2.1 - Specification for Electrical Installation Tender

VISAKH MARKETING INSTALLATION

RESITEMENT PROJECT - BLACK OIL TERMINAL

Doc No: 254625-300-RQ-ELE-003 Rev: B of 25

P:\Andheri\IndiaProject\254625 HPCL- Black Oil Terminal\Procurement\Electrical Bulk\Electrical Work

Tender\08.10.09\Editable\254625-300-RQ-ELE-003.doc

Hindustan Petroleum Corporation Ltd

Visakha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam - 530 014

Andhra Pradesh

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059

SPECIFICATION

FOR

ELECTRICAL INSTALLATION

TENDER






List of Contents Pages

1.0 Introduction ........................................................................................................................... 4

2.0 Location and Environmental Conditions............................................................................... 4

2.1 Plant Location........................................................................................................................ 4

2.2 Environmental Conditions..................................................................................................... 4

2.3 Electrical System Data .......................................................................................................... 4

3.0 Scope of Supply..................................................................................................................... 5

4.0 Codes and Standards ............................................................................................................. 6

5.0 Design requirements.............................................................................................................. 7

6.0 Inspection and testing............................................................................................................ 9

7.0 Vendor documentation ........................................................................................................ 10

8.0 Spares and special tools....................................................................................................... 11

8.1 Spares .................................................................................................................................. 11

8.2 Special tools ........................................................................................................................ 11

9.0 Installation and commissioning........................................................................................... 11

10.0 Packing and transportation .................................................................................................. 11

11.0 Statutory Approval .............................................................................................................. 11

12.0 Guarantee............................................................................................................................. 12

Appendix-A: Table of Compliance ................................................................................................. 13

Appendix-B: Codes & Standards .................................................................................................. 15

Appendix-C: Requisition for Engineering Documents ................................................................. 17

Appendix-D: Technical Data Sheet & Guaranteed Technical Particulars ..................................... 19

[Refer Doc. No. 254625-300-DS-ELE-008 (Pages 1 to 17)] .......................................................... 19

Appendix-E: Specification for Electrical Equipment to be supplied by Contractor ....................... 20

Appendix-F: Specification for Installation, Testing & Commissioning of Electrical Equipment .. 21

Appendix-G: Schedule of Quantity................................................................................................. 22

Appendix – H : Recommended List of vendors ........................................................................... 23

Appendix-I: List of Enclosed Drawings.......................................................................................... 25






1.0 Introduction

1.1 This specification covers the minimum requirements for the Design, Engineering, preparation of

detailed drawings & documents, Obtaining necessary approvals, Material procurement,

Fabrication, Assembly, Painting, Inspection at Vendors works, Delivery to site, Erection, Testing

and Commissioning, Approval from Local statutory authorities for installation etc. for Electrical

Equipment Installation for “Black Oil Terminal Project” of M/s. HPCL, located at Visakhapatnam,

A.P., India.

Following are the definitions:

Owner / Purchaser Hindustan Petroleum Corporation Ltd.

Consultant Mott MacDonald Consultants (India) Pvt. Ltd.[MMCI]

Vendor/ Contractor Electrical Contractor

APSEB Andhra Pradesh State Electricity Board.

Shall This is to be understood as mandatory in relation to the

requirements of this document.

Should This is to be understood as a strong recommendation to

comply with the requirements of this document.

Equipment This is to be understood as vendor supplied equipment

with all accessories.

1.2 The Vendor shall ensure that the design complies with the requirements of this specification and

its referenced specifications and standards. The data sheets, Appendix D, which forms part of this

specification, shall be completed by the Vendor. The Vendor shall highlight any non-compliance

at the offer stage in the Table of Compliance, Appendix A. The Table of Compliance and filled in

data sheets shall form a part of the offer. Not providing completed compliance table and data

sheets can cause rejection of the offer. Failure to clearly identify specific deviations shall be

assumed by the Purchaser to be total compliance with the specification.

1.3 This specification does not relieve the Vendor from final guarantee as to materials, apparatus,

workmanship and performance of the equipment supplied.

2.0 Location and Environmental Conditions

2.1 Plant Location

Black Oil Terminal Project is located at Visakhapatnam, A.P., India. Electrical Equipment

Installation shall be done within plant complex.

2.2 Environmental Conditions

Refer Doc No.: 254625-300-SP-GEN-001 for details.

2.3 Electrical System Data

Refer Doc No.: 254625-300-DS-ELE-001 for details.






3.0 Scope of Supply

The Electrical Equipment shall be supplied & Installed in accordance with this specification,

standards stated herein & enclosed appendices.

3.1 Contactor scope

Scope of Supply includes, but not necessarily be limited to, the following :

•••• Design, supply, manufacturing, inspection / testing, packing and forwarding, delivery at site,

installation, supervision, commissioning, statutory certification and guarantee.

•••• Supply & Installation of electrical equipment as specified in Appendix-E, F & G and Unloading,

handling, erection, testing and commissioning of free issue material / equipment supplied by the

Owner as specified in Appendix-F & G.

•••• The entire scope of work shall comply with the requirements of latest statutory regulations in force

but not limited to the Indian Electricity Rules & Acts, Relevant IS Specifications, Local Statutory

Regulations and Specifications of this Tender.

•••• Electrical Design, Engineering, Preparation of Detail Design Documents, obtaining Approval from

Statutory Authorities / Client / Consultant.

•••• All consumables required for the work such as welding rods, insulation tape etc., conforming to

relevant IS, shall be arranged by the contractor at his own cost.

•••• Tools & tackles required for the work shall be arranged by the contractor and shall be kept at his

own custody.

•••• Engineering Services (Ref.Cl.no.3.2 for details).

•••• Statutory Approvals.

•••• Performance testing of Electrical Equipment. Any Items instruments required for testing shall be

arranged by contactor during the contract period.

•••• For Supply Equipment: Start-up spares and commissioning spares.

•••• For Supply Equipment: Spares for two years normal operation.

•••• List of special tools required (Vendor to provide list with the offer).

•••• Inspection and Testing as specified.

•••• Submission of documents as specified.

•••• Painting as specified.

•••• Installation/Erection and commissioning.

•••• Any other items, required to make system complete.

3.2 Engineering Services

The Vendor shall provide engineering services, which shall include, but not necessarily be limited

to, the following:






•••• Providing/co-ordinating detailed design of all equipment and components within the scope of

supply.

•••• Resolving engineering queries related to the equipment and components within the scope of

supply.

•••• Performing and co-ordinating all aspects of design. Performing all relevant calculations pertaining

to the package design.

•••• Providing progress reports etc.

•••• Providing expediting services for all sub-vendors.

•••• Providing quality assurance, including all sub-vendors with respect to ISO 9000 or equivalent.

•••• Quality Assurance.

•••• Training of client’s personnel at site / Vendor’s shop.

3.3 Following documents attached as Appendices shall be referred

•••• Appendix-E : Specification for Electrical Equipment to be supplied by Contractor [Doc. No.

254625-300-SP-ELE-008]

•••• Appendix-F : Specification for Installation, Testing & Commissioning of Electrical Equipment

[Doc. No. 254625-300-SP-ELE-009]

•••• Appendix-G: Schedule of Quantity [Doc. No. 254625-300-SC-ELE-008(Part A) & 254625-300-

SC-ELE-009 (Part B&C].

•••• Appendix-H : Recommended List of Vendors

•••• Appendix-I : Drawings attached

4.0 Codes and Standards

4.1 General

All Electrical Equipment & Installation shall meet the requirements of this specification and latest

edition of applicable standards listed in enclosed Appendix-B.

4.2 Conflicting Requirements

In case of conflict between documents relating to the enquiry or purchase order, the following

priority of documents shall apply.

First priority : Purchase order and variations thereto

Second priority : Data/requisition sheets and drawings

Third priority : This engineering specification.

Fourth priority : International standards.

Note: Should any conflict arise either before or after order placement the Vendor shall

immediately inform the Purchaser for technical resolution of the conflict.






5.0 Design requirements

5.1 General

5.1.1 It is not the intent of this specification to completely specify all the details of design and

construction. Nevertheless, the equipment to be supplied by the Vendor shall also conform to the

high standards of engineering, design, workmanship, etc. in all respects.

5.1.2 Any part of equipment or component not specifically mentioned in this specification that required

for making the Installation complete, safe and reliable should be provided by the Vendor at no

extra cost.

5.1.3 The Vendor shall make all possible efforts to comply strictly with the requirements of this

specification and other specifications as mentioned in this specification. In case, any deviations

are considered essential by the vendor after making all possible efforts, these shall be separately

listed in the offer under ‘List of deviations to specifications’ for purchaser’s considerations. The

deviations / exceptions shall be listed separately for each specification / document with cross

references and proper reasons for the deviations. In case of any deviation not listed under the ‘List

of deviations to the specifications’, although it is appearing in other part of the offer, shall not be

considered / applicable. Hence all the requirements shall be binding on the vendor without any

cost and schedule implications to the Purchaser.

5.1.4 Compliance to this specification shall not relieve the vendor of the responsibility of supplying the

equipment and auxiliaries of proper design, material and workmanship to meet the operating

requirements specified. In case of requirements of additional instruments, controls, safety devices

and any other auxiliaries for safe, smooth and trouble free operation of the equipment, the Vendor

shall include the same in his scope of supply.

5.1.5 The offered equipment or its accessories shall be sourced from a reputed and established

manufacturer and having requisite design, engineering, manufacturing and testing facility.

5.1.6 The offered model shall be from the regular manufacturing range of the supplier and the design

shall have had a minimum of two years successful field operation with the same model having the

same design and materials of constructions. Relevant information of the offered equipment like

catalogues, references, user’s certificate etc. shall be furnished along with the offer.

5.1.7 All equipment shall be designed to operate satisfactorily under the ambient, environmental and

power supply conditions indicated in of this specification.

5.1.8 Any and all other works not indicated explicitly, but required to complete the job including

obtaining statutory clearances are included in the Vendor’s scope.

5.1.9 Vendor shall take vendor drawing approval from Owner/Consultant for all equipment/systems,

which is included in the Vendor’s scope.

5.1.10 Necessary approval of any other Govt. agencies as required will have to be obtained by the

vendor.

5.2 Services by Purchaser

5.2.1 Graded Site.

5.2.2 Approach to site.






5.3 Electrical Equipment / Panels / Materials:

5.3.1 The quantities mentioned in the Schedule of Quantity are tentative. However these shall be used

for the purpose of estimation only.

5.3.2 The actual quantities of the materials required & its delivery schedule shall be discussed by

contractor with Engineer-in-Charge. Contractor shall adhere to the decisions made by the

Engineer-in-Charge.

5.3.3 Excess material supplied by the contractor if any which are not consumed in the work shall be

returned to the contractor by the Owner.

5.3.4 The material rates quoted by the Contractor are inclusive of all duties, taxes and F.O.R. site basis

and no additional charges shall be paid.

5.3.5 Materials / Equipment / Panels which are in the scope of Owner's supply shall be issued to the

contractor from their stores or anywhere inside the Plant premises.

5.3.6 All materials received by the contractor at site shall be stored in an appropriate manner at a

location as directed by the Engineer-in-Charge.

5.3.7 Material reconciliation shall be carried out by the contractor and relevant documents shall be

produced by him before final bill & got approved by the Engineer-in-Charge.

5.3.8 Balance material as per the reconciliation statement if any shall be returned to stores by the

Contractor.

5.3.9 Suitable recovery shall be made from the contractor's bills for the materials not returned by him.

5.4 Instructions to Vendor

5.4.1 All necessary co-ordination with regard to sub-contracted equipment shall be carried out by the

Vendor.

5.4.2 Prices quoted for the equipment in the price Schedule shall be exclusive of type test charges.

5.4.3 All unit prices quoted shall be valid until the date of successful commissioning of all Electrical

Equipment.

5.4.4 Owner/Consultant has full authority for deletion of items which are not required from the scope

of supply. Rate for deletion will be considered as per the unit rate prices quoted.

5.4.5 Vendor may note that the Owner reserves the right to split the order in any manner.

5.4.6 This being a lumpsum all inclusive contract all expenses for commissioning including

transportation, lodging and boarding of vendors personnel shall be suitably included by

contractor.

5.4.7 As & when the need arises, the vendor shall depute his representative / engineer for discussions

with the Owner/consultant till the completion of the project to finalise outstanding issues.

5.4.8 Makes of all equipment including bought out items & consumables shall be as per

`Recommended list of vendors’ attached in tender document. Equipment of only accepted makes

shall be supplied by vendor without any commercial implications.

5.4.9 Vendor shall submit bar chart indicating schedules of drawing submission, manufacture, delivery

etc. immediately on placement of LOI / PO (whichever is earlier) to enable Owner to monitor

work progress.

5.4.10 Being the Electrical contractor, for the supply & Installation of specified equipment, the overall

responsibility for the timely supply of electrical equipment lies with the vendor.






6.0 Inspection and testing

6.1 The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor.

The Vendor shall specify all of the inspection and testing requirements in the quality plan which

shall identify the activities requiring the Owner’s approval, review, witnessing etc.

Inspection and testing requirements shall be in accordance with this specification, other applicable

standards as listed in this specification and the data sheets.

All Equipment shall be inspected for compliances with:

• Requirement of Owner’s specification & correspondence therefore.

• Applicable codes, standards and specifications, which shall also include sub-referenced

standards therein.

• Test and Inspection Plans produced by the equipment manufacturer.

Inspectors have the right to request additional inspections or tests to ensure that the equipment

complies with the specification and all relevant codes & standards.

6.2 Vendor shall furnish valid Type Test Certificates of similar models along with the offer. Fresh

type tests for the equipment are not needed, provided the Vendor can submit certificates that the

equipment complies with all type tests as prescribed by IEC/IS Standard specifying the test

requirements for that equipment.

6.3 Routine tests on all the equipment shall be carried out as per the relevant IEC/IS. Equipment

offered for final inspection shall be complete and ready for shipment, with the possible exception

of the final paint finish.

6.4 Vendor to furnish required copies (as per RED form) of test certificates, Ref Documents,

Drawings, and Instruction Manuals before equipment are dispatched.

6.5 Factory acceptance test (FAT) is required to be done at no extra cost to the purchaser. The

purchaser or his representative shall be advised of the tentative date for FAT at least 3 weeks in

advance prior to the test date.

6.6 Access to the manufacturing shop of Vendor / Sub-Vendor, at all reasonable times shall be made

available to representative of Purchaser / Consultants / Third Party Inspection Agency for

Inspection & Testing of electrical equipment.

6.7 Any defects found by the TPI or the Owner’s appointed Inspector shall be rectified in his

presence. Where this is not possible or practical, check lists shall be prepared and signed by the

Third Party Inspector stating all “pending items”. Copies of these lists shall be sent to the Owner

to enable their subsequent checking. The equipment shall not leave the Vendor factory before all

defects have been rectified and without the written permission of the Owner.

6.8 All spare parts shall be subjected to the same inspection standards and full material certification as

the main order.

6.9 The equipment shall not leave the Vendor / Sub-Vendor’s factory before all discovered defects

have been rectified and without the written permission of the Owner/Purchaser.

6.10 Any acceptance or release of equipment following an inspection or test activity shall in no way

relieve the Vendor of his contractual responsibility to provide guarantees as to the suitability of






the materials, workmanship and performance of the equipment in accordance with this

Specification.

6.11 Owner/Consultant reserves the right to waive the inspection at any stage. Inspection shall be

carried out only on receipt of Vendor's internal test report of the equipment offered and scrutiny of

the same. In the event, on receipt of inspection call, the Owner/Consultant’s representative reaches

the Vendor's works and finds the material not ready for inspection/incomplete/has short supply,

the inspector will return to his base station and all expenses incurred by the inspector including to

and from travelling expenses from his base station to place of inspection, boarding and lodging etc

shall be reimbursed by Vendor.

6.12 The tests to be carried out by vendor on completion of installation are broadly listed in

Specification for Installation, Testing & Commissioning of Electrical Equipment in Appendix-F.

Vendor shall mobilise all the testing equipment to carry out these tests & for which no extra cost

shall be borne by Owner.

7.0 Vendor documentation

7.1 All information listed here is to be furnished along with the offer as a minimum.

a. Clause wise comments / deviations on specification in `Table of Compliance’ [enclosed

Appendix A]. If not furnished, compliance to all requirements in specifications will be

binding on the Vendor.

b. A detailed scope of supply that fully describes the package offered.

c. Duly filled up guaranteed technical particulars [enclosed Appendix-D].

d. List of all equipment supplied in package with Makes.

e. For Supply Items

• List of recommended spares of each equipment for two years normal operation with

itemised rates.

• Type test certificates of each equipment.

• Technical Catalogues and brochures of major Components.

f. List of clientele for similar installations in last 5 years.

g. Complete list of special tools (if required)

h. Documents as per RED.

7.2 The Vendor shall furnish the drawings and documents as per enclosed Requisition for Engineering

Documents - RED Form [Appendix-C].

7.3 Any other drawing required for approval from APSEB/statutory authority, for installation shall be

included by vendor.

7.4 The Owner/Consultant will review drawings submitted by Vendor & return to the Vendor one

copy of drawings with comments to carry out necessary changes, if any, during the engineering /

manufacturing stage.

7.5 Drawings submitted by Vendor shall clearly indicate schematics, B.O.M., GA, foundation

drawings, terminal diagrams etc. The schematic drawings shall clearly indicate cross reference

catalogue numbers, component relays of each scheme along with range & variable steps of each

component / scheme & the recommended settings.






7.6 The documents required by the Third Party Inspection Agency are not covered under this

specification. The Vendor shall provide all the drawings and documents required by the Third

Party Inspection agency in compliance with the applicable codes and standards.

8.0 Spares and special tools

8.1 Spares

The Vendor shall furnish list of spares and supply all necessary spares for testing, pre-

commissioning, commissioning. Any of the spares if used during testing/commissioning must be

replenished at no extra cost to the purchaser.

The Vendor shall also supply all consumables during erection up to commissioning.

In addition to above, Vendor to supply spares for two years operation.

8.2 Special tools

The Vendor shall supply a set of any special tools, which are required for the installation,

commissioning, operation and maintenance of the equipment being supplied. A list of special

tools shall be furnished along with the offer.

9.0 Installation and commissioning

Installation & commissioning shall be included in vendor scope. Vendor shall despatch

Installation and Commissioning instructions for supply equipment at least 2 weeks before the

arrival of the equipment.

Vendor shall provide qualified personnel to supervise the installation and carryout site testing and

commissioning of all equipment supplied under this package contract.

Prices for these services shall be included by vendor.

10.0 Packing and transportation

Packing, Shipping and delivery at site, unloading etc. of equipment shall be in Vendor’s scope.

Packing, shipping and delivery of equipment at site and unloading requirements shall be as per

agreed Terms & Conditions of HPCL.

Preparation of the equipment for shipment is a crucial step in the completion of this contract. The

Vendor must take into consideration that all equipment shall be prepared for proper transportation.

11.0 Statutory Approval

Electrical equipment supplied & complete installation shall be acceptable to local Statutory

authorities viz. Electrical Inspectorate, APSEB etc. and changes required, if any, shall be carried

out by the vendor without any extra cost. All necessary documents shall be completely filled by

contractor, with all necessary attachments & then submitted to HPCL for the signature.

The Vendor shall provide liaison services, which shall include, but not necessarily be limited to,

the following:

•••• The contractor shall have valid licence to execute Electrical Installation works as given under the

scope of works.






•••• It shall be total responsibility of vendor to obtain approval for Installation of all electrical

Equipment from statutory authorities at no extra cost.

•••• Necessary co-ordination with statutory authorities for Procedures, for supply & installation of

Electrical equipment will be the total responsibility of vendor.

12.0 Guarantee

Equipment & installation shall be guaranteed to meet the specified performance at specified

conditions in terms of power, air flow, thermal performance, design conditions etc.

Equipment and its components & Installation shall be guaranteed against faulty design, defective /

improper materials poor workmanship or failure from normal use during the guarantee period.

Vendor shall make all necessary and desirable alterations, repairs and replacement free of charge

in the event of mal performance or defects occurring in the equipment during guarantee period.

Also refer to guarantee clause as per General Terms & Conditions Clause No. ‘5-n’.






Appendix-A: Table of Compliance

The Vendor shall confirm that clauses of the specification have been complied with/accepted or further

clarifications are desired, or Vendor has taken a deviation with reason thereto.

CLIENT :

HPCL : BLACK OIL TERMINAL

VENDOR REF.

Spec. Clause

No.

Conforms

Yes/No

Alternative

Yes/No Clarification

1

2

2.1

2.2

2.3

3

3.1

3.2

3.3

4

4.1

4.2

5

5.1

5.2

5.3

5.4

6

7

8

9

10

11

12

Appendix A:

Appendix B:






CLIENT :

HPCL : BLACK OIL TERMINAL

VENDOR REF.

Spec. Clause

No.

Conforms

Yes/No

Alternative

Yes/No Clarification

Appendix C:

Appendix D:

Appendix E:

Appendix F:

Appendix G:

Appendix H:

Appendix I:






Appendix-B: Codes & Standards

IS 1248 :Part –I :2003 : Direct Acting Indicating Analogue Electrical Measuring

Instruments and their Accessories

IS-6875 (Part 1 to 3) :1992 : Recommendations for the colour of Local Control Station

IS 12063 :2004 : Classification of degrees of protection provided by enclosures of

electrical equipment.

IS-4794 (Part 1 & 2) :2002 : Push Button Switches – General Requirements and Tests.

IS : 8623 :Part I: 1998 : Factory built assemblies of switchgear and Controlgear.

IS : 8623 :Part III: 1998 : Specification for Low-Voltage Switchgear and Controlgear

Assemblies - Part 3 : Particular Requirements for Equipment

Where Unskilled Persons have Access for Their Use

IS : 13703: Part I : 2002 : Low voltage fuses.

IS : 10118 :Part -1:2006 : Code of practice for selection of switchgear and Controlgear.

IS: 1255: 2001 : Code of practice for installation and maintenance of power

cables upto and including 33 KV rating.

IS: 10810(Part 43):2006

:

Method of Test for cables; Part 43 Insulation resistance.

(Part 43)

IS: 10810(Part45):2006

:

Method of Test for cables; Part 45 High voltage test.

(Part45)

IS-7816 : 2002 : Guide for testing Insulation resistance of rotating machines

IS : 13947 :2004 : General requirement for switchgear and control gear for voltage

not exceeding 1100 V

IS:2309 :2005 : Protection of buildings and allied structures against lightning.

IS:3043 :2006 : Code of practice for earthing

IS:7689 : 2005 : Guide for control of undesirable static electricity

IS-732 : 2005 : Code of practice for electrical installation

IS-2148 : 2004 : Specification for Flameproof Enclosures of Electrical Apparatus

IS-5571 : 2006 : Guide for selection of Electrical Equipment in hazardous areas.

IS-5572 :1999 : Classification of hazardous areas (other than Mines) having

flammable gases & vapours for electrical installation.

IS-6381: 2004 : Construction & Testing of electrical apparatus with type of

protection ’e’

IS-8289 :2001 : Electrical equipment with type of protection ’n’

IS-8224 :2003 : Electrical Lighting fittings for division 2 areas

IS-13346 :2004 : General requirements of electrical apparatus for explosive gas

atmosphere.

IS-13408(Part-I) :2003 :

Code of practice for the selection and maintenance of electrical

apparatus for use in potentially explosive atmospheres.(other

than mining applications or explosive processing and

manufacture).

IS-10028 (Part-2) : Code of practice for selection, installation and maintenance of

transformer : Part 2 - Installation






IS-10028 (Part-3) : Code of practice for selection, installation and maintenance of

switchgear and control gear : Part 3 - Installation

SP-30(BIS) :2005 : National Electrical Code.

OISD-RP-137 : Inspection of electrical equipment

OISD 147 : Inspection and safe practices during electrical installations

OISD-RP-149 : Design aspects for safety in electrical systems

OISD-GDN-180 : Lightning Protection

OISD 110 : Recommended practices on static electricity

SP-30(BIS) :2005 : National Electrical Code.

Indian Electricity Act and Rules. :1956

Indian Factories Act :1948

Indian Explosives Act : 1848

Insurance Regulations of development Authority (IRDA) Rules : 2002

Regulation of local authorities such as Electrical Inspectorate.






Appendix-C: Requisition for Engineering Documents

RED Form

Owner/Purchaser’s Office Distribution Office

M/s. Hindustan Petroleum Corporation Ltd.

Viskaha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam – 530 014

Mott MacDonald Consultants(I) Pvt. Ltd

Kothari House, CTS No. 185

Off Andheri – Kurla Road

Andheri ( East), Mumbai 400059, India

SPECIAL INSTRUCTIONS Prints Documents shall be sent to:

Production Schedule 5 The Purchasing Office via courier service

Manufacturing, inspection & testing sequence plan 5 The Purchasing Office via courier service

DRAWINGS Required number for TIMING FOR SUBMITTAL

OFFER APPROVAL FINAL - for approval 2 weeks after order date

Approval drawings / Final drawings to be

submitted under cover of an ADS form / FDS

form respectively

Prints Prints Disk Prints - final issue 2 weeks after approval date

Documents shall be submitted to:

Submission of Following not limited to:

Guaranteed Technical Particulars 2 5 2 5

All Equipment Vendor Drawings for

Contractor Supply items:

• General Arrangement Drawing including

Plan, Front elevation, Rear elevation,

Side Elevation, & relevant cross sectional

View, weights, main dimensions, etc. of

supplied Electrical equipment.

• Schematic diagram indicating terminal

nos. for external connection with BOM

• Rating & Diagram plate, Name Plate

Drawing for each equipment

• Dimensional drawing of clamps and

connectors

5 2 5

Installation Drawings:

• Earthing & Lightning Protection

• Cabling, Trenches, Conduits, Trays,

Bends, Tees Etc.

• Lighting

• Control Panel drawings indicating

floor/wall/pedestal fixing

arrangements, pad locking

arrangements, Cable entry openings,

etc.

• Any other detailed Installation

drawings

5 2 5

Cable Schedule & Interconnection Schedule

(Refer Note 2) * 5 2 5

List of accessories for testing & maintenance

of each electrical equipment 2 5 2 5

Bill of Material for Electrical equipment 2 5 2 5

List of Make for Electrical Equipment 2 5 2 5

Type Test Certificates of Electrical

Equipment 2 5 2 5

Routine Test Certificates of Electrical

Equipment 5 2 5

Spares List for two Years Operation 2 5 2 5

Technical Catalogues of Electrical equipment. 2 5 2 5

As Built Drawings 2 5

SPARE PARTS DOCUMENTS 2 5 TEST AND INSPECTION DOCUMENTS Prints

Documents to be submitted under transmittal

Manufacturing report 2 5 Documents shall be submitted to:






Test Report / Data Curves foe switch yard equipment 2 5 Calibration Certificates for testing Instruments. 2 5

Bought out Equipment Certificates. 2 5 Purchasing Office via courier service within 4 weeks

OPERATING DOCUMENTS Purchasing Office via courier service not later than time

of

Installation manual 2 5 Dispatch of equipment.

Operational manual 2 5 Combine into one manual

Maintenance instructions 2 5

Notes:

1. Referenced standards / codes shall be the latest issue unless otherwise stated.

2. * Cable Schedule shall be prepared by Contractor based on actual cable routing. Interconnection schedule shall be prepared by Contractor based on

Equipment vendor drawings which will be furnished in the event of order.

REMARKS

Invoice must certify that the drawings and engineering

documents specified above have been dispatched to all parties

concerned.

Any deviation from the timing for submittal of documents shall

be notified to the Approval / Distribution Offices by fax or E

mail.

Shop fabrication shall not be started before the required

approval drawings have been released for construction by the

party concerned, unless otherwise stated on the "Approval

Drawing Specification".

Each document shall bear the item / tag and order reference

number and be dispatched by air mail, unless other instructions

are stated on the RED.

Units / dimensions to be used on Engineering documents shall be SI.

The documents shall be in English. Description on drawings and similar documents

may be in other languages provided English translations are also given.

Drawings and documents shall comply with accepted national or international

standards for the preparation of technical drawings. Only the following standard

drawing sizes should be used: A4, A3, A2, and A1.






Appendix-D: Technical Data Sheet & Guaranteed Technical Particulars

[Refer Doc. No. 254625-300-DS-ELE-008 (Pages 1 to 17)]



Doc No: 254625-300-DS-ELE-008 Rev: B Page 1 of 17


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TECHNICAL DATA SHEET & GUARANTEED TECHNICAL PARTICULARS

NOTE :

1) If Specific Deviations are not taken against Specification Clauses, it will be assumed that Vendor has

accepted the Specification Clause.

A] Cables

Sr. No. Description Vendor Data / Confirmation

A Supplier

B Manufacturer

1.0 General Requirements

1.1 Operating Voltage

1.2 Maximum Voltage

1.3 Frequency

1.4 Ambient Temperature

1.5 Standards

1.6 Marking and Identification

1.7 Applicable Cable catalogues / Cable data

1.8 Maximum possible cable drums length offered

1.9 Tolerance on drum length in %

1.10 Weight of Cable in Kg/Km

2.0 Inspection And Testing

2.1 List of Offered Test

3.0 Cable Specification

3.1 Voltage Grade

3.2 Short Circuit Withstand Capacity for 1 sec. in

kA

For Conductor

For Insulation screen

For Armour

For combined Screen/Armour

3.3 Conductor

Material






Max conductor temperature (on load)

Max conductor temperature (on fault)

3.4 Shape of conductor

3.5 Insulation

Material

Colour Coding

3.6 Armour

3.7 Outer Sheath

Material

Colour coding

3.8 Diameter in mm

Overall diameter of cable

Diameter of cable over armour

Diameter of cable over inner sheath

3.9 Tabulated current carrying capacity in ground

and air with installation conditions

3.10 Tabulated Resistance & Reactance

Note:

Vendor to furnish technical data pertaining to the calculation of derating factors such as ground

temperature, soil resistivity, and depth of laying and grouping of cables for various types of installations.

B] Cable Trays

SR.

NO.

DESCRIPTION VENDOR CONFIRMATION

1 Make & Manufacturer’s Name

2 Type of Cable Trays

3 Material of Cable Trays

4 Material of coating & its thickness

5 Size of Horizontal supports

6 Interval of Clamping the Cable Trays in mm

7 Interval to Support adjacent Cable Trays in mm

8 Cover Sheet

a) Material






SR.

NO.


b) Standard length

9 List of Deviations, if any.

C] Terminations for HT & LT Cables

SR.

NO.


1 Make

2 Name of Manufacturer

3 Catalogues Attached?

4 Voltage Grade of HT & LT Cable Terminations

5 Type of Outdoor cable Glands

6 Type of Indoor cable Glands

7 List of Deviations, if any






D] MLDP, ELDP, YLDP, PDP, PDP FOR MOV, LDB, SELDB, PDB & Outdoor MOV PDB

Note: Vendor shall submit guaranteed technical particulars separately for MLDP, ELDP, YLDP, PDP, PDP

FOR MOV, LDB, SELDB, PDB & outdoor MOV PDB

Sr.

No Description To be filled in by Vendor

A) GENERAL

1) Manufacturer

2) Country of Manufacture

3) Applicable codes & standards

4) Type test certificate furnished

5) List of Routine test offered

B) CONSTRUCTION

1) Enclosure material

2) Type

3) Thickness of sheet metal mm

4) Degree of Protection

5) Paint Shade

6) Cable entry (Incoming & Outgoing)

7) Material & thickness of gland plates mm

8) Overall Dimension of DB ( L x B x H) mm

C) BUSBARS

1) Rated continuous current kA

2) Short circuit rating [1 sec] kA

3) Main Busbar location

4) Busbar material

5) Clearances Ph/Ph, Ph/n & Ph/earth mm

6) Ground Bus Size mm






Sr.


D) MCCB/MCB/ELCB

1) Make

2) Type & Service

3) Voltage, frequency & poles

4) Rated current A

5) Short circuit rating kA

6) Sym. interrupting capacity kA

7) Total interrupting time ms

8) Making current (Peak) kA

9) Operating mechanism

E) SWITCHES

1) Make

2) Type

3) Duty

4) Rating A

5) Interlocking with Door + Defect Interlocking

facility

6) Shrouding of Incoming Terminal

7) Rotary / Link Type

8) Single Break / Double Break

F) FUSES

1) Make

2) Type

3) Rupturing Capacity

4) Rating A






Sr.


5) Control Fuse Make

G) CURRENT TRANSFORMER

1) Make

2) Type & services

3) Voltage & frequency

4) Ratio

5) Rated VA burden

6) Accuracy class

7) Short circuit current rating for 1 sec.

8) Class of Insulation

9) Terminals type

H) INDICATING INSTRUMENTS

1) Make

2) Size

3) Type

4) Range for Incoming & Outgoing

I) WIRING

1) Size

2) Insulation

3) Voltage class

J) EARTHING

1) Earth Bus Size

2) Material

3) Location






Sr.


4) Provision for Connection to Grid

K) LIGHTING TRANSFORMER

1) Manufacturer

4) Rating (at nominal, maximum & minimum

tap)

5) Cooling Method

6) Transformation Ratio (at principal tap)

7) Vector Group

8) Voltage rating of windings

9) Impedance Voltage (at 75°C and continuous

max. rating)

10) Efficiency (at rated power and 0.8 pf)

11) Regulation (at rated power and 0.8 pf)

12) Tap changer

a) Tap Details

b) On HV or LV winding

c) No. of steps (including principal tap)

d) Range

e) Size of each tap %

E] LT Capacitor & APFC Panel

Note: Vendor shall submit guaranteed technical particulars separately for each APFC Panel.

Sr


A) GENERAL

1) Manufacturer

2) Country of Manufacture






Sr


3) Applicable codes & standards

4) Type test certificate furnished

5) List of Routine test offered

6) Documents as per Cl-7 of Doc.

No.254625-300-RQ-ELE-003 furnished?

B) ENCLOSURE

1) Enclosure material

2) Type & Execution

3) Thickness of sheet metal mm

4) Degree of Protection

5) Paint Shade

Inside

Outside

7) Cable entry (Incoming & Outgoing)

8) Material & thickness of gland plates mm

9) Mounting height of components

Minimum

Maximum

mm

10) Overall dimension of APFC Panel

( L x B x H)

mm

13) Panel Heat Load for HVAC Watts

C) BUSBARS

1) Rated continuous current kA

2) Short circuit rating [1 sec] kA

3) Main Busbar location






Sr


4) Busbar material

5) Clearances Ph/Ph, Ph/n & Ph/earth

6) Ground Bus Size mm

D) CAPACITORS

1) Make and type

2) Reference standard

3) Inrush current

4) Voltage rating

5) Over voltage limit

6) Over Current limit

7) Capacitance tolerance

8) Insulation Level.

9) Dielectric material

10) Impregnation

11) Dielectric losses

12) Degree of protection

13) Service life

14) Safety features provided

15) Discharge resistors

16) Maximum permissible transient peak

current

17) Dissipation factor tan δ at 20° C

18) Time constant τ at 20° C , relative

humidity ≤65 % (minimum value)

19) Cooling

20) Mounting position

21) Type of terminal used






Sr


E) APFC RELAY

1) Make

2) Type

3) Control voltage V

4) Location

5) Power Factor Setting Range

6) Auto/Manual Selector Switch Provided? Yes/No

7) Push Button Provided? Yes/No

8) Time Delay

9) List of Controller Features as per

Specification

F) AIR CIRCUIT BREAKER

1) Make

2) Type


4) Rated current A





9) Power Frequency Withstand Voltage kV

10) Lightning Impulse Withstand Voltage kV

11) Anti pumping feature provided

12) Trip-free feature






Sr


13) Provision for pad locking facility in the

“OFF” position

14) No. of auxiliary contacts for owners use

15) Spring charging motor rating at 110V DC VA

16) Time required to charge spring from fully

discharged condition

ms

17) Control Supply voltage V

18) Maximum tripping coil consumption /ACB VA

19) Maximum closing coil consumption /ACB VA

G) MCCB

1) Make


3) Rated current A





8) Operating mechanism

9) Trip - free feature

10) Provision for pad locking facility in the

“OFF” position

11) No. of auxiliary contacts for owners use

H) CONTACTORS

1) Make

2) Type

3) Service

4) Rating A






Sr


5) Duty

I) CURRENT TRANSFORMER

1) Make

2) Type & services

3) Voltage & frequency

4) Ratio

5) Rated burden VA

6) Accuracy class

7) Short circuit current rating kA


9) Shorting link for secondary


J) INDICATING INSTRUMENTS [To be filled for each type of

instruments]

1) Make

2) Size

3) Type

4) Range for Incoming & Outgoing

5) Burden VA

K) WIRING

1) Insulation

2) Voltage class V

3) Size & Colour code

Power Circuits

Control circuits






Sr


L) EARTHING

1) Earth Bus Size

2) Material

3) Location

4) Provision for Connection to Grid

F] Local Control Station

Note: Vendor shall submit guaranteed technical particulars separately for Flame proof Type Local

Control Station

SR.

NO.


A MANUFACTURER

B CONSTRUCTION

1 Type of Enclosure

2 Enclosure Material

3 Degree of Protection

4 Canopy Provided

5 Paint Shade

6 Provision of Local / Remote Switch

7 Provision of Ammeter & Size

C WIRING

1 Size of Wire used

2 Voltage Class

3 Insulation Type






G] Light Fittings

Note: Vendor shall submit guaranteed technical particulars separately for Flame proof Type Light

Fittings

SR.

NO.


1 Make & Manufacturer’s Name

2 Catalogues attached?

3 Light Fixtures

a) Type as per Schedule of Quantity? (yes/No)

b) Body Material

c) Degree of Protection provided

d) Gasket’s Material

e) Earthing Terminal

f) No. of cable Entry

g) Paint Finish

h) Power factor

4

Features Provided for Lamp, Starter, Ballasts,

Lamp/Starter Holder as per specified in 254625-300-SP-

ELE-008/009

5 Reflectors

a) Material

b) Thickness

c) Provision for improving the performance


7 List of test to be performed

8 List of Spares, if any

9 G.A.Drawing for all type of Light fittings with

Dimensions

H] Switch & Socket Outlet

SR.

NO.


1 Make






SR.

NO.



3 Applicable Technical Standards for Switch & Socket


5 Degree o Protection

6 Type of Switch

7 Type of Receptacles


9 List of Spares, if any

I] Junction Box

SR.

NO.


1 Make



4 Degree of Protection

5 Material of Enclosure

6 Canopy Provided

7 No. of Earthing Terminals

8 Weight Kgs

9 Overall Dimensions (H x L x W)mm

10 20% Spare Terminals provided?

11 Paint Finish

12 List of Test to be performed

13 List of Spares, if any.

14 Identification of wires

J] Lighting Poles

SR.

NO.


1.0 Manufacturer’s Name






SR.

NO.


2.0 Make

3.0 Applicable standards

4.0 Material of Construction

5.0 Paint Shade

6.0 Wind Velocity

7.0 No. of Earthing Terminals

8.0 Weight Kgs

K] MISCELLANEOUS EQUIPMENT

SR.

NO.


1 Protective Rubber Mat

a) Size mm

b) Voltage Grade kV

c) Qty. Mtr.

2 Danger Boards

a) Size mm

b) Material & Painted with

c) Qty. Nos.

3 Hand Gloves

a) Material

b) Voltage Grade kV

c) Qty. Nos.

4 Gravels

a) Size of gravels mm

b) Area Covered with Gravels

5 Shock Treatment Chart

a) Size mm

b) Material & Painted with

c) Qty. Nos.






SR.

NO.


6 Cable Markers

a) Engravation on top of Cable Markers

b) Material

c) Size mm

7 Exhaust Fans

a) Size mm

b) Qty. Nos.

8 Fire Extinguisher

a) Type

b) Capacity Kg

c) Working Pressure Kg/Cm2

d) Qty. Nos.

9 Canopy

a) Material

b) Qty. Nos.

10 List of Additional Equipment



Doc No: 254625-300-RQ-ELE-003 Rev: B Page 20 of 25



Appendix-E: Specification for Electrical Equipment to be supplied by Contractor

[Refer Doc. No. 254625-300-SP-ELE-008 (Pages 1 to 26)]



Doc No: 254625-300-SP-ELE-008 Rev: B Page 1 of 26


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SPECIFICATION

FOR

ELECTRICAL EQUIPMENT TO BE

SUPPLIED BY CONTRACTOR






List of Content Page No

1 Scope 4

2 Equipment Specification 4

2.1 H.V. & L.V. Cables & Accessories 4

2.1.1 General Construction 4

2.1.2 Cable Accessories 6

2.1.3 Cable Glands 6

2.1.4 Cable Lugs 6

2.2 Busduct 6

2.2.1 Construction 6

2.2.2 Busbars 7

2.2.3 Busbar Supports 7

2.2.4 Space Heater 8

2.2.5 Earth Bus 8

2.2.6 Termination at the ends of Busduct 8

2.2.7 Special Chambers 8

2.2.8 Marking for Reassembly 8

2.3 L.T. Capacitor & APFC Panel 8

2.3.1 Constructional Features 8

2.3.2 Components 11

2.4 Power Distribution Panel & Lighting Distribution Panel with Energy

Saver Feature 14


2.4.2 Components 15

2.5 Energy Saver Feature in Lighting Distribution Board 16

2.6 Power Distribution Panel for MOVs 17


2.6.2 Components 17

2.7 Outdoor MOV Power Distribution Board 17

2.8 Cable Trays 18

2.9 Flameproof & Industrial type Control Stations 18


2.9.2 Component Specification 19

2.10 Flameproof & Industrial Lighting and Power Panels 19



2.11 Flameproof and Industrial Light Fixtures & Junction Boxes 20


2.11.2 Lighting Fixtures 21

2.11.3 Control Gear Box (Integral Light Fitting) 21

2.11.4 Junction Boxes 22

2.11.5 Lighting Poles 22






2.12 Earthing 22

2.13 Flameproof & Industrial type plugs & Sockets 23



3 Makes of Components 24

4 Nameplate 24

5 Inspection, Testing and Acceptance 25

6 Packing and Despatch 25

6.1 Packing and Despatch of cable drums 25






1 Scope

1.1 This specification covers the requirements of design, manufacture, painting, inspection & testing

at manufacturer’s works and delivery to site inclusive of packing and transportation and

commissioning at site of all electrical equipments covered in clause 2.0 ‘Equipment

Specification’.

1.2 This specification shall be read in conjunction with Specification for “Electrical Installation

Tender” (Doc. No. 254625-300-RQ-ELE-003).

1.3 The equipment offered shall be complete in all respects. Any material or accessories, which may

not have been specifically mentioned in the specifications but which are usually necessary for

satisfactory, safe, trouble free, operation shall be provided without any extra charges.

1.4 It is not the intent to specify completely herein, all details of design and construction of the

equipment. However the equipment shall conform in all respects to high standards of

engineering, design and workmanship and shall be capable of performing in continuous

operation in a manner acceptable to the Owner/Consultant who will interpret the meaning of

drawings and specifications and shall have the power to reject any work or materials which, as

per his judgment are not in full accordance with requirement.

1.5 Vendor shall ensure the quality of workmanship for manufacture of equipment. The equipment

shall be supplied as per the latest applicable standards and as stipulated in this specification.

1.6 Quantity shall be worked out by vendor based on attached drawings. The vendor shall make his

own estimate of quantities for all items, such as equipment, power & control cabling system,

lighting system, earthing system, auxiliary power distribution, civil works, etc.

2 Equipment Specification

2.1 H.V. & L.V. Cables & Accessories

2.1.1 General Construction

The cables shall be suitable for laying in trays, trenches, ducts, pipe sleeves and conduits and for

underground-buried installation with uncontrolled backfill and possibility of flooding by water

and chemicals.

Outer sheath of all PVC and XLPE cables shall be black in colour and the minimum value of

oxygen index shall be 29 at 27 + 2 ° C. In addition suitable chemicals shall be added into the

PVC compound of the outer sheath to protect the cable against rodent and termite attack.

All cables covered in this specification shall be flame retardant low smoke (FRLS). Sequential

marking of the length of the cable in metres shall be provided on the outer sheath at every one

metre. The embossing /engraving shall be legible and indelible.

The overall diameter of the cables shall be strictly as per the values declared by the manufacturer

in the technical information subject to a maximum tolerance of ±2 mm up to overall diameter of

60mm and ±3mm for beyond 60mm.

2.1.1.1 PVC Control Cables

All control cables for use on low voltage systems shall be 650/1100 V grade with copper

conductor, PVC insulated with extruded PVC inner sheathed and extruded FRLS PVC outer

sheathed as per IS-1554 (Part-I) unless specified otherwise.

The core insulation shall be with PVC compound applied over the conductor by extrusion and

shall conform to the requirements of type 'A' compound as per IS: 5831. The thickness of

insulation and the tolerance on thickness of insulation shall be as per Table 2 of IS: 1554 (Part-

1). Control cables having 6 cores and above shall be identified with prominent and indelible






numerals on the outer surface of the insulation. Colour of the numbers shall contrast with the

colour of insulation with a spacing of maximum 50 mm between two consecutive numbers.

Colour coding for cables up to 5 cores shall be as per Indian standard.

The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC

conforming to the requirements of Type ST-1 PVC compound as per IS: 5831. The minimum

thickness of inner sheath shall be as per IS: 1554 (Part-1). Single core cables shall have no inner

sheath.

The outer sheath for the cables shall be applied by extrusion and shall be of PVC compound

conforming to the requirements of type ST-1 compound as per IS: 5831. The minimum and

average thickness of outer sheath for unarmoured cables and minimum thickness of outer sheath

for armoured cables shall be as per IS: 1554 (Part -1).

2.1.1.2 XLPE Power Cables

33 kV Power Cables : 33kV (E) grade, Stranded Aluminium conductor, Screened, XLPE

insulated, Galvanised steel strip Armoured, Extruded FRLS PVC outer sheathed generally

confirming to IS 7098 Part-2 1985.

L.V. Power Cables : 1.1kV grade, XLPE insulated, multi stranded conductor, single/multi core,

steel strip/wire armoured, Extruded PVC inner sheathed & Extruded FRLS PVC outer sheathed

confirming to IS 7098 (Part-1).

The conductors shall be stranded and compacted circular for all cables.

All 33 kV cables shall be provided with both conductor screening and insulation screening. The

conductors shall be provided with non-metallic extruded semi conducting screen.

The core insulation shall be with cross linked polyethylene insulating compound dry cured,

applied by extrusion. It shall be free from voids and shall withstand all mechanical and thermal

stresses under steady state and transient operating conditions. It shall conform to the properties

given in Table-1 of IS: 7098 (Part -2).

The insulation screen shall consist of non-metallic extruded semi-conducting compound in

combination with a non-magnetic metallic copper screen. Unless specified otherwise, the copper

screen for all the three cores together shall be capable of carrying the single line to ground fault

current value and the duration specified in the data sheet.

The conductor screen, XLPE insulation and insulation screen shall all be extruded in one

operation by 'Triple Extrusion' process to ensure perfect bonding between the layers. The core

identification shall be by coloured strips or by printed numerals.

The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the

requirements of type ST 2 compound of IS: 5831. The extruded inner sheath shall be of uniform

thickness. In case of single core cables, there shall be extruded inner sheath between insulation

metallic screen and armouring.

For multicore cables, the armouring shall be by galvanized steel strips as per method (b) of IS-

7098 (Part-2). If armouring is specified for single core cables in the data sheet, the same shall be

with H4 grade hard drawn aluminium round wire of 2.5 mm diameter.

The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of

PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. The

minimum and average thickness of outer sheath for unarmoured cables and minimum thickness

of outer sheath for armoured cables shall be as per IS: 7098 (Part-2)

The thickness of the insulation, inner sheath shall be governed by values given in IS: 7098 (Part

-2).






2.1.2 Cable Accessories

The termination and straight through jointing kits for use on the systems shall be suitable for the

type of cables offered as per this specification.

The accessories shall be supplied in kit form. Each component of the kit shall carry the

manufacturer's mark of origin.

The kit shall include all stress grading, insulating and sealing materials apart from conductor

fittings and consumable items .An installation instruction sheet shall also be included in each kit.

The contents of the accessories kit including all consumable shall be suitable for storage without

deterioration at a temperature of 45° C, with shelf life extending to more than 5 years.

2.1.2.1 Terminating kits

Heat shrinkable terminating kits shall be suitable for termination of H.V. cables to an indoor

switchgear or to a cable box of an outdoor mounted transformer. For outdoor terminations,

weather shields / sealing ends and any other accessories required shall also form part of the kit.

The terminating kits shall be from one of the approved makes.

2.1.2.2 Jointing kits

The straight through jointing kits shall be suitable for installation on overhead trays, trays in

cable cellar, concrete lined trenches, and ducts and for underground burial with uncontrolled

backfill and possibility of flooding by water and chemicals. These shall have protection against

any mechanical damage and suitably designed to be protected against rodent and termite attack.

The inner sheath similar to that provided for cables shall be provided as part of straight through

joint. The jointing kits shall be from one of the approved makes.

2.1.3 Cable Glands

Double compression type nickel plated brass cable glands shall be used. Rubber components

used in cable gland shall be of neoprene. Cable glands shall be of weatherproof or flameproof as

per area classification.

2.1.4 Cable Lugs

Cable lugs shall be of tinned copper for copper cable and aluminium lugs for aluminium cable,

crimping type & of reputed make.

2.2 Busduct

2.2.1 Construction

The Busduct shall be of box frame construction of Sheet Steel enclosure suitably braced to

withstand the maximum mechanical and electrodynamics forces.

The Busduct enclosure shall be fabricated from 2 mm thick Sheet Steel. Eddy current heating, if

applicable, shall be taken into account.

The section of the Busduct shall be rectangle & non-phase segregated. The degree of protection

shall be IP-55.The Busduct shall have fire barriers inside.

The Busduct enclosure shall be suitable for indoor/outdoor installation as specified. The outdoor

portion of Busduct shall be suitable for outdoor installation without any additional protection

from owner’s end. However, rain hood shall be provided as an additional protection for outdoor

installation. Canopy and proper fixing arrangements shall be provided for the same.






The Busduct shall be provided with removable top covers fitted with gaskets secured by

sufficient number of nuts, bolts to ensure that these covers are dustproof. All joints and covers

shall be provided with non-deteriorating type gaskets of neoprene between joints. These covers

shall be of suitable length for ease of removal and shall be arranged to give complete

accessibility to the busbars, joints, bends and supports, etc. The entire busduct shall be dust and

vermin proof. Louvers shall not be provided.

The design of Busduct enclosure shall be such that it will withstand the operating conditions

arising out of the following :

a. Normal operating conditions

b. Momentary short circuit currents

c. Rigours of adverse weather conditions, and

d. Combinations of above.

The busduct shall be provided with flanged ends to connect the busduct to transformer at one

end and switchgear at other end. These flanges shall match with corresponding flanges in the

equipment to which these are connected.

Vendor shall provide suitable flexible termination arrangement at 415V switchgear and

transformer ends. The busduct shall be supplied complete with all the hardware necessary for

making the terminations.

Proper wall sealing arrangements shall be provided at the wall where bus duct enters the

substation building. Busduct with wall mounting flange will be acceptable for the sealing

arrangement.

The enclosure shall be provided with suitable mounting lugs at suitable interval. The mounting

lugs shall be suitable for hanger type supports. Vendor shall design and indicate the supporting

arrangement for busduct.

Under Normal operating conditions, the surface temperature of the enclosure shall not exceed

70°C.

2.2.2 Busbars

The busbars shall be of electrical grade Aluminium flats adequately sized to carry maximum

specified continuous current & short circuit current for 1sec, at maximum site temperature

specified. The final temperature of busbars and connectors at joints between connector and

busbar should not exceed 75°C when carrying rated currents. Also the final busbar temperature

shall not exceed 250°C when specified short circuit current for 1sec duration flows through.

Current density of Busbars shall be 0.8 Amp/mm2 max.

All busbars shall be insulated with heat shrinkable PVC sleeves. All busbars shall be colour

coded such that on removal of any inspection cover the phases shall be identifiable.

Wherever required for long run of busduct, expansion joints with flexible strips shall be

provided to allow for expansion and contraction due to temperature variations arising out of

normal continuous current flow and short circuit current flow for specified duration. Minimum

one expansion joint shall be provided for each 3000 mm long straight length of busduct. In case

this is not provided, Vendor shall substantiate the same with Calculations.

2.2.3 Busbar Supports

The busbars shall be supported by non-deteriorating type (non-hygroscopic, non-carbonising,

Corrosion resistance) Solid core resin cast epoxy insulators of requisite electrical / mechanical

strength. The insulators shall be 1.1 KV grade for 415V system. The mechanical strength shall






be sufficient to withstand forces arising out of peak short circuit current. Each shipping section

shall meet this requirement separately.

Adequate Creepage distance shall be available on insulator to operate under high humid

conditions and effects of condensed moisture due to variations in temperature within busduct

due to different conditions of loading. Minimum number of skirts shall be 3 on each insulator.

The spacing of the insulating supports shall be decided on the basis of the fault withstand

capacity.

2.2.4 Space Heater

Busduct shall be provided with anti-condensation space heaters with controlling thermostats of

adequate capacity to maintain internal temperature above dew point to prevent moisture

condensation in busduct. Space heaters shall be rated for 240V, single phase, 50 Hz AC supply.

Space heater shall be provided on both sides of the fire barrier.

2.2.5 Earth Bus

Two earth bus of 50 mm x 8 mm aluminium shall run on the external side of the busduct through

the whole length of the busduct and shall be positively connected to the body of the busduct

enclosure. At both ends of the earth bus provision shall be made to connect it to main earthing

system.

2.2.6 Termination at the ends of Busduct

The busduct shall be provided with flexible at both ends for connecting it with transformer at

one end and 415V switchgear at other end.

The Flexibles shall be made of thin copper strips. The ends of the flexible shall be clamped by

copper plate. The ends of flexible shall be tin plated.

2.2.7 Special Chambers

To match the phase sequence of the two equipments connected by busduct, a suitable phase

cross over chamber shall be provided; if required, at suitable location. This chamber shall

generally be located in transformer yard.

2.2.8 Marking for Reassembly

All busduct parts like enclosure, adaptor box, rain hoods, enclosure covers, supports, busbar and

busbar fish plates shall be identified distinctly by clear numbers. These shall be indicated in

drawing.

2.3 L.T. Capacitor & APFC Panel

2.3.1 Constructional Features

The APFC Panels shall be totally enclosed, dust and vermin proof, free standing of uniform

height, cubicle multi-tier compartmentalised floor mounting type. The construction shall be

such that extension on the either side shall be possible.

The busbars, incoming and outgoing feeders compartment and capacitor storage space shall be

fabricated from cold rolled sheet steel panel of 2mm thickness. Removable type undrilled gland

plates shall be provided at bottom of the panel. Stiffeners shall be provided wherever necessary.






APFC Panels shall be provided with integral baseframe which shall be bolted/welded on the

cross members provided by owner. Amply dimensioned oblong holes shall be provided on the

base frame. The baseframe shall be of standard sections, re-rolled sections will not be

acceptable. Vendor shall give baseframe details in foundation drawing. Cross members or

foundation on which baseframe is mounted is excluded from Vendor’s Scope of supply.

The APFC Panels shall be properly ventilated by louvers and covered inside with wire mesh.All

cable entries shall be from the Bottom for both incoming and outgoing cables. Terminals shall

be located sufficiently away from gland plate to facilitate easy connection.

The construction of APFC Panel shall conform to a degree of protection to IP-42. All doors,

removable covers, gland plates and joints between adjacent sections shall be gasketed all round

with neoprene gaskets. Lifting facility shall be provided for each shipping section.

The live side of isolating switches must be fully insulated or shrouded. All main isolating

devices shall have provision for padlocking in the "OFF" position only and shall be interlocked

with door.

Each outgoing feeder shall be fixed type with the power switchgear & capacitors in the front

side. Rear access is not possible. The capacitor units shall be integral with the control panel unit

complete with internal wiring. Each capacitor feeder shall be provided with quick-make, quick-

break capacitor duty MCCB & contactor, "ON" and “OFF” indicating lamps, ammeter + ASS

and terminal blocks. Each compartment door shall be interlocked with switch.

The feeder compartment doors & cable alley doors shall be of lift-off type with hinges on one

side and turn lock on other side, which will ensure tight closing of the doors, making the

compartment effectively dust-proof. Care shall be taken while providing gaskets at hinged

points.

The size and layout of feeder compartments, busbars and cable alleys shall be such as to enable

easy maintenance of the equipment mounted inside.

The mounting height of all components on panel door shall be between 300 to 1800 mm from

floor.

The Vendor shall ensure that temperature within the cubicle is within acceptable limits and that

the heat from Capacitor Bank does not get transferred to the Switchgear Assembly. The Vendor

may consider using ventilation fans for effective heat removal.

Space heater for each cubicle / vertical panel shall be located at the bottom of the panel and shall

be controlled through a thermostat with an adjustable setting and a manually operated switch.

Panels shall have fluorescent light fittings for internal illumination with door switch.

2.3.1.1 Busbars

The busbar shall be made out of high conductivity electrolytic grade aluminium with adequate

cross section to carry continuous current.

The busbars shall be insulated with colour coded heat shrinkable PVC sleeves and supported by

non-hygroscopic material insulators with anti-tracking arrangements. Liberal clearance and

Creepage distances shall be provided for the busbar system to minimize the possibility of faults.

The busbar system shall be designed for fault level & maximum operating temp mentioned in

Electrical System Data.

The horizontal and vertical busbar compartment in Panel shall be totally segregated from rest of

the compartments and rendered totally inaccessible under normal circumstances. No equipment

shall be mounted on busbar chambers. All busbar compartments shall be provided with bolted

type gasketed covers.






Inter Panel Metal barriers of full height and width shall be provided between the bus

compartment and the out-going cable compartment.

2.3.1.2 Earthing

Horizontal earth bus bar located at the bottom shall be provided from end-to-end of the

assembly. Earth bus joints shall be solidly bolted. The earth bus shall be connected to the plant-

grounding grid at each end of APFC panel. Two numbers external earth terminal shall be

provided to adopt system earth conductor

All non-current carrying metal parts of APFC panel shall be effectively connected to the earth

bus bar.

All metal doors and removable barriers shall be bonded to the rigid part of structure by stranded

insulated copper wires of 2.5 sq. mm minimum through earthing stabs.

The earth bus shall be connected at each end of APFC panel by accessible removable link.

2.3.1.3 Wiring & Terminations

Internal Power wiring shall be means of tinned copper strips with colour code at regular

intervals. All internal control wiring shall be with stranded conductor insulated copper wires of

2.5 sq. mm, 600 V / 1 kV grade & PVC insulated. Stranded conductors shall be terminated by

means of tinned copper lugs.

Conductor shall run without splices from terminal to terminal.

Sufficient space and supports shall be provided in the enclosure for field cable routing to the

terminals.

Incoming & Outgoing power terminals shall be bolted type. They shall be a minimum 50 mm

wide to provide proper bolt and washer application. Size of hole shall match size of cable lugs.

The power and control devices shall be furnished with finger-safe terminals. Terminals shall be

rated for 600 V A.C.

Control terminals shall be screw compression type.

Each wire shall be marked with the wire number & All terminal blocks shall be furnished with

white marking strips marked with terminal numbers in accordance with the wiring diagrams.

The terminal blocks shall be furnished with minimum 20% spare control terminals.

Colour Coding for internal panel wiring shall be as follows:

Power Wires : Red, Yellow, Blue for Phases.

AC Control Circuits : Red

DC Control circuits

Positive : Blue

Negative : Blue with white strip

Neutral Wires : Black.

Ground Wires : Yellow & Green

Interlock control circuits wired

from an external power source :

Yellow






2.3.2 Components

2.3.2.1 Power Factor Correction Capacitors:

Heavy-duty Film + Foil dielectric capacitors shall be used for the power factor correction. The

capacitors shall be designed to handle over voltages and over currents without reducing

capacitor life.

The Capacitors shall be dry type, hermetically sealed, constructed of All polypropylene two

layer film + foil dielectric with self-healing metallised electrodes. The capacitor cells shall be

impregnated with biodegradable, non-PCB impregnant.

Each capacitor shall be equipped with a Pressure Sensitive Interrupter, for protecting the

capacitor cell from rupturing.

The individual capacitor element shall have current limiting fuses 600 Volts, with wire internal

and blown fuse indicator shall be provided in each phase of each capacitor bank/ step. The fuses

shall provide protection against short circuit currents. The capacitor units shall be provided with

discharge resistors to reduce the residual voltage to 50V or less within 60 seconds of switching-

off. The capacitor shall be rated at 415V. The capacitor shall be suitable for + 10% over voltage.

The container of the capacitor shall be of high quality sheet steel with minimum joints and

suitable for mounting on a base channel. All mating surfaces shall be provided with neoprene

gaskets to render the enclosure dust / vermin proof.

Each 3 phase Capacitor unit shall be formed from basic units of 25/50 kVAr, by connecting

suitable nos. in series or parallel.

The Capacitor Bank shall be robust in construction, maintain rated output for at least 7 - 8 years

and shall have tropicalised design.

The container of the capacitor shall be of high quality sheet steel with minimum joints and

suitable for mounting on a base channel.

The capacitor banks formed from individual units shall have sheet steel cable box complete with

copper links suitable to receive PVC insulated PVC sheathed, copper conductor, un-armoured

cables.

Each Capacitor Bank shall be provided with 2 nos. external earth terminals each complete with 2

plain and 1 spring washers. This Earthing bolt shall be connected to body earth.

The connection from active elements of the capacitor to the terminal box shall be through studs

fixed to cover properly sealed to make the capacitor unit hermetically sealed. The active

elements shall be mixed dielectric type or All Polypropylene.

Each Capacitor Bank shall be fitted with Perspex nameplate.

2.3.2.2 Automatic power factor controller relay

The controller shall be microprocessor based (with adjustable control), having auto / manual

control selection mounted on the front of the panel with indication having minimum 16 steps.

The control circuit shall sense the power factor, KVAR of the connected power system and

based on the desired power factor selected from the front of the panel, it shall close / open the

output relay contacts with a definite time lag to switch ON & OFF the required capacitor banks.

The controller shall tap the reference voltage from the incoming voltage 3 phase, 4- wire supply.

Reference current signal shall be sensed from current transformer with 5A secondary connected

in middle phase mounted in the Low Voltage Switchgear (supplied by others).

The controller shall have a setting range for target power factor from 0.80 inductive to unity. To

avoid 'hunting', minimum set KVAR selection shall be available on the front of the panel. An

auto/manual selector switch shall be provided on the controller for control of capacitor banks






with the set ranges of target power factor and % KVAR, in auto mode and without these ranges

in manual mode.

Push buttons shall be provided on the controller to switch ON & OFF the capacitor banks in

manual mode.

The Controller shall be programmed for setting the timing sequence to take care of the discharge

time of the capacitor. The switching sequence shall be such, as to permit utilization of all the

capacitor banks, thereby increasing the operational life of the capacitors.

The power factor controller relay unit shall comply with the following standard features: -

a. Digital display of operating conditions viz., capacitor step sizes, number of switching

operations per step, defective capacitor step, etc.,

b. Digital display of system parameters viz., active, reactive, and apparent power, power factor,

voltage, current, thermal current load, harmonics, load flow direction etc.,

c. The controller shall have protection against over voltage and current path reversed

connection.

d. Manual/Automatic selector switch for selecting the controller mode of operation.

e. Variable switching programmes viz., fully automatic, conventional and manual operation.

f. Monitoring of out of limit conditions with visual alarm viz., over and under compensation,

power loss of capacitors, current overload, harmonic overload etc.,

g. Adjustable switching ON or OFF time delay from 10 to 60 seconds.

h. Fault output relay for signalling of target power factor is not reached.

i. Automatic rotational switching program to ensure that the steps are used equally.

j. A voltage transformer (control transformer) shall be provided within APFC enclosure for

control power.

k. RS485 – Interface port for data transmission

l. Fault signaling contact for control alarm.

2.3.2.3 Air circuit breaker

Incomers of the APFC Panel shall be provided with ACB for incomer rating 2000Amp. Air

circuit breakers shall confirm to the following requirements:-

Short Circuit breaking capacity (Ics) shall be minimum 50 kA RMS Symmetrical at 415 Volts.

Also, the Short Circuit Withstand capacity shall be 50 kA minimum, for 1 sec at 415 Volts.

The air circuit breaker shall be manually and electrically operated, fixed type equipped with

motor wound spring charged closing & trip mechanism. The spring charging motor shall be

suitable for 110 V, DC supply.

Means shall be provided for slow closing and opening of the breaker for maintenance purpose

and for manual charging and closing of electrically operated breakers during emergencies.

Following safety features and accessories shall be provided in the breaker:-

• It shall not be possible to open the compartment door when the circuit breaker is ON.

• Heavy duty self-aligning earth contact.

• Anti pumping circuit shall be provided such that the breaker shall not reclose after tripping

even though a close signal may be continuously present.






• Position (TRIP-NEUTRAL-CLOSE) Selector Switch with spring return from Trip/Close to

Neutral.

The CB shall be provided with microprocessor based direct acting protection releases for

overload, short circuit, earth fault & Under-voltage. The releases shall be adjustable type.

The Circuit Breaker shall be provided with mechanical ON/OFF, TRIP and SPRING

CHARGED, DISCHARGED indication, T/N/C control switch, mechanical trip push button,

mechanical ‘close' push button, and padlocking facility.

2.3.2.4 Moulded Case Circuit Breaker (MCCB)

All the outgoing feeders shall be equipped with MCCBs.

MCCB shall be equipped with adjustable instantaneous magnetic trip element. The Short Circuit

Breaking capacity (Ics) shall be minimum 50 kA RMS Symmetrical at 415Volts. Also, the Short

Circuit Withstand capacity shall be 50 kA minimum, for 1 sec at 415 Volts.

MCCB shall be designed for application in individual Capacitor bank circuit. They shall operate

on the magnetic principle with a current sensing element in each pole to provide short circuit

protection.

MCCB shall be triple pole manually operated with handle. A padlocking facility shall be

provided to lock the unit MCCB operating handle in the ‘OFF’ position.

MCCB operating mechanism shall be quick-make, quick-break and trip-free. Trip free

mechanism shall be independent of manual operation.

2.3.2.5 Power contactors

All contactors shall be 3 pole air - break, magnetic, capacitor duty type. The rating of contactor

shall be suitably assigned.

The individual capacitor bank/step shall be switched using NEMA rating magnetic contactors

suitable for switching capacitive currents.

The minimum life expectancy of the contactor shall be one million switching operations.

Each Power contactor shall have 2 NO and 2 NC auxiliary contacts wired upto terminal block

for Purchaser's use.

2.3.2.6 Indicating & Measuring Instruments

Indicating lamps shall be LED type. Voltage rating of the bulb shall match control circuit

voltage.

A suitable range of analog ammeter with selector switch and analog voltmeter with selector

switch shall be provided for the incoming feeder.

2.3.2.7 Current transformer

CT shall be epoxy moulded cast resin. Manufacturer shall check the saturation factor, ratio, and

burden and accuracy class of CT before mounting them. Name plates shall be provided on each

CT

The terminals of CT shall be stud type. Loose leads of CT are not acceptable.

The CT’s shall withstand thermal and dynamic stresses due to max. short circuit current

as specified.






2.4 Power Distribution Panel & Lighting Distribution Panel with Energy Saver Feature


The general construction details of the board shall be subject to purchaser's approval and shall be

in line with IS-8321 for Factory's Build Assemblies.

The Power & Lighting Distribution Panels shall be fabricated from CRCA sheet steel of

minimum thickness 2 mm. The load bearing members and the doors with large instruments shall

be fabricated from suitably thicker sheets. Stiffeners shall be provided, wherever required.

The individual panels of the distribution board shall be identical in depth and height and when

bolted together shall give appearance of one continuous panel. The Panels shall be complete

with the base frame of min. height of 75 mm.The cable entry of distribution boards shall be from

bottom with removable undrilled gland plate.

The Panels shall have totally segregated busbar chamber, cable alley and feeder compartment.

Each feeder in the board shall be mounted in separate compartments. The compartment shall be

totally segregated so that, in case of a fault in any feeder, the damage is restricted to that

compartment only. The barriers shall be used to achieve compartmentalisation.

The compartment doors shall be provided with concealed hinges and thumb screws with

retaining washer. The spacing of thumb screws shall ensure proper compression of gasket. The

compartment doors shall be interlocked with the switch of the feeder such that the door can be

opened only when the switch is off.

The cable alley shall be provided with hinged doors & shall be provided with arrangement for

fixing cable clamps.

The distribution board shall be suitable for extension on either side.

The Distribution Board shall be single front & shall have front access only, both for maintenance

and operation. The boards shall be suitable for placing against the wall.

Gaskets shall be provided between all joints, beneath the door and gland plates to ensure

effective dust and vermin proofing. The hardware used shall be high tensile strength steel with

zinc passivation or chromium plated.

A separate vertical section shall be provided for the main incoming power feeder.

Adequate lifting lugs / hooks shall be provided for each shipping section.

The horizontal and vertical busbar compartment in PDP & LDP shall be totally segregated from

rest of the compartments and rendered totally inaccessible under normal circumstances. The

busbar chamber shall be adequately sized and totally enclosed and at the same time maintaining

the temperature rise of busbars within the permissible values as per relevant standards.

Temperature rise of offered busbars shall be specifically stated in the offer by VENDOR. The

busbar chamber shall be complete with bolted cover. No equipment shall be mounted on Busbar

chamber.

The Degree of Protection of LDP & PDP shall be IP-42 or better

LDP shall be provided with lighting transformer to reduce fault level.

2.4.1.1 Wiring & Terminations

All the equipments covered in this specification shall be supplied completely wired internally to

components and terminal blocks and ready for purchaser’s external cable connections.

The Incomer Terminals shall be suitable for termination of Aluminium armoured cables as

indicated in SLD. If Incoming MCCB/MCB terminals are not adequate to receive the incoming

cable size additional terminal shall be provided.






The Terminal Block provided for connecting Outgoing Cables shall have terminals suitable for

terminating the Aluminium armoured cables.

The connection between feeders and the busbars shall be with links of adequate size in case of

feeders above 63 amperes and with 650 V grade PVC insulated copper / aluminium conductor in

case of feeders of rating below 63 ampere.

Terminal blocks shall be rated 600 V. Terminals shall be permanently marked with white

marking strips in accordance with the Wiring Diagram. The terminal blocks shall be furnished

with minimum 10% spare terminals

All cable terminations shall be via lugs. Tin-plated copper lugs suitable for aluminium

conductors shall be provided for the main incoming power feeder. Fork type tin plated copper

lugs shall be provided in the incoming line section for connecting the main grounding conductor.

2.4.1.2 Earthing

The Distribution Board shall be provided with continuous earth busbar complete with 2

terminals for connecting the earth busbar to the system earthing grid. Separate earth A1.busbar

shall be provided throughout inside the panel & shall be brought out at ends.

2.4.2 Components

2.4.2.1 Switches

The switches shall be heavy duty, load break quick break complete with shrouding for incoming

and outgoing terminals.

The switches shall be complete with door interlocking mechanism wherever required in order to

provide interlocking with the compartment door such that the door can be opened only when the

switch is off.

The switch handle shall have clear indication for the ON and OFF position of the switch.

2.4.2.2 Fuses

The fuse shall be HRC type and shall conform to relevant Indian Standards.

The fuses shall be link / diazed type.

The fuse shall be provided with mechanism to indicate fuse blow off.

2.4.2.3 MCCB/ MCB/ ELCB

MCCB / MCB shall be suitable for the fault level as achieved by Lighting Transformer.

The MCCB's shall be complete with over-current and short circuit tripping types.

MCCB shall be triple pole manually operated with handle. A padlocking facility shall be

provided to lock the MCCB unit-operating handle in the ‘OFF’ position. MCCB operating

mechanism shall be quick-make, quick-break and trip-free. Trip free mechanism shall be

independent of manual operation.

ELCB shall be of reputed make.

2.4.2.4 Power contactors

All contactors shall be air break, magnetic conforming to AC3 category of duty.

All power contactors shall have a minimum of 2 NO + 2 NC auxiliary contacts. The auxiliary

contractors shall have 4 No + 4 NC contacts. The spare contacts shall be wired up to the

terminal block.






2.4.2.5 Indicating & Measuring Instruments

The indicating and measuring instrument such as voltmeter, ammeter, MFM meter shall be flush

mounting type. The instruments shall be mounted on the compartment door and the mounting

height shall be above 300 mm but below 1800 mm from the base of the switch board.

The indicating lamps wherever provided shall be filament type complete with series resistance.

2.4.2.6 Current transformer

CT shall be cast resin. They shall be mounted on a stationary part of switchgear. Manufacturer

shall check the saturation factor, ratio, burden and accuracy class of CT before mounting them.

Name plates shall be provided on each CT

The terminals of CT shall be stud type. Loose leads of CT are not acceptable.

The CT’s shall withstand thermal and dynamic stresses due to max. short circuit current as

specified.

2.4.2.7 Lighting Transformer

The plant lighting system shall be fed by the lighting transformer. The lighting transformer shall

be 415 / 415 V, three phase delta-star connected, dry type with OCTC, located inside the

respective lighting distribution board.

Lighting transformer shall be sized to take care of the total lighting load of the plant with a

provision for 10% extra capacity and suitable impedance to reduce the short circuit withstand

capacity. (Refer Single Line diagram for MLDP, EMLDP & Yard Lighting DP). Manufacturer

shall submit lighting transformer calculation for approval.

2.4.2.8 Busbars

The busbar shall be of high conductivity electrolytic grade aluminium with adequate cross

section to carry continuous current with temperature rise limited to value specified in Indian

Standard.

The busbars shall be insulated with colour coded heat shrinkable PVC sleeves and supported by

non-hygroscopic material insulators with anti-tracking arrangements. Liberal clearance and

Creepage distances shall be provided for the busbar system to minimize the possibility of faults.

The joints between busbar as well as between busbars and the links for outgoing connections

shall be complete with spring washers.

2.5 Energy Saver Feature in Lighting Distribution Board

Energy saver feature in LDP shall be with PLC based controller with software interface via RS-

232 and Ethernet, circuit breaker for short circuit & overload protection. The password protected

software shall communicate with the controller to display current schedule and update or add any

new programmes. Energy saver panel shall have LCD display with backlight, it shall display

time/date and current preset level, power & energy used. It shall also have fully programmable

daily/monthly/yearly calendar with holiday scheduler for controlling each outgoing circuit. It

shall have auto start/shutdown facility with 0-30 minute ignition cycle.

The facility operator shall be able to access locally or remotely by using the software & manage

any of the elements listed below:

Schedule or manually implement automatic energy reduction levels and on/off switching

Participate in peak shaving/load shedding/utility energy requirements without disruption of work

View power usage and energy consumption of each circuit






The size and layout of feeder compartments, busbars and cable alleys shall be such as to enable

easy maintenance of the equipment mounted inside.

Space heater for each cubicle / vertical panel shall be located at the bottom of the panel and shall

be controlled through a thermostat with an adjustable setting and a manually operated switch.

Panels shall have fluorescent light fittings for internal illumination with door switch.

2.6 Power Distribution Panel for MOVs


The Power Distribution Panel for MOVs shall be metal enclosed, compartmentalised, floor

mounted, free standing, non-drawout type suitable for indoor installation with degree of

protection IP-42.

The panel shall be fabricated from CRCA sheet steel of minimum thickness 2 mm. The doors and

covers shall be made of minimum 1.6 mm cold rolled sheet steel. All doors and covers shall be

provided with neoprene gaskets. The panel shall be complete with the base frame of min. height

of 75 mm. The cable entry of panel shall be from bottom with removable undrilled gland plate.

The Panel shall be suitable for extension on either side. The panel shall be single front & shall

have front access only, both for maintenance and operation. Adequate lifting lugs/ hooks shall be

provided.

The maximum height of the operating handle/ switches shall not exceed 1800 mm and the

minimum height shall not be below 300 mm. All hardware shall be corrosion resistant. All joints

and connections of panel members shall be made by cadmium plated high quality steel bolts, nuts

and washers secured against loosening.

2.6.2 Components

The two nos. of Incomer feeders shall be Four Pole MCCB of 200A rating. The incomer feeder

shall have voltmeter with selector switch, ammeter with selector switch and 3 nos. pilot lamps for

supply indication and Multi Function Meter. Mechanical interlock between the two nos.

Incomers shall be provided such that any one feeder can be closed at any time. Necessary

adequate Incoming terminals shall be provided to connect suitable size cable as recommended or

as shown in SLD.

Each outgoing circuit shall comprise of Triple pole MCCB of 63A rating with neutral isolating

type bus-bar arrangement . All MCCBs shall be with time delayed O/C, S/C & E/F releases. The

panel shall have 20% spare feeders, which will include minimum of one spare feeder of each

rating. The panel shall be designed to ensure maximum safety during operation, inspection and

maintenance. Necessary adequate out going terminals shall be provided to connect suitable size

cable as recommended or as shown in SLD.

The panel shall be provided with continuous earth busbar complete with 2 terminals for

connecting the earth busbar to the system earthing grid.

2.7 Outdoor MOV Power Distribution Board

The Outdoor MOV Power Distribution Board shall be metal enclosed, non-compartmentalised,

floor mounted, free standing, non-drawout type suitable for outdoor installation with degree of

protection IP-55.

The Incomer feeder shall be Triple Pole Neutral (TPN) MCCB of 63A rating with neutral

isolating type bus-bar arrangement. The incomer feeder shall have voltmeter with selector

switch, ammeter with selector switch and 3 nos. pilot lamps for supply indication. Each outgoing

feeder shall comprise of 10A MCB with thermal overcurrent & magnetic short circuit releases &

shall be of Motor Duty type. The MOV PDB shall be located in the field at strategic locations as






indicated in the Drawing attached in Appendix-I. The location indicated in the drawing is

tentative only, the exact location shall be decided by vendor as per the site conditions.

2.8 Cable Trays

2.8.1 Cable trays shall be ladder type prefabricated hot dip galvanised sheet steel of thickness 2.5mm

trays.

2.8.2 GI Coating thickness shall be of 75 micron.

2.8.3 Dimension details of cable trays shall be provided as per attached Drawing No. 254625-300-

ELE-4801 in Appendix-I.

2.8.4 Outer most tier of all vertical cable trays shall be covered with GI sheet for protection against

physical damage to cables.

2.8.5 Cable trays shall be covered by removable top covers on upper most tier allowing adequate

ventilation in following cases where:

• Mechanical damage of cables is likely to occur during maintenance in the plant.

• Oil or spillage of chemicals can be expected.

• Protection from exposure to sun is required.

2.8.6 The cable trays shall be supplied in standard lengths of 3000 mm and clear width of trays shall

be 150 (for perforated type trays), 300, 500, 700, 900 mm (for ladder type trays).

2.8.7 GI cover sheet shall allow adequate ventilation to the cables and shall be in standard length of

3000 mm, flanged on both sides for fixing on cable tray. Covers shall be complete with required

GI hardware.

2.8.8 The adjacent cable trays shall be supported at every 2 to 2.5mtr depending on tray width.

2.8.9 Clamping arrangement shall be done on the length of cable trays at every interval of 1000 mm

for horizontal trays & 300/500 mm for vertical trays.

2.9 Flameproof & Industrial type Control Stations

2.9.1 Construction

Flameproof control station shall be made of cast light metal alloy and shall be free from

frictional sparking hazard. The magnesium content in the alloy shall be as per IS-13346.

Flameproof enclosure shall be suitable for zone 1 & 2, gas group IIA / IIB & temperature class

T-3. The enclosures of the industrial control station shall be made of CRCA sheet steel (2 mm),

dust & vermin proof and accessories suitable for installation in Industrial outdoor areas and shall

have enclosure protection as per IP-55.

The control stations shall be suitable for use in outdoor open locations and shall have IP-55

degree of protection. They shall preferably be provided with integral canopy. However, where

the enclosure has been certified without integral canopy, a separate canopy can be accepted. The

separate canopy shall be made of at least 14 SWG (2mm) galvanised sheet steel or FRP. The

canopy shall be suitable for providing protection against rain from top and two sides.

Unless otherwise specified all control stations shall be suitable for 240 V AC control supply.

The control stations shall be provided with gaskets made of non-inflammable and self-

extinguishing material.

The enclosures shall be treated and prepared for painting with two coats of epoxy paint with

final colour shade (both internal and external) as Silver grey No. 628 (IS-5)

All accessories like nuts, bolts, washers etc. shall be made of stainless steel SS-304.






The control stations shall be provided with two earthing studs with lugs on the external surface

of the enclosures suitable for termination of 8 SWG GI wire.

Each control station shall be provided with 2 nos. bottom cable entries and 1 no. flameproof

nickel plated brass sealing plug.

The control stations shall have external fixing lugs for mounting on wall or column. The holes

provided on these lugs shall be of oblong type.

2.9.2 Component Specification

Push buttons for START and STOP shall be of GREEN and RED colour respectively. Unless

otherwise specified, each push button shall have one normally open and one normally closed

contact. The STOP push button shall be mushroom type with stay put feature and lockable in

pressed position.

Selector switches shall have three/ four positions (Local, Off & Remote) for Local Control

Station. Unless otherwise specified, all selector switches shall have minimum two poles for each

position. Each position shall be indelibly marked on the control station.

All ammeters shall be of moving iron type having an accuracy class of 3 and suitable for 1

Ampere CT secondary. Unless otherwise specified, min. size of ammeter shall either be 50 mm x

50 mm. 80% of the scale length shall cover 100% of the CT primary current uniformly and the

balance 20% of the scale shall cover 100-600% of the CT primary. A red mark corresponding to

the full load current of the motor shall be provided on the ammeter dial. The ammeter front glass

shall be toughened (Type 'A' glass).

All push button and control switch contacts shall be rated for min. 5 Amps at 240 V AC-15.

Indicating lamp(s) wherever provided shall be clustered LED type (with minimum 3 nos. LEDs,

preferably connected in parallel), mounted inside an enclosure of minimum diameter of 15mm.

2.10 Flameproof & Industrial Lighting and Power Panels

2.10.1 Construction

The enclosures of the flameproof lighting and power panels shall be made of cast light metal

alloy and shall be free from frictional sparking hazard. The magnesium content in the alloy shall

be as per IS-13346. Flameproof enclosure shall be suitable for zone 1 & 2, gas group IIA / IIB &

temperature class T-3. The enclosures of the industrial lighting & power panels shall be made of

2mm thick sheet steel and shall be dust & vermin proof. All metal surfaces shall be cleaned free

of rust. The enclosures shall be sized to facilitate easy maintenance and heat dissipation.

Panels shall be indoor / outdoor type as specified. Indoor type panels shall have IP-42 degree of

protection and panels located in outdoor open locations shall have IP-55 degree of protection.

The panels shall be suitable for surface or flush mounting on wall surface as specified. They

shall preferably be provided with integral canopy. However, where the enclosure has been

certified without integral canopy, a separate canopy can be accepted. The separate canopy shall

be made of at least 2mm galvanised sheet steel or FRP. The canopy shall be suitable for

providing protection against rain from top and two sides.

The lighting and power panels shall be provided with gaskets made of non-inflammable and self-

extinguishing material.


final colour shade (both internal and external) as Silver grey shade 628 (IS-5)







All the non-current carrying metallic parts of the panel shall be inherently bonded together. Each

lighting and power panel shall be provided with two earthing studs with lugs on the exterior of

the panel enclosure suitable for termination of 10 mm dia GI wire rope.

Each outgoing feeder shall be provided with distinct terminals for phase, neutral and earth. The

terminal block enclosures shall be adequately sized to properly terminate the cables by taking

into account the required bending radii of cable cores and shall have the following minimum

gland to terminal distances:

Conductor Size Up to 2.5

mm2

Above 2.5 mm &

Up to 10 mm2

Above 10 mm2 &

Up to 35 mm2

Above 35 mm &

Up to 70 mm2

Gland to terminal

distance 40 mm 100 mm 150 mm 300 mm

The panels shall be provided with suitably sized cable entries at the bottom/ sides, for incoming

and outgoing cables. Flameproof nickel plated brass sealing plugs shall be supplied, for plugging

the unused cable entries. The quantity of sealing plugs shall be equal to 20% of the total number

of outgoing cable entries.

The panels shall have external fixing lugs for mounting on wall or column. The holes provided

on these lugs shall be of oblong type.


Busbars in the lighting and power panels shall be made of high conductivity copper, and shall be

supported by non-hygroscopic insulators. Busbars shall be colour coded for identification of

phases and neutral.

Unless otherwise specified, the incomer shall have one no. TP MCB with neutral link, 3 nos.

fuses for maintenance and 3 nos. 30mA single phase ELCB for each circuit.

Unless otherwise specified, the outgoing feeders shall be provided with double pole 10A MCBs

having overload and short-circuit releases.

Unless otherwise specified, all MCBs shall be with 16kA (M9 category) interrupting capacity.

The ELCB shall be hand reset type. One no. door mounted reset push button shall be provided.

The operating knobs (ON/ OFF/ RESET) shall be provided with a suitable rack and pinion

arrangement for operating them smoothly from outside.

Wherever the size of incoming cable to lighting, power panels is more than 35 sq.mm a suitable

cable adapter box shall be provided and attached to the panel. The incoming cable leads shall be

connected to terminal block (bolted type terminals) of required size. This terminal block shall be

connected to TPN incomer unit through separate PVC insulated copper conductor wires/bus bars.

Sufficient space shall be provided (minimum 300mm) between gland plate and the bottom of

terminal block for easy termination.

2.11 Flameproof and Industrial Light Fixtures & Junction Boxes

2.11.1 Construction

The enclosures of the flameproof lighting fixtures, control gear box and junction boxes shall be

of cast light metal alloy and shall be free from frictional sparking hazard. The magnesium content

in the alloy shall be as per IS-13346. Flameproof enclosure shall be suitable for zone 1 & 2, gas

group IIA / IIB & temperature class T-3. The enclosure of the industrial lighting fixtures, control

gear box and junction boxes shall be of CRCA sheet steel, dust & vermin proof.






All equipment shall be suitable for use in outdoor open locations and shall have IP-55 degree of

protection.

The enclosures shall be provided with gaskets made of non-inflammable and self-extinguishing

material.

The enclosures shall be treated and prepared for painting with two coats of epoxy paint with final

colour shade (both internal and external) as Silver grey shade 628 (IS-5)


All equipments on single phase supply shall be provided with an independent earth terminal with

lug inside the enclosure for terminating the third (earth) core of the cable and shall have facility

for looping.

2.11.2 Lighting Fixtures

Glass used for lighting fixture shall be clear and suitable for use under conditions involving

exceptional risk of mechanical damage.

Well glass lighting fixture for Zone-2 classified area shall meet requirement of IS-8224.

Mechanical strength of well glass shall satisfy requirement of IS-2206 (for type A glass) for

flame proof lighting fixtures, and IS-6381 for Div. 2 lighting fixtures. All well glass fixtures

shall be provided with a protective wire cage using minimum 5 mm welded steel construction

and having mesh dimensions not exceeding 50mm x 70mm.The material of the cage shall be

galvanised steel or epoxy powder coated mild steel.

The fixing parts of the enclosure, which are to be opened for replacement of bulb, shall be so

fastened that they can be unfastened only with special tools.

The lighting fixtures in Zone-2/ Zone-1 area, shall have approved type enclosed break lamp

holder and complete enclosure certified as having restricted breathing type construction. In case

of lighting fixtures, the holder shall additionally have a spring-loaded lock to hold the lamp in

position and to prevent the lamp coming off loose in the holder. Lamp holder shall be Edison

screw type.

All lighting fixtures shall be provided with 2 no. threaded entry and 1 no. double compression

nickel plated brass cable gland. The glands shall be suitable for the specified cable size. All the

fixtures having double cable entry shall be supplied with 1 no. nickel plated brass plug for

sealing the unused entry.

The top of all well glass lighting fixtures shall be identically drilled/ threaded to facilitate

installation on pole/ column or ceiling.

The flood lighting fixtures shall be supplied with adjustable mounting arrangement both in

horizontal and vertical plane.

All lighting fixtures shall be provided with suitable mirror-polished aluminium internal reflector

of suitable thickness to ensure adequate mechanical strength.

2.11.3 Control Gear Box (Integral Light Fitting)

Lighting fixtures suitable for discharge lamps shall be provided with power factor correction

capacitor, choke starter etc., housed in separate compartment. The choke shall be copper wound.

The complete control gear shall have power factor not less than 0.9.

The control gear boxes shall be provided with 3 nos. entries and 3 nos. double compression

nickel plated brass cable glands. The glands shall be suitable for the specified cable size. 20% of

the control gear boxes shall be supplied with 1 no. nickel plated brass plug for sealing the unused

entry.






Control gear box for flame proof fixtures shall be flameproof type unless specified otherwise.

2.11.4 Junction Boxes

Unless otherwise specified, the junction boxes shall be of flameproof construction suitable for

zone 1 & 2, gas group IIA/IIB, temperature class T-3. Each junction box shall be complete with

requisite number of cable entries and double compression flameproof nickel plated brass cable

glands to suit the specified cable size and flameproof sealing plugs.

2.11.5 Lighting Poles

Lighting poles shall be fabricated from MS steel tubular/ octangular pipes with joints, swaged

together when hot and bevelled on outside edges. Lighting poles shall be hot dip galvanised with

thickness of coating 70µm.

Poles shall be coated with bituminous preservative solution on the ground portion of the outside

surface. Remainder of the outside surface shall be given two coats of red oxide primer and

finished with two coats of aluminium paint.

The pole shall have a marshalling box/Junction Box near the bottom to contain HRC fuses, a

neutral link, an earth stud and terminal block. Each pole shall have two distinct earthing points

for connecting to the plant earth grid.

2.12 Earthing

Earthing system shall comply with the requirements of IS- 3043 and IEEE-80.

All materials and hardware to be supplied by the contractor shall be new, unused and of best

quality and shall conform to the specifications given here under and to latest specifications of

Bureau of Indian Standards. Contractor shall bring material samples to site and get it approved

by Engineer-in-charge before installation.

The following conductor materials are proposed for the earthing system :

i) Conductor above ground level, cable

trenches and along cable trays GI Earth strip

ii) Conductors buried in earth and concrete GI Earth strip

iii) Outdoor structure, Plant, Earth pits

A set of three copper-bonded steel earth rods

of 2m each arranged in a triangular fashion &

separated from each other by a flat copper

conductor (copper strip).

iv) TRF Neutral Earth pits & DG Neutral

Copper Plate electrodes of size 600 x 600 x

10mm with 2 Nos.50 x 6mm G.I.Earth strips

as per IS 3043.

v) Lightning protection air terminations and

down conductors for building

A set of three copper-bonded steel earth rods

of 2m each arranged in a triangular fashion &

separated from each other by a flat copper

conductor (copper strip).

The galvanizing of the earthing material shall be done as per IS 2629-1985. Earth Electrodes

shall have disconnecting facility. The rate shall be inclusive of excavation, Earth Electrodes

fixing, backfilling, construction of earth pit chamber and earth pit cover, etc.

Earthing conductors in the plant shall be laid in the form of a grid. Earthing leads of transformer

& D.G.Set’s neutral shall be directly connected to two separate G.I. earth plate electrodes






whereas, in the plant, outdoor structure, towers, tanks, building columns, loading racks, pipe

racks, vessel & heat exchanger etc shall have two distinct earth connections.

All interconnections of the earthing grid conductors shall have welded type joints except at

electrodes with disconnecting facility and at equipment with bolted connections. All indoor

earthing grids shall be suitably interconnected to the external earthing grid.

Steel strips/conduits, cable trays etc shall not be used as earth continuity conductors.

Earth pit marker showing details as indicated in Installation drawings 254625-300-ELE-4804-

Sh-1 attached in Appendix-I shall be provided.

2.13 Flameproof & Industrial type plugs & Sockets

2.13.1 Construction

The enclosures of the flameproof plugs, sockets & transformers shall be made of cast light metal

alloy and shall be free from frictional sparking hazard. The magnesium content in the alloy shall

be as per IS-13346. Flameproof enclosure shall be suitable for zone 1 & 2, gas group IIA / IIB &

temperature class T-3. The enclosures of the industrial plugs, sockets & transformers shall be

made of CRCA sheet steel, dust & vermin proof. The enclosures shall be sized to facilitate easy

maintenance and heat dissipation.

The equipment shall be suitable for use in outdoor open locations and shall have IP-55 degree of

protection. The sockets for fixed installation, i.e. 415 V three phase sockets and 240 V single

phase sockets, shall be provided with integral canopy. However, where the enclosure has been

certified without integral canopy, a separate canopy can be accepted. The separate canopy shall

be made of at least 2mm galvanised sheet steel or FRP. The canopy shall be suitable for

providing protection against rain from top and two sides.

The enclosures shall be provided with gaskets made of non inflammable and self extinguishing

material.


final colour shade (both internal and external) Silver grey No. 628 (IS-5)


All the non current carrying metallic parts of the equipment shall be inherently bonded together.

The TPN sockets shall be provided with two earthing studs, with lugs on the exterior of the

enclosure, suitable for termination of 10 mm dia GI wire rope. Internal earth terminal shall be

provided in each enclosure for all single plugs and sockets for connecting the earth core of the

cables.

The terminal block enclosures shall be adequately sized to properly terminate the cables by

taking into account the required bending radii of cable cores and shall have the following

minimum gland to terminal distances:

Conductor

Size

Up to 2.5 mm2 Above 2.5 mm &

Up to 10 mm2

Above 10 mm2 &

Up to 35 mm2

Above 35 mm &

Up to 70 mm2

Gland to

terminal

distance

40 mm 100 mm 150 mm 300 mm

The sockets shall be provided with 2 nos. suitably sized cable entries at the bottom for specified

cable sizes. The plugs shall be supplied with 1 no. suitably sized cable entry for specified cable

size. Each socket shall be supplied with 1 no. flameproof nickel plated brass sealing plug, for

plugging the unused cable entry.






The sockets shall have external fixing lugs for mounting on wall or column. The holes provided

on these lugs shall be of oblong type.


The sockets shall be provided with a switch and a mechanical interlock so as to break the

electrical circuit before the plug is completely withdrawn and make the circuit after the plug is

fully inserted.

In order to prevent accidental removal of plug from socket, the engagement and disengagement

shall be by two separate and distinct movement and positions.

Unless otherwise specified, 415V, 63A three phase flameproof plug and socket meant for

welding receptacle/ any other three phase auxiliary load, shall be provided with 5 pins

(3P+N+E).

5 pin socket shall be provided with 63A, four pole (TPN) heavy duty switch.

The sockets shall be provided with either a spring loaded hinged cover, or with a cap connected

through metallic chain, to close the same when not in service.

Scraping earth connection shall be provided between the plug and socket. Earth pin of plug shall

first engage with earth pin of switch socket.

The plug assembly shall be mechanically rugged, light and shall not unduly stress the socket or

its own pins when fitted on to the socket. The diameter of the earth pin of the plug and socket

shall be at least 1.1 times the diameter of the phase pins.

3 Makes of Components

Makes of components shall be as per Re-commended list of vendors attached in tender

document.

4 Nameplate

Permanent non-corrosive nameplate with engraved white letters on black background indicating

the switchgear designation shall be fixed at the top of the central panel.

Name plates shall contain the following information:

First line : Equipment Item No.

Second line : Equipment Description

Third line : Equipment Rating.

Fourth Line : System voltage.

The following information shall be inscribed on a non-destructive, corrosion-resistant, indelible

name/rating plate attached to the inner side of the unit enclosure door:

Purchaser's order number.

Year of manufacture.

Name of Manufacturer.

Type and serial number of unit.

Purchaser’s Equipment Number.

Nominal input current and voltage (incl. nature of current & number of phases).

Rated nominal output current and voltage.

Nominal DC / battery voltage.

Ingress protection degree.

All terminals of equipment and components shall be identifiable by alphanumerical markings in

accordance with the Manufacturer's drawings. Terminals of input and output supply cables shall






be clearly and uniquely marked to indicate their purpose and the phase/polarity of the supply.

All wires shall be marked according to the electrical diagrams with closed loop markers

(ferrules) or stamped. Danger labels shall have black letters on a yellow background.

5 Inspection, Testing and Acceptance

During fabrication, the equipment shall be subjected to inspection by Owner or by an agency

authorised by the owner, if specified/ agreed in Inspection Test Plan. Manufacturer shall furnish

all necessary information concerning the supply to Owner's inspector. All routine/ acceptance

tests shall be carried out at manufacturer's works under his care & expense.

Type test certificates from CMRI or equivalent test house, applicable CCE/ DGFASLI/ DGMS

approval certificates, BIS license and original drawings referred in type test certificates shall be

shown to the inspection agency on demand during inspection. The certificates and BIS license

must be valid at the time of despatch.

Test certificates of bought out components shall be shown to the inspection agency on demand

during inspection.

All equipments shall be subjected to various acceptance tests as per standards but not limited to

the following:

General visual inspection

Dimensional inspection

Verification of mechanical and electrical operations

Dielectric tests

Routine pressure test

Any other routine and acceptance test as per applicable standards.

6 Packing and Despatch

All the equipment shall be divided into several sections for protection and ease of handling

during transportation. The equipment shall be properly packed for the selected mode of

transportation, i.e. by ship/ rail or trailer, and shall be wrapped in polythene sheets before being

placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid bottom for

handling. Special notations such as 'Fragile', 'This side up', 'Center of gravity', 'Weight', 'Owner's

particulars', TO no.' etc., shall be clearly marked on the packages together with other details as

per purchase order.

The equipment may be stored in a covered shed for long periods before installation. The packing

should be suitable for such storage.

6.1 Packing and Despatch of cable drums

Cables shall be despatched in non-returnable wooden or steel drums of suitable barrel diameter,

securely battened, with the take-offend fully protected against mechanical damage. The wood

used for construction of the drum shall be properly seasoned, sound and free from defects. Wood

preservatives shall be applied to the entire drum. Ferrous parts used shall be treated with a

suitable rust preventive finish or coating to avoid rusting during transit or storage.

On the flange of the drum, necessary information such as project title, manufacturer's name, type

size, voltage grade of cable, length of cable in metres, drum no., cable code, BIS certification

mark, gross weight etc. shall be printed. An arrow shall be printed on the drum with suitable

instructions to show the direction of rotation of the drum.






PVC / Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per

thousand metre length. In addition, ends of the cables shall be properly sealed with caps to avoid

ingress of water during transportation and storage.






Appendix-F: Specification for Installation, Testing & Commissioning of Electrical

Equipment

[Refer Doc. No. 254625-300-SP-ELE-009 (Pages 1 to 36)]

VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT - BLACK OIL TERMINAL




SPECIFICATION

FOR

INSTALLATION, TESTING &

COMMISSIONING OF ELECTRICAL

EQUIPMENTS






List of Content Page No

1 Scope 3

2 General 3

3 Installation of Equipment 8

3.1 Switchboards and Bus Ducts 8

3.2 Transformers 11

3.3 LV Motors 14

3.4 Batteries/ Battery charger 15

3.5 Welding Receptacles 16

3.6 Push Button/Control Stations 16

3.7 APSEB Overhead Line Conversion 16

3.8 Four Pole Structure (Technical Specifications) 16

3.9 Cables 20

3.10 Earthing 25

3.11 Lighting Installation 29

4 Field Inspection, Testing and Commissioning 32

5 Contractor shall provide the following items in substation, as per Indian Electricity

Rules: 35

6 Miscellaneous equipment 35

7 List of Construction Equipment 35

7.1 Equipment: 35

7.2 Test Instruments 36

8 Clearance and Safety 36






1 Scope

This specification defines the requirements for the installation, field inspection, testing and

commissioning assistance of free issue electrical items and supply , installation, testing and

commissioning of bulk electrical items, forming part of electrical power distribution and

utilisation system.

2 General

2.1 Responsibility of Contractor

2.1.1 In all matters relating to the supply and installation of electrical equipment, the electrical

installation contractor is responsible for the quality and correctness of workmanship and for

the quality and suitability of materials of his supply, in accordance with the relevant

contract documents / drawings, specifications, standards, bills of material, etc. and must be

prepared to re-make any section of the work or replace any materials, including re-

installation thereof, to the satisfaction of Owner/MMCI in accordance with the conditions of

the contract.

2.1.2 All ancillary / minor supply and installation including hardware / accessories are deemed to

be included whether specially stated or not.

2.2 Deviation and Clarification

If the contractor finds it necessary to deviate from the specifications of any items of work,

as described in the schedule or wish to clarify any point particularly with regard to

exclusions / inclusion in the scope of work, he shall list these points in consolidated list at

the time of tendering.

2.3 Completion Programme

2.3.1 The contractor shall draw a detailed programme for the supply of materials and installation

work to fit into the overall project programme of the owner, based on the availability of

plant and free-issue equipment provided by the owner. The contractor shall obtain owner’s /

MMCI representatives acceptance of the programme. The contractor shall work to this and

shall provide sufficient labour and tools / tackles / materials to meet the programme dates.

2.3.2 The contractor shall estimate the percentage of work completed on each section of the

works each week and shall pass this information to the Site Engineer. Site Engineer will

decide whether such percentages are a true record of the actual work carried out. The Site

Engineer, if required, may instruct the contractor in writing to increase the labour force

tools and tackles at site. The contractor shall immediately take action and shall ensure that

progress of the works is brought in line with the progress curves and to the satisfaction of

the site engineer. No idle time claims shall be applicable under this contract.

2.3.3 The contractor shall arrange for his Resident Engineer to be available for a weekly site

meeting to cover general progress.

2.3.4 The delivery of materials, which are to be provided by the contractor, shall be in accordance

with the predetermined programme agreed between the owner / MMCI representative and

the contractor.

2.4 Site Supervision

The contractor shall provide adequate number of competent and qualified full time

supervisors at site. OWNER/ MMCI site engineer shall monitor the work / inspect the

materials supplied by the contractor and issue necessary instructions to the contractor as and

when required.






2.5 Co-Ordination

2.5.1 The contractor shall arrange through OWNER / MMCI site engineer for the co-ordination

of his works with those of other trades and shall arrange his works to avoid interference

with or interruption to the general programme.

2.5.2 The contractor will be required to carry out the installation work side by side with other

installation work being executed by other contractors. The contractor shall extend all co-

operation as may be required to other contractors in carrying out their work.

2.6 Drawings

2.6.1 The contractor shall be supplied with general arrangement, schematic wiring drawings and

layout drawings showing the routing of cables and earthing, location of motors,

switchgears, control panels, push buttons stations, socket outlets, lighting fittings, etc.

2.6.2 The contractor shall prepare where required detailed working drawings and obtain OWNER

/ MMCI site engineer's approval prior to starting the installation.

2.6.3 All field corrections shall be marked up on the copy of relevant drawings and such “As-

Built” drawings shall be submitted to the site engineer on the completion of the work in a

particular section. Two sets of the drawings shall be handed over to the contractor to mark

As-built corrections.

2.7 Measurements

2.7.1 The contractor shall inform the site engineer when various sections of the contract works

are completed.

2.7.2 Contractor's representative on site shall maintain records and measurement sheets as the

work progress. The summarised measured quantities of each cable size, type of equipment,

etc. will be entered on the sheets and initialled by both, contractor's representative and the

site engineer weekly. The contractor shall then submit a copy of the summarised sheets to

substantiate his claim for payment.

2.7.3 The site engineer's signature on the measurement sheet at the completion of each interim

measurement does not commit the owner to payment for the work described. The signature

shall mean that the site engineer and the contractor agree with the measured work. The

liability of the owner to pay the contractor for the measured work shall be defined by the

terms of the contract.

2.7.4 Contractor shall ensure that the measurement of quantities in case of underground activities

will be certified by MMCI engineer before backfilling.

2.7.5 Contractor shall raise only one running bill per month for supply & installation.

2.7.6 Measurement Procedure

a) Cables Measurement shall be from lug to lug.

b) Cable Tray /

Cable

Cable Tray / Duct along Duct with bends, T section, shall be

measured along the centre line.

c) Excavation Average width and depth shall be considered. Length will be

measured along the centre line.

d) Sand Item shall be measured on the basis of stack measurement.

e) Rock Cutting Item shall be measured as per civil standard of collecting the

rocks and giving void allowance.






2.8 Corrective Work

2.8.1 Corrective work when caused by error of the contractor shall be carried out by him free of

cost to the owner.

2.8.2 Corrective work which has been called for by the owner / MMCI representative shall be

cost as follows :

a) The removal of any section of the contract work shall be cost on the day-work basis according to the daily rates for the type of labour involved.

b) Remedial work will be cost according to the schedule of rates or at rates agreed upon in the case of lumpsum contract.

c) Re-erection of any section of the contract works shall be cost according to the Schedule of Work / Rates.

2.9 Extra Items

In the event of any item of work which needs to be carried out for the completion of the

work and which is not covered by this specification, such an item of works shall be termed

an extra item. The contractor shall first notify with provisional rate and get a written

agreement from the site engineer before commissioning the work. In order to facilitate the

finalisation of the rate for items not covered in the schedule of rates, but which are similar

in nature to the items already covered therein, the rates for these items shall be arrived at by

extending the rates for similar extra item as applicable. In case, it is not possible to derive

rates for extra items as mentioned earlier, contractor shall submit detailed rate analysis with

supporting vouchers to substantiate the rate for approval to site engineer.

2.10 Approval of Authorities

The contractor shall co-ordinate the inspection / approval by the authorities of the work

carried out by him for the purpose of compliance with the necessary regulations issued by

them. The owner shall pay any statutory fees required to be to the authorities for obtaining

their approval of the installation work carried out by the contractor.

2.11 Guarantee

2.11.1 Installation of free-issue items

The contractor shall guarantee the installation of all free issue items against faulty

workmanship for a period of 12 months from the date of handing over.

2.12 Consumables

2.12.1 The contractor shall supply all the consumable materials and installation materials required

for complete erection like lubricating oil, kerosene solvents sealing compound, insulating

tapes, asbestos sheets, tapes and cords, connectors, burning / soldering / plumbing materials,

numbering ferrules, numbering tags, saddles, cleats, markers, hardwares, etc. All hardwares

used shall be hot dip galvanised only.

2.12.2 The consumable material such as lubricating oil / grease, etc. required for testing and

commissioning of the equipment such as motors and driven equipment will be arranged by

Owner.

2.13 Painting

2.13.1 The contractor shall paint all fabricated structural item (structures, M.S. Canopy supports

and trays, etc.) erected by contractor with approved anti-corrosive paints as specified. All

welded joints and insulated parts will be thoroughly cleaned with wire brush before

painting. Paint will be applied uniformly on the surface. Painting should be with 2 coats of

red oxide primer followed by 2 coats of finished paint of shade to be informed by MMCI /

Owner’s site engineer.






2.13.2 The contractor shall make all numbering and lettering on the equipment/ panels/ light

fittings, etc. with approved paint, supplied by him, wherever required.

2.14 Civil Engineering Work

2.14.1 MMCI, under separate contract will arrange for all major civil engineering works such as

foundation for plant and equipment, built-up cable trenches / ducts, as shown on the

relevant drawings, etc. Necessary openings in the foundations for fixing of foundation bolts

and anchor plates etc. will be provided by MMCI as shown on the relevant drawings. The

contractor’s scope of work shall include any minor civil work directly connected with his

work and in making good all breakages / damages caused in the execution of his work at no

extra cost to the owner.

The contractor shall be responsible for the true and proper setting out of the work in relation

to original points, lines and levels of reference and for the correctness of levels, dimensions

and alignment of all part of the work and for the provision of all necessary instruments

appliances and labour in connection therewith. The contractor shall layout one or more

permanent bench marks in some central place before starting the work.

2.14.2 The contractor shall check and inform in writing to MMCI Engineer if any discrepancy is

noticed by him in civil work. The site engineer then shall arrange for necessary

rectification, if necessary.

2.14.3 Other openings, sleeves, etc. required to be provided in the brickwork / concrete for

electrical work shall be carried out by the contractor and shall be made good to the

satisfaction of MMCI at no extra cost.

2.14.4 All damages caused to the foundation due to negligence of the contractor shall be rectified

by him at his own cost as directed by the Site Engineer.

2.14.5 Excavation of trench for direct burial of underground cables, including supply and

spreading of sand, supply and laying of concrete slab / brick top cover, G.I. / concrete pipes,

brick separator wherever required and backfilling with good earth shall be included in the

scope of the contractors work.

Definition of IS for soil will be applicable in deciding nature of the soil. Contractor shall

consider as blasting is prohibited for rock cutting. However, blasting for rock cutting may

be allowed in certain cases depending on the site location as considered by site engineer.

2.14.6 The contractor shall also at the end of each day's work, ensure that all the trenches within

the plant buildings are properly covered by means of protection covers, wooden planks,

steel plates, etc. as temporary measures or cordoned off by a bamboo barricade.

2.14.7 For the preformed trenches, the contractor shall supply and install the necessary supporting

steel work, if called for.

2.15 Storage

2.15.1 The contractor shall provide and maintain at no extra cost to the owner suitable temporary

storage facilities and site office within the area allocated to him by the owner free-of-cost.

2.15.2 The contractor shall provide the necessary security services to safeguard the materials

which shall be his responsibility under the terms of the contract.

2.15.3 When the contractor is established on site, he shall off-load, sort out, store or stack and

record to owner's satisfaction all materials, which have been fabricated or ordered by the

contractor.

2.15.4 At the end of the contract, the contractor shall completely remove and dispose of all

temporary works erected on site allocated to him to the satisfaction of the MMCI / Owner’s

representative.






2.16 Clean-up of Work Site

The Contractor's Scope shall include cleaning up of the work site and carting away all

unnecessary materials from the work site from time to time at no extra cost.

2.17 Statutory Licence / Certificate of Competency

All the supervisors / electricians employed to carry out the installation work at site shall

hold the statutory certificates of competency for the nature of work entrusted and shall fully

meet the requirements of the local Electrical Inspectorate prior to commencement of the

work. Also, contractor shall have valid electrical contractors license to work in a state.

2.18 Receipt and Reconciliation of Material

2.18.1 Free-issue items

2.18.1.1 The Owner shall supply major electrical equipment as free-issue items at a given point

within the plant premises.

2.18.1.2 The contractor’s scope of work includes taking delivery of these equipment / materials

packed or unpacked, from Owners store, transporting to place of installation, testing and

commissioning.

2.18.1.3 All costs arising from the transporting of free-issue materials from the owner’s stores to the

final destination of installation shall be included by contractor in installation rate.

2.18.1.4 All necessary tools, tackles and facilities required for transporting of free-issue items shall

be made available by the contractor at no extra cost.

2.18.1.5 The contractor shall visually inspect all free-issue materials for any defects of workmanship

or damage. The contractor shall accept the liability for all the items issued to him till the

same are installed, commissioned and handed over to the owner.

2.18.1.6 The contractor shall inform the owner of the free-issue items that he wishes to requisition

from the owner three days in advance.

2.18.2 Scrap & Excess Material

2.18.2.1 On completion of the work, the contractor shall submit Material Reconciliation Statements

for all material issued by Owner, in the proforma prescribed by site engineer.

2.18.2.2 The following wastage and scrap allowances are permissible :

Nol-Salvageable Unaccountable

a) Structural Steel (Length less than 1

Mtr)

3% 0.5%

b) Pipes (Length less than 0.5M) 2% 0.5%

c) Cables (Length less than 5M) 2% 0.5%

d) Cable tray 0.5% --

2.18.2.3 All excess materials and scrap shall be returned after duly accounting for, to the storage

points, in good condition, without which contract will be deemed to be incomplete.

2.18.2.4 If the contractor fails to return the surplus material aforesaid, the owner will charge the

contractor for such un-returned materials at rates prevailing in the market.






3 Installation of Equipment

Prior to start of installation of the electrical equipment, Contractor shall verify that

equipment and complete materials have been received. Handling, shifting to required site

location, installation, testing and commissioning of all electrical equipment shall be done by

contractor with utmost care. Manufacturer's instructions and the requirements given in their

technical manuals shall be strictly adhered. The substation/switchgear room wherein the

equipment shall be installed shall be kept clean, dry and free from all debris. Panel floor

cutouts not in immediate use shall be suitably covered to avoid any mishap. When handling

the switchboard panels, care shall be taken to observe the correct lifting arrangements and to

make sure that slings are attached to the manufacturer's designated lifting points. No parts

shall be subjected to undue strains or sudden stresses which could cause damage to the

equipment.

The lifting position mark indicated on packing casing shall be adhered to strictly, for

keeping it in required vertical position.

Contractor shall check and report to the Engineer-in-charge about any damaged item and /

or missing component for getting the same replaced as per specifications. During

installation, all accessories and loose items shall also be inspected by the contractor before

their assembly/mounting.

3.1 Switchboards and Bus Ducts

3.1.1 The term switchboard here includes all HV/LV switchboard panels, motor control

centers, power and lighting distribution boards, UPS panels, ACDB, Battery charger panels,

DCDB etc.

The switchboard panels shall be handled with care, avoiding any impact to the equipment.

Dragging of the panels directly on floor shall be avoided. Roller bars may be used for

shifting of panels. Use of a crane and trailer shall be made for handling of equipment. The

switchboard panels shall be properly supported on the truck or trailer by means of ropes to

avoid any chance of tilting. The switchboards shall be lifted after ensuring that panel

supports, nuts and bolts are all intact and tightened. While lifting the panels in packed

conditions, utmost care shall be taken to avoid any damage to insulators, bushings, metering

and protective equipment.

The panels shall be preferably kept inside the packing cases till foundations are ready.

Proper rain/sun/dust protection shall be ensured till switchboards are installed.

3.1.2 The switchboard panels shall be installed on prepared foundations or floor cutouts. Steel

base

channels shall be welded to inserts provided in floor slab. Cross members shall be provided

at

the junctions of each shipping section and other places as required.. It shall be ensured that

the

base plate level of HV switchboard shall match with the finished floor level.

The foundation pockets and the grouted bolts shall be cured for a minimum period of 48

hours. Proper level of base frames shall be maintained throughout and shall be checked with

water level/spirit level. Steel Shims shall be provided below base frame wherever required.

3.1.3 The switchboard panels shall be taken out from the packed cases and shifted one by one to

its proper place. All the panels shall be assembled, aligned and leveled. Alignment of






panels shall be checked in both longitudinal and lateral directions. It shall be ensured that

panel to panel coupling bolts, bus bar links etc. fit properly without any strain on any part.

No new holes for jointing of the panels other than those recommended by the vendor shall

be drilled. No gaps shall be left between the panels. Gap if any found between panels shall

be suitably sealed using sealing compound or T-profile. The lifting, racking in and out

operation of the breaker and all other motions shall be free from any obstruction.

The panels shall be checked for correct vertical position using Plumb line and spirit levels.

The switchboard panels shall be tack welded at suitable intervals at base channel.

After erection of switchboard panels, all uncovered portions of floor cutouts shall be

covered with 6 mm thick removable chequered plates finished with floor level. The design

of the chequered plates shall be such that the maximum allowable deflection is L/200

(where L is the span of the chequered plates in meters) for a live load of 500 kg./sq. meters.

Additional stiffer shall be provided at the bottom if required. Suitable lifting arrangements

shall be provided for chequered plates. The chequered plates shall be painted with a coat of

red oxide zinc chromate primer after proper surface preparation as per specifications.

Where specified, panels' cutouts provided for future use shall be filled with lean concrete.

3.1.4 After completion of Installation of switchboards, all the cubicles, switchboard components

such as switches, starters, CT and PT chambers, bus bar chamber shall be cleaned and

checked for tightness of all the components.

Vacuum circuit breakers shall be checked for integrity of bottle seals. All loosely supplied

items shall be fitted up. Bus bar sections or links shall be inserted and where specified, of

high voltage equipment shall be insulated. Interconnection wiring between shipping

sections shall be made by contractor.

All the wiring connections shall also be checked. Contact resistance of all bus bar joints

and contactors shall be checked. Insulator shall be checked for any damage. All the starters,

switches, contacts shall be cleaned with CTC where required.

All the moving parts shall be checked for easy and free movement. Hinges of panel doors

shall be lubricated to give free and noise free movement. All openings shall be kept

completely closed to avoid ingress of any foreign particles inside the panel.

Functional scheme verification of individual feeder shall be carried out and minor wiring

modifications in the panel wiring, if required shall be done as per the directions of

Engineer-in-charge. Special attention shall be paid to CT circuits' polarity, wiring

continuity and correctness in the protection as well as measurement circuits. Auto transfer

scheme shall be simulated and verified. During the course of scheme verification tests,

defective components if any shall be taken out, after bringing to the notice of Engineer-in-

charge. The same shall be replaced by component supplied by owner.

3.1.5 Where switchboard is damp or having a low IR value due to damaged insulators/

bushings/any other insulated parts, or any other reason, the entire switchboard shall be

dried-up according to the instruction of the Engineer-in-charge for the IR value to improve

to a safe level for commissioning. Care shall be taken to protect the surrounding insulation

from direct local heating during the drying up process.

3.1.6 All moving parts, of closing/tripping mechanism, racking in and racking out mechanism,

spouts and shutter closing mechanism shall be checked for proper operation. All the

auxiliary contacts of breaker shall be checked-up, cleaned and contact pressure measured.






3.1.7 All the control wiring, PTs, bushings, bus bars, other live parts of switchgear, incoming and

outgoing cables shall be meggered.

3.1.8 Electrical simulation tests shall be carried out for all the protective, alarm and annunciation

relays and external interfaces to ascertain proper functioning.

3.1.9 Safety insulation mats of approved make and of required voltage grade shall be provided in

the sub-station.

3.1.10 Pre-Commissioning Check List

Before commissioning any switchboard, following points shall be checked and ensured for

safe energising of the switchboard:

i. That the installation of equipment to be commissioned is complete in all respects

with its auxiliaries and all other mounting including earthing. Openings in floor

within and outside panels have been sealed off. All cover and door gaskets are intact

to make the enclosure vermin proof.

ii. That all the metering instruments have been checked and found in working order.

Indicating lamps are healthy and are in correct position. All power and control fuses

are of proper rating.

iii. That the high voltage tests of incoming and outgoing cables have been conducted and

results are satisfactory.

iv. That IR Value has been recorded for bus bars, circuit breaker, incoming and outgoing

cables, control wiring and potential transformers. Where required joint resistance of

bus bars have been recorded and found to be satisfactory. All the surroundings and

panels have been cleaned and temporary earth leads have been removed.

v. Following tests shall be ensured for all bus bars

- Tightness of all nuts/bolts using Torque wrench

- IR value

- Contact resistance using 100A DC Kit

- Cleaning of bus bar chamber using vacuum cleaner

- Conducting jelly shall be applied on AL/CU joints as per manufacturer's

recommendations

- HV test in case of HV switchboard

vi. Following tests/Checks shall also be performed on the switchboards

- Functional verification of individual feeders including all spare feeders

- Simulation test for under voltage tripping of related feeders such as motor feeder,

capacitor feeders etc

- Verification of control supply schemes

- Checks for all panel illuminations, indicating lamps, sockets

- All upstream and down stream interlocks

3.1.11 Bus Ducts

The bus ducts as per issued drawings will be supplied in parts and all the parts shall be

assembled and the bus bar connections shall be made at site. The insulators in bus ducts

shall be inspected for any possible damage during transit and the defective ones shall be

replaced. The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and nuts

shall be thoroughly cleaned. Petroleum jelly shall then be applied and bolted connection

made. The bus duct enclosure shall be checked for earth continuity and then earthed at two






places. The bus duct shall be properly supported between switchgear and transformer. The

opening in the wall where the bus duct enters the switchgear room shall be completely

sealed to avoid rain water entry. Expansion joints, flexible connections etc. shall be properly

connected. The bus duct levelling shall be checked with spirit level and pendulum weight.

Pre-commissioning check list

Before commissioning any bus duct, following points shall be checked and ensured for safe

energising of the bus ducts

- All joints are tightened using torque trench

- Cleaning of bus duct chamber with vacuums cleaner

- Silica gel breather shall be connected if supplied. If required, silica gel shall be

- reactivated as per the instruction of engineer in charge.

- Space heater circuit shall be checked and tripping through thermostat shall be ensured

- Contact resistance shall be measured for all phases/neutral using 100A DC kit

- High voltage test in case of HV bus ducts

3.2 Transformers

Transformers on receipt at site shall be unloaded by means of crane or lifting devices of

adequate capacity. All lifting lugs shall be used to avoid unbalanced lifting and undue

stresses on lugs. Lifting lugs if any provided for partial lifting (e.g. for active part,

conservator) etc. shall not be used for lifting complete transformer. Parts other than those

identified for lifting of the transformer shall not be used for lifting. While slinging, care

shall be taken to avoid slings touching other parts.

3.2.1 Before lifting transformer, it shall be ensured that all cover bolts are tightened fully. In case

when it is necessary to use jacks for lifting, projections provided for the purposes of jacking

shall be used . Lifting jacks shall not be used under the valves or radiator tubes. For

transporting transformers from stores to site, the transformers shall be loaded on a suitable

capacity truck or trailer. The transformers shall be properly supported by steel ropes and

stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and

vibrations. At no instance the transformer shall be kept on bare ground. Where it is not

possible to unload the transformer directly on a foundation, it shall be unloaded on a

properly built wooden sleeper platform. A transformer shall never be left without putting

stoppers to the wheels.

3.2.2 Transformers shall be examined, for any sign of damage in transit. Particular attention shall

be given to the following in this regard.

i. Dents on tank wall or cooling tubes, radiators

ii. Damage to protruding parts like valves, sight glass etc.

iii. Loosening of bolts due to vibration in transit.

iv. Cracked or broken bushings.

v. Oil leakage particularly along welds.

If any thing adverse is noted the same shall be brought to the notice of Engineer- in-

charge.

3.2.3 Contractor shall examine the transformer base, oil pit, fire walls and foundations laid by the

civil contractor. It shall be ensured that oil spills can not propagate along cable trenches.

Any discrepancy noted will be brought to the notice of Engineer- in- charge. Transformers

shall be placed on channels or rails over concrete foundations. The transformers shall be

levelled, aligned and checked for free movement on the channels or rails. Stoppers shall be






provided to the transformers immediately to prevent any movement. All the accessories like

radiators, cooling fans, valves, conservator tanks, explosion vent pipe, bushings and other

devices which are supplied in different packages shall be checked for any transit damage

and cleaned thoroughly before fixing on the transformer. All loosely supplied parts shall be

assembled as per manufacturer's instruction manuals/ drawings and documents. All the

connections for CTs bushings and other wiring shall be checked for tightness and

correctness before replacing the lid or tightening all the bolts. Gravels shall be filled in the

transformer bay, soak pit as per requirement.

3.2.4 Topping of transformer with oil

Before topping up with oil, transformer shall be fitted with all accessories such as valves,

gauges, thermometers etc. Oil samples shall be taken from each drum and tested for

determination of dielectric strength. Any sign of leakage of the barrel or of its having been

opened shall be recorded and reported. It is necessary to filter the oil before the

transformers are filled. It shall be ensured in oil filling operation that no air pockets are left

in the tank and that no dust or moisture enters the oil. All air vents shall be opened. Oil

shall be filled through a streamline oil filter using metal hose. To prevent aeration of the

oil, the transformer tank shall be filled through the bottom drain valve. In a transformer

with conservator tank, the rate of oil flow shall be reduced when the level is almost upto the

bottom of the main cover to prevent internal pressure from rupturing the pressure relief-

pipe diaphragm. Sufficient time shall be allowed for the oil to permeate the transformers

and also for the locked -up air bubbles to escape. Any air accumulation in the buchholz

relay shall be released.

3.2.5 Transformer Oil

i. Sample of oil from the transformer shall be taken from the bottom of the tank.

ii. Testing of Oil

For dielectric test, the oil shall be tested as described in IS: 335. The oil shall also be

tested for acidity in accordance with the methods prescribed.

3.2.6 Drying out of the transformers, if required, shall be carried out and record maintained in

accordance with IS: 10028. Normally a streamline filter shall be used for drying-up. IR

value

versus time of both windings along with OTI/WTI and filtrations machine temperature

curve

for IR value Vs time shall also be plotted and recorded during the drying-up process.

Precautions when drying

i. The maximum sustained temperature to which transformer oil may be subjected shall

be limited to 80 C.

ii. The transformer shall be carefully monitored throughout the drying out process and all

observations shall be carefully recorded.

iii. Drying out shall be continued so that the insulation resistance as prescribed in the

standard code of practice is attained and the value remains constant for more than 12

hours. However, a minimum number of cycles shall be done for each transformer as

found necessary by the Engineer-in-charge. Generally a Megger reading of 2 megohms

/ kV at 60° C temperature, with a 5 kV Megger may be a rough indication for stopping

the dehydration.






3.2.7 The following work on transformers shall be performed by the contractor if specifically

called for:

i. Before finally commissioning the transformer it may sometimes be desired to run it for

a few hours on short-circuit, applying a low voltage, approximately equal to the

impedance voltage of the transformer. During this process, regular readings of the

insulation resistance of the winding to earth and winding to winding and temperature

against time shall be recorded.

ii. Testing of radiator tubes for any leakage and rectifying these by welding / brazing.

3.2.8 Pre-commissioning Check List:

Before commissioning of any transformer, the following points shall be checked for safe

energisation of the transformer:

i. All the accessories have been fixed properly and transformer body and neutral are

properly earthed. The transformer dehydration is over and results are satisfactory and

approved by the Engineer-in-charge. In case transformers are idle for more than one

month after dehydration, transformer oil has been given at least two circulations.

ii. Oil level, in the transformer conservator tank and all the bushings is upto the marked

point and the oil has been tested for dielectric strength and acidity. Oil filtration (if

required) shall be carried out.

iii. Silicagel is in reactivated condition. The breather pipe is clear from any blocking and

contains oil upto the proper level.

iv. The explosion vent diaphragm does not have any dents. Accumulation of any oil and

air had been released.

v. The tap setting on which the off load tap switch is locked shall be recorded.

Generally the off-load tap switch shall be kept on nominal tap.

vi. Buchholz relay has been tested and checked up for any friction in the movement, and

floats are free. All the other protective relays, alarm and annunciation relays have

been tested.

vii. Metering equipment has been tested and polarity test of PT's and transformer winding

is satisfactory. Phase sequence and connections have been checked for proper vector

group.

viii. Ratio test and winding resistance on all the tap positions is satisfactory.

ix. Gaps of arcing horns for the bushings where provided are in order and earth

connections for the surge diverters have been checked.

x. Winding and oil temperature thermometer pockets contain oil and the winding and

oil temperature settings on dial gauges are in order.

xi. Simulation tests for all external interface connection alarm, annunciation and trip

circuits have been checked and are in order.

xii. Insulation resistance of all the control circuits and IR value of the transformer

windings and all the incoming and outgoing cables have been checked.

xiii. Valves in the cooling system and valve between the buchholz relay and the

conservator tank are in open position.

xiv. Setting of all the protective relays is at the desired value and DC Trip supply is

healthy.

xv. Magnetic, current and magnetic balance test have been conducted






xvi. Simulation test for WTI,OTI,PRV,OSR

xvii. Settings of WTI/OTI as per the instruction of the manufacturer

xviii. Earthing resistance value for the neutral earthing

3.2.9 Observations after Commissioning

After switching on the transformer the following points shall be observed and recorded.

i. The inrush magnetizing current and no-load current.

ii. Alarm, if any, or if any relay flag has operated.

iii. Voltage and current on all the three phases.

iv. Transformer hum or abnormal noise.

v. Circulation of oil and leakages.

vi. Record current, voltage, cooling air temperature, winding temperature and oil

temperature readings, hourly for 24 hours.

vii. Cable end boxes for any over-heating.

3.3 LV Motors

3.3.1 All the motors generally would be erected by the mechanical contractor.

3.3.2 Electrical contractor shall keep the motor space heater energised as per the directions of

Engineer-in-charge. Electrical contractor shall measure the insulation resistance of motor

windings. Insulation resistance of the motors shall be measured between the winding of the

machine and its frame by means of a 500 / 1000 V Meggar in case of 415 V motors. A

minimum value of 1 megohm for 415 V motors shall be considered a safe value. In case of

lower I.R. Value, the insulation value shall be improved by any of the following methods as

directed by the Engineer-in-charge.

i. Blowing hot air from external source.

ii. Putting the motor in oven.

iii. Placing heaters or lamps around and inside after making suitable guarding and covering

arrangements so as to conserve the heat.

In case the insulation is low, the following method of drying has to be adopted, after

consultation with Engineer-in-charge. During drying the temperature rise of winding shall

not exceed the permissible value for the class of insulation used.

i. By locking the motor so that it can not rotate and then applying such a low voltage to

the stator terminals so as to pass full load current in the stator keeping the stator

winding temperature below 90° C . In this case a close watch shall be kept for any

possible overheating and I.R. Values vs. temperature shall be plotted and heating

continued till I.R. value becomes steady.

ii. By blasting hot air from external source, Maximum temperature of winding while

drying shall be 70° C to 80° C (thermometer) or 90° C to 95° C by resistance method.

Heating shall be done slowly first till steady temperature of winding is reached after 4

to 5 hours, and for large machines after 10 hours. A record has to be kept for drying

process, with half an hour readings and, till steady temperature is reached. In case it is

essential, the drying process can be supplemented by blower.

3.3.3 It shall be ensured that the motor leads are correctly connected in the terminal box, as

indicated in the 'Name Plate'. The covers of all terminal boxes shall be properly fixed, the






gaskets intact. The control circuit shall be tested for proper functioning as per circuit

diagram.

3.3.4 In case of synchronous machines, slip rings and brush gear shall be polished and brushes

shall be fixed in their holders with clearance and pressure as recommended by the

manufacturers.

3.3.5 Before commissioning, the ventilation and cooling system of the motor must be inspected.

In case of motor with forced ventilation the air inlet shall be examined to ensure that it is

free from moisture and any foreign material. It shall also be ensured that recommended

flow and pressure of air is available to produce the required cooling effect.

3.3.6 The motor control gear shall also be carefully examined, the over-load settings may be

reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in

event of faults. The direction of rotation of a new motor specially of large capacity , and

phase sequence of supply shall be kept in view while joining and connecting to the motor

terminals

3.3.7 Finally the motor shall be started on no-load after decoupling, and shall be allowed to run

for a minimum period of 4 hours, or for a time as instructed by Engineer-in-charge.

Attention shall be given to the proper running of the bearings, vibration or unusual noises if

any. Voltage, starting current, no load current, stator winding and bearing temperature shall

be recorded after every 1 hour during this test. Direction of rotation shall be checked and

recorded. Normally the motors run in clockwise direction as viewed from the driving end

with reference to the phase sequence R, Y, B.

3.3.8 After switching off the motor, the insulation resistance of the motor shall be recorded under

hot and cold conditions.

3.3.9 If the no load test run is found satisfactory, the motor shall be allowed to run for 8 hours

and all readings shall be recorded.

3.3.10 The following work on motors, may be performed by the contractor if specifically called

for.

i. The proper level of bearing oil has to be checked. The condition of grease in bearings

shall be checked and in case it is necessary, complete replacement of bearing with

specified grade of grease after proper cleaning of the bearing shall have to be done.

Wherever external greasing facility exists, the condition of grease may be checked by

pumping some new grease of specified grade at start. If the grease coming out is

deteriorated grease shall be replaced.

ii. All the motors, motor exciter set and induction generators directly coupled or coupled

through reduction gears shall be checked for abnormal vibration. Any minor defect in a

race or roller may give rise to considerable amount of vibration and noise. Contractor

shall check and bring to the attention of Engineer-in-charge any defect noticed in this

regard.

iii. Due care shall be taken to avoid any damage to bearing insulation wherever provided.

3.4 Batteries/ Battery charger

Battery (VRLA/ SMF type as specified) shall be erected on stands and insulators supplied

by the manufacturer of the batteries. The installation shall be done as per the layout

drawings and manufacturer's instructions. Electrolyte if required / as applicable shall be






filled as per manufacturer's instructions. Interrow connections shall be made with the leads

supplied by the manufacturer. Functional check shall be done on the battery charger

including battery charging and discharging, recharging as per the recommendation of the

manufacturer.

3.5 Welding Receptacles

The welding receptacles shall be erected on steel/concrete structures as per the drawings. In

isolated places a separate support shall be fabricated and installed.

3.6 Push Button/Control Stations

The push buttons / control stations shall be installed near to the motors to be controlled.

Individual channel supports shall be installed as per installation standard. If control stations

for hazardous areas are to be supplied by contractor, these shall be of Ex (d) type, tested by

CMRI and approved by CCOE or other applicable certifying authorities. All outdoor push

buttons / control stations shall preferably have integral canopies for additional weather

protection. The canopy shall be made of 2 mm thick galvanized sheet steel or FRP where

these are not integral with the equipment.

3.7 APSEB Overhead Line Conversion

Vendor shall supply & install cables and necessary accessories to convert the 33kV

overhead line of approx. 60m stretch to underground system. Vendor shall obtain liasioning

with APSEB. Exact pole distance shall be provided at site during execution.

3.8 Four Pole Structure (Technical Specifications)

33kV OUTDOOR FP STRUCTURE COMPONENTS

3.8.1 33 kV Disconnecting Switch (Including earth switch)

3.8.1.1 Design Criteria

Refer Electrical System Detail (Doc. No. 254625-300-DS-ELE-001) & for environmental

conditions refer Doc. No. 254625-300-SP-GEN-001.

3.8.1.2 Technical Features

A) General

i. The disconnecting switch shall be Manual operated air break, triple pole,

outdoor, gang operated, double break suitable for horizontal, upright mounting

on galvanized steel structures, Isolators having contacts moving in horizontal

plane are preferred.

ii. The disconnect switch shall be capable of interrupting small inductive and

capacitive currents such as those while disconnecting lines at no load or

transformer no load currents The isolator blades shall be able to carry the rated

current continuously without exceeding temperature limits mentioned in design

criteria

B) Operating mechanism

i. a) The operating mechanism for disconnect switches shall be suitable for local

manual operation.






ii. b) A signaling device for all poles of the isolator shall be arranged both for

closed and open position, to indicate isolator position on remote panel in

control room.

iii. The manual operation should be easy but not easily accessible. There should be

proper locking arrangement for manual operation

iv. The operating mechanism shall have positive control of blade movements at all

times and under most hazardous conditions. Linkages shall be fitted free from

slack and lost motion

v. All bearings shall be sealed against dust and moisture heavy-duty type

lubricated for life and

vi. The manual operating handle shall be mounted on the base supporting

structure. Guide bearings shall be provided at a height of 750mm above ground

level All brackets, angles, guides, guide bearings & other members necessary

for attaching the operating mechanism & operating handles to supporting

structure, shall be supplied as an integral part of disconnect switch. The

moving blades of isolator shall turn 90 degree after making the contact for

ensuring sufficient contact

C) Earth switch

The isolator shall be provided with Manual operated earth switch forming integral

part The rating of earth switch shall be same as that of isolator with respect to rated

peak short circuit current and making current. The earth switch shall be operated by a

separate operating mechanism, shall be electrically and mechanically (castle key

interlock) interlocked with the isolator, so that, the grounding blade can be closed

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

switch is open

D) Additional interlocks

The isolator shall be electro-magnetically interlocked with the associated circuit

breaker Even manual operation of isolator shall be possible only when the associated

breaker is in the open position The interlock shall be so designed that it shall not be

possible to operate the isolator even locally when the associated circuit breaker is in

the closed position The interlock shall be fool proof in all respects. The interlock

relay/solenoid shall be provided in the cabinet for operating mechanism. Necessary

auxiliary contacts for interlocks with vacuum circuit breaker shall be provided

E) Auxiliary contacts

3 NO + 3 NC auxiliary contacts shall be provided for the main isolator and 3 NO + 3

NC for earthing switch It shall be possible to convert NO to NC and vice versa at site

The auxiliary contacts shall have a continuous current carrying capacity of at least 10

Amps

F) Constructional features

i. The switch-blade of main and earth switch shall be copper It shall be of one

solid piece construction and shall be assembled that no part of the blade can

move relative to the other The thickness and section of the blade shall be such

that it retains its form and straightness under all conditions of operation

including the flow of system fault current for the period specified. It shall also

be capable of withstanding all torsional and bending stresses due to the

operation of switches






ii. The isolators shall have high-pressure self-aligning adjustable contacts The

contacts shall be well protected all round by a metal cover which provides not

only electrostatic screening but also prevents coarse dust from entering

between the contacts. The contacts shall be designed such that the contact

pressure is released before any movement of blades in the opening direction

takes place and is applied after the closing travel is completed There shall be

sufficient wiping action of the contacts to make them self-cleaning The

contacts shall be made of high grade high conductivity heat resistant material

and shall be silver plated.

iii. The earthing switch of disconnect switch shall be complete with all parts that

are necessary or essential for the efficient operation Such parts shall be

deemed to be within the scope

iv. Disconnect switch and earth switch including their operating mechanism shall

be such that they cannot be dislodged from their open or closed position by

gravity, wind pressure. vibrations shocks etc.

v. The disconnect switch/earthing switch contacts shall be of silver faced copper

vi. All live parts shall be of non-rusting and non-corroding metal Current carrying

parts shall be of non-ferrous material such as copper or Aluminum Bolts,

screws shall be provided with lock washers, keys or equivalent locking

facilities and if provided on current carrying parts shall be made of non-rusting

and non-corroding metal such as copper/silicon alloy

vii. Base channels and other structural members such as operating pipes, phase

coupling rods etc., operating mechanism boxes, bolts, pins etc.. shall be hot dip

galvanized. The thickness of galvanizing shall not be less than 100 microns

viii. All similar parts shall be interchangeable.

ix. The disconnect-switch shall be such that no lubrication of any part is required

except at very infrequent intervals

x. During the course of normal operation it is likely that the disconnect

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

xi. Disconnect switch shall be such that it is free from visible corona discharge in

both closed and opened positions.

xii. The clearance between live parts and grounded structures shall not be less than

those specified in relevant standards. The inter-phase clearance shall be as per

switchyard layout. Inter phase clearance and mounting height shall be more

than 1.5m The length of break in open position shall be such that there is

absolutely no possibility of arc over from the live parts to the de-energized

parts on which any maintenance work may have to be done The speed of

opening or closing the switch shall be designed to ensure that the arcing during

the operation is reduced to the minimum.

G) Insulators

i. Insulators shall be made of high strength porcelain and shall be suitable for the

service voltage and BIL specified

ii. Porcelain used for the manufacture of insulators shall be homogeneous and

free from flaws or imperfections that might affect the mechanical and dielectric

quality. They shall be thoroughly vitrified, tough and impervious to moisture.

Glazing of porcelain shall be uniformly brown colour, free blisters, burs and






other similar defects. Insulators of the same rating and type shall be

interchangeable.

iii. iii) The porcelain and metal parts shall be assembled in such a manner that any

thermal expansion differential between the metal and porcelain parts through

the range of temperature variation shall not loosen the parts or create undue

internal stresses which may affect the electrical or mechanical strength and

rigidity Each cap and base shall be of high-grade cast steel or malleable steel

casting and they shall be machine faced smoothly and galvanized Insulators

shall be stack types.

H) Accessories

i. Stainless steel nameplate shall be provided on disconnecting switches, earthing

switches and operating devices The nameplate shall contain the information set

out in IS-9920 & 9921

ii. Suitable locking arrangement with lock shall be provided for the isolator

operating mechanism, so that, it can be locked in either fully open or fully

closed positions

iii. Each pole of the, disconnect switches shall be provided with two grounding

pads at opposite ends, brazed to the base channel. Flexible copper ground

connectors shall be provided. for connecting operating handles of disconnect

switches and earthing switches to the grounding system

iv. Suitable adjustable arcing horns made of tinned electrolytic copper shall be

provided on disconnecting switches.

3.8.2 Lightning Arresters

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

switchyard equipment and transformers against lightning and switching surges The

lightning arresters shall be self-supporting type in single pole Assembly suitable for outdoor

installation

3.8.2.1 Design Criteria

Refer Electrical System Detail (Doc. No. 254625-300-DS-ELE-001) & for environmental

conditions refer Doc. No. 254625-300-SP-GEN-001.

A) Constructional features

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

ii. The arrester shall adequate thermal discharge capacity for switching surges,

long duration surges and multiple strokes. The arrester shall be capable of

withstanding internal pressures developed due to the above discharges

without operation of pressure relief vents.

iii. The arrester shall be provided with pressure relief devices, which will

prevent shattering of porcelain in case of excessive gas pressure build up.

iv. The insulator housing of the arrester shall be of porcelain with high

mechanical strength and rigidity suitable for operation under site conditions

listed in design criteria

v. All metal shall be non-rusting and non-corroding metal. screws etc., shall be

provided with lock washers

vi. Bolts,






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

3.8.3 Four Pole Structure (Construction)

Four pole structure with bracing s and cross arms for supporting installing the pin and / or

strain insulators shall be designed as per the following specification.

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

However it should satisfy APSEB requirements.

ii) The Four Pole structure shall be designed suitable for receiving / terminating 33 kV

overhead conductors or Cables of APSEB.

The structure shall designed for mounting one lightning arrester per phase at incoming

as well as two outgoing feeders and Two triple pole Air-break disconnecting switches.

Further this FP structure shall be provided with extra cross arm(s) arrangement to erect/

install HT XLPE Aluminum cables with outdoor termination It shall facilitate

termination of each core of the HT cable directly without any further links The

arrangement of all the components on this FPS shall be furnished along with the offer

separate double channel (ISMC-100) cross arms shall be provided for installing sets of

lighting arresters and two 3 pole Air Break switch with bus.

iii) Earth shall be excavated to make pits size 1M X 1M X 2.5M (depth) for each pole of

the Four pole structure. The rail pole shall be placed over a small (50-100 mm thick)

padding of concrete in perfectly vertical position and then the entire pit shall be

concreted & compacted using a concrete mix of '1 cement: 3 coarse sand: 6. graded

stone aggregate" including curing thereafter Compacting the soil around, using

boulders / earth shall be carried out if required at no extra cost.

iv) The FP structure shall be complete with bracing's (ISA 50 x 50 6). channels ISMC-100

as cross arms for pin insulators and additionally double channel (ISMC-100) cross arms

for tension / strain insulators, bus and connection conductors (DOG) wherever

applicable.

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

vi) Each FP structure shall be earthed as per the rules of IE

3.9 Cables

3.9.1 Cable Laying

Cable installation shall include power, control, lighting cables. These cables shall be laid in

directly buried trenches or RCC trenches/ cable trays/ pipe sleeves as detailed in the cable

layout drawings. Cable routing given on the cable layout drawings shall be checked in the

field so as to avoid interference with the structures, heat sources, drains, piping, air-

conditioning duct etc. Any change in routing shall be done to suit the field conditions

wherever deemed necessary, after obtaining approval of Engineer-in-charge. H.V., L.V.

power and control cables shall be separated from each other by adequate spacing. Details of

cable routes and cable spacing not shown in detail on these drawing shall be determined by

the contractor and approved by the Engineer-in-charge. When single core cables are laid in

flat formation, the individual cable fixing clamps and spacers shall be non-magnetic

material. As a general practice, the sheath of single core cables shall be earthed at one point

to keep sheath at earth potential unless otherwise stated. Single core cables, when laid in






trefoil formation shall be braced by suitable clamps at a distance, not exceeding 3 meters

along the cable routing.

The lengths indicated in the cables schedule are only approximate. The contractor shall

ascertain the exact length of cable for a particular feeder by measuring at site. All cable

routes shall be carefully measured. Before the start of cable laying, the contractor shall

prepare cable drum schedule and get that approved by Engineer-in-charge to minimize/

avoid straight through joints and then the cables cut to the required lengths, leaving

sufficient lengths for the terminations of cable at both ends. The various cable lengths cut

from the cable reels shall be carefully selected to prevent undue wastage of cables. Extra

loop length shall be given for feeder cables where required as per the directions of

Engineer-in-charge to meet contingencies.

Overhead trays shall be installed 2700 mm (minimum) above grade level and 300 mm

above FGL in case cable trays are installed along with pipe sleepers. At road crossing

overhead trays shall be installed at 7000 mm (minimum) above grade level or cables shall

be routed cable tray culvert / Electrical road crossings as per layout drawings. Sufficient

care shall be taken while laying cables to avoid formation of twist, sharp bend etc. in order

to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables. Cable

installation shall provide minimum cable bending radii as recommended by cable

manufacturer.

Cables shall be neatly arranged in the trenches/ trays in such a manner that criss-crossing is

avoided and final take off to the motor / switchgear is facilitated. Cable routing between

cable trench and equipment / motors shall be taken through PVC/RCC sleeves of adequate

size. Pipe sleeves shall be laid at an angle of maximum 45 to the trench wall. Bending radii

of pipe shall not be less than 12D. It is to be ensured that both the ends of PVC/RCC pipe

sleeves shall be sealed with approved weather proof sealing plastic compound after cabling.

All cables shall be identified close to their termination point by cable tag numbers as per

cable schedule. Cable tag numbers shall be punched on aluminium/ lead straps (2mm thick,

20mm wide and of enough length) securely fastened to the cable and wrapped around it. In

unpaved areas, cable trenches shall be identified by means of cable markers. These cable

markers shall be placed at location of changes in the direction of cables and at intervals of

not more than 30m and also at cable straight through joint locations. All temporary ends of

cables must be protected against dirt and moisture to prevent damage to the insulation. For

this purpose, ends of cables shall be taped with an approved PVC end cap or rubber

insulating tape.

Each row of cables shall be laid in place before covering with sand. All wall opening/ pipe

sleeves shall be effectively sealed after installation of cables to avoid seepage of water

inside building/ lined trench. Every cable shall be given an insulation test in presence of

Engineer-in-charge/ Owner before filling the cable trench with sand. Any cable which is

found defective shall be replaced. Where cables pass through foundation walls, the

necessary openings shall be provided in advance for the same by another agency. However,

should it become necessary to cut holes in existing structures for example floor slab etc. the

electrical contractor shall determine their location and obtain approval of the Engineer-in-

charge before carrying out the same. Cables for road crossings shall be taken through RCC/

Hume pipes as shown in the cable layout drawings. At road crossing and other places where

cables enter pipe sleeves, adequate bed of sand shall be given so that the cables do not slack

and get damaged by pipe ends.

Cables Laid Direct in Ground Cables shall be laid underground in excavated cable trenches where specified in cable

layout drawings. Trenches shall be of sufficient depth and width for accommodation of all






cables. Cables shall be properly placed as per installation standards. Minimum depth of

directly buried cable trench shall be 750 mm for L.V. and 900 mm for H.V. cables. The

depth & width of the trench shall vary depending upon the number of layers of cables. It is

to be ensured by the contractor that the bottom of buried trenches shall be cleared of all

rocks, stones and sharp objects before cables are placed. The trench bottom shall be filled

with a layer of sand or stone dust. This sand/ stone dust shall be levelled and cables laid

over it. These cables shall be covered with 150 mm of sand on top of the largest diameter

cable and sand shall be lightly compacted. A flat protective covering of 75 mm thick second

class red bricks or concrete tiles shall then be laid and the remainder of the trench shall then

be back-filled with soil, rammed and levelled.

Cables Laid in Concrete Trench Minimum depth of RCC cable trench shall be 500 mm for all voltage grades with 300 mm

clearance between the bottoms of the trench cover and top of the cable. The depth and width

of the trench shall vary depending upon the number of layers of cables and bending radius

required for cables. Concrete cable trenches shall be filled with sand/ stone dust in

hazardous area to avoid accumulation of hazardous gases and oil. RCC covers of trenches

shall be effectively sealed to avoid ingress of chemical and oil. Removal of concrete covers

where required for the purpose of cable laying and reinstating them in their proper position

after cables are laid shall be done by electrical contractor.

Above Ground Cables

Cables installed above grade shall be run in cable trays, clamped on walls, ceiling or

structures and shall be run parallel or at right angles to beams, walls or columns. Each cable

tray shall contain only one layer of cables as far as possible for power cables. However

control cables may be laid in double layer in the cable trays.

Individual cable or small group of cables (upto 3 cables) which run along structures/ walls

etc. shall be clamped by means of 16 SWG GI saddles on 25 x 6 mm sadle bars.

Alternatively small group of cables can be taken through 60/100/150 mm slotted channel

tray or channel ISMC-75/100. Cables shall be supported so as to prevent sagging. In

general, distance between supports shall be approximately 300 mm for cables upto 25 mm

diameter and maximum 450 mm for cables larger than 25 mm diameter to prevent the

sagging of cables. Cables laid in supporting angle in cable trenches, structures, columns and

vertical run of cable trays shall be suitably clamped by means of GI saddles/ clamps,

whereas cables in horizontal run of cable tray shall be tied by means of nylon cords.

Distance between supporting angles shall not exceed 600 mm. All cable trays and

supporting steel structures shall be painted before laying of cables. The under surface shall

be properly degreased, derusted, descaled and cleaned. The painting shall be done with two

coats of approved bituminous aluminium paint unless otherwise specified.Where cables rise

from trench to motor, lighting panel, control station, junction box etc. they shall be taken in

PVC/ RCC pipe for mechanical protection upto a minimum of 300 mm above grade for

outdoor area. Cable ends shall be carefully pulled through conduit to prevent damage to

cable.

Following guide shall be used for sizing of PVC/ RCC pipe :

a). 1 cable in a pipe - 53% of pipe cross-sectional area occupied by cables.

b). 2 cables in a pipe - 31% of pipe cross-sectional area occupied by cables.

c). 3 cables in a pipe - 43% of pipe cross-sectional area occupied by cables.

d). 4 and above cables in a pipe - 40% of pipe cross-sectional area occupied by cables.






After the cables are installed and all testing is complete, conduit ends above grade shall be

plugged with a suitable weatherproof plastic compound/ bitumen/ suitable sealing

compound. Alternatively rubber bushes shall be employed for the purpose of sealing. Fire

proofing of end of power cables at least 1 meter at each end as per OISD norms for the

Refinery and Petroleum industry, shall be carried out as per the recommendation of the

paint supplier. Rates for the fire proofing of cables shall be included in the cable installation

and no separate payment shall be made for the painting.

The drums under the custody of the contractor shall be neatly arranged in the yard near his

site office. The drum shall not be rolled for transportation more than 10 mtr. Truck /

Trailer shall be used for transportation for distance more than 10 mtr.

The cables shall be rolled out for equipment and cutting shall be as per site requirement.

Cable jacks and cable rollers shall be used during laying of cable.

Electrical Contractor shall cut all cable length by actual measurement at site as per final

route determined. Cable lengths indicated in Cable Schedules shall be used only to get an

idea of length involved.

The cables shall be tested for insulation value before laying. Drum Schedule to be prepared

by contractor.

Cables/ cable tray opening in walls and floors or through pipe sleeves from one area to

another or one elevation to another shall be sealed by fire-proof sealing system. The fire-

proof sealing system (FPSS) will effectively prevent the spread of fire from the flaming to

non-flaming side, in the event of fire.

3.9.2 Terminations

All XLPE cables upto 1100V grade shall be terminated at the equipment by means of

compression type cable glands suitable for the cable size. They shall have a screwed nipple

with electrical threads and check nut. The cables shall be identified close to their

termination points at both the ends of cable and also along the route at recommended

intervals, by cable tag numbers. All cable entries for outdoor termination shall be preferably

through bottom. Power cables cores wherever colour coding is not available shall be

identified with red, yellow and blue PVC tapes. Where copper to aluminium connections are

made, necessary bimetallic washers shall be used. In case of control cables, all cores shall

be identified at both ends by their terminal numbers by means of PVC ferrules suitable for

core size. Wire numbers shall be as per schematic/ wiring/ inter-connection diagram. All

unused spare cores of control cables shall be neatly bunched and ferruled with cable tag at

both ends, for future use.

Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of

non-magnetic material/ aluminium sheet in case of single core cables. All unused cable

entries on equipment/ panels shall be plugged/ sealed. The cable shall be terminated at

electrical equipment/ switchboards through glands of proper size. The individual cores shall

then be dressed and taken along the cables ways or shall be fixed to the panels with

polyethylene straps. The cable glanding shall be done as per manufacturer’s instructions.

Cable armour shall not be exposed after termination is complete. In case of termination of

cables at bottom of a panel over a cable trench having no access from the bottom close fit

holes shall be drilled in the gland plate for all the cables in one line, then gland plate shall

be split in two parts along the centre line of holes. After fixing bottom plate, uncovered

cable holes/ gaps shall be sealed with cold setting compound.






Crimping of lugs to cable leads shall be done by hand crimping/ hydraulically operated tool

as per requirement. Insulation of the leads shall be removed before crimping. Conductor

surface shall be cleaned and shall not be left open. Suitable conducting jelly shall be applied

on the conductor lead. Lugs shall enclose all strands of cable core. Cutting of strands shall

not be allowed. The contractor shall bring to the notice of Engineer-in-charge any mismatch

in cable glands, lugs provided with the equipment vis-à-vis to the cable size indicated in

cable schedule for taking corrective action.

The cable joints in power & control cables shall be avoided as far as possible. In case a joint

is unavoidable, the following shall be insured :

• The number of joints shall be restricted to minimize as far as possible.

• The location of joints shall be identified with permanent markers.

• No joints shall be allowed in hazardous areas without the approval of Engineer-in-

charge.

The jointing and termination of low voltage power cables shall be carried out by trained

personnel only. Jointing and termination of high voltage cables shall be done by skilled and

experienced jointer duly approved by Engineer-in-charge. Only type tested termination kits

of approved make shall be used.

No unauthorized repairs, modifications shall be carried out on the hazardous area equipment

terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall

be brought to the notice of Engineer-in-charge. After termination is complete, all the bolts,

nuts, hard wares of terminal box shall be properly placed in its position and tightened.

Where required, cable sealing boxes intended to be used with the apparatus shall be filled

with solid setting type bituminous compound unless otherwise specified. All power and

control cables glands installed outdoor shall be provided with suitable sized shrouds and

rates for the same shall be included in the scope of the termination of the cable glands. No

separate payment is envisaged for the same.

3.9.3 Cable Trays

3.9.3.1 The Cable Trays shall be ladder type unless otherwise specified.

3.9.3.2 The Trays shall be painted with two coats of primer followed by two coats of final paint.

3.9.3.3 The Trays shall have suitable provision for clamping at an interval of 500 mm.

3.9.3.4 The Earthing Strip for the earthing ring shall be run along the side of the tray.

3.9.3.5 The connection between individual equipment to the ring shall be by bracing or with lugs.

3.9.3.6 The trays shall be supported as per installation drawings. If necessary, additional supports

shall be provided. The supporting arrangement shall be approved by site engineer.

3.9.3.7 The bending of trays shall be smooth and the curvature sufficient for each bending of cables

in it.

3.9.3.8 Electrical Cable Tray routing shall be co-ordinated by Electrical Contractor at site to check

fouling with pipes, equipment, light fittings and instrument trays, etc. before fixing the

trays.






3.9.4 Cable Glands

Cable glands shall be of nickel plated brass unless otherwise specified. The double

compression type cable glands shall be used for indoor panels/ equipment (e.g. substation,

control room etc). The cable glands for outdoor terminations shall be weather protected,

double compression type. Cable gland forming a part of relevant FLP enclosure shall be

FLP type, tested by CIMFR or other recognized independent testing laboratory and

approved by CCoE/ DGMS or any other statutory authority as applicable. Indigenous FLP

glands shall have valid BIS license as per the requirements of statutory authorities. The size

of cable glands supplied shall be appropriate to the size of cable so that frame proofness of

glands is retained. Entry thread of cable gland shall be compatible to the entry thread

provided in the equipment (BS, ET, NPT, PG as applicable). If required, suitable reducers/

adopters shall be used.

3.9.5 Connectors

Power cable terminations shall be made with crimped type tinned copper solder less lugs

which shall be suitable for the cable size mentioned in cable schedule.

3.9.6 Ferrules

Ferrules shall be of approved type and of size to suit core size mentioned and shall be

employed to designate the various cores of control cable by the terminal numbers to which

the cores are connected, for ease of identification. Ferrule shall be printed type.

3.9.7 Testing and Commissioning of Cables

Before energising, the insulation resistance of every circuit shall be measured from phase to

phase, phase to neutral and from phase/ neutral to earth. Where splices or terminations are

required in circuits rated 650 volts, insulation resistance of each length of cable shall be

measured before splicing and/ or terminating. After completion of splices and/ or

terminations measurements shall be repeated. The insulation resistance of directly buried

cables shall be measured before cable trenches are backfilled. Measurement shall be

repeated after back filling. For cables upto 1.1 kV grade 1000V Meggar and for H.V. cables

2.5 / 5 kV Meggar shall be used.

D.C. High Voltage test shall be conducted on cables given below after installation.

a). All 1100V grade power cables in which straight through joints have been made.

b). All cables above 1100V grade.

D.C. High Voltage test shall be performed as detailed below in the presence of the

Engineer-in-charge or his authorized representative only.

Cables shall be installed in final position with the entire straight through joints complete.

During the high voltage test, all other electrical equipment related to the cable installation,

such as switches, instrument transformers, busbars etc. must be earthed and adequate

clearance shall be maintained from the other equipment and framework to prevent

flashover. In each test, the metallic sheath/ screen/ armour shall be connected to earth. All

test readings shall be recorded and submitted to Engineer-in-charge.

3.10 Earthing

The main earth grid conductor shall be hot galvanised M.S. flat unless otherwise specified.

Sizes for main conductors shall be as indicated on the earthing layout drawing. Amount of

galvanizing shall be 610gm per sq.metre.






3.10.1 Earthing Network

This consists of main earth conductor (grid conductor) forming a closed ring network with

required number of earth electrodes connected to it to provide a common earth for electrical

devices and metallic structures. From each earth electrode two distinct connections shall be

made to the main earth conductor. The earth plates shall be used for taking multiple earth

connections to two or more equipment.

The earth conductor shall be laid along cable trays / cable trench / pipe racks as indicated on

the earthing layout drawing. Where lined cable trenches are available, the earth conductor

shall be laid in the trenches and shall be firmly cleated to the sidewall of concrete trenches

using GI clamps at interval of 400 mm to 500 mm and near to the termination end. The

earthing conductor shall run along one of the cable trays along a cable route. The earthing

conductor shall be suitably cleated and electrically bonded to all the other cable trays on the

same cable route at a regular interval of 25 to 30 meter. The earthing for equipment shall be

tapped from the main earth conductor and not from cable tray support structure. Earth

conductor when laid underground shall be at a depth of 500mm below finished grade level.

Joints and tapping's in the main earth loop shall be made in such a way that reliable and

good electrical connections are permanently ensured. All joints below grade shall be welded

and shall be suitably protected by giving two coats of bitumen and covering with Hessian

tape. Earth strip laid above ground shall be welded across straight through joints and joints

shall be suitably protected by giving two coats of bitumen to avoid oxidation and insulation

film formation of the strip surface. When two earth strips are to be jointed by means of

welding, lap welding with an overlapping of strip equivalent to double the width of the strip

and all four sides shall be continuously welded. All joints at tappings above ground shall be

by means of connector/lugs. A minimum of two bolts of adequate size shall be used for this

purpose. Earthing strip joints at earth plate and equipment shall be through GI bolts, nut etc.

3.10.2 Installation of Maintenance Free Earth Electrode

Earth Electrode shall be installed as shown on installation standard and layout drawings.

The location shown on the layout drawings are indicative. The exact location of earth

electrodes in the field shall be determined by contractor in consultation with the Engineer-

in-charge, depending on the soil strata and resistivity. Earth electrodes shall be located

avoiding interferences with road, building foundation, column, pipelines etc. The civil area

drawings shall be referred for this.

High quality tripod earthing shall be provided to conduct & dissipate the fault current as fast

as possible. The triangular termination is made of a set of three copper-bonded steel earth

rods of 2m each arranged in a triangular fashion and separated from each other by a distance

at least equal to their driven depth and interconnected by a flat copper conductor (copper

strip). For any one of tripod earthing electrode, inspection chamber shall be provided as

indicated in drawing.

Electrodes shall preferably be located in a moist soil which has a fine texture, grain size and

distribution. Wherever practicable the soil shall be dug up, all lumps broken and stones

removed from the immediate vicinity of the electrodes and soil packed by watering and

ramming as tight as possible.

The electrodes shall have a clean surface, not covered by paint, enamel, grease or other

materials of poor conductivity.






All earth electrodes shall be tested for earth resistance by means of standard earth test meter.

The tests shall take place in dry months, preferably after a protracted dry spell.

The disconnect facility shall be provided for the individual earth electrode to check its earth

resistance periodically.

Location of earth electrodes shall be marked by permanent markers for easy identification.

All earth Electrodes shall be serial numbered and also marked on 'As Built' drawing for

future reference.

Individual earth electrodes shall be provided for each lightning arrestor.

Earthing system provided for concrete paved area by other agency where applicable; shall

be connected to the plant earthing system below ground by minimum two earth connections.

3.10.3 Connection

The earth system connections shall generally cover the following:

- Equipment earthing for personnel safety

- System neutral earthing

- Static and lightning protection

The following shall be earthed.

- System neutral

- Current and potential transformer secondary neutral

- Metallic non-current carrying parts of all electrical apparatus such as transformers,

switchboards, bus ducts, motors, neutral earthing resistors, capacitors, UPS, battery

charger panels, welding receptacles, power sockets, lighting/power panels, control

stations, lighting fixtures etc.

- Steel structures/ columns, rail loading platforms etc.

- Cable trays and racks, lighting mast and poles

- Storage tanks, spheres, vessels, columns and all other process equipment.

- Fence and Gate for electrical equipment (e.g. transformer, yard etc.)

- Cable shields and armour

- Flexible earth provision for Wagon, Truck

- Shield wire

Type & size of earth conductor shall be as follows:

Equipment Earthing Strip / Wire Size

(a) Main Grid : GI strip, Size Based on calculations

(b) Motor up to 3.7 kW : 2Nos., 8 SWG Solid wire

(c) Motor 5.5 kW to 30 kW & Welding

Receptacles

: 2Nos., 25 sq.mm earthing cable

(d) Motors 30 kW to 110 kW : 2 Nos., 120 sq.mm earthing cable

(e) Motors above 110 kW : 2Nos., 185 sq.mm earthing cable

(f ) Building columns, (vertical &

horizontal), Loading Racks and

pipe racks.

: 40 x 5 Strip (Building Column-2Nos.

Diagonally opposite, Loading Racks & Pipe

rack- at every 30mt).






(g) Storage Tanks : 2 Nos. 50 x 6 mm Strips for Storage tanks –

(2/3Nos. depending on Tank diameter).

(h) Vessels & Heat Exchangers : 2Nos., 10 mm (3/8”) dia. Wire Rope

(i ) Small Equipment & Instruments,

Local Push Button Stations

: 2Nos., 8 SWG Solid wire

(j ) MV/LV Switchgear, Power Trans.,

Earth Grid around Substation, Main

Grid Process Units

2Nos., 50 x 10 mm G.I. Strip

( k ) Main Earth Grid for Pump House /

Tank Areas MCC Room etc.

50 x 10 mm G.I. Strip

( l ) Lightning conductor-down comers /

Horizontal air termination

: 25 x 6 mm Strip

Location of Earth Conductor : Buried / in Cable Trays

Lightning Protection : For Administration, Control Room, Sub-

station Building & High Masts.

Air Termination : Yes

Down Conductors : 32 x 6 mm thick G.I. Strip

Roof (Horizontal) Conductor : 25 x 6 mm thick G.I. Strip

All process pipelines shall be bonded and earthed at the entry and exist points of battery

limit of hazardous area.

Steel pipe racks in the process units and offsite area shall be earthed at every 24 meters.

Lightning protection shall be provided for the equipment, structures and buildings as shown

on layout drawing. Self conducting structures shall not require separate aerial rod and down

conductors. These shall however be connected to the earthing system at two or more points

as shown on layout drawing. An independent earthing network shall be provided for

lightning protection and this shall be bonded at least at two points with the main earthing

network below ground. Lightning down conductor shall be brought to earth electrode in

shortest straight path as feasible to minimise surge impedance.

The main earthing network shall be used for earthing of equipment to protect against static

electricity.

All medium and high voltage equipment (above 250V) shall be earthed by two separate and

distinct connections with earth.

Plant instrument system clean earthing, UPS system clean/safety earth, Data concentrator

panel, HMI etc shall be separate from the electrical earthing system.

All paint, scale and enamel shall be removed from the contact surface before the earthing

connections are made.

All earthing connections for equipment earthing shall be preferably from the earth plate

mounted above ground wherever provided.

Equipment foundation bolts shall not be used for earthing connection.






Earth connections shall be made through compression type cable lugs/by welded lugs.

All hardware used for earthing installation shall be hot dip galvanised or zinc passivated.

Spring washers shall be used for all earthing connections and all connections adequately

locked against loosening.

Lighting fixtures and receptacles shall be earthed through the extra core provided in the

lighting circuit/cable for this purpose.

3.10.4 Testing and Commissioning of Earthing System

Earthing system / connections shall be tested as follows :

Resistance of individual earth electrodes shall be measured after disconnecting it from the

grid by using standard earth test meggar. Earthing resistance of the grid shall be measured

after connecting all the earth electrodes to the grid. The resistance value of an earth grid to

the general mass of earth shall be as follows :

• For the electrical system and equipment a value that ensures the operation of the

protection device in the electrical circuit but not in excess of 4 ohms. However for plant

grid, resistance value shall not be more than 1 ohm.

• For lightning protection, the value of 5 ohms as earth resistance shall be desirable, but

in no case it shall be more than 10 ohms.

The resistance to earth shall be measured typically at the following points :

a) At each electrical system earth or system neutral earth.

b) At each earth provided for structure lightning protections.

c) At one point on earthing system used to earth electrical equipment enclosures.

d) At one point on earthing system used to earth wiring system, enclosures, such as metal

conduits and cable sheaths or armour.

e) At one point on fence enclosing electrical equipment.

3.11 Lighting Installation

3.11.1 General

The lighting fixtures in the plant shall be fed from lighting panel. All outdoor lighting shall

be group controlled manually or through synchronous timer or photocell. Lighting wiring

between panel and lighting fixtures shall be done with PVC insulated 3-core (phase, neutral

and earth) copper conductor armoured cable for hazardous areas. All joints of conductors in

Switch boards/ JBs Fittings shall be made only by means of approved mechanical

connectors (nylon/PVC connectors). Bare twisted joints shall not be permitted any where in

the wiring system.

The lighting layouts furnished by owner will indicate approximate locations of lighting

fixtures. The electrical contractor shall determine, with approval of Engineer-in-Charge, the

exact locations of each fixture in order to avoid interference with piping or other mechanical

equipment and also with a view to obtain as much uniform illumination as practicable, and

to avoid objectionable shadows.






On walkways, platforms and other outdoor area, lighting fixtures shall be located nearer to

landing of stairs or ladders, gauges, flow meters, panel boards and other equipment to

provide proper illumination.

All outdoor cable terminations to outdoor junction boxes, panels, socket outlets etc. shall be

through bottom or from side. Top entries for cables shall be avoided to avoid water entry.

All cable glands for outdoor terminations shall be double compression type and the gland

shall be covered with PVC or rubber boot shroud. All unused cable entries shall be plugged

with suitable blanking plugs.

Mounting height of equipment shall be as under:-

Top of Switch Box : 200 mm from FFL (Finished floor level)

Top of Lighting/Power Panel : 1800mm from FFL

Lighting fixture : As indicated in layout drawing

Fixtures shall be firmly supported from the structures. Support clamps etc. may be bolted or

welded to the existing steel work or metal inserts. In case of concrete structures, where

metal inserts are not available, fixtures shall be suspended from concrete surfaces with the

help of anchor fasteners. In such cases special care shall be taken to see that anchoring is

firm.

Circuit cables in a group shall be cleated to structure by using galvanised strip clamps or

cable run in cable trays wherever trays are available. Spacers and cleats shall be of required

size to accommodate the cables. All hardware shall be galvanised or zinc passivated.

Underground lighting cables (in paved areas) shall be taken in suitable GI sleeves buried at

a minimum depth of 300mm from FFL. GI pipe sleeves shall be extended to 300mm above

FFL. Exact termination/layout of GI pipes (for protection of cables) shall be decided at site

as per site convenience in consultation with Engineer-in-charge.

Wiring for all outlet sockets shall be done with 3 cores of equal sizes for phase, neutral and

earth. The terminals of switch sockets shall be suitable to receive the size of wire specified.

All lighting fixtures shall be provided with terminal block with required terminals suitable

for connection of wire up to 2.5 sq. mm copper conductor.

The cable shall be straightened after unwinding it from the drum. All cables are clamped/

laid in straight run without any sag and kink.

3.11.2 Hazardous Area Installation

Wiring in hazardous area shall be done by using minimum 2.5mm2 copper conductor

armoured cable. Circuit wiring feeding hazardous areas shall be controlled by two pole

switches/MCBs (for phase as well as neutral isolation).

Correct type of lighting equipment (fixtures and JBs) with regard to hazardous protection as

specified in the drawing shall be installed for the areas classified as Zone 1, Zone 2 etc.

The terminations in the junction boxes and the lighting fittings shall be done avoiding

possibility of loose connections due to vibrations. After the terminations are made the cover

of the junction boxes and the lighting fittings shall be closed properly with all bolts and hard

wares in correct position, retaining its explosion and weather protections. In fixtures having

double cable entries, both the entries shall be used for looping in and looping out

connection, thus minimising the use of a separate junction box. Wherever separate control






gear boxes (CG box) are provided looping in and looping out connections shall be through

CG box, thus avoiding the use of an additional junction box. All unused cable entries shall

be sealed with suitable plugs.

Circuit cables shall be firmly cleated in a group along columns/ beam/ladders/side

channels/platform using 1.6mm thick GI saddles on 25x3 mm GI saddle bar at intervals of

400mm to 500mm for straight run and on either side close to bending and at both

termination ends as per the directions of Engineer-in-charge. Where required 3 or more of

cables shall be taken in perforated 100mm cable tray after getting the approval of Engineer-

in-charge. Cables shall not be routed along hand rails.

Where fire proofing column/structures are encountered, all cabling shall be taken in GI

pipes of required size and both ends shall be sealed, well before fire proofing is done.

Similarly equipment such as lighting fixture, control gear box, lighting/ power panels, field

call stations, junction boxes etc. shall be installed on suitable steel mounting frame/distance

bracket, thereby avoiding direct contact with the concrete used for fire proofing.

Cable glands for terminating cable on flameproof equipment shall be of double compression

FLP type. Any material/equipment specified to be supplied by contractor for installation in

hazardous areas, shall be tested by CMRI and duly approved by CCOE or DGMS or any

other applicable statutory authority. All indigenous FLP equipment shall also have valid

BIS

license as required by statutory authorities.

3.11.3 Testing and Commissioning of Lighting system

3.11.3.1 Lighting installation shall be tested and commissioned by installation contractor as per

specifications. Precommissioning checks and tests shall include but not be limited to the

following:

(i) The insulation resistance of each circuit without the lamps (load) being in place shall

be measured. (Between phases, phases to neutral, phase/ neutral to Earth).

(ii) Current and voltage of all the phases shall be measured at the lighting panel bus bars

with all the circuits switched on with lamps. If required load shall be balanced on the

three phases.

(iii) The earth continuity for all socket outlets shall be checked. A fixed relative position

of the phase and neutral connections inside the socket shall be established for all

sockets.

(iv) After inserting all the lamps and switching on all the circuits, minimum and

maximum illumination level shall be measured in the area and recorded.

(v) It shall be ensured that switch provided for ON/OFF control of point (light/ fan/

socket) is only on LIVE side.

(vi) Operation of ELCB's shall be checked.

Contractor shall duly fill in all the above test results and submit the test reports to Engineer-

in-Charge in triplicate.

3.11.3.2. All lighting layout drawings shall be marked by contractor for 'AS BUILT STATUS' and

two sets of hard copies plus 1 set of soft copy in CD, shall be submitted to Owner.






4 Field Inspection, Testing and Commissioning

4.1 Contractor shall carry out complete field inspection, testing and commissioning of electrical

equipment.

4..2 Before the completed installation or an addition to the existing installation is put into

service, inspection / pre-commissioning checks and tests shall be carried out by contractor.

In the event of defects being found out, the same shall be rectified and the installation

retested as applicable.

4.3 The pre-commissioning inspection among other requirements shall include visual

inspection, checking the workmanship of the installation, the rating of equipment, safety

clearances, sizes of cables installed, conformance to the AFC document, soundness of

switchgear bus connections, wiring properly dressed and labeled, sealing of unused cable

entries, checking of all safety interlocks, control/interface functions as per requirement etc.

4.4 Visual inspection for soundness of bus bar connections of busducts, terminal connections of

equipment/motor shall be carried out. It shall be ensured that no foreign materials are

present inside busduct and equipment terminal boxes. After the visual inspection, all the

covers of terminal boxes, inspection chambers shall be refitted with gaskets, bolts & nuts as

per equipment manufacturer's instructions.

4.5 Pre-commissioning tests shall include but not be limited to the following:

- Continuity test for each winding and power and control circuits.

- Insulation test for each winding and power and control circuit

- High voltage test for cables

- Dielectric strength test on transformer oil.

- Checking the correctness of wiring schemes, control circuit interlocks for intended

functioning.

- Verification of phase sequence.

- Testing of all types of relays/releases for required operation.

- Testing of measuring instruments for proper functioning.

- Earth continuity test for all circuits.

- Checking of safety features for correctness of operation etc.

- Checking of all wired interface contacts (analog, digital input/output contacts) for TAS

interface, at panel and equipment terminal chambers as applicable.

(Electrical contractor shall co-ordinate with other agencies involved for the above and

provide support services for checking interfaces of electrical equipment and the

intended functioning)

- Earth resistance measurement for each earth electrode, and the earthing system as a

whole.

- Lighting installation shall be tested for correct illumination levels, with the fittings

installed. Fittings shall be operated only with specified type of a lamp or tube.

4.6 After the above tests and inspection are completed, control circuits shall be tested for

correct operation under all operating combinations and proved correct before applying

power to main circuits.






4.7 A close visual inspection of electrical equipment in hazardous areas shall be made to ensure

that equipment is suitable for the classified zone and gas group and correctly installed, with

all covers, bolts, nuts and hardwares intact and there is no physical damage mark seen on

the enclosure.

4.8 Site Acceptance Test procedure for specific equipment shall be furnished by the respective

equipment vendor. The contractor shall provide necessary assistance to the equipment

vendor to perform Site acceptance testing to enable the equipment vendor to perform the

same.

4.9 All pre-commissioning checks and tests shall be carried out as per the directions of

Engineer-in-charge. In addition to the equipment manufacturer's instructions, pre-

commissioning check requirements shall also be complied. All tests shall be carried out by

contractor in the presence of Owner's representatives.

4.10 The contractor shall bring to site all required tools, tackles, and testing instruments for

carrying out field testing. Contractor shall use only calibrated measuring and test

instruments and shall maintain calibration records.

4.11 The Insulation Resistance test values for various electrical equipment shall be as below:

4.11.1 Cables

The insulation resistance test values for cables shall be as per following table:

Rated voltage of the Cable DC Test Voltage in

Volts

Minimum Insulation

resistance in Mega

ohms

Lighting and power circuit wiring 250 1

650/1100V grade cables 1,000 10

1,900/3,300V grade cables 1,000 200

19,000/3 3000V grade cables 5,000 200

4.11.2 HV, LV and Miscellaneous Switchboards

The insulation resistance test values for the switchboards shall be as per following table:

Rated voltage of the Switchboard DC Test Voltage in

Volts

Minimum Insulation

resistance in Mega

ohms 33,000V 5,000 200

415V 1,000 100

240V 500 10

110V 500 10






4.11.3 Generators and Motors

The insulation resistance test values for the Generators and Motors shall be as per

following table:

Rated voltage of the Generators and

Motors

DC Test Voltage in

Volts

Minimum Insulation

resistance in Mega

ohms at 40 °C

3,300V 1,000 50

415V 1,000 15

240V 500 12

4.11.4 Transformers

The insulation resistance test values for the Transformers shall be as per following table:

Rated voltage of the Transformers DC Test Voltage in

Volts

Minimum Insulation

resistance in Mega

ohms at 40 °C

Up to 600V 1,000 100

601 to 5000V 2,500 1,000

5001 to 15,000V 5,000 5,000

15001 to 35,000V 5,000 10,000

4.12 It shall be ensured that during insulation tests, electronic devices and components that are

liable to get damaged on applied test voltage shall be disconnected from circuit. The

instructions of equipment/panel manufacturer shall be followed strictly in this regard.

4.13 High-voltage testing

4.13.1 D.C. high voltage test shall be conducted as per following table on all H. V. feeder cables and

also on 1100 V grade cables where straight through joints have been made.

Rated Voltage of

Cable (kV) TEST VOLTAGE (kV) BETWEEN

Duration

(Minutes)

U0/U*

Any Conductor and

Metallic Sheath/

Screen/Armour

Conductor to

Conductor (For

Unscreened Cables)

0.65/1.1 3 3 5

1.9/3.3 5 9 5

19/33 60 - 5

* U0: Phase Voltage

U : Line Voltage

4.13.2 The cable cores must be discharged on completion of DC high voltage test and cable shall

be kept earthed until it is put into service.

4.13.3 DC test voltage for old cables shall be 1.5 times rated voltage or less depending on the age

of cables, repair work or nature of jointing work carried out, etc. In any case, the test

voltage shall not be less than the rated voltage.






4.13.4 Provide commissioning assistance to the major equipment supplied vendor.

4.13.5 It shall be ensured that the electrical inspectorate approval is available before energising the

equipment.

5 Contractor shall provide the following items in substation, as per Indian Electricity Rules:

5.1 First aid boxes containing ointments and medicines for immediate treatment of injuries (As

prescribed by Indian Red Cross Society or equivalent).

5.2 Instructions of restoration of persons suffering from electric shock in English, Hindi and

local language of the district shall be affixed in a conspicuous place.

5.3 Danger boards (HV., MV.) shall be provided on transformer gate, switchboards, entrance to

switchgear room and at other places as required by Engineer-in-charge.

6 Miscellaneous equipment

The miscellaneous equipment includes all the equipment which are not explicitly covered

in equipment specification. This includes mainly following:

i) Protective rubber mats of appropriate grade.

ii) First aid kit in a cabinet.

iii) Danger/Caution boards.

iv) Shock treatment Chart.

v) Hand Gloves of appropriate grade.

vi) Ceiling fans, Exhaust fans & Air Circulator.

vii) Canopy

viii) Anchor fastener

ix) Insert Plates

x) Sealing of pipes & Sealing plugs

xi) Adaptor/Reducer

xii) GI/PVC/Hume pipes

xiii) Conduits & Accessories

xiv) Structural Steel

xv) Gravel spreading in Transformer(s) area.

xvi) Rails for transformer(s).

7 List of Construction Equipment

The contractor shall have all necessary construction equipment, tools and tackles and testing

instruments to carry out the erection works and to commission the system as specified.

These shall include but not be limited to the following and these shall be brought to site by

contractor before the start of work.

7.1 Equipment:

i. Portable grinder

ii. Portable welding machine

iii. Portable gas cutting / welding set.

iv. Pipe threading machine.

v. Pipe bending machine (hydraulic).

vi. Portable drill machine suitable to take up drilling sizes as per requirement.

vii. Dewatering pump sets (diesel driven).

viii. Power Hacksaw.

ix. Conduit dye set.

x. Hydraulic crimping machine with round/ hexagonal dye set.






xi. Hand crimping tool.

xii. Portable electric blowers, vacuum cleaners.

xiii. Miscellaneous items such as slings, pulleys, tarpaulins, wooden sleepers, ladders

etc. as required.

xiv. Safety belts, safety goggles and gloves.

xv. Separate tool kit for each Electrician.

xvi. Hydraulic/ Hand held grease gun.

7.2 Test Instruments

i. Insulation tester 1000V hand driven.

ii. Insulation tester 2500V motor/ hand driven.

iii. Insulation tester 5000V motor/ hand driven.

iv. Phase sequence indicator.

v. Earth resistance tester.

vi. Single phase variac.

vii. 3 phase variac of adequate capacity.

viii. Secondary and primary injection testing kit.

ix. Multimeter, both analogue and digital.

x. Portable Ammeters, Wattmeters, P.F. meters.

xi. Portable Voltmeters.

xii. Clip on meters of different ranges.

xiii. Tacho-meter.

xiv. Kelvins double bridge for measurement of very low resistance.

xv. D.C. high – pot test kit.

xvi. A.C. high – pot test kit.

xvii. Oil filtration machine of adequate capacity.

xviii. Lux Meter to measure illumination levels.

xix. Breaker timing 3 pole kit.

xx. Timers

xxi. 100A D.C. milli volt drop (Contact resistance) kit.

xxii. Vibration measuring instrument.

xxiii. Thermo meters.

8 Clearance and Safety

For every electrical switchboard, control panel, motor control centres, etc, that require back

access the space behind the equipment shall generally be 1,000 mm but in no case be less

than 762 mm. This space shall also be adequate to permit atleast a 90 degree opening of

doors or hinged panels. In such cases where back clearances are provided, there shall be a

passage-way from either end of the equipment clear to a height of 1,800 mm. Where the

equipment are not required to be attended from the back, the equipment shall be placed

along with wall / structure having clearances less than 200 mm.

For all switchboards, control panels, motor control centres, a clear space of not less than

1,000 mm shall be provided in front of the equipment. In case where the equipment is

provided with drawout unit, a minimum clearance of 2,000 mm shall be provided.

For all electrical equipment a minimum clear headroom of 500 mm shall be provided.

All electrical equipment operating on 415V or higher voltage shall be provided with caution

notice boards of approved type and shall be affixed permanently in a conspicuous position.

Where a group of equipment is located within a switch / control room or within a fenced

area, the notice board shall be fixed at the entrance.

In front of all the switch boards, rubber mats shall be provided for personal safety.






Appendix-G: Schedule of Quantity

[Refer Doc. No. 254625-300-SC-ELE- 008 (Part A)]

[Refer Doc. No. 254625-300-SC-ELE- 009 (Part B & C)]

UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

FOUR POLE STRUCTURE

1

SUPPLY OF FOUR POLE STRUCTURE. FOUR POLE STRUCTURE

SHALL BE WITH BRACINGS AND CROSS ARMS FOR SUPPORTING

THE PIN / OR STRAIN INSULATORS. EACH POLE SHALL BE

HEAVY DUTY RAIL (IRS - HSB) HAVING A UNIT WEIGHT OF 52 KG

/ METER. FOUR POLE STRUCTURE SHALL INCLUDE GOD, LA,

EARTH SWITCH, CT, PT, METERING CUIBICAL, INSULATORS AND

JUMPER ETC AS PER SPECIFICATIONS, SLD AND APSEB

GUIDELINES .

SET 1

2

SUPPLY OF 33KV ( E ) 3C X 400 Sq.mm STRANDED ALLUMINIUM

CONDUCTOR SCREENED XLPE INSULATED ARMOURED CABLES

EXTRUDED FRLS PVC OUTER SHEATHED WITH NECESSARY

ACCESSORIES & 33kV OUTDOOR TYPE TERMINATION KITS.

GENERALLY CONFORMING TO IS 7098 PART 2 FOR

CONVERSION OF OVER HEAD LINE TO UNDER GROUND CABLE

SYSTEM.

MTR. 200TWO RUNS EACH OF 100

Mtr.

LOCAL CONTROL STATION

FLAME PROOF LOCAL CONTROL STATIONS

SUPPLY OF FLAME PROOF Ex-d FOLLOWING TYPE LOCAL

CONTROL STATION SUITABLE FOR ZONE - 1 & 2 GASS GROUP II

A & II B. TEMPERATURE CLASS - T3 IP-55. THE ENCLOSURE

SHALL BE MADE OF CAST LIGHT METAL ALLOY WITH 2 NOS

SUITABLE SIZE KNOCK OUTS FOR CABLE CONNECTION WITH

CANOPY.

3 EMERGENCY STOP PUSH BUTTON TYPE A NO. 5

4START / STOP PUSH BUTTON WITH LOCAL / REMOTE SELECTOR

SWITCH & AMMENTIES TYPE BNO. 33

INDUSTRIAL TYPE LOCAL CONTROL STATION

SUPPLY OF INDUSTRIAL FOLLOWING TYPE LOCAL CONTROL

STATION THE ENCLOSURE SHALL BE MADE OF CAST LIGHT

METAL ALLOY IP-55 WITH 2 NOS SUITABLE SIZE KNOCK OUTS

FOR CABLE CONNECTION WITH CANOPY.

5 EMERGENCY STOP PUSH BUTTON TYPE C NO. 2


SWITCH & AMMENTIES TYPE DNO. 22

SOCKET OUTLETS

SUPPLY OF FOLLOWING TYPE SWITCH- SOCKET OUTLETS.

FLAMEPROOF Ex-d TYPE SUITABLE FOR ZONE-1 & ZONE-2,

GAS GROUP IIA/IIB. TEMPERATURE CLASS - T3 IP-55 SWITCH

SOCKET UNITS

763A TPN THREE PHASE 440VOLTS 5PINS SWITCH SOCKET

OUTLETSNO. 13

INDUSTRIAL TYPE (NON FLAME PROOF ) IP-55

8 63A TPN THREE PHASE 440VOLTS 5PIN SOCKET OUTLET NO. 6

REMARKSSR.

NO.DESCRIPTION UNIT QTY.

SCHEDULE OF QUANTITY FOR ELECTRICAL BULKS

PART A : SUPPLY OF EQUIPMENT IN CONTRACTORS SCOPE

Rev B



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P:\Andheri\IndiaProject\254625 HPCL- Black Oil Terminal\Procurement\Electrical Bulk\Electrical Work Tender\08.10.09\Editable\Schedule of Qty for Electrical Bulks-BO-Rev.B_08.10.09Page 1 of 30

UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008

9 16A SINGLE PHASE 240 VOLTS 3PIN SWITCH SOCKET OUTLETS NO. 5

10 16A, 240V SINGLE POLE SWITCH NO. 4

11 FLAMEPROOF RECHARGEABLE TORCHES NO. 4

12 NON-FLAMEPROOF RECHARGEABLE TORCHES NO. 4

MAINTENANCE FREE EARTHING & LIGHTNING PROTECTION

SYSTEM

EARTHING STRIPS

SUPPLY OF HOT DIPPED GALVANISED (GI) BARE EARTH

CONDUCTOR. GI COATING SHALL BE 85 MICRON

13 75 x 12 MM GI STRIP MTR. 1250





GI WIRE ROPES

SUPPLY OF GI WIRE / WIRE ROPE OF STRANDED TYPE WIRES OF

FOLLOWING SIZES

18 8 SWG GI WIRE MTR. 4728

EARTHING CABLES

SUPPLY OF 600VOLT GRADE PVC INSULATED ALLUMINIUM

CONDUCTOR UNARMOURED CABLES OF FOLLOWING SIZES. .

19 1C X 4 Sq.MM CABLE MTR. 800




MAINTENANCE FREE EARTHING PITS & PLATE EARTH

ELECTRODE

SUPPLY OF FOLLOWING EARTH ELECTRODES

TRIPOD EARTH ELECTRODE:

23

TRIANGULAR TERMINATION CONSISTS OF A SET OF THREE

COPPER-BONDED STEEL EARTH RODS OF 2M EACH ARRANGED

IN A TRIANGULAR FASHION & SEPARATED FROM EACH OTHER

BY A DISTANCE AT LEAST EQUAL TO THEIR DRIVEN DEPTH &

INTERCONNECTED BY A FLAT COPPER CONDUCTOR (COPPER

STRIP) WITH INSPECTION CHAMBER AS PER STANDARD

INSTALLATION DRAWING.

NO 78


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008

G.I. PLATE EARTH ELECTRODE

24

G.I.PLATE ELECTRODE OF SIZE 600 x 600 x 10mm WITH 2 NOS. 50 x

6 mm G.I.EARTH STRIPS UP TO TEST LINK, CLASS B 50 mm DIA

G.I.PIPE, FUNNEL WITH WIRE MESH FOR WATERING, ,SALT

CHARCOAL, 12MM G.I.COVER WITH NECESSARY BRICK

INSPECTION CHEMBER ETC. AS PER IS 3043, INCLUDING

SUPPLY & INSTALLTION OF EARTH PIT MARKER. REFER

ATTACHED STANDARD INSTALLATION DRAWING.

NO 4

EARTH BUS

25

SUPPLY OF EARTH BUS MADE WITH 75 X 12MM GI. FLAT OF

APPROXIMATE 850 MM. LENGTH INCLUDING DRILLING HOLE.

REFER ATTACHED STANDARD INSTALLATION DRAWING.

NO. 15

26

SUPPLY OF EARTH BUS MADE WITH 75 X 12MM GI. FALT OF

APPROXIMATE 550MM.LENGTH AS REQUIRED INCLUDING

DRILLING HOLE. REFER ATTACHED STANDARD INSTALLATION

DRAWING.

NO. 171

EARTH PIT MARKER

27

SUPPLY OF EARTH PIT MARKER INDICATING EARTH

RESISTANCE & TESTED DATE, NEXT DUE DATE FOR TESTING.


NO. 78

GI CABLE TRAYS

ALL THE CABLE TRAYS, BENDS AND BRANCHES, AS REQUIRED

SHALL BE SUPPLIED / FABRICATED BY CONTRACTOR.

RATE OF SUPPLY SHALL BE PAID ON THE BASIS OF RUNNING

METER ON THE CABLE TRAY MEASUREMENT. NO SEPARATE

RATE WILL BE PAID FOR BENDS AND BRANCHES.

TRAY COVERS SHALL BE PROVIDED FOR TOP MOST TRAY IN

OUT DOOR AREAS.

LADDER TYPE TRAYS

SUPPLY OF GI LADDER TYPE CABLE TRAYS OF FOLLOWING

SIZES :

28 300 MM WIDE GI TRAY MTR. 286



GI TRAY COVER

SUPPLY OF FRP TRAY COVERS TO SUIT FOLLOWING TRAY SIZES

:

31 300MM WIDE GI TRAY MTR. 160




UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008

SUPPLY OF CABLES OF VARIOUS GRADES (HT/LT) AND TYPES

(XLPE / PVC)

33 kV CABLES

33KV ( E ) EARTHED STRANDED ALLUMINIUM CONDUCTOR

SCREENED XLPE INSULATED ARMOURED CABLES EXTRUDED

FRLS PVC OUTER SHEATHED GENERALLY CONFORMING TO IS

7098 PART 2

34 3C X 300 SQMM A2XFaY MTR. 310

POWER CABLES

POWER CABLES: 600/1100V GRADE, XLPE INSULATED, AL/CU.

CONDUCTOR ARMOURED, EXTRUDED PVC INNER SHEATHED &

EXTRUDED FRLS PVC OUTER SHEATHED CONFORMING TO IS

7098 - PART 1.

35 1C X 630 A2XWaY MTRS. 53850

36 2C x 4 SQ.MM. A2XWY MTRS. 515


38 2C x 25 SQ.MM. A2XFY MTRS. 425

39 3C x 2.5 SQ.MM. Cu2XWY MTRS. 7000


41 3C x 25 SQ.MM. A2XFY MTR. 1985

42 3C x 50 SQ.MM. A2XFY MTR. 1555

43 3C x 70 SQ.MM. A2XFY MTR. 2275

44 3C x 95 SQ.MM. A2XFY MTR. 5485

45 3C x 120 SQ.MM. A2XFY MTR. 3455

46 3C x 150 SQ.MM. A2XFY MTR. 6115

47 3C x 185 SQ.MM. A2XFY MTR. 1625

48 3C x 240 SQ.MM. A2XFY MTR. 360

49 3.5C x 35 SQ.MM. A2XWY MTR. 4515

50 3.5C x 50 SQ.MM. A2XFY MTR. 1355

51 3.5C x 70 SQ.MM. A2XFY MTR. 1155

52 3.5C x 95 SQ.MM. A2XFY MTR. 3000

53 3.5C x 120 SQ.MM. A2XFY MTR. 4390

54 3.5C x 240 SQ.MM. A2XFY MTR. 1125

55 4C x 2.5 SQ.MM. Cu2XFY MTRS. 22650

56 4C x 4 SQ.MM. Cu2XFY MTRS. 220









CONTROL CABLES

CONTROL CABLES: 600/1100V GRADE, PVC INSULATED,COPPER

CONDUCTOR, WITH EXTRUDED PVC INNER SHEATHED,

EXTRUDED FRLS PVC OUTER SHEATHED FRLS CONFORMING TO

IS 1554 (PART 1).


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008

65 3C x 2.5 SQ.MM. YWY MTRS. 15415

66 4C x 2.5 SQ.MM. YWY MTRS. 640

67 7C x 2.5 SQ.MM. YWY MTRS. 18230

TERMINATIONS OF HT & LT CABLES

HT TERMINATION KIT

SUPPLY OF REPUTED MAKE HEAT SHRINKABLE HT

TERMINATION KITS FOR FOLLOWING SIZES OF CABLES.

INDOOR TYPE HEAT SHRINKABLE HT END TERMINATION KITS

SUITABLE FOR 33 kV GRADE XLPE INSULATED ALUMINIUM

CONDUCTOR CABLES OF FOLLOWING SIZES

68 3C X 300 A2XFaY NO. 8

OUTDOOR TYPE HEAT SHRINKABLE HT END TERMINATION KITS


CONDUCTOR CABLES OF FOLLOWING SIZES.

69 3C X 300 A2XFaY NO. 2

SUPPLY OF FLAMEPROOF TYPE DOUBLE COMPRESSION

(INDOOR) NICKEL PLATED BRASS CABLE GLAND, CRIMPING

TYPE TINNED COPPER LUGS & PVC/XLPE CABLE HOODS OF

FOLLOWING CABLES

LV POWER CABLE SIZES:

70 3C x 2.5 SQ.MM. Cu2XWY NO. 214

71 3C x 16 SQ.MM. A2XWY NO. 8

72 3C x 25 SQ.MM. A2XFY NO. 7




76 3C x 120 SQ.MM. A2XFY NO. 13

77 3C x 150 SQ.MM. A2XFY NO. 24



80 3.5C x 35 SQ.MM. A2XWY NO. 21

81 3.5C x 50 SQ.MM. A2XFY NO. 5

82 3.5C x 70 SQ.MM. A2XFY NO. 3

83 3.5C x 95 SQ.MM. A2XFY NO. 8

84 3.5C x 120 SQ.MM. A2XFY NO. 12

85 3.5C x 240 SQ.MM. A2XFY NO. 7

86 4C x 2.5 SQ.MM. Cu2XWY NO. 15






UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008


92 4C x 240 SQ.MM. A2XFY NO. 15


LV CONTROL CABLE SIZES:

94 3C x 2.5 SQ.MM. YWY NO. 54

95 7C x 2.5 SQ.MM. YWY NO. 63

SUPPLY OF INDSTRIAL TYPE DOUBLE COMPRESSION

(OUTDOOR) NICKEL PLATED BRASS CABLE GLAND, CRIMPING

TYPE TINNED COPPER LUGS & PVC/XLPE CABLE HOODS OF

FOLLOWING CABLES


96 1C X 630 A2XWaY NO. 380

97 2C x 4 SQ.MM. Cu2XWY NO. 20



100 3C x 2.5 SQ.MM. Cu2XWY NO. 124






106 3C x 120 SQ.MM. A2XFY NO. 13

107 3C x 150 SQ.MM. A2XFY NO. 24

108 3C x 185 SQ.MM. A2XFY NO. 6

109 3C x 240 SQ.MM. A2XFY NO. 1

110 3.5C x 35 SQ.MM. A2XWY NO. 21

111 3.5C x 50 SQ.MM. A2XFY NO. 5

112 3.5C x 70 SQ.MM. A2XFY NO. 3

113 3.5C x 95 SQ.MM. A2XFY NO. 8

114 3.5C x 120 SQ.MM. A2XFY NO. 12

115 3.5C x 240 SQ.MM. A2XFY NO. 7

116 4C x 2.5 SQ.MM. Cu2XWY NO. 303


118 4C x 10 SQ.MM. Cu2XFY NO. 6

119 4C x 16 SQ.MM. A2XFY NO. 13

120 4C x 25 SQ.MM. A2XFY NO. 13



123 4C x 185 SQ.MM. A2XFY NO. 8

124 4C x 240 SQ.MM. A2XFY NO. 15

125 4C x 300 SQ.MM. A2XFY NO. 8


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008


126 3C x 2.5 SQ.MM. YWY NO. 54

127 4C x 2.5 SQ.MM. YWY NO. 18

128 7C x 2.5 SQ.MM. YWY NO. 63

LIGHT FITTINGS:

NOTE:SUPPLY OF POLES TO BE EXCLUDED.THIS IS

CATEGORISED SEPERATELY UNDER "LIGHTING POLES"

SUPPLY OF FLAMEPROOF EXD TYPE SUITABLE FOR ZONE 1 & 2

GAS GROUP IIA / IIB TEMPERATURE CLASS T-3 WELLGLASS

FIXTURE IP - 55, WITH LAMP, INTEGRAL CONTROL GEAR BOX/

NON-INTEGRAL WITH SEPARATE CONTROL GEAR BOX, WIRE

GUARD & SUITABLE FOR SUSPENDED, BRACKET, POLE

MOUNTING. FIXING BRACKETS SHALL BE PROVIDED. LOOP IN

LOOP OUT FACILITY SHALL BE PROVIDED WITH MINIMUM

3NOS. OF ENTRIES SUITABLE FOR 3Cx2.5 SQ.MM. YWY CABLE

AND 1NO. SEALING PLUG.

129 2 X 26 W CFL - Cat. Ref. CGL-FWL12226IH/B or Equivalent NO. 24

130 150W (MH) - Cat. Ref.FWL 1215MHIH/A or Equivalent NO. 75

131250W (MH) (Non-Integral with separate Control Gear Box & Fuses) - Cat.

Ref. FWL 12/ANO. 49

SUPPLY OF INDUSTRIAL WELLGLASS FIXTURE IP - 55, WITH

LAMP, INTEGRAL CONTROL GEAR BOX/ NON-INTEGRAL WITH

SEPARATE CONTROL GEAR BOX, WIRE GUARD & SUITABLE FOR

SUSPENDED, BRACKET, POLE MOUNTING. FIXING BRACKETS

SHALL BE PROVIDED. LOOP IN LOOP OUT FACILITY SHALL BE

PROVIDED WITH MINIMUM 3NOS. OF ENTRIES SUITABLE FOR

3Cx2.5 SQ.MM. YWY CABLE AND 1NO. SEALING PLUG.

132 2 X 26 W CFL NO. 7

133 150W MH (INTEGRAL) NO. 17

134250W MH (NON-INTEGRAL) WITH SEPARATE CONTROL GEAR

BOX & FUSES.NO. 18

POST TOP LANTERN LIGHTINGS

135

SUPPLY OF INDUSTRIAL TYPE, POST TOP LANTERN FITTINGS,

WITH 125W HPMV TYPE WITH CONICAL COVER, ELECTRONIC

CONTROL GEAR (CAT. REF. PHILIPS-HPC101/125 HPF OR

EQUIVALENT). FIXING BRACKETS SHALL BE PROVIDED. LOOP

IN LOOP OUT FACILITY SHALL BE PROVIDED WITH MINIMUM

3NOS. OF ENTRIES SUITABLE FOR 3Cx2.5 SQ.MM. 2XWY CABLE

AND 1NO. SEALING PLUG. SUPPLY SHALL BE INCLUSIVE OF

NECESSARY HARDWARE.

NO. 4

136BOLLARD FIXTURES - (CAT. REF. PHILIPS-HCS360 1 X PL-C 18W

OR EQUIVALENT)NO. 60

SUPPLY OF INDUSTRIAL FLUROSCENT (FTL) FIXTURE, WITH

LAMP, BALLAST, SUITABLE FOR SUSPENDED/ SURFACE/

BRACKET MOUNTING. LOOP IN LOOP OUT FACILITY SHALL BE

PROVIDED WITH MINIMUM 3 NOS. OF ENTRIES SUITABLE FOR

3CX2.5 SQ.MM CABLE & 1 NO. SEALING PLUG.


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008

137 2 X 36W FTL - Cat. Ref. CGL-IGP 1424HSB or Equivalent NO. 8

138

SUPPLY OF INDUSTRIAL FLUROSCENT (FTL) FIXTURE, WITH

LAMP, BALLAST SUITABLE FOR BRACKET MOUNTING WITH

NECESSARY SUPPORTS FOR TRANSFORMER YARD.

NO. 4

Cat. Ref. CGL-IGP 1424HSB or Equivalent

SUPPLY OF INDUSTRIAL FLOOD LIGHT FIXTURE,WITH LAMP,

INTEGRAL CONTROL GEAR BOX & FUSES. NON CORROSIVE

HIGH PRESSURE DIE CAST ALUMINIUM HOUSING WITH LOW

COPPER CONTENT , HOT DIP GALVANISED STEEL MOUNTING

BRACKET AND COMPLETE WITH ALL THE ACCESSORIES.

LOOP IN LOOP OUT FACILITY SHALL BE PROVIDED WITH

MINIMUM 3NOS. OF M20 ENTRIES AND 1NO PLUG.

139 400W MH MOUNTED ON 11 MTR. POLE NO. 3

Cat. Ref. CGL-FAI40IH/MH or Equivalent

140 NON-FLAMEPROOF CHARGEABLE EMERGENCY LIGHTS NO. 5

CONTROL ROOM

TERMINAL IN-CHARGE ROOM

MCC ROOM-2

MAIN SUBSTATION

LIGHTING POLES

SUPPLY OF LIGHTING POLE AND ACCESSORIES.

141 MS TUBULAR/ OCTAGONAL LIGHTING POLE, HOT NO. 65

DIP GALVANISED, 5M HEIGHT FROM FINISHED

GROUND LEVEL. FOR WELLGLASS FIXTURE (125/250W )

WITH ALL ACCESSORIES



GROUND LEVEL. FOR WELLGLASS FIXTURE (400W )


JUNCTION BOX

SUPPLY OF FLAMEPROOF EXD TYPE SUITABLE FOR ZONE 1 & 2

GROUP IIA / IIB. TEMPERATURE CLASS T-3 JUNCTION BOX WITH

ACCESSORIES AS INDICATED BELOW. ENCLOSURE OF JUNCTION

BOX SHALL BE MADE UP OF CAST LIGHT METAL ALLOY.

JUNCTION BOX SHALL INCLUDE NECESSARY TERMINALS FOR

TERMINATING REQUIRED NUMBER OF CABLES AND WITH

SUITABLE ENTRIES. 16 AMP. CLAMP TYPE TERMINALS OF

ELMEX MAKE OR EQUIV. SHALL BE PROVIDED FOR ALL JBs. JB

SHALL HAVE AN EXTERNAL EARTH TERMINAL. JB SHALL BE

COMPLETE WITH REQUIRED SHORTING LINKS FOR LOOP IN

LOOP OUT OF CABLES.


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008

CONTRACTOR SHALL TAKE THE APPROVAL

OF THE DIMENSIONS FOR THIS JUNCTION

BOX FROM SITE ELECTRIAL ENGINEER.

143 4 WAY, WITH TERMINALS TO BE SUITABLE FOR NO. 1

ACCOMODATING ONE 3.5Cx50 SQ.MM. INCOMING

CABLES AND 3 NOS. 3Cx35 SQ.MM. OUTGOING

CABLES. WITH PLUGS

144 4 WAY, WITH TERMINALS TO BE SUITABLE FOR NO 1



CABLES. WITH PLUGS




CABLES. WITH PLUGS

146 4 WAY, WITH TWO M20 ENTRIES AND ONE M16 ENTRY. NO. 174

TERMINALS TO BE SUITABLE FOR ACCOMODATING

3Cx2.5 SQ.MM. OUTGOING CABLES WITH PLUGS

PANEL:

SUPPLY OF FOLLOWING 415V PANELS. THE PANELS SHALL BE

INDOOR, FLOOR/WALL MOUNTED WITH BOTTOM/TOP CABLE

ENTRY.

147CAPACITOR PANEL WITH CAPACITORS & APFC CONTROLLED

SYSTEM - FLOOR MOUNTED AS PER SLD & SPECIFICATIONSNO. 1

148 POWER DISTRIBUTION PANEL - PDP

FLOOR MOUNTED AS PER SLD & SPECIFICATIONNO. 2

149

MAIN LIGHTING DISTRIBUTION PANEL-MLDP WITH ENERGY

SAVER WITH TIMER & CONTACTOR FOR OUTDOOR LIGHTING

FEEDERS AS PER SLD & SPECIFICATION

(COMPARTMENTALISED, FLOOR MOUNTED, SINGLE FRONT

PANEL)

NO. 1

150

EMERGANCY LIGHTING DISTRIBUTION PANEL WITH ENERGY



(COMPARTMENTALISED, FLOOR MOUNTED, SINGLE FRONT)

NO. 1

151

YARD LIGHTING DISTRIBUTION PANEL WITH ENERGY SAVER

ALONG WITH TIMER FOR LIGHTING AS PER SLD &

SPECIFICATION

NO. 1

LIGHTING DISTRIBUTION BOARDS-LDB [WALL MOUNTED]


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008

FLAME PROOF ExD TYPE SUITABLE FOR ZONE 1 & ZONE 2 GAS

GROUP IIA / IIB, TEMPERATURE CLASS T-3. THE ENCLOSURE

SHALL BE MADE OF CAST LIGHT METAL ALLOY WITH SUITABLE

SIZE KNOCK OUT FOR CABLE CONNECTION WITH CANOPY.

INSTALLATION SHALL BE INCLUSIVE OF NECESSARY

HARDWARE AND EXCLUDING SUPPLY OF STEEL STRUCTURE.

TPN INCOMER WITH 3 NOS OF RCC Bs FOR EACH PHASE AND SP

OUT-GOING MCB (16kA) FOR LIGHTING. OPERATING KNOB

SHALL BE PROVIDED ON TOP SURFACE OF LDB AS PER SLD AND

SPECIFICATION

152 12 WAY NO. 4

153 18 WAY NO. 4

NORMAL INDUSTRIAL TYPE OUT DOOR - IP-55 LIGHTING

DISTRIBUTION BOARD (LDB) HAVING 2MM THICK SHEET STEEL.

TPN INCOMER WITH 3 NOS OF RCCBs FOR EACH PHASE & SP

OUT-GOING MCB (16KA) FOR LIGHTING AS PER SLD AND

SPECIFICATION

154 12 WAY NO. 2

155 18 WAY NO. 1

SMALL POWER DISTRIBUTION BOARD - SDB (WALL MOUNTED)

NORMAL INDUSTRIAL TYPE OUT DOOR IP-55 SMALL POWER

DISTRIBUTION BOARD (SDB) HAVING 2MM THICK SHEET STEEL.

INCOMER WITH 3 NOS OF RCCBs FOR EACH PHASE & SP OUT-

GOING MCB (16KA) FOR LIGHTING

156 18 WAY NO. 7

157 POWER DISTRIBUTION PANEL FOR MOVs


158OUTDOOR POWER DISTRIBUTION BOARD FOR MOVs


415 V BUSDUCT

SUPPLY OF FOLLOWING BUSDUCTS. SCOPE AS PER

SPECIFICATION AND EQUIPMENT LAYOUT INCLUDES SUPPLY

OF CONNECTIONS AT TRANSFORMER END AS WELL AS

SWITCHGEAR END, FLEXIBLE LINKS, CANOPY AND BUSDUCT

SUPPORTING ARRANGEMENTS.

159 BUSDUCT NO. BD-01 NO. 1

RATING : TPN 415V, 3200 AMPS.

NO.OF BENDS = 4

OUTDOOR LENGTH : HORIZONTAL= 2.6 Mtr.

VERTICAL= 4.5 Mtr.

INDOOR LENGTH : HORIZONTAL= 2.2 Mtr.

VERTICAL= 1.2 Mtr.


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008


RATING : 415V, 3200 AMPS.

NO.OF BENDS = 4


VERTICAL= 4.5 Mtr.


VERTICAL= 1.2 Mtr.

FANS ALONG WITH ACCESSORIES

SUPPLY OF EXHAUST FAN WITH STARTER.

EXHAUST / FRESH AIR FAN

161 450 DIA. SINGLE PHASE, 240V AC EXHAUST FAN NO 27

PIPES

GI PIPES

SUPPLY CLASS-B GI PIPE OF SIZES AS SPECIFIED BELOW TO BE

FIXED ON WALL STEEL STRUCTURE BURRIED IN GROUND, LAID

IN TRENCHES FOR PROTECTION OF CABLES EARTHING

CONDUCTORS OF INCLUDING BENDING, THREADING,

COUPLING, WELDING, CLAMPING AS REQUIRED.

162 75 MM DIA GI PIPE MTR. 25


PVC PIPES

SUPPLY OF PVC PIPES OF SIZES AS SPECIFIED BELOW TO BE

FIXED ON WALL OR STEEL STRUCTURE FOR CABLES IN WALL

OR STEEL STRUCTURE FOR CABLES INCLUDED BENDING AS

REQUIRED.


165 150 MM DIA PVC PIPE MTR. 110

HUME PIPES

SUPPLY OF HUME PIPES OF INNER

DIA. AS SPECIFIED BELOW TO BE LAID BURIED

UNDERGROUND FOR PROTECTION OF

CABLES / EARTHING CONDUCTORS WITH

REQUIRED COUPLING RINGS.

166 150 MM DIA HUME PIPE MTR. 25




UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

REMARKSSR.




Rev B



Doc No: 254625-300-SC-ELE-008

STRUCTURAL STEEL

SUPPLY OF

169 STRUCTURAL STEEL IN FORMS OF M.S. TON 35

ANGLES, CHANNELS, BEAMS, FLATS, ETC.

FOR SUPPORTING VARIOUS ITEMS / EQUIPMENT SUCH

AS SWITCHGEARS, PANELS, CABLE TRAYS, PUSH

BUTTON STATIONS, LOCAL CONTROL BOXES, LOCAL

CONTROL PANELS, JUNCTION BOXES, DISTRIBUTION

BOARDS, LIGHTING FITTINGS.

NOTES:-

PAYMENT AGAINST SUPPLY OF ALL ITEMS SHALL BE AS PER EXECUTED QTY. & RECONCILATION WILL BE DONE AT

FINAL BILLING STAGE. NECESSARY DEDUCTIONS SHALL BE MADE FOR CHANGE IN QTY. HENCE VENDOR TO

ASCERTAIN ACTUAL QTY. OF ELECTRICAL ITEMS TO BE SUPPLIED BEFORE PROCURING.

PAYMENT AGAINST SUPPLY OF CABLES SHALL BE AS PER EXECUTED QTY & RECONCILATON WILL BE DONE AT FINAL BILLING

STAGE. ANY EXCESS SUPPLY OF CABLE SHALL BE PROPERTY OF CONTRACTOR & SAME SHALL NOT BE PAID FOR.

IF PAYMENT IS DONE DURING RUNNING BILLS AGAINST SUPPLY, NECESSARY DEDUCTIONS SHALL BE MADE FOR QTY.

HENCE VENDOR TO ASCERTAIN ACTUAL QUANTITY OF CABLE TO BE SUPPLIED BEFORE PROCURING.

IT SHALL BE VENDORS RESPONSIBILITY TO MAKE SUITABLE DRUM SCHEDULE BASED ON SITE ROUTING & ACTUAL REQUIREMENT.

STRAIGHT THROUGH JOINTS SHALL NOT BE ACCEPTABLE.

UNDER EXCEPTIONALLY LONG LENGTHS STRAIGHT THROUGH JOINTS CAN BE ACCEPTED BY SITE ENGINEER AT HIS DISCRETION.

HOWEVER COST FOR SUPPLY & INSTALLATION OF STRAIGHT THROUGH JOINT WILL BE AT RISK & COST OF VENDOR.

ANY PART OF EQUIPMENT OR COMPONENT NOT SPECIFICALLY MENTIONED IN SOQ, BUT REQUIRED FOR MAKING THE

INSTALLATION COMPLETE, SAFE AND RELIABLE SHOULD BE PROVIDED BY THE CONTRACTOR AT NO EXTRA COST.


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)

NOTE : INSTALLATION RATE SHALL INCLUDE SUPPLY OF

CONSUMABLES AND HARDWARE AND EXCLUDING SUPPLY OF

STRUCTURAL STEEL SINCE THIS IS CATEGORISED SEPERATELY.

FOUR POLE STRUCTURE

1

INSTALLATION, TESTING AND COMMISSIONING OF FOUR POLE

STRUCTURE. FOUR POLE STRUCTURE SHALL BE WITH

BRACINGS AND CROSS ARMS FOR SUPPORTING THE PIN / OR

STRAIN INSULATORS. EACH POLE SHALL BE HEAVY DUTY RAIL

(IRS - HSB) HAVING A UNIT WEIGHT OF 52 KG / METER. FOUR

POLE STRUCTURE SHALL INCLUDE GOD, LA, EARTH SWITCH, CT,

PT, METERING CUIBICAL, INSULATORS AND JUMPER ETC AS PER

SPECIFICATIONS , SLD AND APSEB GUIDELINE.

SET 1

2

LAYING OF 33KV ( E ) 3C X 400 Sq.mm STRANDED ALLUMINIUM

CONDUCTOR SCREENED XLPE INSULATED ARMOURED CABLES

EXTRUDED FRLS PVC OUTER SHEATHED WITH NECESSARY

ACCESSORIES & 33kV OUTDOOR TYPE TERMINATION KITS.

GENERALLY CONFORMING TO IS 7098 PART 2 FOR CONVERSION

OF OVER HEAD LINE TO UNDER GROUND CABLE SYSTEM.

MTR. 200TWO RUNS EACH OF 100

Mtr.

LOCAL CONTROL STATION

FLAME PROOF LOCAL CONTROL STATIONS

INSTALLATION, TESTING & COMMISSIONING OF FLAME PROOF Ex-

d FOLLOWING TYPE LOCAL CONTROL STATION SUITABLE FOR

ZONE - 1 & 2 GASS GROUP II A & II B. TEMPERATURE CLASS - T3 IP-

55. THE ENCLOSURE SHALL BE MADE OF CAST LIGHT METAL

ALLOY WITH 2 NOS SUITABLE SIZE KNOCK OUTS FOR CABLE

CONNECTION WITH CANOPY. INSTALLATION SHALL BE

INCLUSIVE OF NECESSARY HARDWARE AND EXCLUDING SUPPLY

OF STRUCTURAL STEEL

3 EMERGENCY STOP PUSH BUTTON TYPE A NO. 5


SWITCH & AMMENTIES TYPE BNO. 33

INDUSTRIAL TYPE LOCAL CONTROL STATION

INSTALLATION, TESTING & COMMISSIONING OF INDUSTRIAL

FOLLOWING TYPE LOCAL CONTROL STATION THE ENCLOSURE

SHALL BE MADE OF CAST LIGHT METAL ALLOY IP-55 WITH 2 NOS

SUITABLE SIZE KNOCK OUTS FOR CABLE CONNECTION WITH

CANOPY. INSTALLATION SHALL BE INCLUSIVE OF NECESSARY

HARDWARE AND EXCLUDING SUPPLY OF STRUCTURAL STEEL

5 EMERGENCY STOP PUSH BUTTON TYPE C NO. 2


SWITCH & AMMENTIES TYPE DNO. 22

SOCKET OUTLETS

INSTALLATION,TESTING AND COMMISSIONING OF FOLLOWING

TYPE SWITCH- SOCKET OUTLETS. INSTALLATION SHALL BE

INCLUSIVE OF NECESSARY HARD WARE AND EXCLUDING

SUPPLY OF STRUCTURAL STELL.

FLAMEPROOF Ex-d TYPE SUITABLE FOR ZONE-1 & ZONE-2,

GAS GROUP IIA/IIB. TEMPERATURE CLASS - T3 IP-55 SWITCH

SOCKET UNITS



Rev BDoc No: 254625-300-SC-ELE-009


PART B : INSTALLATION OF EQUIPMENT IN CONTRACTORS SCOPE

REMARKSSR.


P:\Andheri\IndiaProject\254625 HPCL- Black Oil Terminal\Procurement\Electrical Bulk\Electrical Work Tender\08.10.09\Editable\Schedule of Qty for Electrical Bulks-BO-Rev.B_08.10.0913 of 30

UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


763A TPN THREE PHASE 440VOLTS 5PINS SWITCH SOCKET

OUTLETSNO. 13

INDUSTRIAL TYPE (NON FLAME PROOF ) IP-55

8 63A TPN THREE PHASE 440VOLTS 5PIN SOCKET OUTLET NO. 6

9 16A SINGLE PHASE 240 VOLTS 3PIN SWITCH SOCKET OUTLETS NO. 5

10 16A, 240V SINGLE POLE SWITCH NO. 4

MAINTENANCE FREE EARTHING & LIGHTNING PROTECTION

SYSTEM

EARTHING STRIPS

INSTALLATION OF HOT DIPPED GALVANISED (GI) BARE EARTH

CONDUCTOR OF FULLY WELDED AND COATED WITH TWO

COATS OF BITUMEN PAINT. THE GI COATING SHALL BE 85

MICRON.

TERMINATION SHALL BE BOLTED GI STRIP TO BE LAID IN

GROUND, ON TRAY, CLEATED ALONG BRICK WALL / RCC WALL /

STRUCTURE, ETC. DRILLED AND FIXED WITH 'J' BOLT ON TOP OF

ASBESTOS ROOF, ETC. THE INSTALLATION RATE SHALL INCLUDE

SUPPLY OF ALL HARDWARES MATERIAL.






GI WIRE ROPES

INSTALLATION OF GI WIRE / WIRE ROPE OF STRANDED TYPE

WIRES OF FOLLOWING SIZES. END TERMINATION TO BE BOLTED

AFTER LUGGING WITH SUITABLE SOLDER TYPE ALUMINIUM

LUGS. THE INSTALLATION RATE SHALL INCLUDE SUPPLY OF

LUGS AND ALL HARDWARES MATERIAL.

16 8 SWG GI WIRE MTR. 4728

EARTHING CABLES

INSTALLATION OF 600 V CABLES OF FOLLOWING SIZES WITH

SUPPLY OF LUGS & ALL HARDWARE MATERIALS.





MAINTENANCE FREE EARTHING PITS & PLATE EARTH

ELECTRODE

INSTALLATION, TESTING & COMMISSIONING OF EARTH PITS

INCLUDING ALL CIVIL WORK SUCH AS EXCAVATION BORING FOR

THE FOLLOWING TYPE. REFER ATTACHED STANDARD

INSTALLATION DRAWINGS.


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


NOTE:- CONTRACTOR TO SUBMIT NECESSARY TEST

CERTIFICATES FOR ALL EARTH PITS & COMPLETE EARTHING

SYSTEM AFTER COMPLETION OF WORK.

TRIPOD EARTH ELECTRODE:

21

TRIANGULAR TERMINATION CONSISTS OF A SET OF THREE

COPPER-BONDED STEEL EARTH RODS OF 2M EACH ARRANGED IN

A TRIANGULAR FASHION & SEPARATED FROM EACH OTHER BY A

DISTANCE AT LEAST EQUAL TO THEIR DRIVEN DEPTH &

INTERCONNECTED BY A FLAT COPPER CONDUCTOR (COPPER

STRIP) WITH INSPECTION CHAMBER AS PER STANDARD


NO 78

G.I. PLATE EARTH ELECTRODE

22

G.I.PLATE ELECTRODE OF SIZE 600 x 600 x 10mm WITH 2 NOS. 50 x 6

mm G.I.EARTH STRIPS UP TO TEST LINK, CLASS B 50 mm DIA

G.I.PIPE, WITH FUNNEL AND WIRE MESH FOR WATERING, ,SALT

CHARCOAL, 12MM G.I.COVER WITH NECESSARY BRICK

INSPECTION CHEMBER ETC. AS PER IS 3043, INCLUDING SUPPLY

& INSTALLTION OF EARTH PIT MARKER AS PER ENCLOSED

DRAWING. REFER ATTACHED STANDARD INSTALLATION

DRAWING.

NO 4

EARTH BUS

23

INSTALLATION OF EARTH BUS MADE WITH 75 X 12MM GI. FLAT

OF APPROXIMATE 850 MM. LENGTH INCLUDING DRILLING HOLE

& INSTALLED ON TRAY INCLUDIMG PAINTING WITH

BITUMINOUS PAINT AS REQUIRED. REFER ATTACHED STANDARD

INSTALLATION DRAWINGS.

NO. 15

24

INSTALLATION OF EARTH BUS MADE WITH 75 X 12MM GI. FLAT

OF APPROXIMATE 550MM.LENGTH INCLUDING DRILLING HOLE

INSTALLED ON TRAY INCLUDIMG PAINTING WITH BITUMINOUS

PAINT AS REQUIRED. REFER ATTACHED STANDARD


NO. 171

EARTH PIT MARKER

25

INSTALLATION OF EARTH PIT MARKER INDICATING EARTH

RESISTANCE & TESTED DATE, NEXT DUE DATE FOR TESTING.


NO. 78

GI CABLE TRAYS

INSTALLATION SHALL INCLUDE ALIGNING, JOINING, [INCLUDING

BENDS AND BRANCHES] ALONG WITH NECESSARY ACCESSORIES

& HARDWARE.

-

RATE OF INSTALLATION SHALL BE PAID ON THE BASIS OF

RUNNING METER ON THE CABLE TRAY MEASUREMENT. NO

SEPARATE RATE WILL BE PAID FOR BENDS AND BRANCHES.

LADDER TYPE TRAYS

INSTALLATION OF GI LADDER TYPE CABLE TRAYS OF

FOLLOWING SIZES :





UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


GI TRAY COVER

INSTALLATION OF GI TRAY COVERS TO SUIT FOLLOWING TRAY

SIZES :




HV & LV CABLE LAYING ON TRAYS

LAYING AND DRESSING OF CABLES OF VARIOUS GRADES (HT /

LT) AND TYPES (PVC / XLPE) IN READY TRENCH/ TRAYS

SUPPORTED ON PIPE RACK STRUCTURES AT VARIOUS

LOCATIONS, IN CABLE CELLAR INSIDE SUBSTATION. THE SCOPE

INCLUDES SUPPLY AND FIXING OF ALUMINIUM STRIP NUMBER

TAGS. SUPPLY AND FIXING OF GI SADDLE AND CLAMPS ON

TRAYS AND NECESSARY HARDWARES. THE CABLE LAYING

WORK SHALL INCLUDE TRANSPORTATION OF CABLE DRUMS

FROM OWNER'S STORE, CUTTING OF CABLE LENGTH AS PER

ACTUAL MEASUREMENT AND CABLE SCHEDULE, RETURNING OF

UNUSED CABLES TO THE OWNERS STORE DULY MEASURED IN

THEIR PRESENCE.

33 kV, STRANDED AL CONDUCTOR, SCREENED, XLPE INSULATED,

ARMOURED CABLES, EXTRUDED FRLS PVC OUTER SHEATHED

GENERALLY CONFIRMING TO IS 7098 - PART 2.

32 3C X 300 A2XFaY MTR. 90

POWER CABLES: 600/1100V GRADE, XLPE INSULATED, AL/ CU.

CONDUCTOR, ARMOURED, EXTRUDED PVC INNER SHEATHED &

EXTRUDED FRLS PVC OUTER SHEATHED CONFORMING TO IS 7098

- PART 1.

33 1C X 630 A2XWaY MTRS. 5385




37 3C x 16 SQ.MM. A2XFY MTR. 150





42 3C x 120 SQ.MM. A2XFY MTR. 350

43 3C x 150 SQ.MM. A2XFY MTR. 610

44 3C x 185 SQ.MM. A2XFY MTR. 160


46 3.5C x 35 SQ.MM. A2XWY MTR. 450

47 3.5C x 50 SQ.MM. A2XFY MTR. 140

48 3.5C x 70 SQ.MM. A2XFY MTR. 110

49 3.5C x 95 SQ.MM. A2XFY MTR. 300

50 3.5C x 120 SQ.MM. A2XFY MTR. 440

51 3.5C x 240 SQ.MM. A2XFY MTR. 110





UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.







60 4C x 240 SQ.MM. A2XFY MTR. 720

61 4C x 300 SQ.MM. A2XFY MTR. 450




IS 1554 (PART 1).

62 3C x 2.5 SQ.MM. YWY MTRS. 1540


64 7C x 2.5 SQ.MM. YWY MTRS. 1820

HV & LV CABLES DIRECTLY BURIED IN GROUND

LAYING AND DRESSING OF CABLES OF VARIOUS GRADES (HT /

LT) AND TYPES (PVC / XLPE) OF CABLES DIRECTLY BURIED IN

GROUND AT VARIOUS LOCATIONS. THE SCOPE INCLUDES SUPPLY

AND FIXING OF CABLE ROUTE MARKER. SUPPLY AND FIXING OF

CABLE PROTECTION TILES OR FIRE PROOF INTERLOCKED

BRICKS WITH CEMENT& RIVER SAND ON THE SURFACE, BACK

FILLED CABLE TRENCHES AND NECESSARY HARDWARE. THE

CABLE LAYING WORK SHALL INCLUDE TRANSPORTATION OF

CABLE DRUMS FROM OWNER'S STORE, CUTTING OF CABLE

LENGTH AS PER ACTUAL MEASUREMENT AND CABLE SCHEDULE,

RETURNING OF UNUSED CABLES TO THE OWNERS STORE DULY

MEASURED IN THEIR PRESENCE.

33 kV, STRANDED AL CONDUCTOR, SCREENED, XLPE INSULATED,

ARMOURED CABLES, EXTRUDED FRLS PVC OUTER SHEATHED

GENERALLY CONFORMING TO IS 7098 - PART 2.

65 3C X 300 A2XFaY MTR. 220

POWER CABLES: 600/1100V GRADE, XLPE INSULATED,AL/CU.



IS 7098 - PART 1.

66 1C X 630 A2XWaY MTRS. 48465





71 3C x 16 SQ.MM. A2XFY MTR. 1350

72 3C x 25 SQ.MM. A2XFY MTR. 1785

73 3C x 50 SQ.MM. A2XFY MTR. 1400

74 3C x 70 SQ.MM. A2XFY MTR. 2048

75 3C x 95 SQ.MM. A2XFY MTR. 4935

76 3C x 120 SQ.MM. A2XFY MTR. 3105

77 3C x 150 SQ.MM. A2XFY MTR. 5505

78 3C x 185 SQ.MM. A2XFY MTR. 1465

79 3C x 240 SQ.MM. A2XFY MTR. 325


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


80 3.5C x 35 SQ.MM. A2XWY MTR. 3840

81 3.5C x 50 SQ.MM. A2XFY MTR. 1140

82 3.5C x 70 SQ.MM. A2XFY MTR. 980

83 3.5C x 95 SQ.MM. A2XFY MTR. 2700

84 3.5C x 120 SQ.MM. A2XFY MTR. 3950

85 3.5C x 240 SQ.MM. A2XFY MTR. 1015









94 4C x 240 SQ.MM. A2XFY MTR. 6405

95 4C x 300 SQ.MM. A2XFY MTR. 4075




(PART 1).

96 3C x 2.5 SQ.MM. YWY MTRS. 12330


98 7C x 2.5 SQ.MM. YWY MTRS. 15490

LV CABLES CLEATED ON WALL / SLAB / STRUCTURE

CLEATING OF CABLES OF VARIOUS GRADES (HT / LT) AND TYPES

(PVC / XLPE) OF CABLES ON WALL / STRUCTURE / SLAB. SCOPE

SHALL INCLUDE FIXING OF CLAMP,MATERIAL, SUPPLY OF

CABLE, IDENTIFICATION TAG.

POWER CABLES: 600/1100V GRADE, XLPE INSULATED,AL/CU.



- PART 1.


100 3.5C x 35 SQ.MM. A2XWY MTR. 225

101 3.5C x 50 SQ.MM. A2XFY MTR. 75

102 3.5C x 70 SQ.MM. A2XFY MTR. 65








(PART 1).

107 3C x 2.5 SQ.MM. YWY MTRS. 1545

108 7C x 2.5 SQ.MM. YWY MTRS. 920


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


TERMINATIONS OF HT & LT CABLES

HT TERMINATION KIT

TERMINATION OF HT CABLE WITH REPUTED MAKE HEAT

SHRINKABLE HT TERMINATION KITS FOR FOLLOWING SIZES OF

CABLES. SCOPE ALSO INCLUDES PREPARATION FOR

CONNECTION (CRIMPING OF SUITABLE LONG SHRUNK LUG) AND

HIGH POT TESTING

INDOOR TYPE HEAT SHRINKABLE HT END TERMINATION KITS


CONDUCTOR CABLES OF FOLLOWING SIZES

109 3C X 300 SQ.MM A2XFaY NO. 8

OUTDOOR TYPE HEAT SHRINKABLE HT END TERMINATION KITS


CONDUCTOR CABLES OF FOLLOWING SIZES.

110 3C X 300 SQ.MM A2XFaY NO. 2

TERMINATION OF LT PVC/XLPE INSULATED CABLES INCLUDING

INSTALLATION OF FLAMEPROOF TYPE DOUBLE COMPRESSION

(INDOOR) NICKEL PLATED BRASS CABLE GLAND, CRIMPING TYPE

TINNED COPPER LUGS & PVC/XLPE CABLE HOODS.


111 3C x 2.5 SQ.MM. Cu2XWY NO. 214






117 3C x 120 SQ.MM. A2XFY NO. 13

118 3C x 150 SQ.MM. A2XFY NO. 24

119 3C x 185 SQ.MM. A2XFY NO. 6

120 3C x 240 SQ.MM. A2XFY NO. 1

121 3.5C x 35 SQ.MM. A2XWY NO. 21

122 3.5C x 50 SQ.MM. A2XFY NO. 5

123 3.5C x 70 SQ.MM. A2XFY NO. 3

124 3.5C x 95 SQ.MM. A2XFY NO. 8

125 3.5C x 120 SQ.MM. A2XFY NO. 12

126 3.5C x 240 SQ.MM. A2XFY NO. 7

127 4C x 2.5 SQ.MM. Cu2XWY NO. 15


129 4C x 16 SQ.MM. A2XFY NO. 13

130 4C x 25 SQ.MM. A2XFY NO. 13


132 4C x 185 SQ.MM. A2XFY NO. 6

133 4C x 240 SQ.MM. A2XFY NO. 15

134 4C x 300 SQ.MM. A2XFY NO. 8


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.



135 3C x 2.5 SQ.MM. YWY NO. 54

136 7C x 2.5 SQ.MM. YWY NO. 63

TERMINATION OF LT PVC/XLPE INSULATED CABLES INCLUDING

INSTALLATION OF INDUSTRIAL TYPE DOUBLE COMPRESSION

(OUTDOOR) NICKEL PLATED BRASS CABLE GLAND, CRIMPING

TYPE TINNED COPPER LUGS & PVC/XLPE CABLE HOODS.


137 1C x 630SQ.MM A2XWaY NO. 380

138 2C x 4 SQ.MM. Cu2XWY NO. 20

139 2C x 10 SQ.MM. A2XWY NO. 10


141 3C x 2.5 SQ.MM. Cu2XWY NO. 124






147 3C x 120 SQ.MM. A2XFY NO. 13

148 3C x 150 SQ.MM. A2XFY NO. 24

149 3C x 185 SQ.MM. A2XFY NO. 6

150 3C x 240 SQ.MM. A2XFY NO. 1

151 3.5C x 35 SQ.MM. A2XWY NO. 21

152 3.5C x 50 SQ.MM. A2XFY NO. 5

153 3.5C x 70 SQ.MM. A2XFY NO. 3

154 3.5C x 95 SQ.MM. A2XFY NO. 8

155 3.5C x 120 SQ.MM. A2XFY NO. 12

156 3.5C x 240 SQ.MM. A2XFY NO. 7

157 4C x 2.5 SQ.MM. Cu2XWY NO. 303

158 4C x 4 SQ.MM. Cu2XFY NO. 4


160 4C x 16 SQ.MM. A2XFY NO. 13

161 4C x 25 SQ.MM. A2XFY NO. 13



164 4C x 185 SQ.MM. A2XFY NO. 8

165 4C x 240 SQ.MM. A2XFY NO. 15

166 4C x 300 SQ.MM. A2XFY NO. 8


167 3C x 2.5 SQ.MM. YWY NO. 54

168 4C x 2.5 SQ.MM. YWY NO. 18

169 7C x 2.5 SQ.MM. YWY NO. 63


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


LIGHT FITTINGS:

NOTE:INSTALLTION OF POLES TO BE EXCLUDED.THIS IS

CATEGORISED SEPERATELY UNDER "LIGHTING POLES"

INSTALLTION, TESTING & COMMISSIONING OF FLAMEPROOF

EXD TYPE SUITABLE FOR ZONE 1 & 2 GAS GROUP IIA / IIB

TEMPERATURE CLASS T-3 WELLGLASS FIXTURE, WITH LAMP,

INTEGRAL CONTROL GEAR BOX/ NON-INTEGRAL CONTROL GEAR

BOX, WIRE GUARD & SUITABLE FOR SUSPENDED, BRACKET, POLE

MOUNTING. FIXING BRACKETS SHALL BE PROVIDED. LOOP IN

LOOP OUT FACILITY SHALL BE PROVIDED WITH MINIMUM 3NOS.

OF ENTRIES SUITABLE FOR 3Cx2.5 SQ.MM. YWY CABLE AND 1NO.

SEALING PLUG. INSTALLATION SHALL BE INCLUSIVE OF

NECESSARY HARDWARE AND EXCLUDING SUPPLY OF

STRUCTURAL STEEL.

2 X 26 W CFL - (Cat. Ref. CGL-FWL12226IH/B or Equivalent)

WITH FOLLOWING MOUNTING TYPE

170 GROUND POLE MOUNTED NO. 24

BRACKET/ CEILING MOUNTED NO.

STRUCTURE MOUNTED NO.

150W MH - (Cat. Ref. FWL 1215MHIH/A or Equivalent) NO.


GROUND POLE MOUNTED NO.

171 BRACKET/ CEILING MOUNTED NO. 75


250W MH (Non-Integral with separate Control Gear Box & Fuses) - Cat.

Ref. FWL 12/ANO.





INSTALLTION, TESTING & COMMISSIONING OF INDUSTRIAL

WELLGLASS FIXTURE, WITH LAMP, INTEGRAL CONTROL GEAR

BOX/ NON-INTEGRAL CONTROL GEAR BOX, WIRE GUARD &

SUITABLE FOR SUSPENDED, BRACKET, POLE MOUNTING. FIXING

BRACKETS SHALL BE PROVIDED. LOOP IN LOOP OUT FACILITY

SHALL BE PROVIDED WITH MINIMUM 3NOS. OF ENTRIES

SUITABLE FOR 3Cx2.5 SQ.MM. YWY CABLE AND 1NO. SEALING

PLUG. INSTALLATION SHALL BE INCLUSIVE OF NECESSARY

HARDWARE AND EXCLUDING SUPPLY OF STRUCTURAL STEEL.

2 X 26 W CFL



UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.





150W MH - (INTEGRAL) NO.


GROUND POLE MOUNTED NO.



250W MH - (NON-INTEGRAL) WITH SEPARATE CONTROL GEAR

BOX & FUSES.NO.





POST TOP LANTERN LIGHTINGS

177


TYPE, POST TOP LANTERN FITTINGS, WITH 125W HPMV TYPE

WITH CONICAL COVER, ELECTRONIC CONTROL GEAR (CAT.

REF. PHILIPS-HPC101/125 HPF OR EQUIVALENT). FIXING

BRACKETS SHALL BE PROVIDED. LOOP IN LOOP OUT FACILITY

SHALL BE PROVIDED WITH MINIMUM 3NOS. OF ENTRIES

SUITABLE FOR 3Cx2.5 SQ.MM. 2XWY CABLE AND 1NO. SEALING

PLUG. INSTALLATION SHALL BE INCLUSIVE OF NECESSARY

HARDWARE.

NO. 4

178BOLLARD FIXTURES - (CAT. REF. PHILIPS-HCS360 1 X PL-C 18W

OR EQUIVALENT)NO. 60

INSTALLATION, TESTING & COMMISSIONING OF INDUSTRIAL

TYPE, FLUROSCENT (FTL) FIXTURE, WITH LAMP, BALLAST,

SUITABLE FOR SUSPENDED, SURFACE, BRACKET MOUNTING.

LOOP IN LOOP OUT FACILITY SHALL BE PROVIDED WITH

MINIMUM 3 NOS. OF ENTRIES SUITABLE FOR 3CX2.5 SQ.MM

CABLE & 1 NO. SEALING PLUG. INSTALLATION SHALL BE

INCLUSSIVE OF ALL NECESSARY HARDWARE.

179 2 X 36W FTL - Cat. Ref. CGL-IGP 1424HSB or Equivalent NO. 8

180

INSTALLATION OF INDUSTRIAL FLUROSCENT (FTL) FIXTURE,

WITH LAMP, BALLAST SUITABLE FOR BRACKET MOUNTING WITH

NECESSARY SUPPORTS FOR TRANSFORMER YARD.

NO. 4

Cat. Ref. CGL-IGP 1424HSB or Equivalent


FLOOD LIGHT FIXTURE,WITH LAMP, INTEGRAL CONTROL

GEAR BOX & FUSES. NON CORROSIVE HIGH PRESSURE DIE CAST

ALUMINIUM HOUSING WITH LOW COPPER CONTENT , HOT DIP

GALVANISED STEEL MOUNTING BRACKET AND COMPLETE

WITH ALL THE ACCESSORIES. LOOP IN LOOP OUT FACILITY

SHALL BE PROVIDED WITH MINIMUM 3NOS. OF M20 ENTRIES

AND 1NO PLUG. INSTALLATION SHALL BE INCLUSIVE OF

NECESSARY HARDWARE.


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


181400W MH MOUNTED ON 11 MTR. POLE - Cat. Ref. CGL-

FAI40IH/MH or Equivalent NO. 3

182NON-FLAMEPROOF CHARGEABLE EMERGENCY LIGHTS TO BE

PROVIDED IN THE FOLLOWING AREAS:NO. 5

CONTROL ROOM NO. 1

TERMINAL IN-CHARGE ROOM NO. 1

MCC ROOM-2 NO. 1

MAIN SUBSTATION NO. 2

LIGHTING POLES

INSTALLATION OF LIGHTING POLE AND ACCESSORIES

INCLUSSIVE OF MARSHALLING BOX/ JUNCTION BOX, SUPPLY OF

PVC INSULATED FLEXIBLE WIRE BETWEEN MARSHALLING BOX/

JUNCTION BOX AND LIGHTING FITTING AND ALL NECESSARY

HARDWARE. ALL OTHER CIVIL WORK, AS REQUIRED, INCLUDING

EXCAVATION, PROVIDING SHUTTERING, FOUNDATION,

DEWATERING, CONCRETE PEDESTAL ETC. SHALL BE BY

ELECTRICAL CONTRACTOR.



GROUND LEVEL. FOR WELLGLASS FIXTURE (125W / 250W )




GROUND LEVEL. FOR WELLGLASS FIXTURE (400W )


JUNCTION BOX

INSTALLATION OF FLAMEPROOF EXD TYPE SUITABLE FOR ZONE

1 & 2 GROUP IIA / IIB. TEMPERATURE CLASS T-3 JUNCTION BOX

WITH ACCESSORIES AS INDICATED BELOW. ENCLOSURE OF

JUNCTION BOX SHALL BE MADE UP OF CAST LIGHT METAL

ALLOY.

INSTALLATION SHALL BE INCLUSIVE OF NECESSARY

HARDWARE AND EXCLUDING SUPPLY OF STRUCTURAL STEEL.

185 4 WAY, WITH TERMINALS TO BE SUITABLE FOR NO. 1



CABLES. WITH PLUGS




CABLES. WITH PLUGS




CABLES. WITH PLUGS

188 4 WAY, WITH TWO M20 ENTRIES AND ONE M16 ENTRY. NO. 174

TERMINALS TO BE SUITABLE FOR ACCOMODATING

3Cx2.5 SQ.MM. OUTGOING CABLES WITH PLUGS


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


PANEL:

INSTALLATION, TESTING AND COMMISSIONING OF FOLLOWING

415V PANELS. THE PANELS SHALL BE INDOOR, FLOOR/WALL

MOUNTED WITH BOTTOM/TOP CABLE ENTRY. INSTALLATION

SHALL BE INCLUSIVE OF NECESSARY HARDWARE AND

EXCLUDING SUPPLY OF STEEL STRUCTURE

189CAPACITOR PANEL WITH CAPACITORS & APFC CONTROLLED

SYSTEM - FLOOR MOUNTED AS PER SLD & SPECIFICATIONSNO. 1

190 POWER DISTRIBUTION PANEL - PDP


191

MAIN LIGHTING DISTRIBUTION PANEL-MLDP WITH ENERGY



(COMPARTMENTALISED, FLOOR MOUNTED, SINGLE FRONT

PANEL)

NO. 1

192

EMERGANCY LIGHTING DISTRIBUTION PANEL WITH ENERGY


FEEDERS AS PER SLD & SPECIFICATION (COMPARTMENTALISED,

FLOOR MOUNTED, SINGLE FRONT)

NO. 1

193YARD LIGHTING DISTRIBUTION PANEL WITH ENERGY SAVER

ALONG WITH TIMER FOR LIGHTING AS PER SLD & SPECIFICATIONNO. 1

LIGHTING DISTRIBUTION BOARDS-LDB [WALL MOUNTED]

FLAME PROOF ExD TYPE SUITABLE FOR ZONE 1 & ZONE 2 GAS

GROUP IIA / IIB, TEMPERATURE CLASS T-3. THE ENCLOSURE

SHALL BE MADE OF CAST LIGHT METAL ALLOY WITH SUITABLE

SIZE KNOCK OUT FOR CABLE CONNECTION WITH CANOPY.

TPN INCOMER WITH 3 NOS OF RCC Bs FOR EACH PHASE AND SP

OUT-GOING MCB (16kA) FOR LIGHTING. OPERATING KNOB SHALL

BE PROVIDED ON TOP SURFACE OF LDB AS SLD AND

SPECIFICATION.

194 12 WAY 4

195 18 WAY 4

NORMAL INDUSTRIAL TYPE OUT DOOR - IP-55 LIGHTING

DISTRIBUTION BOARD (LDB) HAVING 2MM THICK SHEET STEEL

WITH SUITABLE SIZE KNOCK OUT FOR CABLE CONNECTION

WITH CANOPY. TPN INCOMER WITH 3 NOS OF RCCBs FOR EACH

PHASE & SP OUT-GOING MCB (16KA) FOR LIGHTING AS PER SLD

AND SPECIFICATION

196 12 WAY NO. 2

197 18 WAY NO. 1

SMALL POWER DISTRIBUTION BOARD - SDB (WALL MOUNTED)


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


NORMAL INDUSTRIAL TYPE OUT DOOR IP-55 SMALL POWER

DISTRIBUTION BOARD (SDB) HAVING 2MM THICK SHEET STEEL

WITH SUITABLE SIZE KNOCK OUT FOR CABLE CONNECTION

WITH CANOPY. INCOMER WITH 3 NOS OF RCCBs FOR EACH

PHASE & SP OUT-GOING MCB (16KA) FOR LIGHTING

198 18 WAY NO. 7

199 POWER DISTRIBUTION PANEL FOR MOVs


200OUTDOOR POWER DISTRIBUTION BOARD FOR MOVs


415 V BUSDUCT

INSTALLATION, TESTING AND COMMISSIONING OF FOLLOWING

BUSDUCTS. SCOPE AS PER SPECIFICATION AND EQUIPMENT

LAYOUT INCLUDES TRANSPORTATION TO THE PLACE OF

INSTALLATION, ASSEMBLY AND JOINING OF SHIPPING SECTIONS,

CONNECTIONS AT TRANSFORMER END AS WELL AS SWITCHGEAR

END INCLUDING FIXING OF FLEXIBLE LINKS, CANOPY AND

BUSDUCT SUPPORTING ARRANGEMENTS. WALL CUTOUTS SHALL

BE SUITABLY SEALED.


RATING : TPN 415V, 3200 AMPS.

NO.OF BENDS = 4


VERTICAL= 4.5 Mtr.


VERTICAL= 1.2 Mtr.


RATING : 415V, 3200 AMPS.

NO.OF BENDS = 4


VERTICAL= 4.5 Mtr.


VERTICAL= 1.2 Mtr.

FANS ALONG WITH ACCESSORIES

INSTALLTION, TESTING & COMMISSIONING OF EXHAUST FAN

WITH STARTER.

EXHAUST / FRESH AIR FAN

203 450 DIA. SINGLE PHASE, 240V AC EXHAUST FAN NO 27

SAFETY EQUIPMENTS

RUBBER MATS (SUPPLY AND INSTALLATION)

RUBBER MAT SHALL BE CHEQUERED TYPE

AS PER RELEVANT INDIAN STANDARD

RUBBER MATS SHALL BE SUPPLIED IN

UNROLLED CUT PIECES (MATS SHALL NOT

BE SUPPLIED IN ROLLED FORM)

CUTTING OF RUBBER MATS SHALL BE

DONE AT FACTORY AND NOT AT SITE.


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


204 415 VOLT GRADE RUBBER MAT OF WIDTH MTR. 78

900 MM. MAXIMUM PIECE LENGTH - 2.4

MTRS. CUT IN FACTORY

205 33 KV GRADE RUBBER MAT OF WIDTH 900 MTR. 4

MM. EACH CUT PIECE OF 1100 MM LENGTH

CUT IN FACTORY

SHOCK TREATMENT CHART

206 SUPPLY & INSTALLATION OF PRINTED AND NO. 4

FRAMED SHOCK TREATMENT CHART IN

ENGLISH AND LOCAL LANGUAGE

CAUTION BOARDS

SUPPLY & INSTALLATION OF METALLIC CAUTION BOARDS AS

PER RELEVANT IS OF VOLTAGE GRADE AS GIVEN BELOW IN

ENGLISH AND LOCAL LANGUAGE

207 440V CAUTION BOARD NO. 10

208 33 KV CAUTION BOARD NO. 4

FIRST AID KIT

209 SUPPLY & INSTALLATION OF FIRST AID KIT SETS 3

TO BE KEPT ON WOODEN STAND AND SHALL

BE SUITABLE FOR 10 PERSONS

HAND GLOVES (SUPPLY AND INSTALLATION)

210 500V ELECTRIC GRADE RUBBER GLOVES PAIR 2

211 33kV GRADE HAND GLOVES PAIR 1

MISCELLANEOUS ITEMS (SUPPLY AND INSTALLATION)

CANOPY

SUPPLY & INSTALLATION OF CANOPY FOR

OUTDOOR MOTORS, CANOPY SHALL BE

MADE UP OF FRP.

SHAPE, SIZE, LEGS, LOUVERS, HANDLES ETC. AS PER

SITE REQUIREMENT. CANOPY FOR OUTDOOR

MOTORS WITH DIFFERENT KW RATINGS AS

SPECIFIED BELOW.

FRAME SIZE OF CANOPY SHALL BE ONE

FRAME HIGHER THAN MOTOR FRAME SIZE.

212 MOTOR RATING UPTO 3.7KW NOS. 3

213 MOTOR RATING ABOVE 5.5KW & UPTO 30KW NOS. 27

214 MOTOR RATING ABOVE 30KW & UPTO 110KW NOS. 15

215 MOTOR RATING ABOVE 110KW NOS. 8

ANCHOR FASTNER

SUPPLY AND INSTALLATION OF ANCHOR FASTNER FOR

SUPPORTING / FIXING CABLE TRAY SUPPORTS &

MISCELLANEOUS ELECTRICAL SWITCHGEAR (SAMPLE SHALL BE

APPROVED BY SITE ENGINEER)

216 6 MM DIA. 60 MM LONG NO. 25


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


217 8 MM DIA. 75 MM LONG NO. 30

218 10 MM DIA. 100 MM LONG NO. 25

219 12 MM DIA. 150 MM LONG NO. 30

INSERT PLATE

SUPPLY AND INSTALLATION OF INSERT PLATE AS PER

INDIAN STANDARDS & INSTALLATION (WITH THE

HELP OF METALLIC ANCHOR FASTNER) FOR SUPPORTING

LIGHT FITTING, SMALL CABLE TRAY AND

MISCELLANEOUS ELECTRICAL ITEMS

220 100 x 100 x 8 MM THICK 25

221 150 x 150 x 6 MM THICK 25

222 150 x 150 x 10 MM THICK 25

SEALING OF PIPES IN SAFE AREA

FILLING OF GI / PVC / HUME PIPE ENDS WITH

INSULATING WOOL ASBESTOS BLANKET

FIBRE GLASS WASTES AND SEALING THE

SAME WITH BITUMEN BASED WATERPROOF

COMPOUND. CONTRACTOR SHALL QUOTE

FOR LABOUR CHARGES BASED ON NUMBER

OF PIPE ENDS TO BE SEALAED OF THE

FOLLOWING SIZES. INSTALLATION

RATE SHALL INCLUDE ALL CONSUMABLES

INCLUDING BITUMEN COMPOUND.

223 75 MM DIA PIPE NOS. 20




ADAPTOR / REDUCER

SUPPLY & INSTALLATION OF FLAMEPROOF TYPE

ADAPTOR / REDUCER FOR HAZARDOUS AREA EQPTS

SUITABLE FOR APPLICATION IN ZONE-1 & ZONE-2

AREA AND TEMPERATURE CLASS T-3.

ADAPTOR SHALL BE ONE SIDE THREADED

AS PER THE THREADS ON EQUIPMENT AND

OTHER END TO SUIT CABLE GLANDS

(AS PER SITE REQUIREMENT)

227 1" x 3/4" NOS. 25

228 1 1/4" x 1" NOS. 15

229 1 1/4" x 3/4" NOS. 20

230 1 1/2" x 1" NOS. 10

231 2" x 1 1/2" NOS. 15

SEALING PLUG

SUPPLY & INSTALLATION OF METALLIC (MS)

SEALING PLUG FOR UNUSED CABLE ENTRIES IN

MOTORS, JUNCTION BOXES, ETC. OF FOLLOWING

SIZES.

(AS PER SITE REQUIREMENT)

232 3/4" ET NOS. 25

233 1" ET NOS. 15

234 1 1/4" ET NOS. 20

235 1 1/2" ET NOS. 10

236 2" ET NOS. 15


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


PIPES

GI PIPES

INSTALLATION OF CLASS-B GI PIPE OF SIZES AS SPECIFIED

BELOW TO BE FIXED ON WALL STEEL STRUCTURE BURRIED IN

GROUND, LAID IN TRENCHES FOR PROTECTION OF CABLES

EARTHING CONDUCTORS OF INCLUDING BENDING, THREADING,

COUPLING, WELDING, CLAMPING AS REQUIRED.



PVC PIPES

INSTALLATION OF PVC PIPES OF SIZES AS SPECIFIED BELOW

TO BE FIXED ON WALL OR STEEL STRUCTURE FOR CABLES IN

WALL OR STEEL STRUCTURE FOR CABLES INCLUDED BENDING

AS REQUIRED.


240 150 MM DIA PVC PIPE MTR. 110

HUME PIPES

INSTALLATION OF HUME PIPES OF INNER

DIA. AS SPECIFIED BELOW TO BE LAID BURIED

UNDERGROUND FOR PROTECTION OF

CABLES / EARTHING CONDUCTORS WITH

REQUIRED COUPLING RINGS.




STRUCTURAL STEEL

INSTALLATION & FABRICATION OF

244 STRUCTURAL STEEL IN FORMS OF M.S. TON 35

ANGLES, CHANNELS, BEAMS, FLATS, ETC.

FOR SUPPORTING VARIOUS ITEMS / EQUIPMENT SUCH

AS SWITCHGEARS, PANELS, CABLE TRAYS, PUSH

BUTTON STATIONS, LOCAL CONTROL BOXES, LOCAL

CONTROL PANELS, JUNCTION BOXES, DISTRIBUTION

BOARDS, LIGHTING FITTINGS, ETC. INCLUDING

DRILLING, WELDING, GROUTING, GRINDING,

CHIPPING, BOLTING WITH SUPPLY OF REQUIRED

HARDWARE.

FABRICATED AND INSTALLED STRUCTURAL

STEEL SHALL BE SUITABLY PAINTED

WITH 2 COATS OF FINSIH EPOXY PAINT

AFTER APPLYING 2 COATS OF PRIMER.

FINISH PAINT SHADE SHALL BE SAME AS

THAT OF MAIN STRUCTURE OR WILL BE

AS PER SITE ENGINEER'S APPROVAL

SURFACE PREPARATION: BRUSHING & CLEANING

PRIMER TYPE : EPOXY BASED (EPILUX - 610 OR

EQ. - 50 MICRON)

FINISH PAINT : EPOXY POLYAMIDE HIGH BUILD

(EPILUX 89 OR EQ.) 125 MICRON

FINISH PAINT SHADE : AS PER SITE REQUIREMENT


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


FREE ISSUE ITEMS - INSTALLATION

NOTE : INSTALLATION RATE SHALL INCLUDE SUPPLY OF

CONSUMABLES AND HARDWARE AND EXCLUDING SUPPLY OF

STRUCTURAL STEEL SINCE THIS IS CATEGORISED SEPERATELY.

INDOOR HT SWITCHGEAR

INSTALLATION, TESTING AND COMMISSIONING ASSISTANCE OF

FOLLOWING FREE ISSUE INDOOR HT SWITCHGEAR. SCOPE

INCLUDES TRANSPORTATION FROM THE OWNER'S STORE TO

THE PLACE OF INSTALLATION, ERECTION ON BASE FRAME /

FOUNDATION,ASSEMBLING OF VARIOUS SHIPPING SECTIONS,

ALIGNING, LEVELLING, FIXING / GROUTING / WELDING TO THE

BASE FRAME OR INSERT PLATES PROVIDED ON THE FLOOR.

SCOPE ALSO INCLUDES INTERCONNECTION OF SHIPPING

SECTIONS AND INTER PANEL WIRING BETWEEN SHIPPING

SECTIONS, TESTING AND CALIBRATION OF ALL THE CT'S, PT'S,

RELAYS, METERS AND ENERGISING OF THE SWITCHGEAR AT

RATED VOLTAGE. INSTALLATION RATE SHALL INCLUDE

SUPPLY OF GI CONSUMABLES AND HARDWARE AND

EXCLUDING SUPPLY OF STRUCTURAL STEEL.

245 33KV MAIN SWITCHGEAR

APSEB PANELNO. 1

246 33KV SWITCHGEAR (1 I/C & 2 O/Gs)

HPCL PANELNO. 1

TRANSFORMER

INSTALLATION, TESTING, COMMISSIONING OF FOLLOWING 2

WINDING TRANSFORMER ON READY MADE FOUNDATION. THIS

SHALL INCLUDE TRANSPORTING FROM OWNER'S ISSUE POINT,

UNLOADING FROM TRUCK (IF ARRIVED AFTER MOBILISATION

OF CONTRACTOR ) SITE ASSEMBLING OF LOOSE SUPPLIED

ACCESSORIES AND FILLING OF OIL, TOPPING UP WITH OIL

(INCLUDING FILTRATION), SUPPLY & SPREADING OF 25 mm

GRAVELS AS PER THE REQUIREMENT.

247 2000 KVA, 33/0.433KV, DYn11, 6.25% WITH OFF CIRCUIT TAP

CHANDER DISTRIBUTION TRANSFORMER FOR PLANT LOAD NO. 1

248 2000 KVA, 33/0.433KV, DYn11, 6.25% WITH OFF CIRCUIT TAP

CHANDER DISTRIBUTION TRANSFORMER FOR ELECTRICAL

HEAT TRACING LOAD

NO. 1

415 V LOW VOLTAGE SWITCHGEARS.

INSTALLATION, TESTING AND COMMISSIONING ASSISTANCE OF

FOLLOWING INDOOR LV SWITCHGEAR. THE PANELS ARE

MOUNTED ON THE FLOOR CUT OUTS. THE EQUIPMENT

FOUNDATION LAYOUT IS TO BE CARRIED BY CONTRACTOR

(THE DWGS. WILL BE GIVEN TO THE SUCCESSFUL BIDDER).

HOWEVER FOR ANY CHANGES IN PANEL DIMENSIONS AT A

LATER STAGE ,SUITABLE ASSUMPTIONS ARE TO BE MADE IN

CONSULTATION WITH SITE ENGINEER TO PLACE PANEL

SUPPORT BASED ON THE SHIPPING SECTION.

249 PMCC-1 (AS PER SLD) NO. 1

PCC (AS PER SLD )

250 TANK TRUCK FILLING MCC (AS PER SLD) NO. 1

251 TANK WAGON FILLING MCC (AS PER SLD) NO. 1

252 SHIPPING/ BUNKERING MCC (AS PER SLD) NO. 1


UNIT RATETOTAL

AMOUNT

(Rs.) (Rs.)






REMARKSSR.


BATTERY & BATTERY CHARGER PANELWITH DCDB

INSTALLATION, TESTING & COMMISSIONING ASSISTANCE OF

FOLLOWING INDOOR TYPE, FLOOR MOUNTED PANELS WITH

BOTTOM CABLE ENTRY & ASSOCIATED BATTERIES.

253 110V, DC BATTERY. INSTALLATION SHALL INCLUDE

POSITIONING OF STAND, STAND INSULATORS, CELL

INSULATORS, LEVELLING, FIXING OF NUMBER PLATS,

INTERCONNECTION OF CELLS (INTERCONNECTING LINKS

SHALL BE SUPPLIED BY BATTERY SUPPLIER). SCOPE ALSO

INCLUDES FILLING OF ACID, FIRST CHARGING, DISCHARGING,

CAPACITY TEST AND RECHARGING OF BATTERY AS PER THE

PROCEDURES PRESCRIBED BY MANUFACTURER.

INTERCONNECTION OF BATTERY BANK WITH BATTERY

BREAKER.

SET 1

254 BATTERY CHARGER WITH DCDB PANEL NO. 1

(FLOAT CHARGER, FLOAT CUM BOOST CHARGER & DCDB )

TESTING, COMMISSIONING OF MOTORS

TESTING AND COMMISSIONING OF FOLLOWING LT MOTORS.

415V, SQUIRREL CAGE, INDUCTION MOTORS

255 MOTORS RATING UPTO 3.7 KW NO. 3

256 MOTORS RATING ABOVE 5.5 KW UPTO 30 KW NO. 27

257 MOTORS RATING ABOVE 30 KW UPTO 110 KW NO. 15

258 MOTORS RATING ABOVE 110 KW NO. 8

NOTE:-

VENDOR HAS TO MARK NUMBERS ON EACH EARTHING PIT.

VENDOR HAS TO PROVIDE TEST CERTIFICATES FOR EACH EARTHING PITS.

PAYMENT AGAINST INSTALLATION OF ALL ITEMS SHALL BE AS PER EXECUTED QTY. & RECONCILATION WILL BE

DONE AT FINAL BILLING STAGE. NECESSARY DEDUCTIONS SHALL BE MADE FOR CHANGE IN QTY.

PAYMENT AGAINST INSTALLATION OF CABLES SHALL BE AS PER EXECUTED QTY. & RECONCILATION WILL BE DONE AT FINAL

BILLING STAGE. IF PAYMENT IS DONE DURING RUNNING BILLS AGAINST INSTALLATION, NECESSARY DEDUCTIONS SHALL BE MADE

FOR ANY EXCESS QTY. OF INSTALLATION CABLES.







Appendix – H : Recommended List of vendors

33kV Power Cables : Finolex cables/ Universal Cables/ Cable Corporation of

India Ltd/ ASIAN/ TORRENT/ KEI/ RPG Cables Co.

L.V. Power & Control Cables : Polycab cables/ Finolex cables/ Universal Cables/ Cable

Corporation of India Ltd/ ASIAN/ TORRENT/ KEI/

RPG Cables Co.

Cable Gland : Baliga/ Hawke/ Victory/ BEECO/ FCG/ COMET/ HMI/

Power Engg.

Cable Lug : DOWELLS/ Usha Ismal/ JENSON

GI Cable Trays : Super Reinforced Plastics Associates Engg. Corp./

GRIP INDIA/ SSB Industries/ ERCON Composites/

General Composutes/ Indiana/ Enduro

Flameproof :

Local Control Station : FEPL/ Baliga/ FCG Power Industries/ Flameproof

Control Gear

Light Fixtures & Accessories : FEPL/ Baliga/ FCG Power Industries/ Flameproof

Control Gear/ Sudhir Switchgear

Junction Boxes : FEPL/ Baliga/ FCG Power Industries/ Flameproof


Sub-Lighting & Power Panels

(SLDB, SELDB, SPDB)

: FEPL/ Baliga/ FCG Power Industries/ Flameproof


Plugs & Sockets : FEPL/ Baliga/ FCG Power Industries/ Flameproof


Industrial :

Local Control Station : FEPL/ Baliga/ FCG Power Industries/ Flameproof

Control Gear/ Mansu/ Pushtron

Light Fixtures & Accessories : Philips/ Crompton Greaves/ Bajaj Electricals/ Wipro

Junction Boxes : Power Controls/ Sudhir Switchgear/ Flexpro/

ELECMECH/ ELMA/ FCG Power Industries

Sub-Lighting & Power Panels

(SLDB, SELDB, SPDB)

: MDS/ INDO ASIAN Switchgears/ Havells/ Standard/

Legrand India

Plugs & Sockets : Bhartia Cutler Hammer/ Best & Crompton/ Schneider

Electric India Ltd/ RB (Ryrol Burn)

Gang Operated Switches & Isolators : ABB/ KRUGGS/ S&S Power/ Danke/ Dreishcher

Panickar/ Hivelum Industries/ CGL/ Sterling Isolators/

Kiran Textiles

Lightning Arrestor : ELPRO International Ltd/ ALSTOM/ OBLUM

Electrical Industries/ ATLAS/ WS Industries/ CGL/

ABB

PIN Insulator, Porceilin Bushes/

Disc/ Post Insulators

: Jaya Shree Insulators/ Modern Insulators/ ALSTOM/

Shesasayee Industries/ WS Industries

Termination/ Jointing Kit : Cable Corporation of India Ltd/ Raychem/ M-Seal/

Pidilite

Busduct : MK Engg./ Stardrive/ Globe Electricals/ ELECMECH/

Elpro

APFC Panel/ LDP with Energy

Saver/ PDP

: Popular Switchgear Pvt.Ltd./ NEEL Industrial Systems

Pvt. Ltd/ ELECMECH/ S&S Power Switchgear/ MK

Engg./ ELMA

Energy Saver NEEL Industrial Systems Pvt. Ltd / Duex Energy

ACB : Siemens / L&T / ABB / Schnieder






MCCB : L&T / Areva / ABB / Siemens / Merlin Gerin

SFU : L&T / Siemens / ABB

Protection Relays, Aux. Relays : Areva / ABB / Siemens / SEL

LT contactor : Siemens / Tele-mechanic / L & T /Control & Switch

Gear / SEL

Selector switches / Control switches : GECALSTHOM / KAYCEE/ ABB / Siemens / Rishab.

CTs, PTs, Lighting Transformer : Automatic electric / ECS / KAPPA electricals / Pragati /

Gemini

PTs : Pragati / KAPPA electricals / ECS / Gemini

Annunciators : GEC / ALSTOM/ Yashmin / Bharani Electronics /

MECO / Minilec

Indicating Meters : Automatic electric industrial Meters Pvt. Ltd., / IMP /

MECO / RISHAB / Enercon / L&T

Indicating lamps (LED type only) &

Push buttons

: GECALSTHOM/ Siemens / L & T / Telemecanique /

Teknic

MCB : L&T / ABB / Siemens / Merlin Gerin / MDS






Appendix-I: List of Enclosed Drawings

Drg. No. 254625-300-ELE-A1-4800-Sh-1, 2 & 3

254625-300-ELE-A1-4502

254625-300-ELE-A1-4503

254625-300-ELE-A1-4504

254625-300-ELE-A0-4700

254625-300-ELE-A1-4804-Sh-1 & 2

254625-300-ELE-A0-4505-Sh-1 & 2

254625-300-ELE-A1-4801-Sh-1, 2, 3 & 4

254625-300-ELE-A0-4605

254625-300-ELE-A1-4803-Sh-1 & 2

254625-300-ELE-A1-4001

254625-300-ELE-A1-4104-Sh-1 & 2

254625-300-ELE-A1-4107-Sh-1 & 2

254625-300-ELE-A1-4108

254625-300-ELE-A1-4110-Sh-1 & 2

2.1 - Specification for Electrical Installation Tender

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Transcript of 2.1 - Specification for Electrical Installation Tender