensile strength, elongation before & after ageing of insulation &outer sheath sheath

marking/surface

finish/cable

MODULE NO. SQE 14

Sequential length

Lay length/Sequence

Spark Test


Chemical Composition


Dimension/surface finish

Item / Components / Sub System Assembly

Make, Type, Rating, T.C


Armour coverage, cross over, looseness, gap between two armour wire

L.T CONTROL CABLES (1.1 KV PVC CABLES)

Thermal stability of insulation and outer sheath

CLAUSE NO

Y Y Y Y Y Copper Conductor (IS8130) PVC Compound (IS-5831) Y Y Y Y Y Y Y FRLS PVC Compound IS- Y 5831 ASTM-D-2843/ IS 10810 (Part-58 ) IEC-754 Part-1 Armour wire/strip (IS- Y Y Y 3975) Insulated Core Y Y Y Y Laid up core Y Y PVC Inner sheath Y Armouring Y Y Outer sheath Y Y Y Y Y Finish cable (IS-1554- 1 ) Y Y Y Y Y Y Y Y Y ASTM-D-2843/ IS 10810 (Part-58) IEC-754 Part-1 Swedish Chimney: SEN SS 424-1475 (F3 category) Flammability test IEC-332 Part-3 Cat-B Y Y Wooden drum( IS : 10418) / Steel drum • 1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the Practice and procedure along with relevant supporting documents.



PART-B CHAPTER-QA

PAGE 83 OF 100

CLAUSE NO


L.T CONTROL CABLES (1.1 KV PVC CABLES) CONTROL CABLE ROUTINE TESTS Routine tests shall be carried out on each drum of finished cables for all types & sizes. Following shall constitute routine tests: 1)

Conductor Resistance test

2)

High voltage test at room temperature ACCEPTANCE TESTS Following Acceptance tests shall be carried out for each type and size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 1554 Part 1

A)

For Conductor

1)

Annealing test

2)

Resistance test

B)

For Armour Wires / Formed Wires ( If applicable )

1)

Measurement of Dimensions

2)

Tensile Tests

3)

Elongation Test

4)

Torsion Test

5)

Wrapping Test

6)

Resistance Test

7)

Mass of Zinc coating test

For G S wires / Formed wires only

8)

Uniformity of Zinc coating

For G S wires / Formed wires Only


For copper conductor only

For Round wires only


PART-B CHAPTER-QA

PAGE 84 OF 100

CLAUSE NO


9)

Adhesion test

10)

Freedom from defects

C)

For PVC insulation & PVC Sheath

1)

Test for thickness

2)

Tensile strength & Elongation before ageing

D)

For completed cables

1)

Insulation resistance test (Volume resistivity method)

2)

High voltage test at room temperature

E)

Following tests shall be carried out and only one sample shall be taken from each offered lot of all sizes for these tests:-

1)

Tensile strength & elongation after ageing on PVC insulation and PVC outer sheath

2)

Thermal stability test on PVC insulation and outer sheath

3)

Oxygen index test on outer sheath

4)

Smoke density rating test on outer sheath as per ASTM –D 2843

5)

Acid gas generation test on outer sheath as per IEC – 754 (Part 1)

6)

Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed cable

7)

Fire resistance test as per SS 4241475 (F3 Category ) on completed cable

F)

Following tests shall be carried on one length of each size of offered lot:

1)

Surface finish, length measurement, sequence of cores, armour coverage, Gap between two consecutive armour wires / formed wires


For G S wires / Formed wires only


PART-B CHAPTER-QA

PAGE 85 OF 100

CLAUSE NO


IP protection

HV & IR

Galvanise Test (If Applicable)

Functional

Bought out items/Bill of material

Routine tests as per specification

Acceptance tests as per relevant standard & specification

Constructional feature as per NTPC Specification

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y Y Y Y

Y Y

Y Y

Y

Y Y Y Y Y

Deflection test*

Pre-treatment of sheet Y

Surface finish

Paint shade, paint thickness, adhesion Y

SUB SYSTEMS

Proof load*

Dimension Y

ITEMS/COMPONENTS /

Wall Mounted-Lighting Panel (IS-513, IS:5, IS:2629, 2633, 6745) Switch box/junction box/ Receptacles Panel (IS-513, IS:5, IS:2629, 2633, 6745) Cable glands(BS-6121) Cable lug(IS-8309) Lighting wire(IS-694) Flexible conduits Conduits(Galvanise & Epoxy) IS-9537 & IS-2629,2633 ,6745 RCC Hume Pipe (IS-458) Cable termination & straight through joint (VDE-0278) Cable Trays, Flexible supports system & accessories IS-513, 2629,2633,6745 Trefoil clamp GI flats for earthing & lighting protection (IS 2062, 2629, 6745,2633) GI wire (IS-280) Fire Sealing System (BS –476)

relevant standard &

CABLING, EARTHING, LIGHTNING PROTECTION ATTRIBUTES / CHARACTERISTICS

Y

Y Y

Y

Y Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y

Y

Y Y

Y

Y

Y

.Note:1.This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2.* Deflection Test on cable trays and Proof Load test on cable trays support system will be as per details given in the NTPC technical specification & approved MQP. The above acceptance tests shall be done only on one sample from each size of offered lot. 3. Make of all items will be subject to NTPC approval.



PART-B CHAPTER-QA

PAGE 86 OF 100

CLAUSE NO


HT LINES

SQE_24 & As per NTCP Make, Type Routine Acceptance Test Technical Rating, Model,TC & as per relevant Specification Standard General Inspection


Items/Components Sub Systems Galvanised Steel Structure (IS:2633 / 2629 / 6745 / 802

Y

Y

Y

Y

Rail Pole (IRS:90L)

Y

Y

Steel Tubular Pole (IS:2713)

Y

Y

ISMC Channel/Angle/Flat (IS:2062)

Y

Y

Harwares (IS:1367)

Y

Y

Hardwares for Insualtor (IS:2486)

Y

Y

Conductor (IS:398-P-II) Strain / Porcelain Insulator (IS:5300)

Y Y

Y Y

Earthwire

Y

Disc/String/Pin Insualtor IEC:305 /575 )

(IS:3188 /

Suspension/Tension clamp for

Y

Y

Y

Y

Y

Y

Y

Vibration Damper ( IS:9708)

Y

Y

Stay Set (IS:2141 )

Y

Y

Y

Y

Y

Earthwire (IS:398-P-II) Danger Plate (IS:2551) G.I.Flat/G.I.Strip ( IS:2629 / 2633 / 6745 )

Primer (Etch) ( IS:5666)

Y

Zinc Paint

Y

Anti Climbing Device

Y

M.S.Rod ( IS:7887)

Y

Notes : 1) This is an indicative list of Test/Checks. The manufacturer to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2) All major Bought Out Items will be subject to NTPC approval. TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4x130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO: CS-5505-500-2


PART-B CHAPTER-QA

PAGE 87 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier )

Approval Desired for Process/item (Rating/Size/Type) : _____________________________________________________________________ 1. Name of Company (Sub-Supplier): 2. Address of Regd. Office: _____________________ Tel______________________

3.

4.

_____________________

Mobile___________________

_____________________

e-mail____________________

_____________________

Fax______________________

Address of Factory/Works _____________________

Tel______________________

_____________________

Mobile___________________

_____________________

e-mail____________________

_____________________ Weekly off day

Fax______________________

Branch/Liaison Office in Delhi: _____________________

Tel______________________

_____________________

Mobile___________________

_____________________

e-mail____________________

_____________________

Fax______________________



PART-C GTR

PAGE 88 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) Weekly off day 5.

Person(s) to be contacted Place Name(s) ------------------Regd. Off.

Official Capacity -------------------------

Telephone No(s) ----------------------

Factory Branch/ Liaison Off. 6.

Nature of Company

: Proprietary/Partnership/Pvt. Ltd./Public Ltd.

Works Details: 7.

Year of Factory Establishment

:

8.

Year of Commencement of Manufacture

:

9.

Total Area/Covered Area

10.

Electric Power-Connected Load Electric Power-Standby Load & System

:

11.

Finance-Total Capital - Annual Turnover & profit For past three years - Limit of Credit Facility Available from the Banks

:

12.

13.

:

Do you have in-house Department for : a) Design

Yes/No

b)

Research & Development

Yes/No

c) d) e)

Manufacturing/Production Quality control/Inspection Clearance from pollution deptt.

Yes/No Yes/No Yes/No

Shift works per day


One/Two/Three TECHNICAL SPECIFICATION SECTION-VI

PART-C GTR

PAGE 89 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) 14.

Details regarding employees :

Division Status Production

Graduate Technical Non-Technical

Diploma

Skilled

Un-Skilled

Remarks

Quality Control Admn & other Supporting Activities

15.

Please enclose a copy of company's organisation chart (for the unit).

16.

Trade Name of Product (if any)

:

17.

Manufacturing capacity details

:

S. N.

18. Sl. No.

Product

Licensed Capacity

Installed Capacity

Brief details of items manufactured : Item & Material

Description (Type/Size/Rating)

Annual Production for last Three years I



II

PART-C GTR

III

PAGE 90 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) 19.Details of foreign collaboration, if any : Sl. No.

Product

Name & Address of Collaborator

Scope

Collaboration Year

Valid upto

20. Have your product been type tested by any external agency? If so, give details Sl. No.

21.

Sl. No.

Product

Test (Size, Type & Class)

Test Report No. & Date

Next Due Date

Indicate Approval/Certification by National/International standards/agencies applicable for the subject product. Product


Code/Standard


License No. & Date

PART-C GTR

PAGE 91 OF 100


Sl. No.

23. Sl. No.

Have you been approved by any third party/statutory agency? If so, indicate details and enclose copies of approval letters. Item/ Material

Description (Size, Type & Class)

Agency

Date of Approval

Next Due Date

Reference list (Experience in the particular type of equipment) : Item/ Material

Type & Capacity


Customer (End User) with Address


Date supply

PART-C GTR

of

Under Operation Since Year/ Month

PAGE 92 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) 24(a) Sl. No.

Specific to process & product facilities : Description of machine


Capacity & Nos.

Location Shop


Make

PART-C GTR

Year of Manufg.

PAGE 93 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) 24(b) Other/General facilities : Sl. No. 1)

2)

Description of machine Material Handling Mobile Crane Fork Lift Over Head Cranes Metal Cutting &

Capacity & Nos.

Location Shop

Make

Year of Mfg.

Bending 3)

Casting

4)

Forging

5)

Fabrication

6)

Welding

7)

Machining

8)

Heat Treatment

9)

Sheet Metal

10)

Fettling & Cleaning Sand Blasting Shot Blasting Pickling

11)

Painting

12)

Metal Coating

13)

Protection before packing

14)

Packing

15

Other



PART-C GTR

PAGE 94 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) 25 (a) Sl. No.

Facilities for Testing & Inspection : Description

Capacity & Nos.

Make & year of Mfg.

Calibration Status

Approval Qualification

25 (b) If In-house testing facilities are not available, indicate source of testing with relevant details: Sl. No.

Source of Testing

Description

Capacity & Nos.

Make year Mfg.

& Calibratio of n Status

Approval/ Qualification

26 (a)

Details of any Govt. laboratory facilities available in area :

26 (b)

Product related testing facilities (Type/Performance/Routine/Acceptance Tests) :

26 (c )

Storage of finish goods (covered / open)



PART-C GTR

PAGE 95 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) 27

Source of Raw Materials (including imported raw materials) : a) Type

Source

b) Raw material storage & identification : 28.

No. of PCs available with internet Connectivity at works:

29.

Quality management

29.1

General

29.1.1. Organisation Chart of Quality Management: Attached: (Y/N) 29.1.2. Head of QC Department reports to : 29.1.3. Do you have a written Quality Control Instruction Manual? If yes, please furnish a copy of the same. 29.1.4. Have written Quality Control Instruction sheets been prepared and properly used ? 29.1.5. Are records generated during inspection maintained & available for review? 29.1.6. Are final inspection areas clean, adequately lighted & of suitable size? 29.1.7. Are written procedure defining stage wise operations and functions on shop floor established and followed? 29.1.8. Are quality control checks adequate to maintain desired quality right from incoming stage to final operation? 29.1.9. Whether 100% or adequate sampling inspection used? 29.1.10. Are statistical quality control techniques used? 29.2.

Corrective Action

29.2.1. Does the system provide for proper detection of inferior quality and correction of its assignable causes? 29.2.2. Is adequate action taken to correct the causes of defects in products? 29.2.3. Are analysis made to identify trends towards product deficiencies? 29.2.4. Does corrective action extend to products?



PART-C GTR

PAGE 96 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) 29.3

Documentation Control

29.3.1. Does a system for clear and precise stipulation of responsibilities for documentation issue & change control exists? 29.3.2. Are changes made in writing? 29.4.

Control of Inspection, measuring & Testing equipments

29.4.1. Are necessary gauges, testing and measuring equipment's, available and used? 29.4.2. Are testing and measuring equipment properly maintained? 29.4.3. Is recorded control on calibration of equipment available? 29.5.

Control of procured supplies & Services

29.5.1. Do the vendor/sub-Supplier's purchasing documents refer to specific design manufacturing and testing requirements? 29.5.2. Do purchasing documents also contain special requirements? 29.5.3. Are requirements for necessary tests and inspection of raw material specified in purchasing documents? 30.

CONSISTENCY IN SUPPLY

30.1.

Has the vendor/sub-Supplier produced items of similar nature in past?

30.2.

Has the vendor/sub-Supplier maintained delivery commitments in past?

30.3.

Has there been frequent labour trouble in past?

30.4.

Has there been major upset due to faulty material management?

30.5

Whether the system of planning and scheduling resilient enough to overcome temporary setbacks and make up lost time?

30.6.

Can the vendor/sub-Supplier quickly off load the work to other reliable subvendors: If Yes, the name of sub-vendors :

31.

Order booking position as on date in terms of: a) Value b) Time

32.

: :

Any special information



PART-C GTR

PAGE 97 OF 100


I CERTIFY THAT THE INFORMATION SUPPLIED HEREIN (INCLUDING ALL PAGES ATTACHED) IS CORRECT TO THE BEST OF MY KNOWLEDGE.

SEAL

SIGNATURE______________________ NAME____________________________ DESIGNATION____________________ M/S.______________________________ PLACE___________________________ DATE____________________________

LIST OF ENCLOSURE 1. 2. 3. _________________________________________________________________________________ Certification by Main Supplier: Above information have been verified and found in order / minor changes which have been marked and initialed on this form itself / observed the following discrepancies.

Name : Designation : Signature : Date : _________________________________________________________________________________ Certification by visiting team : Above information except as under have been verified and found in order.

Name :

Designation :

Signature :

Date :

1. 2



PART-C GTR

PAGE 98 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) SWITCHYARD Attributes / Characteristics

SQE_20 Make, model, Type & Rating, Test Certificate

Routine & Acceptance Test as per IS / IEC


Y

Y

Y

Y

Y

Y

Y Y

Y Y

Y Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y

Y Y

Y Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y




Items/Components Sub Systems Circuit Breaker (IEC:56) Interruptor & hollow insulator (IEC:233/ IS:5284) Isolator (IEC:129 / IEC:694) Current Transformer (IEC:185) Capacitor Voltage Tramsformer (IEC:186 / 358) Bus Post Insualtor (IEC:168 / 273 / IS:2544) Disc,Pin & String Insualtor (IEC:383 / IS:731) Long Rod Insualtor (IEC:433) Surge Arrestor (IEC:99-4) Hardware fittings for Insulator (IS:2486 / BS:3288) Spacer Clamps & Connector (IS:10162 / 5561) Aluminium Tube (IS:5082 / 2673 / 2678) Wave Trap (IEC:353 / IS:8792 / 8793) Conductor (IS:398-P-II)(V) Galvanised Steel Structures (IS:2062/2629/4759/6745) Vibration Damper (IS:9708) Sag Compensating Spring DIN:2089/2096 IS:3195 / 7906 Control & Relay Panel SF6 Gas filling & evacuating plant SF6 Gas Leak Detector Leakage Current Analyser Nitrogen Gas Filling Device Protection Relays Event Logger Operation Analyser Disturbance Recorder Tariff Metering System Synchronising Trolly



PART-C GTR

PAGE 99 OF 100

SUB-SUPPLIER QUESTIONNAIRE (To be filled in by the Sub Supplier ) Make, Type Rating,and Model, Test Certificates

Routine & Acceptance Test as per relevant IS/IEC


Y

Y

Y

Y

Y

Y

Battery IS:1652

Y

Y

Y

Lighting Panels

Y

Y

Y

Surge Monitor

Y

Y

Y


Items/Components Sub Systems Relay Test Kit LT Switchgear /LT Panels (IEC:947 / IS:13947)

Notes : 1)

2)

This is an indicative list of test/checks. The manufacture is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents during QP finalisation for all items. All major Bought Out Items will be subject to NTPC approval.



PART-C GTR

PAGE 100 OF 100

SUPPLIER’S NAME AND ADDRESS

FIELD QUALITY PLAN ITEM :

SUPPLIER’S LOGO SL. NO 1.

QP NO.: REV. NO.: DATE: PAGE: …. OF….

SUB-SYSTEM:

ACTIVITY AND

CHARACTERISTICS / INSTRUMENTS

OPERATION 2.

MANUFACTURER/ SUB-SUPPLIER

3.

MAIN-SUPPLIER

SIGNATURE FORMAT NO.: QS-01-QAI-P-09/F2-R1

CLASS OF CHECK # 4.

PROJECT

:

PACKAGE

:

CONTRACT NO. : MAIN-SUPPLIER:

TYPE OF CHECK

QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE NORMS

5.

6.

7.

8.

LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (√) SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR, C=MINOR; ‘A’ SHALL BE WITNESSED BY NTPC FQA, ‘B’ SHALL BE WITNESSED BY NTPC ERECTION / CONSTRUCTION DEPTT. AND ‘C’ SHALL BE WITNESSED BY MAIN SUPPLIER (A & B CHECK SHALL BE NTPC CHP STAGE)

1/1

FORMAT OF RECORD 9.

REMARKS D*

DOC. NO.:

FOR NTPC USE

REVIEWED BY

10.

REV……

APPROVED BY

APPROVAL SEAL

ENGG. DIV./QA&I

MANUFACTURER’S NAME AND ADDRESS

MANUFACTURING QUALITY PLAN ITEM :

MFGR.’s LOGO

QP NO.: REV.NO.: DATE: PAGE: …. OF….

SUB-SYSTEM:

SL. NO

COMPONENT & OPERATIONS

CHARACTERISTICS

CLASS

TYPE OF CHECK

QUANTUM OF CHECK M C/N

1.

2.

3.

4.

5.

6.

MAIN-SUPPLIER

PACKAGE

:

MAIN-SUPPLIER:

REFERENCE DOCUMENT

ACCEPTANCE NORMS

7.

8.

FORMAT OF RECORD

AGENCY M

* RECORDS, INDENTIFIED WITH “TICK” ( √ ) SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. ** M: MANUFACTURER/SUB-SUPPLIER C: MAIN SUPPLIER, N: NTPC P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE, CHP: NTPC SHALL IDENTIFY IN COLUM “N” AS ‘ W”


:

CONTRACT NO. :

1/1

9.

D*

DOC. NO.:

LEGEND:

MANUFACTURER/ SUB-SUPPLIER

PROJECT

FOR NTPC USE

REVIEWED BY

C **

REMARKS N 11.

10.

REV…… CAT…..

APPROVED BY

APPROVAL SEAL

ENGG. DIV./QA&I

Project Contractor Contractor No. System S. N.

Stage :

SUB-CONTRACTOR APPROVAL SCHEDULE STATUS / EXCEPTION (To be raised by the contractor & Package incharge) For the month of ………………………………………

Sub-

Disci-

Mfg./

SC

QP/

Unit/

QP Type, No.,

of

Sys-

pline

Matl./

Appl.

Insp.

Works

& Revision

Agreed

Tem

(M/E/

Cat.

Cat.

Cat.

(MQP/RQP/S

C&I)

**

***

1/2/3#

QP/FQP)##

list

Item

: : : :

DOC. NO.: REV. NO.: DATE : PAGE :

OF

Date

Remarks

Scheduled

Ist Submission

2nd Submission

Final Submission

Subm. Approval

Subm. Comment

Subm Comment

Subm.

*

Distribution : 1. NTPC QA &I Coordinator NOIDA 2. NTPC. NTPC PE-Coordinator-3……….. FORMAT NO.: QS-01-QAI-P-02/F2-R2 1/1

.

Approval

Anticipated Subm/ Approval

Signature

Engg. Div. / QA&I

Project Contractor Contractor No. System Sl. No.

: : : :

DRG No. for Weld Location Description and Identification mark

of parts to

Stage :

Matl. Spec.

Dimensions

FIELD WELDING SCHEDULE (To be raised by the contractor) Welding Code: ………………………………………

Process of

Type of

Electrode

welding

Weld

filler spec.

welded

WPS. No.

Min. pre-heat

Heat treatment Temp.

Holding time

DOC. NO.: REV. NO.: DATE : PAGE : REF

NDT method/ Quantum

OF

Spec. No.

Remarks

ACC Norm Ref.

NOTES:


1/1

Engg. Div. / QA&I

Project Contractor Contractor No. System S. N.

Stage :

SUB-CONTRACTOR APPROVAL SCHEDULE STATUS / EXCEPTION (To be raised by the contractor & Package incharge)) For the month of ………………………………………


OF

Sub-

Disci-

Mfg./

SC

QP/

Unit/

Proposed Manufacturers /

SC

SC Details

SC Approval

of

Sys-

pline

Matl./

Appl.

Insp.

Works

Suppliers and their Location

Approval

Submission

Schedule

Agreed

Tem

(M/E/

Cat.

Cat.

Cat.

Status/

Schedule

C&I)

**

***

1/2/3#

Comments

list

Item

: : : :

Remarks

*

`


Signature

Engg. Div. / QA&I

Project Contractor Contractor No. System

: : : :

Stage :

SUB-CONTRACTOR APPROVAL SCHEDULE STATUS / EXCEPTION (To be raised by the contractor & Package incharge)) For the month of ………………………………………



OF

Signature

Engg. Div. / QA&I

PART - D



TECHNICAL SPECIFICATION SECTION-VI PART-D

TABLE OF CONTENTS PART - D ERECTION CONDITIONS OF CONTRACT -----------------------------------------------------------------------------------------------------------------------------------CLAUSE NO. DESCRIPTION PAGE NO. -----------------------------------------------------------------------------------------------------------------------------------1.00.00

General

1

2.00.00

Regulation of Local Authorities and Statues

1

3.00.00

Employer’s Lien on Equipment

1

4.00.00

Inspection, Testing and Inspection Certificates

1

5.00.00

Access to Site and Works on Site

2

6.00.00

Contractor’s site office establishment

2

7.00.00

Co-operation with other contractors

2

8.00.00

Discipline of workmen

3

9.00.00

Contractor’s field operation

3

10.00.00

Photographs and Progress Report

3

11.00.00

Man-Power Report

4

12.00.00

Protection of Work

4

13.00.00

Employment of Labour

4

14.00.00

Facilities to be Provided by the Employer

5

15.00.00

Facilities to be provided by the Contractor

6

16.00.00

Lines and Grades

6

17.00.00

Fire Protection

7

18.00.00

Security

7

19.00.00

Contractor’s Area Limits

7

20.00.00

Contractor’s co-operation with the Employer

8



-----------------------------------------------------------------------------------------------------------------------------------CLAUSE NO. DESCRIPTION PAGE NO. -----------------------------------------------------------------------------------------------------------------------------------21.00.00

Pre-commissioning trials and initial operations

8

22.00.00

Materials Handling and Storage

9

23.00.00

Construction Management

11

24.00.00

Field Office Records

11

25.00.00

Contractor’s Materials Brought on to site

12

26.00.00

Protection of property and Contractor’s liability

12

27.00.00

Painting

12

28.00.00

Insurance

13

29.00.00

Unfavourable working conditions

14

30.00.00

Protection of Monuments and Reference points

14

31.00.00

Work & Safety Regulations

14

32.00.00

Foreign Personnel

23

33.00.00

Code Requirements

24

34.00.00

Foundation Dressing & Grouting

24

35.00.00

Dowelling

26

36.00.00

Check out of Control Systems

26

37.00.00

Commissioning Spares

26

38.00.00

Equipment Delivery and erection

26

39.00.00

Cabling

32

40.00.00

Testing Equipment & Facilities

33



CLAUSE NO.


1.00.00

GENERAL

1.01.00

The following provisions shall supplement the conditions already contained in the other parts of these specifications and documents and shall govern that portion of the work or this contract to be performed at site. The erection requirements and procedures not specified in these documents shall be in accordance with the recommendations of the equipment manufacturer, or as mutually agreed to between the Employer and the Contractor prior to commencement of erection work.

1.02.00

The Contractor upon signing of the contract shall, in addition to a Project Coordinator, nominate another responsible officer as his representative at site suitably designated for the purpose of overall responsibility and co-ordination of the works to be performed at site. Such person shall function from the site office of the Contractor during the pendency of contract.

2.00.00

REGULATION OF LOCAL AUTHORITIES AND STATUTES

2.01.00

The Contractor shall comply with all the rules and regulations of local authorities during the performance of his field activities. He shall also comply with the Minimum Wages Act, 1948 and the Payment of Wages Act (both of the Government of India) and the rules made thereunder in respect of any employee or workman employed or engaged by him or his sub-Contractor.

2.02.00

All registration and statutory inspection fees, if any, in respect of his work pursuant to this contract shall be to the account of the Contractor. However, any registration, statutory inspection fees lawfully payable under the provisions of the any statutory laws and its amendments from time to time during erection in respect of the plant equipment ultimately to be owned by the Employer, shall be to the account of the Employer. Should any such inspection or registration need to be re-arranged due to the fault of the Contractor or his Sub-contractor, the additional fees to such inspection and/or registration shall be borne by the Contractor.

3.00.00

EMPLOYER’S LIEN ON EQUIPMENT

3.01.00

The Employer shall have lien on all equipment including those of the Contractor brought to the site for the purpose of erection, testing and commissioning of the plant. The Employer shall continue to hold the lien on all such equipment throughout the period of contract. No material brought to the site shall be removed from the site by the Contractor and/or his Sub-contractors without the prior written approval of the Project Manager.

4.00.00

INSPECTION, TESTING AND INSPECTION CERTIFICATES

4.01.00

The provisions of the clause entitled Inspection, Testing and Inspection Certificates under General Technical Requirements in Part-C shall also be applicable to the erection portion of the works. The Project Manager shall have the right to re-inspect any equipment though previously inspected and approved by him at the Contractor’s works, before and after the same are erected at site. If by the above inspection, the Project Manager rejects any equipment, the Contractor shall make good for such



PART-D

PAGE 1 OF 33

CLAUSE NO.


rejections either by replacement or modification/ repairs as may be necessary to the satisfaction of the Project Manager. Such replacements will also include the replacements or re-execution of such of those works of other Contractors and/or agencies, which might have got damaged or affected by the replacements or re-work done to the Contractor’s work. 5.00.00

ACCESS TO SITE AND WORKS ON SITE

5.01.00

Suitable access to and possession of the Site shall be afforded to the Contractor by the Employer in reasonable time.

5.02.00

The works so far as it is carried out on the Employer’s premises, shall be carried out at such time as the Employer may approve and the Employer shall give the Contractor reasonable facilities for carrying out the works.

5.03.00

In the execution of the works, no person other than the Contractor or his duly appointed representative, Sub-contractor and workmen, shall be allowed to do work on the site, except by the special permission, in writing of the Project Manager or his representative.

6.00.00

CONTRACTOR’S SITE OFFICE ESTABLISHMENT

6.01.00

The Contractor shall establish a site office at the site and keep posted an authorised representative for the purpose of the Contract. Any written order or instruction of the Project Manager or his duly authorised representative, shall be communicated to the said authorised resident representative of the Contractor and the same shall be deemed to have been communicated to the Contractor at his legal address.

7.00.00

CO-OPERATION WITH OTHER CONTRACTORS

7.01.00

The Contractor shall co-operate with all other Contractors or tradesmen of the Employer, who may be performing other works on behalf of the Employer and the workmen who may be employed by the Employer and doing work in the vicinity of the Works under the Contract. The Contractor shall also arrange to perform his work as to minimise, to the maximum extent possible, interference with the work of other Contracts and their workmen. Any injury or damage that may be sustained by the employees of the other Contractors and the Employer, due to the Contractor's work shall promptly be made good at his own expense. The Employer shall determine the resolution of any difference or conflict that may arise between the Contractor and other Contractors or between the Contractor and the workmen of the Employer in regard to their work. If the work of the Contractor is delayed because of the any acts of omission of another Contractor, the Contractor shall have no claim against the Employer on that account other than an extension of time for completing his Works. Employer shall have full access to visit the contractor's site at any time for inspection & surveillance checks.

7.02.00

The Employer shall be notified promptly by the Contractor of any defects in the other Contractor's works that could affect the Contractor's Works. The Employer shall



PART-D

PAGE 2 OF 33

CLAUSE NO.


determine the corrective measures if any, required to rectify this situation after inspection of the works and such decisions by the Employer shall be binding on the Contractor. 8.00.00

DISCIPLINE OF WORKMEN

8.01.00

The Contractor shall adhere to the disciplinary procedure set by the Project Manager in respect of his employees and workmen at site. The Project Manager shall be at liberty to object to the presence of any representative of employee of the Contractor at the site, if in the opinion of the Project Manager such employee has misconducted himself or is incompetent or negligent or otherwise undesirable and then the Contractor shall remove such a person objected to and provide in his place a competent replacement.

9.00.00

CONTRACTOR’S FIELD OPERATION

9.01.00

The Contractor shall keep the Project Manager informed in advance regarding his field activity plans and schedules for carrying out each part of the works. Any review of such plan or schedule or method of work by the Project Manager shall not relieve the Contractor of any of responsibilities towards the field activities. Such reviews shall also not be considered as an assumption of any risk or liability by the Project Manager or the Employer or any of his representatives and no claim of the Contractor will be entertained because of the failure or inefficiency of any such plan or schedule or method of work reviewed. The Contractor shall be solely responsible for the safety, adequacy and efficiency of plant and equipment and his erection methods.

9.02.00

The Contractor shall have the complete responsibility for the conditions of the worksite including the safety of all person employed by him or his Sub-contractor and all the properties under his custody during the performance of the work. This requirement shall apply continuously till the completion of the Contract and shall not be limited to normal working hours. The construction review by the Project Manager is not intended to include review of Contractor’s safety measures in, or of near the work-site, and their adequacy or otherwise.

10.00.00

PHOTOGRAPHS AND PROGRESS REPORT

10.01.00

The Contractor shall furnish three (3) prints each to the Project Manager of progress photographs of the work done at site. Photographs shall be taken as and when indicated by the Project Manager or his representative. Photographs shall be adequate in size and number to indicate various stages of erection. Each photograph shall contain the date, the name of the Contractor and the title of the photograph.

10.02.00

The above photographs shall accompany the monthly progress report detailing out the progress achieved on all erection activities as compared to the schedules. The report shall also indicate the reasons for the variance between the scheduled and actual progress and the action proposed for corrective measures, wherever necessary.



PART-D

PAGE 3 OF 33

CLAUSE NO.


11.00.00

MAN-POWER REPORT

11.01.00

The Contractor shall submit to the Project Manager, on the first day of every month, a man hour schedule for the month, detailing the man hours scheduled for the month, skill-wise and area-wise.

11.02.00

The Contractor shall also submit to the Project Manager on the first day of every month, a man power report of the previous month detailing the number of persons scheduled to have been employed and actually employed, skill-wise and the areas of employment of such labour.

12.00.00

PROTECTION OF WORK

12.01.00

The Contractor shall have total responsibility for protecting his works till it is finally taken over by the Project Manager. No claim will be entertained by the Employer or the Project Manager for any damage or loss to the Contractor’s works and the Contractor shall be responsible for complete restoration of the damaged works to original conditions to comply with the specification and drawings. Should any such damage to the Contractor’s Works occur because or other party not being under his supervision or control, the Contractor shall make his claim directly with the party concerned. If disagreement or conflict or dispute develops between the Contractor and the other party or parties concerned regarding the responsibility for damage to the Contractor’s Works the same shall be resolved as per the provisions of the Clause 7.00.00 above entitled “Co-operation with other Contractors.” The Contractor shall not cause any delay in the repair of such damaged Works because of any delay in the resolution of such disputes. The Contractor shall proceed to repair the Work immediately and no cause thereof will be assigned pending resolution of such disputes.

13.00.00

EMPLOYMENT OF LABOUR

13.01.00

The Contractor will be expected to employ on the work only his regular skilled employees with experience of his particular work. No female labour shall be employed after darkness. No person below the age of eighteen years shall be employed.

13.02.00

All traveling expenses including provisions of all necessary transport to and from site, lodging allowances and other payments to the Contractor’s employees shall be the sole responsibility of the Contractor.

13.03.00

The hours of work on the Site shall be decided by the Employer and the Contractor shall adhere to it. Working hours will normally be eight (8) hours per day - Monday through Saturday.

13.04.00

Contractor’s employees shall wear identification badges while on work at Site.

13.05.00

In case the Employer becomes liable to pay any wages or dues to the labour or any Government agency under any of the provisions of the Minimum Wages Act, Workmen Compensation Act, Contract Labour Regulation Abolition Act or any other



PART-D

PAGE 4 OF 33

CLAUSE NO.


law due to act of omission of the Contractor, the Employer may make such payments and shall recover the same from the Contractor’s bills. 14.00.00

FACILITIES TO BE PROVIDED BY THE EMPLOYER

14.01.00

Construction Power Supply

14.01.01

The Contractor shall submit to the Employer within thirty (30) days from the date of acceptance of the Notification of Award, his electrical power requirements, if any, to allow the planning of the same by the Employer. The Contractor shall be provided with free supply of electricity for the purposes of the Contract, only at one two locations in the Employer's Site at 415V voltage level. The Contractor shall make his own further distribution arrangement. All temporary wiring must comply with local regulations and will be subject to Employer's inspection and approval before connection to supply. It shall be the responsibility of the contractor to take the power supply upto the point of his use.

14.01.02

NTPC does not guarantee maintenance of uninterrupted supply of power and incase of any interruption of supply of power. The contractor shall be responsible for making at his own cost, alternative arrangement for standby power. Contractor shall arrange DG sets of adequate capacity at his own cost to meet backup and emergency power supply requirement including lighting, dewatering etc. No claim for damages will be entertained by NTPC on any account in connection with such standby/emergency supply of power. Where the contractor makes his own arrangements for power required for the works, no separate payment shall be made for the same.

14.01.03

In case the labour & staff colony of the agency is away from NTPC construction power network, they have to arrange power supply from local electricity authority on their own.

14.02.00

Water Contractor shall make all arrangements himself for the supply of construction water as well as potable water for labor and other personnel at the worksite /colony.

14.03.00

EOT Cranes be provided in GIS hall which is being procured under separate package shall be used by the Contractor for erection of the equipment. For equipments which cannot be handled by these cranes, the Contractor shall make his own arrangements.

14.04.00

Bidders shall clearly bring out in his offer the proposed method of installation of GIS and other equipments. This shall be supported by detailed write up drawings & other technical data.



PART-D

PAGE 5 OF 33

CLAUSE NO.


15.00.00

FACILITIES TO BE PROVIDED BY THE CONTRACTOR

15.01.00

Space The Contractor shall make his own arrangements for suitable and adequate land /space & power supply for his office, storage area, pre-assembly and fabrication areas, labour and staff colony area, toilets etc. at a convenient place near the project area. Adequate and suitable security arrangements including lighting to be provided by the Contractor for the storage area & pre-assembly and fabrication areas shall be subject to approval of Project Manager of NTPC.

15.02.00

Tools, tackles and scaffoldings The Contractor shall provide all the construction equipments, tools, tackles and scaffoldings required for pre-assembly, erection, testing and commissioning of the equipments covered under the contract. He shall submit a list of all such materials to the Project Manager before the commencement of pre-assembly at site. These tools and tackles shall not be removed from the site without the written permission of the Project Manager.

15.03.00

First-aid The Contractor shall provide necessary first-aid facilities for all his employees, representatives and workmen working at the site. Enough number of Contractor’s personnel shall be trained in administering first-aid.

15.04.00

Cleanliness

15.04.01

The Contractor shall be responsible for keeping the entire area allotted to him clean and free from rubbish, debris etc. during the period of contract. The Contractor shall employ enough number of special personnel to thoroughly clean his work-area at least once in a day. All such rubbish and scrap material shall be stacked or disposed in a place to be identified by the Project Manager. Materials and stores shall be so arranged to permit easy cleaning of the area. In areas where equipment might drip oil and cause damage to the floor surface, a suitable protective cover of a flame resistant, oil proof sheet shall be provided to protect the floor from such damage.

15.04.02

Similarly the labour colony, the offices and the residential areas of the Contractor’s employees and workmen shall be kept clean and neat to the entire satisfaction of the Project Manager. Proper sanitary arrangements shall be provided by the Contractor, in the work-areas, office and residential areas of the Contractor.

16.00.00

LINES AND GRADES All the works shall be performed to the lines, grades and elevations indicated on the drawings. The Contractor shall be responsible to locate and lay-out the Works. Basic horizontal and vertical control points will be established and marked by the Project Manager at site at suitable points. These points shall be used as datum for the works under the contract. The Contractor shall inform the Project Manager well in advance of the times and places at which he wishes to do work in the area allotted to him so that suitable datum points may be established and checked by the Project



PART-D

PAGE 6 OF 33

CLAUSE NO.


Manager to enable the Contractor to proceed with his works. Any work done without being properly located may be removed and/or dismantled by the Project Manager at Contractor’s expense. 17.00.00

FIRE PROTECTION

17.01.00

The work procedures that are to be used during the erection shall be those which minimise fire hazards to the extent practicable. Combustible materials, combustible waste and rubbish shall be collected and removed from the Site at least once each day. Fuels, oils and volatile or flammable materials shall be stored away from the construction and equipment and materials storage areas in safe containers. Untreated canvas, paper, plastic or other flammable flexible materials shall not at all be used at Site for any other purpose unless otherwise specified. If any such materials are received with the equipment at the site, the same shall be removed and replaced with acceptable material before moving into the construction or storage area.

17.02.00

Similarly corrugated paper fabricated cartons etc. will not be permitted in the construction area either for storage or for handling of materials. All such materials used shall be of water-proof and flame resistant type. All the other materials such as working drawings, plans, etc. which are combustible but are essential for the works to be executed shall be protected against combustion resulting from welding sparks, cutting flames and other similar fire sources.

17.03.00

All the Contractor’s supervisory personnel and sufficient number of workers shall be trained for fire-fighting and shall be assigned specific fire protection duties. Enough of such trained personnel must be available at the site during the entire period of the contract.

17.04.00

The Contractor shall provide enough fire protection equipment of the types and number for the warehouses, office, temporary structures, labour colony area, etc. Access to such fire protection equipment, shall be easy and kept open at all time.

18.00.00

SECURITY The Contractor shall have total responsibility for all equipment and materials in his custody stores, loose, semi-assembled and/or erected by him at site. The Contractor shall make suitable security arrangements including employment of security personnel to ensure the protection of all materials, equipment and works from theft, fire, pilferage and any other damages and loss. All materials of the Contractor shall enter and leave the project site only with the written permission of the Project Manager in the prescribed manner.

19.00.00

CONTRACTOR’S AREA LIMITS The Project Manager will mark-out the boundary limits of access roads, parking spaces, storage and construction areas for the Contractor and the Contractor shall not trespass the areas not so marked out for him. The Contractor shall be responsible to ensure that none of his personnel move out of the areas marked out for his operations. In case of such a need for the Contractor’s personnel to work out



PART-D

PAGE 7 OF 33

CLAUSE NO.


of the areas marked out for him the same shall be done only with the written permission of the Project Manager. 20.00.00

CONTRACTOR’S CO-OPERATION WITH THE EMPLOYER In case where the performance of the erection work by the Contractor affects the operation of the system facilities of the Employer, such erection work of the Contractor shall be scheduled to be performed only in the manner stipulated by the Project Manager and the same shall be acceptable at all times to the Contractor. The Project Manager may impose such restrictions on the facilities provided to the Contractor such as electricity, water, etc. as he may think fit in the interest of the Employer and the Contractor shall strictly adhere to such restrictions and co-operate with the Project Manager. It will be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up and operation of the equipment systems which are erected by him. The Contractor shall also be responsible for flushing and initial filling of all the oil and lubricants required for the equipment furnished and erected by him, so as to make such equipment ready for operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants unless otherwise specified elsewhere in documents and specifications.

21.00.00

PRE-COMMISSIONING TRIALS AND INITIAL OPERATIONS General

21.01.01

The pre-commissioning and commissioning activities including tests, checks and initial operations of the equipment furnished and erected by the Contractor shall be the responsibility of the Contractor as detailed in relevant clauses in Technical Specification. The Contractor shall provide, in addition, test instruments, calibrating devices, etc. and labour required for successful performance of these operations. If it is anticipated that the above test may prolong for a long time, the Contractor's workmen required for the above test shall always be present at Site during such operations.

21.01.02

It shall be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up and operation of the equipment systems which are installed by him. The Contractor shall also be responsible for flushing & initial filling of all SF6 gas, oils & lubricants required for the equipment furnished and installed by him so as to make such equipment ready for operation. The Contractor shall be responsible for supplying such SF6 gas, flushing oil and other lubricants unless otherwise specified elsewhere in these specifications & documents.

21.01.03

The Contractor upon completion of erection of equipments and systems, shall conduct pre-commissioning and commissioning activities, to make the facilities ready for sustained safe, reliable and efficient operation. All pre-commissioning/ commissioning activities considered essential for such readiness of the facilities including those mutually agreed and included in the Contractors quality assurance programme as well as those indicated in clauses elsewhere in the technical specifications shall be performed by the Contractor.



PART-D

PAGE 8 OF 33

CLAUSE NO.

21.02.00


Testing / Commissioning Schedule The Contractor shall submit to the Employer, his testing/ commissioning schedules for various equipments/ systems covered under the contract, for approval, at least 6 months before the actual commissioning of the equipment/ systems. The testing/ commissioning schedule is required to be of a standard format in order to maintain consistency of presentation, content and reporting. The list of documents and commissioning checks to be submitted and their content details shall be agreed upon during preaward discussions.

21.03.00

Pre-Commissioning Activities

21.03.01

General The Contractor shall draw up a detailed sequential & systematic list of checks/ tests and various activities/ procedures connected with pre-commissioning of the complete facilities with all systems, sub-systems and equipment supplied and installed by him and get the same approved by the Employer.

21.04.00

Commissioning of Facilities

21.04.01

General Upon completion of precommissioning activities/test the Contractor shall initiate commissioning of facilities. During commissioning the Contractor shall carryout system checking and reliability trials on various parts of the facilities. Contractor shall carry out these checks/tests at site to prove to the Employer that each equipment of the supply complies with requirements stipulated and is erected in accordance with requirements specified. Before the plant is put into initial operation the Contractor shall be required to conduct test to demonstrate to the Employer that each item of the plant is capable of correctly performing the functions for which it was specified and its performance, parameters etc. are as per the specified/approved values. These tests may be conducted concurrently with those required under commissioning sequence.

21.04.02

Initial Operation Upon completion of system checking/tests as per 20.04.01 above and as a part of commissioning of facilities, complete equipment/systems shall be put on initial operation alongwith the generator units.

22.00.00

MATERIALS HANDLING AND STORAGE

22.01.00

All the equipment furnished under the Contract and arriving at site shall be promptly received, unloaded and transported and stored in the storage spaces by the Contractor.



PART-D

PAGE 9 OF 33

CLAUSE NO.


22.02.00

Contractor shall be responsible for examining all the shipment and notify the Project Manager immediately of any damage, shortage, discrepancy etc. for the purpose of Project Manager’s information only. The Contractor shall submit to the Project Manager every week a report detailing all the receipts during the week. However, the Contractor shall be solely responsible for any shortages or damage in transit, handling and/or in storage and erection of the equipment at site. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor.

22.03.00

The Contractor shall maintain an accurate and exhaustive record detailing out the list of all equipment received by him for the purpose of erection and keep such record open for the inspection of the Project Manager.

22.04.00

All equipment shall be handled very carefully to prevent any damage or loss. No bare wire ropes, slings, etc. shall be used for unloading and/or handling of the equipment without the specific written permission of the Project Manager. The equipment stored shall be properly protected to prevent damage either to the equipment or to the floor where they are stored. The equipment from the store shall be moved to the actual location at the appropriate time so as to avoid damage of such equipment at site.

22.05.00

All electrical panels, controls gear, motors and such other devices shall be properly dried by heating before they are installed and energised. Motor bearings, and other exposed parts shall be protected against moisture ingress and corrosion during storage and periodically inspected. Heavy rotating parts in assembled conditions shall be periodically rotated to prevent corrosion due to prolonged storage.

22.06.00

All the electrical equipment such as motors, CTs, CVTs etc. shall be tested for insulation resistance at least once in three months from the date of receipt till the date of commissioning and a record of such measured insulation values maintained by the Contractor. Such records shall be open for inspection by the Project Manager.

22.07.00

The Contractor shall ensure that all the packing materials and protection devices used for the various equipments during transit and storage are removed before the equipment are installed.

22.08.00

The consumables and other supplies likely to deteriorate due to storage must be thoroughly protected and stored in a suitable manner to prevent damage or deterioration in quality by storage.

22.09.00

All the materials stored in the open or dusty location must be covered with suitable weather-proof and flameproof covering material wherever applicable.

22.10.00

If the materials belonging to the Contractor are stored in areas other than those earmarked for him, the Project Manager will have the right to get it moved to the area earmarked for the Contractor at the Contractor’s cost.

22.11.00

The Contractor shall be responsible for making suitable indoor storage facilities to store all equipment which require indoor storage. Normally, all the electrical equipments such as motors, CTs, CVTs Wave Traps etc and consumables like



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electrodes, lubricants, SF6 gas etc. shall be stored in the closed storage space . The Project Manager, in addition, may direct the Contractor to move certain other materials, which in his opinion will require indoor storage, to indoor storage areas which the Contractor shall strictly comply with. 23.00.00

CONSTRUCTION MANAGEMENT

23.01.00

The field activities of the various contractors executing different contracts for the project, will be coordinated by the Project Manager and the Project Manager’s decision shall be final in resolving any disputes or conflicts between the Contractor and other Contractors and tradesmen of the Employer regarding scheduling and coordination of work. Such decision by the Project Manager shall not be a cause for extra compensation or extension of time for the Contractor.

23.02.00

The Project Manager shall hold weekly meetings of all the Contractors working at Site, at a time and place to be designated by the Project Manager. The Contractor shall attend such meetings and take notes of discussions during the meeting and the decisions of the Project Manager and shall strictly adhere to those decisions in performing his Works. In addition to the above weekly meeting, the Project Manager may call for other meeting either with individual contractors or with selected number of contractors and in such a case the Contractor if called, will also attend such meetings.

23.03.00

Time is the essence of the Contract and the Contractor shall be responsible for performance of his works in accordance with the specified construction schedule. If at any time, the Contractor is falling behind the schedule, he shall take necessary action to make good for such delays by increasing his work force or by working overtime or otherwise accelerate the progress of the work to comply with the schedule and shall communicate such actions in writing to the Project Manager, satisfying that his action will compensate for the delay. The Contractor shall not be allowed any extra compensation for such action.

23.04.00

The Project Manager shall however not be responsible for provision of additional labour and/or materials or supply or any other services to the Contractor except for the co-ordination work between various Contractors as set out earlier.

24.00.00

FIELD OFFICE RECORDS The Contractor shall maintain at his site office up-to-date copies of all drawings, specifications and other contract documents and any other supplementary data complete with all the latest revisions thereto. The Contractor shall also maintain the continuous record of all changes to the above contract documents, drawings, specifications, supplementary data, etc. effected at the field. On completion of his total assignment under the contract, the Contractor shall incorporate all such changes on the drawings and other project engineering data to indicate ‘as installed’ conditions of the equipment furnished and erected under the contract. Such drawings and project engineering data shall be submitted to the Project Manager in required number of copies.



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25.00.00

CONTRACTOR’S MATERIALS BROUGHT ON TO SITE

25.01.00

The Contractor shall bring to site all equipment, components, parts, materials, including construction equipment, tools and tackles for the purpose of the works under intimation to the Project Manager. All such goods shall, from the time of their being brought vest in the Employer, but may be used for the purpose of the works only and shall not on any account be removed or taken away by the Contractor without the written permission of the Project Manager. The Contractor shall nevertheless be solely liable and responsible for any loss or destruction thereof and damage thereto.

25.02.00

The Employer shall have a lien on such goods for any sum or sums which may at any time be due or owing to him by the Contractor, under, in respect of or by reasons of the contract. After giving a fifteen (15) days notice in writing of his intention to do so, the Employer shall be at liberty to sell and dispose off any such goods, in such manner as he shall think fit including public auction or private treaty and to apply the proceeds in or towards the satisfaction of such sum or sums due as aforesaid.

25.03.00

After the completion of the works, the Contractor shall remove from the site under the direction of the Project Manager the materials such as construction equipment, erection tools and tackles, scaffolding etc. with the written permission of the Project Manager. If the Contractor fails to remove such materials, within fifteen (15) days of issue of a notice by the Project Manager to do so then the Project Manager shall have the liberty to dispose off such materials as detailed under clause 25.02.00 above and credit the proceeds thereto to the account of the Contractor.

26.00.00

PROTECTION OF PROPERTY AND CONTRACTOR’S LIABILITY

26.01.00

The Contractor shall be responsible for any damage resulting from his operations. He shall also be responsible for protection of all persons including members of public and employees of the Employer and the employees of other Contractors and Sub-Contractors and all public and private property including structures, buildings, other plants and equipments and utilities either above or below the ground.

26.02.00

The Contractor will ensure provision of necessary safety equipment such as barriers, sign-boards, warning lights and alarms, etc. to provide adequate protection to persons and property. The Contractor shall be responsible to give reasonable notice to the Project Manager and the Employers of public or private property and utilities when such property and utilities are likely to get damaged or injured during the performance or his Works and shall make all necessary arrangements with such Employers, related to removal and/or replacement or protection of such property and utilities.

27.00.00

PAINTING All exposed metal parts of the equipment including pipings, structures railings etc. wherever applicable, after installation unless otherwise surface protected, shall be first painted with at least one coat of suitable primer which matches the shop primer paint used, after thoroughly cleaning all such parts of all dirt, rust, scales, greases,



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oils and other foreign materials by wire brushing, scraping or sand blasting and the same being inspected and approved by the Project Manager for painting. Afterwards, the above parts shall be finished painted with two coats of allowed resin machinery enamel paints. The quality of the finish paint shall be as per the standards of ISI or equivalent and to be of the colour as approved by the Project Manager. 28.00.00

INSURANCE In addition to the conditions covered under the Clause entitled “Insurance” in Section GCC, Conditions of Contract, the following provisions will also apply to the portion of work to be done beyond the Contractor’s own or his subcontractor’s manufacturing works.

28.01.00

Workmen’s Compensation Insurance This insurance shall protect the Contractor against all claims applicable under the workmen’s Compensation Act, 1948 (Government of India). This policy shall also cover the Contractor against claims for injury, disability disease or death of his or his Sub-Contractor’s employees, which for any reason are not covered under the Workmen’s Compensation Act 1948. The liabilities shall not be less than:

28.02.00

Workmen’s Compensation

As per Statutory Provisions

Employee’s liability

As per Statutory Provisions

Comprehensive Automobile Insurance This insurance shall be in such a form to project the Contractor against all claims for injuries, disability, disease and death to members of public including the Employer’s men and damage to the property of other arising from the use of motor vehicles during on or off the Site operations, irrespective of the ownership of such vehicles the liability covered shall be as herein indicated Fatal Injury

Property Damage

:

Rs. 100,000/- each person

:

Rs. 200,000/- each occurrence

:

Rs. 100,000/- each occurrence

28.03.00

Comprehensive General Liability Insurance

28.03.01

The insurance shall protect the Contractor against all claims arising from injuries, disabilities, disease or death of members of public or damage to property of others, due to any act or omission on the part of the Contractor, his agents, his employees, his representatives and Sub-Contractor, his agents, his employees, his representatives and Sub-Contractors or from riots, strikes and civil commotion. This insurance shall also cover all the liabilities of the Contractor arising out of the Clause entitled “Defence of Suits” in Section GCC, Conditions of Contract.



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28.03.02

The hazards to be covered will pertain to all the works and areas where the Contractor, his sub-contractors , his agents and his employees have to perform work pursuant to the Contract.

28.03.03

The above are only illustrative list of Insurance covers normally required and it will be the responsibility of the Contractor to maintain all necessary insurance coverage to the extent both in time and amount to take care of all his liabilities either direct or indirect, in pursuance of the Contract.

29.00.00

UNFAVOURABLE WORKING CONDITIONS The Contractor shall confine all his field operations to those works which can be performed without subjecting the equipment and materials to adverse effects during inclement weather conditions, like monsoon, storms, etc. and during other unfavourable construction conditions. No field activities shall be performed by the Contractor under conditions which might adversely affect the quality and efficiency thereof, unless special precautions or measures are taken by the Contractor in a proper and satisfactory manner in the performance of such Works and with the concurrence of the Project Manager. Such unfavourable construction conditions will in no way relieve the Contractor of his responsibility to perform the Works as per the schedule.

30.00.00

PROTECTION OF MONUMENTS AND REFERENCE POINTS The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc. which he may come across during the course of performance of his works either during excavation or elsewhere, are properly protected and handed over to the Project Manager. Similarly the Contractor shall ensure that the bench marks, reference points, etc., which are marked either with the help of Project Manager or by the Project Manager shall not be disturbed in any way during the performance of his works. If, any work is to be performed which disturb such reference, the same shall be done only after these are transferred to other suitable locations under the direction of the Project Manager. The Contractor shall provide all necessary materials and assistance for such relocation of reference points etc.

31.00.00

WORK & SAFETY REGULATIONS

31.01.00

General i)

The contractor shall comply with all the equipments of "The Building and Other Construction Workers (Regulation of Employment & Conditions of Service) Act," 1996 and its Central Rule 1998 / State Rules and any other statutory requirements as applicable.

ii)

The contractor shall follow NTPC Safety Rules as issued from time to time with respect to safety in construction & erection.

iii)

The contractor shall have the approved Safety, Health and Environment (SHE) Policy in respect of Safety and health of Building Workers and it shall



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be circulated widely and displayed at conspicuous place in Hindi and local language understood by the majority of the workers. A copy of the safety policy should be submitted to Engineer in charge. iv)

The contractor shall submit the safety plan comprising of methods to implement the safety policy/rules, risk assessment and ensuring Safety at work areas, Safety audits, inspections and its compliance, supervision and responsibility to ensure safety at various levels, safety training to employees, review of safety and accident analysis, ensure health and safety procedures to prevent accidents to Engineer I/C for approval as per the format of Safety Plan as annexure at Annexure-I.

v)

The Contractors shall ensure proper safety of all the workmen, material, plant and equipment belonging to him or to the Employer or to others, working at the Site.

vi)

All equipments used in construction and erection by the contractor shall meet BIS/International Standards and where such standards do not exist, the Contractor shall ensure these to be absolutely safe. All equipment shall be strictly operated and maintained by the contractor in accordance with manufacture's operation manual. The contractor should also follow guidelines/rules of the employer in this regard.

vii)

The Contractor shall provide suitable latest Personal Protective Equipments of prescribed standard to all their employees and workmen according to the need. The Engineer I/C shall have the right to examine these safety equipments to determine their suitability, reliability, acceptability and adaptability. The contractor should also ensure these before their use at worksite.

viii)

The Contractor shall provide safe working conditions to all workmen and employees at his workplace including safe means of access, railings, stairs and ladders, scaffolding, work platforms, toe boards etc. The scaffoldings shall be erected under the control and supervision of an experienced and competent person. For erection of scaffolds, access, work platforms etc. shall be good and the contractor shall us standard quality of material.

ix)

The contractor shall flow and comply with all the safety rules, standards, code of practice of NTPC and relevant provisions of applicable laws pertaining to the safety of workmen, employees, plant and equipment as may be prescribed from time to time without any protest or contest or reservation. In case of any unconformity between statutory requirement and the Safety Rules of the Employer referred above, the latter shall be binding on the Contractor unless the statutory provisions are more stringent. As and when required he can refer/obtain copy of NTPC safety documents as stated above.

x)

The contractor shall have his own arrangements with nearby hospitals for shifting and treatment of sick and injured.



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The medical examination of the works employed in hazardous areas shall be conducted as per Rule 223 of the Building and Other Construction Worker (Regulation of Employment and Condition of Service) Central Rule 1998 Their health hazard, the worker should be shifted to suitable place of working and properly treated under intimation to Engineer I/C. The medical fitness certificate to be submitted to Engineer I/C. xi)

31.02.00

First Aid boxes equipped with requisite articles as specified in the Rule 231 of The Building and Other Construction Workers (Regulation of Employment and Condition of Service) Central Rule 1998 shall be provided at construction sites for the use of workers. Training has to be provided on first aid to workmen & office bearers working at site.

Emergency Action Plan The Contractor shall prepare an emergency action plan approved by his competent authority to handle any emergency occurred during construction work. Regular mock drills shall be organized to practice this emergency plan. The Emergency Action Plan should be widely circulated to all the employees and suitable infrastructure shall be provided to handle the emergencies.

31.03.00

Flood Monitoring (Hydro Projects) The contractor shall take necessary measures for monitoring of flood/water levels and develop a forewarning system to evacuate people to safer places well before the flood occurs. For this purpose he may maintain liaison with meteorological department and NTPC. The contractor shall make suitable communication and transporting system to rescuer and workers to safer places. The contractor shall provide suitable shelters, food, drinking water and other requisite facilities till they are brought back to their colonies and normalcy is restored.

31.04.00

Scaffolding The contractor shall take all precautions to prevent any accidental collapse of scaffolding or fall of persons from scaffolding. The contractor should ensure that scaffolding are designed by a competent person and it erection and repairs should be done under the expert supervision. The scaffolding shall meet the required strength and other requirements for the purpose for which the scaffold is erected. The material used for scaffold conform to the BIS / International standards.

31.05.00

Opening The Contractor shall ensure that there is no opening in any working platfore/any floor of the building, which may cause fall of workers or material. Whenever an opening on a platform/any floor of the building is unavoidable, the opening should be suitably fenced and necessary measures for protection against falling objects or building workers from such platform are taken by providing suitable safety nets, safety belts or other similar means.



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31.06.00


Fencing of Machinery The contractor shall provide suitable fencing or guard to all dangerous and moving parts of machinery. The contractor shall not allow any of the employees to clean, lubricate, repair, adjust or examine during machinery in motion, which may cause injury to the person.

31.07.00

Carrying of Excessive Weight by a Worker The worker shall not be allowed to lift by hand or carry over his head, back or shoulder more than the maximum limit set by the prescribed rules for the construction workers.

31.08.00

Dangerous and Harmful Gases/Equipment The contractor shall ensure that the workers are not exposed to any harmful gases during any construction activity including excavation, tunneling, confined spaces etc. The contractor should not allow any worker to go into the confined space unless it is certified by Engineer (I/C) to be safe and fit for the entry to such work place. Proper record and work permits should be followed to carry out such works.

31.09.00

Overhead Protection The contractor shall ensure that any area exposed to risk of falling materials, articles or objects is roped off or cordoned off or otherwise suitably guarded from inadvertent entry of any person. Wherever there is a possibility of falling of any material, equipment or construction workers while working at heights, a suitable and adequate safety net should be provided. The safety net should be in accordance with BIS Standards.

31.10.00

Working at Heights All working platforms, ways and other places of construction work shall be free from accumulations of debris or any other material causing obstructions and tripping. Wherever workers are exposed to the hazard of falling into water, the contractor shall provide adequate equipment for saving the employees from drowning and rescuing from such hazards. The contractor shall provide boat or launch equipped with sufficient number of life buoys, life jackets etc. manned with trained personnel at the site of such work. Every opening at elevation from ground level through which a building worker, vehicle, material equipment etc. may fall at a construction work shall be covered and/or guarded suitably by the contractor to prevent such falls. Wherever the workers are exposed to the hazards of falling from height, the contractor shall provide full harness safety belts fitted with fall arresting systems to



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all the employees working at higher elevations and life line of 8mm diameter wire higher elevations. Safety nets shall also be provided for saving them from fall from heights and such equipment should be in accordance with BIS standards. The contractor shall provide standard prefabricated ladders on the columns where the workers are required to use them as an access for higher elevations till permanent staircase is provided. The workers shall be provided with safety belts fitted with suitable fall arresting system (Fall arrestors) for climbing/getting down through ladders to prevent fall from height. 31.11.00

Handling of Hazardous Chemicals The Contractor will notify well in advance to the Engineer I/C of his intention to bring to the Site any container filled with liquid or gaseous fuel or explosive or petroleum substance or such chemicals which may involve hazards. NTPC shall have the right to prescribe the conditions, under which such container is to be stored, handled and used during the performance of the works and the Contract shall strictly adhere to and comply with such instructions. The Engineer I/C shall have the right at his sole discretion to inspect any such container or such construction plant/equipment for which material in the container is required to b used and if in his opinion, its use is not safe, he may forbid its use. No claim due to such prohibition shall be entertained by NTPC and NTPC shall not entertain any claim of the Contractor towards additional safety provisions/conditions to be provided for/constructed. Further, any such decision of the Engineer I/C shall not, in any way, absolve the Contractor of his responsibilities and in case, use of such a container or entry thereof into the site are is forbidden by NTPC, the Contractor shall use alternative methods with the approval of the NTPC without any cost implication to the NTPC or extension or work schedule. Where it is necessary to provide and/or store petroleum products or petroleum mixtures and explosives, the Contractor shall be responsible for carrying out such provision and / or storage in accordance with the rules and regulations laid down in Petroleum Act 1934, Explosives Act 1948, and Petroleum and Carbide of Calcium Manual published by the Chief Inspector of Explosives of India. All such storage shall have prior approval of the Engineer I/C. In case any approvals are necessary from the Chief Inspection (Explosives) or any statutory authorities, the Contractor shall be responsible for obtaining the same. The Contractor shall be fully responsible for the safe storage of his and his SubContractor's radio-active sources in accordance with BARC/DAE (Bhabha Atomic Research Centre/Department of Atomic Energy, Govt. of India) Rules and other applicable provisions. All precautionary measures stipulated by BARC/DAE in connection with use, the contractor would take storage and handling of such material. The Contractor shall provide suitable personal protective equipments to the workers who are handling the hazardous and corrosive substances including alkalis and acids.



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As a precautionary measure the contractor should keep the bottles filled with distilled water in cupboard / Boxes near work place for emergency eye wash by worker exposed to such hazardous chemicals. 31.12.00

Eye Protection The contractor shall provide suitable personal protective equipment to his workmen depending upon the nature of hazards and ensure their usage by the workers engaged in operations like welding, cutting, chipping, grinding or similar operations which may cause injuries to his eye.

31.13.00

Electrical Hazards The contractor should ensure all the all electrical installations at the construction work comply with the requirements of latest electricity acts/rules. The contractor shall take all adequate measures to prevent any worker from coming into physical contact with any electrical equipment or apparatus, machines or live electrical circuits which may cause electrical hazards during the construction work. The contractor shall provide the sufficient ELCBs/RCCBs for al the portable equipments, electrical switchboards, distribution panels etc. to prevent electrical shocks. The contractor should ensure use of single/double insulated hand tools or low voltage i.e. 110 volts hand tools. The contractor should also ensure that all temporary electrical installations at the construction works are provided with earth leakage circuit breakers.

31.14.00

Vehicular Traffic The contractor should employ vehicle drivers who hold a valid driving license under the Motor Vehicles Act. 1988.

31.15.00

Lifting Appliances, Tools & Tackles, Lifting Gear and Pressure Plant & Equipment etc. The contractor shall ensure all the lifting appliances, tools & tackles including cranes, etc. lifting gear including fixed or movale and any plant or gear, hoists, Pressure Plant and equipment etc. are in good condition and shall be examined by competent person and only certified shall be used at sites. Periodical Examination and the tests for all lifting/hoisting equipment & tackles shall be carried out. A register of such examinations and tests shall be properly maintained by the Contractor and will be promptly produced as and when desired by the Engineer I/C or by the person authorised by him.

31.16.00

Excessive Noise, Vibration The contractor shall take adequate measures to protect the workers against the harmful effect of excessive noise or vibration. The noise should not exceed the limits



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prescribed under the concerned rules. Noise Pollution (Regulation and Control) Rules, 2000. 31.17.00

Electrical Installations The contractor shall not interface or disturb electric fuses, wiring and other electrical equipment belonging to the Employer or other contractors under any circumstances, whatsoever, unless expressly permitted in writing by the Engineer I/C to handle such fuses, wiring or electrical equipment. Before the Contractor connects any electrical appliances to any plug or socket belonging to the other contractor or the NTPC, he shall i)

Satisfy the Engineer I/C that the appliances is in good working condition;

ii)

Inform the Engineer I/C of the maximum current rating, voltage and phases of the appliances;

iii)

Obtain permission of the Engineer I/C detailing the sockets to which the appliances may be connected. The Engineer I/C will not grant permission to connect until he is satisfied that: The appliance is in good condition and is fitted with suitable plug; having earth connection with the body. Wherever armored/metallic sheathed multi core cable is used, the same armored / sheathed should be connected to earth.

iv)

No repair work shall be carried out on any live equipment. The Engineer I/C must declare the equipment safe and a permit to work shall be issued by the NTPC/contractor as the case may be to carry out any repair/maintenance work. While working on electric lines/equipments whether live or dead, suitable type and sufficient quantity of tools will have to be provided by the contractor to electricians / workmen / officers.

v)

The contractor shall employ necessary number of qualified, full time Electricians/Electrical Supervisors to maintain his temporary electrical installation.

The installation are provided with suitable ELCBs and RCCBs wherever required. 31.18.00

Safety Organisation

31.18.01

The contractor employing more than 250 workmen whether temporary, causal, probationary, regular or permanent shall employ at least one full time safety officer exclusively to supervise safety aspects of the equipments and workmen, who will coordinate with the NTPC Safety Officer. Further requirement of safety officers, if any, shall be guided by Rule 209 of the Building and Other Construction Worker (Regulation of Employment and Conditions of Service) Central Rule 1998. In case



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the work is being carried out through subcontractor, the employees/workmen of the sub contractor shall also be considered as the contractor's employees workmen for the above purpose. In case of contractor deploying less than 250 workmen he should designate one of his Engineer/supervisor or the contractor himself (if he is directly supervising the work)as safety officer in addition to his existing responsibilities. The Engineer/supervisor should get atleast 2 days safety training from any reputed organization or from NTPC before resuming the work. If already trained in past the declaration along with trg. certificate to be furnished to NTPC safety officer. 31.18.02

The name and address of such safety officer of the Contractor will be promptly informed in writing to the EIC with a copy to the Project Safety Officer before he stards work or immediately after any change of the incumbent is made during currency of the contract.

31.19.00

Reporting of Accident and Investigation In case any accident occurs during the construction/erection or other associated activities undertaken by the contractor thereby causing any near miss, minor or major or fatal injury to his employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to promptly inform the same to the Engineer I/C, NTPC Safety Officer with a copy to NTPC Head of Project in the prescribed form and also to all the authorities envisaged under the applicable laws.

31.20.00

Right to Stop Work

31.20.01

The Engineer I/C shall have the right at his sole discretion to stop the work, if in his opinion the work is being carried out in such a way that it may cause accidents and endanger the safety of the persons and or property, and / or equipments. In such cases, the contractor shall be informed in writing about the nature of hazards and possible injury/accident and he shall comply to remove shortcomings promptly. The Contractor after stopping the specific work can, if felt necessary appeal against the order or stoppage of work to the Project Manager within 3 days of such stoppage of work and decision of the Project Manager in this respect shall be conclusive and binding on the contractor.

31.20.02

The Contractor shall not be entitled for any damages/compensation for stoppage of work due to safety reasons and the period of such stoppage of work shall not be taken as an extension of time for Completion of the Facilities and will not be the ground for waiver of levy of liquidated damages.

31.21.00

Fire Protection The Contractor shall provide sufficient fire extinguishers at place/s of work. The fire extinguishers shall be properly maintained as per relevant BIS Standards. The employees shall be trained to operate the fire extinguishers/equipment.



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31.22.00


Penalties (i)

If the Contractor fails in providing safe working environment as per the Safety Rules of NTPC or continues the work even after being instructed to stop the work by the Engineer I/C as provided in 31.20.00 above, the Contractor shall be penalized at the rate of Rs.25,000/- per day or part thereof till the instructions are complied with and so certified by the Engineer I/C. However, in case of accident, the provisions contained in 31.22.00 (ii) below shall also apply in addition to the penalties mentioned in this sub-clause.

(ii)

If the Contractor does not take all safety precautions and / or fails to comply with the Safety Rules as prescribed by the Employer or under the applicable law for the safety of the plant and equipment and for the safety of personnel and the contractor does not prevent hazardous conditions which cause injury to this own employees or employees of other contractors, or NTPC's employees or any other person who are at the Site or adjacent thereto, the Contractor shall be responsible for payment of penalty to NTPC as per the following schedule : (a)

Fatel injury or accident causing death : Penalty @10% of contract value or Rs. 5,00,000/- per person, whichever is less.

(b)

Major injuries or accident causing 25% or more permanent disablement to workmen or employees. Penalty @2.5% of contract value or 1,00,000/- per person whichever is less.

Permanent disablement shall have the same meaning as indicated in the Workmen's Compensation Act 1923. The panelty mentioned above shall be in addition to the compensation payable to the workmen/employess under the relevant provisions of the Workmen's Compensation Act 1923 and rules framed there under or any other applicable laws as applicable from time to time. (iii)

If any contractor worker found working without using the safety equipment like safety helment, safety shoes, safety belts, etc. or without anchoring the safety belts while working at height the Engineer I/C Safety Officer or NTPC shall have the right penalize the contractor for Rs. 200/- per person per day and such worker shall be sent out the workplace immediately and shall not be allowed to work on that day. Engineer I/C Safety Officer of NTPC will also issue a notice in this regard to the contractor.

iv)

If two or more fatal accident occur at same NTPC site under the contract of contractor during the period of contract and he has. (1)

not complied with keeping adequate PPEs in stock or



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(2)

defaulted in providing PPEs to his workmen.

(3)

not followed statutory requirements/NTPC safety rules

(4)

been issued warning notice by NTPC head of the project on non observance of safety norms

(5)

not provided safety training to all his workmen,

the contractor can be debarred from getting tender documents in NTPC for two years from the date of last accident. The safety performance will also be one of the overriding criteria for evaluation of overall performance of the contractors by NTPC. The contractor shall submit the accident data including fatal/non-fatal accidents for the last 3 years where he has undertaken the construction activities Projects-wise along with the tender documents. This will also be considered for evolution of tender documents. If the information given by the contractor found incorrect, his contract will be liable to be determined. 31.23.00

Award If the contractor's performance on safety front is found satisfactory i.e. without any fatal/reportable accident in the year of consideration; he may be considered for suitable award "ACCIDENT FREE SAFETY MERITORIOUS AWARD" as per scheme of the Employer.

32.00.00

FOREIGN PERSONNEL

32.01.00

The Contractor shall submit to the Employer data on all personnel he proposes to bring into India for the performance of the Works under the Contract, at least sixty (60) days prior to their departure to India. Such data will include for each person the name, his present address, his assignment and responsibility in connection with the works, and a short resume of his qualification, experience, etc. in relation to the work to be performed by him.

32.02.00

Any person unsuitable and unacceptable to the Employer shall not be brought to India. Any person brought to India, if found unsuitable or unacceptable by the Employer, the Contractor shall within a reasonable time make alternate arrangements for providing a suitable replacement and repatriation of such unsuitable personnel.

32.03.00

No person brought to India for the purposes of the works shall be repatriated without the consent of the Employer in writing, based on a written request from the Contractor for such repatriation giving reasons for such an action to the Project Manager. The Employer may give permission for such repatriation provided he is satisfied that the progress of work will not suffer due to such repatriation.

32.04.00

The cost of passports, visas and all other travel expenses to and from India, incurred by the Contractor shall be to his account. The Employer will not provide any



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residential accommodation and/or furniture for any of the Contractor’s personnel including foreign personnel and Contractor shall make his own arrangements for such facilities in the area allotted at Site, to him by the Employer for that purpose. 32.05.00

The Contractor and his expatriate personnel shall respect all Indian Acts, Laws, rules and regulations and shall not in any way interfere with Indian political and religious affairs and shall conform to any other rules and regulations which the Government of India, the Employer and the Project Manager may establish from time to time, on them. The Contractor’s expatriate personnel shall work and live in close co-operation and coordination with their co-workers and the community and shall not engage themselves in any other employement neither part-time or full-time nor shall they take part in any local politics.

32.06.00

The Employer shall assist the Contractor, to the extent possible, in obtaining necessary permits to travel to India and back, by issue of necessary certificates and other information needed by the Government agencies.

33.00.00

CODE REQUIREMENTS The erection requirements and procedures to be followed during the installation of the equipment shall be in accordance with the relevant Indian Boiler Regulations, ASME codes and accepted good project manageering practice, the Project Manager’s drawings and other applicable Indian recognised codes and laws and regulations of the Government of India.

34.00.00

FOUNDATION DRESSING & GROUTING

34.01.00

The surfaces of foundations shall be dressed to bring the top surface of the foundations to the required level, prior to erection of equipment/equipment bases.

34.02.00

All the equipment bases and structural steel base plates, shall be grouted and finished as per these specifications unless otherwise recommended by the equipment manufacturer.

34.03.00

The concrete foundation surfaces shall be properly prepared by chipping, grinding as required to bring the type of such foundation to the required level, to provide the necessary roughness for bondage and to assure enough bearing strength. All laitance and surface film shall be removed and cleaned.

34.04.00

Grouting Mix The Grouting mixture shall be composed of portland cement, sand and water. The portland cement to be used shall conform to ISI No. 269 or equivalent sand shall conform to ISI No. 383/2386 or equivalent. The grout proportions for flat bases where the grouting space does not exceed 35 mm shall be 50 kg bag of cement to 75 kg of sand. Only the required quantity of water shall be added so as to make the mix quaky and flowable and the mix shall not show excess water on top when it is being puddled in place. For thicker grout beds upto 65 mm, the amount of sand shall be increased to 105 Kg per bag of cement. Bases which are hollow and are to be filled full of grouting shall be filled to a level of 25 mm above the outside rim with



PART-D

PAGE 24 OF 33

CLAUSE NO.


a mortar mix in the volumetric proportions of one part of cement and 1.5 part sand and 1.5 part 6 mm granite gravel. An acceptable plasticiser may be added to the grout mixes in a proportion recommended by the plasticisers manufacturer. All such grouts shall be throughly, mixed for not less than five minutes in an approved mechanical mixer and shall be used immediately after mixing. 34.05.00

Placing of Grout

34.05.01

After the base has been prepared, its alignment and level has been checked/approved and before actually placing the grout, a low dam shall be set around the base at a distance that will permit pouring and manipulation of the grout. The height of such dam shall be at least 25mm above the bottom of the base. Suitable size and number of chains shall be introduced under the base before placing the grout, so that such chains can be moved back and forth to push the grout into every part of the space under the base.

34.05.02

The grout shall be poured either through grout holes it provided or shall be poured at one side or at two adjacent sides giving it a pressure head to make the grout move in a solid mass under the base and out in the opposite side. Pouring shall be continued until the entire space below the base is thoroughly filled and the grout stands at least 25 mm higher all around than the bottom of the base. Enough care should be taken to avoid any air or water pockets beneath the bases.

34.06.00

Finishing of the Edges of the Grout The poured grout should be allowed to stand undisturbed until it is well set. Immediately thereafter, the dam shall be removed and grout which extends beyond the edges of the structural or equipment base plates shall be cut off, flushed and removed. The edges of the grout shall then be pointed and finished with 1:2 cement mortar pressed firmly to bond with the body of the grout and smoothed with a tool to present a smooth vertical surface. The work shall be done in a clean and scientific manner and the adjacent floor spaces, exposed edges of the foundations, and structural steel and equipment base plates shall be thoroughly cleaned of any spillage of the grout.

34.07.00

Checking of Equipment After Grouting After the grout is set and cured, the Contractor shall check and verify the alignment of equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as applicable and the like items to ensure that no displacement had taken place during grouting. The values recorded prior to grouting shall be used during such post grouting check- up and verifications. Such pre and post grout records of alignment details shall be maintained by the Contractor in a manner acceptable to the Project Manager.

34.08.00

SHAFT ALIGNMENTS All the shafts of rotating equipment shall be properly aligned to those of the matching equipments to as perfect an accuracy as practicable. The equipment



PART-D

PAGE 25 OF 33

CLAUSE NO.


shall be free from excessive vibration so as to avoid overheating of bearings or other conditions which may tend to shorten the life of the equipment. All bearings, shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated before starting. 35.00.00

DOWELLING All the motors and other equipment shall be suitable dowelled after alignment of shafts with tapered machined dowels as per the direction of the Project Manager.

36.00.00

CHECK OUT OF CONTROL SYSTEMS After completion of wiring,cabling furnished, and terminated,the Contractor shall check out the operation of all control systems for the equipment furnished and installed under these specifications and documents.

37.00.00

COMMISSIONING SPARES

37.01.00

It will be the responsibility of the Contractor to provide all commissioning spares including consumable spares like indicating lights/lamps, diodes, fuses recorder required for initial operation till the equipment is declared by the Employer as having satisfactorily completed the Trial Operation. The Contractor shall have full responsibilities to supply all commissioning spares so that initial operation do not suffer for want of commissioning spares. All commissioning spares shall be deemed to be included in the scope of the Contract and the cost of the same shall be included in the bid price.

37.02.00

These spare will be received and stored by the Contractor atleast 3 months prior to the schedule date of commencement of trial operation of the respective equipment and utilised as and when required.

38.00.00

EQUIPMENT DELIVERY AND ERECTION

38.01.00

General Requirements a)

This part covers Contractor's responsibilities for packing, shipping, warehousing and the installation of all equipment and materials furnished and installed under this specification.

b)

The Contractor shall submit for Employer's approval draft manual for Equipment Delivery and Erection (EDE Manual) covering detailed instructions, check-lists, documentation formats for all activities after equipment manufacture upto installation of equipment. This manual shall cover general instructions for all equipment and specific instructions for individual equipment wherever required and shall include at least the following : 1)

Instructions for packing, shipping, receiving handling, ware-housing and storage.



PART-D

PAGE 26 OF 33

CLAUSE NO.

38.02.00


2)

Instructions for location and installation of equipment furnished by this specification.

3)

Installation drawings for field mounted equipment, panels, cubicles and other equipment covered under this specification.

4)

Instruction relating laying of cables, support and routing drawings of cable trays.

5)

Check lists and quality assurance hold points.

6)

Format for all related documentation.

c)

The EDE Manual shall conform to the requirements of this specification, all applicable codes and standards, recommendations of equipment manufacturers and accepted good engineering practices and shall be subject to Employer approval during detailed engineering.

d)

The Contractor shall ensure that all work under this part shall be performed as per the requirements of this specification, Employer approved EDE Manual and drawing/documents approved by the Employer during detailed Engg.

Crating a)

All equipment and materials shall be suitably coated, wrapped, or covered and boxed or crated for moist humid tropical shipment and to prevent damage or deterioration during handling and storage at the site.

b)

Equipment shall be packed with suitable dessicants, sealed in water proof vapour-proof wrapping and packed in lumber of plywood enclosures, suitably braced, tied and skidded. Lumber enclosures shall be solid, not slatted.

c)

Dessicants shall be either silica gel or calcium sulphate, sufficiently ground to provide the required surface area and activated prior to placing in the packaging. Calcium sulphate dessicants shall be of a chemical nature to absorb moisture. In any case, the dessicant shall not be of a type that will absorb enough moisture to go into solution. Dessicants shall be packed in porous containers, strong enough to withstand handling encountered during normal shipment. Enough dessicant shall be used for the volumes enclosed in wrapping.

d)

Review by the Employer of the Contractor's proposed packaging methods shall not relieve the Contractor of responsibility for damage or deterioration to the equipment and materials specified.

e)

All accessory items shall be shipped with the equipment. Boxes and crates containing accessory items shall be marked so that they are identified with the main equipment. The contents of each box and crates shall be indicated by markings on the exterior.



PART-D

PAGE 27 OF 33

CLAUSE NO.


f)

All boxes, crates, cases bundles, loose pieces, etc. shall be marked consecutively from No.1 upward throughout all shipments from a given port to completion of the order without repeating the same number.

g)

An itemized list of contents shall be kept inside each case and one other copy securely fastened to the outside of the case in a tin or light weight sheet metal envelope or pocket. The lists shall be plainly marked and placed in accessible locations to facilitate receipt and inspection. The packing list shall indicate whether shipment is partial or complete and shall incorporate the following information on each container, etc., according to its individual shipping number : a)

Export case markings

b)

Case number

c)

Gross weight and net weight in Kilograms

d)

Dimensions in centimeters

e)

Complete description of material

h)

Packaging or shipping units shall be designed within the limitations of unloading facilities and the equipment which will be used for transport. Complications involved with ocean shipment and the limitations of ports, railways and roads shall be considered. It shall be the Contractor's responsibility to investigate these limitations and to provide suitable packaging to permit safe handling during transit and at the job site.

i)

Electrical equipment, control and insulations shall be protected against moisture and water damage. All external gasket surfaces and flange faces, couplings etc. shall be thoroughly cleaned and coated with rust preventive compound as specified above and protected with suitable wood, metal or other substantial type covering to ensure their full protection.

j)

Equipment having antifriction or sleeve bearings shall be protected by weather tight enclosures.

k)

Coated surfaces shall be protected against impact, abrasion, discolouration and other damage. Surfaces which are damaged shall be repaired.

l)

All exposed threaded parts shall be greased and protected with metallic or other substantial type protectors. All female threaded openings shall be closed with forged steel plugs. All pipings, tubing, and conduit equipment and other equipment openings shall be sealed with metallic or other rough usage covers and tapped to seal the interior of the equipment piping, tubing, or conduit.



PART-D

PAGE 28 OF 33

CLAUSE NO.

38.03.00


m)

Provisions shall be made to ensure that water does not enter any equipment during shipment or in storage at the plant site.

n)

Returnable containers and special shipping devices shall be returned by the manufacturer's field representative at the Contractor's expense.

o)

While packaging the material, care shall be taken for the limitation from the point of view of availability of railway wagon sizes in India.

Factory Assembly a)

Instrument enclosures shall be supplied and erected completely in the factory with instrument, air supply and blow down piping with necessary valves, fittings, etc. and also all electrical wiring between the instruments and the enclosure terminal blocks. Control panel and cubicles shall also be fully wired in the factory. Control panel mounted equipments are to be dismounted from the panels before shipment and individually packed for shipment. Electronic control modules of the plug-in type are to be removed from equipment racks after factory checkout are individually packed for shipment. Other equipment shall be fully assembled at the factory, except for necessary shipping splits in panels.

b)

All separately packaged accessories items and parts shall be shipped with the equipment. Containers for separately packaged items shall be marked so that they are identified with the main equipment. An itemized packing slip, indicating what is in that carton only, shall be attached to the outside and inside of each container used for packing. A master packing slip covering all accessories items for a given piece of equipment which are shipped in separate containers, shall be attached to one container.

38.04.00

Equipment Installation a)

General Requirements i)

The Contractor shall furnish all construction materials, tools and equipment and shall perform all work required for complete installation of all control and instrument equipment furnished under this specification.

ii)

Contractor shall prepare detailed installation drawings for each equipment furnished under this specification for Employer's approval. Installation of all equipment/systems furnished by this specification shall be as per Employer's approval.

iii)

Erection procedures not specified herein shall be in accordance with the recommendations of the equipment manufacturers. The procedures shall be acceptable to the Employer.



PART-D

PAGE 29 OF 33

CLAUSE NO.


iv)

b)

The Contractor shall coordinate his work with other suppliers where their instruments and devices are to be installed under specifications.

Installation Materials All materials required for installation, testing and commissioning of the equipment shall be furnished by the Contractor.

c)

Regulatory Requirements All installation procedures shall confirm with the accepted good engineering practice and with all applicable governmental laws, regulations and codes.

d)

Cleaning All equipment shall be cleaned of all sand, dirt and other foreign materials immediately after removal from storage and before the equipment is brought to the GIS hall & other installation sites. All piping and tubes shall be air blown.

e)

Equipment Assembly Equipment installed under these specifications shall be assembled if shipped unassembled. The equipment shall be dismantled and reassembled as required to perform the installation and commissioning work described in these specifications.

f)

Equipment Setting Field mounted instruments and accessories shall be bracket or sub panel mounted on the nearest suitable firm steel work or masonry. The brackets, stands, supports and other miscellaneous hardware required for mounting instruments and accessories such as receiver gauge, air set, valve manifold, purge-meter etc. shall be furnished and installed. No field mounted instruments shall be installed such that it depends for support or rigidity on the impulse piping or on electrical connection to it. Indicating type field mounted instruments shall be installed in such a way that centre of indicating dial shall be about 1600-1800mm from operating floor level. Non-indicating type field instruments shall be installed such that operating handle of manifold block/isolating cock comes within 1600 mm from operating floor level. All free standing instrumentation cabinets and panels shall be located within the construction tolerances of +/- 3 mm of the location dimensions indicated on the arrangement drawings.

g)

Free-Standing Equipment



PART-D

PAGE 30 OF 33

CLAUSE NO.


Free-standing Cabinets shall be attached to the floor, concrete equipment bases or supporting steel as indicated on the manufacturer's drawings and the Employer's Arrangement Drawings. The cabinets shall be shimmed for proper alignment before bolting them to the floor. Adjacent enclosures shall be shimmed to maintain mutually level appearance before they are attached to floor. Vibration dampening mounts shall be installed between supporting structures and panels when specified. h)

i)

Non-free Standing Equipment i)

Non-free standing local enclosures and cabinets shall be mounted in accessible locations on columns, walls, or stands in locations as indicated on the Employer's Arrangement Drawings. Bracket and stands shall be fabricated as required to install the local enclosures and cabinets in a workman like manner.

ii)

Rough edges and welds on all fabricated supports shall be ground smooth. The supports shall be finished with two coats of primer and two coats of paint as specified in this part.

Equipment Location i)

All individual items of equipment not located in cabinets or on panels and racks are located approximately according to the floor elevation and the nearest building column designated by the Employer.

ii)

Solenoid valves not located in enclosures or mounted on valves shall be mounted in easily accessible protected locations near the components with which they are associated.

iii)

All brackets, stands, supports and other miscellaneous hardware required for mounting devices shall be furnished and installed. Any required adapting hardware such as pipe bushings, nipples,

iv) j)

k)

Equipment Checkout 1.

All equipment shall be cleaned after installation. Equipment subject to pressure differentials shall be checked for leakage.

2.

After erection, all equipment having moving parts, having electrical apparatus, or subject to pressure differentials shall be trial-operated.

Defects i)

All defects in erection shall be corrected to the satisfaction of the Employer. The dismantling and reassembly of Contractor furnished equipment to remove defective parts, replace parts, or make adjustments shall be included as a part of the work under these specifications.



PART-D

PAGE 31 OF 33

CLAUSE NO.


ii)

l)

The removal of control and instrument equipment in order to allow bench calibration, if required, and the re-installation of the said equipment after calibration shall also be included as a part of the work under these specifications.

Equipment Protection i)

All equipment to be erected under these specifications shall be protected from damage of any kind from the time of contract award until commissioning of each unit.

ii)

The equipment shall be protected during storage as described herein.

iii)

Equipment shall be protected from weld spatter during construction.

iv)

Protective Guards Suitable guards shall be provided for protection of personnel on all exposed rotating or moving machine parts. All such guards with necessary spares and accessories shall be designed for easy removal and maintenance.

v)

Equipment having glass components such as gauges, or equipment having other easily breakable components, shall be protected during the construction period with plywood enclosures or other suitable means. Broken, stolen, or lost components shall be replaced by the Contractor.

vi)

Machine finished surfaces, polished surfaces, or other bare metal surfaces which are not to be painted, such as machinery shafts and couplings shall be provided temporary protection during storage and constructional periods by a coating of a suitable non- drying, oily type, rust preventive compound.

39.00.00

CABLING

39.01.00

All cables shall be supported by conduits or cable tray run in air or in cable channels. These shall be installed in exposed runs parallel or perpendicular to dominant surfaces with right angle turn made of symmetrical bends for fittings. When cables are run on cable trays, they shall be clamped at a minimum intervals of 2000mm or otherwise as directed by the Project Manager.

39.02.00

Each cable, whether power or control, shall be provided with a metallic or plastic tag of an approved type, bearing a cable reference number indicated in the cable and conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at both ends of the cable adjacent to the terminations. Cable routing is to be done in such a way that cables are accessible for any maintenance and for easy identification.



PART-D

PAGE 32 OF 33

CLAUSE NO.


39.03.00

Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the cable. Installation of other cables like high voltage, coaxial, screened, compensating, mineral insulated shall be in accordance with the cable manufacturer’s recommendations. Wherever cables cross roads, wall, water, oil, sewage etc, special care should be taken for the protection of the cables in designing the cable channels.

39.04.00

In each cable run some extra length shall be kept at a suitable point to enable one or two straight through joints to be made, should the cable develop fault at a later date.

39.05.00

Control cable terminations shall be made in accordance with wiring diagrams, using identifying codes subject to Project Manager’s approval. Multicore control cable jackets shall be removed as required to train and terminate the conductors. The cable jacket shall be left on the cable, as far as possible, to the point of the first conductor branch. The insulated conductors from which the jacket is removed shall be neatly twined in bundles and terminated. The bundles shall be firmly but not tightly tied utilising plastic or nylon ties or specifically treated fungus protected cord made for this purpose. Control cable conductor insulation shall be securely and evenly out.

39.06.00

The connectors for control cables shall be covered with a transparent insulating sleeve so as to prevent accidental contact with ground or adjacent terminals and shall preferably terminate in Elmex terminals and washers. The insulating sleeve shall be fire resistant and shall be long enough to over pass the conductor insulation. All control cables shall be fanned out and connection made to terminal blocks and test equipment for proper operation before cables are corded together.

40.00.00

TESTING EQUIPMENT & FACILITIES Contractor shall provide the testing equipment and facilities necessary to carryout tests & inspections.



PART-D

PAGE 33 OF 33


TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4 X 130 MW)

400 KV SWITCHYARD PACKAGE SECTION – VI PART – E TENDER DRAWINGS BID DOCUMENT NO. : CS-5505- 500-2 CONSULTANT: Central Electricity Authority Sewa Bhavan, R. K. Puram, New Delhi-110066.

CLAUSE NO.

TENDER DRAWINGS

LIST OF TENDER DRAWINGS The following Tender drawings are enclosed with these specifications:

Sl. No

NTPC Drawing no.

1.

5505-500-PEH-A-001

General Project layout

2.

5505-500-PEH-A-002

Project Location Map and Accessibility

3.

5505-500-PEH-A-003

General Layout plan of Power House

4.

5505-500-PEH-A-004

Power House Cross - Section.

5.

5505-500-PEH-A-005

Power House Layout Plan at EL1289.0m.

6.

5505-500-PEH-A-006

Single Line Diagram of 400 KV GIS/AIS Switchyard.

7.

5505-500-PEH-A-007

400KV Switchyard Protection SLD – Line bay

8.

5505-500-PEH-A-008

400KV Switchyard – Bus Coupler Bay

9.

5505-500-PEH-A-009

400KV Switchyard Protection SLD – GT bay

10.

5505-500-PEH-A-010

400KV Switchyard Relay & protection room layout

11.

5505-500-PEH-A-011

Protection Single line Diagram for Hydro Generator, GT, SAT and UAT

12.

5505-500-PEH-A-012

GIS Layout Plan at EL 1300.00m.

13.

5505-500-PEH-A-013

Pothead Yard Layout Plan & Sections


Title


PART-E

Protection

SLD

CONTENTS

PART - F

LIST OF MANDATORY SPARES


TECHNICAL SPECIFICATION SECTION-VI PART-F

CLAUSE NO.

Sl.No.


Item

Quantity

1.00.00

400 KV GIS

1.01.00

SF6/XLPE cable terminations complete gasket and connectors.

1.02.00

420 kV, single phase 2500 A Circuit breaker One No complete with operating mechanism all necessary apparatus and preinsertion resistors etc. for line breakers.

1.03.00

420 kV, three phase 2500 A Disconnecting switch One No. complete with operating mechanism & all necessary apparatus etc.

1.04.00

420 kV, Safety grounding switch complete with One no operating mechanism, all necessary connecting apparatus etc..

1.05.00

420 kV, single phase 2500 A Circuit breaker One No complete with operating mechanism, all necessary apparatus for Generator Transformer feeder.

1.06.00

420 kV three phase high speed fault making One set grounding switch complete with operating mechanism, and all necessary apparatus etc.

1.07.00

400 KV Single phase VT complete accessories of connectors etc.

1.08.00

420 kV Current transformer

1.09.00

400 KV Class, single phase, SF6 gas insulated zinc Three Nos. oxide surge arrestors.

1.10.00

Gas monitoring devices necessary accessories

1.11.00

Control switches control relays

One set consisting of each type & rating

1.12.00

Control circuit fuses

10% of total population

1.13.00

Pilot lamp bulbs

10% of total population

1.14.00

Closing coils of each type and rating for 420 kV Six Nos. circuit breakers.


with

with One No.

all One

Two Nos. of each type & rating

complete

with


all Three Nos. of each type and rating

PART - F

PAGE 1 OF 4

CLAUSE NO.


1.15.00

Trip coils of each type & rating for 420 kV circuit Six Nos. breakers.

1.16.00

Spare auxiliary contacts for disconnecting and One set of each type safety grounding switches.

1.17.00

MCB

One set consisting of one no. of each type & rating.

1.18.00

Semaphore

Six Nos.

2.00.00

ISOLATORS

2.01.00

One complete pole of HCB Isolator with 2 E/S along with operating mechanisms, etc. (without support structure)

1 no.

2.02.00

Copper contact fingers for female contacts

3 nos.

2.03.00

Relay, power contactors, switch fuses for electrical control circuit (one no. of each type and rating)

1 set

2.04.00

Support insulator stack for one pole of isolator

1 no.

2.05.00

Rotary bearings for isolator

3 nos. of each type

2.06.00

Limit switch & aux. switch

3 nos. of each type

2.07.00

Terminal connectors

1 no. of each type

3.00.00

CURRENT TRANSFORMERS

3.01.00

400 KV CURRENT TRANSFORMER complete in 2 Nos. all respects including terminal connectors, common box etc. (excluding structure).

4.00.00

CAPACITIVE VOLTAGE TRANSFORMERS

4.01.00

400 KV CAPACITOR VOLTAGE TRANSFORMER complete in all respects including terminal connectors common box etc. (excluding structure).

4.01.01 4.01.02

8800 pF

2 Nos.

4400 pF

2 Nos.

5.00.00

SURGE ARRESTERS

5.01.00

390 KV SURGE ARRESTER complete in all 1 No. respects with surge counter, terminal connector



PART - F

PAGE 2 OF 4

CLAUSE NO.

LIST OF MANDATORY SPARES etc. (excluding structure).

5.01.02

Portable Leakage current analyzer (for Gapless 1 no. Surge Arrester) based on third harmonic analysis of leakage current with compensation

6.01.00

EACH TYPE OF CLAMPS, CONNECTORS, 10% of total CORONA BELL & SPACERS

6.02.00

Insulator strings & Hardware

7.00.00

SUBSTATION AUTOMATION SYSTEM

7.01.00

Bay Control unit (complete with all components)

2 Nos.

7.02.00

Numerical Relays protection units

1 No. of each type

7.03.00

Numerical Relays comprising GRP

1 No. of each type

7.04.00

Interface relays used in the system

10% of each type of total population (min 1 no.)

7.05.00

Cards/modules of Generator Recorder, Line DR ( if stand-alone)

7.06.00

Operator work station (OWS) along with software, monitor, mouse, keyboard ,printer,etc. 1 No.

7.07.00

Complete Network Controller / Server along with software 1 No.

7.08.00

Complete Programming software, monitor etc.

7.09.00

Hard Disks for OWS

7.10.00

Hard Disk for Network Controller / Server (if 1 No. applicable)

7.11.00

Lamps / LEDs used in the system

100% of Total Quantity

7.12.00

Power supply modules used in the system

2 nos. of each type

7.13.00

LAN switches (If included in main package)

1 No. of each type

7.14.00

Media cleaning solution

2 bottles

7.15.00

Fuses

7.16.00

Terminal Blocks

100% of each type and rating 5 nos. of each type, make, model and rating

7.17.00

Interfacing pre-fab cables ,one of each type of 2 Sets cable with its connector for each type of peripheral MCBs 50% of each type, make and model used in the system

7.18.00


3 sets of each type

comprising

station

various

bay

Disturbance 1 No. of each type

along

with

1 No. 1 No.


PART - F

PAGE 3 OF 4

CLAUSE NO.


7.19.00

RELAYS OTHER THAN NUMERICAL RELAYS

1 no. of each type

7.20.00

GATEWAYS

1 no. of each type

7.21.00

MODEM

1 no. of each type

7.22.00

LIU OF OFC INCLUDING NECESSARY CONNECTORS

1 no. of each type



PART - F

PAGE 4 OF 4


TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4X130 MW)

400 KV SWITCHYARD PACKAGE TECHNICAL DATA SHEET SECTION - VII ATTACHMENT-12 BIDDING DOCUMENT NO. CS-5505-500-2 CONSULTANT : Central Electricity Authority Sewa Bhawan, R.K. Puram, New Delhi-110066

AUGUST - 2007

CONTENTS

TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT-12 -----------------------------------------------------------------------------------------------------------------------------------SUB-SECTION DESCRIPTION ------------------------------------------------------------------------------------------------------------------------------------

CHAPTER E-I


CHAPTER E-2

ISOLATORS

CHAPTER E-3


CHAPTER E-4

SURGE ARRESTERS

CHAPTER E-5

INSULATORS

CHAPTER E-6

WAVE TRAPS

CHAPTER E-7

LIGHTING

CHAPTER E-8

LT SWITCHGEAR & DISTRIBUTION BOARDS

CHAPTER E-9

CABLES

CHAPTER E-10

SUBSTATION AUTOMATION SYSTEM (SAS)

CHAPTER E-11

DC SYSTEM

CHAPTER E-I2

SWITCHYARD AUXILIARY ITEMS


TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT - 12

CONTENTS

PAGE 1 OF 1

CHAPTER - E1 GAS INSULATED SWITCHGEAR



CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... I.

GIS MODULE The bidder shall submit with his bid the following technical particulars for the 420KV gas-insulated switchgear and accessories, complete with any additional data which, in bidder’s opinion, will describe the merits of the equipment offered. 1.

Name of manufacturer & address

………………………….

2.

Place of manufacture, inspection & testing

………………………….

3.

Manufacturer’s type / designation

………………………….

4.

Standard applicable

………………………….

5.

Rated voltage

………………………….

6.

System frequency

………………………….

7.

Maximum (continuous) service rated voltage

………………………….

8.

Single phase or three phase design

………………………….

9.

Normal current rating

………………………….

-

Generator Transformer feeder circuit

Amp.

i)

Line feeder circuit

Amp.

ii)

Bus coupler circuit

Amp.

iii)

Bus bars

Amp.

10.

Rated peak withstand current

11.

Short time current rating

KA

-

1 second rms.

kA

-

3 second rms.

kA

12.

Rated Lightning impulse withstand voltage

…………….kV (peak)

13.

Rated Switching impulse withstand voltage




CHAPTER - E1

PAGE 1 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... 14.

Rated one minute power frequency withstand voltage


15.

Maximum temperature rise over ambient

deg. C.

16.

Thermal rating of current carrying parts at 420 KV for the rated symmetrical short circuit current

Sec

17.

Altitude upto which the switchgear shall operate satisfactorily (m)

……………………..…

18.

Ambient conditions of the operation of the GIS (oC)

………………………….

19.

Earthing details of enclosure

………………………….

20.

-

Features adopted for preventing burn through in the various enclosures of SF6 GIS

………………………….

-

Time in m sec to withstand an ……………………… internal flashover without burn through

21.

22.

Guaranteed number of loaded/unloaded operations of various equipments of SF6 GIS

………………………….

a)

circuit breakers,

………………………….

b)

disconnectors,

………………………….

c)

grounding switches etc

………………………….

Design pressure of the enclosures for a) Circuit breakers

………………………….

b) Disconnectors

………………………….

c) Surge arresters etc.

………………………….

d) GIS duct

………………………….

e) VT

……………………………

f)

……………………………

CT



CHAPTER - E1

PAGE 2 OF 43

CLAUSE NO


24.

25.

Type test pressure of the enclosures a)

Circuit breakers

………………………….

b)

Disconnectors

………………………….

c)

Surge arresters etc

………………………….

d)

GIS duct

………………………….

e)

VT

………………………….

f)

CT

………………………….

Routine test pressure of enclosure a)

Circuit breakers

………………………….

b)

Disconnectors

………………………….

c)

Surge arresters etc

………………………….

d)

GIS duct

………………………….

e)

VT

………………………….

f)

CT

………………………….

Operating pressure of pressure relief valve a)

Circuit breakers

………………………….

b)

Disconnectors

………………………….

c)

Surge arresters etc

………………………….

26.

Maximum permissible gas dew point

………………………….

27.

No of gas compartments

………………………….

a)

Each line bay

………………………….

b)

Each Generator bay

………………………….

c)

Bus coupler bay

………………………….



CHAPTER - E1

PAGE 3 OF 43

CLAUSE NO


a)

Average leakage rate of SF6 gas

b)

Quantity of SF6 gas required to completely charge the 3-pole equipment including any tank storage system

c)

Quantity of SF6 gas required for largest gas compartment

(Kg)…..Compartment

Operating pressure

bar

d)

29.

Circuit breaker

………………………….

-

Others

………………………….

-

CT

………………………….

-

VT

………………………….

-

Disconnector

………………………….

-

SA

…………………………..

…………………………..

Lightning Impulse withstand value (kVp)

…………………………..

Switching Impulse withstand value (kVp)

…………………………..

Type and material of bus bar support insulator

…………………………..

Creepage distance adopted for GIS cable termination bushing (mm)

…………………………..

(c)

32.

-

Power frequency 1 min. withstand value (kV)

(b)

31.

(Kg)

Dielectric withstand voltage of complete GIS assembly (a)

30.

…………….……%/year

Details of the features existing in the equipment to carry out P.D. measurements at works/site



………………………….

CHAPTER - E1

PAGE 4 OF 43

CLAUSE NO


Details of the control wiring used in the equipment

………………………….

34.

The extent of field welding required for site assembly, if any alongwith the procedure to be adopted by the firm at site

………………………….

35.

Details of the documents, drawings & photographs enclosed showing the basic operating principles of the major components of the equipment, presenting a clear picture of the fundamental principle, general arrangements and operating mechanism

Yes/No

36.

Details of the flow diagram/ drgs. enclosed showing all valves and pressures involved, for the hydraulic and gas system, or both

Yes/No

37.

Details of the test data enclosed including test data of the parts indicating the ability of the equipment (including high speed grounding switches)

Yes/No

38.

The values of resistors inserted in the line ………………ohms/pole circuit breaker during closing operations, if any, alongwith the length of time the resistors are left in the circuit.

39.

Values of maximum switching surges generated

40.

Methods adopted to limit switching surges …………………………. for breaker and disconnectors

41.

Heat generated in K.W. when the complete switchgear is operating at its rated capacity

42.

a)

b)


Seismic level for which GIS is designed Noise level in (dB) at distance of (m)


………………………….

………………………….

. …………………………. ………………………….

CHAPTER - E1

PAGE 5 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ......................................

43.

i)

0

………………………….

ii)

50

………………………….

iii)

100

. ………………………….

iv)

150

………………………….

Type and Material of a)

Breaker main contact.

………………………….

b)

Disconnecting switch contact

………………………….

c)

Grounding switch contact

………………………….

d)

Busbars

………………………….

e)

Internal bus contact.

………………………….

f)

Enclosure.

………………………….

g)

Terminal pads.

………………………….

44.

Details of provisions made for movement of maintenance personnel on the equipment

…………………………..

45.

Capacitance per metre of the enclosed bus

.......................pF/ metre

46.

Inductance

.................................H/m

47.

Surge impedance in ohms of the enclosed bus (The bidder should furnish the method used for the calculations of surge impedance and capacitance of insulated bus).

…………………….. ohm

48.

a)


Electric resistance at 75 deg C in ohms/metre. -

Bus enclosure

………………………….

-

Internal bus

………………………….


CHAPTER - E1

PAGE 6 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... b)

49.

50.

51.

52.

53.

Data used for calculation of electric resistance in (a) -

Cross sectional area of bus …………………………. conductor

-

Cross sectional area of bus …………………………. enclosure.

-

Conductivity of material of bus …………………………. conductor

-

Conductivity of material of bus …………………………. enclosure.

-

Current density in bus conductor.

………………………….

Maximum power losses in the bus bar per single phase meter at rated voltage and current at 20oC in a)

Enclosure

W

b)

Conductor

W

Dimensions a)

Bus enclosure outside diameter

(mm)

b)

Bus enclosure wall thickness

(mm)

c)

Internal bus, outside diameter

(mm)

d)

Internal bus thickness

(mm)

Capacity & filling ratio of containers in which SF6 gas would be shipped (m3) and the corresponding pressure (Kg/cm2)

………………………….

Whether GIS are despatched filled with SF6 or required to be filled at site

………………………….

Type and make of SF6 pipe coupling used

........................................



CHAPTER - E1

PAGE 7 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... 54

Type and make of mandatory maintenance equipment to be supplied i)

SF6 gas filling and evacuation plant (portable)

.......................................

SF6 gas filtering, drying, storage and recycling plant

......................................

iii)

Operation analyser

.......................................

iv)

SF6 gas leak detector

.......................................

v)

Gas analyzing equipments

......................................

ii)

55.

56.

Type and material of gaskets used to ensure gas tight joints

………………………….

a)

Type and make of

.......................................

i)

Densimeter

........................................

ii)

Pressure gauge

.......................................

b)

57.

......................................

Densimeter settings

.......................................

i)

Lockout

.......................................

ii)

Alarm

......................................

Whether the following are enclosed a)

Type test reports

Yes/No

b)

Operation manual for equipments

Yes/No

c)

Details of SF6 gas filling, evacuating, filtering, drying storage & recycling plant

Yes/No

Details of SF6 gas leak detector

Yes/No

e)

Details of operations Analyser

Yes/No

f)

SF6 gas analyzing equipment

Yes/No

d)



CHAPTER - E1

PAGE 8 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... g)

Leaflets & literature bringing out salient feature s of equipment offered

Yes/No

58.

Details of equipments and procedure for conducting site test (including power frequency. test) of the bay module as per IEC

59.

Length of longest section for transportation …………………….. mm

60.

Weight of the heaviest piece of equipment to be handled during installation on site.

61.

62.

………………………….

………………………. Kg

The weight of each assembled bay to be indicated separately

(Kg)

SF6 GAS 1.

Name of manufacturer & address

………………………….

2.

standard applicable

………………………….

3.

Electrical properties(please give details)

………………………….

4.

Compatibility with material used in switchgear

………………………….

5.

Impurities in percentage (please mention details of impurities)

………………………….

6.

Condensation temperature

………………………….

7.

Physical properties (please give details)

………………………….

8.

Certification that gas meets the requirement of all the properties

………………………….

9.

Tests to be conducted by the manufacturer at works

………………………….

10.

Tests proposed to be conducted ………………………. at site to detect and limit the moisture content in gas compartments



CHAPTER - E1

PAGE 9 OF 43

CLAUSE NO


Gas Monitoring Devices “Details of the sketches enclosed showing the type and location of gas density, gas pressure, gas moisture content and other fault monitoring devices to be supplied.

63.

Whether the common point of bus disconnectors alongwith Earth Switch has been brought out in a separate compartment

Yes/No

Yes/No

64

Whether details of recommended arrangement for Cable/SF6 gas termination gas enclosed

Yes/No

65.

Whether details of recommended arrangement for oil/SF6 gas termination enclosed

Yes/No

66.

Whether provision exists for extensive of busbars on both ends

Yes/No

67.

Whether arrangement provided for easy dismanting of cable/SF6 & oil/SF6 terminations in case of maintenance

Yes/No

68.

Details of arrangement provided to account for thermal expansion for busbars enclosed

Yes/No

69.

Details of earthing arrangement adopted for the GIS enclosed

Yes/No

Whether layout plan sections of each bay/equipment of GIS/AIS indicating the complete arrangement enclosed

Yes/No

70.



CHAPTER - E1

PAGE 10 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... II.

EQUIPMENTS INCLUDED IN GIS

A.

Circuit Breaker 1.

III.

Name plate data a.

Manufacturer’s name

………………………….

b.

Type / designation

………………………….

c.

Standard applicable

………………………….

d.

Rated frequency

Hz

e.

Rated voltage

kV

f.

Rated current i)

Under normal condition

--------------------------kA

ii)

Under site condition

------------------------- KA

g.

Number of poles per unit

………………………….

h.

Class (indoors)

………………………….

i.

Number of interrupting chambers per pole (No of breaks per pole)

………………………….

j.

Whether 3 pole or single pole design

………………………….

k.

Maximum Operating Voltage Breaking Capacity

…………………….….kV

GUARANTEED RATINGS A)

Making & Breaking

1.a)

Breaking Capacity -

Rated short circuit breaking Current KA(rms)

……………………… KA

-

Symmetrical component at highest system voltage

……………………… KA



CHAPTER - E1

PAGE 11 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... -

DC Component (%)

………………………….

-

Asymmetrical breaking current at highest system voltage

………………………. KA

-

Rated breaking MVA (Symmetrical)

kA(rms)

Breaking time

secs.

b)

Making Capacity -

Rated making current

-

Rated making MVA symmetrical

2.

3.

………………………

Making time

secs

Operating voltages of closing/opening coil -

Maximum operating voltage

V

-

Minimum operating voltage

V

Current ratings Rated continuous current at 400C ambient temp.

A

-

Rated interrupting current for 1s,

kA

-

Rated symmetrical interrupting current

kA

Rated asymmetrical interrupting current

kA

Rated short circuit making current

kA (peak)

-

4.

kA

Rated Insulation level a)

One minute dry power frequency withstand voltage i)


………………………….

Between live terminal and ground (kV rms) TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT - 12

.......................................

CHAPTER - E1

PAGE 12 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... ii)

b)

ii)

ii)

e)

f)

.......................................

Between terminals with breaker contacts open (kV peak)

......................................

........................................

Between live terminal and ground (kV peak)

.......................................

Between terminals with breaker contacts open (kV peak)

.......................................

kV

Minimum allowable moisture content in interrupting medium

ppm/vol.

Maximum total break time for any current upto rated breaking current (ms)

ii)


Between live terminal and ground (kV peak)

Line to ground power frequency withstand voltage at gas pressure equivalent to atmospheric pressure

i)

g)

.......................................

250/2500 micro second impulse switching surge withstand test voltage i)

d)

......................................

1.2/50 micro second impulse withstand test voltage i)

c)

Between terminals with breaker contacts open (kV rms)

For Test duties 2,3 & 4 at rated values

.......................................

........................................

For other duties at limiting conditions of voltage and pressure ........................................

Closing time


………………………….

CHAPTER - E1

PAGE 13 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... h)

i)

j) 5.

6.

Minimum opening time under any condition with limiting voltage and pressure (ms)

.......................................

Maximum opening time under any condition with limiting voltage and pressure (ms)

.......................................

First pole to clear factor

........................................

Maximum temperature rise above ambient at rated load and voltage for -

Contacts

deg C

-

Hottest part

deg C

Operating data -

Rated operating duty cycle a)

Line Breakers

………………………….

b)

Generator Transformers, & Bus Coupler Breakers

………………………….

-

Reclosing duty cycle (Line Breakers) ………………………….

-

Permissible tripping delay

-

Maximum arc duration at

ms

a)

10% rated breaking current

ms

b)

30% — do—

ms

c)

60% — do—

ms

d)

100% — do—

ms

-

Closing time,

ms

-

Total breaking time at

ms


a)


b)

30% — do— TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT - 12

…………………………. ms

CHAPTER - E1

PAGE 14 OF 43

CLAUSE NO


-

c)

60% — do—

ms

d)

100% — do—

ms

e)

Arc duration from separation of arc at contact to instant of arc extinction for full rated interrupting capacity.

ms

Length of arc at a)


mm

b)

30%

— do—

mm

c)

60%

— do—

mm

d)

100% — do—

mm

e)

Max. length of arc at lowest fault current

mm

-

Longest time to interrupt current less than 25% of rated symmetrical short circuit current from energizing trip circuit

ms

-

Minimum time from arc extinction to contact remake for auto reclosing.

ms

-

Minimum dead time for a)

3 phase reclosing

ms

b)

1 phase reclosing

ms

-

Maximum difference of time at opening of series contacts within one pole

ms

-

Maximum difference of time at opening between phases

ms

-

Maximum difference of time at closing between phases

ms

-

Details of the curve enclosed for …………………………. maximum opening time vs. 3 phase fault current



CHAPTER - E1

PAGE 15 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... -

Number of interruptions before …………………………. scheduled maintenance is required

-

Number of mechanical operations before scheduled maintenance is required

………………………….

-

Number of interruptions at rated S.C. current with associated TRV without changing any parts.

………………………….

-

Description and frequency of scheduled maintenance required

………………………….

-

Recovery voltage rate of rise at a)

b)

Rated symmetrical interrupting current

kV/ms

60 percent of rated symmetrical interrupting current

kV/ms

c)

30 percent of rated symmetrical interrupting current

kV/ms

d)

10 percent of rated symmetrical interrupting current data for Restrike voltage

kV/ms

-

Amplitude factor

………………………….

-

Phase factor

………………………….

-

Natural frequency

-

Rate of rise of restriking voltage

-

Devices used for controlling RRRV ………………………….

-

Devices used for uniform voltage distribution

-

Distribution of voltage across breaks ………………………….

-

Pre-insertion resistor (if applicable) ....................................... i)


Value / pole (Ohms)/with tolerance TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT - 12

(Hz) ………………………….

………………………….

........................................

CHAPTER - E1

PAGE 16 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... ii)

iii)

-

7.

........................................

Thermal rating for the C-1m-0-CO-2m-C-1m-O-CO for terminal fault considering maximum resistance and time setting ........................................

Recovery voltage distribution …………………………. between breaks in percent of rated voltage a)

Single line to ground fault

………………………….

b)

Interruption of short lines

………………………….

c)

Switching off an unloaded transformer

………………………….

Operating Mechanism

………………………….

a)

Type of operating mechanism for

. ………………………….

i)

Closing

.......................................

ii)

Opening

.......................................

b)

7.1.

Minimum and maximum duration of insertion per pole (ms)

Normal power consumption (w) at rated voltage of

.......................................

i)

Trip coil

.......................................

ii)

Closing coil

.......................................

Pneumatic operating mechanism a)

b)


........................................

Rated operating pressure (kg/sq.cm)

.......................................

Rated of pressure for (kg/sq.cm)

........................................

i)

Closing

........................................

ii)

Opening

........................................


CHAPTER - E1

PAGE 17 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... c)

d)

e)

f)

g)

h)

i)

Air Consumption at rated pressure for i)

Closing (m3)

........................................

ii)

Opening (m3)

.......................................

iii)

Close -Open (m3)

.......................................

Pressure drop/metre length of piping

........................................

Number and Capacity (m3) of breaker local air storage receivers

........................................

No. of close operations for which sufficient air as available in local receiver

........................................

Capacity of compressor (m3/hr) and working pressure (kg/cm2)

........................................

Maximum time for which compressor can operate continuously (Minutes)

........................................

Time to fill

........................................

i)

ii)

j)

k)


.......................................

Air receiver after one C-O operation (Minutes)

........................................

For making up of losses occuring in 4 hours (Minutes) .......................................

Pressure at which compressor

........................................

i)

Starts (kg/cm2)

.......................................

ii)

Stops (Kg/cm2)

........................................

Material of compressed air piping TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT - 12

........................................

CHAPTER - E1

PAGE 18 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... l)

Inner & outer dia of piping (mm)

........................................

Whether time totaliser for the compressor provided

........................................

n)

Safety valve blow off at (Kg/Cm2)

........................................

o)

Alarm switch closes (Kg/Cm2)

........................................

i)

Closing

........................................

ii)

Opening

........................................

iii)

Auto reclose

........................................

m)

7.2

Hydraulic operating mechanism a)

........................................

Rated pressure of oil in operating cylinder (Kg/cm2)

........................................

b)

Limits of pressure (Kg/cm2)

........................................

c)

Quantity of oil (litre)

........................................

d)

Details of monitoring arrangement for hydraulic pressure

........................................

No. of close-open operation possible after loss of AC supply to drive motor

.......................................

Pressure drop starting from lowest pressure at which motor starts for

........................................

i)

C-operation

........................................

ii)

O-operation

........................................

iii)

CO-operation

........................................

iv)

O-CO-operation

.......................................

v)

2CO-operation

........................................

e)

f)



CHAPTER - E1

PAGE 19 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... g)

h)

7.3

9.

........................................

i)

C-operation

........................................

i)

O-operation

........................................

iii)

CO-operation

........................................

iv)

O-CO-operation

........................................

v)

2CO-operation

........................................

Life expectancy & guaranteed leakage rate of nitrogen accumulators

........................................

Spring charged mechanism a)

8.

Time required to make up pressure upto loss of nitrogen pressure after

........................................

Number of close open operations possible after failure of AC supply to motor

.......................................

b)

Time required for motor to charge the closing spring (minutes) ........................................

c)

Whether indication of spring charged condition provided in central control cabinet

........................................

Motor Data a)

Type

........................................

b)

Rating at site conditions (kW)

......................................

c)

Rated voltage (V)

.......................................

d)

Full load current (A)

.......................................

SF6 gas system -

Normal operating pressure

bar

-

Normal operating density

g/cc



CHAPTER - E1

PAGE 20 OF 43

CLAUSE NO


10

11.

12.

-

Weight of gas per breaker

Kg

-

Lockout pressure

bar

-

Alarm pressure

-

Whether breakers work at single pressure or dual pressure

-

Type of SF6 gas flow(axial or radial) ………………………….

-

Type of nozzles (single flow or double flow)

………………………….

-

Compression ratio for puffer action

………………………….

-

Quantity of compressed gas for puffer action

………………………….

-

Total volume of SF6 gas required per circuit breaker at operating pressure.

………………………….

………………………….

Control power requirement -

Tripping(3poles)current at rated supply voltage (220 V.D.C.)

A

-

Closing(3 poles) current at rated supply voltage (220 VDC)

A

-

Tripping voltage range percent

…………………………

-

Closing voltage range percent

…………………….……

Heaters -

Continuously current rating

A

-

Thermostat power rating

A

Noise level in (dB) at distance of (m) i)

0

........................................

ii)

50

........................................

iii)

100

........................................

iv)

150

......................................



CHAPTER - E1

PAGE 21 OF 43

CLAUSE NO


Interrupters -

Type of main contacts, arcing contacts & Aux. contacts.

........................................

-

Material of main contacts/arcing contacts, silver coated or not

........................................

-

Contact pressure Kg/sq mm

........................................

-

Number of interrupters per pole

........................................

-

Breaker length of an interrupter

mm

-

Length of contact travel

mm

-

Rate of contact travel at tripping

m/sec

-

Rate of contact travel at closing

m/sec

14.

Whether fixed trip or trip free

........................................

15.

Details of anti pumping device

........................................

16.

Maximum line charging breaking current with temporary over voltage up to 1.4 p.u. (kA)

........................................

17.

Rated small capacitive breaking current

........................................

18.

Rated small inductive breaking current

........................................

-

........................................

Generator transformer, Line & Bus coupler breakers

19.

Rated characteristics for short line fault

........................................

20.

a)

Rated transient recovery voltage for terminal faults

........................................

b)

Parameters as per IEC

........................................

21.

Rated value of phase making current

22.

Max. interrupting capacity under phase opposition conditions



kA(rms) …………………….……

CHAPTER - E1

PAGE 22 OF 43

CLAUSE NO


Maximum breaking Capacity under Kilimeteric faults and rated TRV characteristic (kA peak)

........................................

Maximum period between closing of first contact & last contact in a pole (ms)

........................................

25.

Maximum pole discrepancy (ms)

........................................

26.

Capacity for interrupting in-rush current of transformer

........................................

27.

Max. over voltage factor of the circuit breaker when switching off

........................................

a)

Unloaded transformer

........................................

b)

Loaded transformer

........................................

c)

Open circuited lines

........................................

d)

Synchronous system

........................................

24.

28.

Details of operation counter

29.

a)

b)

........................................

Number of auxiliary contacts per pole provided

........................................

i)

NO

........................................

ii)

NC

........................................

iii)

Adjustable

........................................

Rated voltage of auxiliary contacts (V)

.......................................

c)

Current capacity of Aux. contacts

i)

Continuous (Amps)

.......................................

ii)

DC breaking with 20 ms time constant (A)

........................................



CHAPTER - E1

PAGE 23 OF 43

CLAUSE NO



Pico-coulombs

31.

Radio interference level at 266 kV (rms)

microvolt

32.

Maximum impact loading on foundation during breaker operations under fault conditions.

Kg

33.

34.

i)

Closed conditions

........................................

ii)

Open conditions

........................................

Seismic withstand value

........................................

i)

Vertical

........................................

ii)

Horizontal

........................................

Tests to be conducted by the supplier at works (All details to be given)

........................................

a)

Type tests

........................................

b)

Routine tests

........................................

35.

Tests to be conducted at site

........................................

36.

Overall dimensions (LxBxH),

m

37.

Weight of breaker complete with operating mechanism, bushing, frame work,

Kg

a)

with SF6 gas

........................................

b)

without SF6 gas

........................................

38.

Descriptive bulletins and drawings of the circuit breakers giving general details of construction.

........................................

39.

Out of phase switching capability of the circuit breaker

........................................

40.

Comments regarding the suitability of the circuit breaker for restrike free operation of power transformer carrying full load current.

........................................



CHAPTER - E1

PAGE 24 OF 43

CLAUSE NO


Guaranteed time difference between the first pole and last pole operation timing.

42.

Data on operating Coils

ms

(a)

No. of trip coils/pole (No.)

…………………………….

(b)

No. of close coils/pole (No.)

…………………………….

43.

Details of the standard accessories to be supplied alongwith the breaker

........................................

44

No. of the enclosed drg. showing the control scheme of circuit breaker

........................................

45

Details of the provision to be made on ……………………… GIS to reduce H.V. transients to acceptable values.

46.

Guaranteed degraded values of B.I.L. switching surges and 50 Hz rated values during the life of equipment (Test data to support this guarantee to be enclosed by the bidder).

47.

(Whether the following are enclosed)

………………………

a)

Type test reports

Yes/No

b)

Operation manual for breaker

Yes/No

c)

OGA drawing of breaker

Yes/No

B)

Disconnectors/Grounding Switches

B-I

Disconnector Switches 1.

Manufacturer’s name & address

…………………………..

2.

Type & designation

…………………………..

3.

Standard applicable

…………………………..

4.

Rated Frequency

…………………………..



CHAPTER - E1

PAGE 25 OF 43

CLAUSE NO


Whether all the 3 poles are gang operated …………………………..

6.

Rated voltage

7.

…………………………..

i)

Rated

ii)

Max. permissible

…………………………..

Dielectric with-stand capacity of Completely assembled DS and earth switch

.......................................

a)

kV

One minute power frequency withstand test voltage (kV) rms i)

b)

against ground (kV peak)

.......................................

-

.......................................

1.2/50 micro second impulse withstand test voltage ....................................... i)

ii)

c)

ii)

8.


.......................................

across open contacts (kV peak) .......................................

250/2500 micro second switching surge withstand test voltage (dry) i)

d)

dry (kV rms)


.......................................

across open contacts (kV peak) .......................................

Radio interference level ------------------------------at 1.1 x Um/θ3 (in micro volts) for frequency between 0.5 MHz to 2.0 MHz

Rated normal current



CHAPTER - E1

PAGE 26 OF 43

CLAUSE NO


-

Generator Transformer module

A

-

Line module

A

-

Bus coupler module

A

9.

Rated peak short circuit current

kA

10.

Interruption of loop current

A/V

11.

a)

b)

c)

d)

Rated short time current of DS

.......................................

i)

for 1 sec. (kA rms)

.......................................

ii)

for 3 sec. (kA rms)

.......................................

iii)

Dynamic current

.......................................

Opening time of

.......................................

i)

DS (sec)

.......................................

ii)

Earth switch (sec)

.......................................

Closing time of

.......................................

i)

DS (sec)

.......................................

ii)

Earth switch (sec)

.......................................

Temperature rise over 40oC ambient temperature corresponding to maximum continuous current (oC)

.......................................

12.

Rated peak withstand current

kA (peak)

13.

Rated inductive breaking current

A

14.

TRV caused by breaking/making inductive current

kV

Rated capacitive breaking current

A

15.



CHAPTER - E1

PAGE 27 OF 43

CLAUSE NO


17.

18.

TRV caused by breaking/making capacitive current Maximum temperature rise above ambient at rated current -

Contacts,

Deg. C

-

Hottest part

Deg. C

Operating Mechanism a)

.......................................

Rated torque of the mechanism

.......................................

Type and rating (KW) of motor

.......................................

c)

Rated voltage of motor

.......................................

d)


.......................................

b)

19.

kV

Interlockings a)

b)

c)

d)

e) TAPOVAN VISHNUGAD HYDRO ELECTRIC POWER PROJECT (4 X 130 MW) 400 KV SWITCHYARD PACKAGE BID DOC NO.: CS-5505-500-2

.......................................

Whether mechanical/ constructional interlock between DS and Earth switch provided

Yes/No .......................................

Details of electrical interlock enclosed for

.......................................

i)

DS

......................................

ii)

Earth Switch

.......................................

Arrangement provided to prevent electrical or manual operation unless interlock conditions are satisfied

.......................................

Whether interlock coil is continuously rated

.......................................

.

Rated D.C. control voltage TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT - 12

CHAPTER - E1

PAGE 28 OF 43

CLAUSE NO


f) 20.

.......................................

Power consumption (watts)

.......................................

Controls a)

21

and variation allowed

.......................................

Rated D. C. control voltage (Volts)

.......................................

b)

Limits of voltage

.......................................

c)

Power consumption of control coils (W)

.......................................

Constructional Features a)

b)

Whether position of earth switch can be interchanged at site to either side of pole Main contacts

.......................................

i)

Type of contacts

.......................................

ii)

Contact area (cm2)

.......................................

iii)

Material of contacts

.......................................

iv)

Contact pressure (Kg/cm2)

.......................................

v)

Maximum current density under normal current carrying capacity (Amp/cm2)

.......................................

Thickness of silver plating

.......................................

vi)

c)


Yes/No

Auxiliary contacts on Disconnecting switch

.......................................

i)

Total number

.......................................

i)

NO

.......................................

iii)

NC

.......................................


CHAPTER - E1

PAGE 29 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... iv)

Adjustable

.......................................

v)

Make before break

.......................................

vi)

Rated voltage (volts)

.......................................

vii)

Rated continuous current (Amps)

.......................................

Rated DC breaking current with 20 ms time constant (A)

.......................................

viii)

d)


.......................................

i)

Total number

.......................................

ii)

NO

.......................................

iii)

NC

.......................................

iv)

Adjustable

.......................................

v)


.......................................

vi)


.......................................


.......................................

vii)

e)

22.

Whether counter balance spring provided for isolator and earth swtich

.......................................

Design data -

Type of contacts

.......................................

-

Contact area

.......................................

-

Contact pressure Surface treatment and thickness of surface coating/

....................................... .......................................



CHAPTER - E1

PAGE 30 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... silver electrolytic plating. -

-

Overtravel distance after making of contacts

mm

Distance between the contacts in the fully open position

mm

-

Current density at the minimum cross section of switch blade

A/mm2

-

Speed of break

m/s

23.

Partial discharge level at 1.1 Un / √3

24.

a)

b)

pico-coulombs

Total operating time of disconnector along with its operating mechanism

secs.

Total operating time of disconnector after the command is given

secs.

25.

No. of operations the switch can withstand without any need for inspection

.......................................

26.

Type of mounting

.......................................

27.

No. of poles per phase

.......................................

28.

Safety factor taken into account while designing the disconnector.

.......................................

29.

Type and material used for arcing contacts, if provided

30.

.......................................

Weight of 3 pole isolating switch -

with earthing blades

Kg

-

without earthing blades

Kg

31.

Type of interlock between main isolator and earthing switch

.......................................

32.

Details of the type test reports enclosed and the standards as per which these

.......................................



CHAPTER - E1

PAGE 31 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... tests have been carried out 33.

Rated maximum time duration of short circuit

ms

34.

Rated mechanical terminal load.

Kg

35.

Rated supply voltage of operating devices and auxiliary circuits.

V

36.

Rated pressure of SF6 gas

bar

37.

Minimum distance between poles with regard to insulation and forces caused by short circuit currents.

ms

38.

Tests to be conducted at site Whether the following are enclosed: a)

Type test reports

Yes/No

b)

OGA drawing for disconnecting switches with & without earth switches

Yes/No

c)

Operation manual

Yes/No

d)

Details of motor operating mechanism

Yes/No

Leaflets & literature bringing out salient features of equipment offered

Yes/No

Whether details of constructional interlock enclosed

Yes/No

e)

f)

B- II

.......................................

Safety Grounding Switches 1.

Manufacturer’s name & address

.......................................

2.

Type / designation

.......................................

3. 4.

Standard applicable Maximum permissible operating voltage

....................................... kV



CHAPTER - E1

PAGE 32 OF 43

CLAUSE NO


Maximum make and carry current for one sec.

kA (peak)

6.


A

7.


kV

8.


A

9.

TRV caused by breaking/making capacitive current

kV

10.


.......................................


.......................................


.......................................

c)


.......................................

d)


.......................................

b)

11.

Operating voltage range & rated voltage

V

12.

Ground connection insulation

kV

13.

Type of contacts

14.

Over travel distance

mm

15.

Distance of fully open contacts

mm

16.

Size of the removable link

17.

Speed of make

m/s

18.

Partial discharge level at 1.1 Un / √3

pico-coulomb

19.

Radio interference level at 266 kV (rms)

microvolt

20.

Details of type test reports enclosed and the standards as per which these tests have been carried out Auxiliary contacts on earth switch

21.



.......................................

…………………………..

…………………………..

.......................................

CHAPTER - E1

PAGE 33 OF 43

CLAUSE NO


22.

B-III

i)

Total number

.......................................

i)

NO

......................................

iii)

NC

.......................................

iv)

Adjustable

.......................................

v)


.......................................

vi)


Whether the following are enclosed: a)

Type test reports

Yes/No

b)


Yes/No

High Speed Fault Making Grounding Switch 1.

Manufacturer’s name &c address

.......................................

2.

Type/ designation

.......................................

3.

standard applicable

4.

Maximum permissible operating voltage

kV

5.

Maximum make and carry current for 1 sec.

kA (peak)

6.


A

7.


kV

8.


A

9.

TRV caused by breaking/making capacitive current

kV

10.



.......................................

Rated torque of the TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT - 12

CHAPTER - E1

PAGE 34 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... mechanism

.......................................

b)


.......................................

c)


.......................................

d)


.......................................

11.

Making current

12.

Induced current switching capablity

13.

Closing current

A

14.

Closing time

S

15.

Opening current

A

16.

Opening time

S

17.

Operating voltage range, rated voltage

V

18.

Ground connection insulation

kV

19.

Type of contacts

20.

Over travel distance

mm

21.

Distance of fully open contacts

mm

22.

Size of the removable link

23.

Speed of make

m/s

24.

Partial discharge level at 1.1 Un/ √3

pico-coulomb

25.

Radio interference level at 266 kV

microvolt

26.

Has equipment been type tested and to which standards ?

27.


.......................................

i)

Total number

.......................................

ii)

NO

......................................


.


kA .......................................

.......................................

.......................................

.......................................

CHAPTER - E1

PAGE 35 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... iii)

NC

.......................................

iv)

Adjustable

.......................................

v)


.......................................

vi)


.......................................

28.

Total operating time of switch alongwith its operating mechanism

s

29.

Total operating time of switch after the command is given.

s

30.


C)

.......................................


.......................................

b)


.......................................

c)


.......................................

d)


.......................................

CURRENT TRANSFORMERS (Bidder to fill up date separately for each type of CT) 1.

Name of manufacturer

.......................................

2.

Type

.......................................

3.

Manufacturer’s type / designation

.......................................

4.

Standard applicable

.......................................

5.

Rated voltage

.......................................

6.

Rated frequency

.......................................

i)

7.

Rated continuous normal current (A)

Short time current withstand for 1 sec. (kA)



.......................................

.......................................

CHAPTER - E1

PAGE 36 OF 43

CLAUSE NO


Dynamic current withstand (kA peak)

.......................................

9.

Transformation Ratio

.......................................

10.

Rated primary current

.......................................

11.

Rated secondary current

.......................................

12.

Numbers of cores.

.......................................

13.

Number of secondary turns

.......................................

14.

Particulars of for each type of C.T.

.......................................

1.

2

3

4

5

6

7

C O R E

Rated output (VA)

Class of accuracy

Accuracy limit

Current error at rated primary current (%)

Phase displacement at rated primary current (minutes)

Composite errors at cement rated accuracy limited it primary current.

I II III IV V

C

8

9

10

11

12

Knee

Secondary

Secondary

Magnetising

Instrument



CHAPTER - E1

PAGE 37 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... O R E

point voltage (V) (Volts)

limiting voltage

winding resistance (ohm)

current (mA) at knee point voltage

security factor

I II III IV V 15.

One second over current factor & corresponding value of current.

kA

16.

Rated dynamic current (peak value) in amps.

kA

17.

Rated continuous thermal current temperature rise over ambient.

Deg C

18.


Pico-coulomb

19.

Radio Interference voltage at 266 kV (rms)

micro-volt

20.

Total weight

Kg

21.

Magnetisation curves of CT cores

.......................................

22.

Mounting details

.......................................

23.

Overall dimensions

.......................................

24.

Temperature rise over an ambient temp. of 40 oC (oC)

.......................................

Whether CT characteristic curves enclosed

Yes/No

26.

Type Test Reports enclosed

Yes/No .......................................

27.

OGA drawing enclosed

Yes/no .......................................

28.

Tests proposed to be conducted at site.

.......................................

25.



CHAPTER - E1

PAGE 38 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... D)

VOLTAGE TRANSFORMERS 1

Name of manufacturer

.......................................

2.

Type designation

.......................................

3.

Standard applicable

....................................... Wdg - I

Wdg - II

Wdg - III

4.

Rated primary voltage

kV

5. 6.

Rated secondary voltage Rated output per phase

V VA

7.

Rated burden

VA

8

Rated frequency

Hz

9.

Standard values of rated voltage factor

.......................................

10.

Limits of temperature rise

.......................................

11.

One-minute power frequency withstand voltage

12.

1.2/50 microsecond lightning impulse withstand voltage

13.

250/2500 micro second impulse switching surge withstand test voltage of capacitor (dry wet) (kV peak)

kV(rms)

kV(peak)

.......................................

14.

Total weight and dimensions

Kg

15.

Limits of voltage error and phase displacement in %

16.

Error angle

.......................................

17.

Voltage error

.......................................

………………………

18.

Accuracy class at rated burden

.......................................

19.

Voltage factor and rated time

.......................................

20.

Total weight



.......................................

CHAPTER - E1

PAGE 39 OF 43

CLAUSE NO


21.

22. E)

Details of the tests to be conducted by the manufacturer at works i)

Type tests

.......................................

ii)

Routine tests

.......................................

Tests to be conducted at site

For Breaker

For Bus Bar

SURGE ARRESTERS 1. 2.

Manufacturer Type designation

....................................... .......................................

3.

Arrestor Class & Type

.......................................

4.

Rated Voltage of Arrestor

kV

5.

Normal continuous operating voltage (MCOV)

kV

6.

i)

ii)

Minimum discharge capability (kj/kV) reffered to rated voltage at minimum of discharge characteristics

.......................................

Line Discharge class, as per IEC

.......................................

7.

Maximum discharge current (8/20 microsecond wave)

kA

8.

Maximum 0.5 microsecond discharge voltage

kV

9.

Maximum residual voltage for 8/20 micro sec current wave i)

ii)

iii)

10.

.......................................

at 50% nominal discharge current (kVp)

.......................................


.......................................


.......................................

Maximum switching surge protective voltage



kV(peak)

CHAPTER - E1

PAGE 40 OF 43

CLAUSE NO


a)

b)

c)

One minute power frequency (dry) withstand voltage of arrester (kVrms)

.......................................

Impulse withstand test voltage of arrester housing with 1.2/50 micro sec wave, (kVp)

.......................................

Impulse current withstand

.......................................

i)

ii)

High current short duration (4/10 micro sec. wave ) kAp

.......................................

Low current short duration ( A peak)

.......................................

12.


pico-coulomb

13.

Radio interference level at 266 KV (rms)

Microvolts

14.

High current short duration test value

.......................................

15.

Short circuit capability & class of pressure relief device

.......................................

16.

l)Maximum internal ionisation at 50 Hz voltage equal to

.......................................

i)

1.05 COV

.......................................

ii)

1.0 COV

.......................................

Reference voltage and corresponding reference current of arrester

.......................................

17.

a)

b)


Maximum internal leakage current at (mA)

.......................................

i)

COV

.......................................

ii)

1.1 COV

.......................................

iii)

COV at 150 deg. C

.......................................


CHAPTER - E1

PAGE 41 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... iv) c)

G)

H)

Reference voltage


.......................................

18.

Protective level provided by surge arrestor .......................................

19.

Energy level

20.

Details of the type test reports enclosed and the standards as per these tests have been carried out

kJ/kV .......................................

SUPPORT & BARRIER INSULATORS (Details for each type of insulator used to be indicated separately)

Support

Barrier

1.

Manufacturer & address

.......................................

2.

Type of insulators used

.......................................

3.

One-minute power frequency dry withstand test voltage

4.

Dry flashover value

kV(rms)

5.

Wet flashover value

kV(rms)

6.

1.2/50 microsecond lightning impulse withstand test voltage

kV(peak)

7.

Creepage distance

mm

8.

Puncture value of insulator in SF6 gas

kV

9.

Weight of insulators in the SF6 GIS enclosure.

Kg

kV

GROUNDING CONNECTION a.

Type of conductor

.......................................

b.

Arrangement for connecting conductor to ground

.......................................

c.

I)

.......................................

Type of painting, if any required to be carried out at end points of ground riser DESIGN CLEARANCE



.......................................

CHAPTER - E1

PAGE 42 OF 43

CLAUSE NO

GAS INSULATED SWITCHGEAR Bidder’s Name: ...................................... Minimum insulating clearances at nominal rated SF6 gas pressure and rated voltage/BIL voltage for the following : a)

Main bus to ground

.......................................

b)

Circuit breaker

.......................................

-

.......................................

c)

d)

J)

Contact to ground

Across the contacts Isolator switches

....................................... .......................................

-

Contact to ground

.......................................

-

Across the contacts

.......................................

Safety grounding switches

.......................................

-

Contact to ground

.......................................

-

Across the contacts

.......................................

TOLERANCES 1.

Tolerance (vertical & horizontal) and at ....................................... interface of SF6 to Transformer oil bushing

2.

Tolerance (vertical & horizontal) and at ....................................... interface of SF6 to GIS bus Reactor bushing

SIGNATURE AND SEAL OF BIDDER



CHAPTER - E1

PAGE 43 OF 43

CHAPTER - E2 ISOLATORS



CLAUSE NO

ISOLATORS Bidder’s Name: ...................................... (Bidder shall furnish the data for each type of Isolators separately)

1.

General a)

2.

.......................................

Name & country of the Manufacturer

.......................................

b)

Manufacturer's type designation

.......................................

c)

Standard Applicable

.......................................

d)

Rated Voltage (KV)

.......................................

e)

Rated Current (Amps)

.......................................

i)

Under normal

.......................................

ii)

Under site conditions at ambient temperature

.......................................

f)

Rated frequency (Hz)

.......................................

g)

Number of poles

.......................................

h)

Whether all 3 poles are ganged mechanically

.......................................

i)

.......................................

Pole to pole spacing

Guaranteed Ratings a)

.......................................

Rated short time current of Isolators

.......................................

i)

for 1 sec. (kA rms)

.......................................

ii)

for 3 sec. (kA rms)

.......................................

iii)

Dynamic current

.......................................

b)

Opening time of

.......................................

i)

Isolators (sec)

.......................................

ii)

Earth switch (sec)

.......................................



CHAPTER - E2

PAGE 1 OF 6

CLAUSE NO

ISOLATORS Bidder’s Name: ...................................... c)

d)

3.

Closing time of

.......................................

i)

Isolators (sec)

.......................................

ii)

Earth switch (sec)

.......................................

Temperature rise over ambient temperature corresponding to maximum continuous current (oC)

Dielectric with-stand capacity of Completely assembled Isolators and earth switch a)

b)

.......................................

i)


.......................................

- dry (kV rms)

.......................................

- Wet (kV rms)

.......................................

1.2/50 micro second impulse withstand test voltage

.......................................


.......................................

across open contacts (kV peak)

.......................................

250/2500 micro second switching surge withstand test voltage (dry & wet)

.......................................

ii)

i)

ii)

d)

.......................................

One minute power frequency withstand test voltage (kV) rms

i)

c)

.......................................


.......................................

across open contacts (kV peak)

.......................................

Corona extinction voltage (kV rms)



.......................................

CHAPTER - E2

PAGE 2 OF 6

CLAUSE NO

ISOLATORS Bidder’s Name: ...................................... e)

f)

4.

.......................................

Total creepage distance to ground (mm)

.......................................


.......................................


.......................................


.......................................

c)


.......................................

d)


.......................................

b)

4.1

Radio interference level at 1.1 x Um/√3 (in micro volts) for frequency between 0.5 MHz to 2.0 MHz

Interlockings a)

b)

c)

d)

e)

f)

......................................

Whether mechanical/ constructional interlock between DS and Earth switch provided

Yes/No .......................................

Details of electrical interlock enclosed for

.......................................

i)

Isolators

.......................................

ii)

Earth Switch

.......................................

Arrangement provided to prevent electrical or manual operation unless interlock conditions are satisfied

.......................................

Whether interlock coil is continuously rated

.......................................

Rated D.C. control voltage and variation allowed

.......................................

Power consumption (watts)

.......................................



CHAPTER - E2

PAGE 3 OF 6

CLAUSE NO

ISOLATORS Bidder’s Name: ......................................

4.2

Controls a)

5

.......................................

Rated D. C. control voltage (Volts)

.......................................

b)

Limits of voltage

.......................................

c)

Power consumption of control coils (W)

.......................................

Constructional Features a)

b)

Whether position of earth switch can be interchanged at site to either side of pole Main contacts

.......................................

i)

Type of contacts

.......................................

ii)

Contact area (cm2)

.......................................

iii)

Material of contacts

.......................................

iv)

Contact pressure (Kg/cm2)

.......................................

v)

Maximum current density under normal current carrying capacity (Amp/cm2)

.......................................

Thickness of silver plating

.......................................

vi)

c)

Yes/No

Auxiliary contacts on Disconnecting switch

.......................................

i)

Total number

.......................................

i)

NO

.......................................

iii)

NC

.......................................

iv)

Adjustable

.......................................

v)

Make before break

.......................................

vi)


.......................................



CHAPTER - E2

PAGE 4 OF 6

CLAUSE NO

ISOLATORS Bidder’s Name: ...................................... vii)

i)

d)

6.

.......................................


.......................................


.......................................

i)

Total number

.......................................

i)

NO

.......................................

iii)

NC

.......................................

iv)

Adjustable

.......................................

v)


.......................................

vi)


.......................................


.......................................

vii)

e)


Whether counter balance spring provided for isolator and earth switch

Literature

....................................... .......................................

Whether the following are enclosed: a)

Type test reports

Yes/No

b)


Yes/No

c)

Operation manual

Yes/No

d)

Details of motor operating mechanism

Yes/No



CHAPTER - E2

PAGE 5 OF 6

CLAUSE NO

ISOLATORS Bidder’s Name: ...................................... e)

f)

Leaflets & literature bringing out salient features of equipment offered

Yes/No

Whether details of constructional interlock enclosed

Yes/No



CHAPTER - E2

PAGE 6 OF 6

CHAPTER - E3 INSTRUMENT TRANSFORMERS



CLAUSE NO


Bidder’s Name: ...................................... (Bidder to fill up the data for each type of CT/CVT separately) A.

CURRENT TRANSFORMERS 1.

Name & Address

.......................................

2.


.......................................

3.

Standard applicable

.......................................

4.


.......................................

5.

Rated Voltage (KV)

.......................................

6.

i)

ii) 7.

Rated continuous normal current (A)

.......................................

Rated thermal current (A)

.......................................

Short time current withstand for 1 sec. (kA)

.......................................

Dynamic current withstand (kA peak)

.......................................

1.2/50 micro second impulse withstand voltage (kv peak)

.......................................

250/2500 micro second switching withstand voltage (kV peak dry and wet)

.......................................

One minute dry & wet power frequency withstand voltage (kV rms)

.......................................

12.

No. of cores per CT

.......................................

13.

Transformation Ratio

.......................................

14.

Number of secondary turns

.......................................

15.

Rated Out put (VA) at different taps.

.......................................

Accuracy class

.......................................

8.

9.

10.

11.

16.



CHAPTER - E3

PAGE 1 OF 6

CLAUSE NO


Bidder’s Name: ...................................... 17.

18.

Knee - point voltage (volts) at different taps

.......................................

Secondary data

.......................................

a)

Secondary resistance at different taps

.......................................

Oversize factor and transient error under reclosing duty condition

.......................................

Maximum exciting current at

.......................................

a)

100% kpv (mA)

.......................................

b)

25% kpv (mA)

.......................................

c)

20% kpv (mA)

.......................................

d)

10% kpv (mA)

.......................................

Instrument security factor at different ratios

.......................................

Radio interference voltage at 1.1 x Um/√3 (microvolts) for frequency between 0.5 MHz to 2.0 MHz

.......................................

b)

19.

20.

21.

22.

23.

Whether auxiliary CT/reactor provided for metering winding

Yes/No


.......................................

Partial discharge level (pico coulombs)

.......................................

25.

Total creepage distance (mm)

.......................................

26.

a)

No. of primary turns

.......................................

b)

Material and cross section of primary

.......................................

Whether bar type or ring type primary

.......................................

24.

c)



CHAPTER - E3

PAGE 2 OF 6

CLAUSE NO


Bidder’s Name: ...................................... 27.

28.

29.

30.

31.

32.

33.

Whether CT is suitable for transportation horizontally

Yes/No

Composite error at rated burden and at

.......................................

a)

20% rated current

.......................................

b)

120% rated current

.......................................

Composite error at 25% rated burden and at

.......................................

a)

20% rated current

.......................................

b)

120% rated current

.......................................

Quality of oil per CT (litres)

.......................................

Whether -spark gap/surge arrester provided at the primary

Yes/No

- power factor measurement terminal provided

Yes/No

Standard to which oil conforms generally

.......................................

Whether current transformers are hermetically sealed

Yes/No

34.

Total weight (Kg)

.......................................

35.

Transport weight (Kg)

.......................................

36.

Temperature rise over an ambient temp.

.......................................

Whether CT characteristic curves enclosed

Yes/No

37.

38.

Type Test Reports

.......................................

39.


.......................................



CHAPTER - E3

PAGE 3 OF 6

CLAUSE NO


Bidder’s Name: ...................................... B.

CAPACITOR VOLTAGE TRANSFORMER 1.

2.

General

.......................................

a)

Name & Address

.......................................

b)


.......................................

c)

Standard Applicable

.......................................

d)

Rated Voltage (KV rms)

.......................................

e)

Number of secondaries

.......................................

f)


.......................................

Guaranteed Ratings a)

.......................................

Rated output of each secondary winding (VA)

.......................................

b)

Total simultaneous burden (VA)

.......................................

c)

Accuracy class

.......................................

d)

Rated voltage factor

.......................................

e)

i)

Continuous

.......................................

ii)

5 seconds

.......................................

iii)

30 seconds

.......................................

Capacitance i)

ii)

.......................................

of high voltage capacitor (Pico farads) of intermediate voltage capacitor (Pico farads)

iii) for carrier frequency coupling (Pico Farads)



....................................... .......................................

.......................................

CHAPTER - E3

PAGE 4 OF 6

CLAUSE NO


Bidder’s Name: ...................................... f)

i)

ii)

.......................................

Self tuning frequency of CVT (khz) (Capacitor Part only)

.......................................

g)

Band width (kHz)

.......................................

h)

Temperature rise over ambient temperature at 40oC (oC)

.......................................

One minute power frequency test voltage of secondary winding (kV rns)

.......................................

One minute power frequency test voltage of H. F. terminal (kV rms)

.......................................

One minute power frequency test voltage of capacitor (kV rms ) (dry & wet)

.......................................

i)

j)

k)

l)

m)

n)

o)

3.

Natural frequency of coupling (kHz)

1.2/50 micro second impulse withstand test voltage of capacitor (kV peak)

.......................................

250/2500 micro second impulse switching surge withstand test voltage of capacitor(dry wet) (kV peak)

.......................................


.......................................

Radio interference voltage at 1.1 x Um/√3(micro volts) for frequency between 0.5 MHz to 2.0 MHz

.......................................

Constructional Details

.......................................

a)

Total weight (Kg)

.......................................

b)

Quantity of oil (litres)

.......................................

c)

Whether CVTs are hermetically sealed



Yes/No

CHAPTER - E3

PAGE 5 OF 6

CLAUSE NO


Bidder’s Name: ...................................... d)

4.

Standard to which oil Conforms generally

Literature

....................................... .......................................

(Whether the following are enclosed)

5.

a)

Type test reports

Yes/No

b)

OGA drawing

Yes/No

c)

Characteristic curves

Yes/No

Any other information bidder like to provide



----------------------------------

CHAPTER - E3

PAGE 6 OF 6

CHAPTER - E4 SURGE ARRESTORS



CLAUSE NO

SURGE ARRESTERS Bidder’s Name: ......................................

1.00.00

2.00.00.

GENERAL

..................................................

a)

Name & Address

...................................................

b)


...................................................

c)

Applicable Standard

...................................................

ELECTRICAL CHARACTERISTICS a)

Arrestor class and type

...................................................

b)

Rated arrester Voltage (KV)

...................................................

c)

Maximum continuous operating voltage (COV) at design ambient temperature

...................................................

Nominal discharge current (8/20 micro sec. wave ) (kA)

...................................................

d)

e)

i)

ii)

f)

g)

Minimum discharge capability (kj/kV) referred to rated voltage at minimum of discharge characteristics

...................................................

Line Discharge class, as per IEC

...................................................

Maximum equivalent front of wave protection level (discharge voltage with 0.5 x 1.5 micro sec, 10 kA impulse current) i)

ii)

...................................................

Minimum switching surge residual voltage at 1 kA (kVp)

...................................................

Maximum switching surge residual voltage at 1 kA (kVp)

...................................................



CHAPTER - E4

PAGE 1 OF 5

CLAUSE NO

SURGE ARRESTERS Bidder’s Name: ...................................... h)

Maximum residual voltage for 8/20 micro sec current wave i)

ii)

iii)

i)

j)

k)

n)

...................................................


...................................................


...................................................

...................................................

Impulse withstand test voltage of arrestor housing with 1.2/50 micro sec wave, (kVp)

...................................................

Impulse current withstand

...................................................

ii)

m)


One minute power frequency (dry) withstand voltage of arrestor (kV rms)

i)

l)

...................................................

High current short duration (4/10 micro sec. wave ) kAp

...................................................

Low current short duration ( A peak)

...................................................

Maximum internal ionisation at 50 Hz voltage equal to

...................................................

i)

1.05 COV

...................................................

ii)

1.0 COV

...................................................

Reference voltage and corresponding reference current of arrestor

...................................................

Maximum internal leakage current at (mA)

...................................................

i)

...................................................

COV



CHAPTER - E4

PAGE 2 OF 5

CLAUSE NO

SURGE ARRESTERS Bidder’s Name: ...................................... ii)

1.1 COV

...................................................

iii)

COV at 150 deg. C

...................................................

iv)

Reference voltage

...................................................

o)


...................................................

p)

Are the protection levels affected by pollution of external insulation

...................................................

q)

r)

s)

t)

u)

Energy absorption capability in KJ per operation of the arrestor, during a switching surge discharge

...................................................

Maximum amount of energy that may be dispatched into the arrestor during discharge assuming that discharge takes place within 1 min period and state the switching surge current

...................................................

Internal pressure required to operate pressure relief device as a percentage of burst pressure of procelain

...................................................

Dynamic over voltage withstand KVp

...................................................

i)

For 3 peaks

...................................................

ii)

For 0.01 sec

...................................................

iii)

For 0.1 sec.

...................................................

iv)

For 1 sec.

...................................................

Minimum prospective symmetrical fault current (kA rms)

...................................................



CHAPTER - E4

PAGE 3 OF 5

CLAUSE NO

SURGE ARRESTERS Bidder’s Name: ...................................... v)

w)

Rejection rate of ZnO blocks during manufacturing and operation for the past three years (%) separately Rated voltage of ZnO disc (kV)

...................................................

i)

No. of Zno discs in a unit

...................................................

ii)

No. of units/arrestor

...................................................

iii)

Height /Thickness of ZnO discs (mm)

...................................................

Diameter of ZnO disc (mm)

...................................................

Resistive current drawn by complete surge arrester at COV (mA)

...................................................

iv)

v)

3.00.00

...................................................

EXTERNAL INSULATION a)

Type

...................................................

b)

Applicable standard

...................................................

c)

Impulse voltage withstand test voltage of housing with 1.2/50 micro sec wave (mm)

...................................................

One minute power frequency withstand voltage of arrestor housing dry & wet (kV rms)

...................................................

Total creepage distance of arrestor housing (mm)

...................................................

Cantilever strength of complete arrester (Kg)

...................................................

d)

e)

f)



CHAPTER - E4

PAGE 4 OF 5

CLAUSE NO

SURGE ARRESTERS Bidder’s Name: ......................................

4.00.00

LITERATURE Whether following are enclosed a)

b)

c)

d)

e)

f)

g)

h)

A description of design and construction of the arrester. This shall include the diameter, thickness and rating of ZnO block being used.

Yes/No

Evidence of stability of blocks over its designed lifetime

Yes/No

Sectional view of arrestor showing details of electrical contact between blocks and the location of pressure relief device.

Yes/No

Detail/description and details in respect of failure mode of operation , heat removal, thermal time constant of arrestor.

Yes/No

Description and details of operation of discharge counter, leakage current monitor and leakage current analyzer

Yes/No

Description of the effects of contamination on operation of arrestor and design features incorporated to minimise these effects.

Yes/No

Description of operation of pressure relief device and the operation of surge arrester during impulse voltage discharge and transmission line discharge

Yes/No

Type test reports

Yes/No



CHAPTER - E4

PAGE 5 OF 5

CHAPTER - E5 INSULATORS



CLAUSE NO

INSULATORS Bidder’s Name: ......................................

A.

BUSHING / HOLLOW INSULATORS (Bidder shall furnish these data for each equipment separately i.e. for Isolators, Instrument Transformers, Surge Arrestors etc.) 1.

Manufacturer's Name & Address

.........................................

2.

Country of Manufacturer

.........................................

3.

Type

.........................................

4.

Applicable Standards

.........................................

5.

i)

Height

.........................................

ii)

Diameter (Top)

.........................................

iii)

Diameter (Bottom)

.........................................

6.

Creepage distance

.........................................

a)

.........................................

Total (mm)

7.

Rated Voltage

.........................................

8.

Power frequency withstand voltage for 1 min. (kv rms)

.........................................

i)

Dry

.........................................

ii)

Wet

.........................................

9.

1.2/50 micro sec. impulse withstand voltage (kVp)

.........................................

250/2500 Micro sec. switching impulse withstand voltage (kVp)

.........................................

i)

Dry

.........................................

ii)

Wet

.........................................

11.

Weight (Kg)

.........................................

12.

Cantilever Strength (Kg)

.........................................

13.


10.



Yes/No

CHAPTER – E5

PAGE 1 OF 5

CLAUSE NO


B.

BUS POST INSULATOR (Bidder shall furnish these data for solid core Insulators for Isolators, bus support, etc. separately) 1.

Manufacturer's Name

.........................................

2.


.........................................

3.

Type of Insulator (Product No.)

.........................................

4.


.........................................

5.

No. of units per Stack

.........................................

6.

Diameter & No. of Bolts

.........................................

i)

Top

.........................................

ii)

Bottom

.........................................

7.

Bolt circle diameter (mm)

.........................................

i)

Top

.........................................

ii)

Bottom

.........................................

8.

Height of complete stack (mm)

.........................................

9.

Total Creepage distance (mm)

.........................................

10.

Power frequency withstand voltage of insulator with corona ring

.........................................

i)

Dry (kV rms)

.........................................

ii)

Wet (kV rms)

.........................................

1.2/50 micro sec. impulse withstand voltage (kVp) of insulator with corona ring

.........................................

i)

Dry (kV rms)

.........................................

ii)

Wet (kV rms)

.........................................

11.



CHAPTER – E5

PAGE 2 OF 5

CLAUSE NO


C.

12.

Min. Corona Extinction Voltage (kV)

.........................................

13.

Radio Interference Voltage at 1.1 Um/√3(micro volts) for frequency between 0.5 to 2.0 MHz

.........................................

14.

Weight of complete stack (kg)

.........................................

15.

Cantilever strength

.........................................

i)

Upright (kg)

.........................................

ii)

Under (kg)

.........................................

16.

Tensile Strength (kg)

.........................................

17.

Torsional strength (kg/m)

.........................................

18.

Compression strength (kg)

.........................................

19.


Yes/No

20.

Type test report enclosed

Yes/No

STRING INSULATOR 1.

Manufacturer

.........................................

a)

Insulator

.........................................

b)

Hardware

.........................................

2.


.........................................

3.

Type of Insulator

.........................................

a)

Ball & Socket/other

.........................................

b)

Normal/antifog

.........................................

4.

Insulating Material

.........................................

5.

No. of units per String

.........................................



CHAPTER – E5

PAGE 3 OF 5

CLAUSE NO


6.

7.

8.

9.

Size of each unit

.........................................

a)

Diameter of disc (mm)

.........................................

b)

Spacing between adjacent Units (mm)

.........................................

Weight a)

Each Disc (Kg)

.........................................

b)

Complete String (Kg)

.........................................

Creepage distance

.........................................

a)

Each Disc (Kg)

.........................................

b)


.........................................

Power frequency withstand voltage

.........................................

a)

Each Disc

.........................................

i)

Dry (kV)

.........................................

ii)

Wet (kV)

.........................................

b)

10.

.........................................


.........................................

i)

Dry (kV)

.........................................

ii)

Wet (kV)

.........................................

Impulse withstand voltage

.........................................

a)

Each Disc

.........................................

i)

Positive (kVp)

.........................................

ii)

Negative (kVp)

.........................................



CHAPTER – E5

PAGE 4 OF 5

CLAUSE NO


b)

11.

12.

13.


.........................................

i)

Positive (kVp)

.........................................

ii)

Negative (kVp)

.........................................

Switching Surge Withstand

.........................................

a)

Each Disc (kVp)

.........................................

b)

Complete String (kVp)

.........................................

Power Frequency Puncture withstand voltage of each disc (kV rms) .

........................................

Electo Mechanical Strength

Yes/No

a)

Each Disc (Kg)

.........................................

b)


.........................................

i)

Single tension

.........................................

ii)

Double tension

.........................................

14.


Yes/No

15.


Yes/No



CHAPTER – E5

PAGE 5 OF 5

CHAPTER - E6 WAVE TRAPS



CLAUSE NO

WAVE TRAPS

Bidder’s Name: ...................................... 1.

Name of Manufacturer and address

.........................................

2.

Type

.........................................

3.

System Voltage rating

.........................................

4.

Continuous current rating at ambient temperature

.........................................

Continuous current rating at 40oC ambient

.........................................

Maximum Symmetrical short circuit current rating for 1 sec. duration

.........................................

Asymmetric Peak value of first half wave of rated short time current

.........................................

8.

Rated Inductance

.........................................

9.

Blocking Range

.........................................

10.

Minimum Guaranteed Resistive component in blocking Frequency Range

.........................................

11.

Type of Tuning

.........................................

12.

Variation in 50 Hz Impedance per Degree Centrigrade Variation in ambient Temperature

.........................................

Variation in resonant Frequency Band per degree Centrigrade variation in ambient Temperature

.........................................

Details of protection of Capacitor and coils against voltage surges Indicate type of protective device.

.........................................

15.

Basic Insulation Level

.........................................

16.

Standard nominal Discharge current of Protective Device or 8/20 micro Second wave impulse

.........................................

5.

6.

7.

13.

14.



CHAPTER - E6

PAGE 1 OF 3

CLAUSE NO

WAVE TRAPS

Bidder’s Name: ...................................... 17.

Parameter of Protective Device (Gapped Arrestor)

.........................................

a)

Rated voltage

.........................................

b)

Minimum discharge capacity referred to rated voltage (kj/kV)

.........................................

Maximum equivalent front of wave protection level at a discharge voltage with 0.5 x 1.5 microsec (10kA impulse current)

.........................................

c)

d)

i)

ii)

e)

18.

19.

20.

21.

Maximum Switching Surge residual voltage at 1 kA (kVp)

.........................................

Minimum Switching Surge residual voltage at 1 kA (kVp)

.........................................

Maximum Residual Voltage of Protective Device for 8/20 micro impulse discharge current of

.........................................

i)

5, 000 Amps

.........................................

ii)

10, 000 Amps.

.........................................

Parameters of gapless Arrestor filled in as per data sheets of surge Arrestor (E 4)

Yes/No

Class of Insulation of line trap as per Table - 1 of IEC 353 Temperature rise in line trap under rated continuous current

.........................................

Visual corona extinction voltage

.........................................



.........................................

CHAPTER - E6

PAGE 2 OF 3

CLAUSE NO

WAVE TRAPS

Bidder’s Name: ...................................... 22.

Radio Interference Voltage at 1.1 Um/√3 (microvolts) for frequency between 0.5 MHz to 2.0 MHz

.........................................

23.

Type of mounting

.........................................

24.

Maximum working stress

.........................................

25.


.........................................

26.

Material of main coil

.........................................

27.

Net Weight

........................................

28.

Whether corona rings are provided?

Yes/no

Whether bird barriers are provided?

Yes/No

29. 30.

31.

Over all dimensions

.........................................

a)

Diameter

.........................................

b)

Height

.........................................

No. of turns in line trap main coil and no. of layers

.........................................

Type of conductor whether solid or stranded

.........................................

33.

Overall conductor size

.........................................

34.

Cross-sectional area of conductor

.........................................

35.

Type of construction number of coils and whether open type or covered with insulating material)

.........................................

Type & material of turn to turn spacers

.........................................

a)

Material

.........................................

b)

Type of fitting (Internal/External)

.........................................

c)

Dimensional drawing furnished

.........................................

32.

36.



CHAPTER - E6

PAGE 3 OF 3

CHAPTER - E7 LIGHTING



CLAUSE NO

LIGHTING

Bidder’s Name: ...................................... 1.0

Lighting Panel a)

Make

..........................................

b)

Applicable Standard

..........................................

c)

Miniature Circuit Breaker

..........................................

i)

Make

..........................................

ii)

Type designation

..........................................

iii)

Applicable standard

..........................................

iv)

Breaking capacity at 0.6 p.f.

..........................................

v)

Catalogue attached as annexure No.

..........................................

d)

e)

f)

g)

Isolator

..........................................

i)

Make

..........................................

ii)

Applicable standard

..........................................

Fuses

..........................................

i)

Make

..........................................

ii)

Type

..........................................

iii)

Applicable standard

..........................................

Contactor

..........................................

i)

Make

..........................................

ii)

Type & duty

..........................................

iii)

Applicable standard

..........................................

iv)

Rating

..........................................

Synchronous timer i)

..........................................

Make


..........................................


CHAPTER - E7

PAGE 1 OF 4

CLAUSE NO

LIGHTING

Bidder’s Name: ......................................

2.0

b)

c)

4.0

5.0

Type

..........................................

iii)

Applicable standard

..........................................

iv)

Range

..........................................

Lighting fixtures & Accessories a)

3.0

ii)

Make of lighting fixture & accessories

..........................................

Catalogue for each type of fixture attached as Annexure no.

..........................................

Applicable standard

..........................................

Switches a)

Make

..........................................

b)

Type

..........................................

c)


..........................................

d)

Applicable standard

..........................................

e)

Rating

..........................................

Receptacles/Sockets a)

Make

..........................................

b)

Type

..........................................

c)

Applicable standard

..........................................

d)

Rating

..........................................

e)


..........................................

Epoxy coated steel conduits/fittings & accessories a)

Make

..........................................

b)

Applicable standard

..........................................



CHAPTER - E7

PAGE 2 OF 4

CLAUSE NO

LIGHTING

Bidder’s Name: ......................................

6.0

7.0

c)

Material

..........................................

d)

Size

..........................................

e)

Surface coating

..........................................

Lighting Wires a)

Make

..........................................

b)

Applicable standard

..........................................

c)

Voltage grade

..........................................

d)

Size

..........................................

e)

Conductor material

..........................................

f)

Insulation

..........................................

Lighting Fixtures and Accessories a)

b)

c)

Make i.

Fixtures

.........................................

ii.

Accessories

..........................................

Manufacturers Cat. no.& type i.

Fixtures

.........................................

ii.

Accessories

..........................................

Applicable standard

..........................................

i.

Fixtures

.........................................

ii.

Accessories

..........................................

d)

Normal working voltage

..........................................

h)

Ambient temperature within the fitting in continuous operation at the design ambient temperature (deg. C)

.......................................

Average life expectancy of lamps

.......................................

i)



CHAPTER - E7

PAGE 3 OF 4

CLAUSE NO

LIGHTING

Bidder’s Name: ...................................... h)

i)

j)

Lamp output at the design temperature i.

after 100 burning hours (lumens)

......................................

ii.

after 1000 burning hours (lumens)

......................................

Lamp output at the end of the expected life period (lumens)

.......................................

Average light output of the fitting as a percentage of lamp output (%) i.

Downwards

.......................................

ii.

Upwards

.......................................

k)

Cable conduit entry size

.......................................

l)

Earthing terminal i.

Material

......................................

ii.

Suitable for earthing conductor of size

......................................

m)

Weight of fixtures

n)

Lux level

......................................

(i)

General

......................................

(ii)

Equipment

......................................



CHAPTER - E7

PAGE 4 OF 4

CHAPTER - E8 LT SWITCHGEAR & DISTRIBUTION BOARDS



CLAUSE NO


Bidder’s Name: ...................................... (Bidder to furnish following data for each type separately) 1.

TYPICAL DATA a)

General i)


...............................................

ii)

Type designation

...............................................

iii)

Country of origin

...............................................

b)

Rated voltage

c)

Symmetrical short circuit withstand current at rated voltage of switchgear /MCC cubicle. ...............................................

d)

Peak short circuit withstand current

...............................................

e)

Rated current at 40 deg C

...............................................

f)

Degree of protection as per IS:2147

g) .

h)

i)

Breaker / MCC cubicles

...............................................

ii)

Busbar chamber

...............................................

Cubicle sheet metal details i)

Cold rolled / hot rolled

...............................................

ii)

Thickness, structural & load bearing members

...............................................

iii)

Thickness, front & rear

...............................................

iv)

Thickness, Sides & top

...............................................

v)

Thickness of gland plates

...............................................

Painting shade & Thickness as per IS :5 i)


External surfaces TECHNICAL DATA SHEETS SECTION-VII ATTACHMENT - 12

...............................................

CHAPTER - E8

PAGE 1 OF 6

CLAUSE NO


Bidder’s Name: ...................................... ii) i)

j) k)

2.

Internal surfaces

...............................................

Minimum Clearance in air (Busbars) i)

Between phases

...............................................

ii)

Between phase & earth

...............................................

Standard height, width & depth of typical panel

...............................................

Following accessories provided i)

Plug Point with switch fuse

Yes/No

ii)

Cubicle space heater

Yes/No

iii)

Name plates front & rear

Yes/No

iv)

Danger plate rear

Yes/No

POWER BUSBARS & INSULATORS a)

Material & applicable standards

b)

Bare/painted/epoxy insulated/sleeved

........................................

c)

Bus joints silver faced

Yes/No

d)

Minimum clearances

e)

...............................................

i)

Phase to Phase (mm)

...............................................

ii)

Phase to earth (mm)

...............................................

Continuous current rating i)

at 40 deg. C Ambient (Amps)

...............................................

f)

Temperature rise over design ambient temperature of 40 deg. C for continuous current rating (degC) ...............................................

g)

Cross sectional area per phase for different ratings (attached sheet if required) i)

Horizontal busbar

...............................................

ii)

Vertical busbar

...............................................



CHAPTER - E8

PAGE 2 OF 6

CLAUSE NO


Bidder’s Name: ......................................

3.

h)

Material of the support insulators

...............................................

i)

Tracking index in insulators

...............................................

j)

One second current rating (kA)

...............................................

AIR BREAK SWITCHES (The following details shall be furnished for each type & rating) a)

Make

...............................................

b)

Type

...............................................

c)

Applicable standards

...............................................

d)

Rated current at design ambient temperature (Amps) .

..............................................

e)

Design ambient temperature Deg C ...............................................

f)

Derating factor for use under site ambient conditions

...............................................

g)

Rated breaking current (kA)

...............................................

h)

Maximum through fault current withstand kA

...............................................

i)

Maximum size of fuse recommended ...............................................

j)

Temperature rise of contacts when carrying continuous rated current Deg.C ...............................................

k)

Door interlock as specified has been provided

l)

Yes/No

No. of auxiliary contacts and its rating



CHAPTER - E8

PAGE 3 OF 6

CLAUSE NO


Bidder’s Name: ...................................... 4.

CONTACTOR (The following details shall be furnished for each type and rating) a)

Make & Address

...............................................

b)

Type & applicable standards

...............................................

c)

i)

No. of poles

...............................................

ii)

No. and Configuration of auxiliary contacts

...............................................

d)

Rated voltage of main and auxiliary contacts ...............................................

e)

Rated voltage of coils

f)

Limits of operation

...............................................

i)

Supply voltage variation +/-% ...............................................

ii)

Supply frequency variation for closing (+/-)% ...............................................

iii)

Drop out voltage %

...............................................

g)

Rated (thermal) current A

...............................................

h)

Rated duty

...............................................

i)

No. of operations/hour, capability

...............................................

j)

Rated utilisation category as per IS:2459

...............................................

k)

Rated breaking capacity kA

...............................................

l)

Rated making capacity - kA

...............................................

m)

Coil winding insulation class

...............................................

n)

Max. recommended back up HRC fuse size

...............................................

o)

Coil VA burden

...............................................



CHAPTER - E8

PAGE 4 OF 6

CLAUSE NO


Bidder’s Name: ...................................... 5.

AUXILIARY CONTACTOR a)

Make

...............................................

b)

Type

...............................................

c)

Coil voltage

...............................................

d)

Coil Burden

...............................................

e)

Operating time

...............................................

f)

No. of contacts

g) 6.

i)

Normally open

...............................................

ii)

Normally closed

...............................................

Contact rating AC/DC

...............................................

FUSES (The following details shall be provided for each type & rating)

7.

a)

Make

...............................................

b)

Type

...............................................

c)

Applicable standards

...............................................

d)

Rated voltage

...............................................

e)

Prospective breaking current (kA)

...............................................

f)

Peak cut off current (kA)

...............................................

g)

Whether mounted on an insulated carrier

Yes/No ...............................................

SPACE HEATER a)

Make

...............................................

b)

Type designation

...............................................



CHAPTER - E8

PAGE 5 OF 6

CLAUSE NO


Bidder’s Name: ......................................

8.

c)

Rated voltage

...............................................

d)

Heater output (W)

...............................................

e)

Thermostat setting range deg C

...............................................

WIRING & TERMINAL BLOCKS a)

Voltage grade of wires

...............................................

b)

Insulation of wires

...............................................

c)

Minimum size of conductor for

...............................................

i)

Power wiring (mm2)

...............................................

ii)

Control wiring (mm2)

...............................................

d)

Type of control terminal blocks on i)

Fixed portion & drawout portion of drawout MCC modules ...............................................

ii)

Switchgear panels

...............................................

iii)

For CTs

...............................................

e)

Make & type of terminal blocks

...............................................

f)

Minimum current rating of terminal blocks

...............................................

g)

Suitable for 2x2.5 mm2 Cable

Yes/No

Termination on each side



CHAPTER - E8

PAGE 6 OF 6

CHAPTER - E9 CABLES



CLAUSE NO

CABLES Bidder’s Name: ...................................... (The following technical data shall be submitted by the Bidder for each type and size of the cable)

A.

LT CABLES 1.

Make

.................................................

2.


.................................................

3.

Type designation

.................................................

4.

Applicable Standard

.................................................

5.

Cable size

.................................................

6.

Rated voltage

.................................................

7.

Continuous current rating for max. conductor temp.

.................................................

a)

b)

8. .

9.

When laid in air at an ambient temp. of 40 deg. C When buried in soil having thermal resistivity of 150 deg C Cm/N at a depth of 1000 mm at ground amb. temp. of 30 deg.C

................................................. .................................................

Short circuit withstand capacity and duration for

.................................................

a)

Conductor

.................................................

b)

Screen

.................................................

c)

Armour

.................................................

Conductor

.................................................

a)

Material

.................................................

b)

Nominal cross section area in sq.mm

.................................................

D.C. resistance at 20 deg.C

.................................................

c)



CHAPTER – E9

PAGE 1 OF 8

CLAUSE NO

CABLES Bidder’s Name: ...................................... 10.

11.

.................................................

a)

Material

.................................................

b)

Nominal thickness (in mm)

.................................................

c)

Identification for cores

.................................................

Metallic Screen (wherever applicable)

.................................................

a)

.................................................

Material & type

12.

Type of filler material

.................................................

13.

Type of inner sheath material

.................................................

14.

Armour (for armoured cables)

.................................................

a)

.................................................

15.

B.

Insulation

Material & type

Outer Sheath

.................................................

a)

Material

.................................................

b)

Colour

.................................................

16.

Overall dia of cable (in mm)

.................................................

17.

Weight per 1000 m (in kg.)

.................................................

18.

Standard drum length offered

.................................................

1.1 KV GRADE POWER AND CONTROL CABLES (Bidder shall furnish these particulars for each type & size of cable.) 1.

Maker's Name & country of Manufacturer

.................................................

2.

Manufacturer's type & designation

.................................................

3.

Applicable Standard

.................................................

4.

Rated Voltage (Volts)

.................................................



CHAPTER – E9

PAGE 2 OF 8

CLAUSE NO

CABLES Bidder’s Name: ......................................

5.

6.

7.

Suitable for earthed or unearthed system?

.................................................

Continuous current rating when laid in air in an ambient temp. of 40o C and for maximum conductor temp. 90 oC for XLPE cable and 70o for PVC cable

.................................................

Rating factors applicable to the current ratings given in Clause 1.6 for the following variations/ conditions of installation.

.................................................

a)

b)

Variation in ambient air temp. from 25oC to 55 o C in steps of 5oC

.................................................

Group rating factors for different spacing of cables installed in horizontal cable trays, arranged in vertical tiers, under the following methods of laying (in trefoil formation of single core cable)

.................................................

i)

ii)

8.

Cables laid in formed concreted trenches with restricted air circulation

.................................................

Cables laid in Coverhead cable trays

.................................................

Continuous current rating when laid buried in ground under the following conditions of laying i)

ii)

Reference ground temperature 30oC

.................................................

.................................................

Maximum conductor temperature - 70deg C for PVC



CHAPTER – E9

PAGE 3 OF 8

CLAUSE NO


iii)

iv)

9.

b)

c)

d)

Thermal Resistivity of soil 150oC cm/w

.................................................

Depth of laying (to the highest point) 900 mm

.................................................

Variation in ground temp. from 25oC to 50oC in steps of 5oC

..................................................

Variation in thermal resistivity of the soil in the range 100/120/150/ 200/250/300 deg. C cm/w

.................................................

Group rating factor for different spacing of cables installed horizontally (in trefoil formation for single core cables)

.................................................

Variation in depth of burial in the range 600 mm to 1150 mm

.................................................

Short Circuit Capacity a)

Short circuit Amp. (rms) kA

.................................................

b)

Duration of short circuit Sec.

.................................................

c)

Conductor temp. allowed for the short circuit duty, deg. C

.................................................

Formula relating short circuit current (rms) and duration (Sec.)

.................................................

d)

11.

.................................................

Rating Factors applicable to the current rating given in clause 8 for the following variations/ conditions of installation a)

10.

- 90 deg C for XLPE

Loss tangent at normal frequency



.................................................

CHAPTER – E9

PAGE 4 OF 8

CLAUSE NO


12.

Conductor a)

Material (Copper or aluminium)

.................................................

b)

Grade

.................................................

c)

Normal cross section area (Sq. mm)

.................................................

Number and diameter of wire (No. / mm)

.................................................

e)

Form of Conductor

.................................................

f)

Approximate dia over conductor (mm)

.................................................

Direction of lay of Standard layers

.................................................

d)

g)

13.

14.

15.

16.

17.

Conductor resistnace (DC) at 20oC per 1000 metres (ohm)

.................................................

Conductor resistance (AC) at maximum operating temp. per 1000 metres (ohms/km)

.................................................

Reactance per phase at 50 Hz per 1000 metres (Ohms / km)

.................................................

Capacitance at 50 Hz per 1000 metres (Micro Farads / km)

.................................................

Insulation a)

Composition of insulation

.................................................

b)

Nominal thickness of insulation (mm)

.................................................

Tolerance on thickness of insulation

.................................................

c)



CHAPTER – E9

PAGE 5 OF 8

CLAUSE NO


d)

e)

18.

19.

Minimum volume resistivity at 90oC for XLPE cable and at 70oC for PVC cable (ohm / cm)

.................................................

Minimum volume resistivity at 20oC (ohm-cm)

.................................................

Inner Sheath a)

Material

.................................................

b)

Extruded or Wrapped?

.................................................

c)

Calculated diameter over the laid up cores (mm)

.................................................

d)

Thickness of sheath

.................................................

e)

Tolerance on thickness of inner sheath

.................................................

Type and material of armour

.................................................

Direction of lay of armouring

.................................................

Normal diameter of cable over inner sheath (under armour), mm

.................................................

Nominal diameter of round armour wire

.................................................

e)

Number of armour wires

.................................................

f)

A.C. resistance of armour wires at 60oC

.................................................

Armour a)

b)

c)

d)



CHAPTER – E9

PAGE 6 OF 8

CLAUSE NO

CABLES Bidder’s Name: ...................................... g)

h) 20.

.................................................

D.C. resistance at 20oC

.................................................

Outer Sheath

.................................................

a)

Material

.................................................

b)

Calculated diameter under the sheath

.................................................

c)

Thickness of sheath

.................................................

d)

Tolerance on thickness of seath

.................................................

Guaranteed value of minimum oxygen index of outer sheath

.................................................

f)

Colour of sheath

.................................................

a)

Overall diameter of cable (mm)

.................................................

Tolerance on overall diameter (mm)

.................................................

e)

21.

Short circuit capacity of the armour along with formula relating short circuit current and duration

b)

22.

Weight per 1000 metres (Kg)

.................................................

23.

Recommended minmum installation radius

.................................................

Safe pulling force when pulled by pulling eye on the conductor (Kg)

.................................................

Cable Drums

.................................................

a)

Dimensions

.................................................

i)

.................................................

24.

25.


Flange diameter, (mm)


CHAPTER – E9

PAGE 7 OF 8

CLAUSE NO


b)

c)

26.

ii)

Barrel diameter, (mm)

.................................................

iii)

Traverse, (mm)

.................................................

Weight of cable drum with cables (Kg)

.................................................

Maximum / standard length per drum for each size of cable (single length) with plus or minus 5% tolerance (metre)

.................................................

Test Voltage

.................................................

a)

High Voltage test (kV)

.................................................

b)

Water immersion test voltage (kV)

.................................................

27.

Whether progressive sequential marking on outer sheath provided

Yes/No .................................................

28.

Core numbering in case of control cables provided

Yes/No .................................................

29.

Minimum bending radius permissible

.................................................



CHAPTER – E9

PAGE 8 OF 8

CHAPTER - E10 SUBSTATION AUTOMATION SYSTEM (SAS)



CLAUSE NO


Bidder’s Name: ...................................... 1.00.00

GENERAL TECHNICAL DETAILS AND DRAWINGS

1.01.00

SAS Manufacturer’s Name

………………………………..

1.02.00

Make/Model No

………………………………..

1.03.00

Place of Manufacture

………………………………..

1.04.00

Detailed descriptions of SAS proposed by the Bidder including SAS architecture drawing covering all salient features of hardware, software, system configuration for each system/sub-system testing, documentation, post commissioning support facilities, etc. furnished at

Page No. …….. Sec. No. …….

Complete Bill of Materials including all hardware items/equipment and accessories (including maintenance and test equipment) furnished at


Bidder to state any constraints imposed by proposed system as regards to expansion


a)

Addition of BCUs


b)

Addition of OWSs and peripherals (like CRT/Keyboard, printers)


c)

Addition of discreet numerical relays


d)

Increase in communication through put


e)

Memory addition


1.05.00

1.06.00

1.07.00

1.08.00

1.09.00

On-line removal/replacement of BCUs/BPUs possible without switching off power supply to the corresponding rack & without affecting SAS operation

Yes/No. ………………………..

Guaranteed annual system availability (refer to 2.02.00)

………………………………….

Supporting calculations for 1.08.00 above enclosed.

Yes/No. ………………………..



CHAPTER - E10

PAGE 1 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 1.10.00

Self Diagnostics Confirm that on-line self diagnostics have been provided at : -

-

1.11.00

Control Level 2 for HMI and its components including substation Level / Interbay (BCU/BPU) Level LAN

Yes/No. ………………………..

Control Level 1 for each BCU and individual numerical relays comprising various BPUs

Yes/No. ………………………..

Performance figures during system worst case conditions

……….. ………………………..

Overall display response time (alarms, status, analogues)

Page No. …… Sec. No. ……

1.11.02

Expected LAN loading


1.11.03

Expected CPU usage of workstations and controllers


1.11.04

Detailed calculation of DC and AC SAS load requirement


1.11.05

Power Fail Auto Restart (PFAR) facility provided

Yes/No. ……………………..

1.12.00

Accuracy in terms of time for all devices within substation with time synchronization (in line with Clause 1.09.00 of Technical Specification)

…………………………………

Bidder to confirm strict compliance to specification requirements

Yes/No. ……………………..

Clause by clause compliance statement to Chapter 10 of the SAS specification


Detailed description of method of interlocking operation


Detailed description of interface provided to Generation Plant SAS/SCADA, including information required from third party devices to facilitate this interface


1.11.01

1.13.00

1.14.00

1.15.00

1.16.00



CHAPTER - E10

PAGE 2 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 1.17.00

Spares and Repairs :

1.17.01

State availability of spares in country and spares holding in country of origin


1.17.02

Maximum repair turnaround time


1.17.03

Define the proposed repair strategy


1.17.04

Recommended spares list


1.18.00

List of reference sites in operation for more than 1 year


Statement confirming the design life of the system and/or any restrictions/proposed corrective action in this regard (refer to 1.15.00)


1.19.00

2.00.00

HUMAN-MACHINE INTERFACE (HMI) FOR SAS

2.01.00

Bidder to confirm the compliance of HMI to specification requirements

Yes/No. ………………………

No. of Operator’s Workstations (OWS) provided in offered SAS

………………………………..

No of Engineering Workstations provided in offered SAS

…………………………………

Interchangeability of OWS as per the requirements of specification

Yes/No. ……………………….

Bidder to confirm that no single failure in Substation Controller shall lead to non-availability of more than one OWS

Yes/No. ……………………….

Operating system for Operator’s/Engineering Workstation

…………………………………

2.02.00

2.03.00

2.04.00

2.05.00

2.06.00

2.07.00

Workstations

2.07.01

Make / Model No

………………………………...

2.07.02

Processor

…………………………………

2.07.03

Clock speed

…………………………………

2.07.04

Hard disk size

…………………………………


Operator’s programme’s Others


CHAPTER - E10

PAGE 3 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 2.07.05

CD-ROM Drive & DVD Drive

…………………………………

2.07.06

RAM

…………………………………

2.07.07

Please indicate each workstation includes the following :

2.07.08

2.07.09

2.07.10

2.08.00

a)

CRT

Yes/No : Yes/No : Yes/No

b)

Function keyboard


c)

Mouse


a)

Make/Model No

……………………………….

b)

Size of screen

……………………………….

c)

SVGA monitor

Yes/No

d)

Suitable for table-top arrangement

Yes/No

CRTs

Printers a)

Make/Model No

……………………………….

b)

Speed of print (B&W)

……………………………….

c)

Speed of print (colour)

……………………………….

Keyboards a)

Make/Model No

b)

Membrane type

………………………………. Yes/No

Laptop (Notebook) PC a)

Make/Model No

……………………………….

b)

Processor

……………………………….

c)

Clock speed

……………………………….

d)

Hard disk size

……………………………….

e)

CD-ROM drive size

……………………………….

f)

RAM

……………………………….



CHAPTER - E10

PAGE 4 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 2.09.00

Rear Project Mimic Display Unit

……………………………….

2.09.01

Make and type of MIMIC

……………………………….

2.09.02

Country of manufacture

……………………………….

2.09.03

Reference standards

……………………………….

2.09.04

Service intervals of lamps used and details of operating cost of unit

……………………………….

Overall dimensions of MIMIC and number of sub-modules used, if any

……………………………….

2.09.05

3.00.00

COMMUNICATION NETWORK

3.01.00

Data communication speed for Substation LAN

3.02.00

Provide drawing of data communication bus for :

3.03.00

3.04.00

a)

Substation network

Page No………. No…………

b)

Interbay (BCU/BPU) bus including details of cable type, armouring, etc

Page No……….. No…………

Data cable for substation network as well as Interbay (BCU/BPU) bus is armoured as per 8.02.00 & 8.03.00

b)

3.06.00

Yes/No

Communication protocol used for : a)

3.05.00

……………………………….

Devices at Control Level 1 as per specification (i.e. BCU & BPU)

…………………………………

Substation Level LAN at Control Level 2 as per specification

…………………………………

Data communication speed for Substation Network & Interbay Bus Interface with Owner’s OPC-compliant DCS provided in line with the requirements of technical specification

3.07.00

Gateways (Each type)

3.07.01

Protocols supported by each type



…………………………………

Yes/No.

…………………………………

CHAPTER - E10

PAGE 5 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 3.07.02

No. of communication Ports

…………………………………

3.07.03

Details of communication Ports

…………………………………

3.08.00

Bay Control Units (BCU)

3.08.01

Make and type of BCU offered for: 400kV Bays

…………………………………

3.09.00

No of BCU offered for each 400kV bay

…………………………………

3.10.00

No of analog inputs in each BCU

…………………………………

3.11.00

No of digital inputs in each BCU

…………………………………

3.12.00

No of digital outputs in each BCU

…………………………………

3.13.00

Accuracy of analog measurements in BCU : a)

Voltage

…………………………………

b)

Current

…………………………………

c)

Frequency

…………………………………

d)

Power

…………………………………

3.14.00

Bay mimic provided on BCU display

3.15.00

Time resolution, in ms, for events/alarms acquired by BCU

…………………………………

3.16.00

Built-in functions provided (if any) (list out)

…………………………………

3.17.00

Detailed Technical Catalogue for offered BCU enclosed

3.18.00

Yes/No

Yes/No

Synchronization i)

Angle range

…………………………………

ii)

Frequency (slip) range

…………………………………

iii)

Voltage range

…………………………………

iv)

Synchronization source (Line/Phase)

…………………………………



CHAPTER - E10

PAGE 6 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 4.00.00

BAY PROTECTION UNIT (BPU) FOR 400 kV LINES

4.01.00

a)

Main-I

Main-II

Make and type of Main I/Main II Numerical Distance Relay offered

…………………………………

b)


…………………………………

c)

Hardware version number

…………………………………

d)

Firmware version number

…………………………………

e)

Mean-time between failures

…………………………………

f)

Rated Voltage Vn (phase-to-neutral)

…………………………………

g)

Rated Current In

…………………………………

h)

Rated Frequency

…………………………………

i)

Overvoltage capability – continuous

…………………………………

j)

Overvoltage capability – 3s

…………………………………

k)

Burden on voltage transformers (VA per phase) ………………………………

l)

Overcurrent capability – continuous

…………………………………

m)

Overcurrent capability – 1s

…………………………………

n)

Burden on current transformers (VA per phase) …………………………………

o)

Reference standards

…………………………………

p)

Operating principle

…………………………………

q)

Is it a full scheme design i.e. six measuring systems for each zone

Yes/No

Yes/No

Yes/No

Yes/No

r)

s)

Operation indicator provided separately for phase & zone of operation, power swing block/trip, SOTF, A/R Block, etc Maximum operating time for a source to line impedance ratio equal to 15 and fault at Zone 1 reach setting



…………………………………

CHAPTER - E10

PAGE 7 OF 40

CLAUSE NO


Bidder’s Name: ...................................... t)

Setting range (Ohmic, time & angular) : -

Zone 1

…………………………………

-

Zone 2

…………………………………

-

Zone 3

…………………………………

-

Additional Zones, if available

…………………………………

u)

Maximum resetting time

…………………………………

v)

Setting range of offset feature

…………………………………

w)

Suitable for single and three phase trip?

Yes/No

x)

Shape of characteristics for :

Yes/No

-

Earth faults

…………………………………

-

Phase faults

…………………………………

y)

Required minimum voltage at relay terminals …………………………………

z)

Fault resistance coverage

aa)

Zero sequence compensation range (Z0/Z1) …………………………………

bb)

Whether mutual compensation module for double circuit lines included?

Yes/No

cc)

Available compensation setting range

…………………………………

dd)

Self monitoring and cyclical test facilities available?

Yes/No

Yes/No

Display on demand of various measured parameters, alarms, clock, settings, etc available?

Yes/No

Yes/No

Facility for synchronization of internal clock with GPS, in line with specification requirement provided

Yes/No

Yes/No

Yes/No

Yes/No

ee)

ff)

gg)

…………………………………

Yes/No

Built-in functions provided : -

Local overvoltage function



CHAPTER - E10

PAGE 8 OF 40

CLAUSE NO


Bidder’s Name: ......................................

hh)

ii)

-

Voltage setting range

………………………………..

-

Drop off/pick up ratio

………………………………..

-

Timer setting range

………………………………..

-

Open jumper protection

Yes/No

Yes/No

-

Power swing blocking

Yes/No

Yes/No

-

Weak infeed tripping logic

Yes/No

Yes/No

-

Echo function

Yes/No

Yes/No

-

CVT fuse failure function

Yes/No

Yes/No

-

Switch onto fault function

Yes/No

Yes/No

-

Current reversal guard

Yes/No

Yes/No

-

Digital fault recording function

Yes/No

Yes/No

-

Trip coil supervision function

Yes/No

Yes/No

-

Distance to fault locator function

Yes/No

Yes/No

List out the user-configurable carrieraided scheme logics (such as PUTT, POTT, Direct Transfer Trip, etc) and non-carrier aided schemes such as Zone 1 extension etc, provided

……………………………….. ……………………………….. ………………………………..

Multiple settings group feature available (indicate the number of available setting groups)

………………………………..

Back-up earth fault protection functions provided

Yes/No

Yes/No

kk)

Dead Line Charging feature provided

Yes/No

Yes/No

ll)

Communication ports – number and type

………………………………..

mm)

Relay operating and analysis software

………………………………..

jj)



CHAPTER - E10

PAGE 9 OF 40

CLAUSE NO


Bidder’s Name: ...................................... nn)

4.02.00

4.03.00

Built-in sequence of event recording

Yes/No

Yes/No

-

Resolution

………………………………..

-

Number of stored events

………………………………..

oo)

Built-in oscillography

Yes/No

Yes/No

pp)

Self supervision

Yes/No

Yes/No

Open Jumper Protection a)

Built-in or stand alone

………………………………..

b)

If stand alone, manufacturer’s name, type and designation

………………………………..

c)

Operating principle

………………………………..

d)

Operation indicator provided

e)

Setting range

………………………………..

f)

Timer setting range

………………………………..

g)


………………………………..

h)

Built-in fault recording feature available for Open Jumper Protection function

Yes/No

Yes/No

Power Swing Blocking Relay a)

Name and country of manufacturer

………………………………..

b)

Manufacturer's type and designation

………………………………..

c)

Reference standards

………………………………..

d)

Operating principle

………………………………..

e)

Numerical

Yes/No

f)

Operation indicator provided?

Yes/No

g)

Setting range (Ohmic, time & angular)

………………………………..

i)

………………………………..

Ohmic



CHAPTER - E10

PAGE 10 OF 40

CLAUSE NO


Bidder’s Name: ......................................

4.04.00

4.05.00

ii)

Angular

………………………………..

iii)

Time

………………………………..

Fuse Failure Relay a)


………………………………..

b)

Manufacturer type and designation

………………………………..

c)

Contacts-Self reset/hand reset

………………………………..

d)


e)

Operating time

………………………………..

f)

Whether monitors all 3 phases

………………………………..

g)

Whether operates on earth faults?

Yes/No

h)

Whether activates B/up O/C and E/F Protection

Yes/No

i)

Numerical

Yes/No

Yes/No

400 kV Line Over Voltage Relay (59 L) a)

Manufacturer & country of manufacturer

………………………………..

b)

Type designation

………………………………..

c)


………………………………..

d)


………………………………..

e)


………………………………..

f)

Rated voltage

………………………………..

g)

Setting ranges

………………………………..

h)


………………………………..

i)

Timer setting range

………………………………..

j)

Numerical

k)

No. of Voltage stages

………………………………..

l)

No. of time stages

………………………………..


Yes/No


CHAPTER - E10

PAGE 11 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 4.06.00

Auto Reclose and Synchronising Check Relay

4.06.01

a)

Recloser Manufacturer’s name, type and designation

………………………………..

b)


………………………………..

c)


………………………………..

d)


………………………………..

e)


………………………………..

f)


………………………………..

g)

Rated Current In

………………………………..

h)

Rated Frequency

………………………………..

i)


………………………………..

j)


………………………………..

k)

Burden on voltage transformers (VA per phase) ………………………………..

l)


………………………………..

m)


………………………………..

n)

Burden on current transformers (VA per phase) ………………………………..

o)

Reference standards

………………………………..

p)

Operating principle

………………………………..

q)

Suitable for single as well as three phase reclosure

Yes/No

r)

Single Phase Dead Time Setting Range

………………………………..

s)

Three Phase Dead Time Setting Range

………………………………..

t)

Reclaim Time Setting Range

………………………………..

u)

Single shot or multi-shot

………………………………..

v)

Synchronism check ‘window’ time

………………………………..



CHAPTER - E10

PAGE 12 OF 40

CLAUSE NO


Bidder’s Name: ......................................

4.06.02

w)

Communication ports – number and types

………………………………..

x)


Yes/No

y)

Self supervision

Yes/No

z)

Built-in sequence of event recording -

Resolution

………………………………..

-


………………………………..

aa)


a)

Synchronizer Manufacturer’s name, type and designation

………………………………..

b)


………………………………..

c)


………………………………..

d)


………………………………..

e)


………………………………..

f)


………………………………..

g)

Rated Current In

………………………………..

h)

Rated Frequency

………………………………..

i)


………………………………..

j)


………………………………..

k)


l)


………………………………..

m)


………………………………..

n)


o)

Reference standards

………………………………..

p)

Operating principle

………………………………..

q)

Range of angle at closure

………………………………..



Yes/No

CHAPTER - E10

PAGE 13 OF 40

CLAUSE NO


Bidder’s Name: ......................................

4.06.03

4.07.00

r)

Slip frequency setting range

………………………………..

s)

Dead line/bus voltage range

………………………………..

t)

Line line/bus voltage range

………………………………..

u)

Delta synchronizing voltage amplitude

………………………………..

v)

Synchronizing voltage source (line/phase)

………………………………..

w)

Manual close permission selection options

………………………………..

x)

Automatic reclose permission selection options………………………………..

y)


Yes/No

Dead Line Charging Feature a)


………………………………..

b)


………………………………..

c)

Whether two sets of relays present

Yes/No

d)

Whether each set able to monitor the three phase voltage?

Yes/No

e)

Setting of the relay set connected to Line CVT ………………………………..

f)

Setting of the relay set connected to Bus CVT ………………………………..

g)

Operating time

………………………………..

h)

Resetting time

………………………………..

i)

Principle of operation

………………………………..

Stand alone/Built-in Digital Fault Recorder for 400 kV Lines a)

Manufacturer’s name, type and designation

………………………………..

b)


………………………………..

c)


………………………………..



CHAPTER - E10

PAGE 14 OF 40

CLAUSE NO


Bidder’s Name: ...................................... d)


………………………………..

e)


………………………………..

f)


………………………………..

g)

Rated Current In

………………………………..

h)

Rated Frequency

………………………………..

i)


………………………………..

j)


………………………………..

k)


l)


………………………………..

m)


………………………………..

n)


o)

Reference standards

p)

Operating principle

q)

Bidder to confirm compliance to requirements of technical specification

r)

Scan rate range i)

………………………………..

Yes/No ………………………………..

Selectable dual scan rate

Yes/No

s)

No of analog channels offered

………………………………..

t)

No of digital channels offered

………………………………..

u)

By how many numbers can the channels be expanded :

v)

w)

-

Analog channels

………………………………..

-

Digital channels

………………………………..

Following starting sensors provided :

Yes/No

-

Threshold (voltage, current & frequency)

Yes/No

-

Rate of change of voltage & frequency ………………………………..

Pre-fault memory (in milliseconds)



………………………………..

CHAPTER - E10

PAGE 15 OF 40

CLAUSE NO


Bidder’s Name: ...................................... x)

Post-fault memory (in milliseconds)

………………………………..

y)

Frequency response

………………………………..

z)

Resolution of digital channels (in ms)

………………………………..

aa)

Amplitude resolution

………………………………..

bb)

Memory capacity in solid state non-volatile memory

Yes/No

Provision for time synchronization of internal clock with GPS, in line with the specification requirement provided

Yes/No

Whether fault data is available in IEEE/COMTRADE format at Substation Level for analysis as per the requirements of technical specification

Yes/No

Whether alarm output contacts provided for power supply fail, processor fail, memory fail, printer fail, etc provided

Yes/No

Whether software for analysis of fault data provided

Yes/No

cc)

dd)

ee)

ff)

4.08.00

gg)

Detailed technical literature enclosed

…………………………………

hh)


…………………………………

ii)

Self supervision

Yes/No

Distance to Fault Recorder a)

Built-in (with in DFR) or stand alone

…………………………………

b)


…………………………………

c)


…………………………………

d)


…………………………………

e)


…………………………………

f)


…………………………………



CHAPTER - E10

PAGE 16 OF 40

CLAUSE NO


Bidder’s Name: ...................................... g)


…………………………………

h)

Rated Current In

…………………………………

i)

Rated Frequency

…………………………………

j)


…………………………………

k)


…………………………………

l)

Burden on voltage transformers (VA per phase) ………………………………

m)


…………………………………

n)


…………………………………

o)


p)

Reference standards

…………………………………

q)

Operating principle

…………………………………

r)

Whether “Online” type

…………………………………

s)

Whether both phase to phase fault and phase to earth fault measuring units included

Yes/No

Provision for mutual zero sequence compensation provided

Yes/No

t)

4.09.00

u)

Accuracy for all types of faults and fault levels …………………………………

v)

Whether direct display unit provided

Yes/No

w)

Technical literature enclosed

Yes/No

x)


y)

Self supervision

z)

Guaranteed distance to fault accuracy in % including all measurement errors

………………………………… Yes/No

…………………………………

High Speed Trip Relay a)




…………………………………

CHAPTER - E10

PAGE 17 OF 40

CLAUSE NO


Bidder’s Name: ...................................... b)

Manufacturer’s type and designation

…………………………………

c)

Operating principle

…………………………………

d)

No of contacts :

…………………………………

i)

Normally open

…………………………………

ii)

Normally closed

…………………………………

e)

Contacts manual resetting feature from Substation Level as well as BCU Level Provided

Yes/No

f)


Yes/No

g)

i)

Operating time at rated voltage (maximum)

……………………………

ii)

Operating range of voltage

h)

Whether supervisory relays included

i)


5.00.00

RELAYS COMMON TO LINE BAY,GT BAY & BUS COUPLER BAY BCU

5.01.00

Trip Circuit Supervision Relay

Yes/No …………………………………

a)


…………………………………

b)


…………………………………

c)

Operating principle

…………………………………

d)


Yes/No

e)

Whether pre-close and post-close supervision provided?

Yes/No

f)

5.02.00

…………………………………

Time delay

…………………………………

Local Breaker Back-up Protection (50 LLB) a)




…………………………………

CHAPTER - E10

PAGE 18 OF 40

CLAUSE NO


Bidder’s Name: ...................................... b)


…………………………………

c)


…………………………………

d)


…………………………………

e)


…………………………………

f)

Duplicated

g)

Build specify location

…………………………………

h)


…………………………………

i)

Rated Current In

…………………………………

j)

Rated Frequency

…………………………………

k)


…………………………………

l)


…………………………………

m)


n)

Reference standards

…………………………………

o)

Operating principle

…………………………………

p)


q)

Setting ranges :

…………………………………

i)

Current

…………………………………

ii)

Time

…………………………………

r)

Operating time

…………………………………

s)

Resetting time

…………………………………

t)

Communication ports – number and types

…………………………………

u)


…………………………………

v)

No of binary outputs

w)

No of binary inputs

x)

Self supervision


Yes/No

Yes/No

Yes/No ………………………………… Yes/No


CHAPTER - E10

PAGE 19 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 5.03.00

kV ‘Tee’ Protection (87TT-I, 87TT-II)

87TT-I

87TT-II

a)


…………………………………

b)


…………………………………

c)


…………………………………

d)


…………………………………

e)


…………………………………

f)

No of analogue inputs (Minimum 3 windings) …………………………………

g)

Rated Current In

…………………………………

h)

Rated Frequency

…………………………………

i)


…………………………………

j)


…………………………………

k)


l)

Reference standards

…………………………………

m)

Operating principle

…………………………………

n)

Rated current and/or voltage

…………………………………

n)

Setting range

…………………………………

o)

Operating time at :

…………………………………

i)

2 * setting

…………………………………

ii)

5 * setting

…………………………………

p)


…………………………………

q)


…………………………………

r)


Yes/No

-

Resolution

…………………………………

-


…………………………………

s)

Self supervision


Yes/No


CHAPTER - E10

Yes/No

Yes/No

PAGE 20 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 6.00.00

BUSBAR PROTECTION FOR 400 kV BUSBAR a)

Main-1

Main-2

Manufacturer’s name, type and designation of busbar protection relay

…………………………………

b)

Is it complete numerical protection?

Yes/No

c)

Operating principle

…………………………………

d)

Rated current/voltage

…………………………………

e)

Setting ranges

…………………………………

f)

Operating time at 5* setting value

…………………………………

g)

Resetting time

…………………………………

h)

No. of contacts (NO/NC)

…………………………………

i)

Does the relay give 100% security and reliability under all operating conditions and up to 40kA fault level?

Yes/No

Yes/No

CT secondary supervision and protection against CT secondary open provided

Yes/No

Yes/No

Does it require auxiliary CTs for ratio correction?

Yes/No

Yes/No

j)

k)

Yes/No

l)

Does it require external CT switching relays? No

No

m)

Self-monitoring diagnostic provided

Yes/No

Yes/No

n)


…………………………………

o)


…………………………………

p)


…………………………………

q)


…………………………………

r)

Rated Frequency

…………………………………

s)

Selectable Internal or External breaker failure per bay

Yes/No

Yes/No

Overall Check Zone

Yes/No

Yes/No

t)



CHAPTER - E10

PAGE 21 OF 40

CLAUSE NO


Bidder’s Name: ......................................

7.00.00

u)

Bay Out of Service switches for each bay

Yes/No

Yes/No

v)


…………………………………

w)


…………………………………

x)

Burden on current transformers (VA per phase)

…………………………………

y)

Reference standards

…………………………………

z)

Bidder to confirm compliance to requirements of technical specification

Yes/No

aa)

Communication ports (number and type)

…………………………………

bb)


Yes/No

cc)


Yes/No

-

Resolution

…………………………………

-


…………………………………

dd)

Self supervision

Yes/No

ee)


Yes/No

ff)

Device status and operation indications

Yes/No

TIME SYNCHRONISATION EQUIPMENT a)

Manufacturer’s name and country of manufacture

…………………………………

b)

Type designation

…………………………………

c)

Tested to all relevant standards and one copy of test reports enclosed in the bid?

d)

Accuracy

e)

All auxiliary systems and special cables, etc required to meet the specification provided?


Yes/No …………………………………


Yes/No

CHAPTER - E10

PAGE 22 OF 40

CLAUSE NO


Bidder’s Name: ...................................... f)

8.00.00

Suitable protections provided against lightning surges and over voltages?

Yes/No

g)

Details of output ports provided for time synchronization and their specification (such as pps, ppm, pph etc, soft configurable, hard configurable etc) …………………………………

h)

Is output signal programmable at site?

Yes/No

ACTIVE AND REACTIVE ENERGY METERS (KWH & KVARH) a)

Shall be microprocessor-based conforming to IEC 60687 /IEC 62052-11/IEC 62053-22 / IS 14697 …………………………………

b)

Shall carry out measurement of active energy (both import and export) and reactive energy (both import and export) by 3 phase, 4 wire principle suitable for balanced/ unbalanced 3 phase load.

…………………………………

Shall have an accuracy of energy measurement of at least Class 0.2 for active energy and at least Class 0.5 for reactive energy according to IEC 60687, and shall be connected to Class 0.2 CT cores and Class 0.2 VT windings.

…………………………………

The active and reactive energy shall be directly computed in CT & VT primary ratings.

…………………………………

The reactive energy shall be recorded for each metering interval in four different registers as MVARh (lag) when active export, MVARh (Lag) when active import, MVARh (lead) when active export, MVARh (Lead) when active import.

…………………………………

c)

d)

e)

f)

Two separate registers shall be provided to record MVARH when system voltage is >103% and when system voltage is < 97%. …………………………………



CHAPTER - E10

PAGE 23 OF 40

CLAUSE NO


Bidder’s Name: ...................................... g)

Shall compute the net MWh and MVARh during each successive 15-minute block metering interval along with a plus/minus sign, instantaneous net MWh, instantaneous net MVARh, average frequency of each 15 minutes, net active energy at midnight, net reactive energy for voltage low and high conditions at each midnight. …………………………………

h)

Each energy meter shall have a display unit with a seven digit display unit. It shall display the net MWh and MVARh with a plus/minus sign and average frequency during the previous metering interval; peak MWh demand since the last demand reset; accumulated total (instantaneous) MWh and MVARh with a plus/minus sign, date and time; and instantaneous current and voltage on each phases.

…………………………………

All the registers shall be stored in a non-volatile memory. Meter registers for each metering interval, as well as accumulated totals, shall be downloadable. All the net active/reactive energy values displayed or stored shall be with a plus /minus sign for export/import.

…………………………………

i)

j)

At least the following data shall be stored before being over-written for the following parameters. Parameters

details

1. Net MWH

15 min block 40 days in meter……………………………

2. Aver Freq

15 min block 40days in meter

…………………………

3. Net MVARH for V > 103%

15min block 40days in meter

…………………………

4. Net MVARH for V < 97%

15min block 40days in meter

…………………………


Min No of days


CHAPTER - E10

PAGE 24 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 5. Cumulative 10 days in meter/ Net MWH at every40 days in PC Midnight

………………………….

6. Cumulative 10 days in Meter/ Net MVARH for 40 days in PC V> 103% at every midnight

…………………………..

7. Cumulative 10 days in Meter / Net MVARH for 40 days in PC V < 97% At every midnight 8. Date and time blocks of VT failure on any phase. k)

l)

m)

n)

Shall have a built in clock and calendar with an accuracy of less than 15 seconds per month drift without assistance of external time synchronizing pulse.

………………………………...

Date/time shall be displayed on demand. The clock shall be synchronized by GPS time synchronization equipment being supplied by the bidder.

………………………………….

The voltage monitoring of all the three voltages shall be provided and alarm contacts provided to signal failures to the Substation Automation System, as well as alarm contact to indicate meter healthy status. The meter shall be suitable to operate with power drawn from the VT supplies. The burden of the meters shall be less than 2 VA.

………………………………….

The power supply to the meter shall be healthy even with a single-phase VT supply. An automatic backup, in the event of non-availability of voltage in all the phases, shall be provided by a built in long life battery and shall not need replacement for at least 10 years with a continuous VT interruption of at least 2 years. Date and time of VT interruption and restoration shall be automatically stored in a non-volatile memory.

………………………………….



CHAPTER - E10

PAGE 25 OF 40

CLAUSE NO


Bidder’s Name: ...................................... o)

p)

Shall have an optical port on the front of the meter for data collection from either a hand held meter reading instrument (MRI) having a display for energy readings or from a notebook computer with suitable software. The bidder shall supply the MRI and/or notebook complete with all optical interface unit required.

………………………………….

A dedicated Metering Master Station (MMS), hardwired to all the energy meters in bidder’s scope shall be provided. The MMS shall be complete to offer the following functionality:

………………………………….

To automatically downloaded the meter data from each meter point at scheduled daily intervals

………………………………….

To create calculated metering points by addition, subtraction, and applying multiplication factors to meter points

………………………………….

To present the demand of each meter point and calculated meter points in graphical format over specified intervals.

………………………………….

To calculated the total energy exchanged on meter points or calculated meter points for different time-of-use periods over specified intervals. …………………………………. To export meter data to Excel format for external analysis. …………………………………. To calculate the Unscheduled interchanges ( UI ) and the corresponding commercial parameters to suit the ABT requirements ………………………………….

q)

The meter shall have means to test MWh and MVARh accuracy and calibration at site in-situ and test terminal blocks shall be provided for the same.



………………………………….

CHAPTER - E10

PAGE 26 OF 40

CLAUSE NO


Bidder’s Name: ...................................... r)

s)

9.00.00

………………………………….

The MMS shall be connected to substation LAN so as to facilitate display of Energy data at other locations of the LAN. ………………………………….

FREQUENCY RELAY [ISU/F] (FOR ISLANDING SCHEME) a)


………………………………….

b)

Type designation

………………………………….

c)

Rated frequency

………………………………….

d)

Setting Range

………………………………….

e)

Drop off pick up ratio

………………………………….

f)

No. of stages

………………………………….

g)

Numerical

………………………………….

h)

df/dt element

………………………………….

I) j) 10.00.00

Each meter shall have an unique identification code provided by the owner and shall e permanently marked on the front of the meter and stored in the non volatile memory of the meter.

separate trip relay provided Operating time of trip relay

…………………………………. ………………………………….

DYNAMIC RELAY TEST KIT a)


………………………………….

b)

Type designation

………………………………….

c)

Whether Modular in construction?

………………………………….

d)

Suitable to accept the fault data stored in line protection relay, dist. recorder of generator/line in for dynamic testing on relays

………………………………….

e)

Number of modules provided



CHAPTER - E10

PAGE 27 OF 40

CLAUSE NO


Bidder’s Name: ......................................

11.00.00

i)

Current

………………………………….

ii)

Voltage

………………………………….

iii)

Any other

………………………………….

f)

All software and PC etc. required has been provided

g)

Aux. items like phantom load, test plugs, tool kits etc provided

………………………………….

………………………………….

PANELS a)


………………………………….

b)

IP Standard

………………………………….

c)

Lockable front Plexiglass door provided.

………………………………….

12.00.00

BAY PROTECTION UNITS FOR MAIN GENERATOR CIRCUITS

12.01.00

Manufacturer’s name, type and designation of relays providing following protection functions: a)

Generator Differential protection (87G)

………………………………….

b)

Stator E/F Protection (64G1)

………………………………….

c)

Stator Standby E/F Protection (64G2)

………………………………….

d)

Interturn Fault Protection

e)

Loss of Field Protection (40G1 & 40G2)

………………………………….

f)

Back up Impedance Protection (21G)

………………………………….

g)

Negative Sequence Current Protection (46G) ………………………………….

h)

Low Forward Power Protection (37G1 and 37G2) ………………………………

i)

Rotor E/F Protection

………………………………….

j)

Over voltage Protection

………………………………….



CHAPTER - E10

PAGE 28 OF 40

CLAUSE NO


Bidder’s Name: ......................................

12.02.00

12.03.00

k)

Over fluxing Protection for GT (99GT)

………………………………….

l)

Overall Differential Protection

………………………………….

M)

Overhead Line Connection Differential Protection

…………………………………

n)

B/U E/F Protection on GT HV Neutral

…………………………………

o)

Generator Under Frequency Protection

…………………………………

p)

Generator Pole Slipping (98G)

………………………………

q)

Accidental Back Energization (50GDM)

…………………………………

r)

GT Differential Protection

…………………………………

s)

VT fuse Failure Protection

……………………………...

t)

Unit Transformer Differential Protection

…………………………………

u)

Unit Transformer LV REF

…………………………………

v)

Unit Transformer B/U E/F Protection

…………………………………

w)

Unit Transformer Instantaneous / Delayed O/C Protection

…………………………………

Bidder to confirm that all numerical relays providing the above protection functions shall be configured into two protection groups operating on two separate DC supplies, in line with the requirements specified in the technical specification

Yes/No

Yes/No

Also provide the following information for each separate device: -


…………………………………

-


…………………………………

-


…………………………………

-


………………………………

-


…………………………………



CHAPTER - E10

PAGE 29 OF 40

CLAUSE NO


Bidder’s Name: ......................................

12.04.00

-

Rated Current In

…………………………………

-

Rated Frequency

…………………………………

-


…………………………………

-


…………………………………

-

Burden on voltage transformers (VA per phase)

…………………………………

-


…………………………………

-


…………………………………

-


-

Reference standards

…………………………………

-

Operating principle

…………………………………

-


…………………………………

-

Self supervision

…………………………………

-


…………………………………

-


…………………………………

-

Device operation and status information

…………………………………

Generator Differential Protection (87G) a)

Rated current and (or) voltage (a.c.)

.................................…………..

b)

Rated d.c Voltage

........................................…….

c)

Operating time at

........................................…….

i)

2 * setting

........................................…….

ii)

5 * setting

........................................…….

d)

Operating principle

........................................…….

e)

Tuned to system frequency?

Yes/No



CHAPTER - E10

Yes / No

PAGE 30 OF 40

CLAUSE NO


Bidder’s Name: ......................................

12.05.00

12.06.00

.

12.07.00

12.08.00

f)

Setting Range

........................................…….

g)

Non linear voltage limiting Resistors Provided?

Yes/No

Yes / No

Generator Stator Standby Earth Fault Protection (64G2) a)

Operating principle

........................................…….

b)

Rated D.C. Voltage

........................................…….

c)

Setting Range

........................................…….

d)

Time setting range

........................................……..

e)


Yes / No

Yes / No

Generator Inter Turn Fault Protection (95 G) a)

Operating principle

........................................……

b)

Setting Range

........................................…..

c)

Rated D.C. Voltage

........................................……

d)

Burden

........................................…….

e)

Drop off to pick up ratio

........................................…….

f)


Yes/No

Generator Over Voltage Protection (59 G) a)

Rated voltage

........................................…….

b)

Setting Range

........................................…….

c)


........................................……..

d)

Timer setting range

........................................……..

Generator Under Frequency Protection (81 G) a)

Rated frequency

........................................……

b)

Setting Range

........................................…….

c)


........................................…….

d)

No. of stages

........................................……..



CHAPTER - E10

PAGE 31 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 12.09.00

12.10.00

12.11.00

Generator Low Forward Power or Reverse Reverse Power Interlock Protection a)

Rated D.C. voltage

........................................…….

b)

Power Setting Range

........................................…….

c)

Timer setting range

........................................…….

Generator Loss of Excitation Protection a)

Rated current and (or) voltage (AC)

........................................…….

b)

Operating principle

........................................…….

c)

Setting Range

........................................…….

d)

Offset feature

........................................…….

e)

Mho circle

........................................……

f)

Timer setting range

........................................……..

g)

Under voltage relay setting range

........................................…….

Generator Negative Phase Sequence Protection (46 G) a)

Rated current and (or) voltage (A.C.)

........................................…….

b)

i)

Alarm current setting range

........................................……..

ii)

Alarm time setting range

........................................…….

c)

12.12.00

Trip setting range

........................................…….

Generator Pole slipping Protection (98G) a)


b)

Operating principle

........................................………

c)

Setting Ranges

........................................……….

f)

Supervising relay included



........................................……..

Yes/No

CHAPTER - E10

PAGE 32 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 12.13.00

12.14.00

12.15.00

Generator Backup Impedance Protection (21 G) a)


........................................……….

b)

Rated D.C. voltage

........................................……….

c)

Setting Range

........................................………

d)

Timer setting range

........................................………

Generator VT Fuse Failure Relay (60 G) a)

Rated voltage

........................................………

b)

Setting Range

........................................……….

c)

Timer setting range

........................................………

f)


........................................………

Transformer Differential Protection a)

Rated current

........................................……….

b)

Rated D.C. voltage

........................................………

c)

Whether second harmonic restraint feature is provided?

Yes/No ........................................……..

d)

Operating time of differential unit at 2 * setting current

........................................……..

i)

With restraint

........................................……..

ii)

Without restating

........................................………

e)

Whether three instantaneous units provided?

Yes/No

f)

Bias setting range

........................................……..

g)

Operating current setting

........................................………

h)

Resetting time

........................................………



CHAPTER - E10

PAGE 33 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 12.16.00

Generator and Generator Transformer Overfluxing Protection (99G/99GT ) a)

Rated voltage

........................................…….

b)

Principle of operation

........................................…….

c)

Whether inverse time operating characteristics provided?

d)

e)

f)

12.17.00

12.18.00

Yes/No

Setting range

........................................…….

i)

v/f ratio

........................................…….

ii)

time for alarm

........................................………

iii)

time for tripping

........................................……..

Whether different time multiplier settings provided?

Yes/No

Maximum operating time

........................................………

i)

1.4 times the rated value of v/f

........................................……..

ii)

1.5 times the rated value of v/f

........................................………

g)

Accuracy of operating time

........................................……..

h)

Resetting ratio

........................................………

i)

Reset time

........................................……….

Generator Transformer Back Up Earth fault Protection (51 NGT) a)

Rated voltage

........................................……….

b)

Setting ranges

........................................……..

d)

Definite minimum time at 10 times setting current

........................................……….

Unit Transformer Differential Protection (87UT) a)

Rated current

........................................………

b)

Rated D.C. voltage

........................................………



CHAPTER - E10

PAGE 34 OF 40

CLAUSE NO


Bidder’s Name: ...................................... c)

d)

Operating time of differential unit at 2 * setting current

........................................……….

i)

........................................……….

With restraint

........................................………..

f)

Bias setting range

........................................………

g)

Operating current setting

........................................………

h)

Reseting time

........................................………

Yes/No

Unit Transformer Back Up Over Current Protection (51UT) a)


........................................……..

b)

Type designation

........................................………

c)

Rated voltage

........................................………

d)

Setting ranges

........................................……….

i)

definite time unit

........................................………

ii)

high set unit

........................................……….

e) 12.20.00

Yes/No

ii) Without restraint Whether three instantaneous units provided?

e)

12.19.00

Whether second harmonic restraint feature is provided?

Timer setting range

........................................……….

Unit Transformer Back Up Earth Fault Protection (51NUT) a)

Rated voltage

........................................……….

b)

Setting ranges

........................................………

i)

definite time unit

........................................……..

ii)

high set unit

........................................…….

c)

Timer setting range



........................................……..

CHAPTER - E10

PAGE 35 OF 40

CLAUSE NO


Bidder’s Name: ...................................... 12.21.00

12.22.00

12.23.00

12.24.00

Unit Transformer Restricted Earth Fault Protection (64 RUT) a)

Rated voltage

........................................………

b)

Operating principle

........................................………

c)

Burden

........................................………

d)

Operating time at 2 * setting

........................................………

e)

Setting ranges

........................................………

Generator Transformer Bay Circuit Breaker Local Breaker Back Up Protection Relay (50Z) a)

Operating principle

........................................……….

b)

Contacts-Self reset/hand reset

........................................……….

c)


........................................……….

d)

Operating time

........................................………

e)

Resetting time

........................................…….

f)

Setting range

........................................…….

i)

Current

........................................…….

ii)

Time

........................................…….

Generator Trip Relays a)

Rated voltage d.c.

........................................…….

b)


........................................…….

c)

Operating time at rated voltage

........................................…….

d)

No. of contacts available

........................................…….

e)

Whether supervisory relays included

Yes/No

Yes/No

Interposing Relays for Generator Breaker a)

Rated d.c. voltage



........................................…….

CHAPTER - E10

PAGE 36 OF 40

CLAUSE NO


Bidder’s Name: ...................................... b)

Burden

........................................…….

c)

Operating principle

........................................…….

d)

No. of contacts

........................................…….

i)

Normally open

........................................…….

ii)

Normally closed

........................................…….

e)

f)

12.25.00

12.26.00

Satisfactorily operates for voltage variation - 20% to 25%?

Yes/No

Provided with diode rated for 5A and peak inverse voltage of 48 V DC.

Yes/No

Flag Relays a)


........................................…….

b)

Type designation

. ........................................…….

c)

Whether hand rest

d)

No. of elements

........................................…….

e)

No. of contacts

........................................…….

i)

Normally open

........................................…….

ii)

Normally closed

........................................…….

Yes/No

DISTURBANCE RECORDER FOR GENERATOR a)

Name & country of manufacturer

........................................…….

b)


........................................…….

c)

Overall dimensions in mm (maximum)

........................................…….

d)

Scan rate for

........................................…….

i)

Slow scan

........................................…….

ii)

Fast scan

........................................…….



CHAPTER - E10

PAGE 37 OF 40

CLAUSE NO


Bidder’s Name: ...................................... e)

No. of analogue recording channels

........................................…….

f)

No. of event recording channels

........................................…….

g)

By how many numbers can the channels be expanded?

........................................…….

i)

Analogue channels

........................................…….

ii)

Event channels

........................................…….

h)

Whether all starting sensors provided?

i)

Linearity Error (%)

........................................………

j)

i)

Pre-fault memory (milli seconds)

…………………………………….

ii)

Post fault memory (seconds)

........................................………

k)

Yes/No

Frequency Response (Hz) i)

slow scan

........................................………

ii)

fast scan

........................................……..

l)

Resolution of the event channels (ms)

.............................…………….

m)

i)

Resolution

........................................………

a)

Time

b)

Amplitude

........................................….. ........................................……..

n)

Memory capacity for one record of slow scan ........................................… at scan rate of 2.0 Hz

o)

Memory capacity for one record of fast scan ........................................…… at scan rate of 2000 Hz

p)

Whether detailed literature enclosed?

Yes/No

q)

Time display present

Yes/No

r)

i)

Total no. of modules used

........................................…….

ii)

Details of modules

........................................…….



CHAPTER - E10

PAGE 38 OF 40

CLAUSE NO


Bidder’s Name: ...................................... s)

t)

u)

12.27.00

i)

Details of time generator and synchronization facility enclosed?

Yes/No

ii)

Time synchronization with the external time synchronization equipment provided

Yes/No.

Whether man-machine interface as specified, provided?

Yes/No

Whether fault data is made available in IEEE-COMTRADE format and available through MMI for Owner’s analysis?

Yes/No

v)

Whether necessary software for analysis provided?

Yes/ No.

w)

Whether interface provided for remote transmission of fault data?

Yes/No

x)

Whether alarm output contacts provided for Power supply fail, processor fail, memory fail, printer fail etc. as specified, provided?

Yes/No.

y)

Whether interface provided for remote transmission of fault data

Yes/No.

z)

All necessary transducers, as specified, provided?

Yes/No.

Generator Active and Reactive Energy Meters a)

Name & country of manufacturer

........................................…….

b)


........................................…….

c)

Completely type tested to IEC:687?

d)

i)

Type of measurement ........................................……. (3 phase, 4 wire, balanced /unbalanced power)

ii)

Whether 3 element

Yes/No

........................................…….

e)

Accuracy

........................................…….

f)

Input aux. transformers provided for both current circuits?

........................................……



CHAPTER - E10

PAGE 39 OF 40

CLAUSE NO


Bidder’s Name: ...................................... g)

Provided with built-in clock?

h)

Whether time synchronization through external time synchronization equipment under supply provided? ........................................…….

i)

Number of digits up to which meter can register without requiring to reset

j)

k)

Data recorded in Non-volatile memory

........................................……. Yes/No.

i)

Burden

ii)

Current coil

........................................…….

ii)

Voltage coil

........................................…….

Limits of error at unity pf and 0.5 pf for KWH and KVARH meters i)

ii) l)

........................................…….

at 125%, 25% 10% and 5% rated current

........................................…….

at 100% rated current

........................................…….

Short time rating i)

Current coil

........................................…….

ii)

Voltage coil

........................................…….

iii)

Time

........................................…….

m)

Whether monitoring of all three voltages & record of time for loss of any voltage input provided?

n)

Testing facilities provided?

........................................…….

o)

Capacity of non-volatile memory for recording active & reactive energy export & import

........................................…….

Is it possible to read the energy meter in shut-down feeder shut-down state.

........................................…….

p)



Yes/No.

CHAPTER - E10

PAGE 40 OF 40

CHAPTER - E11 DC SYSTEM



CLAUSE NO

DC SYSTEM

Bidder’s Name: ..................................... (Bidder shall furnish the following data for each type of DC system) A.

BATTERY 1.


....................................................

2.

Type of Battery

...................................................

3.

Guaranteed AH capacity at Ten hours discharge rate to

....................................................

i)

ii)

4.

a)

1.85 volts per cell at 400 C for Lead Acid Plante type

...................................................

1.14 Volts per cell at 400C for Ni-Cd Type

..................................................

AH capacity at one hour discharge rate to

.................................................

i)

ii)

b)

ii)

6.

..................................................

1.14 Volts per cell at 400C for Ni-Cd type

...................................................

AH capacity at half hour discharge rate to i)

5.

1.75 Volts per cell at 400C for Lead Acid Plante type

..................................................

1.75 volts per cell at 400C for Lead Acid Plante type

..................................................

1.14 Volts per cell at 400C for Ni-Cd type

..................................................

AH capacity of five hour discharge rate for

..................................................

i)

1.82 volts per cell at 400C

..................................................

a)

Recommended range of floating/trickle charging voltage

...................................................



CHAPTER - E11

PAGE 1 OF 8

CLAUSE NO

DC SYSTEM

Bidder’s Name: ..................................... b)

7.

8.

Recommended range of Boost charging voltage

..................................................

a)

Trickle charging current

..................................................

b)

Boost charging current

..................................................

Open circuit voltage of cell when completely discharged at 400C a)

9.

10.

11.

..................................................

At ten hours discharge rate (for Lead Acid Plante type only)

..................................................

b)

At one hour discharge rate

..................................................

c)

At five hours discharge rate

..................................................

Type of construction of positive plates

..................................................

Type of construction of negative plates

..................................................

Containers

..................................................

a)

Type

.................................................

b)

Material

..................................................

12.

Sediment space (mm) if applicable

..................................................

13.

Cell dimensions (mm)

..................................................

14.

Specific gravity of electrolyte when fully charged at 400 C if applicable

...................................................

Maximum electrolyte temperature that cell can withstand continuously without injurious effects, if applicable

..................................................

15..

16.

Battery racks a)

Type of material



...................................................

CHAPTER - E11

PAGE 2 OF 8

CLAUSE NO

DC SYSTEM

Bidder’s Name: ..................................... b)

Out line dimensions (mm)

..................................................

c)

Whether anti-acid/antialkali coating provided

...................................................

Net weight (Kg)

....................................................

d) 17.

18.

19.

Insulators material (for racks and cells) if applicable

...................................................

Weight per cell i)

Net dry weight (kg)

...................................................

ii)

With electrolyte (kg)

..................................................

Total shipping weight of acid for one battery unit (kg) if applicable

.................................................

Total shipping weight of one battery unit (without electrolyte) if applicable

..................................................

21.

Total shipping weight of one battery

…………………………………….

22.

Recommended floating voltage per cell and maximum variation

...................................................

Recommended maximum period of storage before the first charge

...................................................

Amount of Hydrogen/Gas evolved during boost charging

...................................................

20.

23.

24..

25.

Recommended interval at which battery should be discharged at

26.

Short circuit current at battery terminals

27.

Times for which the battery can withstand short circuit at terminals



...................................................

....................................................

...................................................

CHAPTER - E11

PAGE 3 OF 8

CLAUSE NO

DC SYSTEM

Bidder’s Name: ..................................... 28.

29.

30.

31.

32

33.

34.

35.

Recommended maximum rating of fuses for protecting the battery

...................................................

Internal resistance of each cell at

...................................................

i)

Fully charged condition

...................................................

ii)

Fully discharged condition

..................................................

Time taken to full charge by two step constant current (boost) charging and voltage at the end of this charge

....................................................

Recommended starting and finishing rate of charge (Boost charge)

...................................................

Recommended floating voltage per cell and maximum variation

...................................................

Recommended maximum period of storage before the first charge

...................................................

Amount of Hydrogen/Gas evolved during boost charging

...................................................

Recommended interval at which battery should be discharged at

...................................................

i)

ii)

10 hour discharge rate and boost charged for Lead Acid Plante type

....................................................

5 hour discharge rate and boost charged for Ni-Cd type

...................................................



CHAPTER - E11

PAGE 4 OF 8

CLAUSE NO

DC SYSTEM

Bidder’s Name: ..................................... B.

FLOAT CUM BOOST BATTERY CHARGER 1.

Manufacturer's Name

2.

Charger dimensions :

...................................................

i)

Height (mm)

...................................................

ii)

Depth (mm)

...................................................

iii)

Width (mm)

...................................................

iv)

Sheet thickness (mm)

...................................................

3.

Degree of Protection of charger

...................................................

4.

Charger weight (Kg.)

...................................................

5.

Charger rated output current:

6.

7.

8.

i)

Trickle charging mode

...................................................

ii)

Boost charging mode

...................................................

Load limiter current setting range (Trickle mode)

...................................................

Automatic voltage regulator (Trickle mode) i)

Type

...................................................

ii)

Percentage stablisation of the output D.C. voltage

...................................................

iii)


...................................................

iv)

Response time of Automatic voltage regulator

...................................................

Manual voltage regulator (Trickle mode)

...................................................

i)

Type

...................................................

ii)


...................................................



CHAPTER - E11

PAGE 5 OF 8

CLAUSE NO

DC SYSTEM

Bidder’s Name: ..................................... 9.

10.

11.

Boost charging current setting range

...................................................

Boost charging voltage limit setting range

...................................................

Rectifier assembly i)

Type of semi-conductor

...................................................

ii)

Rated direct current per cell

...................................................

iii)

Rated direct voltage

...................................................

iv)

Rated input voltage

...................................................

v)

Type of connections of rectifier elements

...................................................

vi)

Continuous rating in Amps

...................................................

vii)

Short time rating in Amps and duration

...................................................

Permissible hottest stack temperature

...................................................

Short circuit current on the output terminals of rectifier assembly

...................................................

x)

Overload Capacity

...................................................

xi)

Peak inverse voltage of the Rectifier elements

...................................................

Standard applicable

...................................................

viii)

ix)

xii) 12.

Blocking Diode i)

Continuous rating in Amps



...................................................

CHAPTER - E11

PAGE 6 OF 8

CLAUSE NO

DC SYSTEM

Bidder’s Name: ..................................... ii)

13.

Short time current rating in Amps and duration

....................................................

iii)

Peak inverse voltage

...................................................

iv)

Type of semi-conductor material

....................................................

Rectifier Transformer i)

Type

...................................................

ii)

Rated KVA & % impedance

...................................................

iii)

Input line winding connection in vector representation

...................................................

Cell winding connection in vector representation

...................................................

One minute power frequency withstand voltage (KV)

...................................................

vi)

Overload Capacity

...................................................

vii)

Turns ratio

...................................................

viii)

Standard Applicable

...................................................

iv)

v)

14.

15.

Instruments i)

Type

...................................................

ii)

D.C. Voltmeter range

...................................................

iii)

D.C. Ammeter range

...................................................

iv)

Dial size

...................................................

v)

Accuracy class as per IS

...................................................

Contactor i)

Type

...................................................

ii)

Rated voltage

...................................................



CHAPTER - E11

PAGE 7 OF 8

CLAUSE NO

DC SYSTEM

Bidder’s Name: .....................................

16.

17.

18.

iii)

Rated Current

...................................................

iv)

No. of power contacts

...................................................

v)

No., type and rating of aux. contacts

...................................................

vi)

Operating coil voltage

...................................................

vii)

Drop-out voltage

...................................................

Thermal overload relay i)

Tripping current range

...................................................

ii)

Whether single phasing protection provided

...................................................

iii)

Standard applicable

...................................................

Air break switches i)

Type

...................................................

ii)

Rated voltage

...................................................

iii)

Rated current

...................................................

iv)

Type and material of contacts

...................................................

v)

Standard applicable

...................................................

Output fuses i)

Type

...................................................

ii)

Rupturing capacity

...................................................

iii)

Standard applicable

...................................................



CHAPTER - E11

PAGE 8 OF 8

CHAPTER - E12 SWITCHYARD AUXILIARY ITEMS



CLAUSE NO


Bidder’s Name: ...................................... A.

CONTROL CABINETS (Bidder shall furnish this data for each equipment marshalling Box/operating mechanism box separately i.e. Bay Marshalling Box, Isolators, Instrument transformers, lighting panels, etc.) 1.

Manufacturer's Name and Adddress

.........................................

2.

Indoor/Outdoor application

.........................................

3.

Design ambient air temperature (oC)

.........................................

4.

Standards Applicable

.........................................

5.

Thickness of sheet steel (mm) and whether cold rolled or hot rolled

.........................................

6.

Degree of protection provided

.........................................

7.

Colour of finish paint IS:5

.........................................

a)

Outside

.........................................

b)

Inside

.........................................

8.

Busbars

.........................................

a)

Material & Size

.........................................

b)

Temperature rise at rated current over specified ambient (oC)

.........................................

c)

Continuous current rating (A)

.........................................

d)

One second current ranting (KA)

.........................................



CHAPTER - E12

PAGE 1 OF 5

CLAUSE NO


Bidder’s Name: ...................................... 9.

10.

B.

Control Wiring

.........................................

a)

Size of Conductor

.........................................

i)

For CT circuits

.........................................

ii)

for other circuits

.........................................

b) Conductor Solid/stranded

.........................................

Terminal Blocks

.........................................

a)

Make & Type

.........................................

b)

Current rating

.........................................

i)

Power terminals (A)

.........................................

ii)

Other terminals (A)

.........................................

11.

Space heater rating at 240 VAC

.........................................

12.

Control cabinet drawing enclosed

Yes/No

13.

Type test report

Yes/No

TERMINAL CLAMPS AND CONNECTORS, AND SPACERS (Bidder shall furnish this data for Terminal clamps and connector separately for each type and equipment) 1.

Manufacturer's Name and address

.........................................

2.


.........................................

3.

Type

.........................................

4.

For connection to

.........................................

a)

Conductor size and arrangement

.........................................

b)

Equipment terminal size and arrangement

.........................................

5.

Bitmetalic Liners if any and its thickness



.........................................

CHAPTER - E12

PAGE 2 OF 5

CLAUSE NO


Bidder’s Name: ...................................... 6.

Rated Current (A)

.........................................

7.

a)

Rated terminal load (kg)

.........................................

b)

Factor of safety

.........................................

8.

Minimum thickness of any part (mm)

.........................................

9.

Weight clamp complete with hardware (kg)

.........................................

10.

Maximum temperature rise over reference ambient temperature of 40oC when carrying rated current

.........................................

Radio interference voltage at 1.1 Um/√3 (micro volts ) for frequency between 0.5 MHz to 2.0 MHz

.........................................

Corona extinction voltage (KV rms)

.........................................

13.


Yes/No

14.


Yes/No

15.

Maximum allowable span on equipment terminal pad and with rated fault current of 40 KA rms with specified phase to phase spacing

.........................................

Rated terminal load

.........................................

11.

12.

16. C.

INSULATOR HARDWARE (Bidder shall furnish this data separately for each type and rating) 1.

Manufacturer

.........................................

2.


.........................................

3.

Material

.........................................

a)

Ferrous Parts

.........................................

b)

Nuts & Bolts

.........................................



CHAPTER - E12

PAGE 3 OF 5

CLAUSE NO


Bidder’s Name: ......................................

4.

5.

6.

D.

c)

Cotter Pins

.........................................

d)

Split Pins

.........................................

e)

Strain and Suspension clamps

.........................................

Ultimate Strengths

.........................................

a)

Complete Assembly (Kg)

.........................................

b)

Suspension clamps (kg)

.........................................

c)

Strain clamp (Kg)

.........................................

d)

D - Shackle (Kg)

.........................................

e)

Ball eye (Kg)

.........................................

f)

Ball clevis (kg)

.........................................

g)

Clevis eye (Kg)

.........................................

h)

Socket eye (Kg)

.........................................

I)

Socket clevis (Kg)

.........................................

j)

Yoke Plate (Kg)

.........................................

Magnetic power loss of the suspension clamp assembly at 600 A

.........................................

Magnetic power loss of the drop clamp assembly at 600 A

.........................................

MOOSE CONDUCTOR 1.

Manufacturer

.........................................

2.


.........................................

3.

O.D. and cross section

.........................................

4.

Material

.........................................

5.

Weight per kM

.........................................

6.

UTS

.........................................



CHAPTER - E12

PAGE 4 OF 5

CLAUSE NO


Bidder’s Name: ...................................... E.

EARTHWIRE 1.

Manufacturer

.........................................

2.


.........................................

3.

O.D. and cross section

.........................................

4.

Material

.........................................

5.

Weight per kM

.........................................

6.

UTS

.........................................



CHAPTER - E12

PAGE 5 OF 5

Tech Spec (Switchyard-ntpc)PDF

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