ALIGARH SMART CITY LIMITED II-_637086752521238409.pdf · ALIGARH SMART CITY LIMITED DESIGN,...

ALIGARH SMART CITY LIMITED

DESIGN, CONSTRUCTION OF FOLLOWING PACKAGES

INCLUDING 5 YEARS OF OPERATIONS AND

MAINTENANCE AND 2 YEARS OF DEFECT LIABILITY

PERIOD (UNDER SMART CITY MISSION)

• Rehabilitation of Storm water Drainage system of ABD

Area

• Junctions Improvement

• Development of Smart Road from Ghantaghar to

University Circle

Scope of Work and Specifications

Volume - II

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Volume II- Scope of Work, Standards and Specifications

WORK’S REQUIREMENTS


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TABLE OF CONTENTS

1. PROJECT BACKGROUND ........................................................................................................................... 10

2. NECESSITY OF THE PROJECT ..................................................................................................................... 11

3. OBJECTIVES OF THE PROJECT ................................................................................................................... 12

A. DRAINAGE SYSTEM ........................................................................................................................................... 12

B. JUNCTION IMPROVEMENTS ................................................................................................................................ 12

C. SMART ROAD .................................................................................................................................................. 12

4. PROJECT LOCATION .................................................................................................................................. 13

5. SCOPE OF WORK ...................................................................................................................................... 14

6. DETAILED SCOPE OF WORK FOR STROM WATER DRAINAGE-REHABILITATION OF STORM WATER

DRAINAGE SYSTEM IN ABD AREA ..................................................................................................................... 17

OBJECTIVES OF THE PROJECT ....................................................................................................................................... 17

CONDITIONS OF EXISTING DRAINAGE SYSTEM AND SCOPE OF WORK ................................................................................... 18

SURVEY AND INVESTIGATIONS ..................................................................................................................................... 19

Reconnaissance Survey .................................................................................................................................... 19

Topographic Survey ......................................................................................................................................... 20

Rainfall Analysis: ............................................................................................................................................. 20

Design Storm Frequency: ................................................................................................................................. 20

CATCHMENT AREA DEMARCATION: .............................................................................................................................. 21

STORM WATER DISPOSAL APPROACH: .......................................................................................................................... 21

TIME OF CONCENTRATION .......................................................................................................................................... 21

COMPUTATION OF DESIGN FLOW ................................................................................................................................ 22

SIZING OF THE DRAINS: .............................................................................................................................................. 22

DETERMINATION OF CAPACITY OF DRAIN: ..................................................................................................................... 23

FREE BOARD ............................................................................................................................................................ 23

INLET ARRANGEMENTS .............................................................................................................................................. 23

LIMITING VELOCITIES AND GRADIENTS IN DRAIN ............................................................................................................. 23

CULVERTS ............................................................................................................................................................... 23

ADEQUACY ANALYSIS OF EXISTING DRAINS: ................................................................................................................... 24

REHABILITATION OF DRAINAGE PUMPING STATIONS: ....................................................................................................... 24

7. SUMMARY OF OBLIGATIONS UNDER THE CONTRACT .............................................................................. 25

8. PHASING OF CONTRACT ........................................................................................................................... 28

A. MOBILIZATION PERIOD ..................................................................................................................................... 28

B. PREPARATORY PERIOD (PREPARATION OF DESIGN DURING PREPARATORY PERIOD) ........................................................ 28

I. DELIVERABLE DOCUMENTS FOR SIP ..................................................................................................................... 28

C. OPERATING AND MANAGEMENT RELATED DELIVERABLE .......................................................................................... 29

D. SIP SCHEDULE ................................................................................................................................................. 29

9. METHODOLOGY FOR MEASUREMENT OF PERFORMANCE STANDARDS ................................................... 31

10. METHODOLOGY FOR SITE ACQUAINTANCE .............................................................................................. 32


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11. SURVEY AND MAPPING ............................................................................................................................ 33

12. WASTE DISPOSAL ..................................................................................................................................... 34

13. SIP IMPLEMENTATION ............................................................................................................................. 35

A. STORM WATER DRAINAGE SYSTEM ....................................................................................................................... 35

B. ROAD RESTORATION ......................................................................................................................................... 35

14. MANAGEMENT INFORMATION SYSTEM................................................................................................... 37

15. FROM FINAL TAKE OVER DATE TO EXPIRY OF OPERATION PERIOD OF 5 YEARS ....................................... 38

16. ELECTRICITY CONSUMPTION .................................................................................................................... 39

17. MAINTAINING PERFORMANCE STANDARDS ............................................................................................ 40

18. PERIODIC REPORTS .................................................................................................................................. 41

19. DESIGN CRITERIA ..................................................................................................................................... 42

A. STRUCTURAL DESIGN REQUIREMENTS .................................................................................................................. 43

B. DESIGN SUBMISSIONS ....................................................................................................................................... 43

C. DESIGN STANDARDS ......................................................................................................................................... 43

D. DESIGN LIFE .................................................................................................................................................... 43

E. DESIGN LOADS ................................................................................................................................................ 44

20. ELECTRICAL BRIEF – JUNCTION IMPROVEMENTS...................................................................................... 45

20.1 ELECTRICAL SYSTEM ........................................................................................................................ 45

20.1.1 GENERAL INFORMATION ............................................................................................................ 45

20.1.1.1 EXISTING POWER DISTRIBUTION ................................................................................... 45

20.1.2 PROPOSED SYSTEM .................................................................................................................... 52

20.1.3 SCOPE OF WORK .......................................................................................................................... 53

20.1.3.1 ELECTRICAL .......................................................................................................................... 54

20.1.3.2 CIVIL WORK: .......................................................................................................................... 56

20.1.3.3 TECHNICAL SERVICES ....................................................................................................... 57

20.1.3.4 DRAWING/DOCUMENTS ..................................................................................................... 57

20.1.3.5 NOTE ........................................................................................................................................ 58

20.2 ELECTRIC DESIGN DATA .................................................................................................................. 59

20.2.1 CODES AND STANDARDS ........................................................................................................... 59

20.2.2 CLIMATIC CONDITIONS ............................................................................................................... 62

20.2.2.1 General ..................................................................................................................................... 62

20.2.2.2 Climate and Isokeraunic Conditions: ................................................................................... 62

20.2.2.3 Tropicalization: ........................................................................................................................ 63

20.2.3 SYSTEM SUPPLY ........................................................................................................................... 63

20.2.3.1 INSULATION COORDINATION ........................................................................................... 64

20.2.3.2 SYSTEM NEUTRAL POINT .................................................................................................. 64

20.2.3.3 SHORT CIRCUIT LEVELS .................................................................................................... 65

20.2.3.4 DISTRIBUTION TRANSFORMERS .................................................................................... 65

20.2.3.5 COLOR CODING .................................................................................................................... 65

20.2.3.6 POWER FACTOR .................................................................................................................. 66

20.2.3.7 HV DISTRIBUTION ................................................................................................................ 66


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20.2.4 APPLICABLE STANDARD ............................................................................................................. 67

20.3 SPECIFICATION ................................................................................................................................... 69

20.3.1 SPECIFICATION FOR COMPACT SUBSTATION ..................................................................... 69

3.1.1.1 Quality of Material ....................................................................................................................... 70

3.1.1.2 Design and Standardisation ...................................................................................................... 70

3.1.1.3 Certification offering evidence for the satisfactory operation under such environmental

conditions shall be provided. ........................................................................................................................... 71

3.1.1.4 Painting ......................................................................................................................................... 72

3.1.1.5 Drawings and Manuals ............................................................................................................... 73

3.1.1.6 Quality Control ............................................................................................................................. 74

3.1.1.7 Quality Assurance ....................................................................................................................... 74

20.4 LT DISTRIBUTION FEEDER PILLAR BOX .................................................................................... 137

20.5 JUNCTION BOXES & METER BOXES .......................................................................................... 149

20.6 33KV & 11 KV XLPE INSULATED CABLES .................................................................................. 150

20.7 SPECIFICATION FOR UNDERGROUND DUCTS FOR POWER CABLES ............................. 171

IS:2530 or IS:7328 .......................................................................................................................................... 175

ASTM D 1693 ................................................................................................................................................. 176

20.7.20 CABLING SYSTEM .............................................................................................................. 185

20.7.20.1 CABLE SELECTION CRITERIA: ....................................................................................... 185

20.8 CABLE LAYING ................................................................................................................................. 186

20.8.1 DEPTH OF LAYING & SPACING BETWEEN CABLES: .................................................... 186

20.8.2 ROAD, RAILWAY TRACKS, WATER PIPE LINE CROSSINGS: ...................................... 186

20.8.3 FOOT PATH CUTTING: ........................................................................................................... 186

20.8.4 REINSTATEMENT: ................................................................................................................... 187

20.8.5 JOINTING BAYS: ...................................................................................................................... 187

20.8.6 BENDING RADIUS: .................................................................................................................. 187

20.8.7 JOINTING AND TERMINATION OF CABLES: .................................................................... 187

20.8.8 TENTS / COVERS: ................................................................................................................... 187

20.8.9 PRECAUTIONS BEFORE MAKING A JOINT/ END TERMINATION: .............................. 188

20.8.10 MEASUREMENT OF INSULATION RESISTANCE: ....................................................... 188

20.8.11 IDENTIFICATION: ................................................................................................................ 188

20.8.12 MAKING A JOINT/ END TERMINATION: ......................................................................... 188

20.8.13 CABLE TERMINATIONS: .................................................................................................... 188

20.9 SPECIFICATION FOR EARTHING ................................................................................................. 189

20.9.1 Scope .......................................................................................................................................... 189

20.9.2 Description of Services ............................................................................................................. 190

20.9.3 Design Requirements ............................................................................................................... 190

20.9.4 Earthing Hardware .................................................................................................................... 193

20.9.5 Tests ........................................................................................................................................... 197

20.10 SMART ENERGY METER ........................................................................................................... 198

20.10.1 BASIC REQUIREMENT ...................................................................................................... 198

20.10.2 ADVANTAGES ...................................................................................................................... 199

20.10.3 RATING .................................................................................................................................. 199

20.10.4 SYSTEM COMPONENTS ................................................................................................... 199 20.11 SPECIFICATION OF FRP POLES WITH FIXTURES FOR STREET AND AREA LIGHTING

200

20.11.1 Scope ...................................................................................................................................... 200


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20.11.2 Standard And System Conditions ...................................................................................... 200

20.11.3 Calculations ........................................................................................................................... 202

20.11.4 General Requirement ........................................................................................................... 202

20.11.5 Design and Standardisation ................................................................................................ 203

20.11.6 Drawings ................................................................................................................................ 204

20.11.7 Quality Assurance ................................................................................................................. 205

20.11.8 Material of Poles and Manufacturing ................................................................................. 205

20.11.9 Technical Data ...................................................................................................................... 205

20.11.10 Ultra Violet And Weathering Protection ............................................................................. 206

20.11.11 Mast Arms .............................................................................................................................. 206

20.11.12 Construction Detail ............................................................................................................... 206

20.11.13 Exterior Protection & Spare Paint ....................................................................................... 207

20.11.14 Marking ................................................................................................................................... 207

20.11.15 Design Safety Factor ............................................................................................................ 207

20.11.16 Testing .................................................................................................................................... 207

20.11.17 Installation .............................................................................................................................. 210

20.11.18 Bonding and Earthing ........................................................................................................... 210

20.11.19 Guarantee and Warranty ..................................................................................................... 210

20.11.20 Packing, Shipping and Delivery .......................................................................................... 211

20.11.21 Lighting ................................................................................................................................... 211

20.12 CONTRACTOR’S REQUIREMENT ............................................................................................ 222

20.13 INSPECTION ................................................................................................................................. 222

20.14 DRAWINGS .................................................................................................................................... 222

20.15 STATUTORY APPROVAL ........................................................................................................... 222

20.16 SAFETY .......................................................................................................................................... 222

20.17 SPARES ......................................................................................................................................... 223

20.18 TOOLS ............................................................................................................................................ 223

20.19 TRAINING ....................................................................................................................................... 223

20.20 CONSTRUCTION, ERECTION, TESTING AND COMMISSIONING ..................................... 223

20.20.1 GENERAL .............................................................................................................................. 223

20.21 ERECTION, TESTING & COMMISSIONING ............................................................................ 226

20.21.1 GENERAL .............................................................................................................................. 226

20.21.2 EQUIPMENT, MATERIAL & SERVICES TO BE PROVIDED BY THE TENDERER 226

20.21.3 MAN / MATERIAL SUPPLY ................................................................................................ 227

20.21.4 SUPERVISION DURING ERECTION ............................................................................... 227

20.21.5 SEQUENCE OF ERECTION WORK ................................................................................. 227

20.21.6 ERECTION ............................................................................................................................ 228

20.21.7 EQUIPMENT INSTALLATION & WORKMANSHIP ......................................................... 229

20.21.7.1 ASSEMBLY OF EQUIPMENT ............................................................................................ 229

20.21.8 LUBRICATION ...................................................................................................................... 229

20.22 SAFETY REGULATIONS ............................................................................................................. 230

20.23 INSPECTION ................................................................................................................................. 230

20.24 PRE-COMMISSIONING TEST .................................................................................................... 231

20.25 START- UP (PRE- COMMISSIONING) ...................................................................................... 231

20.26 COMMISSIONING ........................................................................................................................ 231

20.27 ENGINEERING SERVICES ......................................................................................................... 232

20.27.1 GENERAL .............................................................................................................................. 232

20.28 QUALITY MONITORING AND ASSURANCES ........................................................................ 234


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20.28.1 GENERAL: ............................................................................................................................. 234

20.28.2 INSPECTION AND TESTING ............................................................................................. 235

20.28.3 OPERATING MANUALS AND MAINTENANCE INSTRUCTIONS ............................... 235

20.28.4 “AS- BUILT” DOCUMENT ................................................................................................... 236

20.28.5 PROJECT HANDBOOK ...................................................................................................... 237

20.29 LIST OF PREFERRED MANUFACTURERS ............................................................................. 237

21. ELECTRICAL BRIEF – SMART ROAD ......................................................................................................... 241

21.1 ELECTRICAL SYSTEM ...................................................................................................................... 241

21.1.1 GENERAL INFORMATION .......................................................................................................... 241

21.1.1.1 EXISTING POWER DISTRIBUTION ................................................................................. 241

21.1.2 PROPOSED SYSTEM .................................................................................................................. 242

21.1.3 SCOPE OF WORK ........................................................................................................................ 243

21.1.3.1 ELECTRICAL ........................................................................................................................ 244

21.1.3.2 CIVIL WORK: ........................................................................................................................ 246

21.1.3.3 TECHNICAL SERVICES ..................................................................................................... 247

21.1.3.4 DRAWING/DOCUMENTS ................................................................................................... 248

21.1.3.5 NOTE ...................................................................................................................................... 248

21.2 ELECTRIC DESIGN DATA ................................................................................................................ 250

21.2.1 CODES AND STANDARDS ......................................................................................................... 250

21.2.2 CLIMATIC CONDITIONS ............................................................................................................. 252

21.2.2.1 General ................................................................................................................................... 253

21.2.2.2 Climate and Isokeraunic Conditions: ................................................................................. 253

21.2.2.3 Tropicalization: ...................................................................................................................... 253

21.2.3 SYSTEM SUPPLY .................................................................................................................... 254

21.2.3.1 INSULATION COORDINATION ......................................................................................... 254

21.2.3.2 SYSTEM NEUTRAL POINT ................................................................................................ 255

21.2.3.3 SHORT CIRCUIT LEVELS .................................................................................................. 255

21.2.3.4 DISTRIBUTION TRANSFORMERS .................................................................................. 255

21.2.3.5 COLOR CODING .................................................................................................................. 255

21.2.3.6 POWER FACTOR ................................................................................................................ 256

21.2.3.7 HV DISTRIBUTION .............................................................................................................. 256

21.2.3.8 APPLICABLE STANDARD .................................................................................................. 257

22 SPECIFICATION ................................................................................................................................. 259

22.1 SPECIFICATION FOR COMPACT SUBSTATION ....................................................................... 259

3.1.1.8 Quality of Material ..................................................................................................................... 261

3.1.1.9 Design and Standardisation .................................................................................................... 261

3.1.1.10 Certification offering evidence for the satisfactory operation under such environmental

conditions shall be provided. ......................................................................................................................... 261

3.1.1.11 Painting .................................................................................................................................. 263

3.1.1.12 Drawings and Manuals ........................................................................................................ 263

3.1.1.13 Quality Control ....................................................................................................................... 264

3.1.1.14 Quality Assurance ................................................................................................................. 264

22.2 LT DISTRIBUTION FEEDER PILLAR BOX .................................................................................... 327

22.3 JUNCTION BOXES & METER BOXES .......................................................................................... 338

22.4 33KV & 11 KV XLPE INSULATED CABLES .................................................................................. 339


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22.5 SPECIFICATION FOR UNDERGROUND DUCTS FOR POWER CABLES ............................. 360

IS:2530 or IS:7328 .......................................................................................................................................... 364

ASTM D 1693 ................................................................................................................................................. 365

22.5.20 CABLING SYSTEM .............................................................................................................. 374

22.5.20.1 CABLE SELECTION CRITERIA: ....................................................................................... 374

22.6 CABLE LAYING ................................................................................................................................. 375

22.6.1 DEPTH OF LAYING & SPACING BETWEEN CABLES: .................................................... 375

22.6.2 ROAD, RAILWAY TRACKS, WATER PIPE LINE CROSSINGS: ...................................... 375

22.6.3 FOOT PATH CUTTING: ........................................................................................................... 375

22.6.4 REINSTATEMENT: ................................................................................................................... 376

22.6.5 JOINTING BAYS: ...................................................................................................................... 376

22.6.6 BENDING RADIUS: .................................................................................................................. 376

22.6.7 JOINTING AND TERMINATION OF CABLES: .................................................................... 376

22.6.8 TENTS / COVERS: ................................................................................................................... 376

22.6.9 PRECAUTIONS BEFORE MAKING A JOINT/ END TERMINATION: .............................. 377

22.6.10 MEASUREMENT OF INSULATION RESISTANCE: ....................................................... 377

22.6.11 IDENTIFICATION: ................................................................................................................ 377

22.6.12 MAKING A JOINT/ END TERMINATION: ......................................................................... 377

22.6.13 CABLE TERMINATIONS: .................................................................................................... 377

22.7 SPECIFICATION FOR EARTHING ................................................................................................. 378

22.7.1 Scope .......................................................................................................................................... 378

22.7.2 Description of Services ............................................................................................................. 378

22.7.3 Design Requirements ............................................................................................................... 379

22.7.4 Earthing Hardware .................................................................................................................... 382

22.7.5 Tests ........................................................................................................................................... 385

22.8 SMART ENERGY METER ................................................................................................................ 387

22.8.1 BASIC REQUIREMENT ........................................................................................................... 387

22.8.2 ADVANTAGES .......................................................................................................................... 387

22.8.3 RATING ...................................................................................................................................... 387

22.8.4 SYSTEM COMPONENTS ....................................................................................................... 388

22.9 SPECIFICATION OF FRP POLES WITH FIXTURES FOR STREET AND AREA LIGHTING 388

22.9.1 Scope .......................................................................................................................................... 388

22.9.2 Standard and System Conditions ........................................................................................... 388

22.9.3 Calculations ................................................................................................................................ 391

22.9.4 General Requirement ............................................................................................................... 391

22.9.5 Design and Standardisation .................................................................................................... 392

22.9.6 Drawings ..................................................................................................................................... 393

22.9.7 Quality Assurance ..................................................................................................................... 394

22.9.8 Material of Poles and Manufacturing ...................................................................................... 394

22.9.9 Technical Data ........................................................................................................................... 394

22.9.10 Ultra Violet And Weathering Protection ............................................................................. 395

22.9.11 Mast Arms .............................................................................................................................. 395

22.9.12 Construction Detail ............................................................................................................... 395

22.9.13 Exterior Protection & Spare Paint ....................................................................................... 396

22.9.14 Marking ................................................................................................................................... 396

22.9.15 Design Safety Factor ............................................................................................................ 396

22.9.16 Testing .................................................................................................................................... 396

22.9.17 Installation .............................................................................................................................. 399


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22.9.18 Bonding and Earthing ........................................................................................................... 399

22.9.19 Guarantee and Warranty ..................................................................................................... 399

22.9.20 Packing, Shipping and Delivery .......................................................................................... 400

22.9.21 Lighting ................................................................................................................................... 400

22.10 CONTRACTOR’S REQUIREMENT ............................................................................................ 411

22.11 INSPECTION ................................................................................................................................. 411

22.12 DRAWINGS .................................................................................................................................... 411

22.13 STATUTORY APPROVAL ........................................................................................................... 411

22.14 SAFETY .......................................................................................................................................... 411

22.15 SPARES ......................................................................................................................................... 412

22.16 TOOLS ............................................................................................................................................ 412

22.17 TRAINING ....................................................................................................................................... 412

22.18 CONSTRUCTION, ERECTION, TESTING AND COMMISSIONING ..................................... 412

22.18.1 GENERAL .............................................................................................................................. 412

22.19 ERECTION, TESTING & COMMISSIONING ............................................................................ 415

22.19.1 GENERAL .............................................................................................................................. 415

22.19.2 EQUIPMENT, MATERIAL & SERVICES TO BE PROVIDED BY THE TENDERER 415

22.19.3 MAN / MATERIAL SUPPLY ................................................................................................ 416

22.19.4 SUPERVISION DURING ERECTION ............................................................................... 416

22.19.5 SEQUENCE OF ERECTION WORK ................................................................................. 416

22.19.6 ERECTION ............................................................................................................................ 417

22.19.7 EQUIPMENT INSTALLATION & WORKMANSHIP ......................................................... 418

22.19.7.1 ASSEMBLY OF EQUIPMENT ............................................................................................ 418

22.19.8 LUBRICATION ...................................................................................................................... 418

22.20 SAFETY REGULATIONS ............................................................................................................. 419

22.21 INSPECTION ................................................................................................................................. 419

22.22 PRE-COMMISSIONING TEST .................................................................................................... 420

22.23 START- UP (PRE- COMMISSIONING) ...................................................................................... 420

22.24 COMMISSIONING ........................................................................................................................ 420

22.25 ENGINEERING SERVICES ......................................................................................................... 421

22.25.1 GENERAL .............................................................................................................................. 421

22.26 QUALITY MONITORING AND ASSURANCES ........................................................................ 423

22.26.1 GENERAL: ............................................................................................................................. 423

22.26.2 INSPECTION AND TESTING ............................................................................................. 424

22.26.3 OPERATING MANUALS AND MAINTENANCE INSTRUCTIONS ............................... 424

22.26.4 “AS- BUILT” DOCUMENT ................................................................................................... 425

22.26.5 PROJECT HANDBOOK ...................................................................................................... 425

22.27 LIST OF PREFERRED MANUFACTURERS ............................................................................. 425

22.28 STORM WATER DRAINAGE - SPECIFICATION ............................................................................. 428

22.28.1 General ................................................................................................................................... 428

22.28.2 Scope of Work ....................................................................................................................... 429

22.28.3 Design Requirement:............................................................................................................ 429

22.28.4 Civil Works ............................................................................................................................. 431

22.28.5 As Built Drawings .................................................................................................................. 433

22.28.6 Applicable Codes .................................................................................................................. 434

22.28.7 Design Guidelines ................................................................................................................. 434

22.28.8 Samples and Tests ............................................................................................................... 435

22.28.9 Protection of Utilities ............................................................................................................. 435


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22.28.10 Tests During Construction ................................................................................................... 435


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1. Project background

Aligarh city is in the northern Indian state of Uttar Pradesh. The city is located around 140 km southeast

of New Delhi. It is the administrative headquarters of Aligarh District, Aligarh Police Range and Aligarh

Division. It is mostly known as a University town where the famous Aligarh Muslim University is located.

The Aligarh division includes Aligarh, Etah, Hathras, and Kanshi Ram Nagar districts. Aligarh has one of

the best educational institutes in India. Aligarh is also known as City of Locks due to huge presence of

small and big lock industries. With the presence of such prominent institutions and industries, Aligarh

needs to revive and upgrade its drainage and road infrastructure.

In line with city’s requirements and mission objective, ASCL intends to take-up the works of infrastructural improvement with respect to Storm water drainage, improvement of road junctions & development of smart road within ABD area, under Smart city mission.

Board Scope of work for Storm water drainage is as defined below:

• Survey, Design, Engineering, Construction, testing and commissioning including operation and maintenance of constructed storm water drain in ABD area of Aligarh Smart City.

• Storm water drainage network covering entire ABD area.

• Efficiency improvement in Storm water drainage system.

Works under Junction Improvement will include:

• Redesign of junctions along with provisions of median, footpath, pedestrian crossings, signage

etc as per standards and site requirements.

• Achieving uniform carriage ways and adequate public facilities as per standards.

• Widening of RoW as required.

• Undergrounding of electrical and other utilities as per project scope.

• Integration of ITMS and such other provisions as per scope of work.

Works under Smart road will include:

• Redesign of entire road stretch along with provisions of median, footpath, pedestrian crossings,

signage etc as per standards and site requirements.

• Achieving uniform carriage ways and adequate public facilities as per standards.

• Development of activity plazas as per project scope.

• Undergrounding of electrical and other utilities as per project scope.

• Integration of ITMS and such other provisions as per scope of work.


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2. Necessity of the Project

Storm water drainage and road infrastructure is a basic need for measuring infrastructure status of any

Urban Local Body (ULB). Lack of proper drainage system creates inconvenience to the commuters and

nearby residents. This when become severe, can cause severe damage to the property and to the lives

of the nearby residents. During rainy season, due to the inadequate sizes of the drains large quantities

of storm water overflowing the existing drains onto the streets. This water along with sullage/sewage

in the drains obviously results in very unhygienic conditions, often becoming perilous and gets stagnated

in low-lying areas which become breeding places and aids in spreading of water borne diseases besides

presenting unaesthetically appearance. Improvement of road transportation along with drainage

system and electrical distribution as a subset of utilities along road may drastically improve daily living

standards and aesthetic appearance of a city.


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3. Objectives of the Project

a. Drainage system

The objective of the project is to analysis carrying capacity of existing drains and develop drains by

establishing proper outfall systems in Aligarh city. By improving the drainage infrastructure facilities,

relief from water logging could be provided to the municipality area.

The municipal area is severely affected by the prolonged accumulation of rainwater over the streets,

markets and low-lying area of the city due to inadequate drainage infrastructures. The city is severely

affected during rainy season due to water stagnation. The main objectives of providing storm water

drainage system are;

• to dispose of rain water safely

• to prevent flooding of roads and low-lying areas and damage of roads during the storm

• to improve aesthetic value of the city and

• to prevent foundation problems due to water logging

b. Junction improvements

Idea for implementing this component is to develop better junctions by establishing nationally /

internationally accepted standards for smoother traffic and pedestrian flow in Aligarh city. The

objectives are:

• To achieve uniform carriageway width for enhanced traffic flow.

• To provide dedicated pedestrian walkway and crossings for safe and smoother flow.

• To re-align geometric designs as per standards and practise for minimising conflict points.

• To provide adequate pedestrian facilities as per standards.

c. Smart road

Idea for an equitable distribution of road among traffic and pedestrians forms the basis for this

component. It may come up as a pilot project showcasing one of its kind road in Aligarh. The objectives

are:

• To achieve uniform carriageway width for enhanced traffic flow.

• To provide dedicated pedestrian walkway and crossings for safe and smoother flow.

• To re-align geometric designs as per standards and practise for minimising conflict points.

• To provide adequate pedestrian facilities as per standards.


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4. Project location

The project area (ABD area) of Aligarh is spread over 5 square acres in Aligarh. Figure below presents the location of ABD area within Aligarh city and its connectivity.

Figure 4-1 : Aligarh with ABD Area & Regional Context


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5. Scope of work

The Scope of contract for construction (Design Build) and Operating period is detailed out in sections below.

a) SCOPE OF CONTRACT FOR DESIGN BUILD PERIOD The Scope of work for Water supply, Sewerage & Storm water drainage during Construction (Design Build) period is detailed out in Table-1, Table -2 & Table-3 respectively. Table 1: Scope of work and services – Storm water drainage

S.no Description Indicative quantities

1 Preparation of System improvement Plan (SIP) within specified period and according to the contract conditions. SIP Preparation & Implementation shall include but not limited to the Topographical survey to determine existing storm water drains alignment, levels, M/H positions, including tracing of buried manhole chambers along alignment, measurement of exact length between manhole chambers & invert level; Hydraulic modelling all complete

2 Desilting & condition assessment of the existing storm water drainage system by Temporary/ permanent plugging and blocking of storm line, branch connections for diversion of flows and removal of all plugs etc; Provide everything else required for diversion of flow by pumping and/or bypassing and to maintain the storm water drainage system functioning normal and managing the flow without any surcharging, overflows etc. during the de-silting, cleaning of the storm water drain including loosening, desilt and thoroughly cleaning and removing debris and objects such as boulders, bricks etc. bacteriological slimes, roots, encrustations, grease, carbonated deposits, etc. from the drains including disposal of silt / debris/ malba / objects etc. including solidification of silt/ malba /debris for disposal to the dumping sites, CCTV/ Photographic survey including pan and zoom inspection of laterals and defects and submission of reports,

3 Preparation of detailed design & vetting of complete project proposal from vetting institute (IIT / AMU / NIT)

4 Supplying, constructing, testing & commissioning of RCC drains of required size and length, including all necessary earthwork, manhole chamber & Inspection chambers, drain covers, road restoration etc.

5 Operation and maintenance of system. 5 Years of O&M including 2 years of DLP after commissioning


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Table 2: Scope of work and services – Junction improvement works


1 Carrying out detailed surveys and tests in the project area. Surveys shall include topographical surveys, traffic & pedestrian surveys, CBR tests etc required for planning / preparation of designs as per scope of work.

2 Preparation of detailed reports and good for construction drawings / documents for acquiring client’s approval.

3 Preparation of detailed design & vetting of complete project proposal from vetting institute (IIT / AMU / NIT)

4 Supplying, construction and commissioning of all civil works, road and allied works, plantation works, utility works etc including dismantling and rehabilitation as per site requirements and scope of work.

5 Integration of all existing and proposed ITMS and other such utilities.

6 Operation and maintenance of the project area. 5 Years of O&M including 2 years of DLP after commissioning

Table 3: Scope of work and services – Smart road works



3 Preparation of detailed design & vetting of complete project proposal from vetting institute (IIT / AMU / NIT) along with client’s approval.

4 Design, Supplying and commissioning of all civil works, road and allied works, plantation works, utility works etc including dismantling and rehabilitation as per site requirements and scope of work.


6 Operation and maintenance of the project area along with tapping of potential revenue sources.

5 Years of O&M including 2 years of DLP after commissioning

The Scope of Services shall include all technical, managerial, administrative, commercial, environmental and social interventions as required in accordance with acceptable storm water drainage utility, junctions & smart road construction and management practices. The Scope of Services mentioned in Tables above is neither exhaustive nor complete and is indicative only and the contractor is required to undertake his own detailed investigation of the Project Facilities to determine the complete Scope of Services for achieving the Minimum Service Levels as stipulated in the bid document.

b) SCOPE OF OPERATION PHASE AND MAINTENANCE


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The Operation Services are divided in 2 categories. 1) O&M of created assets during DB period. 2) O&M of existing Assets as indicated in this document. The Contractor will be required to operate and maintain the constructed and existing assets in such a way to meet the consumer demands and as agreed upon during the SIP stage. Table 4: Scope of Works under Operation Phase


1 Establishment of Consumer Relation Management Centres (1 No.) and central control centre at a convenient location in agreement with client. This shall include furniture, manpower, computer software and hardware as per requirement.

2 Preparation of half yearly / annual reports for creating database of usage, complaints and redressals under the project.

3 Management & maintenance of the storm water drainage network for collection & conveyance of storm water including maintenance of entire system from gully chamber upto outfall location.

4 Management & maintenance of entire road stretch and junction sites including maintenance of all allied greenery, pedestrian areas, plazas etc. Management shall exclude all such activities which are agreed to be in scope of ULBs or law and order departments.

5 Contractor shall provide continuous on-the-job training that will start from the day the contractor gets mobilized, and other capacity building programs by the contractor as important regular activities so that there is a smooth takeover from contractor on contract completion from commissioning date.

The Scope of Services shall include all technical, managerial, administrative, commercial, environmental and social interventions as required in accordance with acceptable storm water drainage utility, junctions & smart road construction and management practices. The Scope of Services mentioned in Tables above is neither exhaustive nor complete and is indicative only and the contractor is required to undertake his own detailed investigation of the Project Facilities to determine the complete Scope of Services for achieving the Minimum Service Levels as stipulated in the bid document.


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6. Detailed Scope of Work for Strom Water Drainage-Rehabilitation

of Storm Water Drainage system in ABD area

Storm water drainage system is basic need for measuring infrastructure status of any Urban Local

Body (ULB). Lack of proper drainage system creates inconvenience to the commuters and nearby

residents. This when become severe, can cause severe damage to the property and to the lives of

the nearby residents. During rainy season, due to the inadequate sizes of the drains large quantities

of storm water overflowing the existing drains onto the streets. This water along with

sullage/sewage in the drains obviously results in very unhygienic conditions, often becoming

perilous and gets stagnated in low-lying areas which become breeding places and aids in spreading

of water borne diseases besides presenting unaesthetically appearance.

Objectives of the Project

The objective of the project is to analyse carrying capacity of existing drains and develop adequate

sized drains by establishing proper outfall systems in ABD area of Aligarh smart city project. By

improving the drainage infrastructure facilities, relief from water logging could be provided to the

area.

The ABD area is severely affected by the prolonged accumulation of rainwater over the streets,

markets and low-lying area of the city due to inadequate drainage infrastructures. The city is

severely affected during rainy season due to water stagnation. The main objectives of providing

storm water drainage system are;

• to dispose of rain water safely

• to prevent flooding of roads and low-lying areas and damage of roads during the storm

• to improve aesthetic value of the city and

• to prevent foundation problems due to water logging

Condition assessment of existing drainage system is required to be done. Various aspects are to be

considered in the existing situation, locations of drains, catchments which are contributing the

flow, level of accessibility for cleaning and maintenance etc.

Basic problems of drainage system of ABD areas are described below.

1) Drains carry sullage from houses in dry weather and mix with rain water during Monsoon

2) Many drains are filled with plastics, solid waste and silt. Due to this, drains are chocked and

carrying capacity of drains has been reduced significantly.

3) Aligarh city has depressions and low-lying areas in various regions. This cause the runoff

generation flow of water towards central zone resulting in the formation of shallow lakes and

wetland in these areas during rainy season.

4) Poor Drainage Condition due to chocking & siltation add up more severity to the situation which

results in the condition of spilling over of drainage during monsoon period.

5) Poor drainage conditions of existing drains cause water logging in several depressions in the

ABD area.


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6) At present, Aligarh ADB area has drainage system throughout the area. But there are some

existing drainage systems without a definite outfall. Last mile connectivity of these drains is to be

ensured

Conditions of Existing Drainage System and scope of work

Mostly drains are on both side of road, however, there are few stretches where drain is on one side.

It has also been observed that some roads/streets are not having drains. Topography of Whole

Aligarh is such that it is forming a bowl shape. It means that levels are lower in central part and

levels of outer part of city are comparatively higher. Therefore, storm water drainage system is

combination of pumping and gravity drains.

Some part of road /street is not having drain while upstream/downstream of that stretches have

proper drains. It was also observed that drains are in bad shape at many places. Drains are broken

at some place, plaster is stripped at some places or smoothness of base has been affected over a

period of time. Reconnaissance survey of ABD area is needed to be done for finding discontinuity

of drains at various places

Most of the drains are choked due to siltation. Solid waste is also finding its way into the drains and

reducing the discharge carrying capacity. At few places it was observed that even drain is cleaned,

water is being flowed slowly and up to the top of the drain. There is almost negligible free board.

This may be due to inadequate slope or size.

Aligarh city is surrounded by Aligarh drain in the South- West and by Jafri drains in the North East

which caters as an outfall for the storm runoff of entire city. Aligarh drain joins the Jhira River near

Sadabad and Jafri drain joins Lahtoi drain near Adaun village which finally meets to Sengar River.

Both the rivers ultimately meet to Yamuna River.

Some pumps & motors in existing pumping stations have not been replaced even after lapse of 15

years. As per CPHEEO manual, life of electro-mechanical components is 15 years. After 15 years

efficiency of pumps decreases, and it results in reduction of pumping rates during heavy rains. All

old electro mechanical equipment including pumps are to be replaced.

For complete planning of storm water drainage system, necessary survey, data collection, and

analysis of data is needed to be done. It is envisaged to cover each street/pocket of ABD area with

drain so that no water logging is experienced. It is also planned to segregate storm water and

sewerage by providing a separate sewerage system and storm water drainage system. Adequacy of

all existing drains is needed to be checked, and all undersized drains are needed to be dismantled.

However, all recently constructed RCC drains in ABD area which are found adequate are to be

retained.

Construction of entire storm water drainage complete system including networks from

connections of buildings, culverts, facilities and points of generation up to ultimate disposal. The

scope includes excavation, dewatering, ramming, refilling, disposal of surplus excavated soil and

clearance works, bedding, appurtenances etc., complete in all respect.


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Drainage system shall be of Reinforced Cement Concrete (RCC) rectangular drains (covered) with

provision of access manholes (at every 30m interval) and other associated facilities such as RCC

culverts, lined detention ponds, silt traps, screens etc. shall be provided. Drains of width should be

taken as per the CPHEEO guidelines and shall be opened.

Detailed design and drawings including cross-section, long sections and final network plan

Assess the status of the existing storm water drainage at sites, its functionality, structural

soundness, status of equipment wherever pumps are installed (if any) for handling of storm water,

other structures for detention/retention of storm water, any other facilities for handing the storm

water, and assess the levels of deficiencies such as problem areas, clogging/silting of drains,

encroachments on the natural drains, unplanned developments which are likely to be flooded in

storm flows, critical flooding areas and reasons thereof.

Short term measures are already being taken by urban local body to reduce the water logging

problem of the ABD area and improve storm water drainage system as a whole. However, it will

not be a permanent solution. A comprehensive storm water drainage system is required in long

run.

For planning, designing and implementation of adequate and efficient storm water drainage

system, following steps are to be taken up

1) Topographical Survey

2) Rainfall data collection & Analysis

3) Land use map study & Run off coefficient computation

4) Catchment area demarcation

5) Run off Computation

6) Selection of material for drains & Culverts

7) Design of drainage network of drains for sizing, slope etc

8) Provision of culverts for cross drainage works

9) Preparation of Layout plans and other standard drawings

Survey and Investigations

Reconnaissance Survey

Reconnaissance survey is required to be done to assess existing drainage system of ABD area

including various low-lying areas, pumping locations, major and minor nallas, and outfall locations.


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Topographic Survey

Base stations are to be established at the starting of survey connected to Indian Datum. After

establishing base stations, primary stations are to be established at the various locations in the

boundary of the projects for providing control grid within the project area at specific interval using

DGPS.

Secondary stations or control points are to be established for carrying out detailed topographic

survey, using static DGPS survey procedure with observation time of minimum 1hrs.

Separate teams are to be deployed for carrying out detail survey using Total station connected to

the DGPS grids established using DGPS for recording the spot levels and co-ordinate & in collecting

urban features and infrastructure foot prints. Apart from the ground levels and co-ordinates the

following features/establishment are to be collected:

• Major and minor storm water drains.

• Drain dimensions, invert levels.

• Existing ponds/water bodies.

• Foot prints of all buildings, monuments and structures.

• Natural or artificial drain.

• Electrical lines and poles location.

• Route of existing storm water drainage line (Trunk main & internal collection network). (If

any).

• Existing road with ROW. (Bituminous and concrete).

• Existing Kaccha road.

• Bridges and culverts.

• Existing Railway line.

• Wells.

• Transferring of level reference

Details are to be collected like roads, width of the road, type of road, road divider, compound wall,

circle signals, sign board, traffic signals, dust bins, OFC pillars, electrical pillars, junction box,

transformer, electrical post, telephone post, major trees, temple/church/mosque, culverts, bridges,

storm water drain, width of the storm water drain, top level of storm water drain, invert level of

storm water drain at every junction, contouring are covered in this topographic survey.

Rainfall Analysis:

Rainfall analysis is needed to be done as per CPHEEO manual to draw Intensity Frequency

Duration(IDF) Curves.

Design Storm Frequency:

Design storm frequency shall be taken as per CPHEEO manual.


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Catchment Area Demarcation:

Catchment area demarcation of ABD area shall be done considering Topograhical survey, water

bodies, highway/railway, ridge lines and other data.

Storm Water Disposal Approach:

There are 2 major drains in Aligarh i.e. Aligarh drain and Jafri Drain. Drainage network of ABD area

shall be planned in such a way that storm water of ABD area is discharged into these major drains

with last mile connectivity.

Time of Concentration

Time of concentration is another dynamic variable contributing to the runoff catchment depending

upon the distance in the drainage basin to the inlet of the drain, catchment characteristics and the

variation in ground levels. The distance from the farthest point and the ground level difference are

calculated for each length of drain under consideration. Time of concentration (tc) is equal to inlet

time ti plus the time of flow in the drain tf. The inlet time (ti) is dependent on the distance of the

farthest point in the drainage basin to the outfall, the shape, characteristics and topography of the

basin. The inlet time (ti) is calculated by the empirical formula, mentioned in IRC-SP-50 (IRC -

Special publication on urban drainage system). This empirical formula is given below:

ti = (0.87) (L3/H)0.385

Where,

ti = Inlet time in hours

L = Distance (km) of farthest point of catchment to point under consideration

H = Level difference (m) between farthest point of catchment and point of consideration.

Tc= ti + tf;

where tf = time of flow (length/velocity)

Based on time of concentration of respective drain, design intensity to be found out by IDF curves

Runoff coefficient: Run off coefficient shall be calculated depending upon the imperviousness

of are and duration of storm. CPHEEO Manual’s recommendation shall be adopted in design of

drainage system.

The run off to drainage system depends upon the imperviousness of the catchment area. The

imperiousness varies according to soil and the density of built up area in a town.


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The manual on sewerage and sewage treatment published by Central Public Health &

Environmental Engineering Organization (Manual-CPHEEO) has recommended the following

values for adoption. The suggested frequency of flooding in the different areas is as follows:

Commercial and Industrial area 70 to 90%

Residential area

• High density

• Low density

60 to 75%

35 to 60%

Parks and undeveloped area 10 to 20%

The weighted runoff coefficient of a drainage basin for the flow concentrating at a point is estimated

as C=(A1*C1+A2*C2)/(A1+A2).

Computation of Design Flow

The entire storm water would not reach the storm water drains. Fraction of it would flow to storm

water drains, which depends on the imperviousness, topography including the depressions and the

water bodies /pockets, shape of the drainage basin and duration of the storm. The peak runoff at

any given point is calculated using the following formula

Q = CIA / 360

Where,

Q – Discharge in m3/sec

C – Runoff coefficient

I – Design rainfall intensity mm/hr

A – Contributory area in hectares

Sizing of the Drains:

Each drain size shall be calculated based on design flow. Velocity shall be calculated using manning

formula

V = 1/n X R^2/3 X S^1/2

Where R is hydraulic mean radius

S= slope

N = Coefficient of roughness


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Determination of Capacity of Drain:

Discharge carrying capacity= V X b X d in cumec.

Free Board

IRC-SP-50 has recommended the minimum free board as given below.

S. No. Drain Size Free Board

1 300 mm bed width 10 cm

2 Beyond 300 mm & up to 900 mm bed width 15 cm

3 Beyond 900 mm & up to 1500 mm bed width 30 cm

Inlet Arrangements

Road Width Inlet Arrangement

Narrow Road

Perforated slab provided at 10m interval. Drain Cover slab flushed with the Road surface without any reduction in riding surface to facilitate enhanced traffic flow.

Wide Road

Inlet provided through inclined Pipe from catch basin to drain. Top of Cover Slab placed 300 mm above the road formation level. Gratings provided at all inlet points along with PVC 140 mm OD pipe at 10m interval.

Limiting Velocities and Gradients in Drain

It is proposed that minimum gradient to be adopted subject to ensure minimum velocity of 0.6 m/s

and maximum velocity as 3 m/sec.

Culverts

Wherever storm water drain crosses the road, slab culvert has been provided. Slab for the same

has been designed to take designed vehicular load.

Structure design:

Structure design of all rectangular drains, culverts and chambers shall be done as per relevant IS

codes

.


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Adequacy Analysis of Existing Drains:

After calculation of required sizes of drain, it shall be compared with existing drain in size, material,

slope etc. If existing size is inadequate, then it shall be dismantled and new RCC drain shall be

constructed. If material of existing drain is brick, then also it shall be replaced with RCC drain.

However, all new RCC drains of adequate sizes shall be retained.

Outfalls:

Rehabilitation of Drainage Pumping Stations:

Following pumping station are in ABD areas which are needed to be rehabilitated. All pumps and

machineries are more than 15 years old and shall be considered for replacement.

Sarai Rehman Pumping station

Gular Road pumping station

Nai Basti

All pumps, suction header with all fittings, Electrical control panels, vacuum pumps etc are to be

replaced in the pumping station

Geo Technical Investigation: Assess the soil characteristics for finding the infiltration of

rainfall within the basin and hence determine the run off coefficients based on future area

development

Working drawings: Preparation of All working Drawings of network, structure design and

drawings


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7. Summary of obligations under the contract

The summary of obligations related to Water supply, Sewerage and Storm water drainage works under the contract are mentioned in Tables below. Table 5: Storm water drainage

S.no Description Scope

Design Rehab Build Operate Maintain

1 Design, Supplying, testing & commissioning of RCC drains of required size and length, including all necessary earthwork, manhole chamber & Inspection chambers, drain covers, road restoration etc.

Yes yes Yes Yes Yes

2 Operating and Maintenance of entire Storm water drainage System within service area including gully chamber and upto discharge location.

Yes yes Yes Yes Yes

Table 6: Junction improvements




Yes Yes Yes Yes Yes


Yes Yes Yes Yes Yes


Yes Yes Yes Yes Yes


Yes Yes Yes Yes Yes

5 Operation and maintenance of the project area.

Yes Yes Yes Yes Yes


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Table 7: Smart road




Yes Yes Yes Yes Yes


Yes Yes Yes Yes Yes


Yes Yes Yes Yes Yes


Yes Yes Yes Yes Yes

5 Operation and maintenance of the project area along with tapping of potential revenue sources.

Yes Yes Yes Yes Yes

Table 8: Milestones & key time periods

S.no Sectional milestone Completion Time from stipulated date of contract start (days)

Event of start Activities

Design Build Period

1 Mobilisation 30 days Commencement Date

2 Preparatory period - Preparation and approval of Service Improvement Plan (SIP); Preparation of Plans & Design

90 days Commencement Date

3 SIP Implementation 547 days Commencement Date

Design, Construction, testing, commissioning and completion of all works as per milestones to deliver storm


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water drainage, junction improvement & smart road proposals.

Operation Service Delivery

4 Operation and Maintenance of entire existing and new assets in service area as per scope of work.

1825 days From date of takeover

O&M of entire water supply, sewerage and storm water drainage assets

5 Handing over back to Employer 30 days 30 days before End of O&M period

Joint verification of assets, Issuance of O&M period completion certificate and joint signing of Handing over document

Note: To the extent possible, Storm water drainage network, junction improvement works & smart road works on a particular stretch will be carried out simultaneously.


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8. PHASING OF CONTRACT

The contract is divided into two stages as discussed below. It is spread over the contract period from the stipulated date of Contract Commencement up to the Contract Completion Date.

• Mobilization, preparatory and construction period as per approved designs and

• Operation, Maintenance, Manage, Repairs and Service Delivery Period during the contract period till contract completion date.

a. Mobilization Period

During the 30 days mobilization period the contractor is required to:

• Establish a furnished project office in Aligarh

• Employ/mobilize the staff required for starting the preparatory work.

• Mobilize the teams for Survey & Investigation.

• Procure GIS based maps, project management etc.

• Collect and study existing utility networks and facilities.

• Baseline study for rainfall, water discharges, road usage pattern, extrapolation of data, DMAs etc.

• Mobilize vehicles, office (furnished), equipment, communication equipment.

b. Preparatory Period (Preparation of design during preparatory

period)

During the Preparatory Period, the Contractor is required to:

• Familiarize himself with the project site condition after required consultation.

• Collect data and maps etc. and review designs of project components etc.

• Confirm/ conduct topographic surveys & field tests such as soil investigation, water test, CBR etc to ascertain the levels, road width, existing services, soil & water type etc.

• Surveys for all underground utilities up to 3.0 m depth and marking on GIS based maps by linking with geo referenced points.

• Conduct Door to Door consumer survey and prepare data base if required.

• Prepare an asset inventory report for existing infrastructure within service area.

• Prepare & submit detailed design and drawings of entire Storm water drainage, junction improvement & smart road scheme including civil, structural, Electro-mechanical, Instrumentation etc.

• Prepare & submit system improvement plan along with detailed design of Storm water drainage system including hydraulic modelling.

• Get the design & documents vetted by vetting institution such as IIT-Delhi / IIT-Kanpur/IIT-Roorkee/Any other reputed Employer approved institution.

i. Deliverable Documents for SIP

Design should be prepared including sectional completion requirements such as - I. Detailed design, drawings and cost estimates of works.

II. Work plan, Methodology and timelines for implementation should be in line with the Employer’s requirements.

III. Detailing of integrated Contract Management Information System by using latest software like Primavera, Microsoft office architecture, data capture, management and reporting structures, protocols including all related hardware, software, installation.


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IV. Contractor Personnel Deployment Plan. V. Construction Plant and equipment deployment plan.

VI. Cash-flow for the entire contract with sectional completion break up. VII. Asset Replacement Schedule with justification.

VIII. Detailed methodology for continuous monitoring of the performance of the Contractor in achieving and maintaining the Performance Standards for release of the eligible Operating Payments.

IX. Compliance matrix of contract and service requirement, O&M requirement and other requirement like social, environmental, resettlement etc.

c. Operating and Management related Deliverable

I. Annual Operating Plan (AOP) covering all operations, maintenance and management requirements in the Service Area.

II. Emergency Response Plan (ERP); this shall also separately include response plan for effective emergency rectifications against any major break downs occurring in drainage network up to the service area of this contract.

III. Public Relations Plan. IV. Standard Operating Procedures (SOPs) for routine operations and emergency responses. V. Water Quality Monitoring Program, if required. VI. Energy optimization program. VII. Transmission System extension/ expansion policy. VIII. Detailing of an Integrated Management Information System (MIS) including its architecture,

data capture, management and reporting structures, protocols including all related hardware, software, installation, and operation and maintenance requirements.

IX. Periodic reporting plan including the formats for different performance reports. X. The computer hardware and software improvement plan for continued operation of the

MIS, instrumentation etc.

d. SIP Schedule

Schedule of various activities of the design is shown in Table below. Table 9: SIP Schedule & Penalties

S.no Activity Target period for completion from contract commencement date

Amount of penalty to be recovered in case of delayed output

1 Mobilisation on site 30 days

2 Topographical survey, classified traffic surveys, pedestrian surveys, ground profiling of the service and utilities, soil investigations, water tests, CBR tests and any other surveys to ensure accurate design.

45 days Rs. 25,000 per day

3 Development of complete GIS map using Arc GIS for storm water drainage system, existing and proposed utilities, lighting scheme etc on all project sites.



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4 Complete system design and drawings, preparation of abstract of quantities and cost estimates for the designs.


5 Preparing PERT chart, manpower, equipment, mobilisation plan, cash flow plan, detailed methodology of continuous monitoring etc.

90 days

6 Detailed O&M plan, Standard Operating Procedures and policies plan, Performance measurement plan.


7 Compilation and submission of designs and drawings in complete for initiating vetting by vetting institute and client / employer’s approval at earliest.


The contractor shall submit the outcome of each activity for review of Employer’s Representative immediately after completion of the activity. Employer’s Representative will review the outcomes on regular basis and will submit their review comments within 21 days of receipt of the document. Contractor will develop data bases for various service quality and delivery parameters related to storm water, junctions & smart road. Contractor shall also submit the activity wise the Monthly Report for monitoring by the employer. Progress of all activities will be reviewed on weekly basis for design part. Reports will be on Monthly basis during construction part and on weekly basis during operations part. In case of delays in meeting timelines of design activities, penalty as per the sums indicated in table above shall be imposed and recovered from due payments. If the delays that occurred in activity milestones are covered by the Contractor within the stipulated or extended period for Compilation and submission of designs in complete, which is not attributable to Contractor, penalty imposed on account of such delays will be refunded.


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9. Methodology for Measurement of Performance Standards

The Contractor shall develop a robust methodology and framework for measurement and monitoring of Performance Standards stipulated under the contract and proposed as part of the SIP. The Employer with the assistance of the Employer’s representative shall verify the same and upon agreement between the Parties the agreed methodology shall form the basis for monitoring the performance of the Contractor and apply the Non-Performance Adjustments on the eligible Operating Payments in case of failure to meet the performance standards.


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10. Methodology for Site Acquaintance

As part of this activity, contractor is required to: I. Establish contact with all relevant stakeholders NNA, ADA, PWD, NHAI, Electricity

Distribution Company, Telecommunication companies and the local traffic police and other government agencies including consultants.

II. Become familiar with the drainage system in service area, junction sites, smart road stretch and relevant applicable standards and guidelines for design of the components in coordination with existing assets and current on-going works in and around the Service Area. The contractor shall also study the works being carried out by NNA, ADA and other departments being undertaken in and around the area.

III. Satisfy himself with the nature and scope of work and the prevailing Site conditions. IV. Be familiar with governing Laws and regulations in order to undertake studies and

construction activities under the Contract such as:

• Occupational health and safety including workers compensation.

• Signage for construction works.

• Permissions and co-ordination required from the different agencies.


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11. Survey and Mapping

The contractor shall digitize and validate all the footprints, roads, water bodies, electricity poles, water supply and other infrastructure components in the service area on a base map provided by the employer. A detailed topographical survey of the area shall be carried out using Total Station equipment and the spot levels and the contours at 0.5 m interval shall be drawn on the GIS based digitized map in Arc GIS. Contractor will survey all underground utilities upto 3.0 m depth and mark on GIS based maps by linking with geo referenced points. All other relevant surveys like classified traffic volume count, pedestrian count, accident statistics etc are to be procured / carried out simultaneously.


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12. Waste disposal

Contractor has to safely dispose-off and level all the C & D and other waste produced on site on his own cost at earmarked locations by the Employer within municipal limits as per instructions and handling guidelines.


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13. SIP Implementation

The Scope of Services during the implementation period shall essentially comprise of implementing the approved SIP based on rainfall and other relevant data for storm water drainage network. SIP will be implemented in accordance to international best practice and industry standards and sufficient care shall be taken by the Contractor in minimizing interruptions, traffic disruptions and ensuring good and timely communications with the stakeholders in the service Area. During work execution, contractor would be required to inform the residents, say, of a particular street/ stretch, well in advance about the type of work, inconvenience expected, timelines for various works, etc. Contractor has to have a strong Public Relations and Community Outreach team. Contractor will plan sequencing of activities to synchronize storm water drainage works, junction improvement works & smart road works to minimize the road excavation and restoration in the streets. All the Works and interventions proposed as part of the SIP shall be in conformity with the specifications set out in the Employer’s Requirements. Implementation of all the works in a given street / stretch shall be taken up simultaneously so that the people living in the area are not affected multiple times.

a. Storm water drainage system

The Contractor shall augment and rehabilitate the existing storm water drainage system in service area as detailed hereunder and included as per the Bill of Quantities (BOQ) for the purpose of pricing in the Price Bid for laying, jointing, testing and commissioning the storm water drainage network along with manhole chambers and all allied works as per scope indicated in the bid documents.

b. Road restoration

Road restoration is a critical activity which requires special attention of the contractor. Following guidelines shall be followed:

• The contractor shall have to restore the road up to WMM stage including refilling trench in layers, watering, rolling and compacting within 10 days after trenching is completed in a particular street/reach. The contractor shall ensure that uncovered WMM length in total does not exceed 5.0KM at any stage of work and will complete the bituminous work regularly.

• Contractor shall erect informatory board at his own cost showing type of work, inconvenience expected & timeline for various construction activities going to take place in a particular street or a particular reach of road as per direction of Engineer in charge. Contractor shall submit detour and traffic control plan and get approval from Engineer in charge and appropriate government authorities prior to carry out the works. All necessary provisions shall be ensured as defined in bid document.

• Contractor shall deploy a community outreach team to make strong relation with public prior to start of work in a particular ward/ area.

• The contractor shall have to do the sequencing of activities as per direction of engineer in charge to synchronize storm water drain works, junction works, and smart road works to minimize the road excavation and restoration in the street.

• The cutting of existing C.C. pavement shall be done by using mechanical cutter to ensure cutting in regular line and the laying of C.C pavement shall be done below 30-degree ambient temperature.

a) Provisions of road restoration – Bituminous Road

• For laying on B/T Surface - for road width up to 7 m, restoration up to WMM stage in trench width and bituminous work (top wearing surface) in full width of the Existing Road.


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• For road width more than 7 m, restoration up to WMM stage in trench width and bituminous work (top wearing surface) limited to 7 m (2 lanes) duly covering the trenches.

b) Provisions of road restoration – Cement Concrete Road

• For cement concrete roads, restoration of different layers including lean concrete and CC pavement shall be done in trench width only.

In Bituminous road restoration, use of paver is mandatory for carriage way width above 3.75 m of road restoration. Notwithstanding all which has been laid down on road restoration, Employer’s representative with reasons recorded and prior permission of Employer will be authorized to come up with the site-specific solution based on prevailing ground situation.


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14. Management Information System

Contractor shall develop, establish, operate and manage during the entire contract period a comprehensive Integrated Management Information System (MIS) in respect of all matters including but not limited to:

I. Design Built activities. II. All the Operation and maintenance activities. III. Financial management, including accounting systems. IV. Performance information systems. V. Others as identified during SIP preparation and implementation.


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15. From Final Take over date to expiry of Operation Period of 5

years

a) Scope of Operation Services in Storm water drainage Sector: Managing the storm water drainage network for collection and discharge of storm water till outfall including maintenance of entire system including gully chamber/inlet gratings. If the contractor fails to achieve the services defined in performance targets, then the contractor shall be levied with Non-Performance Adjustment as specified in this document.

b) Scope of Operation Services in Junction improvement Sector: Maintaining all the project components for day to day running repairs along with maintaining the existing components and greenery related to scope of work.

c) Scope of Operation Services in Smart road: Maintaining all the project components for day to day running repairs along with maintaining the existing components and greenery related to scope of work. Operating all plazas and public utilities falling under project area.


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16. Electricity Consumption

The contractor shall be responsible to maintain the power factor for all the facilities installed by him during operation and maintenance period. Electricity connections at all proposed permanent installations will be applied by contractor and will be reimbursed to contractor. Power charges will be paid by the Contractor to the Electricity utility company. Penalty if any levied by the electricity company for not maintaining the power factor will be recovered from the contractor as per actual.


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17. Maintaining Performance Standards

The performance standards for the Design Build works during the SIP implementation shall consist of: I. Quality of work as per specifications.

II. The time line for completion as per the milestones defined. The liquidated damages will be levied for non-achievement of these milestones in time, as per the provisions in Particular Conditions of Contract.

The measurement of the quality of work will be as per the tests laid down in the specifications of various items while the measurement of the achievement of milestones is based on the defined works and defined dates. Payment of operation services will be in accordance to the procedures in contractor payments. Operation service contract will be governed by Performance Standards provided in Performance Targets and Measurement attached to Particular Conditions of Contract.


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18. Periodic Reports

The Contractor shall prepare and submit periodic reports on different plans, progress of Works, performance standards etc., including exceptional reports on emergencies if any. The reporting requirements are provided in Table below. The Contractor shall as part of the SIP develop the required formats for the periodic reports and shall also identify any critical reporting requirements in order to enable timely decision making by the Employer. Table 10: Summary of Periodic Reporting Requirements

Deliverable First Report Follow-up Tasks

Design Documents Submit designs not later than 90 days from the Contract commencement date

Not applicable

Annual Operating Plan (AOP) Submit Annual Operating Plan (AOP) not later than 90 days from the Commencement Date

Submit AOP for subsequent years not later than 90 days prior to end of previous year plan

Standard Operating Procedures (SOPs) for operation and management

Submit report not later than 360 days after Commencement Date

Complete implementation and training 30 days before commissioning of first zone and subsequently whenever new employees join for O&M.

Management Information Systems (MIS)

Submit report not later than 90 days after Commencement Date

Generate monthly reports from MIS

Quarterly Performance Report (QPR); the QPR shall include a brief summary of the relevant issues detailed in the Monthly Performance Reports including a summary analysis of water supplies and lapses in billing, if any.

Submit Quarterly Performance Report for any and every quarter before 10th day of subsequent quarter commencing from the Commencement Date

To be submitted every quarter

Annual Performance Report (APR); the APR shall include the annual accounts, cash flow, and financial performance

Submit Annual Performance Report for any and every year before 20th day of subsequent year

Repeat for every year

Asset and Facilities Register Submit Asset and Facilities Register within 150 days from the Commencement Date

Submit updated Asset and Facilities Register before 30th day from the completion of an operating year


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19. Design Criteria

a) For Storm water drainage system Storm water collection systems shall be designed to provide adequate surface drainage. The new network shall be integrated with existing Trunk Strom water drainage network of service area. The general considerations in design of storm water drain shall be:

• Drains shall be design for appropriate design frequency/return period depending on importance of development and economic considerations.

• Drains shall be planned to take into consideration the ground levels, slope of the ground, valley and ridges and also the land uses planned for urban development.

• Drains shall be planned to get good longitudinal slope, considering the nature of soil and subsoil water level.

b) For Junction improvements

Criterion for designing the junctions is based on the basic design principles for intersection which takes into consideration approach speed, land constraints, sight distance, and composition and travel pattern of all road users. Design of the intersections affects the capacity of the any road sections and also facilitate safe movement of all road users. The traffic movement patterns and traffic volumes of the approaching road during peak hour of the day decides;

• Number of lanes including auxiliary lane.

• Traffic control devices and channelization. The basic principle of intersection design is to minimize the number of conflict points and furthermore to reduce speed of MVs so that number and severity of crashes could be reduced especially during collision between MV (e.g. car) and NMT (e.g. pedestrian). Intersection should follow uniform design standards:

• To maintain consistency and continuity of the infrastructure. The uniformity includes design speeds, curves, vehicle turning radius, super elevations, shoulder width, length of speed change lane, channelization types, and signs and markings.

• To include all road users in intersection designs such as raised pedestrian and cyclist crossings, path markings and segregation by posts. The priority should be given to pedestrian crossings and their safety, secondly for public transport and cyclists and the MVs.

• Parking and halting of any MVs should be strictly banned for at least 50 m on each arm of the intersections.

c) For Smart road The ‘Smart Roads’ initiative aims to add value to the Area Based Development (ABD) part of the proposed smart cities by means of bringing in visual and utilitarian changes in existing main roads. Key components under smart road are:

• Development and strengthening of carriage way with uniform lane widths and geometric designs of roads and junctions as per street design standards.

• Development of footpath and cycle lanes wherever feasible - with uniform footpath widths, pedestrian friendly ways and barrier-free designs.

• Construction bus bays, auto bays and on-street parking wherever essential.

• Beautification and landscaping including greenery and carbon sinking.

• Provision of smart street furniture and public utilities such as including communicative signage, lane marking, public leisure spaces etc.

• Smart LED lights, CCTV and various sensors as per city requirement.

• Accessibility standards as prescribed by the MoUD, etc.

• Particular focus on safety of women, children, elderly, etc.

Various Design criterion considered in the project are:


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• Geometric Standards.

• Design Speed.

• Horizontal Alignment.

• Super Elevation on Curves.

• Cross-Sectional Elements.

• Camber.

• Vertical Alignment.

• Road Signage and Markings.

• Junctions.

• Plan & Profile drawing.

• Cycle Track.

• Footpath.

• Sewerage Collection Network.

• Street Lights

a. Structural Design Requirements

This section specifies the Design requirements pertaining to Civil Structural works. The Civil General Technical Specifications and Standard Specifications included in the tender shall be read in conjunction with these requirements.

b. Design Submissions

The Contractor shall to submit 5 (Five) copies of complete detailed design calculations of each of the components such as substructure and superstructure together with general arrangement drawings, construction drawings and explanatory sketches as required by the Employer. Separate calculations for substructures or superstructures submitted independent of each other shall be deemed to be incomplete and will not be accepted by the Employer. The design considerations described hereunder establish the minimum basic design requirements. However, any particular structure shall be designed for the satisfactory performance fulfilling the functions for which the same is being constructed. The Contractor shall also check the stability of completed structures to be used for the project.

c. Design Standards

All designs shall be based on the latest Indian Standard (I.S.) Specifications or Codes of Practice. The design standards adopted shall follow the best, modern and sound Engineering practice in the field based on any other international standard or specialist literature subject to such standard reference or extract of such literature in the English language being supplied to and approved by the Employer’s Representative.

d. Design Life

The minimum design life of all structures and buildings shall be 60 years and for roadworks shall be 10

years.


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e. Design Loads

All buildings and structures shall be designed to resist the worst combination of loads/stresses under test and working conditions; which includes dead load, live load, wind load, seismic load, stresses due to temperature changes, shrinkage and creep in materials, dynamic loads etc as applicable.


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20. Electrical brief – Junction Improvements

20.1 ELECTRICAL SYSTEM

20.1.1 GENERAL INFORMATION

20.1.1.1 EXISTING POWER DISTRIBUTION

(a) There are existing 14 Junctions being planned to be augmented / modified

under Smart City Package.

(b) Dakshin Vidhyut Vitran Nigam Limited (DVVNL) Aligharh is the power

distribution agency in Aligarh. Primary substation in Aligarh is 132kV Sarsaul

substation. 17 nos. 33/11kV substation give power supply to different location

of Aligharh area. DVVNL Aligarh has divided in four division such as EUDD-

I, EUDD-II, EUDD-III & EUDD-IV. Most of the proposed junction falls in

EUDD-I & IV.

(c) Junctions are namely as:

TABLE 20.1-1 : Junction and Electrical Division Details

S. No. Junction Name Division

1 Agrasen Junction EUDD-I

2 Kabarkutta Junction EUDD-I

3 Awanti Bai Junction EUDD-I

4 Abdullah Tiraha EUDD-IV

5 Dubey ka Padao Junction EUDD-I

6 Tasveer Mahal Junction EUDD-IV

7 Tahsil Tiraha EUDD-I

8 Masoodabad Junction EUDD-I

9 Shamshad Market Junctio EUDD-IV

10 Ram Lila Ground Chowk EUDD-I


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11 Mandar Gate Chowk EUDD-I

12 Sabji Mandi Chowk EUDD-I

13 Jama Masjid Chowk EUDD-I

14 Madipura Tiraha EUDD-IV

(d) There are predominantly 33/11kV substations from where the lines are

emanating or terminating. These substations are under EUDD-I & IV.

(e) There are various overhead lines crossing and or passing through the

junctions namely 11kV, 33kV (HT) power lines & 415V (LT) power lines.

(f) The capacity of most of the 11KV/415 Volt transformers is 63KVA, 100KVA,

250 KVA and 400 KVA.

(g) 415-volt supply (LT Supply) is distributed through overhead lines and the

individual consumer is fed through service wire connected from 415 V LT

poles.

(h) Existing overhead lines & transformer details available on below mentioned

table. Cable and transformer details are tentative only. TABLE 20.1-2 :

Existing HV/LV LINES & TRANSFORMER DETAILS AT JUNCTIONS

S. No. Junction Name Voltage

Level /

Distribution

Transformer

Overhead Line and

Transformer Details

1 Agrasen Junction

33kV a) 33kV Conductor S/C G. T.

Road Feeder

b) 33kV Conductor S/C

Malkhan Singh Feeder

11kV a) 11kV Conductor S/C G. T.

Road Feeder

b) 11kV AB Cable G. T. Road

Feeder

LT LT Aerial Bunched Cable

& Overhead Conductor


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Distribution

Transformer

(DT)

1 x 250 KVA Transformer


1 x 25 KVA (Private –

Tower)

2 Kabarkutta Junction

33kV a) 33kV Conductor S/C

Gandhi Park Feeder

11kV a) 11kV Conducor S/C G. T.

Road Feeder + 11kV AB

Cable

b) 11kV S/C Railway Feeder



Distribution

Transformer



3 Awanti Bai Junction

33kV a) 33kV S/C Gandi Park

Feeder

11kV a) 11kV S/C RLG Feeder

b) 11kV S/C G. T. Road

Feeder



Distribution

Transformer




4 Abdullah Tiraha

33Kv -

11kV a) 11kV S/C Laxmi Bai

b) 11kV S/C Marris Road

c) 11kV S/C AMU Feeder

d) 11kV S/C Abdulla Women

College

e) 11kV AB Cable Hathi Dua


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Distribution

Transformer




(Private – Abdullah

Apartment)



5 Dubey ka Padao Junction

33kV -

11kV 11kV S/C Ram Leela

Ground Feeder



Distribution

Transformer




6 Tasveer Mahal Junction

33kV a) 33kV D/C Diwani Feeder

11kV a) 11kV S/C Anup Sahar

Feeder

b) 11kV S/C Tibiya College

Feeder

c) 11kV AB Cable Jail Feeder

d) 11kV S/C Jawahar Park

Tubwell



Distribution

Transformer




7 Tahsil Tiraha

33kV a) 33kV S/C Gandhi Park

Feeder


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b) 33kV S/C Malkhan Singh

Feeder

c) 33kV S/C Lal Tal Feeder

11kV a) 11kV S/C Seema Feeder

b) 11kV S/C Banna Devi

Feeder

c) 11kV S/C Pratibha Colony

Feeder



Distribution

Transformer


8 Masoodabad Junction

33kV a) 33kV S/C Gandhi Park /

Lal Tal Feeder

b) 33kV S/C Malkhan Singh

Feeder

11kV a) 11kV S/C Seema Feeder

b) 11kV S/C Pratibha Colony

Feeder



Distribution

Transformer




(Private-Ram Saroop

Complex)


9 Shamshad Market Junction

33kV a) D/C Diwani Feeder

11kV a) 11kV S/C Anup Sahar

b) 11kV S/C Tibiya College

Blind School Feeder

c) 11kV S/C Alinga

Apartment


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Distribution

Transformer

1 x 630 Transformer

1 x 250 Transformer

1 x 100 Transformer

10 Ram Lila Ground Chowk

33kV -

11kV a) 11kV S/C Achal Feeder



Distribution

Transformer

1 x 250KVA Transformer

11 Mandar Gate Chowk

33kV -

11kV a) 11kV S/C Mandar Gate

Feeder

b) 11kV S/C Agra Road

Feeder (Dead Line)

c) 11kV S/C Tamolipada

Feeder



Distribution

Transformer




12 Sabji Mandi Chowk

33kV -

11kV a) 11kV AB Cable

Mohammad Ali Feeder-1

b) 11kV AB Cable



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Distribution

Transformer



13 Jama Masjid Chowk

33kV a) 33kV S/C Bala Akla

Uparkot Feeder

11kV a) 11kV S/C Mukhtar Hashmi

Feeder

b) 11kV AB Cable Mukhtar

Hashmi Feeder

c) 11kV AB Cable


d) 11kV AB Cable




Distribution

Transformer


(Under Substation Area)


(Under Substation Area)

1 x 100 kVA Transformer

14 Madipura Tiraha

33kV -

11kV a) 11kV S/C Madipura

Feeder

b) 11kV S/C Railway Feeder



Distribution

Transformer



(i) Some of the Street lights are installed on the same LT poles carrying 415 V

Overhead line.

(j) The LT consumers of both sides of road are fed from same 415 V LT poles.

There are have LT consumers and 11 KV consumers.


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(k) Telephone connections to consumers are fed from telephone post.

(l) Energy meter meters are normal type and are installed at the premises of the

consumer.

(m) Under Street lighting National programme (SLNP), Energy efficiency

Services Limited (EESL) will replace all conventional HPSV /MH street light

fixtures with LED light fixtures.

(n) There are many shops, commercial building, residence, vacant plots, and

Govt. offices etc. for power supply connections.

20.1.2 PROPOSED SYSTEM

The proposed system envisages the following:

(a) Supply, laying, termination and commissioning of 33 KV 3Cx300 sq.mm

XLPE armoured cable directly buried in HDPE duct with safety measures.

For details refer tender drawings.

(b) Supply, laying, termination and commissioning of 11 KV 3Cx300 sq.mm

XLPE armoured cable directly buried in HDPE duct with safety measures.

For details refer tender drawings.

(c) Installation of 11/0.443 KV Compact Substations consisting of Ring Main Unit

(RMU), dry type Transformer and LV compartment in one enclosure with

Feeder Remote Terminal Unit (FRTU) and SCADA compatible. For details

refer tender drawing.

(d) Design, fabrication and installation of RCC duct bank for road crossing for

laying 33kV, 11 KV, LT cables with future provisions. For road crossing

details refer tender drawing.

(e) Design, supply and Installation of 33kV, 11kV and LT cable laid in HDPE duct

and HDPE duct shall be directly buried in ground with complete safety

measures.

(f) HDPE duct pipe for laying 415/230 Volt consumer service connection from

feeder pillar, street lighting, telephone and communication system.

(g) Design, Supply and Laying of XLPE/ PVC cables/ telephone ducts for

distribution of power in 11KV and 433 V which replaces the 11KV, 433V and

other overhead lines.

(h) Design, Supply and installation of 11KV Ring main Units shall be installed to

provide 11 KV power to CSS and for transformers installed for interior roads

which are fed from the existing overhead lines.

(i) Installation of 433 Volt feeder pillar for providing service connection to

individual consumers though underground cables.

(j) Installation of Smart Energy meters.


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(k) Installation of Lighting poles, LED lights, lighting feeder pillar with automatic

lighting control system.

(l) Supply and installation and commissioning of DP structure for 33kV and 11

KV tapping point / Jointing with overhead conductor.

(m) The contractor’s scope of work includes but not limited to: Survey, design,

installation, erection, testing and commissioning, civil structural work

completes in all respect.

(n) Detailed design of complete electrical system is in the contractor scope,

tender drawing and bill of quantity is tentative and for reference purpose only.

The contractor is responsible for a complete, thorough and quality design for

the installation, testing commissioning of entire electrical distribution system

at site. The Contractor is responsible for the selection and design of

appropriate equipment and components to provide the best coordinated

performance of the entire system.

20.1.3 SCOPE OF WORK

For all 14 nos. junctions, existing overhead HV/LV lines shall be planned to be

taken underground. All conventional transformer shall be replaced by CSS and

11kV ring main shall be used.

For street lighting existing conventional design shall be replaced by smart street

lighting. Street lighting system is proposed for this road with required number of

smart LED Lighting fixtures, FRP/GRP poles, feeder pillars cabling etc. The

entire lighting system will have SCADA compatible for remote monitoring,

dimming, group controlling and control from central control room.

To implement System Improvement & Augmentation Scheme for existing

Electrical Network in junctions, Aligarh in Uttar Pradesh on “Turnkey basis” with

operation and maintenance of the electrical distribution system for five years.

The scope of works includes execution of the project on turnkey basis. The

contractor’s scope of work includes but not limited to: Survey, design,

manufacturing, shop testing, inspection, packing, dispatching, loading, unloading

and storage at site, transit/storage and construction insurance, assembly,

erection, civil structural work, complete pre-commissioning checks, testing &

commissioning at site, obtaining statutory clearance & certification from State

Electrical Inspector, Uttar Pradesh Electricity Department, Dakshinanchal

Vidhyut vitran nigam limited (DVVNL) Aligarh zone, Municipal Corporation

Aligarh etc. and handing over to the Owner/ concerned department after

satisfactory commissioning of complete augmentation of existing Electrical

Network in Aligarh Smart city Project area.


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20.1.3.1 ELECTRICAL

Design, Supply, installation, testing and commissioning of the Following:

(a) Design, supply, installation, testing and commissioning of 11KV/433 V

Compact Substations with dry type transformer in place of existing oil type

transformers and capable of being monitored and controlled by the Central

SCADA via FRTU and modem.

(b) Design, supply, Installation of 11kV RMU and provide power supply to 11kV

Consumer, transformer and tapping to existing 11kV overhead lines.

(c) Design, supply, laying and termination of 33KV 3Cx300 sq.mm XLPE

Aluminium cable to all junction. These cables shall be laid in HDPE duct

buried in ground at a minimum depth of 1.05m.

(d) Design, supply, laying and termination of 11KV 3Cx300 sq.mm XLPE

Aluminium cable to all junction. These cables shall be laid in HDPE duct


(e) Providing 11 KV supply to the RMU, existing 11 KV consumers/ transformer

/ 11kV Lines.

(f) Design, supply, laying and termination of 1.1 KV XLPE insulated Armoured

cable from secondary of transformer to feeder pillars in HDPE duct.

(g) Design, supply, laying and termination of 1.1 KV cable from compact

substation to feeder pillars through HDPE duct and service cable from feeder

pillar to consumers through HDPE duct banks.

(h) Design, supply, laying and termination of suitable size of Aluminium

Conductor, XLPE and PVC insulated, PVC sheathed, armoured cables of

approved make and using heat shrink type cable joints, terminations of

approved make for terminations.

(i) Design, supply, installation, testing and commissioning of Main Feeder

pillars, Sub Feeder Pillar, submain Distribution boards and smart energy

meters for distribution of LT supply to consumers.

(j) Providing service Connection to existing electrical consumers using UG

cables through cable ducts from feeder pillar.

(k) Provide power supply connection to existing water pumps from feeder pillar

using underground cable.

(l) Design, supply, installation, testing and commissioning of Road Lighting with

Feeder pillars /Lighting Distribution Boards, FRP/GRP Poles with LED lamp

fixtures of suitable wattage, control panels, junction box, cable laying through

duct banks, 433 volts 3 phase, 50 Hz, 0.8 pf of approved make complete with

Lighting Control Panel and Automatic control of lighting circuits.


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(m) Design, supply, installation, testing and commissioning of Road lighting

system with functionality of dimming and group controlling through SCADA

from Control centre.

(n) Design, supply, installation, testing and commissioning of Heritage lighting

poles and fixtures for increased tourism as well as increase site visibility.

(o) Earthing Compact substations and Transformer body, neutral and metal

parts, feeder pillars, lighting poles at each 5th pole, control panels and

junction box, cable trays as per standards and specifications within project

area.

(p) Supply, laying and commissioning of HDPE pipes and all other materials like

cement, steel, sand gravels of suitable size as required shall be in the scope

of contractor.

(q) De energization, dismantling after obtaining work permit from DVVNL /

concerned authorities and dismantling of existing 11 KV Overhead lines,

transformers and 433 V overhead lines the transformers, 11KV /433

structures, poles, overhead lines, cables, insulators, cross arms, lightening

arrestors, cables, telephones lines, lighting poles, light fixtures, energy

meters and all accessories carefully and handing over the materials to the

Store of DVVNL and other respective authorities.

(r) Preparation of G.F.C. drawing as per requirement, to match the requirement

and approval from the owner representative.

(s) Preparation of abstract of quantities of major items, as Cables, Cable Trays

to assure at final quantities before procurement.

(t) Laying of cables in cable ducts, glanding and termination of cables, Laying of

Pipes etc. as required.

(u) Providing cable identification SS aluminium tags in cable trays at suitable

and termination end of cables

(v) Laying of warning tape and other required accessories in buried cable for

protection of cable.

(w) Testing of Cables before Laying, Jointing, Commissioning etc. as required.

(x) Inspection of Cables, Joints and Cable Trays at manufacturing place before

shipment.

(y) Labelling of equipments like CSS, Feeder pillars, light poles earth pits as per

design specifications and relevant standards.

(z) Supply and laying of telephone cables, junction boxes, duct pipe and all

accessories for providing telephone connection to the existing BSNL

consumers.


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20.1.3.2 CIVIL WORK:

The Civil works including Structure design also is part of Contract in following

respect but not limited there of:

(a) Levelling the Complete Area, earmarked for work.

(b) RCC cable Trenches / RCC duct banks for road crossing, manholes, RCC

cover slab etc. as required in the area for incoming and outgoing Cables etc.

(c) Excavation, back filling and levelling for buried cable trenches / earth pits etc.

(d) All materials including cement and steel required for the civil and Electrical

work is in the scope of the contractual / executing agency.

(e) The scope of civil works for bidder covers design, engineering, supply of

labour & materials, transportation, construction and commissioning of entire

civil engineering works required for installation & erection of all the Cables

33kV, 11KV and 1.1 KV Cables for the project area facilities etc. as designed

and / or supplied by him.

(f) Soil excavation and back filling if required for Construction of buried cable in

HDPE duct, RCC cable Trench and Cables and other works trenches / ducts

as and where required.

(g) Buried cable duct connecting the feeding and receiving substation and

encased HDPE pipe at all the locations.

(h) Drainage arrangement in cable manholes.

(i) The scope of work of bidders is not limited to the major item of civil works as

elaborated above but includes all civil works required for the successful

completion & commissioning works concerned of the project without any

extra cost.

(j) The scope of work also includes sampling & testing of construction material

on the specimens taken during execution of the work. The testing shall be

performed by a separate agency, approved by the engineer in charge.

(k) Site office, cement & other construction material storage go downs and

fabrication yard for reinforcement, inserts etc. shall be constructed by the

successful Bidders at his own cost.

(l) All construction equipment required for execution of the work shall be

arranged, procured & hired by successful Bidders at his own cost along with

operations, skilled & semiskilled personnel. The successful Bidders shall also

furnish a list of construction equipment to be deployed by him.

(m) Site for storing the equipment/material within a reasonable distance from the

proposed installation shall be provided by the client. However, construction

of temporary sheds/ barricades for the temporary store, site office as well as

safety and security of equipment shall be in the successful Bidder’s scope.


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(n) Foundation of Compact substation, feeder pillar and lighting poles etc.

20.1.3.3 TECHNICAL SERVICES

The following technical services shall be in the scope of the Bidder:

(a) Liaison with Central/state Government Departments/DVVNL/ CEIG / MCD or

any other authorities concerned on for matters like work entrustment, vendor

approvals, drawing approvals, TA&QC approvals and any other matters

connected with the work and gets the approvals within the specified time for

successful completion of work for all matters including obtaining approved

designs & drawings, and commissioning of the Project including all incidental

costs incurred thereon. Aligarh Smart City Limited, however, will provide only

all the required administrative supports to the contractor in this regard and

also would reimburse to the Contractor all the statutory charges paid to the

departments like /CEIG on production of official receipts thereon.

(b) Liaison with Dakshinanchal Vidhyut vitran nigam limited (DVVNL) for

approval of design, technical specifications, materials, inspection, quality

control, testing and commissioning of newly installed equipment, total

responsibility for the completeness of the project including erection testing

and commissioning.

(c) The successful tenderer shall take the responsibility of obtaining all statutory

clearances from all statutory bodies, on behalf of the Owner. (However, fee

to be reimbursed by the Owner on production of documentary evidence)

(d) Basic design, drawing and layout engineering of Electrical and Civil &

structural work.

(e) Preparation of detailed engineering drawings and documents.

(f) Submission of QAP and Test certificates.

(g) Arranging inspection of the materials by the client/ client representative

(h) Submission of As Built drawing after commissioning of project.

(i) All materials /machinery/items used in the subject package shall be provided

according to specification given herein. All electrical items shall be supplied

from the “List of Preferred makes”. Prior approval from Owner shall be taken

for the equipment/ items not available in the list.

20.1.3.4 DRAWING/DOCUMENTS

The scope of work includes submission of all the drawings, data and documents

related with the scope of work. A tentative list of drawings, data & documents is

indicated below. However, the Bidder shall note that the list is only suggestive.

The final list of drawings shall be finalised with the successful Bidder.


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Drawings/ Data / Documents to be submitted after Placement of Order:

(a) List of drawings and drawing numbering system.

(b) Design calculation for the selection of major items like Compact substations,

Ring Main Unit, Feeder pillars, light poles, light fixtures, cables, Cable trays

and Cable Trench.

(c) Quality assurance plan (QAP) of all material and Test certificate of each

equipment & components including type test certificates.

(d) Single Line Diagram with ratings and three line diagram of HT and LT

distribution.

(e) Cable route drawings and general arrangement (GA) drawings.

(f) Cable schedules, termination schedules and cable routing drawings.

(g) Any other drawings as required shall be finalized during engineering stage

20.1.3.5 NOTE

The Compact Sub Station (CSS) to be supplied against this specification are

required for vital installations where continuity of service is very important. The

design, materials and manufacture of the equipment shall, therefore, be of the

highest order to ensure continuous and trouble-free service over the years. Such

parts will be deemed to be within the scope of the supply irrespective of whether

they are specifically indicated in the commercial order or not. It is not the intent

to specify herein complete details of design and construction. The offered

equipment shall conform to the relevant standards and be of high quality, sturdy,

robust and of good design and workmanship complete in all respects and

capable to perform continuous and satisfactory operations in the actual service

conditions at site and shall have sufficiently long life in service as per statutory

requirements. These specifications, the design and constructional aspects,

including materials and dimensions, will be subject to good engineering practice

in conformity with the required quality of the product, and to such tolerances,

allowances and requirements for clearances etc. as are necessary by virtue of

various stipulations in that respect in the relevant Indian Standards, IEC

standards, I.E. Rules, I.E. Act and other statutory provisions.

The Tenderer/Supplier shall bind himself to abide by these considerations to the

entire satisfaction of the purchaser and will be required to adjust such details at

no extra cost to the purchaser over and above the tendered rates and prices. It

shall also encompass all necessary project management, data engineering,

acceptance testing, training, documentation, warranty services, and installation

site surveys including submission of a detailed plan aimed at installing the new

RMUs as efficiently as possible with minimum interruptions of power to Employer

customers.


Page | 59


Liaison with Central/state Government Departments/DVVNL/ CEIG or any other

authorities concerned on for matters like work entrustment, vendor approvals,

drawing approvals, TA&QC approvals and any other matters connected with the

work and gets the approvals within the specified time for successful completion

of work for all matters including obtaining approved designs & drawings, and

commissioning of the Project including all incidental costs incurred thereon.

Aligarh Smart City Limited, however, will provide only all the required

administrative supports to the contractor in this regard and also would reimburse

to the Contractor all the statutory charges paid to the departments like /CEIG

on production of official receipts thereon.

Civil foundations as recommended by the manufacturers of Compact Substation,

feeder pillars, lighting pole and mounting arrangement for Control panel and

junction box etc. shall be in the scope of the contractor.

All the civil works such as excavation of earth, lying of Hume pipes/ HDPE pipes/

DWC pipes in concreting, back filling of RCC cable trench, providing man holes

as required for cable laying and jointing as per standards.

The quoted price should include all expenses proposed to be incurred by

the bidder for dismantling the existing transformers, 11KV/415 volt poles,

lines and structures, light fittings and all equipment with care and handing

over them to safe custody of concerned authorities.

Field conditions, the bidder may in its own interest, before submitting the bid,

inspect and examine the area involved and satisfy them regarding the existing

system.

Electrical Power Supply and Water for construction purpose shall be

arranged by vendor.

20.2 ELECTRIC DESIGN DATA

20.2.1 CODES AND STANDARDS

The distribution system shall be planned considering the latest version of

applicable Indian and International Codes and Standards, Climate and

Isokeraunic Conditions, and basic electrical data.

The following primary standards and codes (latest editions/

revisions/replacements) shall be used for planning and design of the electrical

system:

TABLE 1: CODES AND STANDARD


Page | 60


Description

Guidelines

Guidelines of Electricity Board and other statutory authorities.

BIS: Bureau of Indian Standard

IEC: International Electro technical Commission standards

IEEE: Institute of Electrical and Electronics Engineers standards

Regulations laid down by Indian Electricity Act and Rules

National Electrical Code (SP 30, 2011) of India

Indian Bureau of Energy Efficiency (BEE) Guidelines

Guidelines issued by Central Electricity Authority (CEA)

CBIP Publications

Any other regulations by the local or state/central government authorities,

Regulations issued by tariff advisory committee / fire insurance regulation

Electrical Codes

IS 3043/IEEE-80 Code of Practice for Earthing

IS/IEC-60947 LV Switchgear

IEC 62271-202 HV Prefabricated Sub-Station (CSS)

IS 3427 / IEC-62271-200 Metal Clad Switchgear

IS 13118/ IEC-62271 -100 HV Circuit Breakers

IS 1180 Part 1 Oil Type Distribution Transformers

IS 5578 Arrangement For Switchgear Bus bars, Main

Connection And Auxiliary Wiring


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Description

IS 2705 Current transformer

IS 3156 Potential transformer

IS 2544 Bus bar support insulators

IS 3231 Electrical Relays For Power System Protection

IS 13703 HRC FUSES

IS 3646 Code of Practice for interior illumination

IS 1944 Code of Practice for road lighting

IS 2309 Protection of buildings and allied structures against

Lightning code of practice

IS 7098 Specification for XLPE insulated PVC sheathed

cables

IS 1554 Specification for PVC insulated cables

IEC: 62259 Secondary cells and batteries containing alkaline

or other non-acid electrolytes-Nickel-cadmium

prismatic secondary single cells with partial gas

recombination

IEC: 60623 / IS 10918 Secondary cells and batteries containing alkaline

or other non-acid electrolytes-vented Nickel

Cadmium prismatic rechargeable single cells

IS 9000 For Basic climatic and mechanical durability tests

for components for electronic and electrical

equipment

IS 6619 For Semiconductor rectifier equipment code

IS 2026 Power transformers


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Description

SP 72 : 2010 National Lighting Code

1944 (Parts 1 Code of

practice for lighting

ofand 2)

Public thoroughfares: Part 1

General principles; Part 2

Lighting of main roads

1944 (Part 5) : 1981

Code of practice for lighting of public

thoroughfares: Part 5 Lighting of grade

separated junctions, bridges and elevated road

(Group D)

1944 (Part 6): 1981


thoroughfares: Part 6 Lighting of town and city

centres and areas of civic importance (Group E)

CEA Manual on Transmission planning Criteria

Other International codes and standards shall be considered if the same are, at

least equivalent to, Indian Standards or any other international standard which

yields a more desirable outcome.

20.2.2 CLIMATIC CONDITIONS

For the Project in Aligarh Smart City Area, the electrical equipment selected

shall be such so as to give trouble free operation during the life of the equipment,

under the most stringent atmospheric conditions prevailing at site.

20.2.2.1 General

The distribution system is planned considering the Climate and Isokeraunic

Conditions, and basic electrical data.

20.2.2.2 Climate and Isokeraunic Conditions:

The electrical equipment selected will be such so as to give trouble free

operation during the life of the equipment, under the most stringent atmospheric

conditions prevailing at site. All equipment’s designed such a way that, it will be

protected from the entry of ground water, tree roots, reptiles, lizards, wild

animals etc. to avoid short circuit.


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20.2.2.3 Tropicalization:

All electrical insulation, Panels or spacers and other materials, which could be

damaged by fungus, termites or other parasitic growths, will be suitably

protected. Enclosures containing electrical control and switching equipment and

instruments will be equipped with electric heaters for moisture control. The

construction of the enclosures and the placement of heaters will ensure effective

circulation of air and prevent damage to equipment by overheating. Heaters will

be of PTC type, without the use of thermostats.

TABLE 20.2-2 : TYPICAL ATMOSPHERIC DATA AT SITE IS CONSIDERED AS BELOW FOR

ELECTRICAL SYSTEM DESIGN:

S.N. DESCRIPTION DATA

1 Upto Maximum Design Ambient

Temperature 50°C

2 Maximum daily average Temperature 45°C

3 Minimum daily average Temperature 33°C

4 Relative Humidity 95% max 10% min

5 Annual Thunder Storms 30 days

6 Number of Average Rainy days 40

7 Rainy months June to Sept

8 Snow storm Nil

9 Average annual Rainfall (CGWB) 755mm

20.2.3 SYSTEM SUPPLY

As per prevailing practice at smart city Site, main HV supply from the substation

and distributed within site shall be at 11kV.

LV supply at the consumer premises shall be 240/433V ± 6% as per latest Indian

Standard IS: 12360. Compact Sub-Station (CSS) are proposed in many


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locations. The distribution transformers shall be at no load LV = 250/433V as

per CEA/CBIP recommendation.

The frequency shall be 50Hz ± 3% as per Indian Electricity Rules and IS: 12360.

11kV supply variation shall be within +6% & -9% as per Indian Electricity Rules.

20.2.3.1 INSULATION COORDINATION

Standardised levels for the highest system voltages Um related to the rated

voltages are defined in IEC 60071-1. According to these levels the test voltages

for the insulation of high voltage equipment are defined. The following levels

have been selected out of IEC 60071-1, IEC 60364 & IS-SP39.

Table 3: Standardised Levels for the Highest System Voltages

Rated Voltage Un

(kVrms) 0.4 11 33 110

Highest system

voltage

Um

(kVrms) 1 12 36 123

Power frequency

withstand

voltages 50 Hz, 1

min, to earth

Upf

(kVrms)

2 28 70 230

Lightning impulse

with stand voltage

1.2/50 µs to earth

Uli

(kVpeak) 8 75 170 550

IEC 60815 defines 4 different pollution levels from light to very heavy pollution.

To each pollution level the corresponding minimum nominal specific creepage

distance is defined. The equipment to be installed in project area will be

exposed to salt, fog conditions and to pollution due to exhausts. To consider

this situation the pollution level “very heavy” according to IEC will be selected.

This pollution level implies a minimum creep age distance of 31.0 mm/kVrms.

20.2.3.2 SYSTEM NEUTRAL POINT

The choice of the system neutral points has been made to conform to the

existing system. The treatment of the neutral point has been selected according

to the following table.

For star connected LV windings of transformers the neutral point of the LV

systems is generally solidly earthed.


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Table 4: System Neutral Point

System Neutral Point

11kV Solidly earthed

0.4kV Neutral of transformers Solidly earthed

20.2.3.3 SHORT CIRCUIT LEVELS

The following short circuit levels shall be adopted for switchgear:

11kV : 25KA

400V : 50KA

20.2.3.4 DISTRIBUTION TRANSFORMERS

All distribution transformers shall be Oil type 11kV/433V with Dyn11 vector

group with off-load tap changer with ± 5% variation in steps of 2.5%. LV star

winding shall be solidly grounded. Distribution transformer shall be chosen from

standard ratings, typically 500 KVA. As a matter of policy only two ratings shall

be standardised to reduce the number of stocked spares ease in replacement.

20.2.3.5 COLOR CODING

Bus bars, bare copper connections, earthing bars, cable cores and mimic

diagrams shall be provided with the following colours:

Table: colour coding

System Colour

Three Phase AC

System

R Red

Y Yellow

B Blue

N Black

Ground Yellow/Green

DC System Positive Light Blue


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System Colour

Negative Grey

20.2.3.6 POWER FACTOR

For LV distribution loads average power factor of 0.85 shall be considered for

designing the electrical system. Power factor improvement system shall be

designed to have a power factor of 0.95, by using Automatic Power Factor

Control via a switching capacitor bank at LV.

20.2.3.7 HV DISTRIBUTION

HV distribution system shall be designed as an economical and technically

viable distribution system. Since the present HV system existing in Smart City

project is at 11kV, the same shall be maintained for new design. For each

location, HV supply shall be provided with two number 11kV feeders in ring

formation, with an open point, so as to operate the system as radial feeders. In

case of fault in any one radial feeder, the other shall be able to take the full load

of those locations. Thus, under normal conditions each feeder shall be operating

at 50% of its full capacity, thereby ensuring 100% redundancy of power. HV

supply from 11kV main shall be distributed in the following way:

To a dedicated switching station (SS) for concentrated and high quality loads

such as for this project. The design of the switching stations and electrical

distribution systems are covered in the scope of works.

As betterment to the DPR concept, customised Compact Sub-Stations (CSS)

are proposed to be used in project areas which shall form a part of the open

ring system. These CSS shall be equipped with an 11kV SF6 insulated

switchboard, oil type transformer with off load tap changer and LV board with

switched capacitor bank. Customization shall be made to make CSS in vertical

formation, so that any of the equipment that is, RMU, distribution transformer,

and LT pane are separate and can be easily replaced. The customised CSS

fabricated structure out of GI channels/ I section / angles / GI wire mesh/ MS

sheet of 2 mm thick or more. The scope of work include, design, preparation of

drawing and submit and get the approval from DVVNL, fabrication of sample

and obtain the approval from DVVNL before installation of the CSS in the field.

All these items shall be enclosed in a rust proof enclosure.

All HV/11KV power distribution to secondary substations (CSS) shall be

installed in underground concrete duct banks. The size, cross section, location

and configuration of the duct banks shall be determined during preliminary and

detailed design phases. Electrical cables on the low voltage side, from the

11KV transformer to the final building/facility location, shall be installed in


Page | 67


appropriate conduit (as specified in technical specifications) but will not be

required to be encased in protective concrete.

11kV HV supply shall be stabilised at the source substation which feeds the

main, through on load tap changer (OLTC), with ±10% voltage variation in steps

of 1.25%.

Each CSS shall include its own power supply unit (including required auxiliary

power transformer, batteries, and battery charger), which shall provide a stable

power source for not only the CSS, but also the FRTU and Ethernet switch that

the it must be capable of housing.

20.2.4 APPLICABLE STANDARD

Table 5: standard

STANDARDS STANDARD DESCRIPTION

IEC 60529 Classification of degrees of protection provided by

enclosures of electrical equipment

IEC 60298 A.C metal-enclosed switchgear and control gear for

rated voltages above 1KV and up to and including

72KV

IEC 1330 High voltage/Low voltage prefabricated

substations

IEC 60694 Common specification for HV switchgear

standards

IEC 60265 High-voltage switches-Part 1: Switches for rated

voltages above 1kV and less than 52 kV

IEC 6081 Monitoring and control

IEC 60185 Current Transformers

IEC 60186 Voltage transformers

BS 159 Busbar

IEC 60137 Bushings

CP 1013(British

Code of Practice)

Earthing

IEC 60255 Specification for Static Protective Relays

BS 6231 Wires and wiring

BS 729 Galvanising


Page | 68



IEC 61000 Electromagnetic compatibility Standard

Description

IEC 60129 Alternating current Disconnector (isolators) and

earthing switches

IEC 62271-100 Circuit Breakers

IEC 60060-1 BS

923

High Voltage test technique

IEC 60056 Vacuum Interrupter

IEC 60034-1 Motors

IEC 60623 Open Ni-Cd prismatic rechargeable cell

IEC 60947-4-1 Control Gears

IEC 376 Filling of SF6 gas in RS 1.6 Environmental

Conditions

IS 1180 Part 1 Distribution Transformer from 250KVA to 2500KVA


Page | 69


20.3 SPECIFICATION

20.3.1 SPECIFICATION FOR COMPACT SUBSTATION

20.3.2 Scope

This specification covers the design, engineering manufacture, Shop testing packing,

transportation to site, site storage, installation, testing and commissioning of a SCADA

operated, prefabricated, factory assembled and fitted, Compact Sub Station [CSS] consisting

of following main components.

12 kV, non-extendable, metal clad SF6 insulated switchgear, sealed for life, Ring Main Unit

(RMU)

Dry type 11/433V distribution transformer

LV switch Board.

Prefabricated weather proof enclosure.

SCADA connection for remote control and monitoring.

All termination and connections to high voltage and low voltage side of distribution transformer,

earthing and any other work to complete the works in all respects whether specifically mentioned

or not in this specification.

Portable Fire extinguishers for electrical fires

Complete Documentation

Training to Owners personnel

The CSS is to be totally free from any external deposit (dust, condensation etc.) and suitable to

operate in highly humid, hot and salty environment without any preventive maintenance,

cleaning etc. It shall be of “fit and forget” type. All nut bolts, frames etc. shall be rust proof,

typically of stainless steel or materials not prone to rusting, in site environmental conditions.

CSS can be placed indoor or outdoor as per requirement. Scope shall also include design,

engineering of all the civil and all other related site works so as to complete the works in all

respects.

The prefabricated substation unit is required for fast installation, to be maintenance free and

with life expectancy of thirty years under site conditions.

Climate and Isocerunic Conditions


Page | 70


For Seabird Project, the electrical equipment selected shall be such so as to give trouble free

operation during the life of the equipment, under the most stringent atmospheric conditions

prevailing at site described in “Outline Design Criteria” –Electrical System.

Basic Design Criteria

The CSS shall be designed with the following design criteria:

For design purpose maximum ambient temperature of 50° C shall be considered.

It shall be factory built and tested and preferably transported as such so that it is ready for site

installation. Only external connections need to be done at site.

Design to comply with latest version of IEC 62271-202.

Maintenance free Ring Main Unit [RMU] with SF6 insulation sealed for life as per IEC standard.

Dry type, epoxy insulated transformer with HV side metering.

LV Switchboard with Capacitor bank for automatic power factor correction [APFC].

Enclosure to have independent compartments for RMU, transformer and LV Board with suitable

entry doors.

The electrical equipment including the enclosure, its supporting structure etc. is to be rust and

corrosion proof throughout its life in saline, humid and tropical hot weather. In case there is no

alternative to items such as mild steel sheet, and other structural items, the same shall be hot

dip galvanized [minimum 610 gm zinc /m2] and epoxy painted. Nut, bolts, washers and other

similar items shall be of rust proof material such as stainless steel.

Cables shall be mostly in ducts and these ducts may be buried directly in the ground or encased

in concrete, as per site conditions. HT cables ducts shall be encased in concrete.

The Enclosure consisting of High Voltage switchgear, Low Voltage switchgear & Transformer

of the Unitized substation shall be designed to be used under Indoor or outdoor service

condition.

3.1.1.1 Quality of Material

(a) All material used shall be new and of best quality and of class most suitable

for working under the conditions specified herein without distortion or

deterioration.

(b) Galvanization of steel shall only be done by hot dip process after the parts

are ready for the purpose of assembly. Alternatively stainless steel of the

quality suitable for site shall be used.

3.1.1.2 Design and Standardisation

(a) The equipment shall be designed to ensure satisfactory operation in which

continuity of service is the first consideration and shall also be designed to


Page | 71


withstand sudden load variations due to short circuits and other fault

conditions.

(b) The design shall incorporate every reasonable precaution and shall have

necessary provision for the safety of all those concerned in the operation

and maintenance of the switchgear.

(c) All mechanism shall be made of such materials as to prevent sluggishness

due to rust or corrosion. All Connections and contacts shall be of ample

section and surface for carrying continuously the specified current without

undue heating and shall be secured rigidly and locked in position.

(d) Standard sizes of bolts, screws, pipes and other fittings are to be used and

number of sizes is to be kept to the minimum.

(e) Cast iron shall not be used for any part of the equipment which may be

subjected to mechanical stresses.

(f) All apparatus shall be so designed and constructed as to obviate the risk of

short circuits of the live parts by reptiles, rodents etc. Metal cubicles,

housings and covers shall be 100% weather / vermin proof.

(g) All parts shall be manufactured in accordance with relevant standard

specifications. Corresponding parts of similar equipment and apparatus

shall be mutually interchangeable.

(h) All apparatus, connections and cabling [FRLS type] shall be designed and

arranged to minimize the risk of fire and any damage, which might be

caused in the event of fire.

(i) Design should take into consideration that equipment is to be operated at

sea level under rainy, hot and humid atmospheric conditions, high humidity

(95%) and surroundings with reptiles and rodents.

3.1.1.3 Certification offering evidence for the satisfactory operation under

such environmental conditions shall be provided.

S. No. Description Technical Data

1 Applicable Standard IEC 62271-202

2 Design Ambient Temperature 50 C

3

Type of Ventilation for

Normal Condition

Hot Condition

Natural

Natural

4 Compartmentalized Yes

5 Rated temperature enclosure class 1K 10


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6

Degree of protection for external

enclosure for Transformer

compartment

IP23


enclosure for HV compartment IP54


enclosure for LV compartment IP54

7 Location Outdoor

8 Rated HV 12kV, RMU, with metering

9 Transformer ≤1000 KVA, Dry Type

10 Nominal rated voltage rating on LV 415V

11 LV Board

Incomer ACB + Outgoing

MCCB + APFC, Capacitor

Bank

12 Enclosure material Resistant to rusting,

saline environment

13 Thickness of sheet (minimum) 2mm for enclosure (main

frame).

14 Base 4mm hot-dip galvanised

14 Enclosure Paint Epoxy, RAL 7032

15 SCADA system / Remote Control yes

Table: Technical Data for CSS

3.1.1.4 Painting

Since the local environment is harsh, even galvanised steel will rust after a few

years. Therefore paint of suitable quality to protect the equipment is of utmost

importance. If steel work is unavoidable it shall be hot dip galvanized not less

than 610 gm / m2 and painted.

All sheet steel work, wherever shall be phosphated in accordance with IS: 6005

'Code of practice for phosphating iron and steel, through seven tank process.


Page | 73


Oil, grease, dirt shall be thoroughly removed by emulsion cleaning. Rust and

scale shall be removed by pickling with dilute acid followed by washing with

running water, rinsing with slightly alkaline hot water and drying. After

phosphating, thorough rinsing shall be carried out with clean water followed by

final rinsing with dilute dichromate solution and oven drying.

The phosphate coating shall be sealed with the application of two coats of ready

mixed zinc chromate primer. The first coat may be air dried while the second

coat shall be stove dried. Panels shall be painted with epoxy paint of superior

quality. ALTERNATIVELY, the panels shall be painted with electrostatic epoxy

powder coating process to have paint of hard coating. Necessary details shall be

provided to Engineer in this regard for prior approval.

(a) Paint Thickness

The final finished thickness of paint film on sheet shall be approximately 60

to 80 micron. The finished painted surface of panels shall present

aesthetically pleasing appearance free form dents and uneven surfaces.

Paints shall not scale off or wrinkle or be removed by abrasion due to

normal handling. The colour for finishing paint shall be Siemens grey as per

RAL 7032. Unless otherwise desired the same shall be got confirmed from

the Engineer before taking up painting. Each coat of primer and finishing

paint shall be of slightly different shade to enable inspection of the painting.

(b) Spare Paint

A small quantity (one litre per board) of finishing paint shall be supplied for

minor touching up required at site after installation of the panel.

3.1.1.5 Drawings and Manuals

The contractor shall furnish all drawings & manuals as called for and given below

and also those which are not specifically included but are necessary for proper

operation and maintenance.

(a) Complete assembly drawing of the Packaged & Ring Main Unit showing

plan, elevations, side & typical sectional views giving complete dimensions.

(b) Assembly drawings & weight of main component parts.

(c) Foundation drawings showing the load on the foundations.

(d) Schematic control & wiring diagram in accordance with BIS / IEC practice.

(e) Bushing drawings & their specification.

(f) Cable termination details & drawings along with terminal connection

drawings.

(g) General arrangement drawing of the complete panels showing CTs, PTs

together with dimensions.

(h) Maintenance Manual.


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(i) Graph indicating short circuit Vs number of tripping for Vacuum Circuit

Breaker.

(j) Permitted mechanical opening and closing operations.

(k) Besides above drawings, the contractor shall submit type test certificates,

leaflets & instruction manuals.

(l) Within 60 days after contract award, the contractor shall furnish to the

engineer three sets of following drawings for approval. No manufacture of

equipment shall commence until the drawings are approved:

i) General arrangement drawing of complete assembly of packaged &

individual RMU including giving dimensions & their salient features.

ii) Schematic wiring diagram.

iii) Foundation drawings.

iv) Locations of cables slots, cable terminations, CTs, PTs & terminal

connections.

v) Any other necessary detail.

vi) Instruction manuals for erection/construction, maintenance and

operation.

vii) Height of centre line of HV and LV connectors of transformers from

the rail top level as well as from the roof of enclosure.

3.1.1.6 Quality Control

All material shall be new and of best quality and of class, most suitable for

working under the environmental conditions specified herein without distortion or

deterioration of equipment during the lifetime of not less than twenty five years.

3.1.1.7 Quality Assurance

Manufacturer shall submit its quality assurance plan for the approval of Engineer

prior to fabrication.

20.3.3 12 KV Ring Main Units

20.3.3.1 General

(a) The RMU for the compact substation shall be 3 way [or 4 way], 12 kV, non-

extendable, free standing, indoor, metal clad SF6 insulated Ring Main Unit

(RMU) along with metering, PTs, CTs etc. This RMU shall form a part of

CSS in an unattended substation, which includes a transformer & LT Board

also and all the three equipment shall be housed in an enclosure.

(b) Two numbers 630 A, fault making / load breaking, motor operated, line side

switches, fitted with indications for phase and earth fault along with


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associated CTs. The load break switches shall be connected via

underground XLPE Cables.

(c) One number 200 A, Tee-off, spring operated, Circuit breaker with sealed

for life vacuum interrupter complete with meters, CTs, Protective and

auxiliary relays to control one number 11/0.433 kV distribution transformer

with complete arrangement to connect the tee-off circuit breaker to the 11

kV side of the power transformer.

(d) The springs for closing the load break switches & tee-off circuit breaker

shall be motor operated.

(e) The opening & closing for the load break switches as well as tee-off circuit

breaker shall be carried out electrically from remote via SCADA, besides

local / hand operation. Built in compact battery [with no maintenance of any

type] with charger shall be part of supply for this purpose.

(f) The breaker shall have necessary over current and low sensitivity earth

fault protection on the delta connected, 11 kV side of the distribution

transformer. Further the protections on distribution transformer shall

operate this breaker with required alarms. It shall have basic metering

features also to monitor these in RMU.

(g) RMU shall also be equipped with necessary Remote Terminal Units,

transducer’s etc. complete in all respects, since these RMU’s shall be

having provision for SCADA with remote control. The requirements for

SCADA have been covered in the subsequent section of these

specifications and the provision for requisite control & indications shall be

provided in the RMU substations.

(h) Fault passage indicators, Feeder Remote Terminal Units, with self-healing

feature, communicating with each other in the Ring circuit shall ensure

automatic isolation of faulty cable and restoration of supply in case of cable

fault in the system, using Fibre-Optic based communication. Faster fault

isolation and service restoration of network with the help of peer to peer

connection to FRTU without any manual decision by operator with

distributed control. Fault clearance less than 20 sec., it can vary in case of

communication delay. No operation interaction required.

(i) There shall be continuous monitoring of supply on 12 kV cables via

capacitive voltage indicators.

(j) The RMU shall be complete in all respects including elbow type cable

termination arrangement [with shrouds] in air from bottom, gland plate,

double compression glands, foundation channels, bolts, inter connection

arrangement etc.

(k) The external dimensions shall be identical throughout the length of the

11kV board.

(l) The operation of any of the switching functions shall be simple with only

three possible positions viz. closed, open and earthed. The earthing switch


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shall be placed on cable side. The earthing of cable is to be done by an

independent fault making switch.

(m) All the necessary safety interlocks between switching devices, earthing

switch and cable box covers shall be integrated.

(n) The accessories and LV auxiliaries (i.e. motor mechanism, coils, auxiliary

switches etc.) shall be the same for the entire range of switching functions,

load break switches or circuit breakers. They can be installed on site

without any dedicated tool and training.

(o) Any other item not included above but required to complete the works shall

be deemed to be included in RMU, without any financial liability to the

purchaser.

20.3.3.2 Standards

Unless otherwise specified, all equipment and material covered in this

specification shall conform to the latest applicable Indian / IEC Standards.

Equipment complying with any other international standards will also be

considered if it ensures performance of equipment equal to or superior to Indian

Standards. Copy of such a standard shall also be supplied.

S. No Standard Number Description

1. IEC 62271-1 High-voltage switchgear and control gear – Part 1:

Common specifications

2. IEC 62271-200

High-voltage switchgear and control gear - A.C. metal-

enclosed switchgear and control gear for rated voltage

above 1 kV and up to and including 52 kV.

3. IEC 62271-103 Switches for rated voltages above 1 kV and less than

52 kV


High-voltage alternating current circuit breakers.

5. IEC 62271-102

High-voltage switchgear and control gear – Part 102:

High-voltage alternating current disconnectors and

earthing switches

6. IEC 61958 High-voltage prefabricated switchgear and control gear

assemblies – Voltage presence indicating systems.

7. IEC 60529 Degrees of protection provided by enclosures (IP

Code)

8. IS:722 A.C. electricity meters


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9. IEC 60044-8 Instrument transformers – Part 8: Low Power Current

Transducers

10. IEC 60044-1 Instrument transformer – Part 1: Curent transformer

11. IEC 60044-2 Instrument transformer – Part 2: Voltage transformer

12. IEC 60255 Electrical relays

13. IS: 5 Colours for ready mixed paints and enamels

14. IS:1248 Electrical Indicating Instruments

15. IS:1554 PVC insulated cables up to and including 1100 volts

16. IS:4794 Push Button Switches

17. IS:6005 Code of practice for phosphate coatings of iron and

steel

18. IS:2099 Bushings for alternating voltages above 1000 V

19. IEC:62271-202 Pre-Fabricated Substation

20. IS: 13118, IS: 3427, IEC:

60694.

11 kV, Switchgear cubicles

21. IS:9920, IEC:60265 Ring main unit 11 kv grade,

22. IS:10118 Code of practice for selection, installation and

maintenance of Switchgear

23. IS: 2026 Distribution Transformer

24. Indian Electricity Rules

25. Indian Electricity Act

26. IS:13072 Sulphur hexafluoride for electrical purposes

Table 15: Codes and Standard


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20.3.3.3 Technical Particulars (Standard Values)

The Ring Main Unit (RMU) should consist of three phase, two load break

switches and one tee-off VCB, Circuit Breaker Compact Unit, SF6 insulated and

sealed for life complying to latest version of IEC 622-71-200

(a) Rated system voltage (kv) 12

(i). Rated current for load break switch [A] 630

(ii). Rated current for tee-off Breaker [A] 200

(iii). Nominal system voltage [kV] 11

(iv). System Earthing Solid

(b) Basic Insulated level

(i). Lightning Impulse withstand voltage (kV) 75

(ii). Power frequency withstand voltage for 28

(iii). one minute (kV rms)

(c) Frequency (Hz) 50

(d) Bus bar rated current (A) 630

(e) Rated short time symmetrical three phase current 20

(kA for 3 sec for load break switches & tee-off breaker)

(a) Earth switch for load break switches (kA for 3 sec) 20

(b) Earth switch for tee-off breaker (kA for 3 sec) 20

(c) Rated making current (kA peak) 50

(d) Rated breaking current for circuit Breaker [kA for 3 s] 20

(e) Filling & rated gas pressure <1 bar, gauge

(f) Internal arc test [kA for 1 sec] for both A & B (RMU Tank & Cable Box)

20

(g) Interrupting time in millisecond less than 40

(h) Operating Duty: (O-3min-CO) As per IEC

(i) Degree of protection for enclosure - (Mimic-IP2X, Cable Box-

IP3X, LV Chamber-IP2X)

(a) Paint thickness (micron) 60

Notes:

(b) Type, routine, internal arc test reports shall be submitted by successful

bidder after award of work during detail design stage and shall be approved

by Engineer.


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(c) RMU shall be non-extendable type. Storage [without heaters, in humid

environment]: from 0°C to +40°C

(d) Operation : °C to +40°C

(e) Partition class: PM

(f) Main HV circuit: IP67

(g) Front connection in cable box, suitable for armoured, XLPE insulated

Aluminium cable, as per specified size. Termination with elbow type plugs

in bushings with insulating boots.

20.3.3.4 Load Break Switch

(a) The switch shall be combining the functions of a load break switch,

disconnector and associated earthing switch. It shall have three positions

(closed, open / disconnected, earthed) earthing to be on cable side. The

mechanism shall be anti-reflex, lever-operated type, with intuitive operation

and clear mimic panel indications.

(b) Switch shall have built-in fail safe interlocks between main switch and

earthing switch. Standard built-in padlocking facility for main switch,

earthing switch and interlock shall be provided.

(c) Switch shall have a provision for remote opening and closing through

SCADA. Earthing switch operation shall be locally.

(d) It shall carry rated current continuously and short circuit current for the

duration specified without exceeding the permitted temperature rise as per

relevant IEC / Indian standard. Switch should not be damaged even when

closed on a dead short circuit for the permitted period of short circuit.

(e) Each load break switch shall be of the triple pole, gang operated, with quick

break contacts.

20.3.3.5 Circuit Breaker For Transformer

(a) The Circuit Breaker shall have a switch disconnecting the circuit breaker

with an associated earthing switch. It shall have three positions (closed,

open / disconnected, earthed) earthing to be on transformer side. Circuit

Breaker shall have a provision for remote opening and closing through


(b) It shall carry rated current continuously and short circuit current for the


relevant IEC / Indian standard.

(c) Circuit breaker shall be opened with a push button and closed with the

“closing lever”. The mechanism shall be anti-reflex, lever-operated type,

with intuitive operation and clear mimic panel indications. Switch shall have

built-in fail safe interlocks between main switch and earthing switch.

Standard built-in padlocking facility for main switch, earthing switch and


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interlock shall be provided. The circuit breaker and load break switch can

be locked in the open, close or earth position by 1 to 3 padlocks of ESI size.

(d) Breaker should not be closed when cable cover is open.

(e) In case of fault the breaker shall be tripped through a self-powered relay.

(f) Circuit Breaker Interrupting Unit

Tee-off Circuit breaker shall have Vacuum interrupting arrangement.

(i) The design & construction of the Vacuum circuit breaker shall be

compatible with the latest Vacuum circuit breaker technology.

(ii) The Vacuum interrupter bottles shall be completely maintenance free

& mechanically strong for 30 years life. Test certificate to be provided.

(iii) Suitable interlock shall be provided against breaker operation in the

event of loss of Vacuum.

(iv) Circuit breaker should allow low chopping current level.

(g) Duty Requirement

(i) The circuit breaker shall be totally restrike free under all duty

conditions and shall be capable of performing the duties satisfactorily.

(ii) The circuit breaker shall meet duty requirement for any type of fault

location, also for line charging current. The operating duty of the

circuit breaker shall be as follows:

(O-3min-CO) as per IEC

(iii) The circuit breaker shall be suitable to break the required induction

current in accordance with the BIS / IEC standard. The value thereof

shall be clearly specified at the time of offer.

(iv) The circuit breaker shall meet its duty requirement in case of

application for controlling U/G cables, power transformer.

(v) The rated transient recovery voltage for terminal fault and short line

faults shall be as provided in the relevant IEC / BIS.

20.3.3.6 Constructional Details

(a) Complete switchgear including bus bars shall be contained in an earth

screened stainless steel tank, filled with SF6 gas, degree of protection not

less than IP-67, as per requirement of IEC standards. To prevent gas

leakage the gas pressure shall be maintained low within one atmospheric

gauge. The filled gas shall provide the required insulation and also current

breaking for load break switches.

(b) There should not be any condensation of SF6 gas on internal insulating

surface of the circuit breaker and Load Break Switches. Temperature

compensation shall be provided and the system shall be an integral part of

breaker.


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(c) SF6 gas shall be sealed for life in the compartment so as to satisfy “Sealed

Pressure Systems” requirement of IEC-60694 (Clause 5.15.3). Throughout

the life of the equipment there shall not be any “topping up” of SF6 gas. The

rated life of the equipment must not be less than 30 years as per IEC-

60694. During this operational life of the switchgear, absolutely no gas

filling is required. The container should be evacuated before gas filling and

it should be diffusion-tight. The design of the RMU housing shall be such

that in the event of an internal arc fault, the safety of the operator shall be

ensured. All the safety requirements as required in IEC 62271-200 shall be

provided.

(d) The switchboard when charged must not have any access to live parts so

as to endanger the life of operating personnel.

(e) The RMU shall be so designed that the position of different devices is

visible to the operator in front of the switchboard. The operating switches,

handles etc. shall be at a height at which these or easy to operate, without

any extra effort. All the items in the equipment shall be identified with long

life labelling, cautions etc. The labelling must clearly indicate the required

function.

(f) All the items in the equipment shall be identified with long life labelling,

precautions etc. The labelling must clearly indicate the required function.

(g) There shall be operation counters for Load Break Switches and breaker

with a provision to sound an alarm when the permitted operations are

approaching. Alternatively operation counter and alarm shall be provided

at FRTU/SCADA level and warning signal to be provided at SCADA.

(h) It shall be possible to lock the operating mechanism in any of the three

positions when the contacts have fully homed and also to independently

lock the “ON” and “EARTH” positions. The position “ON”, “OFF” and

“EARTH” of the switch shall be clearly indicated such that the direction of

movement of the operating handle(s) from one position to another is readily

apparent.

(i) The operating mechanism shall be maintenance free without the need of

any lubrication during its life time of 30 years. The operating mechanism

shall undergo a mechanical endurance test as specified in IS / IEC 62271-

200

(j) The ring main shall be dust, moisture & vermin proof and suitable for indoor

or outdoor installation. All the cabinets shall be free standing floor mounting

type and shall be provided with double hinged doors with padlocking

arrangements.

(k) All door panels, removable covers shall be gasketed all round with

neoprene gaskets. All louvers shall have screen and filters. Vent opening

shall be covered with mesh and so arranged that hot gases or other

material shall not be discharged, injuring operating personnel or

surrounding apparatus and cables.


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(l) . The sheet should be cold rolled with smooth finish, levelled & free from

flaws. However, the structural frame shall be minimum 1.5mm & all load

bearing members of the enclosures shall have a minimum thickness of 2

mm or more. All members shall be properly braced to prevent webbing.

(m) Ring main design shall comprise full compartmental execution having

separate vertical sections for each circuit having internal barriers.

Compartment with doors for access to operating mechanism shall be so

arranged as not to expose high voltage circuit. The ring main cubical

compartment shall be provided with bolted/hinged doors on the front with

facility for padlocking door handles.

(n) All corresponding components of circuit breaker / load break switch

cubicles of same ratings shall be interchangeable with one another.

(o) The board shall be wired with the connection brought on to the terminal

boards for remote operation.

(p) The equipment shall be as compact as possible so as to occupy minimum

space in the sub-station room. Such type of equipment will have

preference.

(q) Temperature rise in the unit shall not exceed as prescribed in IS/IEC.

(r) Minimum clearance between the phases and between live parts &

grounded objects in the switchgear / load break panels shall be in

accordance with IEC.

(s) Operating Mechanism

(i) Circuit breaker as well as load break switches shall be provided with

suitably designed spring charged motor operated mechanism. It shall

be possible to charge the spring manually, if required. The closing /

opening shall be through remote or through locally operated push

button or operating switch.

(ii) It should be “trip free” mechanically under every method of closing

(except during closing for maintenance).

(iii) The operating mechanism shall be such that the failure or any

auxiliary spring will not prevent tripping. When the circuit breaker is

already closed it shall not cause damage to the breaker or endanger

the operator.

(iv) The breaker / load break switch shall also be hand operated, if so

required.

(v) Electrical as well as mechanical indicator shall be provided to show

open & close positions of the breaker / load break switches at RMU

+ FRTU side. It shall be located in a position where it will be visible to

a man standing on the ground with the mechanism housing closed.

An operation counter shall also be provided with each breaker / load

break switch.


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(vi) Working parts of the mechanism shall be of corrosion resisting

material. Bearings, which require grease shall be equipped with

pressure type grease fittings. Bearing pin, bolts, nuts and other parts

shall be adequately pinned or locked to prevent loosening or required

adjustment with repeated operation of the breaker / load break switch.

The mechanism shall be maintenance free.

(vii) The closing mechanism should be able to be operated by one man

standing on the ground & direction of rotation of the handle for

charging / closing shall be clearly defined.

(viii) In case limit switch fails to cutout the spring charging motor when the

springs are fully charged, the motor shall be automatically decoupled

and annunciation for this shall be provided.

(ix) The mechanism shall be complete with opening spring, closing

spring, auxiliary contacts & all other necessary accessories to make

mechanism a complete operating unit. A continuous sequence of

closing and opening operation shall be possible.

(x) Besides the requirements of auxiliary switches used by the

manufacturer, at least 2 NO + 2 NC with multiplex unit for extending

these contacts shall be provided for the use of the purchaser.

20.3.3.7 RMU To Be Maintenance Free

(a) The RMU’s life and its operation must not be affected by environmental

conditions such as foggy atmosphere, extremes of cold, seismic conditions

such as corrosive / salty sea winds, 100% relative humidity (condensing

type) with hot and humid environment, temporary flooding etc.

(b) The equipment shall be of “fit & forget” type requiring little maintenance,

(practically no maintenance), during its life.

(c) RMU should have reliable switching devices and maintenance free drives.

20.3.3.8 Insulating Medium

(a) The RMU shall comply with the requirements of IEC standard for “Sealed

Pressure System”, for which no filling of gas is to be carried out during the

life span of the switchgear. The SF6 gas shall be as per IEC-60376 / IS:

13072 and shall be suitable for its application in the switchgear. It should

continue to have high insulating and arc quenching properties throughout

the switchgear life.

(b) The SF6 gas shall be self-regenerating after the interruption of arc due to

breaking load currents. The gas tank should have material in the tank to

absorb the moisture from SF6 gas.

(c) The use of organic seals on the equipment, grease and oil in the drives

requiring periodic maintenance are not to be used.


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20.3.3.9 SF6 Gas Monitoring and Pressure Relieving

(a) SF6 gas in the RMU tank shall be constantly monitored through a gas

pressure indicator, which should be duly temperature compensated. In

case the pressure is not adequate it should block its operation and give a

warning to isolate the RMU.

(b) The pressure sensors shall feed a microprocessor based analysing unit or

manometer based unit. By this system the gas pressure (temperature

compensated) should be recorded to measure the dielectric strength of the

gas in the compartment.

(c) A loss of gas should be signaled via contact to initiate the low alarm of gas.

(d) If the gas pressure exceeds the permissible limit, such as during short

circuit clearing, the pressure relief device should operate in the underside

of the module. This area must be partitioned from the cable connection

apartment.

20.3.3.10 Voltage Indicator Lamps, Phase Comparators And Monitoring Of RMU Bus Voltage

It shall be possible for each of the functions on the RMU to be equipped with a

continuous voltage indication, to indicate whether or not there is voltage on the

cables. The capacitive dividers will supply low voltage power to sockets at the

front of the unit, an external lamp shall be provided to indicate live cables. Three

outlets can be used to check the synchronization of phases with the use of an

external device. This device shall be in compliance with IEC 1958 standard.

Besides this the voltage monitoring of bus bar shall be provided continuously.

20.3.3.11 Earthing of RMU Circuits

(a) The cables in the RMU on the load break switch sides shall be earthed (only

when these are dead) through integral earthing switch having the short

circuit capacity of the RMU.

(b) The earthing switch should be mechanically interlocked so that it can only

be operated when the main switch is in open condition and circuit is fully

de-energised. Necessary voltage monitoring device in such a case shall be

provided.

(c) The earthing switch shall be operated through the main circuit mechanism

and manual closing shall be through a fast acting mechanism.

(d) Mechanical interlocking system shall be provided to ensure that the switch

is turned to ‘OFF’ position before being turned from ‘ON’ to ‘EARTH’

condition.

(e) Cable box interlocking is to be provided to ensure that before the removal

of the unit cable box cover, the unit earth is applied.

(f) General Earthing Requirement


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(i) All metal parts not intended for carrying current shall be connected to

duplicate earthing system and suitable terminals shall be provided on

each equipment or part of equipment in conformity with the relevant

standards.

(ii) The earth continuity conductor shall be of tinned copper and shall

have sufficient cross sectional area so as to afford a low resistance

path for the full fault current corresponding to the circuit breaker

ratings.

(iii) The size of earth continuity conductor shall be adequate, so as to

restrict the temperature rise to the limit without causing any damage

to the earth connection, while short circuit current flows through it for

the short time rating of the equipment.

(iv) The size of earth continuity conductor shall be as large as possible to

reduce to the barest minimum the potential rise of the metal frame of

the circuit breaker.

(v) No sweated / riveted joints in current conducting path shall be

permitted.

20.3.3.12 Cable End Termination Box

(a) Cable-end termination box shall form an integral part of the equipment. The

cables shall be convenient to install.

(b) There shall be elbow type connection for cable termination with insulating

boots. The boots shall form part of supply.

(c) Each Cable compartment shall be provided with three bushings to

terminate the incoming and outgoing 11kV, 3 Core or single core cables as

the case may be. There shall be minimum 700 mm height from the base of

the mounted switchgear so that the cables can be bent and taken vertically

up to the bushings. The Cable termination shall be done by latest

technology employing cold Termination method so that adequate

clearances shall be maintained between phases for Termination.

(d) The arrangement for earthing the termination point of cables shall form a

part of supply and should be of adequate rating. The standard size of 11

kV XLPE cable being used is as specified for load break switches as well

as for the tee-off transformer.

(e) The cable mounting arrangement on the load break switches shall be over

the trench and no special arrangement is required for installation of the

cables and their terminations. These shall enter directly from the cable

trench through cable glands in gland plate to the load break switches. The

ring type air insulated CTs shall be provided.

(f) All of the cable boxes shall be air insulated suitable for dry type cable

terminations. Compound filled cable boxes are not acceptable.


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(g) The cable boxes at each of the two ring switches suitable for accepting H.V.

cables approaching from below or as per site requirement. The tee-off

circuit breaker shall be suitable for either of the following termination

arrangements:

(i) Direct coupling to a transformer flange

(ii) Cable entry from below via a tee-off cable box

(iii) Cable entry from above via a tee-off cable box

The extended function shall be suitable for cable entry from either above or

below only.

(h) Double compression type, chrome, plated cable brass glands shall be

provided in the gland plate, with necessary cable clamping and earthing

arrangement.

(i) Support frames shall be provided whose height shall be such that cable

connections can be conveniently made after allowing for bending radius of

cables.

Note: The XLPE, outgoing & incoming 12 kV power cables to LBS are not in the

scope of the RMU manufacturer. However, elbow type termination kits for these

cables (including two sets, of new cable termination tools) are included in the

scope of supply.However the supply of outgoing and incoming XLPE, 12kV

cables in the scope of PMC-01 contractor.

(j) Testing of Cables

(i) It shall be possible to test the core or the sheath insulation of the

network cables while the RMU remains energized at rated voltage. It

shall be preferable to carry out the phase by phase testing through a

built-in-facility without necessity to have an access to cable

compartment. The maximum test voltage shall be less than 38 kV DC

for 10 minutes.

(ii) Any cable test access facility which requires the use of an additional

loose devise shall not be acceptable.

(iii) Any switching unit, load-break switch or circuit breaker, shall be able

to receive a dedicated device for cable testing, allowing the cable test

bench to be connected from the front of the cell with opening the cable

compartment. This cable test device must be fully interlocked with the

earthing switch.

20.3.3.13 Bushings

(a) Bushing shall be homogeneous, free from laminations, cavities & other

flaws or imperfection that might affect the mechanical or di-electric quality

& shall be tough and impervious to moisture.

(b) Silicon type bushings shall be used.


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(c) Bushings shall be designed to have ample insulation, mechanical strength

and rigidity for the conditions under which they will be subjected.

(d) When operating at normal rated voltage there shall be no electric discharge

between the conductors & bushings, which could cause corrosion or injury

to the conductors, insulators or supports by the formation of substances

produced by chemical action.

(e) All iron parts shall be hot dip galvanised (not less than 75 micron) & all joints

shall be airtight. Surfaces of the joints shall be smoothened up. Bushing

design shall be such as to ensure a uniform compressive pressure on the

joints.

(f) All current carrying contact surfaces shall be sliver plated; silver plating

shall not be less than 1 mil in thickness.

(g) The creepage distance of the bushings shall be suitable for condensing

type humidity atmosphere.

(h) Bushings shall be tested for type tests & routine tests in accordance with

stipulation of IS: 2099. Routine as well as type test reports in conformity

with above IS shall be furnished to the purchaser.

20.3.3.14 Caution Notice

Caution name plates shall be provided at all points where such safety

requirements are to be met as per Indian Electricity Rules.

20.3.3.15 Safety Interlocks

(a) Disengagement of a circuit breaker or switch shall not be possible unless it

is in open position. Suitable interlocks shall be provided.

(b) The position of the circuit breaker, whether in open or close position shall

be indicted through suitably designed fail-safe mechanical indicators.

(c) The operating position of circuit breakers or isolators, either on bus-bar side

or for earthing, shall be clearly indicted by a reliable indicating device.

(d) Integral earthing facility, when provided, shall be suitable to make earthing

connections only when the associated circuit breaker is in tripped position.

The current rating of earthing facility should be commensurate with the

short circuit rating of the circuit breaker.

20.3.3.16 Metering, Protection, Indication And Auxiliary Switches

(a) General Requirements for Instruments

(i) Multifunctional Measuring instruments, with an accuracy of class 0.5S

(as per IEC 62053-22) or better shall be of digital type, with minimum

3 line LED display and conforming to relevant IS / IEC & shall be of


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an approved type & design suitable for tropical climate and

condensing type humidity. Measurement shall include voltage,

current, pf, KW, KVA, KVAR and Neutral current. It shall have RS 485

communication port. Meter shall have %THD & individual Harmonics

measurement comply to IEC 61557-12.

(ii) All instruments shall be back connected and instruments cases shall

be earthed.

(iii) The instruments safety factor shall be equal to or less than 5.

(b) Protection

The protection on the circuit breaker shall comprise the following

arrangement:

(i) The Tee-off, Circuit breaker unit fitted with 3 protection CTS of

suitable ratio and burden [considering power transformer rating], a

low burden trip coil and auxiliary switch assembly allowing the use of

a self -powered, numerical relay with an open protocol having three

over current and one sensitive earth fault elements. The relay should

be housed within a cubicle box, accessible from the front. This relay

shall also communicate with Feeder Remote Terminal Unit.

(ii) The protection curves and all other settings shall be adjustable in

software through lap top, which when viewed from the front clearly

show the unit settings. (Note DIL type switches are not acceptable).

The protection setting range and minimum pick up current shall be in

accordance with the protection of transformer rating. Typically the

primary settings may be in the following range:

Overcurrent: 20A to 200A

Earth Fault: 2A to 50A

(iii) The relay should give local indication of a fault operation and should

differentiate between overcurrent and earth fault.

(iv) It should be possible for the relay to perform a self-check.

(v) Other auxiliary relays to give trip / alarm [local as well as remote] in

case of operation of transformer protections, gas leakage, ON, OFF

& Earth status of RMU load break / breaker, spring charged etc. shall

be provided.

(vi) Besides the requirements of auxiliary switches used by the

manufacturer, at least 4 NO + 4 NC shall be provided for the use of

the purchaser.

(c) Instrument Transformers

The instrument transformers required for the switchgear shall conform with

the respective standards specification.

(i) Voltage Transformers


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The Voltage Transformers (VT) shall be of dry compound epoxy

insulated. The VT shall be protected on their primary sides by current

limiting fuses. On the secondary side, the circuit shall be protected by

MCB’s. Provision shall be so made that the primary fuses can be

handled only in the drawn out position. The particulars of the voltage

transformer are:

Type: Cast Resin.

Rates Voltage: 11000 110 110 Volts

3 3 3

Accuracy Class : 1.0

Burden : 50 VA or as per system requirement.

Note: Contractor shall design the voltage transformer as per system

requirements, and alternate arrangement, if any, shall also be

considered.

(ii) Current Transformers

(aa) The CT’s shall be cast resin ring type, suitable for metering and

protection requirements, air insulated and shall be able to

withstand the thermal, dynamic and mechanical stresses

resulting from the maximum short circuit and short time current

rating of the switchgear. CT should be suitable for continuous

operation at 130% of its rated current.

(ab) CT’s shall have polarity marks engraved on each transformer

and at the associated terminal blocks. Facility shall be provided

for short circuiting and earthing the CT secondary at the terminal

blocks by the use of shorting type terminals.

(ac) CT ratio, burden, accuracy [1.0 for metering and 5P for

protection] and other requisite parameters shall be suitable for

the self-powered relay. CT calculations in this regard shall be

submitted.

20.3.3.17 Control of the RMU and CSS

(a) Remote & local operation of the RMU’s line switches and Circuit breaker

should be provided using motors fitted to the operating mechanism.

(b) The provision of the motors to the mechanism must not in any way impede

or interfere with the manual operation of the switches or Circuit breaker.

(c) The Contractor shall provide all necessary equipment for remote control

and monitoring of the RMU including other important equipment items in

CSS.

(d) SCADA software provided shall be guaranteed for free replacement (in

case it gets corrupted) and upgradation during the life of the hardware.


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20.3.3.18 Fault Circuit Indicator

(a) To pinpoint the faulty section between a number of series connected, load

break switches, of RMU’s a Fault Circuit Indicator (FCI) shall be provided

with each RMU. This indicator shall operate for earth faults and phase to

phase short circuits between any two RMU’s.

(b) The indicator should be suitable for use on 12 kV RMU’s in an open ring

main system. In case of fault in a cable section between two RMU’s. It shall

be possible to pin point the faulty section and communicate with Feeder

Remote Terminal Unit for automatic faulty cable isolation and supply

restoration.

(c) The FCI supplied should be complete in all respects, with all the necessary

components e.g. LED lamp or LCD display, , Fault Indicator Unit, CTs

cabling etc. and shall form part of RMU. It shall be with display to indicate

current loading and the type of fault.

(d) Since RMU’s are controlled through SCADA system, the FCI indications

shall also be displayed on the central control room. Therefore these FCI’s

shall have additional provision for remote indication besides local

indication.

(e) FCI shall be of proven type and in the manufacturing range of RMU

supplier.

20.3.3.19 Feeder Remote Terminal Unit (FRTU) For RMU

Make of FRTU shall be same as that of the RMU manufacturer. It shall have peer

to peer communication and with the remote switchgear / SCADA at the controlling

substation through fibre optic cable to initiate the required switching operations.

(a) Main Requirements

FRTU cubicle shall be equipped to meet the following main requirements

for compact substation. It shall be possible to mount it on wall if required.

(i) Monitoring and control of 11kV LBS and VCB feeders

(ii) In conjunction with FCI, detection and isolation of faulty cable for

phase to phase and phase to earth cable short circuits and

automatically ensure supply restoration in less than 60 seconds.

(iii) Multifunction measurements.

(iv) Transmit data to the remote control centre.

(v) The system shall have necessary redundancy in communication.

(vi) To incorporate self-healing grid logic for faster restoration of supply

even in the absence of control centre SCADA.

(vii) Data storage.

(viii) Provision for Maintenance


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(ix) FRTU shall be capable to monitor and control 3 Way / 4 ways RMU.

(x) Chronological time stamped event recording.

(xi) Data storage, in the event of mains failure, shall be for at least 8

hours. The minimum storage shall be for about 40000 events.

(b) Control unit

(i) Control Unit shall perform all the required control and monitoring

functions of Compact Substation and shall be equipped with a remote

and local control mode switch on its front panel.

(ii) Operation in Local Mode:

(aa) Transmission of data for remote measurements and time-

stamped events shall not be disturbed.

(ab) Opening and closing operation after validation.

(ac) Inhibition of opening / closing from remote.

(iii) Operation in Remote Mode:

(aa) Transmission of measurements and time stamped events.

(ab) Local electrical control shall get blocked.

(ac) Opening and closing operation from remote control centre.

(iv) All data shall be available locally on the front panel of the enclosure

and remotely from the control centres. LBS / breaker open and close

status can be had from the front mimic of FRTU respectively with the

green / red LED indication. It shall be possible to retrieve and display

the time-stamped events recorded at the enclosure locally as well as

at the remote control centre on a lap top computer.

(v) Power Supply:

Compact, sealed for life 12V battery with a long life and no

maintenance of any kind for 5 to 7 years or more along with charger

[to be supplied 230 V, 50 Hz from CSS] is to be provided in the unit.

The supply shall be conditioned to provide power at required voltage

for motor operation and communication for local and remote SCADA.

The transmission output shall be able to supply a conventional radio

[without battery power of RTU] to inform the remote control centre of

a battery failure. Power from the unit shall be sufficient to supply

control power to all the switch cubicles in the CSS, radio and the

electronics in the enclosure. The standby power unit shall be with a

minimum autonomy of at least 8 hours for 10 opening and closing

cycles. The battery shall be checked at regular intervals by the slave

station and an alarm shall be generated and transmitted to the remote

control centre in the event of a fault. The unit shall be protected

against overvoltage and over loads.


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(vi) Time-tagged data archiving:

(aa) All the archived data shall be retrieved locally and remotely by

means of the configuration and operating software supplied

with the control unit. The data shall also be downloaded locally

or remotely to a PC as a .CSV file.

(ab) Event and measurement time-stamping shall be accurate to

one millisecond [ms] and the discrimination between two events

shall be 10 ms.

(vii) Communication with the remote control centre

(aa) FRTU shall have IEC 870-5-101 / 104 protocol to transfer

information to control center SCADA and Modbus protocol to

communicate with field MFM [Multifunction Meters] on Modbus

RS485. The Modbus protocol shall be open. Security &

communication package provider shall only lay the fibre optic

cable for the same and further connections, repeaters, boosters

and any other communication equipment shall be included in

the scope of supply.

(ab) It shall be possible to configure each measurement to be

transmitted spontaneously to the remote control center.

(ac) Data shall be configured using a PC connected to the control

unit via an Ethernet and / or USB port. It shall also be possible

to configure data remotely.

(viii) Software

The software shall not require a special licence and it can be used

and copied freely.

(ix) Indications

The slave stations shall process at least the following information for remote

indication and for local display purposes:

(aa) Open / closed position of each LBS

(ab) Earth status

(ac) Absence of AC voltage,

(ad) Local / remote control operating mode,

(ae) Detection of phase-to-phase or earth fault current flow,

(af) Load current measurement

(ag) Charger fault

(ah) Battery fault

(ai) Motor drive DC supply fault

(aj) Internal fault


Page | 93


(ak) Detailed diagnosis of the status of the uninterruptible power

supply (charger, batteries).

(al) Indications for LT side status of switches, alarms as required.

(c) Erection / construction / Operating Tools and Tackles

(i) Each RMU will be provided with operating lever and other such

equipment which are necessary for the normal operation of the

equipment. It should also include any spring charging handles for the

manual charging of closing springs. The tenderer shall separately list

out in the tender in the given schedule, sets of tools required for initial

erection/construction and subsequent maintenance. The price of

those should be included in the cost of equipment.

(ii) An anti-reflex mechanism on the operating lever shall prevent any

attempts to re-open immediately after closing of the switch or earthing

switch.

(iii) All manual operations will be carried out on the front of the

switchboard.

(iv) The effort exerted on the lever by the operator should not be more

than 250 N for the switch and circuit breaker.

(v) The overall dimensions of the RMU shall not be increased due to the

use of the operation handle. The operating handle should have two

workable positions 180o apart.

20.3.3.20 Mimic Diagram

(a) The front shall include a clear mimic diagram which indicates the different

functions. The position indicators shall give a true reflection of the position

of the main contacts. They shall be clearly visible to the operator. The lever

operating direction shall be clearly indicted in the mimic diagram. The

manufacturer’s plate shall include the switchboard’s main electrical

characteristics.

(b) Labels and Marking of Connections

All apparatus, control gear and the apparatus mounted thereon shall be

clearly labelled, indicating where necessary, their purpose and the ‘ON’

‘OFF’ and ‘EARTH’ position. The labels shall be clearly lettered on

enamelled surface or other approved materials. Brass should not be used

for labels. Each phase of alternating current and connections shall be

coloured to distinguish phases, neutral and earth. The colouring shall be

red, yellow, blue, black and green respectively.

(c) Bus Bars

(i) Bus bars shall be of uncoated, bare conductor grade electrolytic

copper.


Page | 94


The successful tenderer shall furnish the calculations after award of

work, during Detailed Design stage and shall be approved by

Engineer and establishing thermal and dynamic adequacy of bus bar

sizes with reference to its short circuit ability. The bus bar shall be

integrated completely into the gas filled compartment including the

coupling chambers between two adjacent modules.

(ii) The insulating ability of the entire bus bar system should be monitored

along with the gas filled cladded compartment of the module. The bus

bar size shall be so chosen so as to limit the current density to within

permissible limit and if the fault current restricts the current density

less than that, then lesser density shall be used. The successful

tenderer shall furnish the calculations after award of work during

detail design stage and shall be approved by Engineer.

(d) Temperature rise

The temperature rise and the maximum temperature on any part of the

equipment when in service at site under continuous full load condition or

under short circuit shall not exceed the permissible limit as per relevant IEC

or IS: 13947. This shall not be exceeded when corrected for the difference

between the ambient temperature at site and the ambient temperature

specified in the relevant standard.

(e) RMU Indications

Indication of spring charge, ON, OFF trip etc. shall be provided by means

of mimic. If not covered in mimic and LED which shall be fed from control

supply arrangement designed by contractor If LED’s are provided, the

indicating lamps shall have covers of following colours.

Red closed position of breaker/ load break switch

Green open position of breaker /load break switch

Blue spring charge condition of breaker / load break switch

Amber auto tripped position of breaker

Yellow Earth position

If the manufacturer’s standard design has an alternative arrangement,

instead of the above mentioned, same can also be considered.

(f) Terminal boards and Secondary Wiring

(i) Connection to switchgear, operating mechanism indicating relays and

all instruments shall be deemed to form a portion of equipment of

panel.

Panel connections shall be insulated and shall be healthy and

securely fixed to back of the panel. The wiring must run on porcelain

or non-rusting metal cleats or metal flexible tubes as may be

approved by engineer. All wiring in the vicinity shall be insulated and


Page | 95


shall run in non-rusting flexible tubes from terminal boards

conveniently situated. All control connections instruments and relay

wires shall be provided with numbered ferrules at each terminal and

the numbering shall be in accordance with an approved system. All

wiring diagrams shall be clearly marked with the numbers

corresponding with those on the ferrules of the individual cores. Each

set of current and voltage transformer secondary connection shall be

complete and shall be earthed at one point only. Each such earthing

shall be made through links which can be opened for insulation

testing.

(ii) All the internal control wiring shall be through fire-resistant low smoke

tinned copper wires of 1.5 mm2 and for CT circuits these shall be with

2.5 mm2. The strands in the copper wire shall not be less than 48.

(iii) The CT circuits shall be provided with isolating type of links, to check

the current in the CT circuits during testing. Similar it shall be possible

to isolate PT’s without disconnecting wires to check & test the meters.

All CTs must have provision for shorting through link.

(iv) The air insulated control cabinet shall have provision for lighting.

(v) As the equipment is to be installed in a tropical and high humidity

zone, the air insulated control cabin shall be provided with suitable

space heater of PTC type.

20.3.3.21 Recommended Spares

The contractor shall provide a list of recommended spares along with cost of

each item, in the schedule provided for 15 (fifteen) year operation. The cost of

recommended spares shall not be included in bid evaluation. The Employer /

Engineer shall have the option to select the desired items and it would from a

part of separate order.

20.3.3.22 Type And Routine Tests

All the routine and type tests shall be carried out as per relevant IEC / Indian

Standard. For type test certificates Engineer may consider test certificates at its

absolute discretion.

All the routine tests on the switchboard shall be witnessed by the Engineer or its

authorised representative.

The following type & routine test certificates shall be supplied / carried out on the

RMU:

(a) Impulse withstand test

(b) Temperature-rise test

(c) Short-time withstand current test

(d) Mechanical operation test


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(e) Short circuit type test at L V chamber

(f) Checking of degree of protection

(g) Switch, circuit breaker, earthing switch making capacity.

(h) Switch, circuit breaker breaking capacity.

(i) Internal arc withstand test.

(j) Checking of partial discharge on complete unit

In addition, for switches, test reports on rated breaking and making capacity shall

be supplied.

(a) For earthing switches, test reports on making capacity, short-time withstand

current and peak short circuit current shall be supplied.

(b) The routine tests carried out by the manufacturer shall be backed by test

reports signed by the factory’s quality control department. They shall

include the following:

(i) Conformity with drawings and diagrams,

(ii) Measurement of closing and opening speeds & times

(iii) Measurement of operating torque

(iv) Checking of filling pressure

(v) Checking of gas tightness

(vi) Checking of partial discharges on individual components

(vii) Dielectric testing and main circuit resistance measurement

All of the major type tests shall be certified by an independent authority and an

internationally acceptable test house for the tests carried outside the country of

manufacture.

20.3.3.23 Configuration of Ring Main Unit

(a) Each non-extendable ring main unit shall comprise of three or four

configuration, as in Bill of quantities with a continuous bus bar, SF6

insulated, sealed for life, CTs and PTs as per requirement, pad locks for

locking with a universal key, complete in all respects.

(b) The main items of RMU are given below any other item not specifically

mentioned but required for the successful operation of the equipment shall

be deemed to be included without any financial liability to purchaser.

(c) Each load break switch panel shall be equipped with 12 kV, 630 Amps.

20kA / 3s, Gang operated, SF6 insulated, manual / motor operated, fault

making, load breaking switch, along with associated bus bars, CTs, PTs [as

required] and the same shall consist of the following main items:

(i) Metal clad in door type weather proof housing.


Page | 97


(ii) 12 kV, 630 Amps, fault making, .load breaking, manually / motor

operated, self-aligning, gang operated.

(iii) One set of 630 Amp, bus bar as specified.

(iv) Isolating plug & socket for main & auxiliary contacts if required.

(v) Mechanical interlocks to prevent switching on with cable in earthed

position.

(vi) One set of triple pole gang operated cable earthing contacts.

(vii) Load Current measurement.

(viii) Air Insulated cable box for Cable end termination suitable for 3 core,

12 kV, XLPE armoured cable of specified size, with AL conductor,

along with glands, suitable Gland plate and Cable support.

(ix) Mechanical On/Off/Earth/Test Indicators.

(x) Cable Testing Sockets

(xi) Capacitive Voltage indicator lamps.

(xii) Cable clamps

(xiii) Feeder Remote Terminal Unit [FRTU]

(xiv) Fault Circuit Indicator along with CTs.

(xv) Indicating lamps & auxiliary contacts.

(xvi) Auxiliary relays (if required).

(xvii) Interlocked earthing arrangement.

(d) Tee-off Circuit Breaker Panel, with SF6 insulation, suitable for transformer

feeder shall be equipped with 12 KV, 200 Amps, 20 kA, for 3 sec rated

circuit breaker with associated C.Ts, PTs, spring operated mechanism, bus

bars, compete with instruments, relays, terminal blocks. It shall comprise of

the following main items:

(i) Metal clad / indoor type weather proof housing

(ii) Vacuum circuit breaker, trip free

(iii) One set of 630 Amps. Bus bars (integral part with load break bus bar).

(iv) CTs for protection & Metering to match the transformer – 3 Nos.

(v) 3-overcurrent & one earth fault IDMT relays, direct operating.

(vi) Termination suitable for connection to.,11/0.415 V transformer of

specified rating.

(vii) Multifunction meter

(viii) P.T. 11000/ 3 - 110/ 3 - 110/3, as required.

(ix) On/Off indicator


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(x) Mechanical interlocks

(xi) Tripping, closing coils.

(xii) Indication lamp & spare auxiliary NO/NC contacts.

(xiii) Auxiliary relays for alarm and trip for transformer protections

(xiv) Earthing arrangement duly interlocked.

(xv) Mechanism with spring charging motor.

(e) The common system for the above shall consist mainly of:

(i) Channels, nuts, bolts, glands, gland plates, inter connecting

arrangement of tee-off breaker with transformer, cable termination

kits & supporting arrangement of cable, with the load break switches

etc.

(ii) Cable termination kits to be included for each RMU.

(iii) Gas monitoring device for sealed gas unit.

(iv) Pad locks for locking the panels.

(v) Handles for normal operation, spring charging & other tools required

for normal operation.

(vi) Mandatory spares.

(vii) Arrangement of control supply for breaker / load break closing /

tripping, motor charging indications etc.

(viii) All the necessary indicating lamps.

(ix) SF6 pressure monitoring unit.

(x) Analysis unit for dielectric monitoring of SF6 gas.

(xi) Any other item not included above but required for the operation shall

be deemed to be included though specifically not mentioned, without

any financial liability to purchaser.

(f) Two sets of cable termination and jointing tools for all the substations at

various locations.

(g) Any other item mentioned in text or any other item required for successful

operation but not included here shall be deemed to be included.

20.3.4 Dry Type Distribution Transformer

20.3.4.1 General

The distribution transformer in CSS shall be indoor Dry Type Transformer,

complete with all accessories / fittings and spare parts as specified herein.


Page | 99


Three-phase transformers shall be with cast resin type, class F insulation system

with natural (AN) cooling for indoor installation, for use in three-phase HV/LV

distribution systems.

(a) Specific Technical Requirements (Standard Value)

(i) Rated KVA : As per Approved

drawing of Contractor

(ii) Number of phases : Three

(iii) Type of installation : Indoor

(iv) Frequency : 50 Hz

(v) Cooling medium : AN

(vi) Rated Voltage

High voltage winding : 11 kV (DELTA)

Low voltage : 0.433 kV (STAR) with

Neutral

(vii) Highest Continuous System Voltage:

High Voltage : 12 kV

Low Voltage : 0.450 kV

(viii) Method of System Earthing :

High Voltage : Unearthed

Low Voltage : Solidly grounded

(ix) Type of tap changer : Off Circuit Gang

Operated

(x) Range of tapping : +5% to -5% with 5 steps of 2.5% on

11 kV side

(xi) Impedance at rated KVA : 5.0% at 75oC

(xii) Insulation and level : HV LV

Type of insulation : Uniform Uniform

One minute power : 28 3

Frequency withstand

test voltage (kV)

Impulse withstand : 75 8

test voltage (kVp)

(xiii) Winding

(aa) Connection : Delta (HV) Star (LV)


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(ab) Material : Aluminum

(xiv) Vector group : Dyn-11

(xv) Terminal details

(aa) HV Termination : Suitable for tee-off Breaker

of RMU

(ab) LV Termination : Suitable for phase and neutral

connection between transformer and LT board through an

insulated copper bus bar or a sand witched copper bus bar

enclosed in a non-segregated bus duct. The size of the neutral

bus shall be same as phase bus.

(ac) LT Neutral earthing : A separate Neutral point to

be provided for earthing.

(xvi) Minimum Clearance in Air : 11 kV 0.433 kV

(aa) Phase to phase (mm) : 340 50

(ab) Phase to phase (mm) : 170 50

(xvii) Design Ambient temperature : 50°C

(b) Maximum Temperature Rise of winding over an ambient of 50°C and

1000m altitude, not to exceed 90°C.

Maximum Temp of insulation : 150°C

Over load capacity : As per IEC

(c) Noise level at rated voltage & frequency : As per NEMA Pub. Tr-1

(d) Transformer Losses

The guaranteed losses of the transformer shall not exceed as given in the

Energy Conservation Building Code [ECBC], as per latest guidelines of the

Bureau of Energy Efficiency [BEE] for the required rating of distribution

transformer or as per the Bureau of Indian Standards [BIS] for transformers

having energy efficiency level-3. Transformers not complying to BEE / BIS

loss guidelines shall not be accepted. The guaranteed values of no load

losses and load losses shall be stated in the bid and these shall be firm.

(e) Performance

(i) Transformer shall be capable of withstanding for two seconds the

short circuit at its terminals as per requirements of IS-2026 without

any damage. Source short circuit power on the primary of the

11/0.433 kV transformer shall be assumed as 500 MVA for the short

circuit capability of the transformer. The thermal ability withstand due

to short circuit shall be demonstrated by calculation.


Page | 101


(ii) The maximum flux density in any part of the core and yoke at normal

voltage and Frequency shall be such that the flux density under 10%

over voltage condition shall not exceed 1.9 Tesla.

(iii) Transformer shall, under exceptional circumstances, due to sudden

disconnection of the load, be capable of operating at the voltage

approximately 25% above normal rated voltage for a period of not

exceeding one minute and 40% above normal for a period of 5

seconds.

(iv) The transformer may be operated continuously without danger on any

particular tapping at the rated KVA ±10% of the voltage

corresponding to the tapping.

(f) Miscellaneous

Complete hardware for fixing the transformer as a part of packaged RMU

substation shall be provided whether specifically mentioned or not.

(g) Delivery

The equipment shall be delivered, erected and commissioned at site as a

part of the packaged RMU substation.

(h) Conflict in Clause

In case of any conflict between the Specific Technical Requirements and

General Technical Requirements, the requirements indicated as Specific

Technical Requirement shall prevail over the General Technical

Requirements.

(i) Marine/saline environment: Climatic, Environmental and fire resistant

Requirements

(i) As the equipment is to be installed in a corrosive saline environment

and humid atmosphere, moisture dripping water and tropical

environment the equipment and material provided must resist the

corrosion likely to occur in such cases. Normal mild steel, even

galvanized steel is not suitable for such an atmosphere.

(ii) Further the transformer must comply to the following class

requirements of clause 13 of IS 2026-11 / IEC 60076- 11.

20.3.4.2 Class C1: Operation, transportation and storage at ambient temperature as low as -5ºC

20.3.4.3 Class E2: Frequent condensation combined with high pollution.

20.3.4.4 Fire Class F1: Limited flammability, Self-extinguishing of the fire and to be free from halogens, emission of toxic gases, and minimum of thick smoke.

(a) The above classes will be indicated on the rating plate.


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Note: The manufacturer must produce a test report, complying to above

clauses as per test procedure of IEC-60076-11. Test report shall be from

an accredited laboratory acceptable to Engineer, for a transformer of the

same design.

(b) Name Plate

Transformer rating plate in English and Hindi language shall contain the

information as given in Clause 15 of IS: 2026 (Part-I) / IEC 60076-11. The

details on rating plate shall be finalised during the detailed engineering.

20.3.4.5 General Technical Requirements

Dry type transformer will be manufactured in accordance with a quality system in

conformity with ISO 9001 and complying to latest version of IEC 60076-11

Environmental management system is to be in conformity with ISO 14001, which

shall be certified by an independent recognized organization acceptable to

Engineer.

(a) Codes and Standards

(i) The design, material, fabrication, inspection, testing before dispatch,

erection/construction, testing, commissioning and performance of

distribution transformers shall comply with all currently applicable

statutory regulations and safety codes in the locality where the

equipment will be installed. Nothing in this specification shall be

construed to relieve the contractor of this responsibility.

(ii) Transformers shall conform to the latest applicable standards and

codes of practice as given below.

S. No. Standard Number Description

1 IS: 5 : Colour for ready mixed paints and

enamels.

2 IS: 104 : Ready mixed paint, brushing, zinc

chrome Priming

3 IS: 2026- [Part 1 to 11] Transformers

4 IS: 1180 : Outdoor type three phase distribution

transformer

5 IS: 1271 : Thermal evaluation and classification

of Electrical Insulation

6 IS: 1363 : Hexagon head bolts, screws and nuts

of Product grade C


Page | 103



7 IEC: 60076-11 for F1,

C1 & E2

Dry Type Transformers

8 IS: 2016 : Plain washers

9 IS: 2026 (Part I to IV) : Specification for Power Transformers

10 IS: 2071 : Method of high voltage test

techniques

11 IS: 2074 : Ready mixed paint, air drying, red

oxide-zinc chrome, primary

12 IS: 2099 : High voltage bushing for alternating

voltage above 1000 V.

13 IS: 2633 : Methods for testing uniformity of

coating of zinc coated articles

14 IS: 2932 : Enamel, synthetic, exterior (a)

undercoating (b) finishing

15 IS: 3043 : Code of practice for earthing

16 IS: 3347 : Dimensions for transformer Bushings

17 IS: 3639 : Fittings and accessories for power

transformers

18 IS: 4257

: Dimension for clamping

arrangements for porcelain

transformer bushings

19 IS: 5216 : Guide for safety procedures and

practices in electrical work

20 IS: 5561 : Electric power connectors

21 IS: 7421 : bushing for alternating voltage upto

and including 1000 V.

22 IS: 10028

: Code of practice for selection,

installation and maintenance of

transformers.


Page | 104



23 IS: 12360

: Voltage bands for electrical

installation including preferred

voltages and frequency.

24 C.B.I.P. Publication : Manual on Transformers

Table 16: Codes and Standards

The equipment complying with other internationally accepted standard may also

be considered if they ensure performance superior to the Indian Standards.

(b) Drawings

(i) The contractor shall furnish, within fifteen days after issuing of Letter

of Intent, the following drawings / documents incorporating name of

project and transformer rating for approval.

(aa) Detailed overall general arrangement drawing showing front

and side elevations and plan of the transformer and all

accessories including external features with details of

dimensions, spacing of wheels in either direction of motion,

net weights and shipping weights, crane lift for un-tanking, size

of lugs and eyes, bushing lifting dimensions, clearances

between HV and LV terminals and ground etc.

(ab) Foundation plan showing loading on each wheel and lifting

lugs.

(ac) GA drawings / details of bushing and terminal connectors.

(ad) Name plate drawing with terminal marking and connection

diagrams.

(ae) Wheel locking arrangement drawing.

(af) Transportation dimensions drawings.

(ag) Interconnection diagrams both on HV & LV sides.

(ah) Over fluxing withstand time characteristic of transformer.

(ai) Technical leaflets of major components and fittings.

(aj) As built drawings of schematics, wiring diagram etc.

(ak) Setting of winding temperature indicator.

(al) Completed technical data sheets.

(am) Details including write-up of tap changing gear.

(an) H.V. bushing.

(ao) Bushing Assembly.


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(ap) B-metallic connector for connection to specified conductor /

bus-bar /in bus-duct.

(aq) Assembly.

• Two earthing terminals & core earthing

• Thermometer pockets

• Inspection cover

(ii) All drawings / documents, technical data sheets and test certificates

/ results / calculations shall be furnished.

(c) Any approval given to the detailed drawings by the Engineer shall not

relieve the contractor of the responsibility for correctness of the drawing

and in the manufacture of the equipment for the packaged substation.

20.3.4.6 General Constructional Features

(a) All material used shall be of best quality and of the class most suitable for

working under the conditions specified and shall withstand the variations of

temperature and atmospheric conditions without distortion or deterioration

or the setting up of undue stresses which may impair suitability of the

various parts for the work which they have to perform.

(b) Similar parts, particularly removable ones, shall be interchangeable.

(c) Screws, studs, nuts and bolts used for external connections shall be as per

the relevant standards. Bolts and nuts exposed to atmosphere shall be of

stainless steel.

(d) Exposed parts shall not have pockets where water can collect due to

moisture or otherwise.

(e) Labels, indelibly marked, shall be provided for all identifiable accessories.

All label plates shall be of in-corrodible material.

(f) All internal connections and fastenings shall be capable of operating under

overloads allowed as per specified standards without injury.

(g) Transformer and accessories shall be designed to facilitate proper

operation, inspection, maintenance and repairs.

(h) No patching, plugging, shimming or other such means of overcoming

defects; discrepancies or errors will be accepted.

(i) The galvanizing if required shall be of minimum 610 gm zinc per square

meter and it should be hot dip galvanised.

(j) Painting [as applicable]

(i) The structural steel work shall be cleaned of all scale and rust by shot-

blasting. Steel surfaces exposed to the weather shall be thoroughly

cleaning and have a priming coat of zinc chromate applied. The


Page | 106


second coat shall be of a glossy oil and weather resisting non-fading,

paint of shade No. 631 as per IS: 5.

(ii) Metal parts not accessible for painting shall be made of corrosion

resistant material.

(iii) All paints shall be carefully selected to withstand heat, rain, saline

atmosphere, condensation and extremes of weather. The paint shall

not scale off or crinkle or be removed by abrasion due to normal

handling.

(iv) In case finish paint chips off or crinkle during transit or installation, the

contractor shall arrange for repainting transformer at site at his cost.

The paint for repainting shall be supplied by the contractor.

(k) Under Carriage

The transformer shall be supported on non- corrosive steel structure

with forged steel flanged wheels suitable for moving the transformer

completely. Wheels shall be provided with suitable bearings which

will resist rust and corrosion and shall be equipped with fittings for

lubrication.

(l) Magnetic Core

(i) The magnetic circuit shall be constructed from prime quality high

grade cold rolled, non-ageing, grain oriented silicon steel lamination.

The manufacture shall submit the following documents to prove only

Prime quality Core is used:

(aa) Invoice of the supplier

(ab) Mill’s test Certificate

(ac) Packing list

(ad) Bill of loading

(ae) Bill of entry certificate to custom

The manufacturers shall indicate whether they have in-house

core cutting facilities or not, if not, they shall indicate place of

cutting.

(ii) To reduce the noise produced by the magnetic core, it is to be

equipped with noise-damping devices.

(iii) To reduce the no-load losses, the magnetic core is to be stacked

using overlapping-interlocking technology.

(iv) The laminations shall be free of all burns and sharp projections. Each

sheet shall have an insulating coating.

(v) The insulation structure for the core to bolts and core to clamp plate

shall be such as to withstand a voltage of 2000 V for one minute.


Page | 107


(vi) The completed core and coil shall be so assembled that the axis and

the plane of the outer surface of the core stack shall not deviate from

the vertical plane by more than 25 mm.

(vii) All steel sections used for supporting the core shall be thoroughly shot

or sand blasted, after cutting, drilling and welding.

(viii) The finally assembled core with all the clamping structures shall be

free from deformation and shall not vibrate during operation.

(ix) The core clamping structure shall be designed to minimise eddy

current loss.

(x) The core shall be carefully assembled and rigidly clamped to ensure

adequate mechanical strength.

(xi) The core shall be provided with lugs suitable for lifting the complete

core and coil assembly.

(xii) The design of magnetic circuit shall be such as to avoid static

discharges, development of short circuit paths within itself or to the

earthed clamping structure and production of flux component at right

angle to the plane of the lamination which may cause local heating.

The construction is to be of ‘core’ type.

(m) Internal Earthing

(i) All internal metal parts of the transformer, with the exception of

individual laminations, core bolts and their individual clamping plates

shall be earthed.

(ii) The magnetic circuit shall be connected to the clamping structure at

one point only and this shall be brought out. A dis-connecting link

shall be provided on transformer to facilitate disconnections from

ground for IR measurement purpose.

(iii) Coil clamping rings of metal at earth potential shall be connected to

the adjacent core clamping structure on the same side as the main

earth connections.

(n) Winding

(i) LV windings

The LV winding shall be copper wound. This coil will be insulated

between each layer using a heat-reactivated class F pre-impregnated

epoxy resin film including the ends of the winding. The whole winding

assembly is to be polymerized at suitable temperature to ensure high

level of resistance to saline and highly humid environment and to

have excellent dielectric strength.

(ii) HV Windings


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(aa) HV winding shall be separated from the LV winding to give

an air gap between the MV and LV circuits for easy

maintenance.

(ab) HV winding shall have linear potential gradient from top to

bottom to have low stress between adjacent conductors,

with high dielectric strength and low partial discharge.

(ac) HV winding shall be of Copper wire with class F insulation

cast in vacuum with fire proof / flame retardant epoxy resin.

(ad) The interior and exterior of the windings will be reinforced

with a combination of glass fibre or similar material to

provide thermal shock withstand.

(iii) HV Winding Support Spacers or Coil support blocks

(aa) Winding support spacers are meant to provide sufficient

support in transport, operation, short circuit and earthquake

conditions.

(ab) These spacers will be circular (or suitable shape) in shape for

easy cleaning. They will give an extended tracking line to give

better dielectric withstand under humid or high dust conditions.

(ac) These spacers will include an Elastomer cushion that will allow

it to absorb expansion as peer load conditions. This Elastomer

cushion will be incorporated in the spacer to prevent it being

deteriorated by air or UV.

(o) HV Connections

(i) The connections shall be of copper and made from the top to give a

safe and neat connection. A terminal plate shall be provided.

(ii) The HV connections will be made from the top connection bars. Each

bar will be drilled with a hole for connection of cable lugs on terminal

plates.

(iii) The HV connection bars will be in rigid copper bars protected by heat

shrinkable tubing.

(iv) HV connections in cables are not allowed, in order to avoid all risk of

contact, due to cables flapping.

Depending upon the design of the manufacturer the arrangement

shall be approved by the Engineer.

(p) LV Connections

(i) The LV connections with copper bars will be made from top of coils

on the opposite side to the HV connections.


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(ii) Connection of the LV neutral will be directly made to the LV terminals

between the LV phase bars. There shall be a separate earth point

connected to neutral.

(iii) Depending upon the design of the manufacturer the arrangement


(q) Transformer Thermal and Overload Protection

(i) PTC type sensors [minimum 6] shall be placed in the winding to

measure the winding temperature.

(ii) The transformer shall be equipped with an overload and thermal

protection device with sensors to continuously monitor the LV and HV

winding temperature for each phase.

(iii) Digital monitoring thermometers shall be installed locally in the CSS

on LV Board, with a provision for monitoring the temperatures at

remote SCADA. Necessary alarms and trip contacts along with

warning LEDs shall be provided to protect the transformers from high

temperature.

(iv) Sensors shall be so placed that it shall be possible to replace the

same very easily. All sensors along with enclosures, digital

thermometers, transducers, sensing relays, connecting leads, etc.

complete in all respects shall be in the scope of supply. For this

purpose Security & Communication contractor shall lay a fibre optic

cable from CSS to SCADA control Centre, termination of which to

such devices shall be in the scope of contractor.

(v) Provision shall be made that In case of fire the transformer circuit

breaker should be tripped.

(r) Off Circuit Tap Changer

There shall not be a bolting arrangement for selecting the taps and shifting

the copper bars. Instead the off circuit tap changer shall be operatable by

means of an operating handle / ring brought out-side the tank operable from

ground level. It shall be equipped with an indicating device to show the tap

in use and shall be provided with a locking arrangement to lock the switch

in position. The arrangement shall be such that an operator can change the

tap while standing at ground level with complete ease. There shall be

separate cover for tap changer. If the manufacturer’s standard design

differs from the above given, it shall be subject to approval of Engineer.

(s) Safety of Personnel

Transformer shall be properly fenced/ protected in case the maintenance

personnel are likely to come near the live parts while carrying out normal

maintenance or monitoring activities near the transformer.

(t) Fittings

The following fittings shall be provided on the transformers:


Page | 110


(i) Separate LV neutral point, with two joined points for double earthing

of neutral along with tinned copper strip compatible to transformer

short circuit current rating for earthing.

(ii) One danger Plate

(iii) Temperature indicating device, sensors etc. complete in all respects

with contacts for remote / local indication.

(iv) Lifting eyes or lugs for the top cover, core and coils and for the

complete transformer.

(v) Platform lugs / haulage lugs on under carriage.

(vi) Marshalling box.

(vii) Rating and connection diagram plate.

(viii) Two numbers earthing terminals on opposite sides, associated nuts,

bolts and tinned copper earth strip of suitable section for connections

to purchaser’s grounding strip.

(ix) 4 bidirectional rollers.

(x) Thermal and overload protection devices and equipment, along with

necessary transducers, sensors etc. for local and remote SCADA

indication, Alarm / trip contacts, LED indicators complete in all

respects

Note: The fittings listed above are indicative and any other fittings which

are generally required for satisfactory operation of the transformer are

deemed to be included in the quoted price of the transformer.

(u) Radio Interference and Noise Level

Transformers shall be designed with particular care to suppress at least the

third and fifth harmonic voltages so as to minimise interference with

communication circuits. Transformer noise level, when energised at normal

voltage and frequency shall be as per NEMA stipulations.

(v) Recommended Spare Parts

Contractor shall provide a list of recommended spare parts for 5 years

operations. The cost of these spare parts shall not form part of contractor

proposal.

20.3.4.7 Tests

The Transformers shall be completely factory tested before dispatch in

accordance with the standards and with such other tests as may be necessary

to ensure that the equipment is satisfactory and is in accordance with this

specification.

(a) Routine Tests


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Transformer routine tests shall include tests stated in latest issue of IS:

2026 / IEC 60076-11. These tests shall also include but shall not be limited

to the following:

(i) Measurement of winding resistance.

(ii) Voltage ratio on each tapping and check of voltage vector

relationship.

(iii) Impedance voltage at all tapping.

(iv) Magnetic circuit test

(v) (After routine tests, each core shall be tested for 1 minute at 2 kV

between all bolts, side plates and structural steel work. Immediately

prior to the dispatch of the transformer, the magnetic circuit shall be

pressure tested for 1 minute at 2 kV A.C. between the core and the

earth).

(vi) Load losses.

(vii) No load losses and no load current.

(viii) Absorption index i.e. insulation resistance for 15 seconds and 60

seconds (R60/R15) and polarization index i.e. Insulation Resistance

for 10 minutes and one minute (R10 mt/R1 mt).

(ix) Separate source voltage withstand test (applied potential).

(x) Induced voltage test.

(xi) Measurement of partial discharges.

(aa) partial discharges less than or equal to 10 pC at 1.30 Un, or

(ab) partial discharges less than or equal to 5 pC at 1.30 Un (Special

test)

(xii) Measurement of acoustic noise level.

(xiii) Measurement of Zero sequence impedance.

(xiv) All routine and indicated type tests should be done free of cost. For

other type tests, necessary test certificates from a government

approved test house shall be acceptable provided these are not more

than 5 years old.

When transformers are equipped with a protection enclosure, these

shall be tested in their enclosure.

Moreover, in addition to the routine tests, the transformer shall be

subjected to the following type tests:

(aa) Lightning Impulse Test

This test shall be carried in accordance with clause 12 of the

latest issue of IS: 2026 (Part-III) on one of the transformer of

the lot.


Page | 112


(ab) Temperature Rise Test

The temperature rise test shall be carried out in accordance

with IS: 2026 /IEC-60076. The Temperature rise shall not

exceed the values as in the IS: 2026 / IEC 60076-11

(ac) Noise Level Test:

It shall be carried out as per IEC-60076-10

(ad) Environmental and Firefighting tests

Certificates for tests carried out for Compliance to Class C1,

E2 and F1 as per IEC 60076-11.

(ae) Short Circuit Test

It shall be carried out as per IEC 60076-5. Alternatively

employer at its discretion can ask for calculations instead of

actual test.

(b) Test Waiver, Procedures and Costs

(i) No load losses and exciting current shall be measured at rated

voltage, rated frequency and at 90% and 110% of rated voltage, both

before and after the lightning impulse tests.

(ii) The method of test loading shall be described in the test report for

determination of both average and hottest spot temperature. Where

the winding temperature equipment is specified, data shall also be

included for calibration of hottest spot temperature indicator.

(iii) Resistance of each winding of each phase shall be measured at

principal and at all the taps and corrected to 75°C.

(iv) Impedance voltage shall be measured at principal and at all taps.

(v) No load Loss Measurement at 415 Volt.

(c) Test on Associated Equipment

Bushings, Transformer thermal and overload protection devices, sensors,

digital thermometers, OFF LOAD tap changer, control devices, and other

associated equipment shall be tested by the contractor in accordance with

relevant IS or IEC. If such equipment is purchased by the contractor, he

shall have them tested to comply with these requirements.

(d) Test Measurements

(i) Certified test report and oscillograms shall be furnished to the

Engineer for evaluation as per the schedule of distribution of

documents. Manufacturer’s Test Certificates in respect of all

associated auxiliary and ancillary equipment shall be furnished.

(ii) The contractor shall state in his proposal the testing facilities available

at his works. In case full testing facilities are not available, the

contractor shall state the method proposed to be adopted so as to


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ascertain the transformer characteristics corresponding to full

capacity testing.

(e) Witnessing of Tests

The Engineer reserves the right to witness any or all tests. If required, visits

can be made to the works of manufacturer to ensure that the approved

quality ensuring programme is being followed. In this regard all the

necessary facilities shall be arranged by manufacturer at his end and cost

borne by the contractor.

(f) Site Tests

After the transformer is installed, the following pre-commissioning tests and

checks shall be done before putting the transformer in service.

(i) Visual checks for connections etc.

(ii) Dry out test

(iii) PI / Resistance measurement of windings

(iv) Ratio test

(v) Tap changer test

(vi) Temperature Indicators & alarms

(vii) Magnetising current

(viii) Earth connections are made.

(g) Rejection

The Engineer can reject any transformer if during tests or service any of the

following conditions arise:

(i) No load loss exceeds the guaranteed value.

(ii) Load loss exceeds the guaranteed value.

(iii) Impedance value exceeds the guaranteed value by 10% or more.

(iv) The difference in impedance values of any two phases during single

phase short circuit impedance test exceeds 2% of the average value

guaranteed by the vendor.

(v) Winding temperature rise exceeds the specified value.

(vi) Transformer fails on impulse test.

(vii) Transformer fails on power frequency voltage withstand test.

(viii) Transformer is proved to have been manufactured not in accordance

with the agreed specification.

(h) Instructions Manual

Six sets of the instruction manuals shall be supplied at least four (4) weeks

before the actual dispatch of equipment. The manuals shall be in bound


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volumes and shall contain all the drawings and information required for

erection/construction, testing, operation and maintenance of the

transformer. The manuals shall include amongst others, the following

particulars:

(i) Marked erection/construction prints identifying the components, parts

of the transformer as dispatched with assembly drawings.

(ii) Detailed dimensions, assembly and description of all auxiliaries.

(iii) Detailed views of the core and winding assembly, winding,

connections and tapping’s, tap changer construction etc. These

drawings are required for carrying out overhauling operation at site.

(iv) Salient technical particulars of the transformer.

(v) Copies of all final approved drawings.

(vi) Detailed O&M instructions with periodical check lists etc.

(i) Completeness of Equipment

(i) All fittings and accessories, which may not be specifically mentioned

in the specification but are necessary for the satisfactory operation of

the equipment, shall be deemed to be included in the specification.

These shall be furnished by the contractor without extra charges. The

equipment shall be complete in all details, whether such details are

mentioned in the specification or not.

(ii) All deviations from this specification shall be separately listed under

the requisite schedules, in the absence of which it shall be presumed

that all the provisions of the specifications are accepted by the

contractor.

(j) Tools & Tackles

All the necessary tools and tackles required for the normal operation shall

be supplied by the successful bidder after award of work.

20.3.5 LV Switchboard for Compact Sub-Stations

20.3.5.1 General

The LV switchboard for CSS shall be indoor 3-Phase, 4-wire, 440 V, 50 HZ,

neutral solidly grounded, complete in all respects including base channels,

foundation bolts and other hardware for various packaged RMU distribution sub-

stations.

20.3.5.2 Standards

(a) The equipment covered in these specifications shall conform to the latest

revisions / replacements of the following Indian Standard Specifications.


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S. No. Standard

Number Description

1 IS: 5 Colours for ready mixed paints & enamels

2 IS: 722 AC Electricity Meters

3 IS: 1554 PVC insulated (heavy duty) electric cables

4 IS: 2147 Degrees of protection provided by enclosures

for Low-voltage switchgear and control gear

5 IS: 2419 Dimensions for panel mounted electrical

indicating & recording electrical instrument

6 IS: 2551 Danger notice plates

7 IS: 2633 Methods for testing uniformity of coating of Zinc

coated articles

8 IS: 2705 Current Transformers

9 IS: 3156 Voltage Transformers

10 IS: 3231 Specification for electrical relays for power

system protection

11 IS: 4237 General requirements for Switchgear & Control

gear for voltage not exceeding1000 volts.

12 IS: 4794 Push buttons

13

IS: 5082 Wrought aluminium and aluminium alloy bars

rods, tubes, sections plates, sheets for

electrical application

14 IS: 5578 Guide for making of insulated conductors

15 IS: 6005 Code of practice for phosphate coatings of iron

and steel (First Revision)

16

IS: 6875 Control switches (switching devices for control

and auxiliary circuit including contractor relays)

for voltages up to and including 1000 V AC and

1200 V DC


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S. No. Standard

Number Description

17 IS: 8623 Low voltage Switchgear and Control gear

assemblies

18

IS: 8828 Electrical accessories circuit breakers for over

current protection for home load and similar

installations.

19 IS: 9000 Basic environmental testing procedures for

electronic and electrical items

20 IS: 10580 Service conditions for electrical equipment

21

IS: 11353 Guide for uniform system of marking and

identification of conductors & apparatus

terminals

22 IS: 13703 Low voltage fuses for voltages not exceeding

1000 V AC or 1500 V DC

23 IS: 13942 Low voltage switchgear and control gear

24 SP: 39 Guide for insulation coordination within low

voltage system

25

IEC -60364

IEC: 60664

Low Voltage Electrical Installations [All

applicable series of IEC-60364]

Insulation coordination within low voltage

system including clearance and creepage

distance for equipment.

Table 17: Codes & Standard

(b) The equipment complying with other internationally accepted standards

shall also be considered, if they ensure performance equivalent to or

superior to Indian Standards.

20.3.5.3 System Details

The L.V. Distribution Board shall be a part of a packaged RMU substation having

transformer rating as in the single line diagram for that location and technical data

as given under Specific Technical Requirements. Only the standard size of

transformer shall be selected. Broadly the LV distribution board shall have the

following configuration:

(a) Connection to LV side of Transformer


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20.3.5.4 Connection to LV side of distribution transformer shall be through insulated, three phase, four wire tinned Copper bars. Alternatively tinned Copper bars may be considered with a non-segregated three phase four wire bus duct, or with sand-witched bus bars, conforming to relevant IS Standard as per current requirements.

(b) Incomer and Board Bus bar

20.3.5.5 Incomer shall be Air Circuit Breaker, draw out type, electrically operated, equipped with microprocessor based electronic trip units, complete with CTs & metering. It shall be possible to operate this breaker from remote through SCADA also. Transformer incomer rating shall be same as that of bus rating. LV Bus bars shall be three phase, 4wire, and of tinned copper. Size of neutral conductor shall be same as of phase bars. The LV Board shall be designed for fault level as given in the Specific Technical Requirements.

(c) Outgoing Feeders

20.3.5.6 No HRC fuses are envisaged. All the outgoing feeders shall be equipped with Moulded Case Circuit Breakers of appropriate rating.

(d) External Cabling

20.3.5.7 The external, three phase, four core, LV cables of required size shall be terminated to the outgoing terminals of LV switch board. Necessary cable supports shall be provided in the cable alley of the board


(a) General

(i) The equipment shall be designed to ensure satisfactory operation of

the system in which continuity and quality of service is the first

consideration. It shall also be designed to withstand sudden load

variations due to short circuits and fault conditions or for any other

reason.

(ii) All mechanism shall be made of such materials as to prevent

sluggishness due to rust or corrosion in the salty environment at sea

level. All connections and contacts shall be of ample section and have

sufficient surface area for carrying continuously the specified current

without undue heating and shall be secured rigidly and locked in

position. Standard sizes of stainless steel bolts, screws, pipes and

other fittings are to be used and number of sizes is to be kept to the

minimum.

(iii) Cast Iron shall not be used for any part of the equipment which may

be subjected to mechanical stresses.

(iv) All apparatus shall be so designed and constructed as to obviate the

risks of short circuits of the live parts by lizards, vermin’s etc. Metal

cubicles, housing and covers shall be 100% weather / vermin proof


Page | 118


and shall be able to provide the degree of protection IP-54 in

accordance with latest version of IS-2147.

(v) All parts shall be manufactured in accordance with relevant standard

specifications of IEC / I.S. Corresponding parts of similar equipment

and apparatus shall be mutually interchangeable.

(vi) All apparatus, connections and cabling shall be designed and

arranged to minimise the risk of fire and any damage which might be

caused in the event of such an eventuality.

(b) Specific Technical Particulars

The standard technical particulars (which must be modified considering the

climatic conditions as given in relevant standards) for the LV Switchboard,

are given below:

(i) AC System : 3 phase, 4 wire, solidly earthed

a) Transformer secondary Voltage : 433V

b) System Nominal Voltage : 415 volts +6% / -10%

c) Frequency : 50 Hz 3%

d) Combined variation : Any combination of absolute sum of

Voltage & frequency.

(ii) Bus bar

a) Electrolytic Copper, tinned, Continuous rating [minimum 50%

above transformer rating]

b) 250 KVA : 800 A

c) 500kVA : 1200 A

d) 800kVA : 1600 A

e) Short time (1 Sec) : 50 kA rms

(iii) One Minute Power Frequency / Impulse Withstand Voltage

a) Power circuits : 2.5 kV (rms)

b) Control circuits : 2.5 kV (rms)

c) Basic Insulation Level, kVp : 12

(iv) Flush Mounted Moulded Case Circuit Breaker (MCCB, TPN) with

rotary handle

(v) AC

a) Voltage : 3-Phase, 415 V

b) (-6 to +9%)


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c) Frequency : 50 Hz

d) Short Circuit Performance : P2

e) Short Circuit Capability : 50 kA (rms) for 1

(vi) Sec. (Icw)

a) Making capacity : 62.5 kAp

b) Operating Mechanism : Manual, trip free

c) Temperature rise : As per IS: 2516

d) Mechanical : As per IS: 2516

e) Auxiliary contacts : 4 No., 4 NC

f) Current Rating : As per approved

SLD submitted by

contractor

(vii) Multi-function Meters

a) Accuracy class : 1

b) One Minute Power : 2 kV (rms)

20.3.5.9 Frequency Withstand Voltage

(i) Current Transformers

a) Type : Cast resin, Bar

b) primary

c) Secondary circuit : 1 Amp.

d) Voltage class and Frequency: 1100 v, 50 Hz

e) Class of insulation : E or better

f) Accuracy

g) Accuracy class & VA : Class 1, 10 VA of metering

CT

h) Accuracy class of VA : 5 P 15, 10 VA of protection CT

i) Short time current rating : 50 kA (rms) for 1

j) sec.

k) Dynamic rating : 120 kA (peak)

l) One Minute Power : 2.5 kV (rms)


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(i) Voltage Transformers

a) Type : Cast resin

b) Rated voltage :

Primary : 415 V / √3

Secondary : 110 V / √3

Accuracy class and VA burden

Metering : 1.0, 25 VA

Protection : 3 P, 25 VA

Method of connection

Primary : Star

Secondary : Star

c) Rated voltage factor : 1.1 continuous, 1.5 for

3 sec.

d) Class of insulation : E or better

e) One minute power : 2.5 kV (rms)

20.3.5.11 Frequency withstand voltage

(i) Relay

a) One Minute Power : 2.0 kV (rms)

b) Frequency withstand Voltage

(ii) Cubicle Colour Finish

a) Interior : Glossy White

b) Exterior : Grey shade No. 631 of

IS: 5

(iii) Accessories

c) Plug point with MCB.

a) Space heater PTC type.

b) Name plate on front & rear


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c) Danger plates.

(iv) Cubicle

a) Minimum thickness of CRCA sheet steel 2 mm

b) Base Frame channel 100mmx50mmx6mm

c) Degree of protection IP-54

d) Rubber mat between Panel & base 15mm

20.3.5.12 Clearance and Creepage Distances

The clearances and creepage distances shall be in accordance with

Indian Standard for condensing humidity and highly polluted environment.

20.3.5.13 Labels and Marking of Connections

All equipment, control gear and the apparatus mounted thereon shall be clearly

labelled indicating, their purpose and the ‘ON’ ‘OFF’ and “EARTH’ positions. The

labels shall be clearly lettered on enameled surface or other approved materials.

Brass should not be used for labels. Each phase of alternating current and

connections shall be coloured to distinguish phase, neutral and earth. The

colouring shall be respectively for red, yellow, blue for phases black for neutral

and green for earth.

Each phase of alternating current and connections shall be have coloured heat

shrinkable sleeve. The LT switchboards shall be labelled as per designation

shown in the approved single line diagram submitted by the contractor. The

labelling shall be finalised after the arrangement for the same, is got approved

by the successful contractor during detailed engineering.

20.3.5.14 Drawings and Literature

Four sets of tentative G.A., Schematic drawings and detailed literature of

equipment shall be submitted by successful bidder after award of work, during

detail design stage and shall be duly approved by Engineer clearly giving the

scope of supply and bill of material to enable the Engineer to scrutinise all

aspects of design including arrangement and support of cable accessibility for

maintenance work and future additions, cable connections, general appearance

etc. In addition, the contractor shall submit drawings & literature are to be

furnished by successful tenderer / bidder within 2 weeks after the award of

contract, which shall include the following:

(a) Complete assembly drawings of the boards, showing plan, elevation,

typical section, location of terminal blocks for external wiring connections

and mounting details of various devices with dimension.

(b) Foundation plan, embedment channel frame with associated holes and

suitable size of bolts for fixing to channel frame.


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(c) Wiring diagrams including terminal wiring design and cable schedule.

(d) Schematic control diagram, details of relays, instruments, space heaters,

cubicle illumination and receptacle etc.

(e) Bill of material of each LV board.

(f) Layout plan of each LV board.

20.3.5.15 Bought out Items

All bought out items such as switches, MCCBs, MCB’s meters, terminal blocks,

cables etc. shall be of reputed make. Engineer reserves the right to accept only

materials of proven make at its sole discretion. The list of recommended make

for major items is given in the specification volume.

20.3.5.16 Details of L.V. Switchboard

(a) Constructional Details

(i) The Switchboard shall be made of cold rolled sheet steel of 2 mm

thick having different compartments for bus-bars, cable alley and

instrumentation. The board shall be floor mounted, self-supporting.

(ii) The bus-bars shall be rectangular, of tinned electrolytic copper and

of approved size for current rating for phases as well as for neutral.

The bus bars shall be suitably supported on non-hygroscopic

insulators to withstand forces arising from short circuits in the

system. These shall be suitable for harsh environmental conditions.

(iii) The switch boards shall be of compact design. All doors and covers

shall be fully gasketed. Individual feeder compartments shall be

provided with stainless steel hinged doors, bolted type doors shall

not be acceptable. Indicating instruments shall be of 96x96 mm.

(iv) The interconnections between bus-bars and MCCBs unit shall be

solid insulated, tinned copper strip permanently bolted with the bus-

bars and MCCBs. The bus-bar joints shall be given a thin coating of

conducting grease after fully cleaning both the surfaces. The

terminals shall be of substantial mechanical strength & shall provide

adequate electrical contact area and the contact pressure is

maintained permanently. The bus-bars / tee off shall be insulated

with heat shrinkable sleeve tapes with red, yellow, blue colours for

3 phases and black for neutral. All the bus-bar tapping & markings

shall be in accordance with relevant IS.

(v) The gland plate shall be of Aluminium minimum thickness of 3 mm

and detachable type. A strong supporting channel of 100 x 50 x 6

mm shall be provided beneath the switchboard shell besides anti-

vibration rubber gasket of 15 mm thickness.


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(vi) The connection from 11/0.433 kV transformers to the LV

switchboard shall be through a LV non-segregated bus duct

[alternatively sandwiched bus duct] or through insulated copper bus

bars as per requirement.

(vii) The bus-bars shall have non-hygroscopic support insulators. The

bus bar shall be insulated with heat shrinkable insulating kits.

(viii) The short circuit withstands capacity of all the bus-bars and tap-

connection shall be 50 KA for one second.

20.3.5.17 Details of Circuits : Each switchboard shall have the following circuit arrangement.

(a) Incoming

(i) 1 no. 3 phase, 4 wire incomer four pole air circuit breaker,

electrically operated with microprocessor based trip circuit release.

The breaker shall conform to IEC 60947.

• It shall be withdrawal type. The control supply can be provided from a line connected PT from the LV connection from the transformer or any other arrangement given by contractor can also be considered during detailed engineering.

(ii) 3 Nos. – Metering CTs of required ratio, 10 VA Class 1, with ISF

less than 5.

(iii) 3 Nos. – Protection CTs

(iv) The incomer breaker shall have numerical relay having three over

currents of setting 50% to 100% of 1A rating with IDMTL; current Vs

time characteristics. Short circuit instantaneous trip shall be

included. Alternatively the built in microprocessor based trip units

having Overload protection [IDMTL, IEC characteristics], short

circuit trip [time delayed], Instantaneous short circuit protection,

Ground Fault Protection can also be considered.

(v) 1 no. 96 x 96 mm flush mounted multi-function meter. Meter shall

measure unbalanced neutral current also along with three phase

currents simultaneously.

(vi) 1 no. digital bus voltmeter scale 0-500 V with three line reading.

(vii) 1 no. Automatic Power factor controller [APFC], connected to y-

phase metering CT, with SCADA communication, and five steps to

switch on capacitor banks for power factor improvement to 0.95.

• Note: Number of steps is tentative and shall be finalised during detailed engineering.


Page | 124


(viii) LED type lamps to indicate breaker closed, open, auto trip,

protection operation, spring charged etc. indications.

(b) Outgoing feeders

(i) 3 phase, 4 wire, outgoing cable circuits are envisaged from the

switchboard and each circuit shall have the following items,

indicating instruments, terminal connectors etc.

(ii) 4 pole withdrawable type Moulded Case Circuit Breakers of

appropriate rating.

(iii) Earth leakage relay.

(iv) 3 nos. metering current transformers of secondary rating 1A & 1.0

accuracy class having primary current as per approved SLD

submitted by contractor.

(v) 1 no. 96x96mm flush mounted multifunction meter as per CT rating.

(vi) Termination points for 4C XLPE, Al. Armoured cables with lugs.

(vii) The LV board must have sufficient space of not less than 100 mm

between two termination points for external cables.

(viii) Cable alley along with necessary clamping arrangement for the

outgoing feeder cables.

(ix) Indicating LED lights – red, yellow and blue for the supply.

(c) To have proper reliability, in case of a failure of a distribution transformer,

on LV board a 630A, tie breaker shall be provided to an adjacent CSS, LV

board, to be operated manually and with castle key interlocks with incomer

feeder. These may be connected in pair, for example 1 to 2, 3 to 4 etc. In

case of odd number, then three may be connected.

20.3.5.18 Capacitor Bank and Automatic Power Factor Controller [APFC]

(a) Considering the transformer capacity and load power factor as 0.8, a

suitable size of switched capacitor bank shall be mounted inside the LT

compartment to improve the power factor to 0.95. Necessary calculations,

number of steps and switching details shall be provided for approval.

(b) Capacitor units shall be fuse-less, with loss not exceeding 0.5W / kVAR,

with metallised polypropylene film, double casing insulation, self-healing

feature, non-flammable and with nontoxic material. Reactors shall be non-

resonance, dry type resin embedded. Capacitor unit shall with automatic

operation steps as required, built in discharge resistor and mounted on

stainless steel frame. APFC shall also be supplied by the same

manufacturer. APFC shall have LCD display, programmable, with

monitoring of all parameters locally as well as at remote SCADA on mod

bus via fibre optic cable. It shall be with built in cabinet placed in the cubicle

of LV board with easy access doors.


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20.3.5.19 Earthing

a. The LV switchboard shall be provided with two separate earthing terminals

at the ends. with minimum rated for 50kA for 3 sec running in the board.

All metal parts, enclosure, transformer and neutral have to be

interconnected and ready for connection to the external earthing

arrangement.

b. The earthing terminals shall be identified by means of proper embossed

sign marks adjacent to the terminals.

c. In the cable gland area provision shall be made at cable gland for armour

earthing and then connecting it to main earth bar in a proper way. There

shall be a continuous tinned copper earth bus bar in the board. The size

of the earth bus bar shall be suitable to carry 50 kA for 3 second. The bus

bar shall not be visible or removable from outside the switchboard. The

earth bus bar shall have necessary holes, nuts & bolts including washers

for making earth connection of cable glands / armouring of the cables.

d. For earthing details refer tender drawings and specification.

20.3.5.20 Switchboard Lighting and Heating

A lamp holder with a 11 W LED lamp and operated by an internal SP-MCB shall

be fitted for internal illumination. In addition, a 3 pin 6A/25A socket shall also be

provided with a separate SP-MCB. Space heater of suitable rating of PTC type,

and with SP MCB shall also be provided to avoid any moisture condensation

inside the switchboard.

20.3.5.21 Danger Notice Plates

An enameled sheet steel danger plate of approved design as per IS: 2551 shall

be fixed on the middle upper front of the switchboard.

20.3.5.22 Tests

All tests as required in relevant Indian standard shall be carried out on the LV

switchgear. Engineer shall witness the tests at the works of the manufacturer.

a) Type Tests: The purchaser may ask the manufacturer to conduct the following

type tests on one of the AC Boards.

i) Verification of temperature rise limits test

ii) Verification of rain test to determine the degree of protection against rain.

iii) Verification of dielectric properties.

iv) Necessary type tests as per IS on all the individual items such as ACB’s,

MCB’s, MCCB’s, instruments, links etc.


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v) Short circuit test.

• Note: The Engineer, at its option, may waive the above type tests

provided type test reports of the above type tests carried out on

essentially identical unit in their factory / approved testing

laboratory are furnished by the manufacturer.

b) Routine Tests

i) The switchboard shall be subjected to all the routine tests as per Indian Standard

[IS] and witnessed by the Engineer. For power frequency voltage the test voltage

to be applied shall be for a period of one minute. Insulation tests with 500 volts

megger before and after the high voltage test shall be carried out on the

switchboard.

ii) Routine tests, as per IS shall be carried out on the bought out items viz. MCCB’s,

MCBs, meters etc.

iii) Verification of wiring & earth continuity

iv) Voltage test on auxiliary circuits.

v) Tests for mechanical operation control & interlocks.

c) Commissioning Site Tests

i) Necessary site tests at site shall be carried out to ensure its satisfactory

operation after installation.at site.

ii) Terminations of Incoming and Outgoing Circuits

iii) The cable termination arrangements shall be located at the lowest point above

the cable clamps, for ease of termination.

iv) Cable support shall be provided by a suitable clamp at the bottom of the panel.

These cable supports shall be adequate to support the outgoing cable in

normal service and when subjected to the short circuit current specified. The

distance between these cable supports and the gland plate shall be at least

200 mm.

v) The outgoing cables to be terminated in the switchboard shall be XLPE

insulated PVC sheathed armoured and with aluminium conductors. The cables

shall have bottom entry to the switchboard.

20.3.5.23 Air Circuit Breaker (ACB)

a) 415 V four pole air circuit breakers shall be withdrawal type with manually &

electrically operated mechanism. It shall be supplied for controlling the LV side

of the 11/0.433 kV, distribution transformer. Air circuit breakers shall have

symmetrical short circuit rating of 50 kA for 1 sec. [Icw rating]. The circuit breaker

shall be fitted with direct acting microprocessor based electronic release with

built in thermal memory. It shall be provided with adjustable long time, short time,


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instantaneous and earth fault protection. It shall be possible to have time delay

adjustment for over load, short circuit and earth fault protection and LED display

for the operation of each of these protections. The release shall be with self-

diagnostic feature. Adjustment of the setting should be possible without

disrupting the supply. The release shall have IEC IDMTL characteristics. The

breaker mechanism should be robust, quick making quick breaking and trip free.

ACB shall have LCD display for current and voltage measurement. It should be

possible to close and trip the breaker without opening the compartment & door.

It shall have auxiliary contacts for indications along with spare contacts.

20.3.5.24 The detailed specifications of Air Circuit Breaker shall be as under:

a) No. of poles Four

b) Service voltage 415 Volts

c) Normal current As per approved SLD of Contractor

d) Frequency 50 Hz

e) Rated Symmetrical Breaking 50 kA for 1 Sec.

20.3.5.25 Capacity at 415 V AC/50 Hz

a) Making current 105 kA

b) Rated insulation voltage 1000 V

c) Max Breaking time 30 ms

d) Max Making time 80 ms

e) Impulse Voltage 12 kVp

f) Pollution degree [IEC60664-1] 3 [minimum]

20.3.5.26 ACB Connection to Transformer

The air circuit breakers shall be suitably earthed with the main earth bus. The air

circuit breakers of the LV board shall be connected to the LV side of the

distribution transformer as specified. In case bus duct is provided the connections

at both the ends shall be through proper clamps preferably bimetallic. Suitable

arrangement shall be provided in the bus duct to take care of the expansion.

20.3.5.27 LV Moulded Case Circuit Breaker

a) All the LV outgoing underground feeders from the sub-station shall be controlled

by 4 pole fixed type moulded case circuit breakers, provided in the LV

switchboard.


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b) The moulded case circuit breakers shall be of robust construction and shall

comprise of switching mechanism, contact system, arc extinguishing device and

a tripping unit contained in a compact moulded case and cover. The insulating

case and cover shall be made of high strength, heat-resistance and flame-

retardant thermo-setting insulating material.

c) The switching mechanism shall be quick-make / quick break type, and should be

trip-free.

d) The arc extinguishing device shall comprise of a series of grid plates mounted in

parallel between supports of insulating material. The arc shall be drawn from the

moving contact into the divide chamber and extinguished.

e) The moulded case circuit breakers shall have a thermo-magnetic type tripping

mechanism, where the heating effect and the electromagnetic effect of current

are made use of to provide protection against overload and short-circuit

conditions respectively. The heated-bimetal strip in each phase of the MCCB

shall actuate the tripping system following on inverse-time-current characteristics

depending upon the severity of the overload current. During short-circuits, the

system shall trip instantaneously. The tripping element provided on each pole of

the MCCB shall operate on a common trip bar, thereby preventing single phasing

in the event of fault occurring on any of the phases. The tripping device shall be

ambient temperature compensated type.

f) The MCCB shall have a minimum Ics rupturing capacity of 50 kA. Positive

indication about the position of the MCCB i.e. whether ‘ON’ ‘OFF’ or TRIPPED

shall be provided.

g) The short circuit breaking capacity and operation mechanism of the MCCB shall

be supported by test certificates.

h) All the MCCBs used in LV switchboards for controlling the outgoing feeders shall

have a Thermal current setting of 70 to 100% of its rated current.

The rated currents given are provisional and shall be finalised during

detailed engineering.

The settings given above are provisional and shall be finalised during


i) The detailed specifications of the MCCBs shall be as under:

i) No. of poles 4 pole

ii) Service voltage 415 Volts

iii) Normal current [In] As per Approved

20.3.5.28 SLD of contractor

i) Frequency 50 Hz


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ii) Service [Ics] Breaking capacity at 415V AC, 50 Hz: 50 kA

iii) Making current 120 kA

iv) Pollution Degree 3

a) MCCB shall be provided with rotary handle for manual operation.

20.3.5.29 Internal Wiring

The LV AC distribution boards shall be supplied with complete internal wiring.

The central wiring shall be of 1100 V grade, FRLS, PVC insulated. Stranded

tinned (not less than 48 strands) copper conductor cables of 1.5 mm2 size shall

be used for control circuits and 2.5 mm2 for CT circuits. Engraved identification

ferrules, marked to correspond with the wiring diagram shall be fitted at both ends

of each wire. All wiring shall be terminated on terminal blocks. Terminal blocks

shall be one piece moulded and suitable for 500 V and of recommended make.

Terminals shall be adequately rated for the short circuit current. Typically

terminals of ‘Phoenix ’ make shall be provided which shall be approved by

Engineer during detailed engineering.

For CT circuits, shorting type terminals shall be provided. It shall be possible to

measure the CT current through clip-on-ammeters.

20.3.6 Pre-Fabricated Enclosure For Packaged RMU Substations

20.3.6.1 General

The enclosure for the compact substation also includes the base frame/ channels

and all the necessary fixing hardware accessories required at site. The enclosure

shall be compartmentalized and house RMU, dry distribution transformer, LV

distribution board with capacitor bank and their interconnections both external

and internal. Engineer at its sole discretion may also consider the alternate

designs given by the contractor, if the same are found to be better or equivalent

to the ones given hereunder.

20.3.6.2 Standards

The equipment shall conform (but shall not be limited) to IEC 6227-202 standard.

The requirements of standards for necessary clearances, ventilation etc. shall

also be complied with.

20.3.6.3 Specific Technical Requirements

(a) Typical size : 3.5m x 2.5m with 2.2m height

[Contractor may quote its own size, if

different ]

(b) Construction : Self- standing on concrete base


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(c) Steel base frame : 4mm thick base [hot dip electro-

galvanized steel, with epoxy paint]

(d) Lifting eyes : 4 Nos from the bottom.

(e) Housing enclosure : 2 mm corrosion resistant Zinc /

Aluminium alloy coated sheet steels

(f) Degree of Protection : HV Compartment : IP-54

Transformer Compartment : IP-23

LV Compartment : IP-54

(g) All hinges, supports Nuts,

washers etc.

: Stainless steel

(h) Paint : Epoxy

(i) Roof Design Load [min] : 250 Kg/m2

(j) Roof Design : Slanting on the sides

(k) Top of Roof : Removable

(l) Ventilation : With louvers (no exhaust fans shall be

used)

(m) Sound Level : 60 dB

(n) Standard Applicable : IEC 62271-202

(o) Number of earths : Two (at opposite ends)

(p) Compartments : Three with independent doors

20.3.6.4 Construction

(a) General

(i) The enclosure shall be self-standing on a concrete base. Necessary

civil requirements to be satisfied for the concrete base shall be

provided by the contractor. The levelling of ground and construction

of the concrete base and associated civil works shall also be in the

scope of the contractor.

(ii) The compact substation is completely self-contained, mounted upon

a 4 mm thick galvanised steel base frame, epoxy painted, factory

assembled in a totally enclosed, aesthetically acceptable metal


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cladding, vandal-proof and weatherproof housing ready for placing

into position upon a concrete base.

(iii) The lifting arrangement should be with four lifting eyes from the

bottom of the enclosure & not from the top.

(iv) The structure of the substation shall be capable of supporting the

gross weight of all the equipment & the roof of the substation

compartment shall be designed to support adequate loads. In case of

relocation of the Package Substation, the entire substation should be

capable of getting lifted and placed as a Single Unit without

dismantling of any of the major equipment inside the enclosure. The

complete housing assembly with four lifting eyes should be easy to lift

and position the whole unit at the site by the use of crane. The

substation can be lifted without damage or distortion. The transformer

is located in the middle of the substation while the HV and LV

compartments are located at both ends of the substation adjacent to

the corresponding bushings of the transformer. The arrangement is

subject to the approval of the Engineer.

(v) There shall be adequate ventilation inside the enclosure so that hot

air inside enclosure is directed out by help of duct. Louvers apertures

shall be provided so that there is circulation of natural air inside the

enclosure. The Package Substation should be designed &

engineering to have natural cooling & ventilation only. No forced

cooling / ventilation is acceptable.

(vi) The enclosure must be weather proof in the sea shore area of

installation where weather is saline, having tropical temperature with

high condensing type humidity (resulting in quick rusting of iron parts),

windy, having heavy rainfall and flash floods for about four to six

months in a year.

(vii) The enclosure must also be vermin proof to prevent the entry of

rodents, reptiles, & flying insects, which are prevalent in the area.

(viii) The enclosure should be pre-fabricated such that fire from one

compartment MUST NOT spread to other compartments.

(ix) It should have easy access to all the equipment inside the enclosure,

viz RMU, transformer, LV switchboard, capacitor bank, connections,

and terminations of HV & LV cables.

(x) The metal base and all supporting channels shall be hot dip

galvanised (min. 75 micron). These should ensure rigidity, ease in

transportation to sites and installation.

(xi) The housing of the enclosure shall be made of 2 mm corrosion

resistant Zinc / Aluminium alloy coated steel sheets.


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(xii) All hardware such as hinges, supports, screws, nuts, bolts, washers

etc. should be made of stainless steel. All locking bolts shall be

accessible from inside to prevent the unauthorised dismantling.

(xiii) All the enclosures shall be or of similar type & design.

(xiv) The colour of the enclosure shall be decided by Engineer during

detailed engineering, if different from the one given. The last finish

coat shall be of epoxy paint.

(xv) The roof of the substation enclosure shall be designed to support

loads up to 250 kg/m2. The roof shall be sloped on the sides so that

the rain water cannot stay on roof during rainy days.

(xvi) The pre-fabricated roof of the enclosure shall be removable

whenever required. The locking nuts, bolts to allow the removal of

roof shall be only accessible from inside the enclosure.

(xvii) Covers & Doors:

(aa) Covers & doors are part of the enclosure. When they are

closed, they shall provide the degree of protection specified

for the enclosure. All covers, doors or roof shall be provided

with locking facility or it shall not be possible to open or remove

them before doors in normal operation have been opened.

The doors shall open outward at an angle of at least

90degrees & be equipped with a device able to maintain them

in an open position. Proper padlocking facility shall be

provided for doors of each compartment. Transformer

compartment doors must be open from both the sides.

(ab) Door closing shall be by means of a three point linkage

arrangement (i.e. Centre, top and bottom) and controlled by a

centrally located stainless steel operating handle. Pad locking

facilities along with Master pad locks shall be provided. Master

pad locks shall be operated by a master key for all the

substations.

(ac) The outer doors of the enclosure shall be wide and provided

with heavy duty hinges to prevent distortion and misalignment.

A robust door restraint shall be provided to hold each door in

the 950 open positions. The restraint shall be of a captive

design so that it cannot be easily removed and shall be

self-strong when the door is closed such that it cannot

rattle. With the door in this position, operation of LV and HV

switchgear shall be possible without endangering operator’s

hands, etc.

(ad) When doors are closed, they are firmly locked; as such entry

of dust, vermin and rainwater is completely prevented.

Neoprene gaskets are to be used.


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(ae) The HV doors are provided with a drawing pocket to keep

drawing inside.

(af) A weatherproof nameplate shall be provided on the door.

(ag) The edges of the doors are bended at both sides to assure

they fit properly so that the door jams and misalignment is

prevented.

(ah) The transformer, low voltage and HV compartments are

completely separated by steel sheet. The barrier between the

HV switchgear and the transformer is provided with pressure

relief flaps.

(ai) All compartments are individually accessible by their own

doors from outside.

(xviii) Labyrinthine louvers form the sidings of the transformer room to assure

free entry and exhaust of air, as such the inside temperature is kept within

limits. Openings located at the lower and upper sides of the slanted roof

shall allow air circulation as part of the ventilation design.

(xix) No exhaust fans shall be used. Ventilation louvers shall be required to

provide sufficient ventilation.

(xx) All compartments are equipped with internal lighting consisting of 25

watts LED lamps controlled by their respective door micro switches. MCB

shall be provided to control the supply.

(xxi) Space heaters shall be provided to control condensing type humidity.

(xxii) Labels for warning, manufacturer’s operating instructions etc. & those

according to local standards & regulations shall be pasted / provided

inside and shall be durable & clearly legible.

(xxiii) The substation forms a complete metallic structure bolted together and

each compartment is to be provided with tinned copper, grounding bus-

bar. Bonding and interconnection of the grounding buses shall be made

of 70 mm2 bare stranded copper tinned conductors. The ring main unit

shall have 25x8 mm grounding bus while the low voltage switchgear shall

have 30 x 10 mm tinned copper grounding buses to which connection to

the grounding system at site can be made. At least two grounding points

for bolting to ground conductor shall be provided on opposite ends.

(xxiv) All metallic components shall be earthed to a common earthing point. It

shall be terminated by an adequate terminal intended for connection to

the earth system of the installation, by way of flexible jumpers/strips &

Lug arrangement. The continuity of the earth system shall be ensured

taking into account the thermal & mechanical stresses caused by the

current it may have to carry. The components to be connected to the earth

system shall include :

(aa) The enclosure of Unitized / prefabricated substation.


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(ab) The enclosure of High voltage switchgear & control gear from the

terminal provided for the purpose.

(ac) The metal screen & the low - high voltage cable earth conductor.

(ad) The transformer tank or metal frame of transformer.

(ae) The frame &/or enclosure of low voltage switchgear.

(b) Dimensions

The overall typical dimensions of the enclosure may be around 3.5m x 2.5m

(or 5m2) having height of about 2.2m. To achieve necessary clearances,

contractor may propose alternate size of the enclosure depending upon the

dimensions of the equipment supplied.

(c) Enclosure Requirements

(i) The enclosure must be totally safe to the personnel in the populated

areas as the packaged substation shall be established in the

residential townships.

(ii) The equipment in the enclosure must be accommodated with

necessary clearances, easy access to the RMU, and transformer, LT

switchgear and capacitor bank for testing, maintenance, removal and

normal operation (including operation with normal switchgear

handles).

There shall be unhindered access to the transformer, operation of

OFF load tap changer and other normal operating requirements.

Similarly termination & removal of cables, withdrawals of ACB from

LV board should be easy & comfortable.

(iii) It shall be the sole responsibility of the contractor to satisfy all the

statutory clearances and to provide safety measures against all

possible hazards to the equipment in the enclosures, such as internal

arcing faults in the enclosure considering salty environment near the

sea and area prone to flooding.

(iv) Failure within the unitized substation due either to a defect, or mal-

operation may initiate an internal arc. Such an event may lead to the

risk of injury, if persons are present. It is desirable that the unit shall

be tested for Internal Arc fault test to the tune of at least 20KA for 1

second as per latest IEC 62271-202 standard. The enclosure must

be so designed that internal arc faults are directed away from places

where personnel or public may be present. Test certificates from a

recognised national / international test house [acceptable to

Engineer] shall be supplied for internal arc.

(v) Testing of incoming & outgoing cables and use of testing equipment

for the same shall not entail the dismantling the sides or the roof of

the enclosure.


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(vi) There shall be sufficient space for termination & removal of cables

from Load Break Switches & also from the LV board.

(vii) Sufficient clearance must be kept between the top of any equipment

installed in the pre-fabricated substation and the roof of the substation

for ventilation and operational purposes.

20.3.6.5 Interconnection

The equipment inside the enclosure shall be interconnected as follows:

(a) The RMU shall be directly coupled by VCB feeder to distribution

transformer through insulated copper bars or cables as per manufacturer

standard.

(b) The LV side (three phases plus one neutral conductor) of distribution

transformer shall be connected to LV incomer Air Circuit Breaker via flexible

insulated copper bars or through a four conductor sand-witched insulated

bars or with bus duct enclosure.

(c) The HV termination to Load Break Switches shall be from 11 kV, Al.

armoured XLPE cables, fitted with termination kits, for the ring system.

(d) The earthing of pre-fabrication station shall be provided at two opposite

ends for connection to the outside earth rods. It shall be a bolted

connection.

20.3.6.6 Drawings

The following drawings shall be submitted after award of tender for approval of

Engineer.

(a) The detailed sketch of the enclosure indicating general view, position of

louvers etc.

(b) The drawing showing the layout of HV, transformer & LV switchgear along

with interconnections.

(c) Size & position of doors in the enclosure.

(d) Fixing details of the enclosure including civil foundations (if any).

20.3.6.7 Safety Measures

The enclosure shall have the following safety measures:

(a) Electric shock treatment chart duly framed shall be fixed in a conspicuous

position inside the enclosure.

(b) Danger notice in English/ Hindi/ Kannad language conforming to IS: 2551

shall be fixed on all the four sides of the enclosure.


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(c) Electric insulated rubber mat (non-skid type) with flouted top and plain

border end, 12 mm thick to withstand 12 kV di-electric strength shall be

provided in front of HV/LV boards where people have to work.

(d) Two number portable fire extinguishers typically 2 litres, suitable for

transformer / cable and other electrical equipment fires shall be placed &

fixed in a suitable location in the enclosure, away from the place where fire

is expected.

20.3.6.8 Tests

The following tests shall be carried out on the enclosure as per IEC standard at

the works of the manufacture:

(a) The complete prefabricated substation unit will be tested at full load for

temperature rise. The maximum temperature rise on any part of the

equipment placed inside the enclosure shall not exceed the value as

specified in IEC 62271-202.

(b) Test to verify the sound level of the pre-fabricated substation, which shall

be less than 60 db.

(c) Test to verify the degree of protection of enclosure for various

compartments.

(d) For the internal arc fault test on the enclosure the following need to be

observed and tested as below:

(i) Internal Arc Fault tested to 20 kA 1 sec.

(ii) Test to accessibility of Type “B” that is with unrestricted accessibility

including that of the general public (Annex. AA.2 IEC). Although test

to accessibility of Type “A” is not required, tenderers shall also

provide adequate measures to have any hot gases directed away

from the operator during switching with the door open.

(iii) Arc initiation is made inside the SF6 gas compartment of the RMU

(Annex. AA.3 IEC).

(iv) Assessment of the internal arc fault test is based on the fulfilment of

all 6 criteria as stated in Annex. AA.6 of IEC.

(e) Other Checks

(i) Inspection of conformity with the specification & approved drawings.

(ii) Inspection of devices locking out and interlocks.

(iii) Inspection and checking electrical continuity of metallic frame and

earthing system.

(iv) Dielectric tests of M.V. and L.V. bus bar.

(v) Provision of two earths as per Indian Electricity Rules.

(vi) Tests as per IEC standard.


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20.4 LT DISTRIBUTION FEEDER PILLAR BOX

20.4.1 SCOPE

This specification covers design, engineering, manufacture; shop testing, inspection,

painting, packing, and supply of 415V Sub Feeder Pillar complete with all accessories

for efficient and trouble-free operation of the electric distribution network for power

utilities.

The equipment shall conform in all respects to high standards of Engineering design and

workmanship and shall be capable of performing in a manner acceptable to user.

The general requirements from the installation are low electrical losses, weather

resistance, easy installation & connections, safe & touch proof design, easy

sectionalizing & maintenance & maximum service life.

20.4.2 STANDARDS

The Feeder Pillar shall comply with the requirements stated in the latest editions of the

following recommendations, standard and specifications.

Sr.

No

Title Indian standard

1 IS 5039 Specification for distribution pillars below 1000V AC

2 IS 13947 Part 2 Low voltage switchgear

3 IS 8623 Specification for low voltage switchgear

4 IS 12063 Classification of degrees of protection provided by

Enclosures of Electrical equipment

5 IS 5 Color of ready mixed paints

6 IS 191 Specification for copper

7 IS 5082 Wrought Aluminum & AI alloy plates & sheets for

electrical application.

Service Pillar / Tappat

The TAPPAT link distribution feeder pillar box confirms the standard in accordance with

IEC 60439-5: 2006, IEC 60439-1 : 2004 OR AS/NZS 3947.3 : 2001

20.4.3 SERVICE CONDITIONS

i. Supply voltage- 3 phase neutral, AC 415volt +/-10%

ii. Supply frequency- 50 Hz +/- 3%

iii. Location of panel- Outdoor, on foot path or roadside

iv. Pollution- Corrosive, dust, smoke & rain


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v. Humidity- 90% maximum

vi. Ambient temperature - Average 35" C, Maximum 48" C

vii. Incoming supply to feeder pillar panel- From transformer feeder pillar or other

feeder pillar

20.4.4 CONSTRUCTION

The pillar boxes shall generally conform to the sketches enclosed and comply with the

following requirements.

20.4.5 ENCLOSURE

It shall be made out of GI / Aluzink sheet with 2 mm thickness. Doors shall be made out

of GI/Aluzink sheet with 2 mm. It shall be compact and suitable in all respects for outdoor

installations. The sloping canopy fitted at the top of the pillar shall be given 5 to 10 mm

gradient downward slope at the front so that rain water shall not accumulate at the top.

Sufficient quantity & size of internal hinges shall be fixed shown in the drawing enclosed

for each door. The hinges shall be of such construction the doors can be swung open

by not less than 110 degrees.

All nut bolts and hardware shall be tin platted and electrical nut bolts shall be high tensile

tin platted.

The doors shall be provided with suitable padlocking and antitheft password protected

locking arrangements. All Hinged doors shall be connected to the earth terminal with 2.5

Sq.mm. braided copper wires

The main body of the enclosure should be made out of a single sheet suitably formed

without any welding to avoid corrosion. Provision for closing the doors at front by locks

shall be suitably provided. The MS sheets used for doors, sides, top, bottom etc., shall

have minimum / no joints/welds. The pillar box should be suitable for flush mounting

against compound wall.

The pillar boxes should have louvers made up of ABS material which do not project

more than 6 mm over surface of feeder pillar.

The pillar box shell should be of neat finish and suitably protected against corrosion by

powder coating. Suitable pre-treatment is required with 7 tank / 12 tank process before

powder coating. Polyurethane based powder coating material is to be used. The panel

shall be powder coated with Light grey shade No 631 of IS-5. Minimum coating thickness

is to be 80 microns.

20.4.6 TAPPAT

Turret & base is made up of high density injection moulded polyethylene. It has got

strong but light construction making it easy to transport & installation. The all-weather

polyethylene construction requires no painting or maintenance as protection against

moisture & corrosion is no issue. IP rating is IP55. It has got Danger Electricity Marking.


Page | 139


Turret is easily & simply secured to base with D-bolts made u of stainless steel & can

be tightened using special long handle key, it shall not open easily by other tool.

20.4.7 CIRCUIT WAYS AND BUS BAR:

The feeder pillar box shall be of 3 phase (R, Y, B) arrangement. The centre to centre distance between Bus bar should be 185mm.

20.4.8 BUS BAR ASSEMBLY:

Busbars shall be of electrolytic grade E91 aluminium, rated for minimum Given Rating,

50 kA for 1 sec and shall have adequate cross section to carry the rated continuous and

short time current. Neutral bus also should be of full bus bar rating.

The dimensions for Aluminium busbar in mm:-

Phase & Neutral Busbar: 1Amp = 1Sq mm Earth Bus: 50 X 6. E91 AL

Tin plating of 10 to 12 microns is required on aluminium busbars.

20.4.9 INCOMERS and OUTGOINGS:

The pillar box shall have incomers as per BOQ & Drawings with pole vertical fuse switch

disconnector. The fuse switch at incomer shall be as per IEC/EN 60947-1/-3 / VDE 0660

T-107

The pillar box shall have outgoings as per BOQ & Drawings with vertical fuse switch

disconnector as per IEC/EN 60947-1/-3 / VDE 0660 T-107

The fuse switch disconnector shall be switchable without any special switching

sequence. The incomer fuse switch should be dimensionally compatible to outgoing fuse

switch units.

Technical specifications of the unit should comply according to Annexure 1

Switch on and off with fuse link under load should be performed with single hand

operation, with low switching force and wear free contacts. The fuse switch should have

windows for displaying fuse label, middle and top fuse blown indicator easily visible. It

should be possible to measure voltage across a fuse without opening the switch. The

Fuse switch should be provided with steel frame V type clamp to terminate proper size

of PVC / XLPE Aluminium cable without need for crimping sockets.

20.4.10 CABLE CONNECTION SUPPORT

There should be provision to support incoming & outgoing cables at bottom portion of

feeder pillar. It shall consist of 75 x 6 mm flat of suitable length, held tight to body.

Necessary holes shall be provided in the flat along with clamps, bolts and nuts, check

nuts, washers etc., So as to firmly clamp the cables (incoming and outgoing) by means

of semi-circular cable clamps. The semi-circular clamps shall be made of 6mm thick

plate of width 75mm for two Incomers & four Outgoings.


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20.4.11 EARTHING:

The metal casing of the pillar shall be provided with two separate earthing terminals and

these shall be provided and above all other means provided for securing metallic

enclosures. The earthing terminal shall be readily accessible and so placed that the

earth connections of the pillar are maintained even when the cover or any other movable

part is removed. Under no circumstances a movable metal part of the enclosure shall

be insulated from the part carrying the earthing terminals, when the movable part is in

place. The earthing terminals shall be of adequate size and protected against corrosion

and shall be metallically clean. The earthing terminals should be identified by means of

the sign marked in legible and indelible manner, on or adjacent to the terminals.

20.4.12 MOUNTING ACCESSORIES

This includes inhibitor grease & foundation bolts.

One-Way open point link kit.

Kit is suitable for 1 runs of 3 phase main cables (120 to 300 mm2, 3.5 or 4 core, PVC /

XLPE insulated, solid or stranded) & 3 runs of 3 phase service cables (25 to 50 mm2,

3.5 or 4 core, PVC / XLPE insulated, solid or stranded).

It uses insulated contact blocks to terminate cables. One block is used for each phase.

Separate contact block is provided for neutral connection. Neutral cover & rubber

grommets made up of special grade rubber are provided to cover exposed live parts.

Two-Way open point link kit.




It uses insulated contact blocks, one for each phase. Block is divided into two halves

with one main & three service cable on each side, with single link switch between these

two halves for connection & disconnection. Link switch can be operated on load using

insulated key.

Separate contact block is provided for neutral connection. Link cover, Neutral cover &

rubber grommets made up of special grade rubber are provided to cover exposed live

parts.

Three-Way or multiway open point link kit

Kit is suitable for 3 runs of main cables (120 to 300 mm2, 3.5 or 4 core, PVC / XLPE

insulated, solid or stranded) & 4 runs of service cables (25 to 50 mm2, 3.5 or 4 core,

PVC / XLPE insulated, solid or stranded). Provision is available for additional 4 runs of

service cable.

Two link are used for connection & disconnection between three main cables. Link

switch can be operated on load using insulated key.

Separate arrangement is made for connecting neutral.


Page | 141


20.4.13 OPERATIONAL REQUIREMENT

• Continuous rated operating voltage- 415 volt +/- 10%

• Power frequency high voltage withstand capacity for one minute- 2000 volt

• Insulation resistance value for phase & neutral bus bar- Minimum 100MΏ with

500V Megger

• Temperature rise above ambient - As per IEC 60947

20.4.14 NAME PLATE & MARKING

Name plate- On front door showing

• Manufacturer name & address

• Current Rating & Short circuit Rating

• Incoming & Outgoing details

• Month / year of manufacturing

• As per customer demand (Purchaser Name & PO Number, Property of, etc.)

• Danger board in English & Hindii language

20.4.15 TESTS

Should comply with following test requirements. Type tests according to IEC 60947-3,

IS 5039:1983 & IS 8623-1: 1993. All the Type Tests shall be carried out as per the

relevant standards at National or International labs, capable of carrying out specified

tests.

• Complete sequence of type testing for vertical switch fuse units

• Verification of Short circuit strength – 50kA, 1 Sec

• Verification of degree of protection IP55

Acceptance & routine test.

• Visual inspection, dimension checks.

• Powder coating thickness, Coating adhesion test.

• Colour shade

• Bill of material check

• Continuity check

• Insulation resistance test

• High voltage test

• Operational check


Page | 142


Tappat / Service Pillar :

Following type tests shall be carried out as specified in AS/NZS 3947.3 : 2001

• Verification of dielectric properties before & after short circuit making test

• Short circuit making test at 28 kA rms,

• Leakage current test

• DC resistance before & after load cycle

Load cycle & temperature rise test :

• Half load : 8 hours

• Full load : 4 hours

• Complete cycle time : 12 hours

• Number of cycles performed during test : 28

Following type tests shall be carried out as specified in IEC 60439-5:

2006, IEC 60439-1 : 2004

• Temperature rise test at rated current with all internal shrouds fitted

• Temperature rise test at rated current with all internal shrouds fitted and rear

internal terminal shrouds ventilated.

• Temperature rise test at 1.5 times of rated current to determine performance at

overload

In routine test, visual inspection & dimensional check is performed

20.4.16 DRAWING

Material will be supplied as per drawing attached with this this specification.

20.4.17 PACKING

For packing, wooden base made up of complete wood is required. Panel should be

mounted on it firmly. Complete assembly to be wrapped tightly with stretch film. Then

assembly should be covered with corrugated 2-ply paper sheet. Then again stretch

film to be used.


Page | 143


20.4.18 GTP

GTP of distribution feeder pillar box shall be as per Annexure 2.

Guaranteed Technical Particulars (GTP) Feeder

Pillar

Sr Description Details

A General

1 Name of Manufacturer As per list of manufacturers

2 Product Designation Feeder Pillar

3

Product Details

Multi Way Feeder Pillar – 415 V

With Vertical Switch Fuse Unit arrangement

4 Configuration Incomer and Outgoing as per given Drawings and

SLD

5 Incoming Circuit With vertical switch fuse unit with IEC/EN60947-1/-3/ VDE 0660T-107

6 Outgoing Circuit With vertical switch fuse unit with IEC/EN60947-1/-3/ VDE 0660T-107

7 Incoming fuse

configuration IEC/EN 60947-1

8 Outgoing fuse


9 Vertical SFU make Raychem / Hagger / Schneider / TE connectivity

10 Outgoing / Incomer

cable connection

Suitable for cable connection

11 Type of termination In V-clamp without use of crimping socket

12 Application of product Outdoor

a Humidity 90% maximum

b Ambient

temperature

Average 35" C, Maximum 48" C

B System Information


Page | 144



Pillar


1 Rated Voltage 415V ±10% Between Ph-Ph

2 No. of phases 3 No’s

3 Frequency 50 to 60 Hz


Page | 145


C Busbar configuration

1 Material for phase &

neutral busbar

EC grade Aluminum E91 as per IS 5082

2 Current rating of phase

busbar

As per BOQ & SLD

3 Configuration 3Phase+1Neutral busbar (R-Y-B

coded).

Horizontallymountedat185mmdistanc

e

4 Neutral busbar Full Rated

5 Dimensions of Phase &

Neutral Busbar

80X 10 mm

6 Earth Bus 50 X 6

D Pillar Construction

1 Material of enclosure GI/Aluzinc withPUpaintsheet,2.00/1.60mmthick

2 Material of doors GI / Aluzinc, with PU paint 2 mm thickness

3 Material of Gland plate GI 3.0 thick

4 Door access Front, two door, Min 110 degree opening

5 Door Hinges Three internal Hinges per door (Hinges shall not

be

exposed grom out side

6 Locking arrangement Locking shall be through key

7 Cable Entry From bottom

8 Surface preparation for

painting

7 tank / 12 tank process

9 Painting Powder coated PU paint with min 65-80 micron

Thickness

10 Color Light grey shade RAL 7035

11 Degree of protection IP55


Page | 146


12 Panel Dimensions (H x

W

x D)

AS approved

E Test / Operational

Requirement

1 Main bus bar short

circuit withstand

capacity

50 kA for 1 Sec

2 Verification of dielectric

properties

2000V /1 minute

3 Impulse withstand

voltage

20kV

Guaranteed Technical Particulars (GTP)

for TAPPAT Service pillar box

Sr. No. Particulars

1. Name of Manufacturer

2.

Configurations

1. TAPPAT1-

Waysinglelinkdistribution feeder

pillarbox

2. TAPPAT2-


pillarbox

3. TAPPATMultiway(asperSLD)insulat

ed connection with allenkeybolt

3.

Test standard

AS/NZS 3947.3 : 2001 OR

IEC 60439-5: 2006, IEC 60439-1 : 2004

4. Material for enclosure High density injection moulded

polyethylene

5. Environmental protection IP55

6. Connector material Tin plated brass


Page | 147



W

x D)

AS approved


Requirement


circuit withstand

capacity

50 kA for 1 Sec


properties

2000V /1 minute

3 Impulse withstand

voltage

20kV



Sr. No. Particulars

7.

Suitable for connection

Maincable:1Run/2Runs/3Runs,120to 300

mm2, 3.5 or 4 core, PVC / XLPE

insulated, solid orstranded)

ServiceCable:25to50mm2,3.5or4core,

PVC/XLPE insulated,solid or stranded)

8.

Locking arrangement

Yes

1. Special D-bolt &key

2. Padlocking facility(optional)

9. Rated current 400A

10. Rated Voltage 415 V

11. Short circuit rating

wherever applicable

28 kA rms

12. Load cycling

wherever applicable a. Half load (200A) : 8hours

b. Full load (400A) : 4hours

c. Complete cycle time : 12hours

d. Number of cycles:28


Page | 148



W

x D)

AS approved


Requirement


circuit withstand

capacity

50 kA for 1 Sec


properties

2000V /1 minute

3 Impulse withstand

voltage

20kV



Sr. No. Particulars

13.

Overall dimensions

Height : 660 mm (1-Way & 2-way),

890 mm(3-Way)

Width : 550 mm

Depth : 510 mm

14. Shelf Life Unlimited. To be stored under covers


Page | 149


20.5 JUNCTION BOXES & METER BOXES

20.5.1 JUNCTION BOXES

The following design criteria shall be taken to consideration while designing junction boxes and

meter boxes.

• Shockproof and rustproof

• Rot-proof and termite resistant

• Cable entry from bottom and/or sides

• 100% weatherproof

• Pole mounting arrangement

• Tamper proof

• Pilferage proof

• Restricts unauthorised tapping

• Maintenance-free

• Fire retardant - Class FV-0 as per IS:11731 Part-II or V-0 as per UL-94

• High heat distortion temperature (200°C as per IS:10192)

20.5.2 MEETER BOX – STANDARD FEATURES

• Ingress protection to IP65

• Weatherproof & rigid construction, suitable for outdoor use

• High impact, corrosion & temperature resistant

• Lift-off type chrome plated brass hinges

• Awning type canopy above the door

• Meter viewing window

• Key locks, zinc die cast & chrome plated - 2 nos

• Studs on back wall for mounting plate fixing

• Wall thickness 3 mm generally & 5 mm at stress points

• Fire retardant, self extinguishing to BS 476:Part 7: 1997 Class 2

• External finish: Plain semi gloss light grey gelcoat finish to RAL 7035

• Long life & high temperature resistant EPDM rubber door seal

• All hardware of galvanized steel or non-corrosive material


Page | 150


20.6 33KV & 11 KV XLPE INSULATED CABLES

20.6.1 Scope

This specification covers the design, manufacture, testing at manufacture's work

before dispatch, packing and transportation to site, laying, termination, testing

and commissioning of HT, LT Power, control and instrumentation Cables

required for various sub-stations.

All cables shall comply with relevant Indian standards.

20.6.2 Make

The cables shall be procured from experienced and reputed manufacturers (from

the list of preferred equipment manufacturers), with proven experience in

manufacture of cables for substations and having capability to develop, test and

timely supply of cables as specified in the tender specification. The manufacturer

shall have arrangements for carrying out all the routine, type and acceptance

tests including special tests (such as flammability test, smoke generation test,

HCL gas evaluation test) as per the standards specified and have furnished

satisfactory test results. All cables to be with low smoke with zero halogen.

20.6.3 Design Criteria

20.6.3.1 Standards

The cables under this specification shall comply with the requirements of latest

edition of the following standards including amendments:

S. No. Standard

Number Description

1 IS: 1554

(Part-I)

PVC insulated (heavy duty) electric cables for

working voltage up to and including 1100 V.

2 IS: 1753 Recommended current rating for PVC insulated

and PVC sheathed heavy duty cables.

3 IS: 3961

(Part II)

Metal steel wires, strips and tapes for

armouring of cables

4 IS: 3975 Methods for random sampling.

5 IS: 4905 PVC insulation and sheath of electric cables.

6 IS: 5831

Cross linked polyethylene insulated PVC

sheathed cables for working voltages up to &

including 1100 V.


Page | 151


S. No. Standard

Number Description

7 IS: 7098

(Part II)


sheathed cable for working voltage from 3.3 kV

to 33kV.

8 IS: 8130 Conductors for insulated electric cables and

flexible cords.

9 IS: 10418 Wooden drums for electric cables.

10 IS: 10810 Method of tests for cables.

11 ASTMD- 2863

Standard method for measuring the minimum

oxygen concentration to support candle like

combustion of plastic.

12 IEEE: 383 Standard for type test of IE class of electric

cables.

13 IEC-332 (Part-I) Tests on electric cables under fire conditions.

14 IEC-754

(Part-I)

Test on gases evolved during combustion of

electric cables.

15 ASTMD – 2843 Test method for density of smoke from the

burning on decomposition of plastic.


20.6.4 Cable Design

The cables shall be designed considering the following

20.6.4.1 HT Cables

HT cables shall be 33kV & 11 kV of earthed grade suitable for use in solidly

earthed system, stranded & compacted electrolytic aluminium conductor,

extruded semi conducting screen over conductor, XLPE insulated, armoured or

unarmoured as required, semi-conducting followed by copper tape screened,

extruded PVC, Type ST–2 inner sheathed, overall FRLS, PVC outer sheathed,

conforming to IS 7098 (Part II), IEC 60502 for constructional details and tests.

20.6.4.2 LT Power Cables

LT Power Cable shall be 1100 V grade, single / multi core, stranded electrolytic

aluminium conductor, XLPE insulated, with PVC inner sheath, armoured and


Page | 152


outer sheath made of FRLS PVC compound, generally conforming to IS-7098

(Part-II). The cables used for DC system shall be of two core type. Minimum

conductor cross section of power cables shall be 10 mm2 for aluminium cables

and below 10 mm2 it shall be copper conductor.

20.6.4.3 Control Cables

Control cables shall be 1100 V grade, multi core, minimum 1.5 mm2 cross

section, stranded copper conductor having minimum 7 strands, XLPE insulated,

PVC inner sheathed / galvanised steel wire armoured, overall FRLS, PVC outer

sheathed generally conforming to IS 1554 Part-I. In situations where accuracy of

measurement or voltage drop in control circuit warrants, higher cross sections as

required shall be used.

20.6.4.4 Instrumentation Cables

The instrumentation cables shall be annealed, tinned stranded copper conductor,

0.5 mm2, twisted into pairs, overall screened (L1 type) for digital signals,

individual and overall screened (for L2 type) for low level analogue signals,

individual triplet and overall screened (type L3), PVC insulated, inner PVC

sheathed, GS wire armoured and overall sheathed with FRLS PVC. The

insulation shall be strippable manually as well as by mechanical stripping devices

without damage to the conductor.

20.6.4.5 Lighting Wires

1100 V grade, single core, stranded, copper conductor, PVC insulated wires

conforming to IS 694 / IEC 60227 Part 1 to 5 / IEEE-719. Minimum cross section

of copper wires shall be 2.5 mm2 for lighting circuits and 4 mm2 for receptacle

circuits.

These shall be suitable for installation in a monsoon area having 100% relative

humidity, which is likely to accelerate rusting in steel. However, for reference the

ambient temperature may be taken as -5C (minimum) and 50°C (maximum) with

RH of 100%. The galvanising of steel armour has to be of the highest quality for

such ambient conditions.


Page | 153


20.6.4.6 The user shall consider the derating factor for the various conditions of installation including the following while choosing the conductor size.

20.6.4.7 Maximum ambient air temperature.

20.6.4.8 Maximum ground temperature.

20.6.4.9 Depth of laying wherever applicable.

20.6.4.10 Grouping of cables.

20.6.4.11 The minimum size of all 33kV, 11 kV and 415 V Power Cable shall be chosen considering the following:

(a) Maximum fault level

(b) Full load current of the circuit.

(c) Maximum permitted time as dictated by system protections, switchgear

etc.

(d) The allowable voltage drop at the terminal of the connected equipment shall

be maximum 3% at full load for LV and 4% for HV.

(e) For PVC insulated cables continuous conductor temperature and allowable

maximum conductor temperature during short circuit be taken as 70°C and

160°C and for XLPE insulated cables the corresponding values shall be

90°C and 250°C respectively.

(f) Frequency variation ± 5%, voltage variation ±10% and combined

frequency and voltage variation of ±10%.

20.6.5 General Technical Requirement

20.6.5.1 The cables shall be suitable for laying in racks, ducts, covered trenches, conduits and underground buried installation with chances of flooding by water.

20.6.5.2 Cables shall be designed to withstand mechanical, electrical and thermal stresses developed under steady state and transient operating conditions.

20.6.5.3 The aluminium / copper wires used for manufacturing the cables shall be true circular in shape before stranding and shall be of uniformly good quality free from defects. All aluminium used in the cables shall be of H2 grade.

20.6.5.4 The conductor of control cables shall be manufactured from plain annealed copper. The conductor shall be multi-stranded or solid as per data sheet.

20.6.5.5 The nominal overall diameter of the cables shall be as given in the applicable Indian Standard.

20.6.5.6 The cable cores shall be laid up with fillers between the cores wherever necessary. It should not stick to insulation and inner sheath. All the cables, other


Page | 154


than single core unarmoured cables shall have distinct extruded PVC inner sheath black in colour as per IS 5831.

20.6.5.7 The fillers and inner sheath shall be of non-hygroscopic. Flame retardant material shall be softer than insulation and outer sheath shall be suitable for the operational temperature of the cable.

20.6.5.8 For single core armoured cables, armouring shall be of aluminium wires. For multi-core armoured cables, armouring shall be of galvanized steel as follows.

Size & diameter of cable Type of armour

Up to 13 mm 1.4 mm dia GS wire

Above 13 up to 25 mm 0.8 mm thick GS strip/ 1.6mm dia GS wire

Above 25 up to 40 mm 0.8 mm thick GS strip / 2.0 mm dia GS wire

Above 40 up to 55 mm 1.4 mm thick GS strip/2.5 mm dia GS wire


Above 70 mm 1.4 mm thick GS strip/4 mm dia GS wire

20.6.5.9 The gap between armour wire/ strip shall not exceed one armour wire/strip space and there shall be no cross over/over-riding of armour wire/strip. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire/strip. Zinc rich paint shall be applied on armour joint surface.

20.6.5.10 Suitable chemicals shall be added to the outer sheaths of all cables to protect them from entry of water, UV light, rodent and termite attack. These chemicals shall not have any harmful effect on the human being.

20.6.5.11 The normal current rating of all PVC insulated cables shall be as per IS-3961 and should suit the duty requirements for which it is intended.

20.6.5.12 Outer sheath shall be of PVC black colour for power cables and of grey colour for control cables.

20.6.5.13 In plant repairs to the cables shall not be accepted.

20.6.5.14 As far as feasible, separate cables shall be provided for circuits of different plant and auxiliaries, for circuits of different voltages, and for circuit used separately. Power, control and instrumentation circuit shall invariably be taken through different routes, which shall not be laid together on the same cable tray.

20.6.5.15 At least 20% cores shall be kept as spares in the multi core control cable.

20.6.6 Identification Of Cores

The insulated cores of HT and LT power cables shall be identified by colour code.


Page | 155


20.6.6.1 Cores of the cables of up to 5 cores shall be identified by colour of insulation with the following colour scheme.

No. of cores Colour

1Core Red, Black, Yellow & Blue

2Core Red & Black

3 Core Red, Yellow & Blue

4 Core Red, Yellow, Blue & Black

5 Core Red, Yellow, Blue, Black & Grey

20.6.6.2 For reduced neutral conductors the core shall be black

20.6.6.3 For cables having more than 5 cores, core identification shall be done by numbering insulation of core sequentially, starting by number 1 in the inner layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10). The numbers shall be printed in Hindu-Arabic numerals on the outer surfaces of the cores. All the numbers shall be of same colour, which shall contrast with the colour of insulation. The colour of the insulation for all the cores shall be grey only.

(a) The control cables shall have identification by means if indelible printing of

numbers on its cores at intervals not more than 75 mm.

20.6.6.4 The numerals shall be legible and indelible. The numbers shall be repeated at regular intervals along the core, consecutive numbers being inverted in relation to each other. When number is a single numeral, a dash shall be placed underneath it. If the number consists of two numerals, these shall be disposed


Page | 156


one below the other and a dash placed below the lower numeral. The spacing between consecutive numbers shall not exceed 50 mm.

20.6.6.5 All HT and LT cable shall have embossing at interval of 1 meter for Owner‘s name, size / core type and length.

20.6.6.6 In addition to manufacturer's identification on cables as per IS, following marking shall also be embossed over outer sheath.

20.6.6.7 Cable voltage grade.

20.6.6.8 Sequential marking of length of the cable in meters at every one meter.

20.6.6.9 The embossing shall be progressive, automatic, on line and marking shall be legible and indelible.

20.6.7 Copper Cables

20.6.7.1 Copper cables shall be used for the following services.

20.6.7.2 DC cables from batteries to DC boards

20.6.7.3 DC emergency lighting cables for main building

20.6.7.4 Battery and battery chargers

20.6.7.5 Actuator motors, wherever provided.

20.6.7.6 All other essential system wherever necessary

20.6.8 Constructional Requirements for HT Cables

20.6.8.1 Type of Cable

The cable shall be multi core/ single core XLPE insulated type as specified.

20.6.8.2 Conductor

The cable conductor shall be made from stranded electrolytic Aluminium as

specified to form compact conductor having a resistance within the limits

specified in IS.8130.

All the cables of size 25mm2 and above shall have sector-shaped conductors.

The minimum number of strands in conductor shall be 7 (seven) except as

otherwise specified. Power cables shall be of stranded Aluminium conductor with

a minimum size of 10 mm2 and the control cables shall be of stranded or solid

copper (electrolytic) conductor with a minimum size of 1.5 mm2 as specified.


Page | 157


20.6.8.3 Conductor Semi-Conducting Layer

The conductor having a semi-conducting screen shall ensure perfectly smooth

profile and avoid stress concentration. The conductor screen shall be extruded in

the same operation as the insulation and the semi-conducting polymer shall be

cross-linked for XLPE cables.

20.6.8.4 Insulation

The insulation of the cable shall be extruded type and shall be designed and

manufactured for the specified system voltage. The manufacturing process shall

ensure that insulation shall be free from voids. The insulation shall withstand

mechanical and thermal stresses under steady state and transient operating

conditions. The extrusion method should give very smooth interface between

semi-conducting screen and insulation. The insulation of the cables shall be of

high standard quality. The minimum volume resistivity of the PVC insulation of all

the PVC insulated cables shall be 1 x 1014 ohm cm at 27° C and 1 x 1011 ohm

cm at 70° C.

20.6.8.5 Insulation Shield

In XLPE cables to confine electrical field to the insulation, a non-magnetic semi-

conducting shield shall be put over the insulation. The XLPE cable insulation

shield shall be strippable. Metallic screening, as given in this specification for the

various power and control cables shall be provided.

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 insulation shielding shall consist of non-metallic extruded semi-conducting

compound in combination with a non-magnetic metallic screening of copper.

The copper screen shall be capable of carrying the single line to ground fault

current for the duration specified for the protection employed. Vendor shall furnish

calculation in support of selection of the size of copper screen.

20.6.8.6 Inner Sheath

The sheath shall be suitable to withstand the site conditions and the desired

temperature. It shall be of adequate thickness and applied by a continuous

process to produce a sheath of consistent quality free from all defects. PVC

sheath shall be extruded.

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

conform to the requirements of type ST2compound of IS: 5831. The extruded

inner sheath shall be of uniform thickness.


Page | 158


The dimensions of the insulation, inner sheath and armour materials shall be

governed by values given in Tables 2, 3 & 4 (Method 3) of IS: 7098 Part-II).

20.6.8.7 Armour

Armouring shall be provided wherever specified. For multi core cables, the

armouring shall be by galvanised steel wire/ tape. If armouring is specified for

single core cables, the same shall be with hard drawn aluminium round wire of

2.5mm diameter.

The hard drawn aluminium wire for armour shall be of H4 grade, as per IS: 8130

(having tensile strength above 150 N/mm2). The diameter of the aluminium wire

shall be as per the table for the dimensions of the galvanised steel wire armour

given in the relevant standard. All cables directly buried shall be armoured.

20.6.8.8 Serving/ Outer Sheath

Extruded PVC serving as per IS: 5831 or as specified otherwise shall be applied

over the armouring with suitable additives to prevent attack by rodent and

termites. All serving must be given anti-termite treatment.

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 ST2

compound of IS: 5831. The thickness of outer sheath shall be as per amendment

no. l of table 5 of IS: 7098 Part-2 (Column 3 & 5 for both armoured and

unarmoured cables).

20.6.8.9 Fillers for Multi Core Cables

Cable shall have suitable fillers laid up with the conductors to provide a

substantially circular cross-section before the sheath is applied. Fillers shall be

suitable for the operating temperature of the cable and compatible with the

insulating material. All materials shall be new, unused and of finest quality.

Workmanship shall be neat, clean and of highest grade.

20.6.9 Cable Types

20.6.9.1 11kV System - Power Cable

The cable shall be for 11 kV earthed system, heavy duty, three or single core,

stranded Aluminium / Copper conductor, XLPE insulated, provided with

conductor screening and insulation screening, aluminium armouring for single

core, galvanized steel wire for three core, extruded PVC of Type ST2 outer

sheathed, as per system requirement. The cables shall conform to IS: 7098 (Part

II).


Page | 159








II).

20.6.9.3 415V System

The cable shall be 1.1 kV, grade, heavy duty, stranded Aluminium conductor,

XLPE insulated as specified, 4 or 3 1/2 core, galvanised steel wire/strip armoured,

extruded PVC type STI outer sheathed.


The cable shall be 1.1 kV grade, XLPE, heavy duty, multi core stranded (7 wires)

tinned copper (annealed) conductor, PVC Type-A insulated, galvanised steel

wire/strip armoured, flame retardant low smoke (FRLS) extruded PVC of type-

STl outer sheathed. The following sizes shall be used.

20.6.10 LV Power and Control Cables

20.6.10.1 LV power and control cables shall be XLPE, heavy duty type, 1100 V grade with electrolytic Aluminium conductor, PVC inner sheathed, armoured, if specified and overall PVC sheathed.

20.6.10.2 Copper conductor for control cables shall be PVC insulated whereas for power cables it shall be XLPE.

20.6.10.3 The conductors shall be stranded. The minimum number of strands shall be 7 (seven) except as otherwise specified. Conductors of nominal area less than 25 sq. mm shall be circular only. Cables of nominal area 25 sq. mm and above may

Cable Size (mm2) 1.5/ 2.5 4 6 16

No. of Cores 2,5,7,10,14,19,27

3,5 2,4 4


Page | 160


be circular or shaped. Cables with reduced neutral conductor shall have sizes as per Table 1 of IS: 1554 (Part-I).

20.6.10.4 Power cables shall be of stranded Aluminium conductor with a minimum size of 10 mm2 and control cables shall be stranded copper conductor with a minimum size of 1.5 mm2.

20.6.10.5 If armouring is specified for multi core cables, the same shall be by single round galvanized steel wires where the calculated diameter below armouring does not exceed 13 mm.

20.6.11 Cable Accessories for HT Cables

20.6.11.1 The termination and straight through jointing kits for use on the system shall be cold shrinkable type and suitable for the type of cables offered as per this specifications.

20.6.11.2 The accessories shall be supplied complete in all respects and should be supplied in kit form. Each component of the kit shall carry the manufacturer’s mark of origin.

20.6.11.3 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.

20.6.11.4 The contents of the accessories kit including all consumables shall be suitable for storage without deterioration at a temperature of 50°C with shelf life extending more than 5 years.

20.6.11.5 A set of tools for making joints shall be provided (both for indoor and outdoor joints).

20.6.12 Termination Kits

Modern pre-moulded terminating kits shall be suitable for termination of the HT

cables to indoor switchgear. For outdoor terminations whether shields/sealing

ends and any other accessories required shall also form part of the kit. For RMU

cable termination shall be with plug in type.

20.6.13 Requirement of XLPE Joints and Termination

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

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

backfill along with 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. For ducts suitable man holes shall

be provided for joints. Joint in cables shall meet the following requirements.


Page | 161


20.6.13.1 Conductivity of the jointed conductor shall not be less than that of the main conductor of the cable.

20.6.13.2 Joints between two conductors or conductor lugs shall have a mechanical strength not less than that of the conductor.

20.6.13.3 Adequate insulation level free from voids and impurities.

20.6.13.4 Sufficient stress relief provision.

20.6.13.5 Adequate creepage paths to eliminate system tracking.

20.6.13.6 Ability to withstand electromagnetic thermal stress during flow of short circuit Current.

20.6.13.7 Proper seals for water, dust and chemical fumes for checking their ingress under all conditions.

20.6.13.8 Inner semi-conducting layer with a smooth surface & good contacts and insulation.

20.6.13.9 Outer semi-conducting layer to adhere firmly to the insulation.

20.6.13.10 Earth continuity connection of adequate size shall be a part of the kit.

20.6.13.11 Cable joints with modern technology such as pre-moulded and manufactured in a single piece, in the factory. It should have factory built in functions such as electrical field control, insulation and sealing. It should have flexible rubber to take care of variations in the cable current and to ensure water tightness and increased electrical strength. No special tools or welding equipment should be required for jointing cables. These pre-moulded joints shall be factory tested for routine and type tests as per the appropriate IES/IS standard.

20.6.13.12 Condition for Cable Joints

(a) Under normal condition, no joints in HV & LV cables shall be permitted,

unless the maximum drum length available is less than the cable length

required.

(b) Contractor shall prepare the cable schedule based on the actual cable

length to be laid. Prepare drawing and label these cables. On the basis of

these length, the contractor shall workout the cable length for each drum

and advise the manufacturer accordingly.

(c) Under no condition a cable joint shall be permitted, if the length of the

available cable in the drum from the manufacturer is more than the length

of the cable being laid.


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20.6.13.13 Cable and Joint Markers

(a) Permanent means of indicating the positions of joints on site should be

provided. During the course of permanent reinstatement cable and joint

markers, should be laid directly above the route of the cable and the

position of the joint respectively.

(b) Wherever it is not possible to place the marker directly over the cable route

or joint the marker should be suitably placed near the cable route or joint

on which the distance of the cable route or joint at right angles to and

parallel to the marker should be clearly indicated.

(c) The position of fixing the markers will be approved by Engineer.

20.6.13.14 Jointing of Cables

(a) General: It shall be noted that the U.G. cables are of XLPE insulation and

needs special care in jointing. The cable jointer and his assistant shall have

experience in making joints / terminations. Jointing work should commence

as soon as two or three lengths of cables have been laid. All care should

be taken to protect the factory-plumbed cap/seal by laying the end solid in

bitumen until such time as the jointing is commenced.

(b) Jointing of cables in carriage ways, drives, under costly paving, under

concrete or asphalt surfaces and in proximity to telephone cables and water

mains, should be avoided whenever possible.

(c) Joint Pits: The joint pits should be sufficient dimensions as to allow jointers

to work with as much freedom of movement and comfort as cables

proposed to be jointed. The sides of the pit should be draped with tarpaulin

sheet to prevent loose earth from falling on the joint during the course of

making. The pit should be well shored with timber, if necessary. An overlap

of about 1.0 mtr of the cables to be jointed may be kept, for allowance to

adjust the position of the joint. When two or more cables are laid together

the joints shall be arranged to be staggered by 2 to 2.5 mtr.

(d) Sump Pits: When jointing cables in water logged ground or under monsoon

conditions, a sump pit should be excavated at one end of the joint pit in

such a position so that the accumulating water can be pumped or bailed

out by buckets without causing interference to the jointing operation.

(e) Tents: A tent should be used in all circumstances wherever jointing work is

carried out in the open irrespective of the weather conditions. The tent

should be so covered as to have only one entrance and the back facing the

direction of the wind. The tent cover should be properly weighted or tied

down on the sides.

(f) Measurement of Insulation Resistance: Before jointing is commenced the

insulation resistance of both sections of the cable to be jointed should be

checked by insulation resistance testing instrument. An insulation

resistance – testing instrument of 2.5/5 kV shall be used. The Insulation


Page | 163


Resistance values, between phases and phase to earth shall be recorded.

The actual jointing operation shall start only after the approval of the

Engineer in charge of works.

(g) Precautions before Making a Joint or Cutting A Cable: The cable end seals

should not be opened until all necessary precautions have been taken to

prevent circumstances arising out of rainy/inclement weather conditions,

which might become uncontrollable. The cable seals should be examined

to ascertain if they are intact and also that the cable ends are not damaged,

if the seals are found broken or the lead sheath punctured, the cable ends

should not be jointed until after due examination and testing by the

engineer-in-charge of the works.

(h) Identification Numbers / Colours and Phasing : The cables should be laid

and jointed number to number or colour to colour shown on the core

identifying marks and prevent cross jointing. In all cases, the cables should

be tested and phased out, and more particularly so when the cable

terminates at Ring Main Unit / Sub-station.

(i) Making a Joint: The cold shrinkable joints used shall be made. The

contractor should furnish all the technical particulars of these joints and

obtain approval. heat shrinkable joints which need stove flame are not

acceptable. Epoxy based joints are also not permitted. Comprehensive

jointing instructions obtained from the manufacturer of joint kits shall be

meticulously followed.

The connection of the earth wires should be done using flexible bonds

connected to cable sheath using clips or soldering. Aluminum conductor

strands shall be joined be joined by mechanical compression method, using

suitable die and sleeve with a good quality tool.The joints shall conform to

specification as per IS 13573-1992.

(j) Cable Terminations: Cable terminations required are both indoor and

outdoor type push-on or cold shrinkable type can be used. All the technical

particulars to establish the superiority in the performance of these joints

shall be furnished while seeking approval. The terminations shall conform

to specifications as per IS 13573 – 1992. The instructions furnished by the

manufacturer of termination boxes/kits should strictly be followed.

Whenever a cable is raised from the trench to end in termination, to be

finally connected to transformer, the following instructions should be

complied with –

(i) One coil to made and left in the ground for future needs

(ii) The rise of cable, immediately from the ground level should be

enclosed in suitable diameter pipe to height of 2 mt.

(iii) The balance portion of the cable should be neatly curved, in ‘S’

shape.


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(iv) The cable and pipe should be properly fastened by using appropriate

clamps /support. The hardware of clamps shall be non-rusting metal

alloy [not GI].

(v) The lugs on the termination shall be compressed with a suitable

compression tool.

20.6.13.15 Earthing and Bonding

(a) The metal sheath and Armour should be efficiently bonded and earthed at

all terminals to earth electrodes provided. The cross sectional area of the

bond shall be such that the resistance of each bond connection shall not

exceed the combined resistance of an equal length of the metal sheath and

Armour of the cable.

20.6.13.16 Testing after Laying and Jointing

(a) All cables after laying and jointing works are completed should be tested

systematically and insulation and HT tests should be made on all

underground cables.

(b) All test results should be recorded in tabular form in logbooks kept for the

purpose

(c) The cable cores should be tested for :-

(i) Continuity

(ii) Absence of cross phasing

(iii) Insulation resistance to earth; insulation resistance between

conductors.

20.6.13.17 H.V. Tests

(a) After the laying and jointing work is completed, a high voltage test should

be applied to the cable to ensure that the cable has not been damaged

during or after the laying operations and there is not defect in the joining.

(b) The high voltage tests should be as per IS 1255 or as per international

standards. The H.V. testing instruments shall be brought by the turn key

contractor.

20.6.13.18 Testing and record of Cable Constants :

(a) When the cable is ready, just before commissioning, the cable constants

viz, the resistance, capacitance and inductance of each conductor should

be determined and recorded, along with frequency at which the values of

capacitance and inductance are determined.


Page | 165


20.6.13.19 Cable Records

(a) Accurate neat plans / sketches, drawn to suitable scale (1 cm = 10M)

should be prepared and furnished by the contractor after the completion of

each work.

(b) All relevant information should be collected at site, during the progress of

work and preserved for preparation of drawings.

(c) The following essential data should be incorporated on all drawings.

(i) Size, type of cable or cables.

(ii) Location of the cable in relation to prominent land mark property,

Kerb-line etc., with depths.

(iii) The cross section showing where cables are laid in ducts, giving their

sizes, type and depths.

(iv) Location and type of all joints

(v) Location of other cables which run alongside or across the cable

route.

(vi) Position and depths of all ducts, etc., which are met as obstruction to

the cable route.

(vii) Accurate lengths from joint to joint

(viii) Manufacturers name and drum number of the cable, between

sections / joint to joint.

20.6.13.20 The cable records prepared as above shall be given to the Engineer as a part of the contract as soon as the cable is charged.

20.6.14 Cable Drums

20.6.14.1 Cables shall be supplied in non-returnable wooden or steel drums of heavy construction in proper and suitable packing for shipment to site. For wooden drums the wood used for construction for the drum shall be properly seasoned, sound and free from defects. Wood preservative shall be applied to the entire drum.

20.6.14.2 Contractor shall indicate in the offer the standard length for each size of power and control cable which can be furnished on one drum. The cable length per


Page | 166


drum shall be subject to tolerance of ± 5% of the standard drum length agreed between purchaser and contractor.

20.6.14.3 Cable Joints shall be avoided as far as possible by use of proper cable lengths.

20.6.14.4 The Engineer shall have the option of rejecting cable drums with shorter lengths.as the cable drums shall be selected so that through joints is eliminated.

20.6.14.5 A layer of water proof paper shall be applied to the surfaces of the drums and over the outer most cables layer. A clear space of at least 40 mm shall be left between the cables and the logging.

20.6.14.6 Each drum shall carry the manufacturer's name, the purchaser/ supplier’s name and contract number, owner's name, address, item number, type, size, length of cable, net and gross weight stencilled on both sides of drum. A tag containing the same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wordings shall be marked on one end of the reel indicating the direction in which it should be rolled.

20.6.14.7 On the drum the number of cores, type of cable, voltage rating, code, direction of drum rotation, BIS certification mark and year of manufacture shall also be mentioned.

20.6.14.8 Packing shall be sturdy and adequate to protect the cables from any injury due to mishandling or other conditions encountered during transportation handling and storage.

20.6.14.9 Both cable ends shall be sealed with PVC/ Rubber caps so as to eliminate ingress of water during transportation, storage and erection/ construction.

20.6.15 Inspection

20.6.15.1 Before dispatch the cables offered shall be made available for inspection by the Engineer. Inspection may also be made at any stage of manufacture at the option of the purchaser and the cables found unsatisfactory due to the material used or poor workmanship shall be rejected.

20.6.15.2 The contractor shall guarantee free access to the places of manufacture to the Engineer at all times when the work is in progress. The contractor shall inform the Engineer in advance the time of starting of manufacture and the progress of manufacture of the cables offered by him so that arrangement can be made for inspection.

20.6.15.3 Inspection and acceptance of cables by the Engineer shall not relieve the contractor of his obligation of furnishing cables in accordance with the


Page | 167


specification and shall not prevent subsequent rejection if such cables are later found to be defective.

20.6.15.4 The cables shall comply with type tests stipulated in prescribed section and the relevant standards. Test reports for all type tests shall be submitted with the tender.

20.6.15.5 All type and sizes of cables shall be subjected to routine and acceptance tests as stipulated in relevant standards without any extra cost to the purchaser. Cables should not be dispatched until the test reports are duly approved by the Purchaser or his authorized representative and specific instructions to despatch the inspected items issued.

20.6.15.6 The purchaser reserves the right of having any other special tests of reasonable nature carried out at site or at manufacturer's works or at any other place in addition to the aforesaid type and routine tests to satisfy himself that the cables comply with the specification, without any financial liability.

20.6.15.7 Six copies of test reports (or as indicated in the Schedule of Vendor Drawings) shall be supplied for approval. The reports shall indicate clearly the governing standards and the standard values specified for each test to facilitate checking of the test reports. Six bound copies of the test reports shall be submitted after approval of test reports along with the cables.

20.6.16 Tests

20.6.16.1 All types and sizes of cables being supplied shall be subjected to type tests, routine tests and acceptance tests as specified below and according to relevant standards.

20.6.16.2 The Engineer at its discretion may ask the contractor to conduct any or all the type tests for which at least 15 days advance notice shall be given.

20.6.16.3 Charges for acceptance test and routine test shall be deemed to be included in the bid price of individual cables.

20.6.16.4 Type Tests

20.6.16.5 Type tests shall be carried out on all the types and sizes of cables if desired or alternatively test certificates shall be supplied at the sole discretion of purchaser.

The following shall constitute type tests:

Test Remarks

For Conductor

Annealing test For copper conductor only

Tensile test For aluminium conductor only

Wrapping test For aluminium conductor only

Resistance test


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For Armour Wires/Strips

Measurement of Dimensions

Tensile test

Elongation test

Torsion test For round wires only

Winding test For strips only

Resistance test

Zinc Coating test For G.S. strips/ wires only

FOR PVC/ XLPE Insulation &PVC Sheath

Test for thickness

Tensile strength and elongation

test before aging and after aging

Aging in air ovens

Loss of mass test For PVC insulation & sheath only.

Hot deformation test -do-

Heat stock test -do-

Shrinkage test ~do-

Cold bend/cold Impact test -do-

Colour fastness to -do-

Thermal stability test -do-

Bleeding and blooming test -do-

Hot set test For XLPE insulation only

Water absorption test For XLPE insulation only

For Completed Cables

Insulation resistance test

High voltage test For HT cables

Partial discharge test -do-

Bending test -do-

Dielectric Power factor test -do-

as a function of voltage -do

as a function of temperature -do-

Heating cycle test -do-

Impulse with stand test -do-


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Measurement of eccentricity and -do-

ovality

20.6.16.6 Short Circuit Test.

(a) Short Circuit Test

(i) Short circuit test on conductors shall be carried out on cable samples.

(ii) During each short circuit test, the cable shall be subjected to thermal

(rms) and dynamic (peak) short circuit current of specified duration.

(iii) The test sample shall be subject to following tests before carrying out

the short circuit test and after completion of short circuit test (when

cable has cooled down to ambient temperature).

(aa) Conductor resistance measurement.

(ab) High voltage test.

(ac) Tan delta measurement.

(ad) Partial discharge measurement (for HT cables).

(ae) Volume resistivity.

(iv) Before applying the short circuit current, the test sample shall be

heated up to the specified maximum conductor temperature. This

may be done by eddy current heating or by giving intermittent high

current impulses as per the convenience of test station. After

establishing specified conductor temperature the cable shall be

subjected to short circuit test.

(v) Acceptance Criteria

After the short circuit test the test specimen shall meet the following

requirements:

(aa) HV Test

(ab) Pd test

(ac) Tan delta values as per standard.

(ad) Conductor resistance not more than ±5%.

(ae) Volume resistivity shall not be below the standard acceptance

value.

20.6.16.7 Acceptance Test

Acceptance tests shall be carried out on each type and size of the cable on the

cable drums selected at random.

The following shall constitute acceptance test:

(a) Annealing test


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(b) Tensile test

(c) Wrapping test

(d) Resistance test

(e) Test for thickness

(f) Tensile strength and elongation test before aging and after aging

(g) Aging in air ovens

(h) Hot set test

(i) Insulation resistance test

(j) High voltage test

(k) Partial discharge test

(l) Measurement of eccentricity and ovality.

20.6.16.8 Routine Test

Routine test shall be carried out for each drum of cables of all type and sizes.

Following shall constitute routine tests:

(a) Resistance test.

(b) Insulation resistance test.

(c) High voltage test.

20.6.17 Technical Particulars

20.6.17.1 HT Cables

(a) Voltage Grade (E) 33/19 kV & 11/6.35 kV as per IS-

7098 (Part 2).

(b) Type 3 core, XLPE, armoured, screened

cables.

(c) System earthing Solid grounded

(d) Size As per requirement

(e) Conductor Aluminium/Copper stranded conductor

(f) Conductor Screening Semi conducting compound

by extrusion.

(g) Insulation Properties & Table 1 of IS-7098 (Part-II)

process of application and application by extrusions.


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(h) Nominal thickness of As per IS:7098

(i) Insulation screening

Non-metallic part Semi- conducting compound over the

insulation1

Metallic part Armouring may constitute

metallic part of screening. where both

metallic screen & armouring are used,

extruded inner sheath shall be there in

between and its thickness as per Table 3 of

IS 7098 (Part-II).

(j) Core Identification Coloured strips application on cores

or different colours of XLPE insulation or by

numeral (1,2,3) either by applying

numbered strips or by printing on the cores.

(k) Armouring Galvanized steel round wire/strips

(l) Outer Sheath thickness Not less than value specified in

Column 5 of Table 5 of IS 7098.

20.6.17.2 L.T. Power and Control Cables

(a) Size of Cable As per requirement

(b) Voltage rating 650/1100 V

20.6.17.3 Cable Accessories

Description HT Cables LT Cables

(a) Voltage Rating As per cable rating As per cable

(b) Type of termination Cold shrinkable Compressed

(c) Clamps/ terminals Aluminium compression Aluminium

Material

20.7 SPECIFICATION FOR UNDERGROUND DUCTS FOR POWER CABLES

20.7.1 Scope

This specification covers the design, manufacture, testing at manufacture's works

before dispatch, packing and transportation to site, of underground cable ducts

for laying of HT, LT Power Cables required for various sub-stations under PMC-

01 contractor scope of work.

All cable ducts shall comply with latest Indian / IEC-61386-1 and IS/IEC-61386-

24 standards.


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20.7.2 Make

The cable ducts shall be procured from experienced and reputed manufacturers,

with proven experience in manufacture of underground ducts for HV/LV power

cables and having capability to develop, test and timely supply of ducts as

specified in the tender specification. The manufacturer shall have arrangements

for carrying out all the routine, type and acceptance tests including special tests

as per the standards specified and have furnished satisfactory test results.

20.7.3 Codes and Standards

The ducts under this specification shall comply with the requirements of latest

edition of the following Indian and international standards including latest

amendments. Ducts manufactured to other international standards which provide

equivalent or superior performance shall also be accepted.

S. No. Standard

Number Description

1 IS:14930 Pt.-I General requirements of Conduit system for

Electrical and Communication installation.

2 IS:14930 Pt.-II Particular requirements of Conduit system for

Electrical and Communication installation

3 IS:2530 Method for test for Polyethylene moulding

materials and polyethylene compounds.

4 IS:7328 HDPE materials for moulding and extrusion

5 IS:12063 Classification of degrees of protection provided

by enclosures of electrical equipment

6 IS:11000 (Pt- Glow-Wire Test and Guidance, Test

Methods for Fire 2/Sec1) Hazard Testing

7 ASTM D 1693 Test method for environmental stress –

cracking of ethylene plastics

8 ASTM D 638 Standard test method for tensile properties of

plastic

9 ASTM D 790

Test method for flexural properties of

Unreinforced and Reinforced Plastics and

Electrical Insulating Materials.

10 ASTM D 2240 Standard Test method for Rubber property


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S. No. Standard

Number Description

11 ASTM D 648

Standard Test method for deflection

temperature of plastic under flexure load in the

Edgewise Position.

12 IEC-61386-24 Conduit system for cable management Part-24,

Conduit system buried underground

13 IEC-61386-I Conduit System for Electrical installation Part-I


20.7.4 Duct Material and Design

Material for the ducts can be HDPE. The Ducts shall be designed considering

the following:

The ducts shall be designed considering the following:

20.7.4.1 Duct For High Voltage And Low Voltage Electric Power Cables

(a) All ducts shall be as detailed in the relevant sections of Indian Standard or

IEC and this Specification.

(b) The ducts shall be non-coil able / semi-rigid, “single smooth walled”,

manufactured in HDPE. Each duct type shall have a smooth inner surface.

(c) As the design stresses and the physical properties of HDPE and are

different, duct bore/wall thickness ratios are likely to be different. However,

ducts intended to be buried and used with high voltage power cables and

low voltage mains distribution cables shall be capable of meeting the 5%

deflection requirements with an applied force of 450N compression

strength at 75°C.

(d) The cross section of all ducts shall be circular and ends cleanly cut and

square with the longitudinal axis. They shall have no sharp edges, burrs or

surface projections which are likely to damage the cables and shall not

present any impedance to the installation or withdrawal of cable throughout

its length.

(e) There shall be solid polymer coating for permanent silicore lubrication and

low co-efficient of friction. No built in lubricant is acceptable.

(f) Cable duct shall be with low smoke zero halogen plastic.

(g) Duct shall be designed to withstand and repel rodent attacks.

(h) Duct should be suitable for pulling armoured HT & LT cables.


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20.7.4.2 Fibre Optic Cable Ducts

(a) Fibre Optic Cable ducts shall be manufactured as 96.5mm (OD) / 90mm

(ID) Green HDPE solid wall cable ducts designed in accordance with IEC

61386-24. The ducts shall be supplied in 6m lengths with a 100mm heat

formed taper socket at one end and a parallel spigot at the other end to

provide an IP rating of IP57.

(b) The duct shall be designed to provide a min compression test of 450N as

per Indian / IEC Standard.

(c) The duct shall be designed to withstand a 5kN striker (normal duty) impact

test as detailed in Indian / IEC standard.

(d) The duct shall be designed to provide a minimum tensile test capability of

>44.1N/mm2.

(e) Duct shall be provided with a co-extruded highly conductive electrolytic

copper wire encased in the HDPE duct along it running length. To locate

the position of the buried duct in one end of the cable a GPS enabled

transmitter shall be connected. The compatible receiver to this transmitter

shall also be GPS enabled. Receiver shall be able to trace the route of the

cable, along with the depth of the buried duct and its longitude and latitude

co-ordinates.

Both receiver and transmitter systems shall be upgradable, and shall have

built up battery systems complete in all respects. Two sets of such systems

shall be supplied for the ducts under the scope of PMC-01 project.

Contractor shall supply the technical data for such a system for the

approval of Engineer.

Contractor shall also ensure that the effects of any induced voltages in the

copper wire extruded in the ducts, due to high currents of power cables

(inside the ducts) is taken care of by proper earthing, if required.


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20.7.5 General Requirements

20.7.5.1 The Duct shall be with the inner layer plain and smooth.

20.7.5.2 Duct and conduit fittings within the scope of this specification shall be so designed and constructed that in normal use their performance is reliable and without danger to the user or surroundings.

20.7.5.3 When assembled in accordance with manufacturer’s instruction as part of a conduit system, they shall provide mechanical protection to Cables contained therein.

20.7.5.4 Within the conduit system there shall be no sharp edge, burrs or surface projections which are likely to damage insulated conductors or cables or inflict impurity to the installer or user.

20.7.5.5 The protective properties of the joint between conduit and conduit fittings shall be not less than that declared for the conduit system.

20.7.5.6 The Duct and fittings shall withstand the stresses likely to occur during transport, storage, recommended installation practice and application.

20.7.5.7 The duct shall be supplied in continuous length in coil form or straight length, suitable for shipping and handling purpose.

20.7.5.8 For conduit systems that are assembled by means other than threads, the manufacturer shall indicate whether the system can be disassembled and if, so, how this can be achieved.

20.7.6 Colour of Power Ducts

All ducts meant for HV/LV power cables shall be in red colour.

20.7.7 Requirements Of Raw Materials Used For The HDPE Ducts

20.7.7.1 The base HDPE resin used for the outer and inner layer of the HDPE Duct shall conform to any designation of IS:7328 or to any equivalent standard meeting the requirements given in Table below, when tested as per the standards given therein. However, the manufacturers shall furnish the designation for the HDPE resin as per IS: 7328 as applicable.

S. No. Parameter Specified Limit Test Method

1 Density 0.940 to 0.958 g/cc at

27ºC IS:2530 or IS:7328

2 Melt Flow Index 0.2 to 1.1 g/10 min IS:2530 at 190ºC, 5 kg

load

3 Tensile Strength

at 20 N/mm2 Minimum ASTM D 638-IV


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4 Elongation at

Break 600 % Minimum ASTM D 638-IV

5 Hardness Shore

D

Between 60 and 65

units ASTM D 2240

6 Environmental

Stress

No cracking after 96

hrs. ASTM D 1693

7 Flexural modulus

at 1 % strain 690 N/mm2 minimum ASTM D 790

8 Heat Deflection ASTM D 648

9 Temperature at

45 g/mm OIT (in Aluminium Pan) 30 minutes minimum

Table 10: Raw Material Requirement

20.7.7.2 The anti-oxidants used shall be physiologically harmless.

20.7.7.3 None of the additives shall be used separately or together in quantities as to impair long term physical and chemical properties of the duct.

20.7.7.4 No rework / regrind material shall be used.

20.7.7.5 The raw material used for extrusion shall be dried to bring the moisture content to less than 0.1%.

20.7.7.6 Suitable UV stabilizers shall be used only for manufacture of the nonblack coloured HDPE duct to protect against UV degradation, when stored in open for minimum 8 months period. The Engineer may ask for UV content test. The test result for UV Content test by FTIR method from any recognized laboratory shall be accepted and the Hindered Amine Light Stabiliser shall be minimum 0.15 %. UV Content test need not to be conducted in case of UV Stabilized raw material is used.

20.7.8 Requirement for HDPE Ducts

20.7.8.1 Visual Requirement

The ducts shall be of good workmanship and shall be free from holes, breaks

and other defects. The ends shall be cleanly cut and shall be square with axis of

the ducts.

20.7.8.2 Colour

The colour of the duct shall be green for fibre optic duct and Red for power cable.


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20.7.8.3 Dimensions

The dimensions of the HDPE Ducts shall be selected based on the cable size.

The cable occupancy in duct shall not exceed 65% based on the internal cross

sectional area of the duct. Typical size of power duct may be 117mm inner dia

and 125mm or more outer dia.

20.7.8.4 Standards Length

Duct up to 50 mm OD nominal size shall be supplied in standard length of 100

mtr. ± 1% or 6 mtr ± 1 % and all higher other sizes will be supplied in standard

length of 6 mtr. ± 1%.

20.7.8.5 Other Main Requirements

(a) Ducts shall comply with the following requirements of Indian / IEC

standards.

(b) Compression Strength

(c) Impact Strength

(d) Bending Strength

(e) Oxidation Induction Test (OIT)

(f) Resistance to flame Propagation

(g) anti-rodent Properties & tests.

(h) safety of ducts from the direct attack of subterranean organism.

(i) Resistance to external influences such as ingress of water and dust on

HDPE Duct Accessories as per IS-12063.

(j) Test certificate from accredited third party laboratory is mandatory for the

above tests.

20.7.8.6 Marking Identification:

At every 1/3 meter it shall be marked ELECTRIC CABLE DUCT. Further the

conduit shall be prominently marked at regular intervals along their length of 1m

using indelible ink with following:

(a) Manufacturers name & code

(b) Specification No.

(c) Duct size both inner and outer diameter

(d) Incremental meter mask

(e) Date of manufacture

(f) Employer’s name / symbol


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(g) The lettering shall be 8mm high in yellow or white and repeated 3 times

with a120° spacing around the circumstances along the length of the duct.

20.7.9 Duct Accessories for Power Cables

The following requirements shall be met for accessories for Ducts.

20.7.9.1 Plastic Coupler:

The coupler shall be of compression type with O-ring. It is used for jointing two or

more ducts. The design of this shall be simple, easy to install and shall provide air

tight and water tight joint between the two ducts. The coupler shall insure that the

two ducts are butted smoothly without any step formation in the inner surface. The

coupler may be straight, bands, T-joints type as per requirements of Engineer.

20.7.9.2 End Cap:

This cap made of suitable plastic material shall be fitted on the both ends of duct,

coil after manufacturing the duct. This shall avoid entry of dust, mud and rainwater

into the duct during the transit & storage. Water tight and to prevent entry of

vermin’s, caps shall be provided for sealing the ducts after cable installation or

otherwise ducts kept as spare. The dimensions of accessories shall be suitable for

joining the ducts.

20.7.9.3 Straight Coupling

All duct couplings shall not present any internal projection or impedance to the

installation or withdrawal of cable through the duct run.

20.7.10 Packing Requirement

Ducts shall be supplied in standard size for delivery and shall be so packed as to

permit convenient handling and to protect against loss or damage during transit and

storage.


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20.7.11 Type Tests

20.7.11.1 Complete Duct systems for each offered size of the duct on fresh samples shall be subjected to tests minimum after 240 hrs of manufacture as per Indian / IEC Standard.

20.7.11.2 The raw material tests of the duct.as given for each grade of raw material shall be conducted.

20.7.11.3 Unless otherwise specified each tests shall be made on three new samples.

20.7.12 Routine And Acceptance Tests

These shall be conducted as per Indian / IEC standard. Each tests shall be made

on three new samples.

Inspecting Engineer may cut the duct in between to check the uniformity of

thickness of ducts and for other tests.

20.7.13 Inspection

20.7.13.1 All the gauges/ test & measuring instruments shall be calibrated at the time of inspection and proof to this office shall be produced.

20.7.13.2 Inspection and testing shall be carried out by the inspecting authority nominated by the Employer/ Engineer, to ensure that all the requirements of this specification are complied with for the acceptance of the materials offered for inspection.

20.7.13.3 The Employer / Engineer or his nominee shall have free access to the works of the manufacturer and to be present at all reasonable times and shall be given facilities by the manufacturer to inspect the manufacturing of the duct at any stage of manufacture.

20.7.13.4 Inspecting Authority shall have the right to reject whole or part of any work or material that does not conform to this specification, Indian / IEC standards. Employer / Engineer may order the same to be removed / replaced or altered at the expense of the manufacturer. All facilities considered necessary by the inspecting authorities for the inspection of the ducts shall be supplied by the manufacturer free of cost.

20.7.13.5 The manufacturer shall supply the duct samples and samples of the raw materials free of charge as required by the inspecting authority and shall at his own cost prepare and furnish the necessary test pieces and appliances for such testing as


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may be carried out at his own premises in accordance with this specification and Indian / IEC standards.

20.7.13.6 Failing the existence of any required facilities at his own premises for the prescribed tests, the manufacturer shall bear the cost of carrying out the tests in an approved laboratory, workshop or test house.

20.7.14 Sampling

Ducts of the same length, nominal size, similar construction and class,

manufactured from the same material and under similar conditions of production

shall be grouped together to constitute a lot. For judging the conformity of a lot

to the requirements of the acceptance tests, sampling shall be done for each lot

separately. For this purpose, the number of lengths to be selected at random

from the lot shall be in accordance with Table below:

S. No. Lot size

Samples for Dimension

Checking

Samples for

Other

Acceptance

Tests

(Number) Number

Permissible

Rejection

1 Up to 300 13 0 2

2 301 - 500 20 0 3

3 501 - 1000 32 1 4

4 1000 - 3000 50 2 5

5 Above 3001 80 3 7

Table 21: Sample

Theses lengths will be selected at random from the lot for taking samples. From

each of these lengths, sample of duct shall be taken. The length of the sample

shall be sufficient so as to provide test pieces of required lengths as laid down in

various test clauses.

20.7.15 Defects in Ducts

The manufacturer shall be responsible to ensure that ducts supplied under the

specifications are free from defects in design, material and workmanship under

the service conditions given in the specifications. Contractor shall replace free of

cost those parts which shall be found defective.


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20.7.16 Rejection

In case the duct tested and inspected in accordance with this specification, fail to

pass the tests or comply with the requirement of the specification, the whole

consignment shall be rejected at the risk and responsibility of contractor.

20.7.17 Information To Be Supplied

20.7.17.1 Normally the duct will be supplied as per the standard dimensions and length as Indicated in this document. However contractor may specify his own dimensions / lengths / packing requirements etc. to comply with the specifications.

20.7.17.2 The manufacturer shall provide the proof of purchase of HDPE and other raw material after the date of placement of order before commencing the production of the Ducts.

20.7.17.3 The manufacturer of ducts shall submit a declaration that only virgin material has been used for manufacturing of HDPE Ducts failing which supply shall not be accepted.

20.7.17.4 The manufacturer shall have an ISO 9001, ISO 14001 and ISO 18001 certified manufacturing unit.

20.7.17.5 The manufacturer shall submit his Quality Assurance Plan, ISO related documentation and manufacturing process details prior to fabrication, failing which ducts shall not be accepted.

20.7.17.6 Power Duct/fiber duct laying and Power Cable Installation training shall be provided at their training centre by manufacturer and they shall depute their technical team to train the site engineers for duct laying and supervision for two weeks free of cost.

20.7.17.7 Owner/Engineer may visit the plant to check the capability of manufacturer to supply quality products.

20.7.18 Cable Duct Tile Tape and Tiles

20.7.18.1 Cable Duct Tile Tape for LV and HV Cables

(a) The tile tape is intended to, during excavation work; give a clear visual

warning to contractors and other utilities of the presence of underground

cables, joints or cable ducts.

(b) The tile tape shall be manufactured from reconstituted low or medium

density Polythene or a similar material, which shall be rot-proof and

resistant to a wide variety of virgin and tipped soil conditions. The material

used shall have no detrimental effect on the environment.

(c) The tile tape shall comply with the general requirements of relevant

standards including being laminated with suitable marker tape

identification.


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(d) The tile tape shall be marked with the following legend. “SEABIRD PMC-

01” or as advised. The lettering shall be repeated every 300mm along the

length in the centre of the tile tape.

20.7.18.2 Tiles For Use On 11kv Cables and Ducts

(a) The tile is intended to, during excavation work; give a clear visual warning

to contractors and other utilities of the presence of underground cables,

joints or cable ducts. The tile shall be manufactured from any thermoplastic

material and comply with the requirements of BS EN50520-2009. The use

of reworked, reprocessed or recycled materials is permitted; however any

material used shall have no detrimental effects on the environment and

shall be rot-proof and resistant to a wide variety of virgin and tipped soil

conditions. The tile shall have a suitable standard warning text laminated

along its longitudinal length complying with the standard.

(b) The tile ends shall be cleanly cut, square with the longitudinal axis of the

tile, shall have no sharp edges.

(c) To allow interconnection of the tiles; located 25mm from each end of the

tile along its centre line, each tile shall have pre drilled 12mm hole.

(d) A suitable peg or cable tie is provided to enable tiles to be connected

together.

(e) Tile dimensions are to be provided for approval.

20.7.18.3 Concrete Route Markers

Concrete route markers posts shall be used as an aid to locate and identify the

route and the presence of buried underground cables and cable ducting systems.

After installation, the marker posts can be expected to be subjected to the full

range of climatic conditions encountered at site. The buried section of the marker

post may also be surrounded by standing ground water for most of its functional

life.

The marker posts shall be pre-cast concrete not less than C30 grade with a mix

ratio in the range 1:2:3 (Cement-Sand-Fine/Medium Aggregate). When utilized,

6mm 43A grade steel reinforcing rods shall be incorporated into the casting where

a minimum of 10mm coverage of concrete shall be applied around all faces.

For the fixing of the relevant marker plate (not supplied with the marker post); 4

x 16mm diameter holes shall be drilled or precast into marker post. The proposed

location of the fixing holes, details of approximate physical size of the route

markers are to be provided by contractor.


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20.7.18.4 Cable Laying In Ducts Broad Guide Lines

Contractor shall design the duct system and obtain approval of Engineer for the

procedure to be followed for duct laying. Below are given the broad guide lines

for the same.

General Requirement for HV and LV Cable Laying

(a) Armoured Cables shall be laid in Ducts and relevant Indian / IEC standards

shall be followed for the same. In case there is any conflict in the

requirements given below the stringent clauses as per decision of Engineer

shall apply.

(b) Minimum depth below finished ground level shall be 600 mm measured

from the top of duct.

(c) Only one cable shall be laid in one duct.

(d) Outer Duct surface shall have minimum 300 mm clearance from normal

pipes of other services which shall be increased to 600 mm for very large

pipelines or high pressure pipes.

(e) Minimum spacing of 75mm shall be kept between two ducts both

horizontally as well as vertically when a number of ducts are installed. From

the trench wall it shall be 100mm.

(f) The bottom bedding shall be 50mm minimum of the surround material.

(g) HV ducts can be encased in concrete and for LT ducts unless these are on

the same route can be buried in ground as explained below.

(h) Duct surround material thermal resistivity shall be maximum 1.0km/watt at

zero percent moisture content. Only unwashed sand graded to BS 882 or

equivalent Indian Standard shall be used. This material must be compacted

well around the ducts.

(i) When the ducts are laid the surround sand shall cover up to 75 mm of top

of duct. After this sand cover of 75mm, a marker of width covering the ducts

below shall be placed. Then on top of this marker backfill of Red Cement

bound granular Mixture [15N after 7 days] shall be filled up to 225 mm. On

it Warning tape of about 250mm shall be placed. After that the same

granular mixture shall be placed so that the marker is about 300mm below

the finished surface.

(j) Mandrel shall be passed through each duct before concreting or covering

so as to ensure that cable will not be damaged during pulling due to

incorrect duct joints. Then a 5 meter sample of same cable can be passed

and if there is any cut or damage to cable after concreting or backfilling the

ducts shall be rejected. Typical duct drawing is enclosed in tender

drawings.


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20.7.19 Man Hole

20.7.19.1 General

(a) Contractor shall provide man holes for pulling the cables so that the pulling

tension of cable is not exceeded. These man holes shall also be at cable

jointing pits, cable turning, cable crossing roads. The size will depend on

the number of cables, ease in pulling and jointing cables. It shall have

provision of built in ladders, cable supports etc. These shall be of material

such as aluminium alloy and under no condition any rusting material such

as GI or steel shall be used. All the duct ends shall be sealed for water, gas

and vermin entry including the spare ones through proper sealing split

sockets meant for this purpose so that same can be removed when cable

replacement is to be done. No compound or foam sealing is acceptable.

Sealing must be 100% under all the operating conditions throughout the life

of the cable duct. Contractor must ensure that there is high water table at

site and this shall be taken into consideration while designing the drainage

from the manhole. In such as situation contractor may propose to have

manholes at higher level of ground.

(b) There shall be a sump hole with gravel inside with a proper size of mesh to

drain water towards the sea. All slopes in manhole shall be towards this

sump hole. It is the responsibility of contractor that under no condition water

stays inside the manhole due to rain or otherwise and manhole not

complying to this requirement shall not be acceptable under any

circumstances. Contractor to submit the drainage arrangement for approval

of Engineer.

(c) Typical sizes of man holes for LT cables depending upon the number of

cables can be 1600 mm x 1600mm or 1200mm x 1200mm depth not

exceeding 1600mm. For HT cables Man Hole can be of 2000mm x 2000mm

with a maximum depth of 1600mm to 2000mm or as determined by

contractor with the approval of Engineer considering the number of cables,

one above the other.

(d) Man hole can be of concrete or prebuilt of Glass Reinforced Plastic,

provided the required strength is ensured when the foot paths or roads

above are operating under full designed loads of pedestrians or vehicles

above. FRP man holes of sufficient strength shall be preferred because of

rusting environment at site.

(e) There shall be sufficient space to pull the cables in the ducts.

(f) Cables inside the manhole shall be supported by providing cable bearers

as per requirement. Turning radius of cable must not be less than as per

the recommendation of manufacturer.

(g) Each manhole shall be numbered for ease maintenance.


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(h) For drainage the soak way of size 150x150mm (or round) excavated to

about 300 to 600mm deep filled with coarse gravel is to be provided in one

corner to allow water drainage. Alternatively for area with high water table

a pumping sump may be provided. In either case a flush fitting protective

grating shall be provided.

20.7.19.2 Earthing

If any metallic build in ladders, supports etc. are provided, same shall be grounded near man

holes. For this purpose grounding shall be provided for the safety by rod or pipe grounding as

per IS-3043.

20.7.20 CABLING SYSTEM

All HV and LV power cable shall be XLPE insulated, PVC sheathed, FRLS with anti-rodent

coating with stranded aluminium conductor. All 11 KV cables LV cables from CSS to feeder

pillar are laid in RCC cable trenches. The service cable from feeder pillar to consumers and

street light cables are laid in HDPE / DWC duct pipe.

20.7.20.1 CABLE SELECTION CRITERIA:

Cable sizes shall be selected considering the following:

• Permissible current carrying capacity

• Voltage drop

• Short time current / overload requirements

• Fault current carrying capacity

• Ambient conditions, cable laying and other related criteria.

Generally for 11kV distribution, 3-core aluminium cable of size 300 mm2 shall be adopted to

cater to a load of about 5MVA. Under normal conditions, the voltage drop shall be restricted to

6%. Similarly for LV cables, generally 3.5-core XLPE Aluminium cable of 300 mm2 shall be

adopted with a voltage drop of about 3%.

For loads where available 3-core cables are unable to take load currents, single core cable with

trefoil configuration shall be used.

All cables shall be de-rated as per the usage/installation factors as recommended by the cable

manufacturer considering ambient and laying conditions.

All HV/11KV cables installed between the SUBSTATION and the CSS/transformer shall be

installed in concrete duct banks, sized, configured and located as per detailed design

requirements.


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20.8 CABLE LAYING

20.8.1 DEPTH OF LAYING & SPACING BETWEEN CABLES:

Minimum depth of laying from ground surface to top of cable shall be as following:

• 11 kV cable: 1.0 meter.

• 415 volt cable: 0.75 meter.

• 11kV, 415 V Cables at Road crossing: 1.2 meter.

• 11Kv, 415V Cables at Railway crossing (Measured from bottom of sleeper to top

of pipe.): 1.0 meter.

Whenever 2Nos. 11kV Cables have common route, they can be laid in same corridor (Trench)

at the specified depth as indicated in the drawing.

Wherever the proper depth is not achievable due to presence of other services or for other

reasons, the cable shall be laid deeper or HDPE /GI pipe as required depending upon the site

condition.

Note: In certain colonies /areas where the road width is about 10 feet or less, and LT consumers

are both side of the road, excavation of cable trench for laying cable on both side of the road

and placing feeder pillar on road side is difficult. In such cases, suitable site decision is to be

taken in consultation with engineer in charge.

20.8.2 ROAD, RAILWAY TRACKS, WATER PIPE LINE CROSSINGS:

Pre -fabricated RCC duct bank consists of HDPE pipe encased concrete shall be used for

crossing of Road and cast iron or GI pipes for railway track and water pipe line. One spare pipe

at each location of 11 kV cable crossing shall be laid. Cable /pipe size/ laying details shall be

as per IS 1255-1983. The road cutting for cable trench, whether cement concrete, asphalt or

macadam road surface shall be undertaken after obtaining approval for cutting from the road

authorities, telephone authorities and work should be planned to be completed in the shortest

possible time. Where necessary the work shall be planned during night or light traffic periods.

The railway track crossing design shall be got approved from the railway authorities and the

contractor shall do work in coordination with them. In the excavated trench across the road the

pipes shall be laid, excavation backfilled compacted and surface shall be redone in the shortest

possible time. Open Drain Crossing: Where ever the cable has to cross open drains, with long

span, the cable shall be laid in suitable size HDPE /G. I. pipe properly joined with suitable collars.

The GI pipe shall be firmly supported on pillars, columns, or suitable support of RCC foundation.

20.8.3 FOOT PATH CUTTING:

The slabs, curbstones, on the roads/ footpath shall be removed and reinstated without damage.


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20.8.4 REINSTATEMENT:

After the cables and pipes have been laid and before the trench is backfilled, all joints and cable

positions should be carefully plotted in drawing and preserved and provided to the Engineer of

Employer. The protective covers shall then be provided, the excavated soil riddled, sieved and

replaced.

20.8.5 JOINTING BAYS:

The bidder shall identify the location of the joint bays after carrying out detailed survey of the

cable route and excavation of the trial pits. The delivery lengths of the cables shall match the

location. The joint bay should have a flat and level surface. At the bottom in a corner, a sump

pit shall be made, if necessary, for bailing out water. The contractor shall follow standard

practice in making joint bay, jointing and back filling after making joint and testing for the voltage

class required. All works shall be carried out in presence and supervision of the Engineer of

Employer.

20.8.6 BENDING RADIUS:

Care shall be taken during laying to avoid sharp bending, and twisting. Recommended minimum

bending radius for LT/HT cables: LT HT Single Core 15xD 20xD D= Dia of cable in MM.

Multicore 12xD 15xD 12.4

20.8.7 JOINTING AND TERMINATION OF CABLES:

General: The cable jointing personnel and his crew shall have good experience in the type of

joints and terminations that are used. The jointing work shall commence as soon as two or three

lengths of cables have been laid. All care should be taken to protect the factory-plumbed caps/

seals on the cable ends, and the cable end shall be resealed whenever the end is exposed for

tests. Jointing of cables in carriage ways, drive ways under costly paving, under concrete or

asphalt surfaces and in proximity to telephone cables and water mains should be avoided

wherever possible. Sufficient overlap of cables shall be allowed for making the joints. The joint

bay should be of sufficient dimensions to allow the jointers to work with as much freedom of

movement and comfort as possible. Sufficient space should be kept below the cable to be

jointed. The joints of different phases shall be staggered. All jointing works shall be done by

licensed jointers.

20.8.8 TENTS / COVERS:

An enclosure or suitable protection cover shall be used in all circumstances wherever jointing

work is carried out in the open irrespective of the weather conditions. The joint shall be made in

dust free and clean atmosphere.


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20.8.9 PRECAUTIONS BEFORE MAKING A JOINT/ END TERMINATION:

The cable end seals should not be opened until all arrangement have been made for jointing

and all necessary precautions have been taken to prevent circumstances arising out of rainy/

inclement weather conditions, which might become uncontrollable. If the cable end seals or

cable ends are found to have suffered damage the cables should not be jointed, without tests

and rectification.

20.8.10 MEASUREMENT OF INSULATION RESISTANCE:

Before and after jointing, the insulation resistance of both sections of cables shall be

checked.

20.8.11 IDENTIFICATION:

The identification of each phase shall be clearly and properly noted. The cables shall be jointed

as per the design approved by the Employer based on the proposal submitted by the Contractor.

Each cable shall have identification for phase and circuit at joint bays.

20.8.12 MAKING A JOINT/ END TERMINATION:

Comprehensive jointing instructions should be obtained from the manufacture of jointing/end

kits and meticulously followed. The materials used in the joints/ end kits like ferrules, screen /

armour continuity bonds, lugs etc., shall be of good quality and conform to standards. The

jointing tools shall be appropriate and as per the requirement of jointing XLPE, PVC cables.

20.8.13 CABLE TERMINATIONS:

The cable terminations used are to be of outdoor type. The preparation of the cable end for

installing the terminations and the precautions to be taken before fixing the terminations shall

be followed as in the case of the cable jointing procedures. The instructions furnished by the

termination manufacturer shall be strictly followed. All terminations shall be done by joint

manufacturer’s jointers or under their supervision. At cable terminating end, the following

provisions for supply and erection are to be included.

A terminating structure should be provided where necessary for supporting the cable to be

terminated (except at the ring main unit ends)

A sufficient length of spare cable shall be left in the ground, for future needs.

The rise of the cable immediately from the ground shall be enclosed in suitable size of PVC / GI

pipe to protect against direct exposure to the sun.

The cable shall be properly fastened to the support using non-metallic clamps.


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Appropriate labels shall be fixed identifying the phase circuit, voltage and date of commissioning

etc., on the cable supporting structure.

20.9 SPECIFICATION FOR EARTHING

20.9.1 Scope

20.9.1.1 This specification covers the technical and associated requirements for the entire earthing system substations, required to protect persons and equipment and to allow safe service and maintenance of the installations. The earthing system includes the underground grid, ground rods and connections. The earthing system shall be designed to minimise the dangers from step, touch and transferred potentials which can occur under maximum fault conditions. The Contractor shall design, furnish and install the substation earthing system in accordance with the provision on latest IEEE Std. 80, Guide for Safety in Substation Earthing, IS: 3043, Code of Practice For Earthing and the provision of this specification. The contractor shall submit calculations in support of his design.

20.9.1.2 In addition to the above codes and standards, the Contractor shall comply with applicable national and local laws, codes, regulations, statutes and ordinances.

20.9.1.3 The Contractor shall bear full responsibility that the earthing system materials have been designed and fabricated in accordance with all codes and standards and that they perform under the conditions and to the standards specified herein.

20.9.1.4 The Contractor shall carry out earth resistivity measurement for the substation site. Based on the result of this measurement and the system parameter, the appropriate design and the calculation will be determined whether impermissible touch and step voltages occur at any place of the station (including outside area) which may be endangered. These calculations will decide on the provisions for earthing to be made


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with the relevant part of the civil works related to foundations. It shall be agreed between Engineer and Contractor, about special arrangements, if calculations prove that touch and step voltages are higher than permitted and the Contractor proves that he modified the earthing grid to its optimum. Only calculations built up on computer generated design programmes shall be accepted. A special software for providing detailed analysis of the actual step and touch voltages likely to be generated has to be used.

20.9.1.5 The HV and LV systems are solidly earthed at the neutral point of the power transformer. The size of earthing conductors to be connected with the earthing system shall be designed for an earth fault level of 40 kA (1 sec). The material for earthing in particular for jointing shall be selected to prevent corrosion at the connection points as well as at the earthing material itself, both underground and exposed to air. If necessary, cathodic protection of an approved design shall be applied. In order to minimise the effect of seasonal variations of earth resistance, the earthing system shall be designed for the worst conditions.

20.9.2 Description of Services

The Contractor shall provide a complete earthing system consisting of:

20.9.2.1 The main outdoor subsoil earthing system, with individual loops around each building, foundation, structure, etc., of the site.

20.9.2.2 Sub-earthing systems for buildings, foundations, structures, tanks, etc., being connected to the subsoil earthing system as required

20.9.2.3 All electrical equipment such as motors, transformers, substations, foundations, switchboards, control boards, relay and auxiliary relay boards, all other subsidiary electrical equipment as well as all metal parts of civil construction or the mechanical equipment such as transformer rails, pumps, pipes, steel structure, tanks, cable trays, etc. shall be connected to the earthing system.

20.9.2.4 All materials and parts which are not specifically mentioned herein but are necessary for the safety of operating personnel and safe operation of the substation shall be furnished and determined by the Contractor at no increase in cost to the Owner.

20.9.3 Design Requirements

20.9.3.1 General

(a) The ground grid shall be composed of a system of copper conductors

buried approximately 500 mm below finished ground level, excluding

crushed rock surfacing. The grid system shall cover the entire fenced

substation area and shall be extended to the outer of the substation fence.

A perimeter conductor shall run around the substation in a distance of 0.5m

to the fence and shall be connected to the inner earthing grid and to the

fence in regular intervals. Where necessary to reduce the overall earth

resistance, earth electrodes shall be provided and connected to the

perimeter of the main earth grid. A minimum of four (4) of the specified


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ground rods must be installed (one at each corner of the ground grid). The

Contractor shall determine the spacing of ground grid conductors and the

total number and location of ground rods and their lengths.

(b) Earthing conductors buried in the soil shall be of stranded copper, coated

if and as necessary. Earthing conductors embedded in concrete shall be of

copper cables. Adequate corrosion protection shall be provided when

conductors leave the concrete, respectively the soil.

(c) The design of the earthing system and the materials to be used shall

comply with the requirements for the specified cathodic corrosion

protection.

(d) Earthing conductors laid on cable trays or similar shall be stranded copper.

(e) All interconnections of the earthing grid to equipment and the connections

be-tween the earthing grid and the earthing rods shall be made by the

termite welding process. Only those connections located in earthing pits

and occasion-ally intended to be opened for testing purposes shall be of

the bolted type.

(f) When a substation is located adjacent to the existing earthing system of

Phase-1 of Seabird Project, the ground systems of the existing or new

facilities shall be connected together by at least three copper conductors

appropriately sized for mechanical strength and the specified fault current

with minimum conductor size to be 100 mm2.

(g) Drawings and calculations shall be submitted for approval giving sufficient

in-formation on the earthing, lightning protection, the earthing of structure

mounted equipment, as well as on methods of measuring the earth

resistance, respectively the earth voltage, the touch and the step voltage.

(h) If the actually measured resistance of the Contractor-designed and

installed ground grid is higher than one ohm or as specified, the Contractor

shall install, at no extra cost to the Owner, additional earthing rods, mats,

earthing electrodes, etc., until the field-measured resistance is equal to or

less than the specified value.

(i) Joints which are indicated as test points shall be bolted or clamped. Joints

in tape, other than at test points, shall be made by the exothermic welding

process. Overlap of conductors shall be not less than 100mm.

(j) Joints and connections shall be protected by a coating which will form a

seal and exclude moisture in all weather conditions. At connections to earth

electrodes the coating shall cover all exposed conductors. Protective

coatings shall be of a water proof, inert, tenacious material.

(k) Bolts, screws, nuts, washers and rivets for coppers conductors shall be of

phosphor-bronze, naval brass or copper-silicon and for aluminium

conductors they shall be of stainless steel.


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20.9.3.2 Equipment and Materials Requirements

The equipment and materials shall be suitable for outdoor installation and use at

specified service condition without corrosion, deterioration or degradation of

performance characteristics.

20.9.3.3 Earthing Conductors

(a) Earthing conductor shall be copper conductor of soft drawn concentric

stranding bare copper conductor.

(b) Ground leads running down from the lightning rod or air terminal rods shall

be hard drawn concentric standing copper PVC-insulated (600 V class) and

shall be provided with the required clamp supports mounted on the steel

structure at approximately 1.5 m intervals. The PVC insulation shall be

yellow with green stripes.

(c) The cross sections of the various earth conductors shall be determined in

accordance with IEEE standard / IS: 3043, however, the minimum copper

conductor cross sections shall be as follows:

HV and LV switchgear 150 mm2

Motor 50 mm2

Metal raceways and cable trays 35 mm2

Intermediate terminal boxes, cabinets, panels 10 mm2

Other metal parts as may be required 10 mm2

20.9.3.4 Ground Rods

(a) The ground rod shall be copper-covered steel of circular cross section, with

a nominal diameter of 19 mm and not less than 3 meters long in section of

1.5 meters. If more than one earthing rod are necessary they shall not be

less than 3 m apart.

(b) Each ground rod shall have a conical swaged point at one end and shall

have a continuous smooth copper covering of at least 0.254 mm thickness

molten-welded or copper bonded (electro-deposit) to a steel core. The

copper clad or pressed type will not be accepted.

(c) Where earth plates are indicated, they shall be 600mm x 600mm minimum,

of solid or lattice copper not less than 3mm thick.

(d) Electrodes shall be installed in undisturbed ground. The distance between

any two electrodes shall be not less than the sum of the lengths of the two

electrodes.


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(e) Backfill immediately surrounding plate electrodes shall have a low specific

resistivity and good water retention properties, and shall be well

compacted.

20.9.3.5 Exothermic Welding Materials (If Exothermic Process is required)

(a) The Contractor shall supply exothermic welding materials for conductor-to-

conductor, conductor-to-ground rod and conductor-to-steel structure

earthing connections. These materials shall be Cad-weld or similar type. If

the Contractor proposes to supply a exothermic process other than Cad-

weld, detailed information describing the proposed process shall be

included in his tender.

(b) The exothermic welding materials shall include removable clamp type

moulds, handle flint gun, exothermic powder cartridges, metal discs and

other devices required to complete the earthing connection.

(c) The exothermic powder cartridges shall be designed to provide an installed

connection having a current capacity equal to conductor being welded. The

ignition powder shall be packed in the bottom of the cartridge to permit the

ignition powder to fall on top of the welding powder when dumped into the

old. The powder cartridges shall be complemented with metal discs.

(d) The moulds shall be designed to withstand the high temperature

associated with the welding operation and shall provide a minimum of 50

acceptable connections without maintenance or replacement.

20.9.3.6 Inspection Pits

(a) Unless otherwise indicated or required, connection between an earth

conductor and its associated earth electrode system shall be in an

enclosure.

(b) The enclosure shall have a removable top cover, which shall be flush with

finished ground level. The enclosure shall be a purpose made inspection

pit made of concrete. The earth electrode connection shall be just below

the lid of the inspection pit with adequate access for testing purposes. The

enclosure shall be clearly labelled to indicate the electrodes function and,

where appropriate, its identification number.

20.9.4 Earthing Hardware

20.9.4.1 Terminal Lugs

Terminal lugs shall be one hole, socket type, rounded edge lug, cast of high

strength corrosion resistant copper alloy.

Machine screws, nuts, and washers used with the lugs shall be bronze.


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20.9.4.2 Flexible Copper Braids

All flexible copper braids shall be made of flat, extra-flexible copper braid which

has been tinned before weaving. Both ends shall be encased in a seamless

copper ferrule drilled in accordance with NEMA Standard or equivalent. Ferrules

shall be formed under high pressure ensuring dependable contact.

20.9.4.3 Steel Structure Earthing

(a) Every steel structure that carries insulators or apparatuses shall be

connected to the earthing grid. To ensure contact even if a connection fails

or a conductor is cut off, every structure must be connected via two different

risers to two different parts of the earthing grid.

(b) Steel structures with more than one leg should have two legs connected to

the grid, with one connection to each leg. The legs with the greatest

spacing between shall be chosen for the earth connection.

(c) Circuit breaker framework is not considered as proper connections

between steel structures. If there are no connections between the legs

which are able to carry the current, all legs must be connected to the grid

with their own risers.

(d) Operating mechanisms and motor drives placed on separate stands shall

be connected as above.

20.9.4.4 Transformer Earthing

(a) The transformer tank shall be connected to earth following the same

principles as for steel structures.

(b) The neutral point of transformers shall be connected to the earthing grid

via an isolated link or conductor. The connection to the two earthing rods,

which are also connected to earthing grid, shall be made by two

independent strips from the neutral.

20.9.4.5 Earthing of Switchgear

(a) Earthing switches are to be connected via a direct earthing connection and

not via the steel structure. Connections between any type of earthing

device, e.g. earthing switch, and risers from the earthing grid shall be made

through a copper wire connected between the earth contact of the earthing

device and a riser. The neutral of the primary winding of Voltage

Transformer, shall be grounded via a separate earthing connection to

earthing rod and not via the steel structure.

(b) Each lighting arrester shall be grounded separately with a full rated earthing

connection and not via the steel structure. In addition, an earthing rod shall

be driven into the ground at each earthing point of a lighting arrester as

close as possible to the lighting arrester and connected to it.


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20.9.4.6 Earthing Inside Buildings

(c) For potential equalising of the building an earthing grid of 8 mm

reinforcement bars shall be cast into the surface concrete of all floors of all

switchgear room or basements with power cables installed. The connection

points shall be welded. The mesh size shall not be greater than 3 x 3 m.

Suitable connection points shall be brought out of the concrete to allow

connection to the main earthing and to all parts of equipment and building

to be earthed. The part of these connecting points which protrudes from

the concrete shall be tinned. The earthing grids of the different levels shall

be connected at 8 to 10 m. on the periphery distributed locations.

(d) The size of the main earthing shall be defined by earthing calculations. The

design value for the main earthing grid shall be 40 kA (1 s) rating and with

consideration of CADWELDED joints.

(e) To ensure that reinforcement grid is made electrical continuous, a sufficient

number of connection points shall be brought out of the concrete. Together

with the detailed civil engineering drawings, the earthing design is to be

checked before releasing for construction.

(f) The connections to these parts should be of tinned copper of adequate

cross section of at least 70 mm². Further similar connection points shall be

installed at a number of places for the connection of portable earthing

equipment when working in the station. All iron parts of the building and the

reinforcement shall be connected to this common earthing installation.

(g) Generally, each electrical device must be equipped with an earthing screw

of sufficient diameter for connection to the earthing system. The same

applies to all metallic parts such as panels, doors, rails, fences,

transformers, etc. are effectively connected by earth conductors.

(h) High voltage equipment and each GIS or metal enclosed switchgear bay

shall be equipped with at least two terminal bolt M 16 in diameter or suitable

earthing pads of adequate size to accommodate at least two bolts for

proper connection to the earthing system.

(i) For connection to all kind of control, protection, LV, panels etc. an earthing

grid shall be laid in all cable trenches of at least 50 x 5 mm tinned copper

bar.

(j) Control panels and desks, switchboards, etc. consisting of several

individual sections or compartments shall each be connected to this tinned

copper earth bar unless all panels are solidly welded together, or other

approved means are applied ensuring solid earthing connections. In such

a case, provisions for earthing must be made at one end at least.


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20.9.4.7 Earthing Outside Buildings

(a) As a minimum, one grading ring of 185 mm2 tinned copper conductor shall

be laid around each building at a distance of 1 m (each) and at a depth of

0.6 m.

(b) The connections to the building earthing installation shall be made within

the building. An earthing grid of sufficient size, defined by earthing

calculations and consisting of tinned, annealed copper conductor with a

maximum mesh size of 3 x 3 m shall also be installed in the transformer

bays.

(c) All individual earthing grids shall be interconnected at spacing by not more

than 5 meters by tinned plated high conductivity annealed copper strips/

wires of an cross-sectional area not less than 185 mm2, buried in ground

or supported on building structures, cable trenches, walls, etc. by means

of brass clamps with spacing of not more than 1.25 m.

(d) Steel fences within and around the substation area shall be connected to

the earthing system at least at two different points and at maximum 10

meters intervals. All metal parts have to be connected through by welding

or suitable earthing conductors.

20.9.4.8 Other Earthing Arrangements

Connection boxes for low voltage or control cables shall be connected via one

50 mm2 wire (35 mm2 copper if the terminal of the box does not allow more),

irrespective of whether the box is mounted on an otherwise earthed steel

structure or not.

Poles for lighting and other types of metal structures within the substation area,

not mentioned hitherto, shall be connected to the earthing grid via 35 mm2

copper, one connection for each item. The only exception is radio antennas, the

earthing of which follows other principles not stated here.

20.9.4.9 Earthing Equipment

To meet the safety regulations before any maintenance or repair works are

started on the HV/ LV power equipment, the disconnected "live" parts of the

equipment shall be grounded by means of mobile earthing sets. The portable or

mobile earthing sets (Substation Earthing Sets) shall be supplied by the

Contractor. One earthing set shall be supplied per substation and voltage level.


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20.9.5 Tests

20.9.5.1 General

The Contractor shall carry out at his own expense all tests necessary to ensure

the satisfactory design and manufacture of all earthing equipment and materials

in accordance with Indian / IEC Standard.

20.9.5.2 Design Tests

Conductors, hardware’s and materials shall be subjected to the design (or type)

tests in accordance with applicable Indian or equivalent IEC standards. Even

though the Engineer witnesses the required tests and the earthing, hardware’s

and materials meet the acceptance criteria, the Contractor shall not be relieved

of the responsibility of providing conductors, hard-ware’s and materials

conforming to all the requirements of the specification.

20.9.5.3 Quality Conformance and Routine Test

(a) Earthing Conductors

The tests shall be performed in accordance with IEC 60621-2 and shall

include, but not limited to the following:

(i) Tensile strength tests

(ii) Elongation tests

(iii) Conductor resistivity tests

(iv) Dimension measurement

(v) Surface finish inspection

(vi) Weight of conductor

(b) Miscellaneous Hardware

The test shall be performed in accordance with IEC 60621-2 and the

manufacturer standard. The routine tests shall be performed by selecting the

samples from each lot of equipment. The number of samples required for

the tests shall be: all for 1-3 sets; 3 for 4-30 sets; and 10% for over 30 sets.

(i) General inspection

(ii) Measurement of dimensions

(iii) Tensile tests No. of samples required: 1 for 20-50 sets;

(iv) 2 for 51-100 sets; and

(v) 4 for over 100 sets

(vi) Galvanising tests

(c) Earthing Materials


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Quality conformance tests are required to verify the quality of materials and

workmanship. They are to be made on fittings taken on random from the

various lots offered for acceptance.

20.9.5.4 Routine Tests

These tests are intended to eliminate defective materials and fittings. They are

to be made on all materials and fittings of the type to which they are applicable,

per applicable standards and / or per Contractor's quality assurance methods if

accepted by the Engineer.

20.9.5.5 Field Tests

Field tests and acceptance tests, if any shall be performed by the contractor as

per IS: 3043 / IEC /IEEE-80 standard. The Contractor shall provide instructions

and acceptance criteria including the calculated value of the resistance of the

installed earthing grid for field testing and measurement prior to energising the

substation / equipment.

Measurement of the earth voltage by the voltmeter/ ammeter method, test

current 100 - 300 A or an equivalent approved method.

Measurement of the step and touch voltage.

20.9.5.6 Test Report

Five (5) copies of test reports of all standard tests as per IS: 3043 / IEEE-80,

performed subsequent to the date of award. All routine tests shall be certified by

the inspector and submitted to the Engineer within fifteen (15) days after test.

The Contractor shall bear the costs of furnishing these records and reports.

20.10 SMART ENERGY METER

20.10.1 BASIC REQUIREMENT

There are more approximately consumers in which 50 numbers are 3 phase and

balance are single phase consumers. Static whole current energy meters for single

phase and three phase domestic and commercial applications with 0.5 accuracy. The

energy meters shall conform to IS standard IS 13779-99/CBIP88 with IEC 62053-21,

IEC 1107 for optical fibre port. The energy meter shall have the provision for external

communication by using RS 232 port of IRDA for communication to a hand held unit or

AMR. Energy meter capable of detecting and recording anti tamper features including

neutral missing and abnormal voltage/ frequency protection.


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20.10.2 ADVANTAGES

(a) Timely availability of billing data for 100 % meters

(b) Reduce manual intervention

(c) Load reversal

(d) Billing history for 12 months

(e) Instantaneous voltage, current, load/ frequency

(f) Average power for 30 min interval

(g) Communication facility using optical port, infrared, RS 232

(h) Reduce operational and maintenance cost

(i) Detection of power outage

(j) Power failure log

(k) Detect pilferage and thefts

(l) Collect accurate base line data for consumption patterns

(m) Programming

20.10.3 RATING

Meter rating : As per customer requirement

Meter type :

Display : LCD

Meter class : 0.5

Power consumption : 1 W to 1.5 W

Application: Single phase / Three Phase

20.10.4 SYSTEM COMPONENTS

(a) LPRF module

(b) Hand held unit software (HHU)

(c) Data concentrator unit (DCU)

(d) Base computer software (BCS)

(e) Meter data management system (MDMS)

(f) SmartMesh – Optimized mesh networking algorithm

(g) Diagnostic tools


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20.11 SPECIFICATION OF FRP POLES WITH FIXTURES FOR STREET AND AREA LIGHTING

20.11.1 Scope

This specification covers the design, engineering, material, fabrication, ultra

violet protection, testing, inspection, packing, forwarding supply, delivery and

installation of Fibre Reinforced Plastic (FRP) composite street light and area light

poles, LED lights fittings complete in all respects for the street lighting system by

underground cables under the project. Exterior lighting shall be provided for

streets, parking areas, open areas developed areas, as per BEAP.

The composite pole supplied under this specification shall present the most

pleasing appearance possible consistent with strength, cost and serviceability

requirements. In general, the poles shall be circular in cross section.

20.11.2 Standard And System Conditions

20.11.2.1 The equipment covered in the specification shall conform to the underground street and area lighting with LED lights. The specification mentioned below shall be applicable to the materials, design and process used in the manufacture of these equipment. The standard specification mentioned below shall be applicable.


1. IS: 4091 Code of practice for design of foundations

for transmission towers and poles

2. IS1885 (Part 16)

Section 1,2 & 3

Electrical vocabulary Part 16 lighting,

Section 1 General aspects, Section 2

General Illumination, lighting fitting and

lighting for traffic and signalling, Section 3

Lamps & auxiliary apparatus.

3. IS:2551-1982 Danger Notice Plates

4. SP 30: 2011 National Electric Code

5. IS: 875-2015 Code of practice for Design loads (other

than earthquake) for Building and Structure

6. AASHTO LTS-4

Specification for Structural supports for

Highway signs, Luminaires and Traffic

signals

7. ANSI C 136.20-1990 Standard for Fiber-Reinforced-Plastic

(FRP) Lighting Poles


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8. ASTM D4923-01 Standard Specification for Reinforced

Thermosetting Plastic Poles (51)

9. ASTM G154-00a

Standard Practice for Operating

Fluorescent Light Apparatus for UV

Exposure of Non-Metallic Material (66)

10. ASTM D635-98

Standard Test Method for Rate of Burning

and/or Extent and Time of Burning of

Plastics on a Horizontal Position (67)

11. IS 2713-1980 Specification for Tubular Street Light Pole

and Overhead Power Line

12. IS 875 (Part 3) - 1987 Code of practice for design loads for

Building & Structures – Wind Load

13. ANSI 05.1 Standard Specification for Wood poles &

class of Poles

14. IS 6746 Polyester Resin System

15. BS EN 40-7:2002 Requirement for FRP Composites Lighting

column


Note: Only latest version of above standard shall be applicable. Any other

reputed International standard having performance equivalent to above shall

also be considered for acceptance.

20.11.2.2 System

FRP poles covered in this specification are required for the street and area

lighting purposes within thePMC-01 Project. The terrain is hilly and high speed

winds with salty environment are prevalent.

(a) The poles should give an attractive outlook as during the day, they serve

no other purpose. See BEAP for pole and lighting objectives.

(b) All the street and area lights shall be mounted on the top overhang and

shall be fed from a typical dedicated underground XLPE copper cable.

Contractor shall provide its arrangement for approval.


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(c) As during an accident a vehicle on road tends to move out of carriage way

and may hit the pole, accordingly the pole is proposed to be installed at a

distance not less than 1.5m from the edge of the carriage way.

(d) The width of carriage way is as per the road section provided, on which

these poles shall be installed for street light purposes.

(e) Each FRP pole shall have a 240V, 50Hz rated, single phase luminaire fitted

on the overhang. A 4 core three phase copper XLPE cable laid in an

underground duct shall enter into the pole up to junction box. There it shall

be looped out to next pole. An MCB shall be provided along with

disconnecting links for phase & neutral to isolate the supply to luminaire.

Isolating links shall also be provided to disconnect the power in the

incoming and outgoing cables so as to test the cables in case of fault

without disconnecting any cable from the terminals. There shall be a niche

for this purpose to house the above supply terminals, on a plate. This niche

shall be covered with removable cover, so as to give a uniform pole

appearance outside. Attaching any junction box to pole shall not be

acceptable.

(f) Pole shall be tested with the niche cut in the pole with cover removed.

20.11.3 Calculations

20.11.3.1 Contractor shall submit the necessary calculations for the size of poles with bracket selected and the provision of terminal box inside the pole. considering the wind load as 50m/sec. for the site, as per latest IS-875-2015 Part 3.

20.11.3.2 The lux levels with computer generated charts indicating the lux levels for the fittings provided, at locations around the pole shall be provided.

20.11.3.3 The required FRP pole strength must exceed the factored load as indicated in subsequent clauses.

20.11.4 General Requirement

20.11.4.1 Street light pole height and spacing for different width of carriageway shall be as per latest National Electrical Code, SP-30: published by Bureau of Indian Standards. Non-street lighting for other open areas in the development shall be installed at locations and heights as suggested in the BEAP, or as required to maintain a pleasant and safe community.

Lighting for streets is classified into the following groups:

Group A – For main roads

Group B – For other main roads which do not require lighting up

to group A standard


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Group C Lighting for residential and unclassified roads not

included in previous groups

Group D Lighting for bridges and flyovers if any

Group E Lighting for town and city centres

Group F Lighting for roads with special requirements, such as

roads near airfield, railway and docks

Corresponding to above the recommended pole heights as given in SP-30 shall

be adopted for the road width and types.

20.11.4.2 FRP poles shall consist of round conical tapered type poles having pleasant appearance with aluminium mast arms.

20.11.4.3 Pole should be designed to meet the testing requirements as are given for tabular poles in latest version of IS 2713.

20.11.4.4 Poles shall be hollow, tapered, non-conductive and chemically inert and shall conform to the requirements in "Standard Specifications for Structural Supports for Signs, Luminaires, and Traffic Signals" published by AASHTO, and ANSI Standard: C136.20, "Fiberglass-Reinforced Plastic (FRP) Lighting Poles."

20.11.4.5 Pole shall not deform under impact.

20.11.4.6 Adverse climates at site such as sea winds, high humidity, saline environment, soil with salt, shall have no effect on the life and capability of pole.

20.11.4.7 It should have pleasant look with smooth surface and finish.

20.11.4.8 Poles shall be loaded 300 mm below the tip.

20.11.4.9 FRP pole shall have anchor base with high grade non-corrosive aluminium alloy anchor and base plate. These shall be painted with same paint as that of pole. Fixing of the same to the concrete foundation shall be with stainless steel bolts or of any other non-rusting material (GI bolts are not acceptable). Holes shall be provided in base plate to drain water if required.

20.11.5 Design and Standardisation

20.11.5.1 The pole shall be designed to ensure satisfactory operation of the lighting system, in which continuity of service is the first consideration and shall also be designed to with stand sudden variations due to short circuits and fault conditions. The design shall incorporate all reasonable precautions and shall have necessary provision for the safety of all those concerned in the operation and maintenance of the lighting system.

20.11.5.2 The design, materials, fabrication, inspection procedures, shipping and assembly procedures for the composite poles shall generally conform to latest best


Page | 204


engineering practices. ASCE manual no. 104, “Recommended practice for Fiber-Reinforced Polymer Products for overhead utility line structures” may also be used as a general reference guide where appropriate.

20.11.5.3 To verify the ability of composite poles to meet given loading, deflection or other applicable requirements, structural analysis software, may be utilized to perform the analysis and overall structure stability (buckling) under combined loading.

20.11.5.4 The composite poles shall present the most pleasing appearance possible consistent with the strength, cost and serviceability requirements. The composite poles shall be symmetrical about the transverse and longitudinal axes, and any tapered filament-wound composite poles shall have a gradual and relatively constant taper rate from top to bottom.

20.11.5.5 The manufacturer shall certify that the composite poles meet or exceed the loading or other requirements, in accordance with applicable provisions of the Indian Standard which are applicable to tubular poles or other relevant standards and as verified by design calculations and/or full-scale testing.

20.11.6 Drawings

The contractor is to submit drawings and instruction manuals after award of

contract.

However after the award of contract the detailed drawings along with necessary

manuals are to be submitted (with any other particulars, the contractor may deem

necessary) for approval of Engineer. The poles shall be manufactured only after

the drawings submitted by contractor have been approved by Engineer in the

manner indicated therein, to incorporate the modifications suggested. The copies

of finally in built approved drawings shall be furnished along with the delivery of

poles.


Page | 205


20.11.7 Quality Assurance

20.11.7.1 The manufacturer of FRP Poles shall have an approved testing and quality control program for fabrication of poles.

20.11.7.2 The manufacturer shall conform to ISO 9001:2008, a recognized quality assurance program.

20.11.7.3 The manufacturer shall afford the Engineer reasonable opportunity, without charge, to allow them to verify that the finished products and materials being furnished are in accordance with the requirements in this specification.

20.11.7.4 Composite samples and details regarding the quality with the type of glass fibers and resins used along with the manufacturing process shall be submitted by the manufacturer, before fabrication for approval of Engineer.

20.11.7.5 In general manufacturer shall submit its quality assurance plan (before fabrication) to be approved by Engineer

20.11.8 Material of Poles and Manufacturing

20.11.8.1 All material used shall be new and of best quality and of class, most suitable for working under the conditions specified herein without distortion or deterioration.

20.11.8.2 The polyester resin binders used in the manufacture of the composite poles shall be of the highest quality and the material properties shall be submitted. Thermoplastic resin binders are not acceptable for use in the composite poles.

20.11.8.3 The fiber reinforcement used in the manufacture of the composite poles shall be minimum “E-Glass” with acceptable forms being continuous strand and /or fabric.

20.11.8.4 Fabrication shall be performed in accordance with the composite pole detail drawings. Material substitutions or deviations from the approved drawings shall not be made without prior written approval by the Engineer.

20.11.8.5 The composite poles shall be produced by filament winding. For the poles manufactured using filament winding, the wind schedule will include both circumferential and axial fiber placement in the pole wall laminate.

20.11.8.6 When required drilling of holes shall be done in such a manner as to produce cylindrical holes perpendicular to the plane of the pole.

20.11.9 Technical Data

FRP poles shall meet the following minimum technical criteria.

Density : 1.5 to 1.9 gm/cm³

Minimum E-Glass Fiber : 65% (By Weight)

Water Absorption : ≤ 0.5%

Tensile Strength : 200 M Pa


Page | 206


Bending/Flexural Strength : 250 M Pa

Compression Strength : 200 M Pa

Impact Energy : >180 KJ/m²

Dielectric Strength : 35kV / 25.4 mm

Overall length : 2 to 12 m

Top Dia (2-8m Poles) : 89 mm


Conicity (Slope to Determine bottom) : Approx. 10mm per

linear meter

Base Plate : Stainless Steel, with

GRP cover

20.11.10 Ultra Violet And Weathering Protection

20.11.10.1 General

The composite poles shall be manufactured with the best available protection

against UV degradation. The use of UV-stable “aliphatic” resins with pigment

additives is the preferred protection method. Resins enriched with UV inhibitors

and UV stable colour pigment additives are also acceptable. The use of standard

paint or coating for UV protection is not acceptable.

20.11.11 Mast Arms

Mast arms shall be aluminium alloy and shall conform to the requirements in

Aluminium Association Publication 30, “Specification for Aluminium Structures.”

The aluminium mast arm connected to the pole and with an approved luminaire

attached to it, shall withstand the vibrations as per the Standard.

20.11.12 Construction Detail

20.11.12.1 Poles shall be constructed from ultraviolet-resistant resin which shall be pigmented light gray and of uniform colour throughout the entire body of the poles. The poles shall be finished with polyurethane coating. The finish of poles shall be smooth.

20.11.12.2 Each pole shall have a niche to mount integral type junction box and the cover of niche shall bear the name of the owner. The box cover shall be securely attached to


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the pole with tamper-resistant hardware. The junction box bottom shall be located at about 750mm from the ground.

20.11.12.3 The base shall be bonded to the pole with a suitable adhesive and coated with an aliphatic-type acrylic-modified polyurethane finish.

20.11.12.4 Poles shall have a grommeted conduit / conductor entrance and exit located 600 mm (±25 mm) below finished grade after installation. The entrance shall be located directly below the junction box.

20.11.12.5 Each pole shall be provided with a removable non-corrosive aluminium pole top cap.

20.11.13 Exterior Protection & Spare Paint

An aliphatic-type acrylic-modified polyurethane coating shall be applied to the

exterior of the fiberglass pole. The coating shall be semi-gloss, highly weather

resistant and light gray in color matching the color of the resin and shall have a

minimum 0.075mm dry film thickness. A one litre can of the coating matching the

poles shall be supplied with poles for site touching. The polyurethane coating

shall be tested for adhesion to the pole surface in conformance with the

requirements in ASTM: D 3359, Method A and shall have a scale rating of 5A.

The adhesion testing shall be conducted before and after the accelerated

weathering evaluation.

20.11.14 Marking

The pole shall be marked with designation, height, strength, manufacturer’s

identification, date of manufacture, pole length and name of Owner. This marking

shall be at about junction box niche location for ease in reading.

20.11.15 Design Safety Factor

FRP shall be designed considering the safety factor for failure against

(a) Bending

(b) Torsion

The safety factor in each case shall not be less than 2 though ASTM D4923

specifies it to be 1.5. For this the manufacturer shall submit the calculations

before fabrication.

20.11.16 Testing

20.11.16.1 Visual Inspection

Each component of the composite poles shall be inspected for conformance to

the approved manufacturing drawings and drill patterns. The inspection shall

include, but not be limited to:

(a) Dimensional check to verify manufacturing tolerances are being met.


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(b) Verification that drilled holes do not have ragged or tone edges; and

(c) Aesthetic appearance such as colour consistency and surface roughness.

20.11.16.2 Deflection

Tests shall be performed with reference to ASTM D 4923.

(a) Limits of Deflection

(i) The pole deflection under dead loads, luminaire with arm load and

wind load, should not exceed 10% of the height of the pole through

ASTM D4923 permits 15% deflection.

(ii) 30mm/m maximum slope at top of the pole under dead load from arm

and attachments (maximum slope).

(iii) Deflection of 5% of the pole height under a force of 890 N lateral top

load. This is to ensure that pole will not deflect excessively even if

ladders are used by workers to access attachments.

(b) Method

(i) The lateral deflection shall be measured from the deflected tip end of

the pole along a line at 90° to the longitudinal axis of the un deflected

pole.

(ii) The junction box niche on the FRP pole should be placed on the

compression side of the pole and the niche cover shall be removed

during testing

(iii) Deflection shall be recorded with each 223N load increment.

(iv) The maximum permanent deflection after testing should not exceed

2% of the maximum recorded deflection of the pole during test and

this deflection should be recorded 5 minutes after unloading.

20.11.16.3 Torsion Test

This test shall be done as per method in ASTM D4923, but with a load increment

of 223N, with deflection recorded at each load increment.

20.11.16.4 Fatigue Test

Bending or torsional fatigue loads applied to the pole correspond to an equivalent

pressure of 110Pa. The fatigue load shall be applied for 106 Cycles, per minute

with no more than 200 cycles per minute.

20.11.16.5 Destructive Testing

Destructive testing of the pole for bending and/or torsion strength should be

performed after application of fatigue loads.


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20.11.16.6 Ultra Violet Weather Performance

The finished surface of the pole shall withstand a minimum of 2500 hours of

accelerated weathering when tested in conformance with requirements in ASTM

G154.

In this test Ultra Violet (UV) Bulb lamps with 313nm wave length and testing cycle

of 4 hours of UV exposure at 60°C and 4 hours of condensation at 40°C shall be

done. After testing the finished surface shall not exhibit fading, fiber exposure,

chalking, cracking or crazing as given below:

Fiber Exposure: None

Crazing: None

Chinks: None

Chalking: Very slight

Change in color: May dull slightly

20.11.16.7 Permanent Deflection

The pole with specified luminaire and mast arm installed, shall withstand the

bending strength test load with the maximum possible loading conditions as per

Indian Standard-IS 875. The pole shall not exceed a maximum deflection of 10

percent of the length of the pole above the ground line when subjected to

maximum wind load condition and not more than 1% permanent deflection.

20.11.16.8 Flame Resistance

FRP poles shall be flame resistant to prevent fire propagation due to short circuits

or oil spills. The specimen shall be tested as per ASTM D635 and fabricated with

the same material and process as that of poles.

The sample shall cease to burn before the gauge mask of 100mm is reached.

20.11.16.9 Dielectric Breakdown Voltage test shall be as per ASTM-D149.

20.11.16.10 Glass Content: Test as per ASTM D-2584-11.

20.11.16.11 Rejection of Material

Issues related to any material delivered under this specification, which as

mutually agreed by the manufacturer and the Engineer does not meet the

requirements set forth herein with regard to material, fabrication and testing the

poles shall be rejected without financial liability to the Owner under any

circumstances.


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20.11.17 Installation

20.11.17.1 Installation of FRP Poles shall be in conformance with the provisions for tubular steel poles, as per Indian Standard.

20.11.17.2 Cable Termination and Supply to Luminaire

(a) As indicated in specification, an integral type junction box is to be provided

in a niche in the FRP pole.

(b) The junction box shall have the following main items

(i) Terminal box for looping in & looping out, 3 phase, 4 wire copper

cable size of which shall be worked out by contractor for approval.

(ii) Single phase, 2 pole MCB of 2A, 10kA rating for luminaire.

(iii) 2.5mm², 3 core (3rd core for earth) copper connection to luminaire.

20.11.17.3 The junction box shall have a weather proof cover & to prevent entry of rain water in to junction box.

20.11.17.4 Provision for earthing terminal for the arm and associated LED fitting.

20.11.17.5 Cable Entry to FRP Pole

Main power cable for street light shall be laid in ducts both for entry to the pole

and exit from the pole. There shall be a small cable pulling box near the base of

the FRP pole.

In the concrete base of the FRP pole conduits shall be laid up to the niche in

FRP pole. So that the 4 core copper, loop in and loop out cables can be brought

in and taken out.

20.11.18 Bonding and Earthing

Each fiberglass-reinforced plastic lighting pole shall have its luminaire, mast arm,

and anchor bolts grounded in conformance with the earthing Specifications. A

separate bonding connection to the mast arm will not be required provided there

is a non-insulated contact between the luminaire and the mast arm.

20.11.19 Guarantee and Warranty

20.11.19.1 Guarantee

The composite poles shall be provided by a lifetime performance guarantee that

covers pole failure as a result of:

(a) The physical load of light fittings the weight of pole itself and the

attachment.


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(b) The direct force of wind from storm, tornadoes, hurricanes or blizzards that

has caused the failure of a composite pole mounted with fittings as per

designed wind load.

(c) A lightning strike on composite pole itself and/or an attachment.

(d) Damage to pole due to weather effects ultra violet radiation from sun light.

20.11.19.2 Warranty

The composite poles shall be covered by a minimum 25-year warranty against

manufacturing defects.

20.11.20 Packing, Shipping and Delivery

20.11.20.1 Each pole is spiral wrapped in its entirety with a weather proof wrap for protection during shipping at storage.

20.11.20.2 Reasonable care shall be taken to avoid damage to the composite poles during handling and transportation.

20.11.20.3 The manufacturer shall take all reasonable steps to ensure that the composite poles covered by this specification shall be delivered to the Owner’s designated storage facility during the period stated in the Contractor’s Proposal, or as previously agreed and detailed in the purchase order.

20.11.21 Lighting

20.11.21.1 Recommended Lux levels

Taking into account consideration of vision, criteria of quality, and characteristics

of sources and luminaries, table below gives the desirable level of recommended

illumination which is as per Institute of Urban Transport (IUT).

S. No. Particulars Required Illumination level

1 Main Roads 30 lux

2 Pedestrian Crossing 50 lux

3 Residential street lighting 1-10 lux

4 Cycle Track 20 lux

Table 25: Recommended Lux Levels

20.11.21.2 Lighting Fixtures with LED

LED type luminaries shall be used in the entire area. The following selection

criterial shall be used for selecting fixtures.


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(a) Luminaries selected shall be compatible to mast arm of the standard size.

(b) Luminaries shall pass the 3G vibration test as per ANSI C136.31.

(c) The housing shall be of non-corrosive material and the paint finish on the

same shall exceed the rating of six per ATSM D 1654 after 1000 hours of

salt spray testing in compliance to ASTM B 117. This is to ensure that finish

will not be dimmed in the coastal area.

(d) LED shall have colour temperature (Tc) of 4000k + 300k to provide a

“natural white” colour of light.

(e) Luminaires selected shall spread light downwards, producing zero light at

or above 90°. Lens shall be ultraviolet stabilised for high efficiency and

vandal resistance.

(f) The contractor shall provide lumens, efficiency, watts, Tc and Colour

Rendering Index (CRI) for prior approval. Lumens per watt shall be

maximum and the same shall be indicated in data sheet. Lumen/watt shall

be 110 or higher value shall be preferred.

(g) Luminaires shall be certified to be suitable for wet locations and

applications.

(h) LED lamps shall have minimum 5 years warranty.

(i) Electro Magnetic Interference (EMI) shall meet or exceed FCC 47 CFR part

15, Transient Voltage complies with ANSI C62.41 Cat C High. This is to

ensure that electronics in LED lamp will not interface with broadcast or

cable system.

20.11.21.3 Street And Area Lighting Arrangement

There will be main distribution board which will be dedicated to supply power for

street and area lighting feeder pillar. Each feeder pillar shall be capable to feed

supply 500 meter in either side. Not more than 1000W or 10 No. of light fixture

which one is earlier shall be kept on a single circuit. All the feeder pillar shall be

placed in such a location, which cannot be accessible to common public. All the

feeder pillar shall be IP-65 rated, dear front, front operated, form 4b type. Feeder

pillar construction shall be as per IEC-61439.

20.11.21.4 Lighting Management System

The lights shall be with astronomical clock device to automatically set the timings

for lights ON/OFF throughout the year.

Lighting management system shall be locally mounted in street light feeder

pillars.

Inefficient use of light may lead energy waste and create impact on burning hours

of luminary as well. To protect luminary from afore said point automatically light

control system is to be provided.


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A centralized solution shall be adopted for intelligent operation such that if

required alternate light poles can be switch on/off. Hardware modules shall be

installed in control cabinet (Lighting feeder pillars) and shall enable

communication from the central server location to control cabinet via fiber optics

cable. All the data is to send to the central server, where it is stored and

accessible for reports, fault rectification, load balancing and emergencies such

as accident, flooding etc.

The system shall be consisting of following typical components & modules:

(a) System Central Processing Unit (CPU)

This is the central processing unit of the module system. This will be

equipped with microprocessor unit and run on linux/ MS Window. Direct

communication between modules take place by means of an A-bus

interface, which is based on industrially proven RS-485 technology. The

CPU module serves as a WAN communications and data concentrator

module. Two-way communication with the central server takes place via

Ethernet, GPRS or SMS. The module will have the ability to automatically

switch between different available communication carriers in order to

provide the stable and reliable communication. Data are either delivered to

the server immediately or stored locally in the built in flash memory of CPU

module until scheduled delivery. Software and configuration can be

updated remotely from the server and stored on the CPU module enabling

it to autonomously execute tasks e.g. turn the street light on/off or collect

meter reading based on the configuration set up by the user. Voltage value

on all three phases of the main supply shall also be monitored by the CPU

module.

(b) Battery Module

Battery module is the client module in the system. It is a backup / UPS

module which are used for supplying other modules with emergency power

in the event of the failure of supply. This system will incorporate an A-Bus

interface which is based on the industrially proven RS-485 technology. The

A-Bus interface is used for power supply and for direct communication

between modules. The battery will be recharged with the power as long as

the battery is supplied with 12V from A-Bus interface.

If main power fails, battery will instantaneously take over the supply of A-

Bus. This will enable the CPU module to store data and send main power

failure alarm to the central server before it is shut down safely.

(c) Switch Module

Switch module is a client interface module in the system. It will consist of

two individually controllable relays. These relays are isolated and are used

for switching minor loads on and off directly and three phase or larger loads

via an intermediate breaker.

(d) Current Module


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The current module is a client interface module in the system. It will detect

asymmetrical earth leakage in electrical system and for monitoring current

changes in each phase. For this purpose, one leakage transformer and two

three phase current transformer are connected to the module. Leakage and

current threshold value can easily be configured to fit specific needs in web

application that will run on a central server. Current module will be used for

wide range of monitoring purpose. Power failure, cable breakage, street

lamp failure, leakage etc. are immediately reported to the central server.

(e) M-Bus Module

M-bus module is designed for two-way communication with M-Bus

compatible equipment from various manufacturers. It is used for two-way

communication with M-Bus compatible electricity meter. The M-module will

collect data reading and other data from the meters and subsequently

transfer these data to CPU module that act as a data concentrator. The

CPU module delivers the data to the central server when required. Direct

communication and power supply between M-Bus module and CPU

Module are handled by A-Bus interface which is based on RS-485

technology.

(f) Dimming Module

This module will allow increasing and decreasing the light and thereby

reduced electricity consumption. The light is dimmed from the control

cabinet, allowing making individual dimming setting for each sector. This is

useful in energy saving. Dimming shall be with Real Time Clock (RTC)

system.

(g) Fault Monitoring

When a fault is detected, an alarm is sent to the web platform, where all

faults are monitored and reported real time.

Typical faults that can be monitored are as given below:

(i) Under / over voltage detection

(ii) Main Breaker error

(iii) Contactor fault

(iv) Circuit Breaker off

(v) Main Power failure

(vi) Leakage to ground

(vii) Manual switch activated

(viii) Phase current out of range

(ix) Feeder pillars door open

(x) Flashing bulbs

(xi) Bulb failures


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20.11.21.5 POWER DISTRIBTUION FOR STREET LIGHTING

There will be installed a main distribution board which will be dedicated to supply power

for street lighting feeder pillar. Each feeder pillar shall be capable to feed supply 500

meter in either side. Not more than 1000 W load of all LED bulbs or 10 No. of light

fixtures, either of which is achievable shall be kept on a single circuit. All feeder pillars

shall be IP-65 degree of protection and front operated. Feeder pillar construction shall

be as per IEC-61439.

(a) ed pole.

20.11.21.6 415 V OUT DOOR LIGHTING CONTROL PANEL

(a) SCOPE

This section covers the detailed requirements for design, supply, installation, testing and

commissioning of 415 Volts, 3 phase, 50 Hz 4 wire system, street/ road light feeder panel

for road lights to switching ON/ OFF function.

(b) TYPE OF BOARD

The medium voltage panel shall comprise of the following type of switchgears as

specified. The panel shall be capable of fault withstand capacity of 31 MVA for duration

of one second up to 200 Amp rating.

The Panel shall be metal enclosed, outdoor type having incoming, sectionalisation and

outgoing switchgears as specified. The design shall be cubicle type. The degree of

protection for enclosure shall be IP 55.

(c) GENERAL CONSTRUCTION

The Panel shall be floor/ foundation mounted freestanding totally enclosed and non-

extensible type. The switchboard shall be dust & vermin proof with lockable

arrangement with degree of protection IP55 as per IS 2147 and shall be suitable for the

climate conditions as specified. The design shall include all provisions for safety of

operating and maintenance personnel. The general construction shall conform to IS:

8623 for factory assembled switchboard.

The panel shall be equipped with space heater with thermostat. Along with lamp for

lighting of panel controlled by door switch & MCB and also 6/16 A socket & switch

(d) CUBICLE TYPE PANEL

Outdoor type panel of approximate dimension 1200 mm (W) x 350 mm (D) x 1475 mm

(H) shall be fabricated out of CRCA sheet steel 2.5 mm thick (Load bearing Main Frame)


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with double door arrangement out of 2.0 mm thick. Sheet and canopy on all four sides.

Wherever necessary, such sheet steel member shall be stiffened by angle iron

framework. The general arrangement shall be got approved before fabrication. Cable

entries for various feeders shall be from the bottom. All cable entries shall be through

gland plates of 3 mm thick. There shall be separate gland plate for each cable entry so

that there will not be dislocation of already wired circuit when new feeders are added.

Cable entry plates shall therefore be sectionalized. The panel will be provided with 75x40

mm base channel to be painted in black to facilitate mounting on concrete platform

(e) INDICATOR LAMPS

On the incomer of L.T Panel, ON phase indicator neon type lamps shall be provided

suitable for operation on AC 230 Volts supply. Necessary filter G/Y/R/A shall be provided

depending upon the function. All lamps shall be protected by proper HRC fuses. Where

phase indicator lamps are provided, these shall be associated with necessary ON/OFF

toggle switch.

(f) SMALL WIRING

All small wiring controls, indication etc. shall be with suitable stranded copper conductor

cables PVC insulated conforming to IS: 1554 Part 1. Wiring shall be suitably protected

within the switchboard. Runs of wires shall be neatly bunched and suitably supported

and clamped. Means shall be provided for easy identification of the wires. Where wires

are drawn through PVC conduits, the works shall conform to IS 732. Identification

ferrules shall be used at both ends of the wires. All control wiring meant for external

connection is to be brought out on terminal block. All wiring shall be minimum 1.5 sq.

mm and for CT. Circuits it shall be 4.00 sq. mm. Brass/ copper thimbles, insulation tape

etc. shall be provided at joints and terminations as required.

(g) BUS BAR & BUS BAR CHAMBERS

Bus Bar and Connections

The bus bar shall be high conductivity copper alloy of E 91 grade and of adequate

section having current density not less than 1.0 Amp. / Sq. mm. Set of copper bus bar

shall be completed shrouded with acrylic sheet to avoid accidental touch. All connections

to individual circuits from the bus bar shall be with solid connections in case current

exceeds 63 Amp. All bus bars and connections shall be suitably sleeved with PVC or

suitably insulated in an approved manner. The bus bar temperature should not exceed

85 degree C i.e. 35 degree C temperature rise over 50 degree C ambient. The

calculation for temperature rise and bus bar sizing should be furnished along with shop

drawing for approval.

(h) BUS BAR SUPPORT AND ARRANGEMENTS

Supports


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Bus bar shall be firmly fixed on supports constructed from SMC (glass fiber reinforced

thermosetting plastic). The supports shall be sufficiently robust to effectively withstand

electro-mechanical stresses produced in the event of short circuit.

Connections to Bus Bars

The bolts and nuts used for connections to bus bars shall be of copper, alloy, and tinned

forged brass or galvanized iron. Suitable precaution shall be taken against heating due

to bi-metallic contact.

Further for tapping off connections from bus bars, VIR/PVC insulated wire may be used

up to current capacities up to 63 amps and for higher current capacities solid conductors/

strips suitably be insulated with PVC sleeves / tape as per requirement.

Clearances

The minimum clearances to be maintained for open and closed indoor air insulated bus

bars/ electrically non-exposed and working at system voltages up to 600 volts shall be

as follows:

Between ……………………………………………. Minimum Clearances

Phase to Earth………………………………………. 22 mm

Phase to Phase ……………………………………… 32 mm

Bus Bar Markings

The colours and letters (or symbols) for bus bars: -

Main bus bar connections and auxiliary wiring etc. shall conform to relevant Indian

Standard. A brief from IS 375-1963 (revised) is given below: -

For AC bus bars and Main connections:

S.No. Bus Bar & Main Connection Colour Letter/ Symbol

1 Three Phase

Red

R, Y, B Yellow

Blue

2 Single Phase Red R

3 Neutral Connection White N

4 Connection to earth Green G

(i) PHASE SEQUENCE AND POLARITY


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Bus bars and main connections, when marked shall be marked in accordance with the

following table to indicate the order in which the voltage in phases reach their maximum

values.

System As indicated by colour or letters Phase sequence as indicated vector ally

Three Phase Red, Yellow, Blue R, Y, B

Two Phase Red, Blue R, B

(j) ARRANGEMENT OF BUS BAR & MAIN CONNECTIONS:

Bus bars and main connections, which are substantially in one plane, shall be arranged

in order given as follows: -

(k) A.C SYSTEM

The order of phase connections shall be Red, Yellow and Blue.

When the run of the conductors is horizontal, the red shall be on the top or on the left or

farthest away as viewed from the front.

When the run of the conductor is vertical, the red shall be on the left or farthest away as

viewed from the front.

When the system has a neutral connection in the same plane as the phase connections,

the neutral shall occupy an outer position.

Unless the neutral connections can be readily distinguished from the phase connections,

the order shall be red, yellow, blue and black.

(l) TERMINATIONS

Incomer terminals shall be suitable for receiving cables.

(m) MOULDED CASE CIRCUIT BREAKERS

Moulded case circuit breakers shall comply with IEC 60947.2 & 13947 part 2. They shall

have the voltage and current ratings of 440 Volt & 200 Amp respectively whereas short

circuit breaking capacity and rated short – time withstand current should be as indicated

below.

The breaking capacity performance certificates shall be available for category A to the

above mentioned standards. The test shall be carried out under the breaking

performance during the ultimate breaking capacity (Icu), Ics rating=100% Icu. Certificate

for all the sequences (Sequence 1 mandatory) should be available.’

MCCB’s shall be of the independent manual closing air-break type, rated for an

uninterrupted duty.

Auxiliary facilities, including power closing and under voltage releases, shall be provided

as indicated.


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Each MCCB shall have a facility for padlocking in the “OFF” position.

Necessary set of CT’s together with an ammeter and selector switch as specified.

Necessary inter-connections to bus bars.

Necessary isolating plugs and sockets for front operated switches to enable withdrawing

the entire unit and replacing with another unit disconnecting the cable for maintenance

operation.

Each MCCB shall provide with a rotary operating mechanism.

(n) CONTACTOR

3 Pole contactor of 60 Amp rating type AC-1 should conform to IEC 60947-4-1, IS 13947

Various parameters shall be as under: -

Insulation voltage—690 V

Impulse withstand voltage (Uimp)—8 KV

Shock resistance 10/5 gn

Shock pick up @85—110% of control voltage

Should drop @30—60% of control voltage

Operating time—15 to 35 ms

(o) CURRENT TRANSFORMERS

Cast Resin current transformer shall be provided for main distribution boards carrying

current in excess of 60 amps wherever shown in drawing. All phases shall be provided

with current transformers of accuracy 0.5 and suitable VA burden to operate associated

metering.

Current transformers shall be in accordance with IS 2705.

(p) EARTHING

All components, frame etc. shall be properly earthed.

GI earth bars of 25 x 5 mm shall be provided for the LT panel for the full length of the

panel and connected to the framework. Provisions shall be made for connection from

this earth bar to the main earthing bar on both sides of LT panel.

The Streetlight Control System will be auto controlled with a solar based real time clock

/Timer with the following features.


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The system should have a provision for remote and local operation with a three-way

selector switch.

Street/Road Light Control Panel shall be equipped with the following: -

Sr. no.

Description Quantity

1 200 Amp. TPN insulated copper Bus Bar 1 set

2 200 Amp TPN. MCCB with O/C & E/F protection releases make Merlin Gerlin or L&T

1 no.


1 no.

4 24 Hours& 7days (Real Time Clock) digital Timer make 1 no.

5 415 V, TPN 200 Amp, service cutout 1 nos.

6 RYB indicating LED lamps with fuses & 1 set of ON/ OFF LED lamp make

1 set each (5 nos.)

7 Ammeter with selector switch 1 no.

8 3-pole contactor of 60 Amp. Rating with prescribed heavy duty, type AC-1 with 240 V AC coil

4 nos.

9

220 V AC, 2 Amps. 2 Pole MCB of 9 KA short ckt. Breaking capacity

1 no.

10

3 positions AUTO/ OFF/ Manual selector switch of suitable rating.

1 no.

11 Elmex make bolted type Bus Bar Terminals type CBT—100

24 nos.

12 Set of CTs (Cast Resin, Class 0.5, 200/5) – 3 Nos. 1 no.

13 100A TP strip fuse way with size - 00 'DIN' type 63A HRC Fuses make

4 nos.

14 Door switch (Snap action with push rod) make Kaycee / any reputed

1 no.

15 Push button make Telemecanique 2 no.

16 240V AC, power socket make Legrand/ any reputed 1 no.

17 240V AC, 60W bulkhead light make Reputed 1 no.

18 32A, 1P isolatable fuse carrier make – any reputed 4A, 10x38 Distribution fuse, Type gl-gg

4 nos.

19 4A, 10x38 Distribution fuse, Type gl-gg make any reputed

4 nos.

20 0-5 A Static/ Electronic KWH meter with set of CT’s 1 set

21 63A, 10KA TP MCB make – any reputed make 6 nos.

(q) PAINTING

All sheet steel shall undergo a process of degreasing, pickling in acid, cold rinsing,

phosphating, passivating and then sprayed with a high corrosive resistant primer. The

primer shall be baked in an oven. The finishing treatment shall be by application of two

coats of epoxy paint of approved colour and stoved.

(r) TESTS AT MANUFACTURERS WORK


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All routine tests specified in IS: 8623:1977 shall be carried out and test certificates

produced to the Engineer-in-charge. Typical type test certificate shall be furnished.

20.11.21.7 INSTALLATIONS AND COMMISSIONING OF STREET LIGHT CONTROL PANEL

The installation work shall cover assembly of various sections of the panels, lining up,

grounding the units etc. In the case of multiple panel switchboards after connecting up

the bus bars etc. all joints shall be protected with necessary insulated shrouding. A

common earth bar as per IS specifications shall be run at the back of switch board

connecting all the sections for connection to frame earth system. All protections and

other small wirings for indication etc. shall be completed before calibration and

commissioning checks are commended. All equipments, meters etc. shall be mounted

and connected with appropriate wiring.

Testing and Commissioning

Commissioning checks and tests shall include all wiring checks and checking up of

connections. Primary/ Secondary injection tests for the relay adjustment/ setting shall

be done before commissioning in addition to routine meggar test. Checks and tests shall


Operation checks and lubrication of all moving parts.

Interlock function checks.

Continuity checks of wiring, fuses etc. as required.

Insulation test: when measured with 500 V megger the insulation resistance shall not be

less than 100 mega ohms.

Trip test and protection gear test.

MAJOR COMPONENTS

The major components of the system have been summarized below with some brief

specification.

(a) Feeder Pillar: Feeder pillar shall be installed for distribution of power to

different light poles. Ref drawing no. GA& SLD of lighting control panel

(a) Power Factor correction: A poor power factor is a major (and avoidable) cost

factor. As such light fitting with in-built capacitor has been considered to

improve the system power factor to 0.90 lagging or better.

(b) Surge Protector : Surge protector shall be installed for individual lights or for

lighting circuit as per the design.

(c) Earthing: All light poles, feeder pillar and junction boxes shall be earthed as

per standards.


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20.12 CONTRACTOR’S REQUIREMENT

(a) Contractor should get Inspected all the works involved in the project, from the

CEI Govt. of Uttar Pradesh, duly paying the necessary requisite fees and

submitting the Certificate-Unless and until such clearance are obtained, the

commissioning activities will not be considered as completed.

(b) It is obligatory on the part of contractor that the guaranteed technical

particulars of all the equipments ordered on the vendors will be got approved

from the owner / DVVNL before effecting their purchase.

(c) The Contractor shall provide necessary drawings and documents required by

statutory authorities and obtain approval before taking up erection.

20.13 INSPECTION

All the bought out items/ equipments/ panels will be got inspected at Vendor’s

premises from the owner before it is transported at the site failing which it will be

treated as breach of contract.

20.14 DRAWINGS

The contractor will furnish three sets of all the drawings required for execution of

work after detailed design and engineering on the basis of SLD for approval to

the owner at the earliest but not later than one month after award of contract.

The owner/ consultant will approve the drawings within 15 days after receipt and

these approved drawings will be considered as GFC for execution at site.

Similarly all the drawings in respect of equipments to be purchased from

approved Vendors shall be submitted to owner/ consultant for approval and

these drawings. It shall also be approved within 15 days after receipt. Any

equipment purchased by the contractor without the approved drawing will be

treated as a breach of contract.

20.15 STATUTORY APPROVAL

Obtaining Approvals & Consents from relevant authorities like Chief Electrical

Inspectorate, State Electricity Board, PTCC, all statutory agencies etc like PWD

, NHA etc. However, any statutory fees paid by the contractor shall be

reimbursed against sub-mission of documentary proof.

20.16 SAFETY

Work is to be done on substations in operation; therefore, the following factors

are of paramount importance:

(a) Minimization of outage time

(b) Adaptation to operational constraints. All the work shall be conducted in

adhere to all instructions and safety rules approved by the DVVNL/Aligarh

Smart City Engineer –in- Charge.


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20.17 SPARES

Recommended spares: The Tenderer shall furnish in his offer a list of

recommended spares with unit rates for each set of equipment that may be

necessary for satisfactory operation and maintenance of circuit breaker and

Isolators for a period of 5 years.

The purchaser reserves right of selection of items and quantities of these spares

to be ordered. The cost of such spares shall not be considered for tender

evaluation.

20.18 TOOLS

The Tenderer shall submit a list and unit rates of all the special tools, equipment

and instruments required for erection, testing, commissioning and maintenance

of all electrical equipments. The purchaser shall decide the quantity of tools to

be ordered. Prices of these tools shall not be considered for tender evaluation.

However, the list of necessary tools/equipment which will be supplied free of cost

with each equipment may be furnished separately.

20.19 TRAINING

Provide training on CSS/ SCADA, telecommunications equipment to the

operation and maintenance staff of DVVNL/ Client.

20.20 CONSTRUCTION, ERECTION, TESTING AND COMMISSIONING

20.20.1 GENERAL

The Tenderer shall keep a competent Technical Person experienced in similar

works as Project-Manager and shall remain as overall in charge of Tenderer’s

work-site and also remain answerable to the Owner for all activities of the

Tenderer at site. Before his placement at site, the Tenderer shall submit his

resume to the Owner for his approval.

The Project-Manager shall supervise the work of all technical and specialized

staff including all section in-charge who is associated with work at site and or at

some outside place of fabrication for associated items; etc. He shall work in

complete harmony and co-operation with Owner’s engineers and manufacturer’s

engineers working at site. All statutory rules and labour laws prevailing in the

area must be observed by the Tenderer. All safety measures against occurrence

of accidents must be taken effectively. Project Manager shall not be withdrawn

without written permission of the Owner. If any of the Tenderer’s personnel is

found unsuitable for the job, the Tenderer shall remove him forthwith and a

suitable replacement shall be posted at site within a reasonable time without any

suffering to work. No compensation for withdrawal of unsuitable or unqualified


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person(s) from site or for posting suitable persons(s) to site at any stage of the

project shall be allowed by the Engineer - In - Charge.

• The Tenderer shall execute the works in a professional manner so as to achieve

the target schedule without any sacrifice on quality and maintaining highest

standards of safety and cleanliness.

• The Tenderer shall co-operate with the Owner and any other

Contractors’/Agencies working at site and arrange to perform his work in a

manner so as to minimize interference with other Contractors’/Agencies works.

The Engineer - In - Charge shall be notified promptly of any defect in other

Contractor’s /Agencies works that could affect the Tenderer’s work. If

rescheduling of Tenderer’s work is requested by the Engineer in the interest of

overall site activities, the Tenderer shall comply the same with. In all cases of

controversy, the decision of the Engineer - In - Charge shall be final and binding

on the Tenderer without any commercial implication.

• The Engineer - In - Charge may hold meetings of all the Tenderers /Agencies

working at Site at a time and a place to be decided by the Engineer - In - Charge.

The Tenderer shall attend such meetings if called upon to do so, take note of the

decisions of the Engineer - In - Charge and shall strictly adhere to those

decisions in performing his Work.

• The Tenderer shall be responsible for performance of his Work in accordance

with the specified construction schedule. If at any time the tenderer is falling

behind the schedule, he shall take necessary action to make good such delays

by or otherwise accelerate the progress of the work to comply with the schedule

and shall communicate such action in writing to the Engineer - In - Charge,

satisfying that his action will compensate for the delay. The Tenderer shall not

be allowed any extra compensation for such action.

• The works under execution shall be open to inspection and supervision by the

Engineer - In - Charge at all times. The Tenderer shall give reasonable notice to

the Engineer - In - Charge before covering up or otherwise placing beyond the

reach of inspection any work in order that same may be verified, if so desired by

the Engineer - In - Charge.

• The Tenderer shall comply with all the rules and regulations of the local

authorities, all statutory laws including Minimum Wages, Workmen

Compensation etc. All registration and statutory inspection fees, if any, in respect

of the work executed by the Tenderer shall be to Tenderer’s account.

• All the works such as cleaning, checking, levelling, aligning, assembling,

temporary erection, opening, dismantling, surface and edge preparation,

fabrication, machining, chipping, scraping, fitting-up, bolting / welding, etc., as

may be applicable in such erection and are necessary to complete the work

satisfactorily, are to be treated as incidental and the same shall be carried out by

the Tenderer as part of the work.


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• Equipment and material, which are wrongly installed, shall be removed and

reinstalled to comply with the design requirement at the Tenderer’s expense, to

the satisfaction of the Engineer - In - Charge.

• Throughout the period of construction of the Works the Tenderer shall maintain

the whole area of his operations in a clean, tidy and safe condition and shall

arrange his materials in an orderly manner, all the satisfaction of the Engineer.

• All rubbish, wooden planks, cable’s scrap, empty cable drums etc. shall be

systematically cleared from the working areas and, if not removed directly from

the Site, shall be deposited at general collecting points provided by the Tenderer

and agreed with the Engineer - In - Charge, pending removal from the Site.

Where practicable, screening shall be provided to prevent the ingress of dust

and dirt to any part of the Works. The Tenderer shall clearly state, in the

appropriate schedule, what provision is being made for disposal of waste

materials both on and off-site.

• The Tenderer shall not cause pollution of the Site land drainage system or any

water course by waste products from any source whatsoever. Whenever any

pollution is attributable to any act or omission on the part of the Tenderer, the

Tenderer shall clear the pollution as soon as possible and make early

arrangements to remedy the cause.

• The Tenderer shall make himself familiar with all statutory requirements relating

to the discharge of effluent from the Plant and shall take all steps to ensure that

these are not contravened by the disposal of effluent from the site. No dangerous

or noxious waste products, chemicals or materials shall be disposed of, on or off

the Site without proper treatment to make the quality comply with environmental

regulation.

• The Tenderer shall take all necessary measures to ensure the safe collection

and disposal of waste oils pertaining to those Works or plant for which he has

responsibility and to ensure the prohibition of any discharge of waste oils into

surface waters, ground waters or drainage systems of any kind and any deposit

and/or discharge of waste oils on to the ground or floors of buildings and any

uncontrolled discharge of residues resulting from the processing of waste oils or

the cleaning of oil contaminated surfaces with solvents.

• In the event that the Tenderer fails to comply with the above, the Owner reserves

the right to carry out such work on his behalf and to recharge accordingly.

• Damage to Public or Existing Site Roads

• The Tenderer shall carry out all repairs to damage to roads, drains, footways,

paved areas, boundary walls and fences etc. and clean all fouled roads and

paving etc., whether public or existing at site, caused by or in any way attributable

to the handling/transport of plant or materials by the Tenderer or any Sub-

contractor and indemnify the Employer against loss damage or claims by the


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Local Authority or others for damage to or fouling of roads, paving etc., by reason

of unusual traffic or other causes.

• Cleanliness of Public or Existing Site Roads. The Tenderer shall at all times

ensure that the public roads, giving access to site, are kept clean of any materials

deposited by traffic from the Tenderer or his subcontractors. The tenderer shall

also ensure dust suppression of site roads.

• The tenderer shall be responsible for the Watch and ward to ensure security and

safety of materials under the Tenderer’s custody.

20.21 ERECTION, TESTING & COMMISSIONING

20.21.1 GENERAL

The tenderer shall furnish all labour, supervision, consumable materials, tools and

tackle and services necessary for receiving, unloading and storing, transportation

pre-assembly at site, if required, complete erection, testing and commissioning of

all items included to complete the plant unit as specified in the specification.

Omission of any specific reference to any method, parts, accessories or materials

required for proper and efficient execution of the work shall not, in any way relieve

the Tenderer from his responsibilities from providing such facilities and performing

the complete erection, testing and commissioning at no extra cost to the Owner &

without any time over-run.

20.21.2 EQUIPMENT, MATERIAL & SERVICES TO BE PROVIDED BY THE TENDERER

i. Receiving of materials.

ii. Unloading of materials from ships, rails and other means of surface or air,

transport carriages, clearing from ports and customs.

iii. Transportation / shifting of unloaded material to storage area.

iv. Proper stacking and storing of materials under Tenderer’s custody.

v. Checking of all materials with shipment list/consignment note, reporting for

missing or damaged items, repairing damages and cleaning before

erection, claiming from insurance agencies etc. Preservation of plant &

equipment at storage area/ site.

vi. Maintaining proper record of the materials and place of storage for quick

identification as and when required.

vii. Issue of materials from stores and maintaining detail account of the same

as required.

viii. Transportation / shifting of material from stores to erection site.


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ix. Final adjustment of foundation levels by chipping and dressing, checking

location, elevation etc. of anchor bolts and grouting of anchor bolts and

base- plates.

x. Pre-assembly at site after proper checking / overhauling as required.

xi. Erection and subsequent cleaning/flushing as required, re-commissioning

check to ensure correctness of erection.

xii. Testing and commissioning services as required.

20.21.3 MAN / MATERIAL SUPPLY

The Tenderer shall furnish all labour (supervisory, skilled, unskilled and

administrative), all consumable materials, transport vehicles, mobile cranes, other

lifting devices, hydraulic jacks, all erection tools, tackles and equipment, precision

levels including micro levels, dial and other gauges, surface plates, straight edges,

special tools like hydraulic crimping tools, blowers, cable rollers, jack all other

necessary implements such as shuttering materials in sufficient numbers as may

be required for timely and efficient execution of the contract. The materials

supplied shall be of the best quality, the specification and quality of which have to

be as per agreement and or otherwise added by the Engineer - In - Charge.

20.21.4 SUPERVISION DURING ERECTION

The Tenderer shall be required to provide, at proper time, the necessary

supervisory engineers, supervisors and other supervisory personnel duly qualified

and in sufficient number for transportation, erection, pre-commissioning and post

commissioning check-up, start-up, trail operation, testing and commissioning of

yard / plants and equipment.

20.21.5 SEQUENCE OF ERECTION WORK

All packing cases and packages shall be opened in presence of the Engineer -

In - Charge or his authorized representative. Timber packing cases shall be

carefully opened to avoid damage to materials or timber. Nails and packing strips

should be pulled out with suitable appliances and kept separately in a container

and not thrown away at random. All timber of packing cases shall have to be sorted

out and stored properly at a suitable place as directed by the Engineer - In -

Charge. From time to time packing materials, timber, nails and strips shall be

delivered back to the Engineer - In - Charge or otherwise disposed of as directed

by the Engineer - In - Charge. The timber reclaimed from the packing cases or any

other material shall not be used by Tenderer for rendering facility in the erection

work or any other job without prior permission of the Engineer - In - Charge.

All timber and packing materials shall remain the property of the Engineer - In -

Charge.


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Each material after stripping from boxes or received loose, shall be carefully

inspected, checked with shipping list and identified with erection drawing if

necessary. The Tenderer shall be completely responsible to make all necessary

arrangements, application and follow procedure to process claim on underwriters,

obtain replacement/repair/rectify and modify as required of all such

damaged/defective/lost equipment and material at no extra cost to the Engineer -

In - Charge in order to execute the work in satisfaction to the Engineer - In - Charge

within the stipulated contract time.

Once the materials are inspected, the same shall be preserved properly and

adequately protected from theft and deterioration or damage due to rain, storm,

dust, and water, tampering by causal visitors or workers. The Tenderer shall

prepare and maintain stores, ledgers and bin cards for all materials in his custody.

Carrying out all repairs to damages that might have occurred during transit and in

subsequent storage or handling and modifications and rectification work and

replacement of all lost parts, are under the Tenderer’s Scope. All modifications and

rectification work and replacement shall be carried out in the presence of Engineer

- In - Charge.

20.21.6 ERECTION

a. Erection work shall be carried out in the manner and sequence as may be directed

by respective equipment manufacturer’s supervisory engineers and the Engineer -

In - Charge. The work shall be carried out as per applicable specifications, codes of

practice including drawings and instructions of Engineer - In - Charge where

applicable.

b. As erection proceeds each assembled part before being boxed up with a view to

erecting it finally shall be inspected and approved by the concerned supervisor.

Should any defect be found out during such inspection, the Tenderer shall make it

good as per directives from Engineer - In - Charge.

c. The equipment shall be placed on respective foundation or support, levelled and

aligned with precision measuring instruments, checked for proper clearance

between moving and stationary parts wherever applicable and grouted on the

foundation.

d. All fabrication and engineering work incidents to erection like scaffoldings, structural

forming for pre-assembly, transport and erection etc. shall have to be done by the

Tenderer at his own cost. The structural steel required for such work shall be

arranged by the tenderer. Also, any fabrication work like cutting, grinding, welding,

fitting up etc. which in the opinion of the Owner are incidental to the erection at site

shall have to be done by the tenderer. Any defect in the fabrication shall have to be

rectified by the Tenderer at his cost without any commercial/contractual implication.


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e. Particular attention shall be given towards removal of buckles and other forms of

distortion.

f. Holes in plate work to assist in erection should be avoided. Lugs required for

erection shall be removed and projections of weld shall be chipped and ground flush.

g. All equipment shall be safe guarded from wind or other external causes by providing

suitable steel cables/guys until completion of erection.

h. Welding sequence shall be adopted in such a way so as to minimize distortion due

to weld shrinkage and shall be got approved from the owner prior to commencement

of work.

i. Welding shall not be carried out on wet surfaces and shall be protected from high

winds/rains water.

j. All materials such as electrodes, gaskets, bolts, nuts, etc. shall be of reputed make

and conforming to relevant Indian Standards. Prior approval of Engineer - In -

Charge shall have to be obtained before commencement of work. Manufacturer’s

test certificate shall have to be provided when called for.

20.21.7 EQUIPMENT INSTALLATION & WORKMANSHIP

The equipment installation and workmanship shall be as follows:

20.21.7.1 ASSEMBLY OF EQUIPMENT

i. Units, which due to weight, size or other consideration arrive in a disassembled

state, shall be assembled at site.

ii. Protection of equipment from damage, dust and exposure to corrosive factors

shall be a prime consideration throughout the period of installation,

commissioning and final handling over to Engineer - In - Charge.

iii. Prior to installing equipment, related work of other trades shall be inspected to

ensure that anchor bolts, inserts, sleeves, openings, foundations etc. are

provided at the proper time and in the correct locations and at the correct level.

20.21.8 LUBRICATION

i. The Tenderer shall be responsible for the lubrication requirements of all

equipment from the initial run to final lubrication before handing over to Engineer

- In - Charge. All lubrications shall be supplied by the tenderer for the equipment

supplied by them.

ii. Equipment shall be lubricated in accordance with manufacturer’s

recommendation.

iii. Bearings for driving and driving and driven equipment shall be checked and

lubricated in accordance with the manufacturer’s instructions.


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iv. All packing, glands and flange joints shall be checked and tightened as

necessary during trial runs and commissioning. Should any packing or gasket or

gland require renewal or replacement during the period, such renewals shall be

made by the Tenderer from the materials to be supplied by him.

20.22 SAFETY REGULATIONS

a. Only scaffolds which meet the requirements of any governing laws shall be used

in the projects.

b. All burning and welding equipment shall conform to, and be used in accordance

with, regulations governing such equipment. No burning or welding shall be done

at any place on the site until location where such work is to be done is approved.

Welding near/at/in hazardous areas (like gas/oil etc.) shall be done only after

having all the fire protection/fighting equipment at hand.

c. Adequate fire protection shall be available before work shall proceed.

d. All warning signs shall be observed.

e. Use of explosives shall comply with all regulations.

f. Tenderer shall require his employees/staff/ workers to wear hard hats of ISI mark

at all times at the site of work.

g. Goggles shall be worn whenever there is a possibility of flying particles or

splashing corrosive fluid and during the gas cutting and welding.

h. Safety belts shall be used by men working in high places (above 3mtrs high).

i. Any loose materials like cotton/jute/oiled clothes etc. shall not be thrown hither

and hither and thither but dispose to safe places to avoid any accident/fire etc.

j. Tenderer shall be solely responsible for the dissemination of all safety

regulations including those written here, those promulgated by Owner and those

dictated by good practice, and shall ensure that all his employees and those of

his subcontractors and conversant with same.

20.23 INSPECTION

i. All works to be carried out by the Tenderer shall be subjected to inspection by

the Engineer - In - Charge as well as statutory authorities. The Tenderer shall

provide necessary facilities, instruments, personnel etc. for carrying out the

inspection as above the shall comply with the instructions given.

ii. After completion of erection and/or installation and before start-up, each item and

equipment and all its appurtenances shall be thoroughly cleaned and then,

inspected in the presence of Engineer - In - Charge for correctness, soundness

and completeness of installation and acceptability for start-up.

iii. A checklist in triplicate shall be furnished for the approval of Engineer in-charge

wherein all items to be checked and necessary instructions shall be listed.

Inspection and checking shall strictly follow this checklist. On conclusion of the


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Joint Inspection and checking (2) copies of the inspection report shall have to be

handed over to the Engineer - In - Charge. The report shall have to be jointly

signed by the Tenderer’s supervisor and the Engineer - In - Charge to ensure

that all inspection and checking have been properly carried out. However, such

endorsement by Engineer - In - Charge shall not relieve the tenderer from the

responsibility in ensuring proper erection/installation.

20.24 PRE-COMMISSIONING TEST

i. After verification of correct installation, Plant/ equipment material shall be subject

to a program of pre-commissioning tests. All equipment including tools, tackles,

instruments, test kits etc. and required manpower shall be made available by the

tenderer. Pre-commissioning tests shall include operational and functional tests,

measurement of parameters such as IR values/ Earthing resistance etc, relay/

meter calibration, high voltage tests etc. the list of pre-commissioning tests shall

be prepared by tenderer and got approved by Engineer - In - Charge.

ii. The tenderer shall prepare test records for each equipment and after conclusion

of tests, it shall be his responsibility to prepare required copies of test records

and get them counter signed by the Engineer - In - Charge.

iii. Any defects brought to light during these tests shall be recorded in the test

records and Tenderer shall rectify the same.

20.25 START- UP (PRE- COMMISSIONING)

i. On completion of erection of the equipment material and before the start-up,

equipment shall be inspected by the Engineer - In - Charge and the Tenderer for

correctness and completeness of installation and acceptability of start-up,

tending to initial pre-commissioning tests at site. The list of pre-commissioning

tests to be performed shall be as mutually agreed and included in the Tender’s

quality assurance programme.

ii. The Tenderer’s Engineers for commissioning and start-up specifically identified

shall carryout all the pre-commissioning tests at site. On completion of

inspection, checking and after the pre-commissioning tests are satisfactorily

over, the complete equipment shall be placed on initial operation during which

period the complete equipment shall be operated integral with sub-systems and

supporting equipment on no load, on successful completion of which the Owner

will issue Preliminary Acceptance Certificate.

20.26 COMMISSIONING

i. The electrical equipment shall be energised after rectification of all defects

noticed during the site inspection/ Pre-commissioning tests and after tenderer

has obtained approval from statutory bodies for the installation, If required, the

system may be energised in parts and for short duration of time to establish the

correctness/ healthiness of the equipment material. These shall be deemed as

trial runs of the equipment.


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ii. The complete installation shall be deemed to have been commissioned

successfully if the entire installation operates without any defect for a continuous

period of 72 hours over any period of 6 (Six) days. Any defects brought to light

during the test run of 72 hours shall be rectified by the tenderer.

iii. The tenderer shall maintain records of the measurements, minor repairs carried

out the trial run of the Plant/ continuous test run of the plant and get the same

certified by Owner. Required copies of these tests-records shall be submitted by

the tenderer.

iv. After successful commissioning including of defects, submission of test reports/

records, submission of O&M manuals etc., the plant system/ work will be taken

over by the Engineer - In - Charge and will operated by the Engineer - In - Charge

expect otherwise mentioned in the project B.O.Q. and or in other conditions.

v. Final Acceptance Certificate will be issued by the Engineer - In - Charge on

successful commissioning and after the tenderer has completed all his

obligations.

20.27 ENGINEERING SERVICES

20.27.1 GENERAL

The Tenderer shall be responsible for providing all equipment, material and

services including design and construction of all works specified or otherwise

which are required for a complete project as per agreement meeting the intent of

this specification, ensuring high degree of reliability, availability, operability and

maintainability. The equipment, system/sub-systems and components shall

conform in all respects to high standards of engineering, design and workmanship

and shall be capable of performing in continuous commercial operation in a

manner acceptable to the Owner and shall also be in line with the current practices

for reliable and efficient functioning of plants of similar size and rating.

The Tenderer shall render complete engineering services for the project including

complete detailed engineering, design submission and documentation as specified

and as required for a good design and installation ensuring efficiency, operability,

availability, maintainability and reliability of the plant and efficient archiving of plant

documentation for future reference. As part of the overall project management

activity, the Tenderer shall be responsible for proper engineering, co-ordination

and management during various phases of execution of the contract.

At any stage during the performance of the work, the Owner may require up-

gradation/improvements in the Contracted Plant and consequent modification in

the equipment/system designs in view of additional information available at a later

date(s) or feedback(s) received during execution / operation of similar units. If so

desired by the Owner, the Tenderer shall make the necessary design modifications

and carry out the up-gradation/improvements in the Plant. Commercial and time


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implications of such action shall be mutually agreed between the Owner and the

Tenderer.

It is not the intent to give details of every single task to be carried out by Tenderer.

However, all engineering, supply and erection of plant and equipment work

required for the satisfactory completion of the plant / systems as specified shall be

carried out by the Tenderer. Broadly, the following are the minimum requirements

in respect of scope of major items of work.

i) Tenderer shall submit design calculations, criteria for selection and

sizing of equipment and systems, for approval by the Owner/Consultant.

ii) Interface engineering and complete coordination work among various sub-

vendors of equipment / packages included in the Tender’s scope.

iii) Preparation of detailed technical specifications including data sheets, tender

drawings and bill of material for all bought out items, as also finalization of

corresponding sub-contractors.

iv) Review of sub-contractors data, drawings, design calculations, schedules, bill of

materials, instruction manuals etc., for all equipment, before forwarding them of

Owner/consultant for approval.

v) Preparation of civil construction drawings for all works including if any buildings

and equipment showing foundation details and full details regarding equipment

loads, floor openings, details of embodiments etc. these documents shall be

preceded by appropriate design calculations, static and dynamic analysis as

necessary.

vi) Preparation of consolidated schedules and bill of materials.

vii) Sizing of all equipment as per the stipulated design criteria to meet the

requirements.

viii) Final revision of all documents.

ix) Preparation and compilation of operating Manuals and Maintenance Instructions.

x) Preparation and submission of certified final as-built drawings and documents.

xi) Preparation and submission of all erection and assembly drawing schedules and

instructions, which may be required at, site.

xii) Preparation and submission of procedure strategy for erection of major

equipment taking into consideration the layout of plant and auxiliaries.

Electrical Drawing / design data

i) Levels of different voltage grade, Transformer details, metering and protection

with CT / PT cores / ratio / burden / accuracy class.

ii) Complete BOQ of the project with technical details.

iii) Single Line Diagram of 415 V AC Distribution board


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iv) Single Line Diagram of 11KV distribution system

v) Overall Site Layout Plan

vi) Maximum & Minimum fault level calculation

vii) Insulation coordination.

viii) Switchgear/Control building layout – Plan.

ix) Cable duct routing, layout Plan & Section – outdoor.

x) Cable duct layout Plan & Section – Indoor.

xi) Sizing calculation of HV& LV Cables

xii) Power cable & Control cable schedules.

xiii) Cable tag marking concept.

xiv) Earth design calculation based on actual site soil investigation.

xv) Outdoor equipment grounding arrangement and details.

xvi) Outdoor Illumination system design Calculation.

xvii) Drawing of Outdoor Illumination with erection details.

xviii) Cabling, earthing & lightning concept

xix) CSS, Lighting pole, Feeder Pillar, Transformer foundation details

xx) Relay setting with calculations.

xxi) Material inspection report

xxii) Pre commissioning / commissioning reports of all equipments

xxiii) As built documentation of the drawing / documents

Minimum three sets of drawings / documents are to be submitted unless specified otherwise.

20.28 QUALITY MONITORING AND ASSURANCES

20.28.1 GENERAL:

All materials, components and equipment covered under the technical

specification for this Project shall be procured, manufactured, tested, erected and

commissioned as per a comprehensive Quality Assurance Programme. It shall be

the primary responsibility of the Tenderer to draw up and implement such a

programme, which shall be duly, approved by the Engineer - In -

Charge/Authorised Inspection Agency.


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The detailed Quality Assurance Plan (QAP) for manufacturing and testing of

equipment shall be prepared by the Tenderer and submitted for approval by the

Engineer - In - Charge/Authorised Inspection Agency.

20.28.2 INSPECTION AND TESTING

The material shall be inspected by the Engineer - In - Charge/Authorised

Inspection Agency at manufacturer’s works prior to dispatch. The material will be

inspected as per the tests pre-identified in the approved QAP to ensure conformity

of the same with relevant approved drawings, data sheets, technical specification,

National / International Standard.

• The Tenderer shall furnish all relevant documents and test Certificates as

required by the Inspection Agency during inspection.

• The Inspection Agency shall have the right to demand for re-testing of

any material / re-calibration of the instrument and testing machine & the

charges for the above will be borne by the Tenderer.

• Performance tests of any particular equipment which cannot be

conducted / demonstrated either partially or wholly at the manufacturer’s

works, shall be conducted after erection at site in presence of Engineer -

In - Charge/Authorised Inspection Agency. In such cases, prior approval

of the Engineer - In - Charge shall be obtained.

• No equipment shall be dispatched before inspection and issue of

Inspection Certificate and dispatch clearance from the Engineer - In -


• The issue of Inspection Certificate / Waiver Certificate for any material or

part thereof does not absolve the Tendered from his contractual

obligations towards subsequent satisfactory performance of the

equipment at site. Should any equipment be found defective, in whole or

part thereof after receipt at site or during erection / commissioning and

testing shall be made good by the Tenderer at free of cost.

20.28.3 OPERATING MANUALS AND MAINTENANCE INSTRUCTIONS

i. The Tenderer shall submit to the Owner, instruction manuals for all equipment

/ system / material covered under the contract at least thirty (30) days before

the first dispatch of the equipment.


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ii. The operating manuals and maintenance instructions shall be in sufficient detail

to enable the Owner to operate, maintain, dismantle, re-assemble, adjust or

replace all equipment and components during the life time of the plant. The

manuals shall be specifically prepared for the contracted plant. Only a collection

of manufacturer’s standard leaflets shall not be acceptable as the manuals.

iii. The operating manuals and maintenance instructions manual shall be

submitted in the form of one (1) reproducible original and two (2) copies.

iv. The information provided shall include:

v. A complete inventory of all items of plant, with identification details; procedure

for ordering spares.

vi. Service manuals for equipment giving full descriptions, drawings and

specifications of the main items and auxiliary items.

vii. A schedule of recommendations of routine maintenance of all electrical

equipment, recommended inspection point, information on detection, cause

and rectification of troubles and faults

viii. Manufacturer’s literature.

ix. The instruction manuals shall be subject to the approval of Owner.

x. If after the commissioning and the initial operation of the plant, the instruction

manuals require modifications/additions, the same shall be incorporated by the

Tenderer and the updated final version of the manuals shall be submitted

20.28.4 “AS- BUILT” DOCUMENT

The Tenderer shall provide and keep up to date “As built drawings” of all works

including civil and structural works constructed and all equipment and accessories

and miscellaneous metal works erected or installed. These drawings shall show

all changes and revisions from the original drawings and specifications, including

the exact “As-built” locations, sizes and kinds of equipment and accessories,

miscellaneous metal works, embedded piping and electrical systems and other

concealed items of work. These drawings shall be kept in Tender’s field office but

shall be made available at all times for review of the Engineer. At the end of every

work, all entries, changes or revisions made in the drawings by the Tenderer shall

be checked and approved by the Engineer. One soft copy of all

“Drawings in CD”s and Reproducible prints with requisite copies of all “As-built”

drawings shall be progressively handed over to the Owner after taking over of the

plant by the Owner.


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20.28.5 PROJECT HANDBOOK

The Tenderer shall submit to the Owner, a project handbook which shall contain

all approved design basis and design calculations, the design and performance

data of various plant, equipment and systems covering the complete project

including single line diagrams, etc. prior to handing over the plant.

The project handbook shall be submitted in three (3) copies in original and Compact Disks

(CDs).

20.29 LIST OF PREFERRED MANUFACTURERS

The list of “Preferred Equipment Manufacturers” is as given below:

S. No. Description Make

1. 33/11kV Transformer Schneider / BHEL / ABB / Bharat

Bijlee / EMCO / Toshiba

2. 33kV & 11kV Gas Insulated

Switchgear

Schneider / Siemens / ABB

3. 11/0.4kV Distribution

Transformer (As part of

packaged RMU substation)

BHEL / Crompton / ABB / GE/

Voltamp

4. SF6 gas insulated RMU (As

part of packaged RMU

substation

BHEL / ABB / Siemens / Schneider

5. Enclosure (as part of


Schneider / Siemens / ABB / BHEL

6. LT Switch Board (As part of



7. CTs and PTs AE / Kappa / Siemens / Crompton /

ABB / Schneider/ Gilbert & Maxwell/

Pragati

8. Insulators BHEL / Jai Shree / WSI

9. Protective Relays (for

Packaged substation)

Alstom / Siemens / ABB / Schneider

10. DC batteries / POWER

PACK

Exide / Amar-Raja / HBL

11. Battery Chargers Amar-Raja / Exide / AE /HBL


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12. H.T. Cables CCI / Universal / RPG / KEI / Finolex

/ CMI

13. L.T. & Control Cables CCI / Universal / RPG / KEI / Finolex/

CMI

14. Lighting Cables Kalinga / Delton / Finolex / Havells /

KEI

15. Lighting Fixtures Phillips / GEC / Bajaj / Crompton /

Wipro

16. H.T. & L.T. termination kits Raychem / CCI / M-

SEAL/Denson/Birla-3M

17. Light Poles Bajaj / Valmont / Sumip

18. Smart Energy Meters ABB / Schneider / L&T / Secure

Meters / Automatic Electric

19. HV and LV bushings BHEL / Jayshree / WSI / CGL / SSB

21. Cable Glands HMI / Gripwel / Comet/ Baliga

Lighting/ Cosmos / Dowells

22. Cable lugs Dowells / AMP (Tyco Electronics) /

Comet / Cosmos / Hax Brass

(Copper alloy India)

23. PVC terminals & terminal

blocks

ELMEX / ESSEN / Phonix / Connect

Well / Wago

24. Semaphore Alstom / ABB / Siemens / Schneider

25. Modular type switches Wipro North West / MK / MDS /

Schneider / Legrand/ ABB Lumina

26. Indicating meters AE/ Schneider/ABB/ Secure

27. Pushing button & indicating

light

L&T / BCH / Siemens / C&S/ Altos /

Schneider Electric / Siemens /

Teknik

28. Selector & Control Switches Alstom / Siemens / Kaycee / Salzer

(L&T) / Schneider

29. MCB, MCCB & LT Breaker Legrand / Siemens / ABB /

Schneider / Mitsubishi

30. Switch Sockets & Modular

type receptacles

BCH / Crompton / Schneider / ABB

Lumina / Wipro North west/ Legrand


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31. MCB distribution board Siemens / ALSTOM / Schneider/

ABB / Legrand /Mitsubishi

32. Lighting panels Siemens / Schneider /ABB OR Their

authorized system integrator

33. Indicating Lamps Siemens / BCH / Tecnic / Schneider

/ Altos

34. Contactors L&T / Siemens / ALSTOM /

Schneider / ABB

35. Portable Fire Extinguishers Minimax / Mather Platt / Ceasefire

36. SCADA including

Communication equipment

ALSTOM / Schneider / ABB /

Siemens

37. DG Set with AMF Panel Cater Pillar / Kirloskar / Sudhir /

Cummins / Sterling Generators

38. Underground HDPE Ducts Duraline, Bajaj, Reliance

39. Feeder Pillar Schneider, Vidhyut, Siemens, ABB,

C&S

40. 11/3.3kV Transformer BHEL / Crompton / ABB / GE/

Voltamp

41 11kV RMU Siemens / ABB / Schneider

42 Fire Alarm System Edward EST3 / Honeywell-XLS

Series / Siemens Fire Finds Series /

Simplex / Notifier

43 Fire Suppression Novac / Inergen / Ansul

44. UPS Socomac / Mitsubhishi / Emerson

Network Power / ETON

45. Cable Tray RMCON / Profab / OBO Bellerman

46 GIS Panels Termination Nexans / NKT Cables / Raychem /

Sudkabel / Pfisteres

47 Earthing Erico/Terrect/Jef echo safe

48 MCC/LT Panels/PDB /

ACDB / DCDB

ABB/ Schneider/Siemens / Sterling

Generator OR their Authorised

System Integrator

49 Conduit AKG/BEC/Polycab/Polypack

Table 51: Preferred List of Manufacturers / Vendors


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21. Electrical brief – Smart Road

21.1 ELECTRICAL SYSTEM

21.1.1 GENERAL INFORMATION

21.1.1.1 EXISTING POWER DISTRIBUTION

(c) There are predominantly two 33/11kV substations in vicinity to the smart road

stretch from where the lines are emanating or terminating. These two

substations are namely, Ghanta Ghar substation & Lal Diggi substation both

are under EUDD-IV.

(d) Power supply to the smart Road from Ghanta Ghar junction till University

Junction area is fed from 33/11 KV Ghantaghar Substation and 33/11kV Lal

Diggi Substation through 11 KV Overhead line.

(e) There are various overhead lines crossing and or passing through the smart

road section namely 11kV, 33kV (HT) power lines & 415V (LT) power lines.

(f) Ghanta ghar substation feeding power to 11kV Government press feeder ,

11kV Sudhama puri feeder, 11kV central point feeder, 11kV Railway feeder,

11kV Jail feeder and 11kV Anup shehar, however Lal Diggi substation

feeding power to, 11kV Substation Colony feeder, 11kV Gol market feeder,

11kV Ameernisha feeder, 11kV Laxmi bai marg feeder, 11kV Marris road

feeder and 11kV Hathi Dua feeder.

(g) 1 no. 33kV line from Sarsaul to Ghanta Ghar substation are passing through

smart stretch from University Circle to BSNL Circle.

(h) 3 nos. of 11kV outgoing feeders are passing through smart street stretch from

Ghanta ghar substation these are Marris Road, Laxmi Bai marg and

Government press Feeder.

(i) 4 nos. of 11kV outgoing feeders are passing through smart street stretch from

Lal diggi substation to Marris Road, Laxmi Bai marg, Substation and Hathi

Dua.

(j) 1 no. of 11kV outgoing Abdulla Girl College feeder are passing through smart

street stretch from IG Khan Circle to University Circle.

(k) LT lines are running along the median in the smart street stretch.

(l) There are approximately 09 nos. 11KV/415 V transformers feeding the LT

consumers. There are some 11 KV consumers. Some transformers are

installed on two pole structures and some transformers are installed on

foundation.

(m) The capacity of most of the 11KV/415 Volt transformers is 63KVA, 100KVA,

250 KVA and some are of 400 KVA.


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(n) 415 volt supply (LT Supply) is distributed through overhead lines and the

individual consumer is fed through service wire connected from 415 V LT

poles.

(o) Some of the Street lights are provided installed on the same LT poles carrying

415 V Overhead line.

(p) The LT consumers of both sides of road are fed from same 415 V LT poles.

There are have LT consumers and 11 KV consumers.

(q) Telephone connections to consumers are fed from telephone post.

(r) Energy meter meters are normal type and are installed at the premises of the

consumer.

(s) Under Street lighting National programme (SLNP), Energy efficiency

Services Limited (EESL) will replace all conventional HPSV /MH street light

fixtures with LED light fixtures..

(t) There are many vacant plots, pond, and Govt. offices.

21.1.2 PROPOSED SYSTEM

The proposed system envisages the following:

(o) Supply, laying, termination and commissioning of 33 KV 3Cx300 sq.mm

XLPE armoured cable directly buried in HDPE duct with safety measures

from University junction to BSNL junctions. For details refer drawing no. URS-

ASCL-DPR-ELEC-DWG-600-003.

(p) Supply, laying, termination and commissioning of 11 KV 3Cx300 sq.mm

XLPE armoured cable directly buried in HDPE duct with safety measures

from 33/11kV Ghantaghar Substation to University junction. For details refer

drawing no. URS-ASCL-DPR-ELEC-DWG-600-004.

Supply, laying, termination and commissioning of 11 KV 3Cx300 sq.mm

XLPE armoured cable from University junction to Ghantaghar junction. For

details refer drawing no. URS-ASCL-DPR-ELEC-DWG-600-004.

(q) Installation of 11/0.443 KV Compact Substations consisting of Ring Main Unit

(RMU), dry type Transformer and LV compartment in one enclosure with

Feeder Remote Terminal Unit (FRTU) and SCADA compatible. For details

refer drawing no. URS-ASCL-DPR-ELEC-DWG-600-004.

(r) Design, fabrication and installation of RCC duct bank for road crossing for

laying 33kV, 11 KV, LT cables with future provisions. For road crossing

details refer drawing no. URS-ASCL-DPR-ELEC-DWG-600-015 & URS-

ASCL-DPR-ELEC-DWG-600-019

(s) Design, supply and Installation of 33kV, 11kV and LT cable laid in HDPE duct

and HDPE duct shall be directly buried in ground with complete safety

measures.


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(t) HDPE duct pipe for laying 415/230 Volt consumer service connection from

feeder pillar, street lighting, telephone and communication system.

(u) Design, Supply and Laying of XLPE/ PVC cables/ telephone ducts for

distribution of power in 11KV and 433 V which replaces the 11KV, 433V and

other overhead lines.

(v) Design, Supply and installation of 11KV Ring main Units shall be installed to

provide 11 KV power to CSS and for transformers installed for interior roads

which are fed from the existing overhead lines.

(w) Installation of 433 Volt feeder pillar for providing service connection to

individual consumers though underground cables.

(x) Installation of Smart Energy meters.

(y) Installation of Lighting poles, LED lights, lighting feeder pillar with automatic

lighting control system.

(z) Supply and installation and commissioning of DP structure for 11 KV tapping

point / Jointing using 11 KV 3Cx300 Sq.mm cable to ring main for providing

11 KV supply to existing transformers and transformer to the interior roads

from smart Road.

(aa) For tentative/approximate quantity and length of cables, CSS and feeder

pillar etc. refer tender drawings and BOQ.

(bb) Detailed design of complete electrical system is in the contractor scope,

tender drawing and bill of quantity is for reference only. The contractor is

responsible for a complete, thorough and quality design for the installation,

testing commissioning of entire electrical distribution system at site. The

Contractor is responsible for the selection and design of appropriate

equipment and components to provide the best coordinated performance of

the entire system.

21.1.3 SCOPE OF WORK

For this 1km stretch of road, existing overhead HV/LV lines shall be planned to

be taken underground. All conventional transformer shall be replaced by CSS

and 11kV ring main shall be used.

For street lighting existing conventional design shall be replaced by smart street

lighting. Street lighting system is proposed for this road with required number of

smart LED Lighting fixtures, FRP/GRP poles, feeder pillars cabling etc. The

entire lighting system will have SCADA compatible for remote monitoring,

dimming, group controlling and control from central control room.

To implement System Improvement & Augmentation Scheme for existing

Electrical Network in Smart road from Ghantaghar junction to University junction,


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Aligarh in Uttar Pradesh on “Turnkey basis” with operation and maintenance of

the electrical distribution system for five years.

The scope of works includes execution of the project on turnkey basis. The

contractor’s scope of work includes but not limited to: Survey, design,

manufacturing, shop testing, inspection, packing, dispatching, loading, unloading

and storage at site, transit/storage and construction insurance, assembly,

erection, civil structural work, complete pre-commissioning checks, testing &

commissioning at site, obtaining statutory clearance & certification from State

Electrical Inspector, Uttar Pradesh Electricity Department, Dakshinanchal

Vidhyut vitran nigam limited (DVVNL) Aligarh zone, Municipal Corporation

Aligarh etc. and handing over to the Owner/ concerned department after

satisfactory commissioning of complete augmentation of existing Electrical

Network in Aligarh Smart city Project area.

21.1.3.1 ELECTRICAL

Design, Supply, installation, testing and commissioning of the Following:

(aa) Design, supply, installation, testing and commissioning of 11KV/433 V

Compact Substations with dry type transformer in place of existing oil type

transformers and capable of being monitored and controlled by the Central

SCADA via FRTU and modem.

(bb) Installation of 11kV RMU and provide power supply to 11kV Consumer,

transformer and tapping to existing 11kV overhead lines.

(cc) Supply, laying and termination of 33KV 3Cx300 sq.mm XLPE Aluminium

cable from the proposed two pole structure at University circle to proposed

two pole structure at BSNL circle. These cables shall be laid in HDPE duct


(dd) Providing 11 KV supply to the RMU, existing 11 KV consumers/

transformer / 11kV Lines.

(ee) Supply, laying and termination of 1.1 KV XLPE insulated Armoured cable

from secondary of transformer to feeder pillars in HDPE duct.

(ff) Supply, laying and termination of 1.1 KV cable from compact substation to

feeder pillars through HDPE duct and service cable from feeder pillar to

consumers through HDPE duct banks.

(gg) Supply, laying and termination of suitable size of Aluminium Conductor,

XLPE and PVC insulated, PVC sheathed, armoured cables of approved

make and using heat shrink type cable, joints, terminations of approved make

for terminations.

(hh) Main Feeder pillars, Sub Feeder Pillar, submain Distribution boards and

smart energy meters for distribution of LT supply to consumers.


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(ii) Providing service Connection to existing electrical consumers using UG

cables through cable ducts from feeder pillar.

(jj) Provide power supply connection to existing water pumps from feeder pillar

using underground cable.

(kk) Road Lighting with Feeder pillars /Lighting Distribution Boards, FRP/GRP

Poles with LED lamp fixtures of suitable wattage, control panels, junction box,

cable laying through duct banks, 433 volts 3 phase, 50 Hz, 0.8 pf of approved

make complete with Lighting Control Panel and Automatic control of lighting

circuits.

(ll) Supply, installation, testing and commissioning of Road lighting system with

functionality of dimming and group controlling through SCADA from Control

centre.

(mm) Supply, installation, testing and commissioning of Heritage lighting poles

and fixtures for increased tourism as well as increase site visibility.

(nn) Earthing Compact substations and Transformer body, neutral and metal

parts, feeder pillars, lighting poles at each 5th pole, control panels and

junction box, cable trays as per standards and specifications within project

area.

(oo) Supply, laying and commissioning of HDPE pipes and all other materials

like cement, steel, sand gravels of suitable size as required shall be in the

scope of contractor.

(pp) De energization, dismantling after obtaining work permit from DVVNL /

concerned authorities and dismantling of existing 11 KV Overhead lines,

transformers and 433 V overhead lines the transformers, 11KV /433

structures, poles, overhead lines, cables, insulators, cross arms, lightening

arrestors, cables, telephones lines, lighting poles, light fixtures, energy

meters and all accessories carefully and handing over the materials to the

Store of DVVNL and other respective authorities.

(qq) Preparation of G.F.C. drawing as per requirement, to match the

requirement and approval from the owner representative.

(rr) Preparation of abstract of quantities of major items, as Cables, Cable Trays

to assure at final quantities before procurement.

(ss) Laying of cables in cable ducts, glanding and termination of cables,

Laying of Pipes etc. as required.

(tt) Providing cable identification SS aluminium tags in cable trays at suitable

and termination end of cables

(uu) Laying of warning tape in buried cable trenches for protection of cable.

(vv) Testing of Cables before Laying, Jointing, Commissioning etc. as

required.


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(ww) Inspection of Cables, Joints and Cable Trays at manufacturing place

before shipment.

(xx) Labelling of equipments like CSS, Feeder pillars, light poles earth pits as

per design specifications and relevant standards.

(yy) Supply and laying of telephone cables, junction boxes, duct pipe and all

accessories for providing telephone connection to the existing BSNL

consumers.

21.1.3.2 CIVIL WORK:

The Civil works including Structure design also is part of Contract in following

respect but not limited there of:

(o) Levelling the Complete Area, earmarked for work.

(p) RCC cable Trenches / RCC duct banks for road crossing, manholes, RCC

cover slab etc. as required in the area for incoming and outgoing Cables etc.

(q) Excavation, back filling and levelling for buried cable trenches / earth pits etc.

(r) All materials including cement and steel required for the civil and Electrical

work is in the scope of the contractual / executing agency.

(s) The scope of civil works for bidder covers design, engineering, supply of

labour & materials, transportation, construction and commissioning of entire

civil engineering works required for installation & erection of all the Cables

33kV, 11KV and 1.1 KV Cables for the project area facilities etc. as designed

and / or supplied by him.

(t) Soil excavation and back filling if required for Construction of buried cable in

HDPE duct, RCC cable Trench and Cables and other works trenches / ducts

as and where required.

(u) Buried cable duct connecting the feeding and receiving substation and

encased HDPE pipe at all the locations.

(v) Drainage arrangement in cable manholes.

(w) The scope of work of bidders is not limited to the major item of civil works as

elaborated above but includes all civil works required for the successful

completion & commissioning works concerned of the project without any

extra cost.

(x) The scope of work also includes sampling & testing of construction material

on the specimens taken during execution of the work. The testing shall be

performed by a separate agency, approved by the engineer in charge.

(y) Site office, cement & other construction material storage go downs and

fabrication yard for reinforcement, inserts etc. shall be constructed by the

successful Bidders at his own cost.


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(z) All construction equipment required for execution of the work shall be

arranged, procured & hired by successful Bidders at his own cost along with

operations, skilled & semiskilled personnel. The successful Bidders shall also

furnish a list of construction equipment to be deployed by him.

(aa) Site for storing the equipment/material within a reasonable distance from

the proposed installation shall be provided by the client. However,

construction of temporary sheds/ barricades for the temporary store, site

office as well as safety and security of equipment shall be in the successful

Bidder’s scope.

(bb) Foundation of Compact substation, feeder pillar and lighting poles etc.

21.1.3.3 TECHNICAL SERVICES

The following technical services shall be in the scope of the Bidder:

(j) Liaison with Central/state Government Departments/DVVNL/ CEIG / MCD or

any other authorities concerned on for matters like work entrustment, vendor

approvals, drawing approvals, PTCC, TA&QC approvals and any other

matters connected with the work and gets the approvals within the specified

time for successful completion of work for all matters including obtaining

approved designs & drawings, and commissioning of the Project including all

incidental costs incurred thereon. Aligarh Smart City Limited, however, will

provide only all the required administrative supports to the contractor in this

regard and also would reimburse to the Contractor all the statutory charges

paid to the departments like /CEIG on production of official receipts thereon.

(k) Liaison with Dakshinanchal Vidhyut vitran nigam limited (DVVNL) for

approval of design, technical specifications, materials, inspection, quality

control, testing and commissioning of newly installed equipment, total

responsibility for the completeness of the project including erection testing

and commissioning.

(l) The successful tenderer shall take the responsibility of obtaining all statutory

clearances from all statutory bodies, on behalf of the Owner. (However, fee

to be reimbursed by the Owner on production of documentary evidence)

(m) Basic design, drawing and layout engineering of Electrical and Civil &

structural work.

(n) Preparation of detailed engineering drawings and documents.

(o) Submission of QAP and Test certificates.

(p) Arranging inspection of the materials by the client/ client representative

(q) Submission of As Built drawing after commissioning of project.

(r) All materials /machinery/items used in the subject package shall be provided

according to specification given herein. All electrical items shall be supplied


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from the “List of Preferred makes”. Prior approval from Owner shall be taken

for the equipment/ items not available in the list.

21.1.3.4 DRAWING/DOCUMENTS

The scope of work includes submission of all the drawings, data and documents

related with the scope of work. A tentative list of drawings, data & documents is

indicated below. However, the Bidder shall note that the list is only suggestive.

The final list of drawings shall be finalised with the successful Bidder.

Drawings/ Data / Documents to be submitted after Placement of Order:

(h) List of drawings and drawing numbering system.

(i) Design calculation for the selection of major items like Compact substations,

Ring Main Unit, Feeder pillars, light poles, light fixtures, cables, Cable trays

and Cable Trench.

(j) Quality assurance plan (QAP) of all material and Test certificate of each

equipment & components including type test certificates.

(k) Single Line Diagram with ratings and three line diagram of HT and LT

distribution.

(l) Cable route drawings and general arrangement (GA) drawings.

(m) Cable schedules, termination schedules and cable routing drawings.

(n) Any other drawings as required shall be finalized during engineering stage

21.1.3.5 NOTE

The Compact Sub Station (CSS) to be supplied against this specification are

required for vital installations where continuity of service is very important. The

design, materials and manufacture of the equipment shall, therefore, be of the

highest order to ensure continuous and trouble-free service over the years. Such

parts will be deemed to be within the scope of the supply irrespective of whether

they are specifically indicated in the commercial order or not. It is not the intent

to specify herein complete details of design and construction. The offered

equipment shall conform to the relevant standards and be of high quality, sturdy,

robust and of good design and workmanship complete in all respects and

capable to perform continuous and satisfactory operations in the actual service

conditions at site and shall have sufficiently long life in service as per statutory

requirements. These specifications, the design and constructional aspects,

including materials and dimensions, will be subject to good engineering practice

in conformity with the required quality of the product, and to such tolerances,

allowances and requirements for clearances etc. as are necessary by virtue of

various stipulations in that respect in the relevant Indian Standards, IEC

standards, I.E. Rules, I.E. Act and other statutory provisions.


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The Tenderer/Supplier shall bind himself to abide by these considerations to the

entire satisfaction of the purchaser and will be required to adjust such details at

no extra cost to the purchaser over and above the tendered rates and prices. It

shall also encompass all necessary project management, data engineering,

acceptance testing, training, documentation, warranty services, and installation

site surveys including submission of a detailed plan aimed at installing the new

RMUs as efficiently as possible with minimum interruptions of power to Employer

customers.

Liaison with Central/state Government Departments/DVVNL/ CEIG or any other

authorities concerned on for matters like work entrustment, vendor approvals,

drawing approvals, PTCC, TA&QC approvals and any other matters connected

with the work and gets the approvals within the specified time for successful

completion of work for all matters including obtaining approved designs &

drawings, and commissioning of the Project including all incidental costs incurred

thereon. Aligarh Smart City Limited, however, will provide only all the required

administrative supports to the contractor in this regard and also would reimburse

to the Contractor all the statutory charges paid to the departments like /CEIG

on production of official receipts thereon.

Civil foundations as recommended by the manufacturers of Compact Substation,

feeder pillars, lighting pole and mounting arrangement for Control panel and

junction box etc. shall be in the scope of the contractor.

All the civil works such as excavation of earth, lying of Hume pipes/ HDPE pipes/

DWC pipes in concreting, back filling of RCC cable trench, providing man holes

as required for cable laying and jointing as per standards.

The quoted price should include all expenses proposed to be incurred by

the bidder for dismantling the existing transformers, 11KV/415 volt poles,

lines and structures, light fittings and all equipment with care and handing

over them to safe custody of concerned authorities.

Field conditions, the bidder may in its own interest, before submitting the bid,

inspect and examine the area involved and satisfy them regarding the existing

system.

Electrical Power Supply and Water for construction purpose shall be

arranged by vendor.


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21.2 ELECTRIC DESIGN DATA

21.2.1 CODES AND STANDARDS

The distribution system shall be planned considering the latest version of

applicable Indian and International Codes and Standards, Climate and

Isokeraunic Conditions, and basic electrical data.

The following primary standards and codes (latest editions/

revisions/replacements) shall be used for planning and design of the electrical

system:

TABLE 1: CODES AND STANDARD

Description

Guidelines

Guidelines of Electricity Board and other statutory authorities.

BIS: Bureau of Indian Standard

IEC: International Electro technical Commission standards

IEEE: Institute of Electrical and Electronics Engineers standards

Regulations laid down by Indian Electricity Act and Rules

National Electrical Code (SP 30, 2011) of India

Indian Bureau of Energy Efficiency (BEE) Guidelines

Guidelines issued by Central Electricity Authority (CEA)

CBIP Publications

Any other regulations by the local or state/central government authorities,

Regulations issued by tariff advisory committee / fire insurance regulation

Electrical Codes

IS 3043/IEEE-80 Code of Practice for Earthing

IS/IEC-60947 LV Switchgear


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Description

IEC 62271-202 HV Prefabricated Sub-Station (CSS)

IS 3427 / IEC-62271-200 Metal Clad Switchgear

IS 13118/ IEC-62271 -100 HV Circuit Breakers

IS 1180 Part 1 Oil Type Distribution Transformers

IS 5578 Arrangement For Switchgear Bus bars, Main

Connection And Auxiliary Wiring

IS 2705 Current transformer

IS 3156 Potential transformer

IS 2544 Bus bar support insulators

IS 3231 Electrical Relays For Power System Protection

IS 13703 HRC FUSES

IS 3646 Code of Practice for interior illumination

IS 1944 Code of Practice for road lighting

IS 2309 Protection of buildings and allied structures against

Lightning code of practice

IS 7098 Specification for XLPE insulated PVC sheathed

cables

IS 1554 Specification for PVC insulated cables

IEC: 62259 Secondary cells and batteries containing alkaline

or other non-acid electrolytes-Nickel-cadmium

prismatic secondary single cells with partial gas

recombination


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Description

IEC: 60623 / IS 10918 Secondary cells and batteries containing alkaline

or other non-acid electrolytes-vented Nickel

Cadmium prismatic rechargeable single cells

IS 9000 For Basic climatic and mechanical durability tests

for components for electronic and electrical

equipment

IS 6619 For Semiconductor rectifier equipment code

IS 2026 Power transformers

SP 72 : 2010 National Lighting Code

1944 (Parts 1 Code of

practice for lighting

ofand 2)

Public thoroughfares: Part 1

General principles; Part 2

Lighting of main roads

1944 (Part 5) : 1981


thoroughfares: Part 5 Lighting of grade

separated junctions, bridges and elevated road

(Group D)

1944 (Part 6): 1981


thoroughfares: Part 6 Lighting of town and city

centres and areas of civic importance (Group E)

CEA Manual on Transmission planning Criteria

Other International codes and standards shall be considered if the same are, at

least equivalent to, Indian Standards or any other international standard which

yields a more desirable outcome.

21.2.2 CLIMATIC CONDITIONS

For the Project in Aligarh Smart City Area, the electrical equipment selected

shall be such so as to give trouble free operation during the life of the equipment,

under the most stringent atmospheric conditions prevailing at site.


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21.2.2.1 General

The distribution system is planned considering the Climate and Isokeraunic

Conditions, and basic electrical data.

21.2.2.2 Climate and Isokeraunic Conditions:

The electrical equipment selected will be such so as to give trouble free

operation during the life of the equipment, under the most stringent atmospheric

conditions prevailing at site. All equipment’s designed such a way that, it will be

protected from the entry of ground water, tree roots, reptiles, lizards, wild

animals etc. to avoid short circuit.

21.2.2.3 Tropicalization:

All electrical insulation, Panels or spacers and other materials, which could be

damaged by fungus, termites or other parasitic growths, will be suitably

protected. Enclosures containing electrical control and switching equipment and

instruments will be equipped with electric heaters for moisture control. The

construction of the enclosures and the placement of heaters will ensure effective

circulation of air and prevent damage to equipment by overheating. Heaters will

be of PTC type, without the use of thermostats.

TABLE 21.2-2 : TYPICAL ATMOSPHERIC DATA AT SITE IS CONSIDERED AS BELOW FOR

ELECTRICAL SYSTEM DESIGN:

S.N. DESCRIPTION DATA

1 Upto Maximum Design Ambient

Temperature

50°C

2 Maximum daily average Temperature 45°C

3 Minimum daily average Temperature 33°C

4 Relative Humidity 95% max 10% min

5 Annual Thunder Storms 30 days

6 Number of Average Rainy days 40

7 Rainy months June to Sept

8 Snow storm Nil

9 Average annual Rainfall (CGWB) 755mm


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21.2.3 SYSTEM SUPPLY

As per prevailing practice at smart city Site, main HV supply from the substation

and distributed within site shall be at 11kV.

LV supply at the consumer premises shall be 240/433V ± 6% as per latest Indian

Standard IS: 12360. Compact Sub-Station (CSS) are proposed in many

locations. The distribution transformers shall be at no load LV = 250/433V as

per CEA/CBIP recommendation.

The frequency shall be 50Hz ± 3% as per Indian Electricity Rules and IS: 12360.

11kV supply variation shall be within +6% & -9% as per Indian Electricity Rules.

21.2.3.1 INSULATION COORDINATION

Standardised levels for the highest system voltages Um related to the rated

voltages are defined in IEC 60071-1. According to these levels the test voltages

for the insulation of high voltage equipment are defined. The following levels

have been selected out of IEC 60071-1, IEC 60364 & IS-SP39.

Table 3: Standardised Levels for the Highest System Voltages

Rated Voltage Un

(kVrms) 0.4 11 33 110

Highest system

voltage

Um

(kVrms) 1 12 36 123

Power frequency

withstand

voltages 50 Hz, 1

min, to earth

Upf

(kVrms)

2 28 70 230

Lightning impulse

with stand voltage

1.2/50 µs to earth

Uli

(kVpeak) 8 75 170 550

IEC 60815 defines 4 different pollution levels from light to very heavy pollution.

To each pollution level the corresponding minimum nominal specific creepage

distance is defined. The equipment to be installed in project area will be

exposed to salt, fog conditions and to pollution due to exhausts. To consider

this situation the pollution level “very heavy” according to IEC will be selected.

This pollution level implies a minimum creep age distance of 31.0 mm/kVrms.


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21.2.3.2 SYSTEM NEUTRAL POINT

The choice of the system neutral points has been made to conform to the

existing system. The treatment of the neutral point has been selected according

to the following table.

For star connected LV windings of transformers the neutral point of the LV

systems is generally solidly earthed.

Table 4: System Neutral Point

System Neutral Point

11kV Solidly earthed

0.4kV Neutral of transformers Solidly earthed

21.2.3.3 SHORT CIRCUIT LEVELS

The following short circuit levels shall be adopted for switchgear:

11kV : 25KA

400V : 50KA

21.2.3.4 DISTRIBUTION TRANSFORMERS

All distribution transformers shall be Oil type 11kV/433V with Dyn11 vector

group with off-load tap changer with ± 5% variation in steps of 2.5%. LV star

winding shall be solidly grounded. Distribution transformer shall be chosen from

standard ratings, typically 500 KVA. As a matter of policy only two ratings shall

be standardised to reduce the number of stocked spares ease in replacement.

21.2.3.5 COLOR CODING

Bus bars, bare copper connections, earthing bars, cable cores and mimic

diagrams shall be provided with the following colours:

Table: colour coding

System Colour

Three Phase AC

System

R Red

Y Yellow

B Blue

N Black


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System Colour

Ground Yellow/Green

DC System

Positive Light Blue

Negative Grey

21.2.3.6 POWER FACTOR

For LV distribution loads average power factor of 0.85 shall be considered for

designing the electrical system. Power factor improvement system shall be

designed to have a power factor of 0.95, by using Automatic Power Factor

Control via a switching capacitor bank at LV.

21.2.3.7 HV DISTRIBUTION

HV distribution system shall be designed as an economical and technically

viable distribution system. Since the present HV system existing in Smart City

project is at 11kV, the same shall be maintained for new design. For each

location, HV supply shall be provided with two number 11kV feeders in ring

formation, with an open point, so as to operate the system as radial feeders. In

case of fault in any one radial feeder, the other shall be able to take the full load

of those locations. Thus, under normal conditions each feeder shall be operating

at 50% of its full capacity, thereby ensuring 100% redundancy of power. HV

supply from 11kV main shall be distributed in the following way:

To a dedicated switching station (SS) for concentrated and high quality loads

such as for this project. The design of the switching stations and electrical

distribution systems are covered in the scope of works.

As betterment to the DPR concept, customised Compact Sub-Stations (CSS)

are proposed to be used in project areas which shall form a part of the open

ring system. These CSS shall be equipped with an 11kV SF6 insulated

switchboard, oil type transformer with off load tap changer and LV board with

switched capacitor bank. Customization shall be made to make CSS in vertical

formation, so that any of the equipment that is, RMU, distribution transformer,

and LT pane are separate and can be easily replaced. The customised CSS

fabricated structure out of GI channels/ I section / angles / GI wire mesh/ MS

sheet of 2 mm thick or more. The scope of work include, design, preparation of

drawing and submit and get the approval from DVVNL, fabrication of sample

and obtain the approval from DVVNL before installation of the CSS in the field.

All these items shall be enclosed in a rust proof enclosure.

All HV/11KV power distribution to secondary substations (CSS) shall be

installed in underground concrete duct banks. The size, cross section, location

and configuration of the duct banks shall be determined during preliminary and


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detailed design phases. Electrical cables on the low voltage side, from the

11KV transformer to the final building/facility location, shall be installed in

appropriate conduit (as specified in technical specifications) but will not be

required to be encased in protective concrete.

11kV HV supply shall be stabilised at the source substation which feeds the

main, through on load tap changer (OLTC), with ±10% voltage variation in steps

of 1.25%.

Each CSS shall include its own power supply unit (including required auxiliary

power transformer, batteries, and battery charger), which shall provide a stable

power source for not only the CSS, but also the FRTU and Ethernet switch that

the it must be capable of housing.

21.2.3.8 APPLICABLE STANDARD

Table 5: standard


IEC 60529 Classification of degrees of protection provided by

enclosures of electrical equipment

IEC 60298 A.C metal-enclosed switchgear and control gear for

rated voltages above 1KV and up to and including

72KV

IEC 1330 High voltage/Low voltage prefabricated

substations

IEC 60694 Common specification for HV switchgear

standards

IEC 60265 High-voltage switches-Part 1: Switches for rated

voltages above 1kV and less than 52 kV

IEC 6081 Monitoring and control

IEC 60185 Current Transformers

IEC 60186 Voltage transformers

BS 159 Busbar

IEC 60137 Bushings

CP 1013(British

Code of Practice)

Earthing

IEC 60255 Specification for Static Protective Relays

BS 6231 Wires and wiring

BS 729 Galvanising


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IEC 61000 Electromagnetic compatibility Standard

Description

IEC 60129 Alternating current Disconnector (isolators) and

earthing switches

IEC 62271-100 Circuit Breakers

IEC 60060-1 BS

923

High Voltage test technique

IEC 60056 Vacuum Interrupter

IEC 60034-1 Motors

IEC 60623 Open Ni-Cd prismatic rechargeable cell

IEC 60947-4-1 Control Gears

IEC 376 Filling of SF6 gas in RS 1.6 Environmental

Conditions

IS 1180 Part 1 Distribution Transformer from 250KVA to 2500KVA


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22 SPECIFICATION

22.1 SPECIFICATION FOR COMPACT SUBSTATION

22.1.1 Scope

This specification covers the design, engineering manufacture, Shop testing packing,

transportation to site, site storage, installation, testing and commissioning of a SCADA

operated, prefabricated, factory assembled and fitted, Compact Sub Station [CSS] consisting

of following main components.

12 kV, non-extendable, metal clad SF6 insulated switchgear, sealed for life, Ring Main Unit

(RMU)

Dry type 11/433V distribution transformer

LV switch Board.

Prefabricated weather proof enclosure.

SCADA connection for remote control and monitoring.

All termination and connections to high voltage and low voltage side of distribution transformer,

earthing and any other work to complete the works in all respects whether specifically mentioned

or not in this specification.

Portable Fire extinguishers for electrical fires

Complete Documentation

Training to Owners personnel

The CSS is to be totally free from any external deposit (dust, condensation etc.) and suitable to

operate in highly humid, hot and salty environment without any preventive maintenance,

cleaning etc. It shall be of “fit and forget” type. All nut bolts, frames etc. shall be rust proof,

typically of stainless steel or materials not prone to rusting, in site environmental conditions.


Page | 260


CSS can be placed indoor or outdoor as per requirement. Scope shall also include design,

engineering of all the civil and all other related site works so as to complete the works in all

respects.

The prefabricated substation unit is required for fast installation, to be maintenance free and

with life expectancy of thirty years under site conditions.

Climate and Isocerunic Conditions

For Seabird Project, the electrical equipment selected shall be such so as to give trouble free

operation during the life of the equipment, under the most stringent atmospheric conditions

prevailing at site described in “Outline Design Criteria” –Electrical System.

Basic Design Criteria

The CSS shall be designed with the following design criteria:

For design purpose maximum ambient temperature of 50° C shall be considered.

It shall be factory built and tested and preferably transported as such so that it is ready for site

installation. Only external connections need to be done at site.

Design to comply with latest version of IEC 62271-202.

Maintenance free Ring Main Unit [RMU] with SF6 insulation sealed for life as per IEC standard.

Dry type, epoxy insulated transformer with HV side metering.

LV Switchboard with Capacitor bank for automatic power factor correction [APFC].

Enclosure to have independent compartments for RMU, transformer and LV Board with suitable

entry doors.

The electrical equipment including the enclosure, its supporting structure etc. is to be rust and

corrosion proof throughout its life in saline, humid and tropical hot weather. In case there is no

alternative to items such as mild steel sheet, and other structural items, the same shall be hot

dip galvanized [minimum 610 gm zinc /m2] and epoxy painted. Nut, bolts, washers and other

similar items shall be of rust proof material such as stainless steel.

Cables shall be mostly in ducts and these ducts may be buried directly in the ground or encased

in concrete, as per site conditions. HT cables ducts shall be encased in concrete.

The Enclosure consisting of High Voltage switchgear, Low Voltage switchgear & Transformer

of the Unitized substation shall be designed to be used under Indoor or outdoor service

condition.


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3.1.1.8 Quality of Material

(c) All material used shall be new and of best quality and of class most suitable

for working under the conditions specified herein without distortion or

deterioration.

(d) Galvanization of steel shall only be done by hot dip process after the parts

are ready for the purpose of assembly. Alternatively stainless steel of the

quality suitable for site shall be used.


(j) The equipment shall be designed to ensure satisfactory operation in which

continuity of service is the first consideration and shall also be designed to

withstand sudden load variations due to short circuits and other fault

conditions.

(k) The design shall incorporate every reasonable precaution and shall have

necessary provision for the safety of all those concerned in the operation

and maintenance of the switchgear.

(l) All mechanism shall be made of such materials as to prevent sluggishness

due to rust or corrosion. All Connections and contacts shall be of ample

section and surface for carrying continuously the specified current without

undue heating and shall be secured rigidly and locked in position.

(m) Standard sizes of bolts, screws, pipes and other fittings are to be used and

number of sizes is to be kept to the minimum.

(n) Cast iron shall not be used for any part of the equipment which may be

subjected to mechanical stresses.

(o) All apparatus shall be so designed and constructed as to obviate the risk of

short circuits of the live parts by reptiles, rodents etc. Metal cubicles,

housings and covers shall be 100% weather / vermin proof.

(p) All parts shall be manufactured in accordance with relevant standard

specifications. Corresponding parts of similar equipment and apparatus

shall be mutually interchangeable.

(q) All apparatus, connections and cabling [FRLS type] shall be designed and

arranged to minimize the risk of fire and any damage, which might be

caused in the event of fire.

(r) Design should take into consideration that equipment is to be operated at

sea level under rainy, hot and humid atmospheric conditions, high humidity

(95%) and surroundings with reptiles and rodents.

3.1.1.10 Certification offering evidence for the satisfactory operation under

such environmental conditions shall be provided.


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1 Applicable Standard IEC 62271-202

2 Design Ambient Temperature 50 C

3

Type of Ventilation for

Normal Condition

Hot Condition

Natural

Natural

4 Compartmentalized Yes

5 Rated temperature enclosure class 1K 10

6


enclosure for Transformer

compartment

IP23


enclosure for HV compartment IP54


enclosure for LV compartment IP54

7 Location Outdoor

8 Rated HV 12kV, RMU, with metering

9 Transformer ≤1000 KVA, Dry Type

10 Nominal rated voltage rating on LV 415V

11 LV Board

Incomer ACB + Outgoing

MCCB + APFC, Capacitor

Bank

12 Enclosure material Resistant to rusting,

saline environment

13 Thickness of sheet (minimum) 2mm for enclosure (main

frame).

14 Base 4mm hot-dip galvanised

14 Enclosure Paint Epoxy, RAL 7032


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15 SCADA system / Remote Control yes

Table: Technical Data for CSS

3.1.1.11 Painting

Since the local environment is harsh, even galvanised steel will rust after a few

years. Therefore paint of suitable quality to protect the equipment is of utmost

importance. If steel work is unavoidable it shall be hot dip galvanized not less

than 610 gm / m2 and painted.

All sheet steel work, wherever shall be phosphated in accordance with IS: 6005

'Code of practice for phosphating iron and steel, through seven tank process.

Oil, grease, dirt shall be thoroughly removed by emulsion cleaning. Rust and

scale shall be removed by pickling with dilute acid followed by washing with

running water, rinsing with slightly alkaline hot water and drying. After

phosphating, thorough rinsing shall be carried out with clean water followed by

final rinsing with dilute dichromate solution and oven drying.

The phosphate coating shall be sealed with the application of two coats of ready

mixed zinc chromate primer. The first coat may be air dried while the second

coat shall be stove dried. Panels shall be painted with epoxy paint of superior

quality. ALTERNATIVELY, the panels shall be painted with electrostatic epoxy

powder coating process to have paint of hard coating. Necessary details shall be

provided to Engineer in this regard for prior approval.

(c) Paint Thickness

The final finished thickness of paint film on sheet shall be approximately 60

to 80 micron. The finished painted surface of panels shall present

aesthetically pleasing appearance free form dents and uneven surfaces.

Paints shall not scale off or wrinkle or be removed by abrasion due to

normal handling. The colour for finishing paint shall be Siemens grey as per

RAL 7032. Unless otherwise desired the same shall be got confirmed from

the Engineer before taking up painting. Each coat of primer and finishing

paint shall be of slightly different shade to enable inspection of the painting.

(d) Spare Paint

A small quantity (one litre per board) of finishing paint shall be supplied for

minor touching up required at site after installation of the panel.

3.1.1.12 Drawings and Manuals

The contractor shall furnish all drawings & manuals as called for and given below

and also those which are not specifically included but are necessary for proper

operation and maintenance.


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(m) Complete assembly drawing of the Packaged & Ring Main Unit showing

plan, elevations, side & typical sectional views giving complete dimensions.

(n) Assembly drawings & weight of main component parts.

(o) Foundation drawings showing the load on the foundations.

(p) Schematic control & wiring diagram in accordance with BIS / IEC practice.

(q) Bushing drawings & their specification.

(r) Cable termination details & drawings along with terminal connection

drawings.

(s) General arrangement drawing of the complete panels showing CTs, PTs

together with dimensions.

(t) Maintenance Manual.

(u) Graph indicating short circuit Vs number of tripping for Vacuum Circuit

Breaker.

(v) Permitted mechanical opening and closing operations.

(w) Besides above drawings, the contractor shall submit type test certificates,

leaflets & instruction manuals.

(x) Within 60 days after contract award, the contractor shall furnish to the

engineer three sets of following drawings for approval. No manufacture of

equipment shall commence until the drawings are approved:

viii) General arrangement drawing of complete assembly of packaged &

individual RMU including giving dimensions & their salient features.

ix) Schematic wiring diagram.

x) Foundation drawings.

xi) Locations of cables slots, cable terminations, CTs, PTs & terminal

connections.

xii) Any other necessary detail.

xiii) Instruction manuals for erection/construction, maintenance and

operation.

xiv) Height of centre line of HV and LV connectors of transformers from

the rail top level as well as from the roof of enclosure.

3.1.1.13 Quality Control

All material shall be new and of best quality and of class, most suitable for

working under the environmental conditions specified herein without distortion or

deterioration of equipment during the lifetime of not less than twenty five years.

3.1.1.14 Quality Assurance


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Manufacturer shall submit its quality assurance plan for the approval of Engineer

prior to fabrication.

22.1.2 12 KV Ring Main Units

22.1.2.1 General

(p) The RMU for the compact substation shall be 3 way [or 4 way], 12 kV, non-

extendable, free standing, indoor, metal clad SF6 insulated Ring Main Unit

(RMU) along with metering, PTs, CTs etc. This RMU shall form a part of

CSS in an unattended substation, which includes a transformer & LT Board

also and all the three equipment shall be housed in an enclosure.

(q) Two numbers 630 A, fault making / load breaking, motor operated, line side

switches, fitted with indications for phase and earth fault along with

associated CTs. The load break switches shall be connected via

underground XLPE Cables.

(r) One number 200 A, Tee-off, spring operated, Circuit breaker with sealed

for life vacuum interrupter complete with meters, CTs, Protective and

auxiliary relays to control one number 11/0.433 kV distribution transformer

with complete arrangement to connect the tee-off circuit breaker to the 11

kV side of the power transformer.

(s) The springs for closing the load break switches & tee-off circuit breaker

shall be motor operated.

(t) The opening & closing for the load break switches as well as tee-off circuit

breaker shall be carried out electrically from remote via SCADA, besides

local / hand operation. Built in compact battery [with no maintenance of any

type] with charger shall be part of supply for this purpose.

(u) The breaker shall have necessary over current and low sensitivity earth

fault protection on the delta connected, 11 kV side of the distribution

transformer. Further the protections on distribution transformer shall

operate this breaker with required alarms. It shall have basic metering

features also to monitor these in RMU.

(v) RMU shall also be equipped with necessary Remote Terminal Units,

transducer’s etc. complete in all respects, since these RMU’s shall be

having provision for SCADA with remote control. The requirements for

SCADA have been covered in the subsequent section of these

specifications and the provision for requisite control & indications shall be

provided in the RMU substations.

(w) Fault passage indicators, Feeder Remote Terminal Units, with self-healing

feature, communicating with each other in the Ring circuit shall ensure

automatic isolation of faulty cable and restoration of supply in case of cable

fault in the system, using Fibre-Optic based communication. Faster fault

isolation and service restoration of network with the help of peer to peer

connection to FRTU without any manual decision by operator with


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distributed control. Fault clearance less than 20 sec., it can vary in case of

communication delay. No operation interaction required.

(x) There shall be continuous monitoring of supply on 12 kV cables via

capacitive voltage indicators.

(y) The RMU shall be complete in all respects including elbow type cable

termination arrangement [with shrouds] in air from bottom, gland plate,

double compression glands, foundation channels, bolts, inter connection

arrangement etc.

(z) The external dimensions shall be identical throughout the length of the

11kV board.

(aa) The operation of any of the switching functions shall be simple with only

three possible positions viz. closed, open and earthed. The earthing switch

shall be placed on cable side. The earthing of cable is to be done by an

independent fault making switch.

(bb) All the necessary safety interlocks between switching devices, earthing

switch and cable box covers shall be integrated.

(cc) The accessories and LV auxiliaries (i.e. motor mechanism, coils, auxiliary

switches etc.) shall be the same for the entire range of switching functions,

load break switches or circuit breakers. They can be installed on site

without any dedicated tool and training.

(dd) Any other item not included above but required to complete the works shall

be deemed to be included in RMU, without any financial liability to the

purchaser.

22.1.2.2 Standards

Unless otherwise specified, all equipment and material covered in this

specification shall conform to the latest applicable Indian / IEC Standards.

Equipment complying with any other international standards will also be

considered if it ensures performance of equipment equal to or superior to Indian

Standards. Copy of such a standard shall also be supplied.



Common specifications

28. IEC 62271-200

High-voltage switchgear and control gear - A.C. metal-

enclosed switchgear and control gear for rated voltage

above 1 kV and up to and including 52 kV.

29. IEC 62271-103 Switches for rated voltages above 1 kV and less than

52 kV


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High-voltage alternating current circuit breakers.

31. IEC 62271-102

High-voltage switchgear and control gear – Part 102:

High-voltage alternating current disconnectors and

earthing switches

32. IEC 61958 High-voltage prefabricated switchgear and control gear

assemblies – Voltage presence indicating systems.

33. IEC 60529 Degrees of protection provided by enclosures (IP

Code)

34. IS:722 A.C. electricity meters

35. IEC 60044-8 Instrument transformers – Part 8: Low Power Current

Transducers

36. IEC 60044-1 Instrument transformer – Part 1: Curent transformer

37. IEC 60044-2 Instrument transformer – Part 2: Voltage transformer

38. IEC 60255 Electrical relays

39. IS: 5 Colours for ready mixed paints and enamels

40. IS:1248 Electrical Indicating Instruments

41. IS:1554 PVC insulated cables up to and including 1100 volts

42. IS:4794 Push Button Switches

43. IS:6005 Code of practice for phosphate coatings of iron and

steel

44. IS:2099 Bushings for alternating voltages above 1000 V

45. IEC:62271-202 Pre-Fabricated Substation

46. IS: 13118, IS: 3427, IEC:

60694.

11 kV, Switchgear cubicles

47. IS:9920, IEC:60265 Ring main unit 11 kv grade,


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48. IS:10118 Code of practice for selection, installation and

maintenance of Switchgear

49. IS: 2026 Distribution Transformer

50. Indian Electricity Rules

51. Indian Electricity Act

52. IS:13072 Sulphur hexafluoride for electrical purposes


22.1.2.3 Technical Particulars (Standard Values)

The Ring Main Unit (RMU) should consist of three phase, two load break

switches and one tee-off VCB, Circuit Breaker Compact Unit, SF6 insulated and

sealed for life complying to latest version of IEC 622-71-200

(h) Rated system voltage (kv) 12

(iv). Rated current for load break switch [A] 630

(v). Rated current for tee-off Breaker [A] 200

(vi). Nominal system voltage [kV] 11

(vii). System Earthing Solid

(i) Basic Insulated level

(viii). Lightning Impulse withstand voltage (kV) 75

(ix). Power frequency withstand voltage for 28

(x). one minute (kV rms)

(j) Frequency (Hz) 50

(k) Bus bar rated current (A) 630

(l) Rated short time symmetrical three phase current 20

(kA for 3 sec for load break switches & tee-off breaker)

(m) Earth switch for load break switches (kA for 3 sec) 20

(n) Earth switch for tee-off breaker (kA for 3 sec) 20

(o) Rated making current (kA peak) 50

(p) Rated breaking current for circuit Breaker [kA for 3 s] 20

(q) Filling & rated gas pressure <1 bar, gauge


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(r) Internal arc test [kA for 1 sec] for both A & B (RMU Tank & Cable Box)

20

(s) Interrupting time in millisecond less than 40

(t) Operating Duty: (O-3min-CO) As per IEC

(u) Degree of protection for enclosure - (Mimic-IP2X, Cable Box-

IP3X, LV Chamber-IP2X)

(v) Paint thickness (micron) 60

Notes:

(w) Type, routine, internal arc test reports shall be submitted by successful

bidder after award of work during detail design stage and shall be approved

by Engineer.

(x) RMU shall be non-extendable type. Storage [without heaters, in humid

environment]: from 0°C to +40°C

(y) Operation : °C to +40°C

(z) Partition class: PM

(aa) Main HV circuit: IP67

(bb) Front connection in cable box, suitable for armoured, XLPE insulated

Aluminium cable, as per specified size. Termination with elbow type plugs

in bushings with insulating boots.

22.1.2.4 Load Break Switch

(f) The switch shall be combining the functions of a load break switch,

disconnector and associated earthing switch. It shall have three positions

(closed, open / disconnected, earthed) earthing to be on cable side. The

mechanism shall be anti-reflex, lever-operated type, with intuitive operation

and clear mimic panel indications.

(g) Switch shall have built-in fail safe interlocks between main switch and

earthing switch. Standard built-in padlocking facility for main switch,

earthing switch and interlock shall be provided.

(h) Switch shall have a provision for remote opening and closing through


(i) It shall carry rated current continuously and short circuit current for the


relevant IEC / Indian standard. Switch should not be damaged even when

closed on a dead short circuit for the permitted period of short circuit.

(j) Each load break switch shall be of the triple pole, gang operated, with quick

break contacts.


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22.1.2.5 Circuit Breaker For Transformer

(h) The Circuit Breaker shall have a switch disconnecting the circuit breaker

with an associated earthing switch. It shall have three positions (closed,

open / disconnected, earthed) earthing to be on transformer side. Circuit

Breaker shall have a provision for remote opening and closing through


(i) It shall carry rated current continuously and short circuit current for the


relevant IEC / Indian standard.

(j) Circuit breaker shall be opened with a push button and closed with the

“closing lever”. The mechanism shall be anti-reflex, lever-operated type,

with intuitive operation and clear mimic panel indications. Switch shall have

built-in fail safe interlocks between main switch and earthing switch.

Standard built-in padlocking facility for main switch, earthing switch and

interlock shall be provided. The circuit breaker and load break switch can

be locked in the open, close or earth position by 1 to 3 padlocks of ESI size.

(k) Breaker should not be closed when cable cover is open.

(l) In case of fault the breaker shall be tripped through a self-powered relay.

(m) Circuit Breaker Interrupting Unit

Tee-off Circuit breaker shall have Vacuum interrupting arrangement.

(v) The design & construction of the Vacuum circuit breaker shall be

compatible with the latest Vacuum circuit breaker technology.

(vi) The Vacuum interrupter bottles shall be completely maintenance free

& mechanically strong for 30 years life. Test certificate to be provided.

(vii) Suitable interlock shall be provided against breaker operation in the

event of loss of Vacuum.

(viii) Circuit breaker should allow low chopping current level.

(n) Duty Requirement

(vi) The circuit breaker shall be totally restrike free under all duty

conditions and shall be capable of performing the duties satisfactorily.

(vii) The circuit breaker shall meet duty requirement for any type of fault

location, also for line charging current. The operating duty of the

circuit breaker shall be as follows:

(O-3min-CO) as per IEC

(viii) The circuit breaker shall be suitable to break the required induction

current in accordance with the BIS / IEC standard. The value thereof

shall be clearly specified at the time of offer.


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(ix) The circuit breaker shall meet its duty requirement in case of

application for controlling U/G cables, power transformer.

(x) The rated transient recovery voltage for terminal fault and short line

faults shall be as provided in the relevant IEC / BIS.

22.1.2.6 Constructional Details

(t) Complete switchgear including bus bars shall be contained in an earth

screened stainless steel tank, filled with SF6 gas, degree of protection not

less than IP-67, as per requirement of IEC standards. To prevent gas

leakage the gas pressure shall be maintained low within one atmospheric

gauge. The filled gas shall provide the required insulation and also current

breaking for load break switches.

(u) There should not be any condensation of SF6 gas on internal insulating

surface of the circuit breaker and Load Break Switches. Temperature

compensation shall be provided and the system shall be an integral part of

breaker.

(v) SF6 gas shall be sealed for life in the compartment so as to satisfy “Sealed

Pressure Systems” requirement of IEC-60694 (Clause 5.15.3). Throughout

the life of the equipment there shall not be any “topping up” of SF6 gas. The

rated life of the equipment must not be less than 30 years as per IEC-

60694. During this operational life of the switchgear, absolutely no gas

filling is required. The container should be evacuated before gas filling and

it should be diffusion-tight. The design of the RMU housing shall be such

that in the event of an internal arc fault, the safety of the operator shall be

ensured. All the safety requirements as required in IEC 62271-200 shall be

provided.

(w) The switchboard when charged must not have any access to live parts so

as to endanger the life of operating personnel.

(x) The RMU shall be so designed that the position of different devices is

visible to the operator in front of the switchboard. The operating switches,

handles etc. shall be at a height at which these or easy to operate, without

any extra effort. All the items in the equipment shall be identified with long

life labelling, cautions etc. The labelling must clearly indicate the required

function.

(y) All the items in the equipment shall be identified with long life labelling,

precautions etc. The labelling must clearly indicate the required function.

(z) There shall be operation counters for Load Break Switches and breaker

with a provision to sound an alarm when the permitted operations are

approaching. Alternatively operation counter and alarm shall be provided

at FRTU/SCADA level and warning signal to be provided at SCADA.

(aa) It shall be possible to lock the operating mechanism in any of the three

positions when the contacts have fully homed and also to independently


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lock the “ON” and “EARTH” positions. The position “ON”, “OFF” and

“EARTH” of the switch shall be clearly indicated such that the direction of

movement of the operating handle(s) from one position to another is readily

apparent.

(bb) The operating mechanism shall be maintenance free without the need of

any lubrication during its life time of 30 years. The operating mechanism

shall undergo a mechanical endurance test as specified in IS / IEC 62271-

200

(cc) The ring main shall be dust, moisture & vermin proof and suitable for indoor

or outdoor installation. All the cabinets shall be free standing floor mounting

type and shall be provided with double hinged doors with padlocking

arrangements.

(dd) All door panels, removable covers shall be gasketed all round with

neoprene gaskets. All louvers shall have screen and filters. Vent opening

shall be covered with mesh and so arranged that hot gases or other

material shall not be discharged, injuring operating personnel or

surrounding apparatus and cables.

(ee) . The sheet should be cold rolled with smooth finish, levelled & free from

flaws. However, the structural frame shall be minimum 1.5mm & all load

bearing members of the enclosures shall have a minimum thickness of 2

mm or more. All members shall be properly braced to prevent webbing.

(ff) Ring main design shall comprise full compartmental execution having

separate vertical sections for each circuit having internal barriers.

Compartment with doors for access to operating mechanism shall be so

arranged as not to expose high voltage circuit. The ring main cubical

compartment shall be provided with bolted/hinged doors on the front with

facility for padlocking door handles.

(gg) All corresponding components of circuit breaker / load break switch

cubicles of same ratings shall be interchangeable with one another.

(hh) The board shall be wired with the connection brought on to the terminal

boards for remote operation.

(ii) The equipment shall be as compact as possible so as to occupy minimum

space in the sub-station room. Such type of equipment will have

preference.

(jj) Temperature rise in the unit shall not exceed as prescribed in IS/IEC.

(kk) Minimum clearance between the phases and between live parts &

grounded objects in the switchgear / load break panels shall be in

accordance with IEC.

(ll) Operating Mechanism

(xi) Circuit breaker as well as load break switches shall be provided with

suitably designed spring charged motor operated mechanism. It shall


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be possible to charge the spring manually, if required. The closing /

opening shall be through remote or through locally operated push

button or operating switch.

(xii) It should be “trip free” mechanically under every method of closing

(except during closing for maintenance).

(xiii) The operating mechanism shall be such that the failure or any

auxiliary spring will not prevent tripping. When the circuit breaker is

already closed it shall not cause damage to the breaker or endanger

the operator.

(xiv) The breaker / load break switch shall also be hand operated, if so

required.

(xv) Electrical as well as mechanical indicator shall be provided to show

open & close positions of the breaker / load break switches at RMU

+ FRTU side. It shall be located in a position where it will be visible to

a man standing on the ground with the mechanism housing closed.

An operation counter shall also be provided with each breaker / load

break switch.

(xvi) Working parts of the mechanism shall be of corrosion resisting

material. Bearings, which require grease shall be equipped with

pressure type grease fittings. Bearing pin, bolts, nuts and other parts

shall be adequately pinned or locked to prevent loosening or required

adjustment with repeated operation of the breaker / load break switch.

The mechanism shall be maintenance free.

(xvii) The closing mechanism should be able to be operated by one man

standing on the ground & direction of rotation of the handle for

charging / closing shall be clearly defined.

(xviii) In case limit switch fails to cutout the spring charging motor when the

springs are fully charged, the motor shall be automatically decoupled

and annunciation for this shall be provided.

(xix) The mechanism shall be complete with opening spring, closing

spring, auxiliary contacts & all other necessary accessories to make

mechanism a complete operating unit. A continuous sequence of

closing and opening operation shall be possible.

(xx) Besides the requirements of auxiliary switches used by the

manufacturer, at least 2 NO + 2 NC with multiplex unit for extending

these contacts shall be provided for the use of the purchaser.

22.1.2.7 RMU To Be Maintenance Free

(d) The RMU’s life and its operation must not be affected by environmental

conditions such as foggy atmosphere, extremes of cold, seismic conditions

such as corrosive / salty sea winds, 100% relative humidity (condensing

type) with hot and humid environment, temporary flooding etc.


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(e) The equipment shall be of “fit & forget” type requiring little maintenance,

(practically no maintenance), during its life.

(f) RMU should have reliable switching devices and maintenance free drives.

22.1.2.8 Insulating Medium

(d) The RMU shall comply with the requirements of IEC standard for “Sealed

Pressure System”, for which no filling of gas is to be carried out during the

life span of the switchgear. The SF6 gas shall be as per IEC-60376 / IS:

13072 and shall be suitable for its application in the switchgear. It should

continue to have high insulating and arc quenching properties throughout

the switchgear life.

(e) The SF6 gas shall be self-regenerating after the interruption of arc due to

breaking load currents. The gas tank should have material in the tank to

absorb the moisture from SF6 gas.

(f) The use of organic seals on the equipment, grease and oil in the drives

requiring periodic maintenance are not to be used.

22.1.2.9 SF6 Gas Monitoring and Pressure Relieving

(e) SF6 gas in the RMU tank shall be constantly monitored through a gas

pressure indicator, which should be duly temperature compensated. In

case the pressure is not adequate it should block its operation and give a

warning to isolate the RMU.

(f) The pressure sensors shall feed a microprocessor based analysing unit or

manometer based unit. By this system the gas pressure (temperature

compensated) should be recorded to measure the dielectric strength of the

gas in the compartment.

(g) A loss of gas should be signaled via contact to initiate the low alarm of gas.

(h) If the gas pressure exceeds the permissible limit, such as during short

circuit clearing, the pressure relief device should operate in the underside

of the module. This area must be partitioned from the cable connection

apartment.

22.1.2.10 Voltage Indicator Lamps, Phase Comparators And Monitoring Of RMU Bus Voltage

It shall be possible for each of the functions on the RMU to be equipped with a

continuous voltage indication, to indicate whether or not there is voltage on the

cables. The capacitive dividers will supply low voltage power to sockets at the

front of the unit, an external lamp shall be provided to indicate live cables. Three

outlets can be used to check the synchronization of phases with the use of an

external device. This device shall be in compliance with IEC 1958 standard.

Besides this the voltage monitoring of bus bar shall be provided continuously.


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22.1.2.11 Earthing of RMU Circuits

(g) The cables in the RMU on the load break switch sides shall be earthed (only

when these are dead) through integral earthing switch having the short

circuit capacity of the RMU.

(h) The earthing switch should be mechanically interlocked so that it can only

be operated when the main switch is in open condition and circuit is fully

de-energised. Necessary voltage monitoring device in such a case shall be

provided.

(i) The earthing switch shall be operated through the main circuit mechanism

and manual closing shall be through a fast acting mechanism.

(j) Mechanical interlocking system shall be provided to ensure that the switch

is turned to ‘OFF’ position before being turned from ‘ON’ to ‘EARTH’

condition.

(k) Cable box interlocking is to be provided to ensure that before the removal

of the unit cable box cover, the unit earth is applied.

(l) General Earthing Requirement

(vi) All metal parts not intended for carrying current shall be connected to

duplicate earthing system and suitable terminals shall be provided on

each equipment or part of equipment in conformity with the relevant

standards.

(vii) The earth continuity conductor shall be of tinned copper and shall

have sufficient cross sectional area so as to afford a low resistance

path for the full fault current corresponding to the circuit breaker

ratings.

(viii) The size of earth continuity conductor shall be adequate, so as to

restrict the temperature rise to the limit without causing any damage

to the earth connection, while short circuit current flows through it for

the short time rating of the equipment.

(ix) The size of earth continuity conductor shall be as large as possible to

reduce to the barest minimum the potential rise of the metal frame of

the circuit breaker.

(x) No sweated / riveted joints in current conducting path shall be

permitted.

22.1.2.12 Cable End Termination Box

(k) Cable-end termination box shall form an integral part of the equipment. The

cables shall be convenient to install.

(l) There shall be elbow type connection for cable termination with insulating

boots. The boots shall form part of supply.


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(m) Each Cable compartment shall be provided with three bushings to

terminate the incoming and outgoing 11kV, 3 Core or single core cables as

the case may be. There shall be minimum 700 mm height from the base of

the mounted switchgear so that the cables can be bent and taken vertically

up to the bushings. The Cable termination shall be done by latest

technology employing cold Termination method so that adequate

clearances shall be maintained between phases for Termination.

(n) The arrangement for earthing the termination point of cables shall form a

part of supply and should be of adequate rating. The standard size of 11

kV XLPE cable being used is as specified for load break switches as well

as for the tee-off transformer.

(o) The cable mounting arrangement on the load break switches shall be over

the trench and no special arrangement is required for installation of the

cables and their terminations. These shall enter directly from the cable

trench through cable glands in gland plate to the load break switches. The

ring type air insulated CTs shall be provided.

(p) All of the cable boxes shall be air insulated suitable for dry type cable

terminations. Compound filled cable boxes are not acceptable.

(q) The cable boxes at each of the two ring switches suitable for accepting H.V.

cables approaching from below or as per site requirement. The tee-off

circuit breaker shall be suitable for either of the following termination

arrangements:

(iv) Direct coupling to a transformer flange

(v) Cable entry from below via a tee-off cable box

(vi) Cable entry from above via a tee-off cable box

The extended function shall be suitable for cable entry from either above or

below only.

(r) Double compression type, chrome, plated cable brass glands shall be

provided in the gland plate, with necessary cable clamping and earthing

arrangement.

(s) Support frames shall be provided whose height shall be such that cable

connections can be conveniently made after allowing for bending radius of

cables.

Note: The XLPE, outgoing & incoming 12 kV power cables to LBS are not in the

scope of the RMU manufacturer. However, elbow type termination kits for these

cables (including two sets, of new cable termination tools) are included in the

scope of supply.However the supply of outgoing and incoming XLPE, 12kV

cables in the scope of PMC-01 contractor.

(t) Testing of Cables

(iv) It shall be possible to test the core or the sheath insulation of the

network cables while the RMU remains energized at rated voltage. It


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shall be preferable to carry out the phase by phase testing through a

built-in-facility without necessity to have an access to cable

compartment. The maximum test voltage shall be less than 38 kV DC

for 10 minutes.

(v) Any cable test access facility which requires the use of an additional

loose devise shall not be acceptable.

(vi) Any switching unit, load-break switch or circuit breaker, shall be able

to receive a dedicated device for cable testing, allowing the cable test

bench to be connected from the front of the cell with opening the cable

compartment. This cable test device must be fully interlocked with the

earthing switch.

22.1.2.13 Bushings

(i) Bushing shall be homogeneous, free from laminations, cavities & other

flaws or imperfection that might affect the mechanical or di-electric quality

& shall be tough and impervious to moisture.

(j) Silicon type bushings shall be used.

(k) Bushings shall be designed to have ample insulation, mechanical strength

and rigidity for the conditions under which they will be subjected.

(l) When operating at normal rated voltage there shall be no electric discharge

between the conductors & bushings, which could cause corrosion or injury

to the conductors, insulators or supports by the formation of substances

produced by chemical action.

(m) All iron parts shall be hot dip galvanised (not less than 75 micron) & all joints

shall be airtight. Surfaces of the joints shall be smoothened up. Bushing

design shall be such as to ensure a uniform compressive pressure on the

joints.

(n) All current carrying contact surfaces shall be sliver plated; silver plating

shall not be less than 1 mil in thickness.

(o) The creepage distance of the bushings shall be suitable for condensing

type humidity atmosphere.

(p) Bushings shall be tested for type tests & routine tests in accordance with

stipulation of IS: 2099. Routine as well as type test reports in conformity

with above IS shall be furnished to the purchaser.

22.1.2.14 Caution Notice

Caution name plates shall be provided at all points where such safety

requirements are to be met as per Indian Electricity Rules.


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22.1.2.15 Safety Interlocks

(e) Disengagement of a circuit breaker or switch shall not be possible unless it

is in open position. Suitable interlocks shall be provided.

(f) The position of the circuit breaker, whether in open or close position shall

be indicted through suitably designed fail-safe mechanical indicators.

(g) The operating position of circuit breakers or isolators, either on bus-bar side

or for earthing, shall be clearly indicted by a reliable indicating device.

(h) Integral earthing facility, when provided, shall be suitable to make earthing

connections only when the associated circuit breaker is in tripped position.

The current rating of earthing facility should be commensurate with the

short circuit rating of the circuit breaker.

22.1.2.16 Metering, Protection, Indication And Auxiliary Switches

(d) General Requirements for Instruments

(iv) Multifunctional Measuring instruments, with an accuracy of class 0.5S

(as per IEC 62053-22) or better shall be of digital type, with minimum

3 line LED display and conforming to relevant IS / IEC & shall be of

an approved type & design suitable for tropical climate and

condensing type humidity. Measurement shall include voltage,

current, pf, KW, KVA, KVAR and Neutral current. It shall have RS 485

communication port. Meter shall have %THD & individual Harmonics

measurement comply to IEC 61557-12.

(v) All instruments shall be back connected and instruments cases shall

be earthed.

(vi) The instruments safety factor shall be equal to or less than 5.

(e) Protection

The protection on the circuit breaker shall comprise the following

arrangement:

(vii) The Tee-off, Circuit breaker unit fitted with 3 protection CTS of

suitable ratio and burden [considering power transformer rating], a

low burden trip coil and auxiliary switch assembly allowing the use of

a self -powered, numerical relay with an open protocol having three

over current and one sensitive earth fault elements. The relay should

be housed within a cubicle box, accessible from the front. This relay

shall also communicate with Feeder Remote Terminal Unit.

(viii) The protection curves and all other settings shall be adjustable in

software through lap top, which when viewed from the front clearly

show the unit settings. (Note DIL type switches are not acceptable).

The protection setting range and minimum pick up current shall be in


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accordance with the protection of transformer rating. Typically the

primary settings may be in the following range:

Overcurrent: 20A to 200A

Earth Fault: 2A to 50A

(ix) The relay should give local indication of a fault operation and should

differentiate between overcurrent and earth fault.

(x) It should be possible for the relay to perform a self-check.

(xi) Other auxiliary relays to give trip / alarm [local as well as remote] in

case of operation of transformer protections, gas leakage, ON, OFF

& Earth status of RMU load break / breaker, spring charged etc. shall

be provided.

(xii) Besides the requirements of auxiliary switches used by the

manufacturer, at least 4 NO + 4 NC shall be provided for the use of

the purchaser.

(f) Instrument Transformers

The instrument transformers required for the switchgear shall conform with

the respective standards specification.

(iii) Voltage Transformers

The Voltage Transformers (VT) shall be of dry compound epoxy

insulated. The VT shall be protected on their primary sides by current

limiting fuses. On the secondary side, the circuit shall be protected by

MCB’s. Provision shall be so made that the primary fuses can be

handled only in the drawn out position. The particulars of the voltage

transformer are:

Type: Cast Resin.

Rates Voltage: 11000 110 110 Volts

3 3 3

Accuracy Class : 1.0

Burden : 50 VA or as per system requirement.

Note: Contractor shall design the voltage transformer as per system

requirements, and alternate arrangement, if any, shall also be

considered.

(iv) Current Transformers

(ad) The CT’s shall be cast resin ring type, suitable for metering and

protection requirements, air insulated and shall be able to

withstand the thermal, dynamic and mechanical stresses

resulting from the maximum short circuit and short time current


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rating of the switchgear. CT should be suitable for continuous

operation at 130% of its rated current.

(ae) CT’s shall have polarity marks engraved on each transformer

and at the associated terminal blocks. Facility shall be provided

for short circuiting and earthing the CT secondary at the terminal

blocks by the use of shorting type terminals.

(af) CT ratio, burden, accuracy [1.0 for metering and 5P for

protection] and other requisite parameters shall be suitable for

the self-powered relay. CT calculations in this regard shall be

submitted.

22.1.2.17 Control of the RMU and CSS

(e) Remote & local operation of the RMU’s line switches and Circuit breaker

should be provided using motors fitted to the operating mechanism.

(f) The provision of the motors to the mechanism must not in any way impede

or interfere with the manual operation of the switches or Circuit breaker.

(g) The Contractor shall provide all necessary equipment for remote control

and monitoring of the RMU including other important equipment items in

CSS.

(h) SCADA software provided shall be guaranteed for free replacement (in

case it gets corrupted) and upgradation during the life of the hardware.

22.1.2.18 Fault Circuit Indicator

(f) To pinpoint the faulty section between a number of series connected, load

break switches, of RMU’s a Fault Circuit Indicator (FCI) shall be provided

with each RMU. This indicator shall operate for earth faults and phase to

phase short circuits between any two RMU’s.

(g) The indicator should be suitable for use on 12 kV RMU’s in an open ring

main system. In case of fault in a cable section between two RMU’s. It shall

be possible to pin point the faulty section and communicate with Feeder

Remote Terminal Unit for automatic faulty cable isolation and supply

restoration.

(h) The FCI supplied should be complete in all respects, with all the necessary

components e.g. LED lamp or LCD display, , Fault Indicator Unit, CTs

cabling etc. and shall form part of RMU. It shall be with display to indicate

current loading and the type of fault.

(i) Since RMU’s are controlled through SCADA system, the FCI indications

shall also be displayed on the central control room. Therefore these FCI’s

shall have additional provision for remote indication besides local

indication.


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(j) FCI shall be of proven type and in the manufacturing range of RMU

supplier.

22.1.2.19 Feeder Remote Terminal Unit (FRTU) For RMU

Make of FRTU shall be same as that of the RMU manufacturer. It shall have peer

to peer communication and with the remote switchgear / SCADA at the controlling

substation through fibre optic cable to initiate the required switching operations.

(d) Main Requirements

FRTU cubicle shall be equipped to meet the following main requirements

for compact substation. It shall be possible to mount it on wall if required.

(xii) Monitoring and control of 11kV LBS and VCB feeders

(xiii) In conjunction with FCI, detection and isolation of faulty cable for

phase to phase and phase to earth cable short circuits and

automatically ensure supply restoration in less than 60 seconds.

(xiv) Multifunction measurements.

(xv) Transmit data to the remote control centre.

(xvi) The system shall have necessary redundancy in communication.

(xvii) To incorporate self-healing grid logic for faster restoration of supply

even in the absence of control centre SCADA.

(xviii) Data storage.

(xix) Provision for Maintenance

(xx) FRTU shall be capable to monitor and control 3 Way / 4 ways RMU.

(xxi) Chronological time stamped event recording.

(xxii) Data storage, in the event of mains failure, shall be for at least 8

hours. The minimum storage shall be for about 40000 events.

(e) Control unit

(x) Control Unit shall perform all the required control and monitoring

functions of Compact Substation and shall be equipped with a remote

and local control mode switch on its front panel.

(xi) Operation in Local Mode:

(ad) Transmission of data for remote measurements and time-

stamped events shall not be disturbed.

(ae) Opening and closing operation after validation.

(af) Inhibition of opening / closing from remote.

(xii) Operation in Remote Mode:

(ad) Transmission of measurements and time stamped events.


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(ae) Local electrical control shall get blocked.

(af) Opening and closing operation from remote control centre.

(xiii) All data shall be available locally on the front panel of the enclosure

and remotely from the control centres. LBS / breaker open and close

status can be had from the front mimic of FRTU respectively with the

green / red LED indication. It shall be possible to retrieve and display

the time-stamped events recorded at the enclosure locally as well as

at the remote control centre on a lap top computer.

(xiv) Power Supply:

Compact, sealed for life 12V battery with a long life and no

maintenance of any kind for 5 to 7 years or more along with charger

[to be supplied 230 V, 50 Hz from CSS] is to be provided in the unit.

The supply shall be conditioned to provide power at required voltage

for motor operation and communication for local and remote SCADA.

The transmission output shall be able to supply a conventional radio

[without battery power of RTU] to inform the remote control centre of

a battery failure. Power from the unit shall be sufficient to supply

control power to all the switch cubicles in the CSS, radio and the

electronics in the enclosure. The standby power unit shall be with a

minimum autonomy of at least 8 hours for 10 opening and closing

cycles. The battery shall be checked at regular intervals by the slave

station and an alarm shall be generated and transmitted to the remote

control centre in the event of a fault. The unit shall be protected

against overvoltage and over loads.

(xv) Time-tagged data archiving:

(ac) All the archived data shall be retrieved locally and remotely by

means of the configuration and operating software supplied

with the control unit. The data shall also be downloaded locally

or remotely to a PC as a .CSV file.

(ad) Event and measurement time-stamping shall be accurate to

one millisecond [ms] and the discrimination between two events

shall be 10 ms.

(xvi) Communication with the remote control centre

(ad) FRTU shall have IEC 870-5-101 / 104 protocol to transfer

information to control center SCADA and Modbus protocol to

communicate with field MFM [Multifunction Meters] on Modbus

RS485. The Modbus protocol shall be open. Security &

communication package provider shall only lay the fibre optic

cable for the same and further connections, repeaters, boosters

and any other communication equipment shall be included in

the scope of supply.


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(ae) It shall be possible to configure each measurement to be

transmitted spontaneously to the remote control center.

(af) Data shall be configured using a PC connected to the control

unit via an Ethernet and / or USB port. It shall also be possible

to configure data remotely.

(xvii) Software

The software shall not require a special licence and it can be used

and copied freely.

(xviii) Indications

The slave stations shall process at least the following information for remote

indication and for local display purposes:

(am) Open / closed position of each LBS

(an) Earth status

(ao) Absence of AC voltage,

(ap) Local / remote control operating mode,

(aq) Detection of phase-to-phase or earth fault current flow,

(ar) Load current measurement

(as) Charger fault

(at) Battery fault

(au) Motor drive DC supply fault

(av) Internal fault

(aw) Detailed diagnosis of the status of the uninterruptible power

supply (charger, batteries).

(ax) Indications for LT side status of switches, alarms as required.

(f) Erection / construction / Operating Tools and Tackles

(vi) Each RMU will be provided with operating lever and other such

equipment which are necessary for the normal operation of the

equipment. It should also include any spring charging handles for the

manual charging of closing springs. The tenderer shall separately list

out in the tender in the given schedule, sets of tools required for initial

erection/construction and subsequent maintenance. The price of

those should be included in the cost of equipment.

(vii) An anti-reflex mechanism on the operating lever shall prevent any

attempts to re-open immediately after closing of the switch or earthing

switch.

(viii) All manual operations will be carried out on the front of the

switchboard.


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(ix) The effort exerted on the lever by the operator should not be more

than 250 N for the switch and circuit breaker.

(x) The overall dimensions of the RMU shall not be increased due to the

use of the operation handle. The operating handle should have two

workable positions 180o apart.

22.1.2.20 Mimic Diagram

(g) The front shall include a clear mimic diagram which indicates the different

functions. The position indicators shall give a true reflection of the position

of the main contacts. They shall be clearly visible to the operator. The lever

operating direction shall be clearly indicted in the mimic diagram. The

manufacturer’s plate shall include the switchboard’s main electrical

characteristics.

(h) Labels and Marking of Connections

All apparatus, control gear and the apparatus mounted thereon shall be

clearly labelled, indicating where necessary, their purpose and the ‘ON’

‘OFF’ and ‘EARTH’ position. The labels shall be clearly lettered on

enamelled surface or other approved materials. Brass should not be used

for labels. Each phase of alternating current and connections shall be

coloured to distinguish phases, neutral and earth. The colouring shall be

red, yellow, blue, black and green respectively.

(i) Bus Bars

(iii) Bus bars shall be of uncoated, bare conductor grade electrolytic

copper.

The successful tenderer shall furnish the calculations after award of

work, during Detailed Design stage and shall be approved by

Engineer and establishing thermal and dynamic adequacy of bus bar

sizes with reference to its short circuit ability. The bus bar shall be

integrated completely into the gas filled compartment including the

coupling chambers between two adjacent modules.

(iv) The insulating ability of the entire bus bar system should be monitored

along with the gas filled cladded compartment of the module. The bus

bar size shall be so chosen so as to limit the current density to within

permissible limit and if the fault current restricts the current density

less than that, then lesser density shall be used. The successful

tenderer shall furnish the calculations after award of work during

detail design stage and shall be approved by Engineer.

(j) Temperature rise

The temperature rise and the maximum temperature on any part of the

equipment when in service at site under continuous full load condition or

under short circuit shall not exceed the permissible limit as per relevant IEC

or IS: 13947. This shall not be exceeded when corrected for the difference


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between the ambient temperature at site and the ambient temperature

specified in the relevant standard.

(k) RMU Indications

Indication of spring charge, ON, OFF trip etc. shall be provided by means

of mimic. If not covered in mimic and LED which shall be fed from control

supply arrangement designed by contractor If LED’s are provided, the

indicating lamps shall have covers of following colours.

Red closed position of breaker/ load break switch

Green open position of breaker /load break switch

Blue spring charge condition of breaker / load break switch

Amber auto tripped position of breaker

Yellow Earth position

If the manufacturer’s standard design has an alternative arrangement,

instead of the above mentioned, same can also be considered.

(l) Terminal boards and Secondary Wiring

(vi) Connection to switchgear, operating mechanism indicating relays and

all instruments shall be deemed to form a portion of equipment of

panel.

Panel connections shall be insulated and shall be healthy and

securely fixed to back of the panel. The wiring must run on porcelain

or non-rusting metal cleats or metal flexible tubes as may be

approved by engineer. All wiring in the vicinity shall be insulated and

shall run in non-rusting flexible tubes from terminal boards

conveniently situated. All control connections instruments and relay

wires shall be provided with numbered ferrules at each terminal and

the numbering shall be in accordance with an approved system. All

wiring diagrams shall be clearly marked with the numbers

corresponding with those on the ferrules of the individual cores. Each

set of current and voltage transformer secondary connection shall be

complete and shall be earthed at one point only. Each such earthing

shall be made through links which can be opened for insulation

testing.

(vii) All the internal control wiring shall be through fire-resistant low smoke

tinned copper wires of 1.5 mm2 and for CT circuits these shall be with

2.5 mm2. The strands in the copper wire shall not be less than 48.

(viii) The CT circuits shall be provided with isolating type of links, to check

the current in the CT circuits during testing. Similar it shall be possible

to isolate PT’s without disconnecting wires to check & test the meters.

All CTs must have provision for shorting through link.

(ix) The air insulated control cabinet shall have provision for lighting.


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(x) As the equipment is to be installed in a tropical and high humidity

zone, the air insulated control cabin shall be provided with suitable

space heater of PTC type.

22.1.2.21 Recommended Spares

The contractor shall provide a list of recommended spares along with cost of

each item, in the schedule provided for 15 (fifteen) year operation. The cost of

recommended spares shall not be included in bid evaluation. The Employer /

Engineer shall have the option to select the desired items and it would from a

part of separate order.

22.1.2.22 Type And Routine Tests

All the routine and type tests shall be carried out as per relevant IEC / Indian

Standard. For type test certificates Engineer may consider test certificates at its

absolute discretion.

All the routine tests on the switchboard shall be witnessed by the Engineer or its

authorised representative.

The following type & routine test certificates shall be supplied / carried out on the

RMU:

(k) Impulse withstand test

(l) Temperature-rise test

(m) Short-time withstand current test

(n) Mechanical operation test

(o) Short circuit type test at L V chamber

(p) Checking of degree of protection

(q) Switch, circuit breaker, earthing switch making capacity.

(r) Switch, circuit breaker breaking capacity.

(s) Internal arc withstand test.

(t) Checking of partial discharge on complete unit

In addition, for switches, test reports on rated breaking and making capacity shall

be supplied.

(c) For earthing switches, test reports on making capacity, short-time withstand

current and peak short circuit current shall be supplied.

(d) The routine tests carried out by the manufacturer shall be backed by test

reports signed by the factory’s quality control department. They shall


(viii) Conformity with drawings and diagrams,

(ix) Measurement of closing and opening speeds & times


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(x) Measurement of operating torque

(xi) Checking of filling pressure

(xii) Checking of gas tightness

(xiii) Checking of partial discharges on individual components

(xiv) Dielectric testing and main circuit resistance measurement

All of the major type tests shall be certified by an independent authority and an

internationally acceptable test house for the tests carried outside the country of

manufacture.

22.1.2.23 Configuration of Ring Main Unit

(h) Each non-extendable ring main unit shall comprise of three or four

configuration, as in Bill of quantities with a continuous bus bar, SF6

insulated, sealed for life, CTs and PTs as per requirement, pad locks for

locking with a universal key, complete in all respects.

(i) The main items of RMU are given below any other item not specifically

mentioned but required for the successful operation of the equipment shall

be deemed to be included without any financial liability to purchaser.

(j) Each load break switch panel shall be equipped with 12 kV, 630 Amps.

20kA / 3s, Gang operated, SF6 insulated, manual / motor operated, fault

making, load breaking switch, along with associated bus bars, CTs, PTs [as

required] and the same shall consist of the following main items:

(xviii) Metal clad in door type weather proof housing.

(xix) 12 kV, 630 Amps, fault making, .load breaking, manually / motor

operated, self-aligning, gang operated.

(xx) One set of 630 Amp, bus bar as specified.

(xxi) Isolating plug & socket for main & auxiliary contacts if required.

(xxii) Mechanical interlocks to prevent switching on with cable in earthed

position.

(xxiii) One set of triple pole gang operated cable earthing contacts.

(xxiv) Load Current measurement.

(xxv) Air Insulated cable box for Cable end termination suitable for 3 core,

12 kV, XLPE armoured cable of specified size, with AL conductor,

along with glands, suitable Gland plate and Cable support.

(xxvi) Mechanical On/Off/Earth/Test Indicators.

(xxvii) Cable Testing Sockets

(xxviii) Capacitive Voltage indicator lamps.

(xxix) Cable clamps


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(xxx) Feeder Remote Terminal Unit [FRTU]

(xxxi) Fault Circuit Indicator along with CTs.

(xxxii) Indicating lamps & auxiliary contacts.

(xxxiii) Auxiliary relays (if required).

(xxxiv) Interlocked earthing arrangement.

(k) Tee-off Circuit Breaker Panel, with SF6 insulation, suitable for transformer

feeder shall be equipped with 12 KV, 200 Amps, 20 kA, for 3 sec rated

circuit breaker with associated C.Ts, PTs, spring operated mechanism, bus

bars, compete with instruments, relays, terminal blocks. It shall comprise of

the following main items:

(xvi) Metal clad / indoor type weather proof housing

(xvii) Vacuum circuit breaker, trip free

(xviii) One set of 630 Amps. Bus bars (integral part with load break bus bar).

(xix) CTs for protection & Metering to match the transformer – 3 Nos.

(xx) 3-overcurrent & one earth fault IDMT relays, direct operating.

(xxi) Termination suitable for connection to.,11/0.415 V transformer of

specified rating.

(xxii) Multifunction meter

(xxiii) P.T. 11000/ 3 - 110/ 3 - 110/3, as required.

(xxiv) On/Off indicator

(xxv) Mechanical interlocks

(xxvi) Tripping, closing coils.

(xxvii) Indication lamp & spare auxiliary NO/NC contacts.

(xxviii) Auxiliary relays for alarm and trip for transformer protections

(xxix) Earthing arrangement duly interlocked.

(xxx) Mechanism with spring charging motor.

(l) The common system for the above shall consist mainly of:

(xii) Channels, nuts, bolts, glands, gland plates, inter connecting

arrangement of tee-off breaker with transformer, cable termination

kits & supporting arrangement of cable, with the load break switches

etc.

(xiii) Cable termination kits to be included for each RMU.

(xiv) Gas monitoring device for sealed gas unit.

(xv) Pad locks for locking the panels.


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(xvi) Handles for normal operation, spring charging & other tools required

for normal operation.

(xvii) Mandatory spares.

(xviii) Arrangement of control supply for breaker / load break closing /

tripping, motor charging indications etc.

(xix) All the necessary indicating lamps.

(xx) SF6 pressure monitoring unit.

(xxi) Analysis unit for dielectric monitoring of SF6 gas.

(xxii) Any other item not included above but required for the operation shall

be deemed to be included though specifically not mentioned, without

any financial liability to purchaser.

(m) Two sets of cable termination and jointing tools for all the substations at

various locations.

(n) Any other item mentioned in text or any other item required for successful

operation but not included here shall be deemed to be included.

22.1.3 Dry Type Distribution Transformer

22.1.3.1 General

The distribution transformer in CSS shall be indoor Dry Type Transformer,

complete with all accessories / fittings and spare parts as specified herein.

Three-phase transformers shall be with cast resin type, class F insulation system

with natural (AN) cooling for indoor installation, for use in three-phase HV/LV

distribution systems.

(j) Specific Technical Requirements (Standard Value)

(xviii) Rated KVA : As per Approved

drawing of Contractor

(xix) Number of phases : Three

(xx) Type of installation : Indoor

(xxi) Frequency : 50 Hz

(xxii) Cooling medium : AN

(xxiii) Rated Voltage

High voltage winding : 11 kV (DELTA)

Low voltage : 0.433 kV (STAR) with

Neutral

(xxiv) Highest Continuous System Voltage:

High Voltage : 12 kV


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Low Voltage : 0.450 kV

(xxv) Method of System Earthing :

High Voltage : Unearthed

Low Voltage : Solidly grounded

(xxvi) Type of tap changer : Off Circuit Gang

Operated

(xxvii) Range of tapping : +5% to -5% with 5 steps of

2.5% on 11 kV side

(xxviii) Impedance at rated KVA : 5.0% at 75oC

(xxix) Insulation and level : HV LV

Type of insulation : Uniform Uniform

One minute power : 28 3

Frequency withstand

test voltage (kV)

Impulse withstand : 75 8

test voltage (kVp)

(xxx) Winding

(ac) Connection : Delta (HV) Star (LV)

(ad) Material : Aluminum

(xxxi) Vector group : Dyn-11

(xxxii) Terminal details

(ad) HV Termination : Suitable for tee-off Breaker

of RMU

(ae) LV Termination : Suitable for phase and neutral

connection between transformer and LT board through an

insulated copper bus bar or a sand witched copper bus bar

enclosed in a non-segregated bus duct. The size of the neutral

bus shall be same as phase bus.

(af) LT Neutral earthing : A separate Neutral point to

be provided for earthing.

(xxxiii) Minimum Clearance in Air : 11 kV 0.433 kV

(ac) Phase to phase (mm) : 340 50

(ad) Phase to phase (mm) : 170 50

(xxxiv) Design Ambient temperature : 50°C


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(k) Maximum Temperature Rise of winding over an ambient of 50°C and

1000m altitude, not to exceed 90°C.

Maximum Temp of insulation : 150°C

Over load capacity : As per IEC

(l) Noise level at rated voltage & frequency : As per NEMA Pub. Tr-1

(m) Transformer Losses

The guaranteed losses of the transformer shall not exceed as given in the

Energy Conservation Building Code [ECBC], as per latest guidelines of the

Bureau of Energy Efficiency [BEE] for the required rating of distribution

transformer or as per the Bureau of Indian Standards [BIS] for transformers

having energy efficiency level-3. Transformers not complying to BEE / BIS

loss guidelines shall not be accepted. The guaranteed values of no load

losses and load losses shall be stated in the bid and these shall be firm.

(n) Performance

(v) Transformer shall be capable of withstanding for two seconds the

short circuit at its terminals as per requirements of IS-2026 without

any damage. Source short circuit power on the primary of the

11/0.433 kV transformer shall be assumed as 500 MVA for the short

circuit capability of the transformer. The thermal ability withstand due

to short circuit shall be demonstrated by calculation.

(vi) The maximum flux density in any part of the core and yoke at normal

voltage and Frequency shall be such that the flux density under 10%

over voltage condition shall not exceed 1.9 Tesla.

(vii) Transformer shall, under exceptional circumstances, due to sudden

disconnection of the load, be capable of operating at the voltage

approximately 25% above normal rated voltage for a period of not

exceeding one minute and 40% above normal for a period of 5

seconds.

(viii) The transformer may be operated continuously without danger on any

particular tapping at the rated KVA ±10% of the voltage

corresponding to the tapping.

(o) Miscellaneous

Complete hardware for fixing the transformer as a part of packaged RMU

substation shall be provided whether specifically mentioned or not.

(p) Delivery

The equipment shall be delivered, erected and commissioned at site as a

part of the packaged RMU substation.

(q) Conflict in Clause


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In case of any conflict between the Specific Technical Requirements and

General Technical Requirements, the requirements indicated as Specific

Technical Requirement shall prevail over the General Technical

Requirements.

(r) Marine/saline environment: Climatic, Environmental and fire resistant

Requirements

(iii) As the equipment is to be installed in a corrosive saline environment

and humid atmosphere, moisture dripping water and tropical

environment the equipment and material provided must resist the

corrosion likely to occur in such cases. Normal mild steel, even

galvanized steel is not suitable for such an atmosphere.

(iv) Further the transformer must comply to the following class

requirements of clause 13 of IS 2026-11 / IEC 60076- 11.

22.1.3.2 Class C1: Operation, transportation and storage at ambient temperature as low as -5ºC

22.1.3.3 Class E2: Frequent condensation combined with high pollution.

22.1.3.4 Fire Class F1: Limited flammability, Self-extinguishing of the fire and to be free from halogens, emission of toxic gases, and minimum of thick smoke.

(c) The above classes will be indicated on the rating plate.

Note: The manufacturer must produce a test report, complying to above

clauses as per test procedure of IEC-60076-11. Test report shall be from

an accredited laboratory acceptable to Engineer, for a transformer of the

same design.

(d) Name Plate

Transformer rating plate in English and Hindi language shall contain the

information as given in Clause 15 of IS: 2026 (Part-I) / IEC 60076-11. The

details on rating plate shall be finalised during the detailed engineering.

22.1.3.5 General Technical Requirements

Dry type transformer will be manufactured in accordance with a quality system in

conformity with ISO 9001 and complying to latest version of IEC 60076-11

Environmental management system is to be in conformity with ISO 14001, which

shall be certified by an independent recognized organization acceptable to

Engineer.

(d) Codes and Standards

(iii) The design, material, fabrication, inspection, testing before dispatch,

erection/construction, testing, commissioning and performance of

distribution transformers shall comply with all currently applicable

statutory regulations and safety codes in the locality where the


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equipment will be installed. Nothing in this specification shall be

construed to relieve the contractor of this responsibility.

(iv) Transformers shall conform to the latest applicable standards and

codes of practice as given below.


1 IS: 5 : Colour for ready mixed paints and

enamels.

2 IS: 104 : Ready mixed paint, brushing, zinc

chrome Priming

3 IS: 2026- [Part 1 to 11] Transformers

4 IS: 1180 : Outdoor type three phase distribution

transformer

5 IS: 1271 : Thermal evaluation and classification

of Electrical Insulation

6 IS: 1363 : Hexagon head bolts, screws and nuts

of Product grade C

7 IEC: 60076-11 for F1,

C1 & E2

Dry Type Transformers

8 IS: 2016 : Plain washers

9 IS: 2026 (Part I to IV) : Specification for Power Transformers

10 IS: 2071 : Method of high voltage test

techniques

11 IS: 2074 : Ready mixed paint, air drying, red

oxide-zinc chrome, primary

12 IS: 2099 : High voltage bushing for alternating

voltage above 1000 V.

13 IS: 2633 : Methods for testing uniformity of

coating of zinc coated articles

14 IS: 2932 : Enamel, synthetic, exterior (a)

undercoating (b) finishing

15 IS: 3043 : Code of practice for earthing


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16 IS: 3347 : Dimensions for transformer Bushings

17 IS: 3639 : Fittings and accessories for power

transformers

18 IS: 4257

: Dimension for clamping

arrangements for porcelain

transformer bushings

19 IS: 5216 : Guide for safety procedures and

practices in electrical work

20 IS: 5561 : Electric power connectors

21 IS: 7421 : bushing for alternating voltage upto

and including 1000 V.

22 IS: 10028

: Code of practice for selection,

installation and maintenance of

transformers.

23 IS: 12360

: Voltage bands for electrical

installation including preferred

voltages and frequency.

24 C.B.I.P. Publication : Manual on Transformers


The equipment complying with other internationally accepted standard may also

be considered if they ensure performance superior to the Indian Standards.

(e) Drawings

(iii) The contractor shall furnish, within fifteen days after issuing of Letter

of Intent, the following drawings / documents incorporating name of

project and transformer rating for approval.

(ar) Detailed overall general arrangement drawing showing front

and side elevations and plan of the transformer and all

accessories including external features with details of

dimensions, spacing of wheels in either direction of motion,

net weights and shipping weights, crane lift for un-tanking, size

of lugs and eyes, bushing lifting dimensions, clearances

between HV and LV terminals and ground etc.

(as) Foundation plan showing loading on each wheel and lifting

lugs.


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(at) GA drawings / details of bushing and terminal connectors.

(au) Name plate drawing with terminal marking and connection

diagrams.

(av) Wheel locking arrangement drawing.

(aw) Transportation dimensions drawings.

(ax) Interconnection diagrams both on HV & LV sides.

(ay) Over fluxing withstand time characteristic of transformer.

(az) Technical leaflets of major components and fittings.

(aaa) As built drawings of schematics, wiring diagram etc.

(abb) Setting of winding temperature indicator.

(acc) Completed technical data sheets.

(add) Details including write-up of tap changing gear.

(aee) H.V. bushing.

(aff) Bushing Assembly.

(agg) B-metallic connector for connection to specified conductor /

bus-bar /in bus-duct.

(ahh) Assembly.

• Two earthing terminals & core earthing

• Thermometer pockets

• Inspection cover

(iv) All drawings / documents, technical data sheets and test certificates

/ results / calculations shall be furnished.

(f) Any approval given to the detailed drawings by the Engineer shall not

relieve the contractor of the responsibility for correctness of the drawing

and in the manufacture of the equipment for the packaged substation.

22.1.3.6 General Constructional Features

(w) All material used shall be of best quality and of the class most suitable for

working under the conditions specified and shall withstand the variations of

temperature and atmospheric conditions without distortion or deterioration

or the setting up of undue stresses which may impair suitability of the

various parts for the work which they have to perform.

(x) Similar parts, particularly removable ones, shall be interchangeable.

(y) Screws, studs, nuts and bolts used for external connections shall be as per

the relevant standards. Bolts and nuts exposed to atmosphere shall be of

stainless steel.


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(z) Exposed parts shall not have pockets where water can collect due to

moisture or otherwise.

(aa) Labels, indelibly marked, shall be provided for all identifiable accessories.

All label plates shall be of in-corrodible material.

(bb) All internal connections and fastenings shall be capable of operating under

overloads allowed as per specified standards without injury.

(cc) Transformer and accessories shall be designed to facilitate proper

operation, inspection, maintenance and repairs.

(dd) No patching, plugging, shimming or other such means of overcoming

defects; discrepancies or errors will be accepted.

(ee) The galvanizing if required shall be of minimum 610 gm zinc per square

meter and it should be hot dip galvanised.

(ff) Painting [as applicable]

(v) The structural steel work shall be cleaned of all scale and rust by shot-

blasting. Steel surfaces exposed to the weather shall be thoroughly

cleaning and have a priming coat of zinc chromate applied. The

second coat shall be of a glossy oil and weather resisting non-fading,

paint of shade No. 631 as per IS: 5.

(vi) Metal parts not accessible for painting shall be made of corrosion

resistant material.

(vii) All paints shall be carefully selected to withstand heat, rain, saline

atmosphere, condensation and extremes of weather. The paint shall

not scale off or crinkle or be removed by abrasion due to normal

handling.

(viii) In case finish paint chips off or crinkle during transit or installation, the

contractor shall arrange for repainting transformer at site at his cost.

The paint for repainting shall be supplied by the contractor.

(gg) Under Carriage

The transformer shall be supported on non- corrosive steel structure

with forged steel flanged wheels suitable for moving the transformer

completely. Wheels shall be provided with suitable bearings which

will resist rust and corrosion and shall be equipped with fittings for

lubrication.

(hh) Magnetic Core

(xiii) The magnetic circuit shall be constructed from prime quality high

grade cold rolled, non-ageing, grain oriented silicon steel lamination.

The manufacture shall submit the following documents to prove only

Prime quality Core is used:

(af) Invoice of the supplier


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(ag) Mill’s test Certificate

(ah) Packing list

(ai) Bill of loading

(aj) Bill of entry certificate to custom

The manufacturers shall indicate whether they have in-house

core cutting facilities or not, if not, they shall indicate place of

cutting.

(xiv) To reduce the noise produced by the magnetic core, it is to be

equipped with noise-damping devices.

(xv) To reduce the no-load losses, the magnetic core is to be stacked

using overlapping-interlocking technology.

(xvi) The laminations shall be free of all burns and sharp projections. Each

sheet shall have an insulating coating.

(xvii) The insulation structure for the core to bolts and core to clamp plate

shall be such as to withstand a voltage of 2000 V for one minute.

(xviii) The completed core and coil shall be so assembled that the axis and

the plane of the outer surface of the core stack shall not deviate from

the vertical plane by more than 25 mm.

(xix) All steel sections used for supporting the core shall be thoroughly shot

or sand blasted, after cutting, drilling and welding.

(xx) The finally assembled core with all the clamping structures shall be

free from deformation and shall not vibrate during operation.

(xxi) The core clamping structure shall be designed to minimise eddy

current loss.

(xxii) The core shall be carefully assembled and rigidly clamped to ensure

adequate mechanical strength.

(xxiii) The core shall be provided with lugs suitable for lifting the complete

core and coil assembly.

(xxiv) The design of magnetic circuit shall be such as to avoid static

discharges, development of short circuit paths within itself or to the

earthed clamping structure and production of flux component at right

angle to the plane of the lamination which may cause local heating.

The construction is to be of ‘core’ type.

(ii) Internal Earthing

(iv) All internal metal parts of the transformer, with the exception of

individual laminations, core bolts and their individual clamping plates

shall be earthed.

(v) The magnetic circuit shall be connected to the clamping structure at

one point only and this shall be brought out. A dis-connecting link


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shall be provided on transformer to facilitate disconnections from

ground for IR measurement purpose.

(vi) Coil clamping rings of metal at earth potential shall be connected to

the adjacent core clamping structure on the same side as the main

earth connections.

(jj) Winding

(iv) LV windings

The LV winding shall be copper wound. This coil will be insulated

between each layer using a heat-reactivated class F pre-impregnated

epoxy resin film including the ends of the winding. The whole winding

assembly is to be polymerized at suitable temperature to ensure high

level of resistance to saline and highly humid environment and to

have excellent dielectric strength.

(v) HV Windings

(ae) HV winding shall be separated from the LV winding to give

an air gap between the MV and LV circuits for easy

maintenance.

(af) HV winding shall have linear potential gradient from top to

bottom to have low stress between adjacent conductors,

with high dielectric strength and low partial discharge.

(ag) HV winding shall be of Copper wire with class F insulation

cast in vacuum with fire proof / flame retardant epoxy resin.

(ah) The interior and exterior of the windings will be reinforced

with a combination of glass fibre or similar material to

provide thermal shock withstand.

(vi) HV Winding Support Spacers or Coil support blocks

(ad) Winding support spacers are meant to provide sufficient

support in transport, operation, short circuit and earthquake

conditions.

(ae) These spacers will be circular (or suitable shape) in shape for

easy cleaning. They will give an extended tracking line to give

better dielectric withstand under humid or high dust conditions.

(af) These spacers will include an Elastomer cushion that will allow

it to absorb expansion as peer load conditions. This Elastomer

cushion will be incorporated in the spacer to prevent it being

deteriorated by air or UV.

(kk) HV Connections

(v) The connections shall be of copper and made from the top to give a

safe and neat connection. A terminal plate shall be provided.


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(vi) The HV connections will be made from the top connection bars. Each

bar will be drilled with a hole for connection of cable lugs on terminal

plates.

(vii) The HV connection bars will be in rigid copper bars protected by heat

shrinkable tubing.

(viii) HV connections in cables are not allowed, in order to avoid all risk of

contact, due to cables flapping.

Depending upon the design of the manufacturer the arrangement


(ll) LV Connections

(iv) The LV connections with copper bars will be made from top of coils

on the opposite side to the HV connections.

(v) Connection of the LV neutral will be directly made to the LV terminals

between the LV phase bars. There shall be a separate earth point

connected to neutral.

(vi) Depending upon the design of the manufacturer the arrangement


(mm) Transformer Thermal and Overload Protection

(vi) PTC type sensors [minimum 6] shall be placed in the winding to

measure the winding temperature.

(vii) The transformer shall be equipped with an overload and thermal

protection device with sensors to continuously monitor the LV and HV

winding temperature for each phase.

(viii) Digital monitoring thermometers shall be installed locally in the CSS

on LV Board, with a provision for monitoring the temperatures at

remote SCADA. Necessary alarms and trip contacts along with

warning LEDs shall be provided to protect the transformers from high

temperature.

(ix) Sensors shall be so placed that it shall be possible to replace the

same very easily. All sensors along with enclosures, digital

thermometers, transducers, sensing relays, connecting leads, etc.

complete in all respects shall be in the scope of supply. For this

purpose Security & Communication contractor shall lay a fibre optic

cable from CSS to SCADA control Centre, termination of which to

such devices shall be in the scope of contractor.

(x) Provision shall be made that In case of fire the transformer circuit

breaker should be tripped.

(nn) Off Circuit Tap Changer

There shall not be a bolting arrangement for selecting the taps and shifting

the copper bars. Instead the off circuit tap changer shall be operatable by


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means of an operating handle / ring brought out-side the tank operable from

ground level. It shall be equipped with an indicating device to show the tap

in use and shall be provided with a locking arrangement to lock the switch

in position. The arrangement shall be such that an operator can change the

tap while standing at ground level with complete ease. There shall be

separate cover for tap changer. If the manufacturer’s standard design

differs from the above given, it shall be subject to approval of Engineer.

(oo) Safety of Personnel

Transformer shall be properly fenced/ protected in case the maintenance

personnel are likely to come near the live parts while carrying out normal

maintenance or monitoring activities near the transformer.

(pp) Fittings

The following fittings shall be provided on the transformers:

(xi) Separate LV neutral point, with two joined points for double earthing

of neutral along with tinned copper strip compatible to transformer

short circuit current rating for earthing.

(xii) One danger Plate

(xiii) Temperature indicating device, sensors etc. complete in all respects

with contacts for remote / local indication.

(xiv) Lifting eyes or lugs for the top cover, core and coils and for the

complete transformer.

(xv) Platform lugs / haulage lugs on under carriage.

(xvi) Marshalling box.

(xvii) Rating and connection diagram plate.

(xviii) Two numbers earthing terminals on opposite sides, associated nuts,

bolts and tinned copper earth strip of suitable section for connections

to purchaser’s grounding strip.

(xix) 4 bidirectional rollers.

(xx) Thermal and overload protection devices and equipment, along with

necessary transducers, sensors etc. for local and remote SCADA

indication, Alarm / trip contacts, LED indicators complete in all

respects

Note: The fittings listed above are indicative and any other fittings which

are generally required for satisfactory operation of the transformer are

deemed to be included in the quoted price of the transformer.

(qq) Radio Interference and Noise Level

Transformers shall be designed with particular care to suppress at least the

third and fifth harmonic voltages so as to minimise interference with


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communication circuits. Transformer noise level, when energised at normal

voltage and frequency shall be as per NEMA stipulations.

(rr) Recommended Spare Parts

Contractor shall provide a list of recommended spare parts for 5 years

operations. The cost of these spare parts shall not form part of contractor

proposal.

22.1.3.7 Tests

The Transformers shall be completely factory tested before dispatch in

accordance with the standards and with such other tests as may be necessary

to ensure that the equipment is satisfactory and is in accordance with this

specification.

(k) Routine Tests

Transformer routine tests shall include tests stated in latest issue of IS:

2026 / IEC 60076-11. These tests shall also include but shall not be limited

to the following:

(xv) Measurement of winding resistance.

(xvi) Voltage ratio on each tapping and check of voltage vector

relationship.

(xvii) Impedance voltage at all tapping.

(xviii) Magnetic circuit test

(xix) (After routine tests, each core shall be tested for 1 minute at 2 kV

between all bolts, side plates and structural steel work. Immediately

prior to the dispatch of the transformer, the magnetic circuit shall be

pressure tested for 1 minute at 2 kV A.C. between the core and the

earth).

(xx) Load losses.

(xxi) No load losses and no load current.

(xxii) Absorption index i.e. insulation resistance for 15 seconds and 60

seconds (R60/R15) and polarization index i.e. Insulation Resistance

for 10 minutes and one minute (R10 mt/R1 mt).

(xxiii) Separate source voltage withstand test (applied potential).

(xxiv) Induced voltage test.

(xxv) Measurement of partial discharges.

(ac) partial discharges less than or equal to 10 pC at 1.30 Un, or

(ad) partial discharges less than or equal to 5 pC at 1.30 Un (Special

test)

(xxvi) Measurement of acoustic noise level.


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(xxvii) Measurement of Zero sequence impedance.

(xxviii) All routine and indicated type tests should be done free of cost.

For other type tests, necessary test certificates from a government

approved test house shall be acceptable provided these are not more

than 5 years old.

When transformers are equipped with a protection enclosure, these

shall be tested in their enclosure.

Moreover, in addition to the routine tests, the transformer shall be

subjected to the following type tests:

(af) Lightning Impulse Test

This test shall be carried in accordance with clause 12 of the

latest issue of IS: 2026 (Part-III) on one of the transformer of

the lot.

(ag) Temperature Rise Test

The temperature rise test shall be carried out in accordance

with IS: 2026 /IEC-60076. The Temperature rise shall not

exceed the values as in the IS: 2026 / IEC 60076-11

(ah) Noise Level Test:

It shall be carried out as per IEC-60076-10

(ai) Environmental and Firefighting tests

Certificates for tests carried out for Compliance to Class C1,

E2 and F1 as per IEC 60076-11.

(aj) Short Circuit Test

It shall be carried out as per IEC 60076-5. Alternatively

employer at its discretion can ask for calculations instead of

actual test.

(l) Test Waiver, Procedures and Costs

(vi) No load losses and exciting current shall be measured at rated

voltage, rated frequency and at 90% and 110% of rated voltage, both

before and after the lightning impulse tests.

(vii) The method of test loading shall be described in the test report for

determination of both average and hottest spot temperature. Where

the winding temperature equipment is specified, data shall also be

included for calibration of hottest spot temperature indicator.

(viii) Resistance of each winding of each phase shall be measured at

principal and at all the taps and corrected to 75°C.

(ix) Impedance voltage shall be measured at principal and at all taps.

(x) No load Loss Measurement at 415 Volt.


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(m) Test on Associated Equipment

Bushings, Transformer thermal and overload protection devices, sensors,

digital thermometers, OFF LOAD tap changer, control devices, and other

associated equipment shall be tested by the contractor in accordance with

relevant IS or IEC. If such equipment is purchased by the contractor, he

shall have them tested to comply with these requirements.

(n) Test Measurements

(iii) Certified test report and oscillograms shall be furnished to the

Engineer for evaluation as per the schedule of distribution of

documents. Manufacturer’s Test Certificates in respect of all

associated auxiliary and ancillary equipment shall be furnished.

(iv) The contractor shall state in his proposal the testing facilities available

at his works. In case full testing facilities are not available, the

contractor shall state the method proposed to be adopted so as to

ascertain the transformer characteristics corresponding to full

capacity testing.

(o) Witnessing of Tests

The Engineer reserves the right to witness any or all tests. If required, visits

can be made to the works of manufacturer to ensure that the approved

quality ensuring programme is being followed. In this regard all the

necessary facilities shall be arranged by manufacturer at his end and cost

borne by the contractor.

(p) Site Tests

After the transformer is installed, the following pre-commissioning tests and

checks shall be done before putting the transformer in service.

(ix) Visual checks for connections etc.

(x) Dry out test

(xi) PI / Resistance measurement of windings

(xii) Ratio test

(xiii) Tap changer test

(xiv) Temperature Indicators & alarms

(xv) Magnetising current

(xvi) Earth connections are made.

(q) Rejection

The Engineer can reject any transformer if during tests or service any of the

following conditions arise:

(ix) No load loss exceeds the guaranteed value.

(x) Load loss exceeds the guaranteed value.


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(xi) Impedance value exceeds the guaranteed value by 10% or more.

(xii) The difference in impedance values of any two phases during single

phase short circuit impedance test exceeds 2% of the average value

guaranteed by the vendor.

(xiii) Winding temperature rise exceeds the specified value.

(xiv) Transformer fails on impulse test.

(xv) Transformer fails on power frequency voltage withstand test.

(xvi) Transformer is proved to have been manufactured not in accordance

with the agreed specification.

(r) Instructions Manual

Six sets of the instruction manuals shall be supplied at least four (4) weeks

before the actual dispatch of equipment. The manuals shall be in bound

volumes and shall contain all the drawings and information required for

erection/construction, testing, operation and maintenance of the

transformer. The manuals shall include amongst others, the following

particulars:

(vii) Marked erection/construction prints identifying the components, parts

of the transformer as dispatched with assembly drawings.

(viii) Detailed dimensions, assembly and description of all auxiliaries.

(ix) Detailed views of the core and winding assembly, winding,

connections and tapping’s, tap changer construction etc. These

drawings are required for carrying out overhauling operation at site.

(x) Salient technical particulars of the transformer.

(xi) Copies of all final approved drawings.

(xii) Detailed O&M instructions with periodical check lists etc.

(s) Completeness of Equipment

(iii) All fittings and accessories, which may not be specifically mentioned

in the specification but are necessary for the satisfactory operation of

the equipment, shall be deemed to be included in the specification.

These shall be furnished by the contractor without extra charges. The

equipment shall be complete in all details, whether such details are

mentioned in the specification or not.

(iv) All deviations from this specification shall be separately listed under

the requisite schedules, in the absence of which it shall be presumed

that all the provisions of the specifications are accepted by the

contractor.

(t) Tools & Tackles

All the necessary tools and tackles required for the normal operation shall

be supplied by the successful bidder after award of work.


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22.1.4 LV Switchboard for Compact Sub-Stations

22.1.4.1 General

The LV switchboard for CSS shall be indoor 3-Phase, 4-wire, 440 V, 50 HZ,

neutral solidly grounded, complete in all respects including base channels,

foundation bolts and other hardware for various packaged RMU distribution sub-

stations.

22.1.4.2 Standards

(c) The equipment covered in these specifications shall conform to the latest

revisions / replacements of the following Indian Standard Specifications.

S. No. Standard

Number Description

1 IS: 5 Colours for ready mixed paints & enamels

2 IS: 722 AC Electricity Meters

3 IS: 1554 PVC insulated (heavy duty) electric cables

4 IS: 2147 Degrees of protection provided by enclosures

for Low-voltage switchgear and control gear

5 IS: 2419 Dimensions for panel mounted electrical

indicating & recording electrical instrument

6 IS: 2551 Danger notice plates

7 IS: 2633 Methods for testing uniformity of coating of Zinc

coated articles

8 IS: 2705 Current Transformers

9 IS: 3156 Voltage Transformers

10 IS: 3231 Specification for electrical relays for power

system protection

11 IS: 4237 General requirements for Switchgear & Control

gear for voltage not exceeding1000 volts.

12 IS: 4794 Push buttons


Page | 306


S. No. Standard

Number Description

13

IS: 5082 Wrought aluminium and aluminium alloy bars

rods, tubes, sections plates, sheets for

electrical application

14 IS: 5578 Guide for making of insulated conductors

15 IS: 6005 Code of practice for phosphate coatings of iron

and steel (First Revision)

16

IS: 6875 Control switches (switching devices for control

and auxiliary circuit including contractor relays)

for voltages up to and including 1000 V AC and

1200 V DC

17 IS: 8623 Low voltage Switchgear and Control gear

assemblies

18

IS: 8828 Electrical accessories circuit breakers for over

current protection for home load and similar

installations.

19 IS: 9000 Basic environmental testing procedures for

electronic and electrical items

20 IS: 10580 Service conditions for electrical equipment

21

IS: 11353 Guide for uniform system of marking and

identification of conductors & apparatus

terminals

22 IS: 13703 Low voltage fuses for voltages not exceeding

1000 V AC or 1500 V DC

23 IS: 13942 Low voltage switchgear and control gear

24 SP: 39 Guide for insulation coordination within low

voltage system

25

IEC -60364

IEC: 60664

Low Voltage Electrical Installations [All

applicable series of IEC-60364]

Insulation coordination within low voltage

system including clearance and creepage

distance for equipment.


Page | 307



(d) The equipment complying with other internationally accepted standards

shall also be considered, if they ensure performance equivalent to or

superior to Indian Standards.

22.1.4.3 System Details

The L.V. Distribution Board shall be a part of a packaged RMU substation having

transformer rating as in the single line diagram for that location and technical data

as given under Specific Technical Requirements. Only the standard size of

transformer shall be selected. Broadly the LV distribution board shall have the

following configuration:

(e) Connection to LV side of Transformer

22.1.4.4 Connection to LV side of distribution transformer shall be through insulated, three phase, four wire tinned Copper bars. Alternatively tinned Copper bars may be considered with a non-segregated three phase four wire bus duct, or with sand-witched bus bars, conforming to relevant IS Standard as per current requirements.

(f) Incomer and Board Bus bar

22.1.4.5 Incomer shall be Air Circuit Breaker, draw out type, electrically operated, equipped with microprocessor based electronic trip units, complete with CTs & metering. It shall be possible to operate this breaker from remote through SCADA also. Transformer incomer rating shall be same as that of bus rating. LV Bus bars shall be three phase, 4wire, and of tinned copper. Size of neutral conductor shall be same as of phase bars. The LV Board shall be designed for fault level as given in the Specific Technical Requirements.

(g) Outgoing Feeders

22.1.4.6 No HRC fuses are envisaged. All the outgoing feeders shall be equipped with Moulded Case Circuit Breakers of appropriate rating.

(h) External Cabling

22.1.4.7 The external, three phase, four core, LV cables of required size shall be terminated to the outgoing terminals of LV switch board. Necessary cable supports shall be provided in the cable alley of the board


(c) General

(vii) The equipment shall be designed to ensure satisfactory operation of

the system in which continuity and quality of service is the first

consideration. It shall also be designed to withstand sudden load


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variations due to short circuits and fault conditions or for any other

reason.

(viii) All mechanism shall be made of such materials as to prevent

sluggishness due to rust or corrosion in the salty environment at sea

level. All connections and contacts shall be of ample section and have

sufficient surface area for carrying continuously the specified current

without undue heating and shall be secured rigidly and locked in

position. Standard sizes of stainless steel bolts, screws, pipes and

other fittings are to be used and number of sizes is to be kept to the

minimum.

(ix) Cast Iron shall not be used for any part of the equipment which may

be subjected to mechanical stresses.

(x) All apparatus shall be so designed and constructed as to obviate the

risks of short circuits of the live parts by lizards, vermin’s etc. Metal

cubicles, housing and covers shall be 100% weather / vermin proof

and shall be able to provide the degree of protection IP-54 in

accordance with latest version of IS-2147.

(xi) All parts shall be manufactured in accordance with relevant standard

specifications of IEC / I.S. Corresponding parts of similar equipment

and apparatus shall be mutually interchangeable.

(xii) All apparatus, connections and cabling shall be designed and

arranged to minimise the risk of fire and any damage which might be

caused in the event of such an eventuality.

(d) Specific Technical Particulars

The standard technical particulars (which must be modified considering the

climatic conditions as given in relevant standards) for the LV Switchboard,

are given below:

(viii) AC System : 3 phase, 4 wire, solidly earthed

e) Transformer secondary Voltage : 433V

f) System Nominal Voltage : 415 volts +6% / -10%

g) Frequency : 50 Hz 3%

h) Combined variation : Any combination of absolute

sum of Voltage & frequency.

(ix) Bus bar

f) Electrolytic Copper, tinned, Continuous rating [minimum 50%

above transformer rating]

g) 250 KVA : 800 A

h) 500kVA : 1200 A


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i) 800kVA : 1600 A

j) Short time (1 Sec) : 50 kA rms

(x) One Minute Power Frequency / Impulse Withstand Voltage

d) Power circuits : 2.5 kV (rms)

e) Control circuits : 2.5 kV (rms)

f) Basic Insulation Level, kVp : 12

(xi) Flush Mounted Moulded Case Circuit Breaker (MCCB, TPN) with

rotary handle

(xii) AC

f) Voltage : 3-Phase, 415 V

g) (-6 to +9%)

h) Frequency : 50 Hz

i) Short Circuit Performance : P2

j) Short Circuit Capability : 50 kA (rms) for 1

(xiii) Sec. (Icw)

g) Making capacity : 62.5 kAp

h) Operating Mechanism : Manual, trip free

i) Temperature rise : As per IS: 2516

j) Mechanical : As per IS: 2516

k) Auxiliary contacts : 4 No., 4 NC

l) Current Rating : As per approved

SLD submitted by

contractor

(xiv) Multi-function Meters

c) Accuracy class : 1

d) One Minute Power : 2 kV (rms)


(ii) Current Transformers

m) Type : Cast resin, Bar

n) primary


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o) Secondary circuit : 1 Amp.

p) Voltage class and Frequency: 1100 v, 50 Hz

q) Class of insulation : E or better

r) Accuracy

s) Accuracy class & VA : Class 1, 10 VA of metering

CT

t) Accuracy class of VA : 5 P 15, 10 VA of protection CT

u) Short time current rating : 50 kA (rms) for 1

v) sec.

w) Dynamic rating : 120 kA (peak)

x) One Minute Power : 2.5 kV (rms)


(ii) Voltage Transformers

f) Type : Cast resin

g) Rated voltage :

Primary : 415 V / √3

Secondary : 110 V / √3

Accuracy class and VA burden

Metering : 1.0, 25 VA

Protection : 3 P, 25 VA

Method of connection

Primary : Star

Secondary : Star

h) Rated voltage factor : 1.1 continuous, 1.5 for

3 sec.

i) Class of insulation : E or better

j) One minute power : 2.5 kV (rms)


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22.1.4.11 Frequency withstand voltage

(v) Relay

c) One Minute Power : 2.0 kV (rms)

d) Frequency withstand Voltage

(vi) Cubicle Colour Finish

d) Interior : Glossy White

e) Exterior : Grey shade No. 631 of

IS: 5

(vii) Accessories

f) Plug point with MCB.

d) Space heater PTC type.

e) Name plate on front & rear

f) Danger plates.

(viii) Cubicle

e) Minimum thickness of CRCA sheet steel 2 mm

f) Base Frame channel 100mmx50mmx6mm

g) Degree of protection IP-54

h) Rubber mat between Panel & base 15mm

22.1.4.12 Clearance and Creepage Distances

The clearances and creepage distances shall be in accordance with

Indian Standard for condensing humidity and highly polluted environment.

22.1.4.13 Labels and Marking of Connections

All equipment, control gear and the apparatus mounted thereon shall be clearly

labelled indicating, their purpose and the ‘ON’ ‘OFF’ and “EARTH’ positions. The

labels shall be clearly lettered on enameled surface or other approved materials.

Brass should not be used for labels. Each phase of alternating current and

connections shall be coloured to distinguish phase, neutral and earth. The

colouring shall be respectively for red, yellow, blue for phases black for neutral

and green for earth.

Each phase of alternating current and connections shall be have coloured heat

shrinkable sleeve. The LT switchboards shall be labelled as per designation

shown in the approved single line diagram submitted by the contractor. The


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labelling shall be finalised after the arrangement for the same, is got approved

by the successful contractor during detailed engineering.

22.1.4.14 Drawings and Literature

Four sets of tentative G.A., Schematic drawings and detailed literature of

equipment shall be submitted by successful bidder after award of work, during

detail design stage and shall be duly approved by Engineer clearly giving the

scope of supply and bill of material to enable the Engineer to scrutinise all

aspects of design including arrangement and support of cable accessibility for

maintenance work and future additions, cable connections, general appearance

etc. In addition, the contractor shall submit drawings & literature are to be

furnished by successful tenderer / bidder within 2 weeks after the award of

contract, which shall include the following:

(g) Complete assembly drawings of the boards, showing plan, elevation,

typical section, location of terminal blocks for external wiring connections

and mounting details of various devices with dimension.

(h) Foundation plan, embedment channel frame with associated holes and

suitable size of bolts for fixing to channel frame.

(i) Wiring diagrams including terminal wiring design and cable schedule.

(j) Schematic control diagram, details of relays, instruments, space heaters,

cubicle illumination and receptacle etc.

(k) Bill of material of each LV board.

(l) Layout plan of each LV board.

22.1.4.15 Bought out Items

All bought out items such as switches, MCCBs, MCB’s meters, terminal blocks,

cables etc. shall be of reputed make. Engineer reserves the right to accept only

materials of proven make at its sole discretion. The list of recommended make

for major items is given in the specification volume.

22.1.4.16 Details of L.V. Switchboard

(b) Constructional Details

(ix) The Switchboard shall be made of cold rolled sheet steel of 2 mm

thick having different compartments for bus-bars, cable alley and

instrumentation. The board shall be floor mounted, self-supporting.

(x) The bus-bars shall be rectangular, of tinned electrolytic copper and

of approved size for current rating for phases as well as for neutral.

The bus bars shall be suitably supported on non-hygroscopic

insulators to withstand forces arising from short circuits in the

system. These shall be suitable for harsh environmental conditions.


Page | 313


(xi) The switch boards shall be of compact design. All doors and covers

shall be fully gasketed. Individual feeder compartments shall be

provided with stainless steel hinged doors, bolted type doors shall

not be acceptable. Indicating instruments shall be of 96x96 mm.

(xii) The interconnections between bus-bars and MCCBs unit shall be

solid insulated, tinned copper strip permanently bolted with the bus-

bars and MCCBs. The bus-bar joints shall be given a thin coating of

conducting grease after fully cleaning both the surfaces. The

terminals shall be of substantial mechanical strength & shall provide

adequate electrical contact area and the contact pressure is

maintained permanently. The bus-bars / tee off shall be insulated

with heat shrinkable sleeve tapes with red, yellow, blue colours for

3 phases and black for neutral. All the bus-bar tapping & markings

shall be in accordance with relevant IS.

(xiii) The gland plate shall be of Aluminium minimum thickness of 3 mm

and detachable type. A strong supporting channel of 100 x 50 x 6

mm shall be provided beneath the switchboard shell besides anti-

vibration rubber gasket of 15 mm thickness.

(xiv) The connection from 11/0.433 kV transformers to the LV

switchboard shall be through a LV non-segregated bus duct

[alternatively sandwiched bus duct] or through insulated copper bus

bars as per requirement.

(xv) The bus-bars shall have non-hygroscopic support insulators. The

bus bar shall be insulated with heat shrinkable insulating kits.

(xvi) The short circuit withstands capacity of all the bus-bars and tap-

connection shall be 50 KA for one second.

22.1.4.17 Details of Circuits : Each switchboard shall have the following circuit arrangement.

(d) Incoming

(ix) 1 no. 3 phase, 4 wire incomer four pole air circuit breaker,

electrically operated with microprocessor based trip circuit release.

The breaker shall conform to IEC 60947.

• It shall be withdrawal type. The control supply can be provided from a line connected PT from the LV connection from the transformer or any other arrangement given by contractor can also be considered during detailed engineering.

(x) 3 Nos. – Metering CTs of required ratio, 10 VA Class 1, with ISF

less than 5.

(xi) 3 Nos. – Protection CTs


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(xii) The incomer breaker shall have numerical relay having three over

currents of setting 50% to 100% of 1A rating with IDMTL; current Vs

time characteristics. Short circuit instantaneous trip shall be

included. Alternatively the built in microprocessor based trip units

having Overload protection [IDMTL, IEC characteristics], short

circuit trip [time delayed], Instantaneous short circuit protection,

Ground Fault Protection can also be considered.

(xiii) 1 no. 96 x 96 mm flush mounted multi-function meter. Meter shall

measure unbalanced neutral current also along with three phase

currents simultaneously.

(xiv) 1 no. digital bus voltmeter scale 0-500 V with three line reading.

(xv) 1 no. Automatic Power factor controller [APFC], connected to y-

phase metering CT, with SCADA communication, and five steps to

switch on capacitor banks for power factor improvement to 0.95.

• Note: Number of steps is tentative and shall be finalised during detailed engineering.

(xvi) LED type lamps to indicate breaker closed, open, auto trip,

protection operation, spring charged etc. indications.

(e) Outgoing feeders

(x) 3 phase, 4 wire, outgoing cable circuits are envisaged from the

switchboard and each circuit shall have the following items,

indicating instruments, terminal connectors etc.

(xi) 4 pole withdrawable type Moulded Case Circuit Breakers of

appropriate rating.

(xii) Earth leakage relay.

(xiii) 3 nos. metering current transformers of secondary rating 1A & 1.0

accuracy class having primary current as per approved SLD

submitted by contractor.

(xiv) 1 no. 96x96mm flush mounted multifunction meter as per CT rating.

(xv) Termination points for 4C XLPE, Al. Armoured cables with lugs.

(xvi) The LV board must have sufficient space of not less than 100 mm

between two termination points for external cables.

(xvii) Cable alley along with necessary clamping arrangement for the

outgoing feeder cables.

(xviii) Indicating LED lights – red, yellow and blue for the supply.

(f) To have proper reliability, in case of a failure of a distribution transformer,

on LV board a 630A, tie breaker shall be provided to an adjacent CSS, LV

board, to be operated manually and with castle key interlocks with incomer


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feeder. These may be connected in pair, for example 1 to 2, 3 to 4 etc. In

case of odd number, then three may be connected.

22.1.4.18 Capacitor Bank and Automatic Power Factor Controller [APFC]

(c) Considering the transformer capacity and load power factor as 0.8, a

suitable size of switched capacitor bank shall be mounted inside the LT

compartment to improve the power factor to 0.95. Necessary calculations,

number of steps and switching details shall be provided for approval.

(d) Capacitor units shall be fuse-less, with loss not exceeding 0.5W / kVAR,

with metallised polypropylene film, double casing insulation, self-healing

feature, non-flammable and with nontoxic material. Reactors shall be non-

resonance, dry type resin embedded. Capacitor unit shall with automatic

operation steps as required, built in discharge resistor and mounted on

stainless steel frame. APFC shall also be supplied by the same

manufacturer. APFC shall have LCD display, programmable, with

monitoring of all parameters locally as well as at remote SCADA on mod

bus via fibre optic cable. It shall be with built in cabinet placed in the cubicle

of LV board with easy access doors.

22.1.4.19 Earthing

e. The LV switchboard shall be provided with two separate earthing terminals

at the ends. with minimum rated for 50kA for 3 sec running in the board.

All metal parts, enclosure, transformer and neutral have to be

interconnected and ready for connection to the external earthing

arrangement.

f. The earthing terminals shall be identified by means of proper embossed

sign marks adjacent to the terminals.

g. In the cable gland area provision shall be made at cable gland for armour

earthing and then connecting it to main earth bar in a proper way. There

shall be a continuous tinned copper earth bus bar in the board. The size

of the earth bus bar shall be suitable to carry 50 kA for 3 second. The bus

bar shall not be visible or removable from outside the switchboard. The

earth bus bar shall have necessary holes, nuts & bolts including washers

for making earth connection of cable glands / armouring of the cables.

h. For earthing details refer tender drawings and specification.

22.1.4.20 Switchboard Lighting and Heating

A lamp holder with a 11 W LED lamp and operated by an internal SP-MCB shall

be fitted for internal illumination. In addition, a 3 pin 6A/25A socket shall also be

provided with a separate SP-MCB. Space heater of suitable rating of PTC type,

and with SP MCB shall also be provided to avoid any moisture condensation

inside the switchboard.


Page | 316


22.1.4.21 Danger Notice Plates

An enameled sheet steel danger plate of approved design as per IS: 2551 shall

be fixed on the middle upper front of the switchboard.

22.1.4.22 Tests

All tests as required in relevant Indian standard shall be carried out on the LV

switchgear. Engineer shall witness the tests at the works of the manufacturer.

d) Type Tests: The purchaser may ask the manufacturer to conduct the following

type tests on one of the AC Boards.

vi) Verification of temperature rise limits test

vii) Verification of rain test to determine the degree of protection against rain.

viii) Verification of dielectric properties.

ix) Necessary type tests as per IS on all the individual items such as ACB’s,

MCB’s, MCCB’s, instruments, links etc.

x) Short circuit test.

• Note: The Engineer, at its option, may waive the above type tests

provided type test reports of the above type tests carried out on

essentially identical unit in their factory / approved testing

laboratory are furnished by the manufacturer.

e) Routine Tests

vi) The switchboard shall be subjected to all the routine tests as per Indian Standard

[IS] and witnessed by the Engineer. For power frequency voltage the test voltage

to be applied shall be for a period of one minute. Insulation tests with 500 volts

megger before and after the high voltage test shall be carried out on the

switchboard.

vii) Routine tests, as per IS shall be carried out on the bought out items viz. MCCB’s,

MCBs, meters etc.

viii) Verification of wiring & earth continuity

ix) Voltage test on auxiliary circuits.

x) Tests for mechanical operation control & interlocks.

f) Commissioning Site Tests

vi) Necessary site tests at site shall be carried out to ensure its satisfactory

operation after installation.at site.

vii) Terminations of Incoming and Outgoing Circuits


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viii) The cable termination arrangements shall be located at the lowest point above

the cable clamps, for ease of termination.

ix) Cable support shall be provided by a suitable clamp at the bottom of the panel.

These cable supports shall be adequate to support the outgoing cable in

normal service and when subjected to the short circuit current specified. The

distance between these cable supports and the gland plate shall be at least

200 mm.

x) The outgoing cables to be terminated in the switchboard shall be XLPE

insulated PVC sheathed armoured and with aluminium conductors. The cables

shall have bottom entry to the switchboard.

22.1.4.23 Air Circuit Breaker (ACB)

b) 415 V four pole air circuit breakers shall be withdrawal type with manually &

electrically operated mechanism. It shall be supplied for controlling the LV side

of the 11/0.433 kV, distribution transformer. Air circuit breakers shall have

symmetrical short circuit rating of 50 kA for 1 sec. [Icw rating]. The circuit breaker

shall be fitted with direct acting microprocessor based electronic release with

built in thermal memory. It shall be provided with adjustable long time, short time,

instantaneous and earth fault protection. It shall be possible to have time delay

adjustment for over load, short circuit and earth fault protection and LED display

for the operation of each of these protections. The release shall be with self-

diagnostic feature. Adjustment of the setting should be possible without

disrupting the supply. The release shall have IEC IDMTL characteristics. The

breaker mechanism should be robust, quick making quick breaking and trip free.

ACB shall have LCD display for current and voltage measurement. It should be

possible to close and trip the breaker without opening the compartment & door.

It shall have auxiliary contacts for indications along with spare contacts.

22.1.4.24 The detailed specifications of Air Circuit Breaker shall be as under:

f) No. of poles Four

g) Service voltage 415 Volts

h) Normal current As per approved SLD of Contractor

i) Frequency 50 Hz

j) Rated Symmetrical Breaking 50 kA for 1 Sec.

22.1.4.25 Capacity at 415 V AC/50 Hz

g) Making current 105 kA

h) Rated insulation voltage 1000 V

i) Max Breaking time 30 ms


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j) Max Making time 80 ms

k) Impulse Voltage 12 kVp

l) Pollution degree [IEC60664-1] 3 [minimum]

22.1.4.26 ACB Connection to Transformer

The air circuit breakers shall be suitably earthed with the main earth bus. The air

circuit breakers of the LV board shall be connected to the LV side of the

distribution transformer as specified. In case bus duct is provided the connections

at both the ends shall be through proper clamps preferably bimetallic. Suitable

arrangement shall be provided in the bus duct to take care of the expansion.

22.1.4.27 LV Moulded Case Circuit Breaker

j) All the LV outgoing underground feeders from the sub-station shall be controlled

by 4 pole fixed type moulded case circuit breakers, provided in the LV

switchboard.

k) The moulded case circuit breakers shall be of robust construction and shall

comprise of switching mechanism, contact system, arc extinguishing device and

a tripping unit contained in a compact moulded case and cover. The insulating

case and cover shall be made of high strength, heat-resistance and flame-

retardant thermo-setting insulating material.

l) The switching mechanism shall be quick-make / quick break type, and should be

trip-free.

m) The arc extinguishing device shall comprise of a series of grid plates mounted in

parallel between supports of insulating material. The arc shall be drawn from the

moving contact into the divide chamber and extinguished.

n) The moulded case circuit breakers shall have a thermo-magnetic type tripping

mechanism, where the heating effect and the electromagnetic effect of current

are made use of to provide protection against overload and short-circuit

conditions respectively. The heated-bimetal strip in each phase of the MCCB

shall actuate the tripping system following on inverse-time-current characteristics

depending upon the severity of the overload current. During short-circuits, the

system shall trip instantaneously. The tripping element provided on each pole of

the MCCB shall operate on a common trip bar, thereby preventing single phasing

in the event of fault occurring on any of the phases. The tripping device shall be

ambient temperature compensated type.

o) The MCCB shall have a minimum Ics rupturing capacity of 50 kA. Positive

indication about the position of the MCCB i.e. whether ‘ON’ ‘OFF’ or TRIPPED

shall be provided.

p) The short circuit breaking capacity and operation mechanism of the MCCB shall

be supported by test certificates.


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q) All the MCCBs used in LV switchboards for controlling the outgoing feeders shall

have a Thermal current setting of 70 to 100% of its rated current.

The rated currents given are provisional and shall be finalised during


The settings given above are provisional and shall be finalised during


r) The detailed specifications of the MCCBs shall be as under:

iv) No. of poles 4 pole

v) Service voltage 415 Volts

vi) Normal current [In] As per Approved

22.1.4.28 SLD of contractor

v) Frequency 50 Hz

vi) Service [Ics] Breaking capacity at 415V AC, 50 Hz: 50 kA

vii) Making current 120 kA

viii) Pollution Degree 3

b) MCCB shall be provided with rotary handle for manual operation.

22.1.4.29 Internal Wiring

The LV AC distribution boards shall be supplied with complete internal wiring.

The central wiring shall be of 1100 V grade, FRLS, PVC insulated. Stranded

tinned (not less than 48 strands) copper conductor cables of 1.5 mm2 size shall

be used for control circuits and 2.5 mm2 for CT circuits. Engraved identification

ferrules, marked to correspond with the wiring diagram shall be fitted at both ends

of each wire. All wiring shall be terminated on terminal blocks. Terminal blocks

shall be one piece moulded and suitable for 500 V and of recommended make.

Terminals shall be adequately rated for the short circuit current. Typically

terminals of ‘Phoenix ’ make shall be provided which shall be approved by

Engineer during detailed engineering.

For CT circuits, shorting type terminals shall be provided. It shall be possible to

measure the CT current through clip-on-ammeters.

22.1.5 Pre-Fabricated Enclosure For Packaged RMU Substations

22.1.5.1 General

The enclosure for the compact substation also includes the base frame/ channels

and all the necessary fixing hardware accessories required at site. The enclosure

shall be compartmentalized and house RMU, dry distribution transformer, LV


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distribution board with capacitor bank and their interconnections both external

and internal. Engineer at its sole discretion may also consider the alternate

designs given by the contractor, if the same are found to be better or equivalent

to the ones given hereunder.

22.1.5.2 Standards

The equipment shall conform (but shall not be limited) to IEC 6227-202 standard.

The requirements of standards for necessary clearances, ventilation etc. shall

also be complied with.

22.1.5.3 Specific Technical Requirements

(q) Typical size : 3.5m x 2.5m with 2.2m height

[Contractor may quote its own size, if

different ]

(r) Construction : Self- standing on concrete base

(s) Steel base frame : 4mm thick base [hot dip electro-

galvanized steel, with epoxy paint]

(t) Lifting eyes : 4 Nos from the bottom.

(u) Housing enclosure : 2 mm corrosion resistant Zinc /

Aluminium alloy coated sheet steels

(v) Degree of Protection : HV Compartment : IP-54

Transformer Compartment : IP-23

LV Compartment : IP-54

(w) All hinges, supports Nuts,

washers etc.

: Stainless steel

(x) Paint : Epoxy

(y) Roof Design Load [min] : 250 Kg/m2

(z) Roof Design : Slanting on the sides

(aa) Top of Roof : Removable

(bb) Ventilation : With louvers (no exhaust fans shall be

used)

(cc) Sound Level : 60 dB


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(dd) Standard Applicable : IEC 62271-202

(ee) Number of earths : Two (at opposite ends)

(ff) Compartments : Three with independent doors

22.1.5.4 Construction

(d) General

(xxv) The enclosure shall be self-standing on a concrete base. Necessary

civil requirements to be satisfied for the concrete base shall be

provided by the contractor. The levelling of ground and construction

of the concrete base and associated civil works shall also be in the

scope of the contractor.

(xxvi) The compact substation is completely self-contained, mounted upon

a 4 mm thick galvanised steel base frame, epoxy painted, factory

assembled in a totally enclosed, aesthetically acceptable metal

cladding, vandal-proof and weatherproof housing ready for placing

into position upon a concrete base.

(xxvii) The lifting arrangement should be with four lifting eyes from the

bottom of the enclosure & not from the top.

(xxviii) The structure of the substation shall be capable of supporting the

gross weight of all the equipment & the roof of the substation

compartment shall be designed to support adequate loads. In case of

relocation of the Package Substation, the entire substation should be

capable of getting lifted and placed as a Single Unit without

dismantling of any of the major equipment inside the enclosure. The

complete housing assembly with four lifting eyes should be easy to lift

and position the whole unit at the site by the use of crane. The

substation can be lifted without damage or distortion. The transformer

is located in the middle of the substation while the HV and LV

compartments are located at both ends of the substation adjacent to

the corresponding bushings of the transformer. The arrangement is

subject to the approval of the Engineer.

(xxix) There shall be adequate ventilation inside the enclosure so that hot

air inside enclosure is directed out by help of duct. Louvers apertures

shall be provided so that there is circulation of natural air inside the

enclosure. The Package Substation should be designed &

engineering to have natural cooling & ventilation only. No forced

cooling / ventilation is acceptable.

(xxx) The enclosure must be weather proof in the sea shore area of

installation where weather is saline, having tropical temperature with

high condensing type humidity (resulting in quick rusting of iron parts),


Page | 322


windy, having heavy rainfall and flash floods for about four to six

months in a year.

(xxxi) The enclosure must also be vermin proof to prevent the entry of

rodents, reptiles, & flying insects, which are prevalent in the area.

(xxxii) The enclosure should be pre-fabricated such that fire from one

compartment MUST NOT spread to other compartments.

(xxxiii) It should have easy access to all the equipment inside the

enclosure, viz RMU, transformer, LV switchboard, capacitor bank,

connections, and terminations of HV & LV cables.

(xxxiv) The metal base and all supporting channels shall be hot dip

galvanised (min. 75 micron). These should ensure rigidity, ease in

transportation to sites and installation.

(xxxv) The housing of the enclosure shall be made of 2 mm corrosion

resistant Zinc / Aluminium alloy coated steel sheets.

(xxxvi) All hardware such as hinges, supports, screws, nuts, bolts,

washers etc. should be made of stainless steel. All locking bolts shall

be accessible from inside to prevent the unauthorised dismantling.

(xxxvii) All the enclosures shall be or of similar type & design.

(xxxviii) The colour of the enclosure shall be decided by Engineer during

detailed engineering, if different from the one given. The last finish

coat shall be of epoxy paint.

(xxxix) The roof of the substation enclosure shall be designed to support

loads up to 250 kg/m2. The roof shall be sloped on the sides so that

the rain water cannot stay on roof during rainy days.

(xl) The pre-fabricated roof of the enclosure shall be removable

whenever required. The locking nuts, bolts to allow the removal of

roof shall be only accessible from inside the enclosure.

(xli) Covers & Doors:

(aj) Covers & doors are part of the enclosure. When they are

closed, they shall provide the degree of protection specified

for the enclosure. All covers, doors or roof shall be provided

with locking facility or it shall not be possible to open or remove

them before doors in normal operation have been opened.

The doors shall open outward at an angle of at least

90degrees & be equipped with a device able to maintain them

in an open position. Proper padlocking facility shall be

provided for doors of each compartment. Transformer

compartment doors must be open from both the sides.

(ak) Door closing shall be by means of a three point linkage

arrangement (i.e. Centre, top and bottom) and controlled by a

centrally located stainless steel operating handle. Pad locking


Page | 323


facilities along with Master pad locks shall be provided. Master

pad locks shall be operated by a master key for all the

substations.

(al) The outer doors of the enclosure shall be wide and provided

with heavy duty hinges to prevent distortion and misalignment.

A robust door restraint shall be provided to hold each door in

the 950 open positions. The restraint shall be of a captive

design so that it cannot be easily removed and shall be

self-strong when the door is closed such that it cannot

rattle. With the door in this position, operation of LV and HV

switchgear shall be possible without endangering operator’s

hands, etc.

(am) When doors are closed, they are firmly locked; as such entry

of dust, vermin and rainwater is completely prevented.

Neoprene gaskets are to be used.

(an) The HV doors are provided with a drawing pocket to keep

drawing inside.

(ao) A weatherproof nameplate shall be provided on the door.

(ap) The edges of the doors are bended at both sides to assure

they fit properly so that the door jams and misalignment is

prevented.

(aq) The transformer, low voltage and HV compartments are

completely separated by steel sheet. The barrier between the

HV switchgear and the transformer is provided with pressure

relief flaps.

(ar) All compartments are individually accessible by their own

doors from outside.

(xlii) Labyrinthine louvers form the sidings of the transformer room to assure

free entry and exhaust of air, as such the inside temperature is kept within

limits. Openings located at the lower and upper sides of the slanted roof

shall allow air circulation as part of the ventilation design.

(xliii) No exhaust fans shall be used. Ventilation louvers shall be required to

provide sufficient ventilation.

(xliv) All compartments are equipped with internal lighting consisting of 25

watts LED lamps controlled by their respective door micro switches. MCB

shall be provided to control the supply.

(xlv) Space heaters shall be provided to control condensing type humidity.

(xlvi) Labels for warning, manufacturer’s operating instructions etc. & those

according to local standards & regulations shall be pasted / provided

inside and shall be durable & clearly legible.


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(xlvii) The substation forms a complete metallic structure bolted together and

each compartment is to be provided with tinned copper, grounding bus-

bar. Bonding and interconnection of the grounding buses shall be made

of 70 mm2 bare stranded copper tinned conductors. The ring main unit

shall have 25x8 mm grounding bus while the low voltage switchgear shall

have 30 x 10 mm tinned copper grounding buses to which connection to

the grounding system at site can be made. At least two grounding points

for bolting to ground conductor shall be provided on opposite ends.

(xlviii) All metallic components shall be earthed to a common earthing point. It

shall be terminated by an adequate terminal intended for connection to

the earth system of the installation, by way of flexible jumpers/strips &

Lug arrangement. The continuity of the earth system shall be ensured

taking into account the thermal & mechanical stresses caused by the

current it may have to carry. The components to be connected to the earth

system shall include :

(af) The enclosure of Unitized / prefabricated substation.

(ag) The enclosure of High voltage switchgear & control gear from the

terminal provided for the purpose.

(ah) The metal screen & the low - high voltage cable earth conductor.

(ai) The transformer tank or metal frame of transformer.

(aj) The frame &/or enclosure of low voltage switchgear.

(e) Dimensions

The overall typical dimensions of the enclosure may be around 3.5m x 2.5m

(or 5m2) having height of about 2.2m. To achieve necessary clearances,

contractor may propose alternate size of the enclosure depending upon the

dimensions of the equipment supplied.

(f) Enclosure Requirements

(viii) The enclosure must be totally safe to the personnel in the populated

areas as the packaged substation shall be established in the

residential townships.

(ix) The equipment in the enclosure must be accommodated with

necessary clearances, easy access to the RMU, and transformer, LT

switchgear and capacitor bank for testing, maintenance, removal and

normal operation (including operation with normal switchgear

handles).

There shall be unhindered access to the transformer, operation of

OFF load tap changer and other normal operating requirements.

Similarly termination & removal of cables, withdrawals of ACB from

LV board should be easy & comfortable.

(x) It shall be the sole responsibility of the contractor to satisfy all the

statutory clearances and to provide safety measures against all


Page | 325


possible hazards to the equipment in the enclosures, such as internal

arcing faults in the enclosure considering salty environment near the

sea and area prone to flooding.

(xi) Failure within the unitized substation due either to a defect, or mal-

operation may initiate an internal arc. Such an event may lead to the

risk of injury, if persons are present. It is desirable that the unit shall

be tested for Internal Arc fault test to the tune of at least 20KA for 1

second as per latest IEC 62271-202 standard. The enclosure must

be so designed that internal arc faults are directed away from places

where personnel or public may be present. Test certificates from a

recognised national / international test house [acceptable to

Engineer] shall be supplied for internal arc.

(xii) Testing of incoming & outgoing cables and use of testing equipment

for the same shall not entail the dismantling the sides or the roof of

the enclosure.

(xiii) There shall be sufficient space for termination & removal of cables

from Load Break Switches & also from the LV board.

(xiv) Sufficient clearance must be kept between the top of any equipment

installed in the pre-fabricated substation and the roof of the substation

for ventilation and operational purposes.

22.1.5.5 Interconnection

The equipment inside the enclosure shall be interconnected as follows:

(e) The RMU shall be directly coupled by VCB feeder to distribution

transformer through insulated copper bars or cables as per manufacturer

standard.

(f) The LV side (three phases plus one neutral conductor) of distribution

transformer shall be connected to LV incomer Air Circuit Breaker via flexible

insulated copper bars or through a four conductor sand-witched insulated

bars or with bus duct enclosure.

(g) The HV termination to Load Break Switches shall be from 11 kV, Al.

armoured XLPE cables, fitted with termination kits, for the ring system.

(h) The earthing of pre-fabrication station shall be provided at two opposite

ends for connection to the outside earth rods. It shall be a bolted

connection.

22.1.5.6 Drawings

The following drawings shall be submitted after award of tender for approval of

Engineer.

(e) The detailed sketch of the enclosure indicating general view, position of

louvers etc.


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(f) The drawing showing the layout of HV, transformer & LV switchgear along

with interconnections.

(g) Size & position of doors in the enclosure.

(h) Fixing details of the enclosure including civil foundations (if any).

22.1.5.7 Safety Measures

The enclosure shall have the following safety measures:

(e) Electric shock treatment chart duly framed shall be fixed in a conspicuous

position inside the enclosure.

(f) Danger notice in English/ Hindi/ Kannad language conforming to IS: 2551

shall be fixed on all the four sides of the enclosure.

(g) Electric insulated rubber mat (non-skid type) with flouted top and plain

border end, 12 mm thick to withstand 12 kV di-electric strength shall be

provided in front of HV/LV boards where people have to work.

(h) Two number portable fire extinguishers typically 2 litres, suitable for

transformer / cable and other electrical equipment fires shall be placed &

fixed in a suitable location in the enclosure, away from the place where fire

is expected.

22.1.5.8 Tests

The following tests shall be carried out on the enclosure as per IEC standard at

the works of the manufacture:

(f) The complete prefabricated substation unit will be tested at full load for

temperature rise. The maximum temperature rise on any part of the

equipment placed inside the enclosure shall not exceed the value as

specified in IEC 62271-202.

(g) Test to verify the sound level of the pre-fabricated substation, which shall

be less than 60 db.

(h) Test to verify the degree of protection of enclosure for various

compartments.

(i) For the internal arc fault test on the enclosure the following need to be

observed and tested as below:

(v) Internal Arc Fault tested to 20 kA 1 sec.

(vi) Test to accessibility of Type “B” that is with unrestricted accessibility

including that of the general public (Annex. AA.2 IEC). Although test

to accessibility of Type “A” is not required, tenderers shall also

provide adequate measures to have any hot gases directed away

from the operator during switching with the door open.


Page | 327


(vii) Arc initiation is made inside the SF6 gas compartment of the RMU

(Annex. AA.3 IEC).

(viii) Assessment of the internal arc fault test is based on the fulfilment of

all 6 criteria as stated in Annex. AA.6 of IEC.

(j) Other Checks

(vii) Inspection of conformity with the specification & approved drawings.

(viii) Inspection of devices locking out and interlocks.

(ix) Inspection and checking electrical continuity of metallic frame and

earthing system.

(x) Dielectric tests of M.V. and L.V. bus bar.

(xi) Provision of two earths as per Indian Electricity Rules.

(xii) Tests as per IEC standard.

22.2 LT DISTRIBUTION FEEDER PILLAR BOX

22.2.1 SCOPE

This specification covers design, engineering, manufacture; shop testing, inspection,

painting, packing, and supply of 415V Sub Feeder Pillar complete with all accessories

for efficient and trouble-free operation of the electric distribution network for power

utilities.

The equipment shall conform in all respects to high standards of Engineering design and

workmanship and shall be capable of performing in a manner acceptable to user.

The general requirements from the installation are low electrical losses, weather

resistance, easy installation & connections, safe & touch proof design, easy

sectionalizing & maintenance & maximum service life.

22.2.2 STANDARDS

The Feeder Pillar shall comply with the requirements stated in the latest editions of the

following recommendations, standard and specifications.

Sr.

No

Title Indian standard

1 IS 5039 Specification for distribution pillars below 1000V AC

2 IS 13947 Part 2 Low voltage switchgear

3 IS 8623 Specification for low voltage switchgear

4 IS 12063 Classification of degrees of protection provided by

Enclosures of Electrical equipment

5 IS 5 Color of ready mixed paints


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6 IS 191 Specification for copper

7 IS 5082 Wrought Aluminum & AI alloy plates & sheets for

electrical application.

Service Pillar / Tappat

The TAPPAT link distribution feeder pillar box confirms the standard in accordance with

IEC 60439-5: 2006, IEC 60439-1 : 2004 OR AS/NZS 3947.3 : 2001

22.2.3 SERVICE CONDITIONS

viii. Supply voltage- 3 phase neutral, AC 415volt +/-10%

ix. Supply frequency- 50 Hz +/- 3%

x. Location of panel- Outdoor, on foot path or roadside

xi. Pollution- Corrosive, dust, smoke & rain

xii. Humidity- 90% maximum

xiii. Ambient temperature - Average 35" C, Maximum 48" C

xiv. Incoming supply to feeder pillar panel- From transformer feeder pillar or other

feeder pillar

22.2.4 CONSTRUCTION

The pillar boxes shall generally conform to the sketches enclosed and comply with the

following requirements.

22.2.5 ENCLOSURE

It shall be made out of GI / Aluzink sheet with 2 mm thickness. Doors shall be made out

of GI/Aluzink sheet with 2 mm. It shall be compact and suitable in all respects for outdoor

installations. The sloping canopy fitted at the top of the pillar shall be given 5 to 10 mm

gradient downward slope at the front so that rain water shall not accumulate at the top.

Sufficient quantity & size of internal hinges shall be fixed shown in the drawing enclosed

for each door. The hinges shall be of such construction the doors can be swung open

by not less than 110 degrees.

All nut bolts and hardware shall be tin platted and electrical nut bolts shall be high tensile

tin platted.

The doors shall be provided with suitable padlocking and antitheft password protected

locking arrangements. All Hinged doors shall be connected to the earth terminal with 2.5

Sq.mm. braided copper wires

The main body of the enclosure should be made out of a single sheet suitably formed

without any welding to avoid corrosion. Provision for closing the doors at front by locks

shall be suitably provided. The MS sheets used for doors, sides, top, bottom etc., shall


Page | 329


have minimum / no joints/welds. The pillar box should be suitable for flush mounting

against compound wall.

The pillar boxes should have louvers made up of ABS material which do not project

more than 6 mm over surface of feeder pillar.

The pillar box shell should be of neat finish and suitably protected against corrosion by

powder coating. Suitable pre-treatment is required with 7 tank / 12 tank process before

powder coating. Polyurethane based powder coating material is to be used. The panel

shall be powder coated with Light grey shade No 631 of IS-5. Minimum coating thickness

is to be 80 microns.

22.2.6 TAPPAT

Turret & base is made up of high density injection moulded polyethylene. It has got

strong but light construction making it easy to transport & installation. The all-weather

polyethylene construction requires no painting or maintenance as protection against

moisture & corrosion is no issue. IP rating is IP55. It has got Danger Electricity Marking.

Turret is easily & simply secured to base with D-bolts made u of stainless steel & can

be tightened using special long handle key, it shall not open easily by other tool.

22.2.7 CIRCUIT WAYS AND BUS BAR:

The feeder pillar box shall be of 3 phase (R, Y, B) arrangement. The centre to centre distance between Bus bar should be 185mm.

22.2.8 BUS BAR ASSEMBLY:

Busbars shall be of electrolytic grade E91 aluminium, rated for minimum Given Rating,

50 kA for 1 sec and shall have adequate cross section to carry the rated continuous and

short time current. Neutral bus also should be of full bus bar rating.

The dimensions for Aluminium busbar in mm:-

Phase & Neutral Busbar: 1Amp = 1Sq mm Earth Bus: 50 X 6. E91 AL

Tin plating of 10 to 12 microns is required on aluminium busbars.

22.2.9 INCOMERS and OUTGOINGS:

The pillar box shall have incomers as per BOQ & Drawings with pole vertical fuse switch

disconnector. The fuse switch at incomer shall be as per IEC/EN 60947-1/-3 / VDE 0660

T-107

The pillar box shall have outgoings as per BOQ & Drawings with vertical fuse switch

disconnector as per IEC/EN 60947-1/-3 / VDE 0660 T-107

The fuse switch disconnector shall be switchable without any special switching

sequence. The incomer fuse switch should be dimensionally compatible to outgoing fuse

switch units.


Page | 330


Technical specifications of the unit should comply according to Annexure 1

Switch on and off with fuse link under load should be performed with single hand

operation, with low switching force and wear free contacts. The fuse switch should have

windows for displaying fuse label, middle and top fuse blown indicator easily visible. It

should be possible to measure voltage across a fuse without opening the switch. The

Fuse switch should be provided with steel frame V type clamp to terminate proper size

of PVC / XLPE Aluminium cable without need for crimping sockets.

22.2.10 CABLE CONNECTION SUPPORT

There should be provision to support incoming & outgoing cables at bottom portion of

feeder pillar. It shall consist of 75 x 6 mm flat of suitable length, held tight to body.

Necessary holes shall be provided in the flat along with clamps, bolts and nuts, check

nuts, washers etc., So as to firmly clamp the cables (incoming and outgoing) by means

of semi-circular cable clamps. The semi-circular clamps shall be made of 6mm thick

plate of width 75mm for two Incomers & four Outgoings.

22.2.11 EARTHING:

The metal casing of the pillar shall be provided with two separate earthing terminals and

these shall be provided and above all other means provided for securing metallic

enclosures. The earthing terminal shall be readily accessible and so placed that the

earth connections of the pillar are maintained even when the cover or any other movable

part is removed. Under no circumstances a movable metal part of the enclosure shall

be insulated from the part carrying the earthing terminals, when the movable part is in

place. The earthing terminals shall be of adequate size and protected against corrosion

and shall be metallically clean. The earthing terminals should be identified by means of

the sign marked in legible and indelible manner, on or adjacent to the terminals.

22.2.12 MOUNTING ACCESSORIES

This includes inhibitor grease & foundation bolts.

One-Way open point link kit.




It uses insulated contact blocks to terminate cables. One block is used for each phase.

Separate contact block is provided for neutral connection. Neutral cover & rubber

grommets made up of special grade rubber are provided to cover exposed live parts.

Two-Way open point link kit.





Page | 331


It uses insulated contact blocks, one for each phase. Block is divided into two halves

with one main & three service cable on each side, with single link switch between these

two halves for connection & disconnection. Link switch can be operated on load using

insulated key.

Separate contact block is provided for neutral connection. Link cover, Neutral cover &

rubber grommets made up of special grade rubber are provided to cover exposed live

parts.

Three-Way or multiway open point link kit

Kit is suitable for 3 runs of main cables (120 to 300 mm2, 3.5 or 4 core, PVC / XLPE

insulated, solid or stranded) & 4 runs of service cables (25 to 50 mm2, 3.5 or 4 core,

PVC / XLPE insulated, solid or stranded). Provision is available for additional 4 runs of

service cable.

Two link are used for connection & disconnection between three main cables. Link

switch can be operated on load using insulated key.

Separate arrangement is made for connecting neutral.

22.2.13 OPERATIONAL REQUIREMENT

• Continuous rated operating voltage- 415 volt +/- 10%

• Power frequency high voltage withstand capacity for one minute- 2000 volt

• Insulation resistance value for phase & neutral bus bar- Minimum 100MΏ with

500V Megger

• Temperature rise above ambient - As per IEC 60947

22.2.14 NAME PLATE & MARKING

Name plate- On front door showing

• Manufacturer name & address

• Current Rating & Short circuit Rating

• Incoming & Outgoing details

• Month / year of manufacturing

• As per customer demand (Purchaser Name & PO Number, Property of, etc.)

• Danger board in English & Hindii language

22.2.15 TESTS

Should comply with following test requirements. Type tests according to IEC 60947-3,

IS 5039:1983 & IS 8623-1: 1993. All the Type Tests shall be carried out as per the

relevant standards at National or International labs, capable of carrying out specified

tests.


Page | 332


• Complete sequence of type testing for vertical switch fuse units

• Verification of Short circuit strength – 50kA, 1 Sec

• Verification of degree of protection IP55

Acceptance & routine test.

• Visual inspection, dimension checks.

• Powder coating thickness, Coating adhesion test.

• Colour shade

• Bill of material check

• Continuity check

• Insulation resistance test

• High voltage test

• Operational check

Tappat / Service Pillar :

Following type tests shall be carried out as specified in AS/NZS 3947.3 : 2001

• Verification of dielectric properties before & after short circuit making test

• Short circuit making test at 28 kA rms,

• Leakage current test

• DC resistance before & after load cycle

Load cycle & temperature rise test :

• Half load : 8 hours

• Full load : 4 hours

• Complete cycle time : 12 hours

• Number of cycles performed during test : 28

Following type tests shall be carried out as specified in IEC 60439-5:

2006, IEC 60439-1 : 2004

• Temperature rise test at rated current with all internal shrouds fitted

• Temperature rise test at rated current with all internal shrouds fitted and rear

internal terminal shrouds ventilated.

• Temperature rise test at 1.5 times of rated current to determine performance at

overload

In routine test, visual inspection & dimensional check is performed


Page | 333


22.2.16 DRAWING

Material will be supplied as per drawing attached with this this specification.

22.2.17 PACKING

For packing, wooden base made up of complete wood is required. Panel should be

mounted on it firmly. Complete assembly to be wrapped tightly with stretch film. Then

assembly should be covered with corrugated 2-ply paper sheet. Then again stretch

film to be used.


Page | 334


22.2.18 GTP

GTP of distribution feeder pillar box shall be as per Annexure 2.


Pillar


A General

1 Name of Manufacturer As per list of manufacturers

2 Product Designation Feeder Pillar

3

Product Details

Multi Way Feeder Pillar – 415 V

With Vertical Switch Fuse Unit arrangement

4 Configuration Incomer and Outgoing as per given Drawings and

SLD

5 Incoming Circuit With vertical switch fuse unit with IEC/EN60947-1/-3/ VDE 0660T-107

6 Outgoing Circuit With vertical switch fuse unit with IEC/EN60947-1/-3/ VDE 0660T-107

7 Incoming fuse


8 Outgoing fuse


9 Vertical SFU make Raychem / Hagger / Schneider / TE connectivity

10 Outgoing / Incomer

cable connection

Suitable for cable connection

11 Type of termination In V-clamp without use of crimping socket

12 Application of product Outdoor

a Humidity 90% maximum

b Ambient

temperature

Average 35" C, Maximum 48" C

B System Information


Page | 335



Pillar


1 Rated Voltage 415V ±10% Between Ph-Ph

2 No. of phases 3 No’s

3 Frequency 50 to 60 Hz


Page | 336


C Busbar configuration

1 Material for phase &

neutral busbar

EC grade Aluminum E91 as per IS 5082

2 Current rating of phase

busbar

As per BOQ & SLD

3 Configuration 3Phase+1Neutral busbar (R-Y-B

coded).

Horizontallymountedat185mmdistanc

e

4 Neutral busbar Full Rated

5 Dimensions of Phase &

Neutral Busbar

80X 10 mm

6 Earth Bus 50 X 6

D Pillar Construction

1 Material of enclosure GI/Aluzinc with PU paint sheet, 2.00/1.60mmthick

2 Material of doors GI / Aluzinc, with PU paint 2 mm thickness

3 Material of Gland plate GI 3.0 thick

4 Door access Front, two door, Min 110 degree opening

5 Door Hinges Three internal Hinges per door (Hinges shall not

be

exposed grom out side

6 Locking arrangement Locking shall be through key

7 Cable Entry From bottom

8 Surface preparation for

painting

7 tank / 12 tank process

9 Painting Powder coated PU paint with min 65-80 micron

Thickness

10 Color Light grey shade RAL 7035

11 Degree of protection IP55


Page | 337




Sr. No. Particulars

1. Name of Manufacturer

2.

Configurations

4. TAPPAT1-Way single link

distribution feeder pillar box

5. TAPPAT2-


pillar box

6. TAPPAT Multiway (as per SLD)

insulated connection with Allen key-

bolt

3. Test standard AS/NZS 3947.3: 2001 OR

IEC 60439-5: 2006, IEC 60439-1: 2004

4. Material for enclosure High density injection molded

polyethylene

5. Environmental protection IP55

6. Connector material Tin plated brass

7.

Suitable for connection

Maincable:1Run/2Runs/3Runs,120to 300

mm2, 3.5 or 4 core, PVC / XLPE

insulated, solid or stranded)

ServiceCable:25to50mm2,3.5or4core,

PVC/XLPE insulated, solid or stranded)

8.

Locking arrangement

Yes

3. Special D-bolt &key

4. Padlocking facility(optional)

9. Rated current 400A

10. Rated Voltage 415 V

11. Short circuit rating

wherever applicable

28 kA rms


Page | 338




Sr. No. Particulars

12. Load cycling

wherever applicable c. Half load (200A) : 8hours

d. Full load (400A) : 4hours

e. Complete cycle time : 12hours

f. Number of cycles:28

13.

Overall dimensions

Height : 660 mm (1-Way & 2-way),

890 mm(3-Way)

Width : 550 mm

Depth : 510 mm

14. Shelf Life Unlimited. To be stored under covers


Requirement

1 Main bus bar short circuit

withstand capacity 50 kA for 1 Sec


properties

2000V /1 minute

3 Impulse withstand

voltage

20kV

22.3 JUNCTION BOXES & METER BOXES

22.3.1 JUNCTION BOXES

The following design criteria shall be taken to consideration while designing junction boxes and

meter boxes.

• Shockproof and rustproof

• Rot-proof and termite resistant

• Cable entry from bottom and/or sides

• 100% weatherproof


Page | 339


• Pole mounting arrangement

• Tamper proof

• Pilferage proof

• Restricts unauthorised tapping

• Maintenance-free

• Fire retardant - Class FV-0 as per IS:11731 Part-II or V-0 as per UL-94

• High heat distortion temperature (200°C as per IS:10192)

22.3.2 MEETER BOX – STANDARD FEATURES

• Ingress protection to IP65

• Weatherproof & rigid construction, suitable for outdoor use

• High impact, corrosion & temperature resistant

• Lift-off type chrome plated brass hinges

• Awning type canopy above the door

• Meter viewing window

• Key locks, zinc die cast & chrome plated - 2 nos

• Studs on back wall for mounting plate fixing

• Wall thickness 3 mm generally & 5 mm at stress points

• Fire retardant, self-extinguishing to BS 476: Part 7: 1997 Class 2

• External finish: Plain semi-gloss light grey gelcoat finish to RAL 7035

• Long life & high temperature resistant EPDM rubber door seal

• All hardware of galvanized steel or non-corrosive material

22.4 33KV & 11 KV XLPE INSULATED CABLES

22.4.1 Scope

This specification covers the design, manufacture, testing at manufacture's work

before dispatch, packing and transportation to site, laying, termination, testing

and commissioning of HT, LT Power, control and instrumentation Cables

required for various sub-stations.

All cables shall comply with relevant Indian standards.

22.4.2 Make

The cables shall be procured from experienced and reputed manufacturers (from

the list of preferred equipment manufacturers), with proven experience in


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manufacture of cables for substations and having capability to develop, test and

timely supply of cables as specified in the tender specification. The manufacturer

shall have arrangements for carrying out all the routine, type and acceptance

tests including special tests (such as flammability test, smoke generation test,

HCL gas evaluation test) as per the standards specified and have furnished

satisfactory test results. All cables to be with low smoke with zero halogen.

22.4.3 Design Criteria

22.4.3.1 Standards

The cables under this specification shall comply with the requirements of latest

edition of the following standards including amendments:

S. No. Standard

Number Description

1 IS: 1554

(Part-I)

PVC insulated (heavy duty) electric cables for

working voltage up to and including 1100 V.

2 IS: 1753 Recommended current rating for PVC insulated

and PVC sheathed heavy duty cables.

3 IS: 3961

(Part II)

Metal steel wires, strips and tapes for

armouring of cables

4 IS: 3975 Methods for random sampling.

5 IS: 4905 PVC insulation and sheath of electric cables.

6 IS: 5831


sheathed cables for working voltages up to &

including 1100 V.

7 IS: 7098

(Part II)


sheathed cable for working voltage from 3.3 kV

to 33kV.

8 IS: 8130 Conductors for insulated electric cables and

flexible cords.

9 IS: 10418 Wooden drums for electric cables.

10 IS: 10810 Method of tests for cables.


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S. No. Standard

Number Description

11 ASTMD- 2863

Standard method for measuring the minimum

oxygen concentration to support candle like

combustion of plastic.

12 IEEE: 383 Standard for type test of IE class of electric

cables.

13 IEC-332 (Part-I) Tests on electric cables under fire conditions.

14 IEC-754

(Part-I)

Test on gases evolved during combustion of

electric cables.

15 ASTMD – 2843 Test method for density of smoke from the

burning on decomposition of plastic.


22.4.4 Cable Design

The cables shall be designed considering the following

22.4.4.1 HT Cables

HT cables shall be 33kV & 11 kV of earthed grade suitable for use in solidly

earthed system, stranded & compacted electrolytic aluminium conductor,

extruded semi conducting screen over conductor, XLPE insulated, armoured or

unarmoured as required, semi-conducting followed by copper tape screened,

extruded PVC, Type ST–2 inner sheathed, overall FRLS, PVC outer sheathed,

conforming to IS 7098 (Part II), IEC 60502 for constructional details and tests.

22.4.4.2 LT Power Cables

LT Power Cable shall be 1100 V grade, single / multi core, stranded electrolytic

aluminium conductor, XLPE insulated, with PVC inner sheath, armoured and

outer sheath made of FRLS PVC compound, generally conforming to IS-7098

(Part-II). The cables used for DC system shall be of two core type. Minimum

conductor cross section of power cables shall be 10 mm2 for aluminium cables

and below 10 mm2 it shall be copper conductor.


Control cables shall be 1100 V grade, multi core, minimum 1.5 mm2 cross

section, stranded copper conductor having minimum 7 strands, XLPE insulated,

PVC inner sheathed / galvanised steel wire armoured, overall FRLS, PVC outer


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sheathed generally conforming to IS 1554 Part-I. In situations where accuracy of

measurement or voltage drop in control circuit warrants, higher cross sections as

required shall be used.

22.4.4.4 Instrumentation Cables

The instrumentation cables shall be annealed, tinned stranded copper conductor,

0.5 mm2, twisted into pairs, overall screened (L1 type) for digital signals,

individual and overall screened (for L2 type) for low level analogue signals,

individual triplet and overall screened (type L3), PVC insulated, inner PVC

sheathed, GS wire armoured and overall sheathed with FRLS PVC. The

insulation shall be strippable manually as well as by mechanical stripping devices

without damage to the conductor.

22.4.4.5 Lighting Wires

1100 V grade, single core, stranded, copper conductor, PVC insulated wires

conforming to IS 694 / IEC 60227 Part 1 to 5 / IEEE-719. Minimum cross section

of copper wires shall be 2.5 mm2 for lighting circuits and 4 mm2 for receptacle

circuits.

These shall be suitable for installation in a monsoon area having 100% relative

humidity, which is likely to accelerate rusting in steel. However, for reference the

ambient temperature may be taken as -5C (minimum) and 50°C (maximum) with

RH of 100%. The galvanising of steel armour has to be of the highest quality for

such ambient conditions.

22.4.4.6 The user shall consider the derating factor for the various conditions of installation including the following while choosing the conductor size.

22.4.4.7 Maximum ambient air temperature.

22.4.4.8 Maximum ground temperature.

22.4.4.9 Depth of laying wherever applicable.

22.4.4.10 Grouping of cables.

22.4.4.11 The minimum size of all 33kV, 11 kV and 415 V Power Cable shall be chosen considering the following:

(g) Maximum fault level

(h) Full load current of the circuit.

(i) Maximum permitted time as dictated by system protections, switchgear

etc.

(j) The allowable voltage drop at the terminal of the connected equipment shall

be maximum 3% at full load for LV and 4% for HV.


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(k) For PVC insulated cables continuous conductor temperature and allowable

maximum conductor temperature during short circuit be taken as 70°C and

160°C and for XLPE insulated cables the corresponding values shall be

90°C and 250°C respectively.

(l) Frequency variation ± 5%, voltage variation ±10% and combined

frequency and voltage variation of ±10%.

22.4.5 General Technical Requirement

22.4.5.1 The cables shall be suitable for laying in racks, ducts, covered trenches, conduits and underground buried installation with chances of flooding by water.

22.4.5.2 Cables shall be designed to withstand mechanical, electrical and thermal stresses developed under steady state and transient operating conditions.

22.4.5.3 The aluminum / copper wires used for manufacturing the cables shall be true circular in shape before stranding and shall be of uniformly good quality free from defects. All aluminum used in the cables shall be of H2 grade.

22.4.5.4 The conductor of control cables shall be manufactured from plain annealed copper. The conductor shall be multi-stranded or solid as per data sheet.

22.4.5.5 The nominal overall diameter of the cables shall be as given in the applicable Indian Standard.

22.4.5.6 The cable cores shall be laid up with fillers between the cores wherever necessary. It should not stick to insulation and inner sheath. All the cables, other than single core unarmored cables shall have distinct extruded PVC inner sheath black in colour as per IS 5831.

22.4.5.7 The fillers and inner sheath shall be of non-hygroscopic. Flame retardant material shall be softer than insulation and outer sheath shall be suitable for the operational temperature of the cable.

22.4.5.8 For single core armoured cables, armoring shall be of aluminum wires. For multi-core armoured cables, armoring shall be of galvanized steel as follows.

Size & diameter of cable Type of armour

Up to 13 mm 1.4 mm dia GS wire

Above 13 up to 25 mm 0.8 mm thick GS strip/ 1.6mm dia GS wire

Above 25 up to 40 mm 0.8 mm thick GS strip / 2.0 mm dia GS wire



Above 70 mm 1.4 mm thick GS strip/4 mm dia GS wire

22.4.5.9 The gap between armour wire/ strip shall not exceed one armour wire/strip space and there shall be no cross over/over-riding of armour wire/strip. The minimum


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area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire/strip. Zinc rich paint shall be applied on armour joint surface.

22.4.5.10 Suitable chemicals shall be added to the outer sheaths of all cables to protect them from entry of water, UV light, rodent and termite attack. These chemicals shall not have any harmful effect on the human being.

22.4.5.11 The normal current rating of all PVC insulated cables shall be as per IS-3961 and should suit the duty requirements for which it is intended.

22.4.5.12 Outer sheath shall be of PVC black colour for power cables and of grey colour for control cables.

22.4.5.13 In plant repairs to the cables shall not be accepted.

22.4.5.14 As far as feasible, separate cables shall be provided for circuits of different plant and auxiliaries, for circuits of different voltages, and for circuit used separately. Power, control and instrumentation circuit shall invariably be taken through different routes, which shall not be laid together on the same cable tray.

22.4.5.15 At least 20% cores shall be kept as spares in the multi core control cable.

22.4.6 Identification Of Cores

The insulated cores of HT and LT power cables shall be identified by colour code.

22.4.6.1 Cores of the cables of up to 5 cores shall be identified by colour of insulation with the following colour scheme.

No. of cores Colour

1Core Red, Black, Yellow & Blue

2Core Red & Black

3 Core Red, Yellow & Blue

4 Core Red, Yellow, Blue & Black

5 Core Red, Yellow, Blue, Black & Grey

22.4.6.2 For reduced neutral conductors the core shall be black

22.4.6.3 For cables having more than 5 cores, core identification shall be done by numbering insulation of core sequentially, starting by number 1 in the inner layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10). The numbers shall be printed in Hindu-Arabic numerals on the outer surfaces of the cores. All the numbers shall be of same colour, which shall contrast with the colour of insulation. The colour of the insulation for all the cores shall be grey only.

(b) The control cables shall have identification by means if indelible printing of

numbers on its cores at intervals not more than 75 mm.


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22.4.6.4 The numerals shall be legible and indelible. The numbers shall be repeated at regular intervals along the core, consecutive numbers being inverted in relation to each other. When number is a single numeral, a dash shall be placed underneath it. If the number consists of two numerals, these shall be disposed one below the other and a dash placed below the lower numeral. The spacing between consecutive numbers shall not exceed 50 mm.

22.4.6.5 All HT and LT cable shall have embossing at interval of 1 meter for Owner‘s name, size / core type and length.

22.4.6.6 In addition to manufacturer's identification on cables as per IS, following marking shall also be embossed over outer sheath.

22.4.6.7 Cable voltage grade.

22.4.6.8 Sequential marking of length of the cable in meters at every one meter.

22.4.6.9 The embossing shall be progressive, automatic, on line and marking shall be legible and indelible.

22.4.7 Copper Cables

22.4.7.1 Copper cables shall be used for the following services.

22.4.7.2 DC cables from batteries to DC boards

22.4.7.3 DC emergency lighting cables for main building

22.4.7.4 Battery and battery chargers

22.4.7.5 Actuator motors, wherever provided.

22.4.7.6 All other essential system wherever necessary

22.4.8 Constructional Requirements for HT Cables

22.4.8.1 Type of Cable

The cable shall be multi core/ single core XLPE insulated type as specified.

22.4.8.2 Conductor

The cable conductor shall be made from stranded electrolytic Aluminium as

specified to form compact conductor having a resistance within the limits

specified in IS.8130.

All the cables of size 25mm2 and above shall have sector-shaped conductors.

The minimum number of strands in conductor shall be 7 (seven) except as

otherwise specified. Power cables shall be of stranded Aluminium conductor with

a minimum size of 10 mm2 and the control cables shall be of stranded or solid

copper (electrolytic) conductor with a minimum size of 1.5 mm2 as specified.


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22.4.8.3 Conductor Semi-Conducting Layer

The conductor having a semi-conducting screen shall ensure perfectly smooth

profile and avoid stress concentration. The conductor screen shall be extruded in

the same operation as the insulation and the semi-conducting polymer shall be

cross-linked for XLPE cables.

22.4.8.4 Insulation

The insulation of the cable shall be extruded type and shall be designed and

manufactured for the specified system voltage. The manufacturing process shall

ensure that insulation shall be free from voids. The insulation shall withstand

mechanical and thermal stresses under steady state and transient operating

conditions. The extrusion method should give very smooth interface between

semi-conducting screen and insulation. The insulation of the cables shall be of

high standard quality. The minimum volume resistivity of the PVC insulation of all

the PVC insulated cables shall be 1 x 1014 ohm cm at 27° C and 1 x 1011 ohm

cm at 70° C.

22.4.8.5 Insulation Shield

In XLPE cables to confine electrical field to the insulation, a non-magnetic semi-

conducting shield shall be put over the insulation. The XLPE cable insulation

shield shall be strippable. Metallic screening, as given in this specification for the

various power and control cables shall be provided.

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 insulation shielding shall consist of non-metallic extruded semi-conducting

compound in combination with a non-magnetic metallic screening of copper.

The copper screen shall be capable of carrying the single line to ground fault

current for the duration specified for the protection employed. Vendor shall furnish

calculation in support of selection of the size of copper screen.

22.4.8.6 Inner Sheath

The sheath shall be suitable to withstand the site conditions and the desired

temperature. It shall be of adequate thickness and applied by a continuous

process to produce a sheath of consistent quality free from all defects. PVC

sheath shall be extruded.

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

conform to the requirements of type ST2compound of IS: 5831. The extruded

inner sheath shall be of uniform thickness.


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The dimensions of the insulation, inner sheath and armour materials shall be

governed by values given in Tables 2, 3 & 4 (Method 3) of IS: 7098 Part-II).

22.4.8.7 Armour

Armouring shall be provided wherever specified. For multi core cables, the

armouring shall be by galvanised steel wire/ tape. If armouring is specified for

single core cables, the same shall be with hard drawn aluminium round wire of

2.5mm diameter.

The hard drawn aluminium wire for armour shall be of H4 grade, as per IS: 8130

(having tensile strength above 150 N/mm2). The diameter of the aluminium wire

shall be as per the table for the dimensions of the galvanised steel wire armour

given in the relevant standard. All cables directly buried shall be armoured.

22.4.8.8 Serving/ Outer Sheath

Extruded PVC serving as per IS: 5831 or as specified otherwise shall be applied

over the armouring with suitable additives to prevent attack by rodent and

termites. All serving must be given anti-termite treatment.

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 ST2

compound of IS: 5831. The thickness of outer sheath shall be as per amendment

no. l of table 5 of IS: 7098 Part-2 (Column 3 & 5 for both armoured and

unarmoured cables).

22.4.8.9 Fillers for Multi Core Cables

Cable shall have suitable fillers laid up with the conductors to provide a

substantially circular cross-section before the sheath is applied. Fillers shall be

suitable for the operating temperature of the cable and compatible with the

insulating material. All materials shall be new, unused and of finest quality.

Workmanship shall be neat, clean and of highest grade.

22.4.9 Cable Types







II).


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II).

22.4.9.3 415V System

The cable shall be 1.1 kV, grade, heavy duty, stranded Aluminium conductor,

XLPE insulated as specified, 4 or 3 1/2 core, galvanised steel wire/strip armoured,

extruded PVC type STI outer sheathed.


The cable shall be 1.1 kV grade, XLPE, heavy duty, multi core stranded (7 wires)

tinned copper (annealed) conductor, PVC Type-A insulated, galvanised steel

wire/strip armoured, flame retardant low smoke (FRLS) extruded PVC of type-

STl outer sheathed. The following sizes shall be used.

22.4.10 LV Power and Control Cables

22.4.10.1 LV power and control cables shall be XLPE, heavy duty type, 1100 V grade with electrolytic Aluminium conductor, PVC inner sheathed, armoured, if specified and overall PVC sheathed.

22.4.10.2 Copper conductor for control cables shall be PVC insulated whereas for power cables it shall be XLPE.

22.4.10.3 The conductors shall be stranded. The minimum number of strands shall be 7 (seven) except as otherwise specified. Conductors of nominal area less than 25 sq. mm shall be circular only. Cables of nominal area 25 sq. mm and above may

Cable Size (mm2) 1.5/ 2.5 4 6 16

No. of Cores 2,5,7,10,14,19,27

3,5 2,4 4


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be circular or shaped. Cables with reduced neutral conductor shall have sizes as per Table 1 of IS: 1554 (Part-I).

22.4.10.4 Power cables shall be of stranded Aluminum conductor with a minimum size of 10 mm2 and control cables shall be stranded copper conductor with a minimum size of 1.5 mm2.

22.4.10.5 If armouring is specified for multi core cables, the same shall be by single round galvanized steel wires where the calculated diameter below armouring does not exceed 13 mm.

22.4.11 Cable Accessories for HT Cables

22.4.11.1 The termination and straight through jointing kits for use on the system shall be cold shrinkable type and suitable for the type of cables offered as per this specifications.

22.4.11.2 The accessories shall be supplied complete in all respects and should be supplied in kit form. Each component of the kit shall carry the manufacturer’s mark of origin.

22.4.11.3 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.

22.4.11.4 The contents of the accessories kit including all consumables shall be suitable for storage without deterioration at a temperature of 50°C with shelf life extending more than 5 years.

22.4.11.5 A set of tools for making joints shall be provided (both for indoor and outdoor joints).

22.4.12 Termination Kits

Modern pre-moulded terminating kits shall be suitable for termination of the HT

cables to indoor switchgear. For outdoor terminations whether shields/sealing

ends and any other accessories required shall also form part of the kit. For RMU

cable termination shall be with plug in type.

22.4.13 Requirement of XLPE Joints and Termination

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

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

backfill along with 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. For ducts suitable man holes shall

be provided for joints. Joint in cables shall meet the following requirements.


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22.4.13.1 Conductivity of the jointed conductor shall not be less than that of the main conductor of the cable.

22.4.13.2 Joints between two conductors or conductor lugs shall have a mechanical strength not less than that of the conductor.

22.4.13.3 Adequate insulation level free from voids and impurities.

22.4.13.4 Sufficient stress relief provision.

22.4.13.5 Adequate creepage paths to eliminate system tracking.

22.4.13.6 Ability to withstand electromagnetic thermal stress during flow of short circuit Current.

22.4.13.7 Proper seals for water, dust and chemical fumes for checking their ingress under all conditions.

22.4.13.8 Inner semi-conducting layer with a smooth surface & good contacts and insulation.

22.4.13.9 Outer semi-conducting layer to adhere firmly to the insulation.

22.4.13.10 Earth continuity connection of adequate size shall be a part of the kit.

22.4.13.11 Cable joints with modern technology such as pre-moulded and manufactured in a single piece, in the factory. It should have factory built in functions such as electrical field control, insulation and sealing. It should have flexible rubber to take care of variations in the cable current and to ensure water tightness and increased electrical strength. No special tools or welding equipment should be required for jointing cables. These pre-moulded joints shall be factory tested for routine and type tests as per the appropriate IES/IS standard.

22.4.13.12 Condition for Cable Joints

(d) Under normal condition, no joints in HV & LV cables shall be permitted,

unless the maximum drum length available is less than the cable length

required.

(e) Contractor shall prepare the cable schedule based on the actual cable

length to be laid. Prepare drawing and label these cables. On the basis of

these length, the contractor shall workout the cable length for each drum

and advise the manufacturer accordingly.

(f) Under no condition a cable joint shall be permitted, if the length of the

available cable in the drum from the manufacturer is more than the length

of the cable being laid.


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22.4.13.13 Cable and Joint Markers

(d) Permanent means of indicating the positions of joints on site should be

provided. During the course of permanent reinstatement cable and joint

markers, should be laid directly above the route of the cable and the

position of the joint respectively.

(e) Wherever it is not possible to place the marker directly over the cable route

or joint the marker should be suitably placed near the cable route or joint

on which the distance of the cable route or joint at right angles to and

parallel to the marker should be clearly indicated.

(f) The position of fixing the markers will be approved by Engineer.

22.4.13.14 Jointing of Cables

(k) General: It shall be noted that the U.G. cables are of XLPE insulation and

needs special care in jointing. The cable jointer and his assistant shall have

experience in making joints / terminations. Jointing work should commence

as soon as two or three lengths of cables have been laid. All care should

be taken to protect the factory-plumbed cap/seal by laying the end solid in

bitumen until such time as the jointing is commenced.

(l) Jointing of cables in carriage ways, drives, under costly paving, under

concrete or asphalt surfaces and in proximity to telephone cables and water

mains, should be avoided whenever possible.

(m) Joint Pits: The joint pits should be sufficient dimensions as to allow jointers

to work with as much freedom of movement and comfort as cables

proposed to be jointed. The sides of the pit should be draped with tarpaulin

sheet to prevent loose earth from falling on the joint during the course of

making. The pit should be well shored with timber, if necessary. An overlap

of about 1.0 mtr of the cables to be jointed may be kept, for allowance to

adjust the position of the joint. When two or more cables are laid together

the joints shall be arranged to be staggered by 2 to 2.5 mtr.

(n) Sump Pits: When jointing cables in water logged ground or under monsoon

conditions, a sump pit should be excavated at one end of the joint pit in

such a position so that the accumulating water can be pumped or bailed

out by buckets without causing interference to the jointing operation.

(o) Tents: A tent should be used in all circumstances wherever jointing work is

carried out in the open irrespective of the weather conditions. The tent

should be so covered as to have only one entrance and the back facing the

direction of the wind. The tent cover should be properly weighted or tied

down on the sides.

(p) Measurement of Insulation Resistance: Before jointing is commenced the

insulation resistance of both sections of the cable to be jointed should be

checked by insulation resistance testing instrument. An insulation

resistance – testing instrument of 2.5/5 kV shall be used. The Insulation


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Resistance values, between phases and phase to earth shall be recorded.

The actual jointing operation shall start only after the approval of the

Engineer in charge of works.

(q) Precautions before Making a Joint or Cutting A Cable: The cable end seals

should not be opened until all necessary precautions have been taken to

prevent circumstances arising out of rainy/inclement weather conditions,

which might become uncontrollable. The cable seals should be examined

to ascertain if they are intact and also that the cable ends are not damaged,

if the seals are found broken or the lead sheath punctured, the cable ends

should not be jointed until after due examination and testing by the

engineer-in-charge of the works.

(r) Identification Numbers / Colours and Phasing : The cables should be laid

and jointed number to number or colour to colour shown on the core

identifying marks and prevent cross jointing. In all cases, the cables should

be tested and phased out, and more particularly so when the cable

terminates at Ring Main Unit / Sub-station.

(s) Making a Joint: The cold shrinkable joints used shall be made. The

contractor should furnish all the technical particulars of these joints and

obtain approval. heat shrinkable joints which need stove flame are not

acceptable. Epoxy based joints are also not permitted. Comprehensive

jointing instructions obtained from the manufacturer of joint kits shall be

meticulously followed.

The connection of the earth wires should be done using flexible bonds

connected to cable sheath using clips or soldering. Aluminium conductor

strands shall be joined be joined by mechanical compression method, using

suitable die and sleeve with a good quality tool. The joints shall conform to

specification as per IS 13573-1992.

(t) Cable Terminations: Cable terminations required are both indoor and

outdoor type push-on or cold shrinkable type can be used. All the technical

particulars to establish the superiority in the performance of these joints

shall be furnished while seeking approval. The terminations shall conform

to specifications as per IS 13573 – 1992. The instructions furnished by the

manufacturer of termination boxes/kits should strictly be followed.

Whenever a cable is raised from the trench to end in termination, to be

finally connected to transformer, the following instructions should be

complied with –

(vi) One coil to made and left in the ground for future needs

(vii) The rise of cable, immediately from the ground level should be

enclosed in suitable diameter pipe to height of 2 mt.

(viii) The balance portion of the cable should be neatly curved, in ‘S’

shape.


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(ix) The cable and pipe should be properly fastened by using appropriate

clamps /support. The hardware of clamps shall be non-rusting metal

alloy [not GI].

(x) The lugs on the termination shall be compressed with a suitable

compression tool.

22.4.13.15 Earthing and Bonding

(b) The metal sheath and Armour should be efficiently bonded and earthed at

all terminals to earth electrodes provided. The cross-sectional area of the

bond shall be such that the resistance of each bond connection shall not

exceed the combined resistance of an equal length of the metal sheath and

Armour of the cable.

22.4.13.16 Testing after Laying and Jointing

(d) All cables after laying and jointing works are completed should be tested

systematically and insulation and HT tests should be made on all

underground cables.

(e) All test results should be recorded in tabular form in logbooks kept for the

purpose

(f) The cable cores should be tested for:-

(iv) Continuity

(v) Absence of cross phasing

(vi) Insulation resistance to earth; insulation resistance between

conductors.

22.4.13.17 H.V. Tests

(c) After the laying and jointing work is completed, a high voltage test should

be applied to the cable to ensure that the cable has not been damaged

during or after the laying operations and there is not defect in the joining.

(d) The high voltage tests should be as per IS 1255 or as per international

standards. The H.V. testing instruments shall be brought by the turn key

contractor.

22.4.13.18 Testing and record of Cable Constants :

(b) When the cable is ready, just before commissioning, the cable constants

viz, the resistance, capacitance and inductance of each conductor should

be determined and recorded, along with frequency at which the values of

capacitance and inductance are determined.


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22.4.13.19 Cable Records

(d) Accurate neat plans / sketches, drawn to suitable scale (1 cm = 10M)

should be prepared and furnished by the contractor after the completion of

each work.

(e) All relevant information should be collected at site, during the progress of

work and preserved for preparation of drawings.

(f) The following essential data should be incorporated on all drawings.

(ix) Size, type of cable or cables.

(x) Location of the cable in relation to prominent land mark property,

Kerb-line etc., with depths.

(xi) The cross section showing where cables are laid in ducts, giving their

sizes, type and depths.

(xii) Location and type of all joints

(xiii) Location of other cables which run alongside or across the cable

route.

(xiv) Position and depths of all ducts, etc., which are met as obstruction to

the cable route.

(xv) Accurate lengths from joint to joint

(xvi) Manufacturers name and drum number of the cable, between

sections / joint to joint.

22.4.13.20 The cable records prepared as above shall be given to the Engineer as a part of the contract as soon as the cable is charged.

22.4.14 Cable Drums

22.4.14.1 Cables shall be supplied in non-returnable wooden or steel drums of heavy construction in proper and suitable packing for shipment to site. For wooden drums the wood used for construction for the drum shall be properly seasoned, sound and free from defects. Wood preservative shall be applied to the entire drum.

22.4.14.2 Contractor shall indicate in the offer the standard length for each size of power and control cable which can be furnished on one drum. The cable length per


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drum shall be subject to tolerance of ± 5% of the standard drum length agreed between purchaser and contractor.

22.4.14.3 Cable Joints shall be avoided as far as possible by use of proper cable lengths.

22.4.14.4 The Engineer shall have the option of rejecting cable drums with shorter lengths.as the cable drums shall be selected so that through joints is eliminated.

22.4.14.5 A layer of water proof paper shall be applied to the surfaces of the drums and over the outer most cables layer. A clear space of at least 40 mm shall be left between the cables and the logging.

22.4.14.6 Each drum shall carry the manufacturer's name, the purchaser/ supplier’s name and contract number, owner's name, address, item number, type, size, length of cable, net and gross weight stenciled on both sides of drum. A tag containing the same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wordings shall be marked on one end of the reel indicating the direction in which it should be rolled.

22.4.14.7 On the drum the number of cores, type of cable, voltage rating, code, direction of drum rotation, BIS certification mark and year of manufacture shall also be mentioned.

22.4.14.8 Packing shall be sturdy and adequate to protect the cables from any injury due to mishandling or other conditions encountered during transportation handling and storage.

22.4.14.9 Both cable ends shall be sealed with PVC/ Rubber caps so as to eliminate ingress of water during transportation, storage and erection/ construction.

22.4.15 Inspection

22.4.15.1 Before dispatch the cables offered shall be made available for inspection by the Engineer. Inspection may also be made at any stage of manufacture at the option of the purchaser and the cables found unsatisfactory due to the material used or poor workmanship shall be rejected.

22.4.15.2 The contractor shall guarantee free access to the places of manufacture to the Engineer at all times when the work is in progress. The contractor shall inform the Engineer in advance the time of starting of manufacture and the progress of manufacture of the cables offered by him so that arrangement can be made for inspection.

22.4.15.3 Inspection and acceptance of cables by the Engineer shall not relieve the contractor of his obligation of furnishing cables in accordance with the


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specification and shall not prevent subsequent rejection if such cables are later found to be defective.

22.4.15.4 The cables shall comply with type tests stipulated in prescribed section and the relevant standards. Test reports for all type tests shall be submitted with the tender.

22.4.15.5 All type and sizes of cables shall be subjected to routine and acceptance tests as stipulated in relevant standards without any extra cost to the purchaser. Cables should not be dispatched until the test reports are duly approved by the Purchaser or his authorized representative and specific instructions to despatch the inspected items issued.

22.4.15.6 The purchaser reserves the right of having any other special tests of reasonable nature carried out at site or at manufacturer's works or at any other place in addition to the aforesaid type and routine tests to satisfy himself that the cables comply with the specification, without any financial liability.

22.4.15.7 Six copies of test reports (or as indicated in the Schedule of Vendor Drawings) shall be supplied for approval. The reports shall indicate clearly the governing standards and the standard values specified for each test to facilitate checking of the test reports. Six bound copies of the test reports shall be submitted after approval of test reports along with the cables.

22.4.16 Tests

22.4.16.1 All types and sizes of cables being supplied shall be subjected to type tests, routine tests and acceptance tests as specified below and according to relevant standards.

22.4.16.2 The Engineer at its discretion may ask the contractor to conduct any or all the type tests for which at least 15 days advance notice shall be given.

22.4.16.3 Charges for acceptance test and routine test shall be deemed to be included in the bid price of individual cables.

22.4.16.4 Type Tests

22.4.16.5 Type tests shall be carried out on all the types and sizes of cables if desired or alternatively test certificates shall be supplied at the sole discretion of purchaser.

The following shall constitute type tests:

Test Remarks

For Conductor

Annealing test For copper conductor only

Tensile test For aluminium conductor only

Wrapping test For aluminium conductor only

Resistance test


Page | 357


For Armour Wires/Strips

Measurement of Dimensions

Tensile test

Elongation test

Torsion test For round wires only

Winding test For strips only

Resistance test

Zinc Coating test For G.S. strips/ wires only

FOR PVC/ XLPE Insulation &PVC Sheath

Test for thickness

Tensile strength and elongation

test before aging and after aging

Aging in air ovens

Loss of mass test For PVC insulation & sheath only.

Hot deformation test -do-

Heat stock test -do-

Shrinkage test ~do-

Cold bend/cold Impact test -do-

Colour fastness to -do-

Thermal stability test -do-

Bleeding and blooming test -do-

Hot set test For XLPE insulation only

Water absorption test For XLPE insulation only

For Completed Cables

Insulation resistance test

High voltage test For HT cables

Partial discharge test -do-

Bending test -do-

Dielectric Power factor test -do-

as a function of voltage -do

as a function of temperature -do-

Heating cycle test -do-

Impulse with stand test -do-


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Measurement of eccentricity and -do-

ovality

22.4.16.6 Short Circuit Test.

(b) Short Circuit Test

(vi) Short circuit test on conductors shall be carried out on cable samples.

(vii) During each short circuit test, the cable shall be subjected to thermal

(rms) and dynamic (peak) short circuit current of specified duration.

(viii) The test sample shall be subject to following tests before carrying out

the short circuit test and after completion of short circuit test (when

cable has cooled down to ambient temperature).

(af) Conductor resistance measurement.

(ag) High voltage test.

(ah) Tan delta measurement.

(ai) Partial discharge measurement (for HT cables).

(aj) Volume resistivity.

(ix) Before applying the short circuit current, the test sample shall be

heated up to the specified maximum conductor temperature. This

may be done by eddy current heating or by giving intermittent high

current impulses as per the convenience of test station. After

establishing specified conductor temperature, the cable shall be

subjected to short circuit test.

(x) Acceptance Criteria

After the short circuit test the test specimen shall meet the following

requirements:

(af) HV Test

(ag) Pd test

(ah) Tan delta values as per standard.

(ai) Conductor resistance not more than ±5%.

(aj) Volume resistivity shall not be below the standard acceptance

value.

22.4.16.7 Acceptance Test

Acceptance tests shall be carried out on each type and size of the cable on the

cable drums selected at random.

The following shall constitute acceptance test:

(m) Annealing test


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(n) Tensile test

(o) Wrapping test

(p) Resistance test

(q) Test for thickness

(r) Tensile strength and elongation test before aging and after aging

(s) Aging in air ovens

(t) Hot set test

(u) Insulation resistance test

(v) High voltage test

(w) Partial discharge test

(x) Measurement of eccentricity and ovality.

22.4.16.8 Routine Test

Routine test shall be carried out for each drum of cables of all type and sizes.

Following shall constitute routine tests:

(d) Resistance test.

(e) Insulation resistance test.

(f) High voltage test.

22.4.17 Technical Particulars

22.4.17.1 HT Cables

(m) Voltage Grade (E) 33/19 kV & 11/6.35 kV as per IS-

7098 (Part 2).

(n) Type 3 core, XLPE, armoured, screened

cables.

(o) System earthing Solid grounded

(p) Size As per requirement

(q) Conductor Aluminium/Copper stranded conductor

(r) Conductor Screening Semi conducting compound

by extrusion.

(s) Insulation Properties & Table 1 of IS-7098 (Part-II)

process of application and application by extrusions.


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(t) Nominal thickness of As per IS:7098

(u) Insulation screening

Non-metallic part Semi- conducting compound over the

insulation1

Metallic part Armouring may constitute

metallic part of screening. where both

metallic screen & armouring are used,

extruded inner sheath shall be there in

between and its thickness as per Table 3 of

IS 7098 (Part-II).

(v) Core Identification Coloured strips application on cores

or different colours of XLPE insulation or by

numeral (1,2,3) either by applying

numbered strips or by printing on the cores.

(w) Armouring Galvanized steel round wire/strips

(x) Outer Sheath thickness Not less than value specified in

Column 5 of Table 5 of IS 7098.

22.4.17.2 L.T. Power and Control Cables

(c) Size of Cable As per requirement

(d) Voltage rating 650/1100 V

22.4.17.3 Cable Accessories

Description HT Cables LT Cables

(d) Voltage Rating As per cable rating As per cable

(e) Type of termination Cold shrinkable Compressed

(f) Clamps/ terminals Aluminium compression Aluminium

Material

22.5 SPECIFICATION FOR UNDERGROUND DUCTS FOR POWER CABLES

22.5.1 Scope

This specification covers the design, manufacture, testing at manufacture's works

before dispatch, packing and transportation to site, of underground cable ducts

for laying of HT, LT Power Cables required for various sub-stations under PMC-

01 contractor scope of work.

All cable ducts shall comply with latest Indian / IEC-61386-1 and IS/IEC-61386-

24 standards.


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22.5.2 Make

The cable ducts shall be procured from experienced and reputed manufacturers,

with proven experience in manufacture of underground ducts for HV/LV power

cables and having capability to develop, test and timely supply of ducts as

specified in the tender specification. The manufacturer shall have arrangements

for carrying out all the routine, type and acceptance tests including special tests

as per the standards specified and have furnished satisfactory test results.

22.5.3 Codes and Standards

The ducts under this specification shall comply with the requirements of latest

edition of the following Indian and international standards including latest

amendments. Ducts manufactured to other international standards which provide

equivalent or superior performance shall also be accepted.

S. No. Standard

Number Description

1 IS:14930 Pt.-I General requirements of Conduit system for

Electrical and Communication installation.

2 IS:14930 Pt.-II Particular requirements of Conduit system for

Electrical and Communication installation

3 IS:2530 Method for test for Polyethylene moulding

materials and polyethylene compounds.

4 IS:7328 HDPE materials for moulding and extrusion

5 IS:12063 Classification of degrees of protection provided

by enclosures of electrical equipment

6 IS:11000 (Pt- Glow-Wire Test and Guidance, Test

Methods for Fire 2/Sec1) Hazard Testing

7 ASTM D 1693 Test method for environmental stress –

cracking of ethylene plastics

8 ASTM D 638 Standard test method for tensile properties of

plastic

9 ASTM D 790

Test method for flexural properties of

Unreinforced and Reinforced Plastics and

Electrical Insulating Materials.

10 ASTM D 2240 Standard Test method for Rubber property


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S. No. Standard

Number Description

11 ASTM D 648

Standard Test method for deflection

temperature of plastic under flexure load in the

Edgewise Position.

12 IEC-61386-24 Conduit system for cable management Part-24,

Conduit system buried underground

13 IEC-61386-I Conduit System for Electrical installation Part-I


22.5.4 Duct Material and Design

Material for the ducts can be HDPE. The Ducts shall be designed considering

the following:

The ducts shall be designed considering the following:

22.5.4.1 Duct For High Voltage And Low Voltage Electric Power Cables

(i) All ducts shall be as detailed in the relevant sections of Indian Standard or

IEC and this Specification.

(j) The ducts shall be non-coil able / semi-rigid, “single smooth walled”,

manufactured in HDPE. Each duct type shall have a smooth inner surface.

(k) As the design stresses and the physical properties of HDPE and are

different, duct bore/wall thickness ratios are likely to be different. However,

ducts intended to be buried and used with high voltage power cables and

low voltage mains distribution cables shall be capable of meeting the 5%

deflection requirements with an applied force of 450N compression

strength at 75°C.

(l) The cross section of all ducts shall be circular and ends cleanly cut and

square with the longitudinal axis. They shall have no sharp edges, burrs or

surface projections which are likely to damage the cables and shall not

present any impedance to the installation or withdrawal of cable throughout

its length.

(m) There shall be solid polymer coating for permanent silicore lubrication and

low co-efficient of friction. No built-in lubricant is acceptable.

(n) Cable duct shall be with low smoke zero halogen plastic.

(o) Duct shall be designed to withstand and repel rodent attacks.

(p) Duct should be suitable for pulling armoured HT & LT cables.


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22.5.4.2 Fibre Optic Cable Ducts

(f) Fibre Optic Cable ducts shall be manufactured as 96.5mm (OD) / 90mm

(ID) Green HDPE solid wall cable ducts designed in accordance with IEC

61386-24. The ducts shall be supplied in 6m lengths with a 100mm heat

formed taper socket at one end and a parallel spigot at the other end to

provide an IP rating of IP57.

(g) The duct shall be designed to provide a min compression test of 450N as

per Indian / IEC Standard.

(h) The duct shall be designed to withstand a 5kN striker (normal duty) impact

test as detailed in Indian / IEC standard.

(i) The duct shall be designed to provide a minimum tensile test capability of

>44.1N/mm2.

(j) Duct shall be provided with a co-extruded highly conductive electrolytic

copper wire encased in the HDPE duct along it running length. To locate

the position of the buried duct in one end of the cable a GPS enabled

transmitter shall be connected. The compatible receiver to this transmitter

shall also be GPS enabled. Receiver shall be able to trace the route of the

cable, along with the depth of the buried duct and its longitude and latitude

co-ordinates.

Both receiver and transmitter systems shall be upgradable, and shall have

built up battery systems complete in all respects. Two sets of such systems

shall be supplied for the ducts under the scope of PMC-01 project.

Contractor shall supply the technical data for such a system for the

approval of Engineer.

Contractor shall also ensure that the effects of any induced voltages in the

copper wire extruded in the ducts, due to high currents of power cables

(inside the ducts) is taken care of by proper earthing, if required.


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22.5.5 General Requirements

22.5.5.1 The Duct shall be with the inner layer plain and smooth.

22.5.5.2 Duct and conduit fittings within the scope of this specification shall be so designed and constructed that in normal use their performance is reliable and without danger to the user or surroundings.

22.5.5.3 When assembled in accordance with manufacturer’s instruction as part of a conduit system, they shall provide mechanical protection to Cables contained therein.

22.5.5.4 Within the conduit system there shall be no sharp edge, burrs or surface projections which are likely to damage insulated conductors or cables or inflict impurity to the installer or user.

22.5.5.5 The protective properties of the joint between conduit and conduit fittings shall be not less than that declared for the conduit system.

22.5.5.6 The Duct and fittings shall withstand the stresses likely to occur during transport, storage, recommended installation practice and application.

22.5.5.7 The duct shall be supplied in continuous length in coil form or straight length, suitable for shipping and handling purpose.

22.5.5.8 For conduit systems that are assembled by means other than threads, the manufacturer shall indicate whether the system can be disassembled and if, so, how this can be achieved.

22.5.6 Colour of Power Ducts

All ducts meant for HV/LV power cables shall be in red colour.

22.5.7 Requirements Of Raw Materials Used For The HDPE Ducts

22.5.7.1 The base HDPE resin used for the outer and inner layer of the HDPE Duct shall conform to any designation of IS:7328 or to any equivalent standard meeting the requirements given in Table below, when tested as per the standards given therein. However, the manufacturers shall furnish the designation for the HDPE resin as per IS: 7328 as applicable.


1 Density 0.940 to 0.958 g/cc at

27ºC IS:2530 or IS:7328

2 Melt Flow Index 0.2 to 1.1 g/10 min IS:2530 at 190ºC, 5 kg

load

3 Tensile Strength

at 20 N/mm2 Minimum ASTM D 638-IV


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4 Elongation at

Break 600 % Minimum ASTM D 638-IV

5 Hardness Shore

D

Between 60 and 65

units ASTM D 2240

6 Environmental

Stress

No cracking after 96

hrs. ASTM D 1693

7 Flexural modulus

at 1 % strain 690 N/mm2 minimum ASTM D 790

8 Heat Deflection ASTM D 648

9 Temperature at

45 g/mm OIT (in Aluminium Pan) 30 minutes minimum

Table 10: Raw Material Requirement

22.5.7.2 The anti-oxidants used shall be physiologically harmless.

22.5.7.3 None of the additives shall be used separately or together in quantities as to impair long term physical and chemical properties of the duct.

22.5.7.4 No rework / regrind material shall be used.

22.5.7.5 The raw material used for extrusion shall be dried to bring the moisture content to less than 0.1%.

22.5.7.6 Suitable UV stabilizers shall be used only for manufacture of the nonblack coloured HDPE duct to protect against UV degradation, when stored in open for minimum 8 months period. The Engineer may ask for UV content test. The test result for UV Content test by FTIR method from any recognized laboratory shall be accepted and the Hindered Amine Light Stabiliser shall be minimum 0.15 %. UV Content test need not to be conducted in case of UV Stabilized raw material is used.

22.5.8 Requirement for HDPE Ducts

22.5.8.1 Visual Requirement

The ducts shall be of good workmanship and shall be free from holes, breaks

and other defects. The ends shall be cleanly cut and shall be square with axis of

the ducts.

22.5.8.2 Colour

The colour of the duct shall be green for fibre optic duct and Red for power cable.


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22.5.8.3 Dimensions

The dimensions of the HDPE Ducts shall be selected based on the cable size.

The cable occupancy in duct shall not exceed 65% based on the internal cross

sectional area of the duct. Typical size of power duct may be 117mm inner dia

and 125mm or more outer dia.

22.5.8.4 Standards Length

Duct up to 50 mm OD nominal size shall be supplied in standard length of 100

mtr. ± 1% or 6 mtr ± 1 % and all higher other sizes will be supplied in standard

length of 6 mtr. ± 1%.

22.5.8.5 Other Main Requirements

(k) Ducts shall comply with the following requirements of Indian / IEC

standards.

(l) Compression Strength

(m) Impact Strength

(n) Bending Strength

(o) Oxidation Induction Test (OIT)

(p) Resistance to flame Propagation

(q) anti-rodent Properties & tests.

(r) safety of ducts from the direct attack of subterranean organism.

(s) Resistance to external influences such as ingress of water and dust on

HDPE Duct Accessories as per IS-12063.

(t) Test certificate from accredited third party laboratory is mandatory for the

above tests.

22.5.8.6 Marking Identification:

At every 1/3 meter it shall be marked ELECTRIC CABLE DUCT. Further the

conduit shall be prominently marked at regular intervals along their length of 1m

using indelible ink with following:

(h) Manufacturers name & code

(i) Specification No.

(j) Duct size both inner and outer diameter

(k) Incremental meter mask

(l) Date of manufacture

(m) Employer’s name / symbol


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(n) The lettering shall be 8mm high in yellow or white and repeated 3 times

with a120° spacing around the circumstances along the length of the duct.

22.5.9 Duct Accessories for Power Cables

The following requirements shall be met for accessories for Ducts.

22.5.9.1 Plastic Coupler:

The coupler shall be of compression type with O-ring. It is used for jointing two or

more ducts. The design of this shall be simple, easy to install and shall provide air

tight and water tight joint between the two ducts. The coupler shall insure that the

two ducts are butted smoothly without any step formation in the inner surface. The

coupler may be straight, bands, T-joints type as per requirements of Engineer.

22.5.9.2 End Cap:

This cap made of suitable plastic material shall be fitted on the both ends of duct,

coil after manufacturing the duct. This shall avoid entry of dust, mud and rainwater

into the duct during the transit & storage. Water tight and to prevent entry of

vermin’s, caps shall be provided for sealing the ducts after cable installation or

otherwise ducts kept as spare. The dimensions of accessories shall be suitable for

joining the ducts.

22.5.9.3 Straight Coupling

All duct couplings shall not present any internal projection or impedance to the

installation or withdrawal of cable through the duct run.

22.5.10 Packing Requirement

Ducts shall be supplied in standard size for delivery and shall be so packed as to

permit convenient handling and to protect against loss or damage during transit and

storage.


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22.5.11 Type Tests

22.5.11.1 Complete Duct systems for each offered size of the duct on fresh samples shall be subjected to tests minimum after 240 hrs of manufacture as per Indian / IEC Standard.

22.5.11.2 The raw material tests of the duct.as given for each grade of raw material shall be conducted.

22.5.11.3 Unless otherwise specified each tests shall be made on three new samples.

22.5.12 Routine And Acceptance Tests

These shall be conducted as per Indian / IEC standard. Each tests shall be made

on three new samples.

Inspecting Engineer may cut the duct in between to check the uniformity of

thickness of ducts and for other tests.

22.5.13 Inspection

22.5.13.1 All the gauges/ test & measuring instruments shall be calibrated at the time of inspection and proof to this office shall be produced.

22.5.13.2 Inspection and testing shall be carried out by the inspecting authority nominated by the Employer/ Engineer, to ensure that all the requirements of this specification are complied with for the acceptance of the materials offered for inspection.

22.5.13.3 The Employer / Engineer or his nominee shall have free access to the works of the manufacturer and to be present at all reasonable times and shall be given facilities by the manufacturer to inspect the manufacturing of the duct at any stage of manufacture.

22.5.13.4 Inspecting Authority shall have the right to reject whole or part of any work or material that does not conform to this specification, Indian / IEC standards. Employer / Engineer may order the same to be removed / replaced or altered at the expense of the manufacturer. All facilities considered necessary by the inspecting authorities for the inspection of the ducts shall be supplied by the manufacturer free of cost.

22.5.13.5 The manufacturer shall supply the duct samples and samples of the raw materials free of charge as required by the inspecting authority and shall at his own cost prepare and furnish the necessary test pieces and appliances for such testing as


Page | 369


may be carried out at his own premises in accordance with this specification and Indian / IEC standards.

22.5.13.6 Failing the existence of any required facilities at his own premises for the prescribed tests, the manufacturer shall bear the cost of carrying out the tests in an approved laboratory, workshop or test house.

22.5.14 Sampling

Ducts of the same length, nominal size, similar construction and class,

manufactured from the same material and under similar conditions of production

shall be grouped together to constitute a lot. For judging the conformity of a lot

to the requirements of the acceptance tests, sampling shall be done for each lot

separately. For this purpose, the number of lengths to be selected at random

from the lot shall be in accordance with Table below:

S. No. Lot size

Samples for Dimension

Checking

Samples for

Other

Acceptance

Tests

(Number) Number

Permissible

Rejection

1 Up to 300 13 0 2

2 301 - 500 20 0 3

3 501 - 1000 32 1 4

4 1000 - 3000 50 2 5

5 Above 3001 80 3 7

Table 21: Sample

Theses lengths will be selected at random from the lot for taking samples. From

each of these lengths, sample of duct shall be taken. The length of the sample

shall be sufficient so as to provide test pieces of required lengths as laid down in

various test clauses.

22.5.15 Defects in Ducts

The manufacturer shall be responsible to ensure that ducts supplied under the

specifications are free from defects in design, material and workmanship under

the service conditions given in the specifications. Contractor shall replace free of

cost those parts which shall be found defective.


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22.5.16 Rejection

In case the duct tested and inspected in accordance with this specification, fail to

pass the tests or comply with the requirement of the specification, the whole

consignment shall be rejected at the risk and responsibility of contractor.

22.5.17 Information To Be Supplied

22.5.17.1 Normally the duct will be supplied as per the standard dimensions and length as Indicated in this document. However contractor may specify his own dimensions / lengths / packing requirements etc. to comply with the specifications.

22.5.17.2 The manufacturer shall provide the proof of purchase of HDPE and other raw material after the date of placement of order before commencing the production of the Ducts.

22.5.17.3 The manufacturer of ducts shall submit a declaration that only virgin material has been used for manufacturing of HDPE Ducts failing which supply shall not be accepted.

22.5.17.4 The manufacturer shall have an ISO 9001, ISO 14001 and ISO 18001 certified manufacturing unit.

22.5.17.5 The manufacturer shall submit his Quality Assurance Plan, ISO related documentation and manufacturing process details prior to fabrication, failing which ducts shall not be accepted.

22.5.17.6 Power Duct/fiber duct laying and Power Cable Installation training shall be provided at their training centre by manufacturer and they shall depute their technical team to train the site engineers for duct laying and supervision for two weeks free of cost.

22.5.17.7 Owner/Engineer may visit the plant to check the capability of manufacturer to supply quality products.

22.5.18 Cable Duct Tile Tape and Tiles

22.5.18.1 Cable Duct Tile Tape for LV and HV Cables

(e) The tile tape is intended to, during excavation work; give a clear visual

warning to contractors and other utilities of the presence of underground

cables, joints or cable ducts.

(f) The tile tape shall be manufactured from reconstituted low or medium

density Polythene or a similar material, which shall be rot-proof and

resistant to a wide variety of virgin and tipped soil conditions. The material

used shall have no detrimental effect on the environment.

(g) The tile tape shall comply with the general requirements of relevant

standards including being laminated with suitable marker tape

identification.


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(h) The tile tape shall be marked with the following legend. “SEABIRD PMC-

01” or as advised. The lettering shall be repeated every 300mm along the

length in the centre of the tile tape.

22.5.18.2 Tiles For Use On 11kv Cables and Ducts

(f) The tile is intended to, during excavation work; give a clear visual warning

to contractors and other utilities of the presence of underground cables,

joints or cable ducts. The tile shall be manufactured from any thermoplastic

material and comply with the requirements of BS EN50520-2009. The use

of reworked, reprocessed or recycled materials is permitted; however, any

material used shall have no detrimental effects on the environment and

shall be rot-proof and resistant to a wide variety of virgin and tipped soil

conditions. The tile shall have a suitable standard warning text laminated

along its longitudinal length complying with the standard.

(g) The tile ends shall be cleanly cut, square with the longitudinal axis of the

tile, shall have no sharp edges.

(h) To allow interconnection of the tiles; located 25mm from each end of the

tile along its centre line, each tile shall have pre drilled 12mm hole.

(i) A suitable peg or cable tie is provided to enable tiles to be connected

together.

(j) Tile dimensions are to be provided for approval.

22.5.18.3 Concrete Route Markers

Concrete route markers posts shall be used as an aid to locate and identify the

route and the presence of buried underground cables and cable ducting systems.

After installation, the marker posts can be expected to be subjected to the full

range of climatic conditions encountered at site. The buried section of the marker

post may also be surrounded by standing ground water for most of its functional

life.

The marker posts shall be pre-cast concrete not less than C30 grade with a mix

ratio in the range 1:2:3 (Cement-Sand-Fine/Medium Aggregate). When utilized,

6mm 43A grade steel reinforcing rods shall be incorporated into the casting where

a minimum of 10mm coverage of concrete shall be applied around all faces.

For the fixing of the relevant marker plate (not supplied with the marker post); 4

x 16mm diameter holes shall be drilled or precast into marker post. The proposed

location of the fixing holes, details of approximate physical size of the route

markers are to be provided by contractor.


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22.5.18.4 Cable Laying In Ducts Broad Guide Lines

Contractor shall design the duct system and obtain approval of Engineer for the

procedure to be followed for duct laying. Below are given the broad guide lines

for the same.

General Requirement for HV and LV Cable Laying

(k) Armoured Cables shall be laid in Ducts and relevant Indian / IEC standards

shall be followed for the same. In case there is any conflict in the

requirements given below the stringent clauses as per decision of Engineer

shall apply.

(l) Minimum depth below finished ground level shall be 600 mm measured

from the top of duct.

(m) Only one cable shall be laid in one duct.

(n) Outer Duct surface shall have minimum 300 mm clearance from normal

pipes of other services which shall be increased to 600 mm for very large

pipelines or high-pressure pipes.

(o) Minimum spacing of 75mm shall be kept between two ducts both

horizontally as well as vertically when a number of ducts are installed. From

the trench wall it shall be 100mm.

(p) The bottom bedding shall be 50mm minimum of the surround material.

(q) HV ducts can be encased in concrete and for LT ducts unless these are on

the same route can be buried in ground as explained below.

(r) Duct surround material thermal resistivity shall be maximum 1.0km/watt at

zero percent moisture content. Only unwashed sand graded to BS 882 or

equivalent Indian Standard shall be used. This material must be compacted

well around the ducts.

(s) When the ducts are laid the surround sand shall cover up to 75 mm of top

of duct. After this sand cover of 75mm, a marker of width covering the ducts

below shall be placed. Then on top of this marker backfill of Red Cement

bound granular Mixture [15N after 7 days] shall be filled up to 225 mm. On

it Warning tape of about 250mm shall be placed. After that the same

granular mixture shall be placed so that the marker is about 300mm below

the finished surface.

(t) Mandrel shall be passed through each duct before concreting or covering

so as to ensure that cable will not be damaged during pulling due to

incorrect duct joints. Then a 5-meter sample of same cable can be passed

and if there is any cut or damage to cable after concreting or backfilling the

ducts shall be rejected. Typical duct drawing is enclosed in tender

drawings.


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22.5.19 Man Hole

22.5.19.1 General

(i) Contractor shall provide man holes for pulling the cables so that the pulling

tension of cable is not exceeded. These man holes shall also be at cable

jointing pits, cable turning, cable crossing roads. The size will depend on

the number of cables, ease in pulling and jointing cables. It shall have

provision of built in ladders, cable supports etc. These shall be of material

such as aluminium alloy and under no condition any rusting material such

as GI or steel shall be used. All the duct ends shall be sealed for water, gas

and vermin entry including the spare ones through proper sealing split

sockets meant for this purpose so that same can be removed when cable

replacement is to be done. No compound or foam sealing is acceptable.

Sealing must be 100% under all the operating conditions throughout the life

of the cable duct. Contractor must ensure that there is high water table at

site and this shall be taken into consideration while designing the drainage

from the manhole. In such as situation contractor may propose to have

manholes at higher level of ground.

(j) There shall be a sump hole with gravel inside with a proper size of mesh to

drain water towards the sea. All slopes in manhole shall be towards this

sump hole. It is the responsibility of contractor that under no condition water

stays inside the manhole due to rain or otherwise and manhole not

complying to this requirement shall not be acceptable under any

circumstances. Contractor to submit the drainage arrangement for approval

of Engineer.

(k) Typical sizes of man holes for LT cables depending upon the number of

cables can be 1600 mm x 1600mm or 1200mm x 1200mm depth not

exceeding 1600mm. For HT cables Man Hole can be of 2000mm x 2000mm

with a maximum depth of 1600mm to 2000mm or as determined by

contractor with the approval of Engineer considering the number of cables,

one above the other.

(l) Man, hole can be of concrete or prebuilt of Glass Reinforced Plastic,

provided the required strength is ensured when the foot paths or roads

above are operating under full designed loads of pedestrians or vehicles

above. FRP man holes of sufficient strength shall be preferred because of

rusting environment at site.

(m) There shall be sufficient space to pull the cables in the ducts.

(n) Cables inside the manhole shall be supported by providing cable bearers

as per requirement. Turning radius of cable must not be less than as per

the recommendation of manufacturer.

(o) Each manhole shall be numbered for ease maintenance.


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(p) For drainage the soak way of size 150x150mm (or round) excavated to

about 300 to 600mm deep filled with coarse gravel is to be provided in one

corner to allow water drainage. Alternatively, for area with high water table

a pumping sump may be provided. In either case a flush fitting protective

grating shall be provided.

22.5.19.2 Earthing

If any metallic build in ladders, supports etc. are provided, same shall be grounded near man

holes. For this purpose, grounding shall be provided for the safety by rod or pipe grounding as

per IS-3043.

22.5.20 CABLING SYSTEM

All HV and LV power cable shall be XLPE insulated, PVC sheathed, FRLS with anti-rodent

coating with stranded aluminium conductor. All 11 KV cables LV cables from CSS to feeder

pillar are laid in RCC cable trenches. The service cable from feeder pillar to consumers and

street light cables are laid in HDPE / DWC duct pipe.

22.5.20.1 CABLE SELECTION CRITERIA:

Cable sizes shall be selected considering the following:

• Permissible current carrying capacity

• Voltage drop

• Short time current / overload requirements

• Fault current carrying capacity

• Ambient conditions, cable laying and other related criteria.

Generally, for 11kV distribution, 3-core aluminium cable of size 300 mm2 shall be adopted to

cater to a load of about 5MVA. Under normal conditions, the voltage drop shall be restricted to

6%. Similarly, for LV cables, generally 3.5-core XLPE Aluminium cable of 300 mm2 shall be

adopted with a voltage drop of about 3%.

For loads where available 3-core cables are unable to take load currents, single core cable with

trefoil configuration shall be used.

All cables shall be de-rated as per the usage/installation factors as recommended by the cable

manufacturer considering ambient and laying conditions.

All HV/11KV cables installed between the SUBSTATION and the CSS/transformer shall be

installed in concrete duct banks, sized, configured and located as per detailed design

requirements.


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22.6 CABLE LAYING

22.6.1 DEPTH OF LAYING & SPACING BETWEEN CABLES:

Minimum depth of laying from ground surface to top of cable shall be as following:

• 11 kV cable: 1.0 meter.

• 415 volt cable: 0.75 meter.

• 11kV, 415 V Cables at Road crossing: 1.2 meter.

• 11Kv, 415V Cables at Railway crossing (Measured from bottom of sleeper to top

of pipe.): 1.0 meter.

Whenever 2Nos. 11kV Cables have common route, they can be laid in same corridor (Trench)

at the specified depth as indicated in the drawing.

Wherever the proper depth is not achievable due to presence of other services or for other

reasons, the cable shall be laid deeper or HDPE /GI pipe as required depending upon the site

condition.

Note: In certain colonies /areas where the road width is about 10 feet or less, and LT consumers

are both side of the road, excavation of cable trench for laying cable on both side of the road

and placing feeder pillar on road side is difficult. In such cases, suitable site decision is to be

taken in consultation with engineer in charge.

22.6.2 ROAD, RAILWAY TRACKS, WATER PIPE LINE CROSSINGS:

Pre -fabricated RCC duct bank consists of HDPE pipe encased concrete shall be used for

crossing of Road and cast iron or GI pipes for railway track and water pipe line. One spare pipe

at each location of 11 kV cable crossing shall be laid. Cable /pipe size/ laying details shall be

as per IS 1255-1983. The road cutting for cable trench, whether cement concrete, asphalt or

macadam road surface shall be undertaken after obtaining approval for cutting from the road

authorities, telephone authorities and work should be planned to be completed in the shortest

possible time. Where necessary the work shall be planned during night or light traffic periods.

The railway track crossing design shall be got approved from the railway authorities and the

contractor shall do work in coordination with them. In the excavated trench across the road the

pipes shall be laid, excavation backfilled compacted and surface shall be redone in the shortest

possible time. Open Drain Crossing: Where ever the cable has to cross open drains, with long

span, the cable shall be laid in suitable size HDPE /G. I. pipe properly joined with suitable collars.

The GI pipe shall be firmly supported on pillars, columns, or suitable support of RCC foundation.

22.6.3 FOOT PATH CUTTING:

The slabs, curb stones, on the roads/ footpath shall be removed and reinstated without damage.


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22.6.4 REINSTATEMENT:

After the cables and pipes have been laid and before the trench is backfilled, all joints and cable

positions should be carefully plotted in drawing and preserved and provided to the Engineer of

Employer. The protective covers shall then be provided, the excavated soil riddled, sieved and

replaced.

22.6.5 JOINTING BAYS:

The bidder shall identify the location of the joint bays after carrying out detailed survey of the

cable route and excavation of the trial pits. The delivery lengths of the cables shall match the

location. The joint bay should have a flat and level surface. At the bottom in a corner, a sump

pit shall be made, if necessary, for bailing out water. The contractor shall follow standard

practice in making joint bay, jointing and back filling after making joint and testing for the voltage

class required. All works shall be carried out in presence and supervision of the Engineer of

Employer.

22.6.6 BENDING RADIUS:

Care shall be taken during laying to avoid sharp bending and twisting. Recommended minimum

bending radius for LT/HT cables: LT HT Single Core 15xD 20xD D= Dia of cable in MM.

Multicore 12xD 15xD 12.4

22.6.7 JOINTING AND TERMINATION OF CABLES:

General: The cable jointing personnel and his crew shall have good experience in the type of

joints and terminations that are used. The jointing work shall commence as soon as two or three

lengths of cables have been laid. All care should be taken to protect the factory-plumbed caps/

seals on the cable ends, and the cable end shall be resealed whenever the end is exposed for

tests. Jointing of cables in carriage ways, drive ways under costly paving, under concrete or

asphalt surfaces and in proximity to telephone cables and water mains should be avoided

wherever possible. Sufficient overlap of cables shall be allowed for making the joints. The joint

bay should be of sufficient dimensions to allow the jointers to work with as much freedom of

movement and comfort as possible. Sufficient space should be kept below the cable to be

jointed. The joints of different phases shall be staggered. All jointing works shall be done by

licensed jointers.

22.6.8 TENTS / COVERS:

An enclosure or suitable protection cover shall be used in all circumstances wherever jointing

work is carried out in the open irrespective of the weather conditions. The joint shall be made in

dust free and clean atmosphere.


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22.6.9 PRECAUTIONS BEFORE MAKING A JOINT/ END TERMINATION:

The cable end seals should not be opened until all arrangement have been made for jointing

and all necessary precautions have been taken to prevent circumstances arising out of rainy/

inclement weather conditions, which might become uncontrollable. If the cable end seals or

cable ends are found to have suffered damage the cables should not be jointed, without tests

and rectification.

22.6.10 MEASUREMENT OF INSULATION RESISTANCE:

Before and after jointing, the insulation resistance of both sections of cables shall be

checked.

22.6.11 IDENTIFICATION:

The identification of each phase shall be clearly and properly noted. The cables shall be jointed

as per the design approved by the Employer based on the proposal submitted by the Contractor.

Each cable shall have identification for phase and circuit at joint bays.

22.6.12 MAKING A JOINT/ END TERMINATION:

Comprehensive jointing instructions should be obtained from the manufacture of jointing/end

kits and meticulously followed. The materials used in the joints/ end kits like ferrules, screen /

armour continuity bonds, lugs etc., shall be of good quality and conform to standards. The

jointing tools shall be appropriate and as per the requirement of jointing XLPE, PVC cables.

22.6.13 CABLE TERMINATIONS:

The cable terminations used are to be of outdoor type. The preparation of the cable end for

installing the terminations and the precautions to be taken before fixing the terminations shall

be followed as in the case of the cable jointing procedures. The instructions furnished by the

termination manufacturer shall be strictly followed. All terminations shall be done by joint

manufacturer’s jointers or under their supervision. At cable terminating end, the following

provisions for supply and erection are to be included.

A terminating structure should be provided where necessary for supporting the cable to be

terminated (except at the ring main unit ends)

A sufficient length of spare cable shall be left in the ground, for future needs.

The rise of the cable immediately from the ground shall be enclosed in suitable size of PVC / GI

pipe to protect against direct exposure to the sun.

The cable shall be properly fastened to the support using non-metallic clamps.


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Appropriate labels shall be fixed identifying the phase circuit, voltage and date of commissioning

etc., on the cable supporting structure.

22.7 SPECIFICATION FOR EARTHING

22.7.1 Scope

22.7.1.1 This specification covers the technical and associated requirements for the entire earthing system substations, required to protect persons and equipment and to allow safe service and maintenance of the installations. The earthing system includes the underground grid, ground rods and connections. The earthing system shall be designed to minimise the dangers from step, touch and transferred potentials which can occur under maximum fault conditions. The Contractor shall design, furnish and install the substation earthing system in accordance with the provision on latest IEEE Std. 80, Guide for Safety in Substation Earthing, IS: 3043, Code of Practice For Earthing and the provision of this specification. The contractor shall submit calculations in support of his design.

22.7.1.2 In addition to the above codes and standards, the Contractor shall comply with applicable national and local laws, codes, regulations, statutes and ordinances.

22.7.1.3 The Contractor shall bear full responsibility that the earthing system materials have been designed and fabricated in accordance with all codes and standards and that they perform under the conditions and to the standards specified herein.

22.7.1.4 The Contractor shall carry out earth resistivity measurement for the substation site. Based on the result of this measurement and the system parameter, the appropriate design and the calculation will be determined whether impermissible touch and step voltages occur at any place of the station (including outside area) which may be endangered. These calculations will decide on the provisions for earthing to be made with the relevant part of the civil works related to foundations. It shall be agreed between Engineer and Contractor, about special arrangements, if calculations prove that touch and step voltages are higher than permitted and the Contractor proves that he modified the earthing grid to its optimum. Only calculations built up on computer generated design programmes shall be accepted. A special software for providing detailed analysis of the actual step and touch voltages likely to be generated has to be used.

22.7.1.5 The HV and LV systems are solidly earthed at the neutral point of the power transformer. The size of earthing conductors to be connected with the earthing system shall be designed for an earth fault level of 40 kA (1 sec). The material for earthing in particular for jointing shall be selected to prevent corrosion at the connection points as well as at the earthing material itself, both underground and exposed to air. If necessary, cathodic protection of an approved design shall be applied. In order to minimise the effect of seasonal variations of earth resistance, the earthing system shall be designed for the worst conditions.

22.7.2 Description of Services

The Contractor shall provide a complete earthing system consisting of:


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22.7.2.1 The main outdoor subsoil earthing system, with individual loops around each building, foundation, structure, etc., of the site.

22.7.2.2 Sub-earthing systems for buildings, foundations, structures, tanks, etc., being connected to the subsoil earthing system as required

22.7.2.3 All electrical equipment such as motors, transformers, substations, foundations, switchboards, control boards, relay and auxiliary relay boards, all other subsidiary electrical equipment as well as all metal parts of civil construction or the mechanical equipment such as transformer rails, pumps, pipes, steel structure, tanks, cable trays, etc. shall be connected to the earthing system.

22.7.2.4 All materials and parts which are not specifically mentioned herein but are necessary for the safety of operating personnel and safe operation of the substation shall be furnished and determined by the Contractor at no increase in cost to the Owner.

22.7.3 Design Requirements

22.7.3.1 General

(l) The ground grid shall be composed of a system of copper conductors

buried approximately 500 mm below finished ground level, excluding

crushed rock surfacing. The grid system shall cover the entire fenced

substation area and shall be extended to the outer of the substation fence.

A perimeter conductor shall run around the substation in a distance of 0.5m

to the fence and shall be connected to the inner earthing grid and to the

fence in regular intervals. Where necessary to reduce the overall earth

resistance, earth electrodes shall be provided and connected to the

perimeter of the main earth grid. A minimum of four (4) of the specified

ground rods must be installed (one at each corner of the ground grid). The

Contractor shall determine the spacing of ground grid conductors and the

total number and location of ground rods and their lengths.

(m) Earthing conductors buried in the soil shall be of stranded copper, coated

if and as necessary. Earthing conductors embedded in concrete shall be of

copper cables. Adequate corrosion protection shall be provided when

conductors leave the concrete, respectively the soil.

(n) The design of the earthing system and the materials to be used shall

comply with the requirements for the specified cathodic corrosion

protection.

(o) Earthing conductors laid on cable trays or similar shall be stranded copper.

(p) All interconnections of the earthing grid to equipment and the connections

be-tween the earthing grid and the earthing rods shall be made by the

termite welding process. Only those connections located in earthing pits

and occasion-ally intended to be opened for testing purposes shall be of

the bolted type.


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(q) When a substation is located adjacent to the existing earthing system of

Phase-1 of Seabird Project, the ground systems of the existing or new

facilities shall be connected together by at least three copper conductors

appropriately sized for mechanical strength and the specified fault current

with minimum conductor size to be 100 mm2.

(r) Drawings and calculations shall be submitted for approval giving sufficient

in-formation on the earthing, lightning protection, the earthing of structure

mounted equipment, as well as on methods of measuring the earth

resistance, respectively the earth voltage, the touch and the step voltage.

(s) If the actually measured resistance of the Contractor-designed and

installed ground grid is higher than one ohm or as specified, the Contractor

shall install, at no extra cost to the Owner, additional earthing rods, mats,

earthing electrodes, etc., until the field-measured resistance is equal to or

less than the specified value.

(t) Joints which are indicated as test points shall be bolted or clamped. Joints

in tape, other than at test points, shall be made by the exothermic welding

process. Overlap of conductors shall be not less than 100mm.

(u) Joints and connections shall be protected by a coating which will form a

seal and exclude moisture in all weather conditions. At connections to earth

electrodes the coating shall cover all exposed conductors. Protective

coatings shall be of a water proof, inert, tenacious material.

(v) Bolts, screws, nuts, washers and rivets for coppers conductors shall be of

phosphor-bronze, naval brass or copper-silicon and for aluminium

conductors they shall be of stainless steel.

22.7.3.2 Equipment and Materials Requirements

The equipment and materials shall be suitable for outdoor installation and use at

specified service condition without corrosion, deterioration or degradation of

performance characteristics.

22.7.3.3 Earthing Conductors

(d) Earthing conductor shall be copper conductor of soft drawn concentric

stranding bare copper conductor.

(e) Ground leads running down from the lightning rod or air terminal rods shall

be hard drawn concentric standing copper PVC-insulated (600 V class) and

shall be provided with the required clamp supports mounted on the steel

structure at approximately 1.5 m intervals. The PVC insulation shall be

yellow with green stripes.

(f) The cross sections of the various earth conductors shall be determined in

accordance with IEEE standard / IS: 3043, however, the minimum copper

conductor cross sections shall be as follows:


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HV and LV switchgear 150 mm2

Motor 50 mm2

Metal raceways and cable trays 35 mm2

Intermediate terminal boxes, cabinets, panels 10 mm2

Other metal parts as may be required 10 mm2

22.7.3.4 Ground Rods

(f) The ground rod shall be copper-covered steel of circular cross section, with

a nominal diameter of 19 mm and not less than 3 meters long in section of

1.5 meters. If more than one earthing rod are necessary they shall not be

less than 3 m apart.

(g) Each ground rod shall have a conical swaged point at one end and shall

have a continuous smooth copper covering of at least 0.254 mm thickness

molten-welded or copper bonded (electro-deposit) to a steel core. The

copper clad or pressed type will not be accepted.

(h) Where earth plates are indicated, they shall be 600mm x 600mm minimum,

of solid or lattice copper not less than 3mm thick.

(i) Electrodes shall be installed in undisturbed ground. The distance between

any two electrodes shall be not less than the sum of the lengths of the two

electrodes.

(j) Backfill immediately surrounding plate electrodes shall have a low specific

resistivity and good water retention properties, and shall be well

compacted.

22.7.3.5 Exothermic Welding Materials (If Exothermic Process is required)

(e) The Contractor shall supply exothermic welding materials for conductor-to-

conductor, conductor-to-ground rod and conductor-to-steel structure

earthing connections. These materials shall be Cad-weld or similar type. If

the Contractor proposes to supply a exothermic process other than Cad-

weld, detailed information describing the proposed process shall be

included in his tender.

(f) The exothermic welding materials shall include removable clamp type

moulds, handle flint gun, exothermic powder cartridges, metal discs and

other devices required to complete the earthing connection.

(g) The exothermic powder cartridges shall be designed to provide an installed

connection having a current capacity equal to conductor being welded. The

ignition powder shall be packed in the bottom of the cartridge to permit the


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ignition powder to fall on top of the welding powder when dumped into the

old. The powder cartridges shall be complemented with metal discs.

(h) The moulds shall be designed to withstand the high temperature

associated with the welding operation and shall provide a minimum of 50

acceptable connections without maintenance or replacement.

22.7.3.6 Inspection Pits

(c) Unless otherwise indicated or required, connection between an earth

conductor and its associated earth electrode system shall be in an

enclosure.

(d) The enclosure shall have a removable top cover, which shall be flush with

finished ground level. The enclosure shall be a purpose made inspection

pit made of concrete. The earth electrode connection shall be just below

the lid of the inspection pit with adequate access for testing purposes. The

enclosure shall be clearly labelled to indicate the electrodes function and,

where appropriate, its identification number.

22.7.4 Earthing Hardware

22.7.4.1 Terminal Lugs

Terminal lugs shall be one hole, socket type, rounded edge lug, cast of high

strength corrosion resistant copper alloy.

Machine screws, nuts, and washers used with the lugs shall be bronze.

22.7.4.2 Flexible Copper Braids

All flexible copper braids shall be made of flat, extra-flexible copper braid which

has been tinned before weaving. Both ends shall be encased in a seamless

copper ferrule drilled in accordance with NEMA Standard or equivalent. Ferrules

shall be formed under high pressure ensuring dependable contact.

22.7.4.3 Steel Structure Earthing

(e) Every steel structure that carries insulators or apparatuses shall be

connected to the earthing grid. To ensure contact even if a connection fails

or a conductor is cut off, every structure must be connected via two different

risers to two different parts of the earthing grid.

(f) Steel structures with more than one leg should have two legs connected to

the grid, with one connection to each leg. The legs with the greatest

spacing between shall be chosen for the earth connection.

(g) Circuit breaker framework is not considered as proper connections

between steel structures. If there are no connections between the legs


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which are able to carry the current, all legs must be connected to the grid

with their own risers.

(h) Operating mechanisms and motor drives placed on separate stands shall

be connected as above.

22.7.4.4 Transformer Earthing

(c) The transformer tank shall be connected to earth following the same

principles as for steel structures.

(d) The neutral point of transformers shall be connected to the earthing grid

via an isolated link or conductor. The connection to the two earthing rods,

which are also connected to earthing grid, shall be made by two

independent strips from the neutral.

22.7.4.5 Earthing of Switchgear

(k) Earthing switches are to be connected via a direct earthing connection and

not via the steel structure. Connections between any type of earthing

device, e.g. earthing switch, and risers from the earthing grid shall be made

through a copper wire connected between the earth contact of the earthing

device and a riser. The neutral of the primary winding of Voltage

Transformer, shall be grounded via a separate earthing connection to

earthing rod and not via the steel structure.

(l) Each lighting arrester shall be grounded separately with a full rated earthing

connection and not via the steel structure. In addition, an earthing rod shall

be driven into the ground at each earthing point of a lighting arrester as

close as possible to the lighting arrester and connected to it.

22.7.4.6 Earthing Inside Buildings

(m) For potential equalising of the building an earthing grid of 8 mm

reinforcement bars shall be cast into the surface concrete of all floors of all

switchgear room or basements with power cables installed. The connection

points shall be welded. The mesh size shall not be greater than 3 x 3 m.

Suitable connection points shall be brought out of the concrete to allow

connection to the main earthing and to all parts of equipment and building

to be earthed. The part of these connecting points which protrudes from

the concrete shall be tinned. The earthing grids of the different levels shall

be connected at 8 to 10 m. on the periphery distributed locations.

(n) The size of the main earthing shall be defined by earthing calculations. The

design value for the main earthing grid shall be 40 kA (1 s) rating and with

consideration of CADWELDED joints.

(o) To ensure that reinforcement grid is made electrical continuous, a sufficient

number of connection points shall be brought out of the concrete. Together


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with the detailed civil engineering drawings, the earthing design is to be

checked before releasing for construction.

(p) The connections to these parts should be of tinned copper of adequate

cross section of at least 70 mm². Further similar connection points shall be

installed at a number of places for the connection of portable earthing

equipment when working in the station. All iron parts of the building and the

reinforcement shall be connected to this common earthing installation.

(q) Generally, each electrical device must be equipped with an earthing screw

of sufficient diameter for connection to the earthing system. The same

applies to all metallic parts such as panels, doors, rails, fences,

transformers, etc. are effectively connected by earth conductors.

(r) High voltage equipment and each GIS or metal enclosed switchgear bay

shall be equipped with at least two terminal bolt M 16 in diameter or suitable

earthing pads of adequate size to accommodate at least two bolts for

proper connection to the earthing system.

(s) For connection to all kind of control, protection, LV, panels etc. an earthing

grid shall be laid in all cable trenches of at least 50 x 5 mm tinned copper

bar.

(t) Control panels and desks, switchboards, etc. consisting of several

individual sections or compartments shall each be connected to this tinned

copper earth bar unless all panels are solidly welded together, or other

approved means are applied ensuring solid earthing connections. In such

a case, provisions for earthing must be made at one end at least.

22.7.4.7 Earthing Outside Buildings

(e) As a minimum, one grading ring of 185 mm2 tinned copper conductor shall

be laid around each building at a distance of 1 m (each) and at a depth of

0.6 m.

(f) The connections to the building earthing installation shall be made within

the building. An earthing grid of sufficient size, defined by earthing

calculations and consisting of tinned, annealed copper conductor with a

maximum mesh size of 3 x 3 m shall also be installed in the transformer

bays.

(g) All individual earthing grids shall be interconnected at spacing by not more

than 5 meters by tinned plated high conductivity annealed copper strips/

wires of an cross-sectional area not less than 185 mm2, buried in ground

or supported on building structures, cable trenches, walls, etc. by means

of brass clamps with spacing of not more than 1.25 m.

(h) Steel fences within and around the substation area shall be connected to

the earthing system at least at two different points and at maximum 10


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meters intervals. All metal parts have to be connected through by welding

or suitable earthing conductors.

22.7.4.8 Other Earthing Arrangements

Connection boxes for low voltage or control cables shall be connected via one

50 mm2 wire (35 mm2 copper if the terminal of the box does not allow more),

irrespective of whether the box is mounted on an otherwise earthed steel

structure or not.

Poles for lighting and other types of metal structures within the substation area,

not mentioned hitherto, shall be connected to the earthing grid via 35 mm2

copper, one connection for each item. The only exception is radio antennas, the

earthing of which follows other principles not stated here.

22.7.4.9 Earthing Equipment

To meet the safety regulations before any maintenance or repair works are

started on the HV/ LV power equipment, the disconnected "live" parts of the

equipment shall be grounded by means of mobile earthing sets. The portable or

mobile earthing sets (Substation Earthing Sets) shall be supplied by the

Contractor. One earthing set shall be supplied per substation and voltage level.

22.7.5 Tests

22.7.5.1 General

The Contractor shall carry out at his own expense all tests necessary to ensure

the satisfactory design and manufacture of all earthing equipment and materials

in accordance with Indian / IEC Standard.

22.7.5.2 Design Tests

Conductors, hardware’s and materials shall be subjected to the design (or type)

tests in accordance with applicable Indian or equivalent IEC standards. Even

though the Engineer witnesses the required tests and the earthing, hardware’s

and materials meet the acceptance criteria, the Contractor shall not be relieved

of the responsibility of providing conductors, hard-ware’s and materials

conforming to all the requirements of the specification.

22.7.5.3 Quality Conformance and Routine Test

(d) Earthing Conductors

The tests shall be performed in accordance with IEC 60621-2 and shall

include, but not limited to the following:

(vii) Tensile strength tests

(viii) Elongation tests


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(ix) Conductor resistivity tests

(x) Dimension measurement

(xi) Surface finish inspection

(xii) Weight of conductor

(e) Miscellaneous Hardware

The test shall be performed in accordance with IEC 60621-2 and the

manufacturer standard. The routine tests shall be performed by selecting the

samples from each lot of equipment. The number of samples required for

the tests shall be: all for 1-3 sets; 3 for 4-30 sets; and 10% for over 30 sets.

(vii) General inspection

(viii) Measurement of dimensions

(ix) Tensile tests No. of samples required: 1 for 20-50 sets;

(x) 2 for 51-100 sets; and

(xi) 4 for over 100 sets

(xii) Galvanising tests

(f) Earthing Materials

Quality conformance tests are required to verify the quality of materials and

workmanship. They are to be made on fittings taken on random from the

various lots offered for acceptance.

22.7.5.4 Routine Tests

These tests are intended to eliminate defective materials and fittings. They are

to be made on all materials and fittings of the type to which they are applicable,

per applicable standards and / or per Contractor's quality assurance methods if

accepted by the Engineer.

22.7.5.5 Field Tests

Field tests and acceptance tests, if any shall be performed by the contractor as

per IS: 3043 / IEC /IEEE-80 standard. The Contractor shall provide instructions

and acceptance criteria including the calculated value of the resistance of the

installed earthing grid for field testing and measurement prior to energising the

substation / equipment.

Measurement of the earth voltage by the voltmeter/ ammeter method, test

current 100 - 300 A or an equivalent approved method.

Measurement of the step and touch voltage.


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22.7.5.6 Test Report

Five (5) copies of test reports of all standard tests as per IS: 3043 / IEEE-80,

performed subsequent to the date of award. All routine tests shall be certified by

the inspector and submitted to the Engineer within fifteen (15) days after test.

The Contractor shall bear the costs of furnishing these records and reports.

22.8 SMART ENERGY METER

22.8.1 BASIC REQUIREMENT

There are more approximately consumers in which 50 numbers are 3 phase and

balance are single phase consumers. Static whole current energy meters for single

phase and three phase domestic and commercial applications with 0.5 accuracy. The

energy meters shall conform to IS standard IS 13779-99/CBIP88 with IEC 62053-21,

IEC 1107 for optical fibre port. The energy meter shall have the provision for external

communication by using RS 232 port of IRDA for communication to a hand held unit or

AMR. Energy meter capable of detecting and recording anti tamper features including

neutral missing and abnormal voltage/ frequency protection.

22.8.2 ADVANTAGES

(a) Timely availability of billing data for 100 % meters

(b) Reduce manual intervention

(c) Load reversal

(d) Billing history for 12 months

(e) Instantaneous voltage, current, load/ frequency

(f) Average power for 30 min interval

(g) Communication facility using optical port, infrared, RS 232

(h) Reduce operational and maintenance cost

(i) Detection of power outage

(j) Power failure log

(k) Detect pilferage and thefts

(l) Collect accurate base line data for consumption patterns

(m) Programming

22.8.3 RATING

Meter rating : As per customer requirement

Meter type :

Display : LCD


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Meter class: 0.5

Power consumption: 1 W to 1.5 W

Application: Single phase / Three Phase

22.8.4 SYSTEM COMPONENTS

(n) LPRF module

(u) Hand held unit software (HHU)

(v) Data concentrator unit (DCU)

(w) Base computer software (BCS)

(x) Meter data management system (MDMS)

(y) SmartMesh – Optimized mesh networking algorithm

(z) Diagnostic tools

22.9 SPECIFICATION OF FRP POLES WITH FIXTURES FOR STREET AND AREA LIGHTING

22.9.1 Scope

This specification covers the design, engineering, material, fabrication, ultra

violet protection, testing, inspection, packing, forwarding supply, delivery and

installation of Fibre Reinforced Plastic (FRP) composite street light and area light

poles, LED lights fittings complete in all respects for the street lighting system by

underground cables under the project. Exterior lighting shall be provided for

streets, parking areas, open areas developed areas, as per BEAP.

The composite pole supplied under this specification shall present the most

pleasing appearance possible consistent with strength, cost and serviceability

requirements. In general, the poles shall be circular in cross section.

22.9.2 Standard and System Conditions

22.9.2.1 The equipment covered in the specification shall conform to the underground street and area lighting with LED lights. The specification mentioned below shall be


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applicable to the materials, design and process used in the manufacture of these equipment. The standard specification mentioned below shall be applicable.


16. IS: 4091 Code of practice for design of foundations

for transmission towers and poles

17. IS1885 (Part 16)

Section 1,2 & 3

Electrical vocabulary Part 16 lighting,

Section 1 General aspects, Section 2

General Illumination, lighting fitting and

lighting for traffic and signalling, Section 3

Lamps & auxiliary apparatus.

18. IS:2551-1982 Danger Notice Plates

19. SP 30: 2011 National Electric Code

20. IS: 875-2015 Code of practice for Design loads (other

than earthquake) for Building and Structure

21. AASHTO LTS-4

Specification for Structural supports for

Highway signs, Luminaires and Traffic

signals

22. ANSI C 136.20-1990 Standard for Fiber-Reinforced-Plastic

(FRP) Lighting Poles

23. ASTM D4923-01 Standard Specification for Reinforced

Thermosetting Plastic Poles (51)

24. ASTM G154-00a

Standard Practice for Operating

Fluorescent Light Apparatus for UV

Exposure of Non-Metallic Material (66)

25. ASTM D635-98

Standard Test Method for Rate of Burning

and/or Extent and Time of Burning of

Plastics on a Horizontal Position (67)

26. IS 2713-1980 Specification for Tubular Street Light Pole

and Overhead Power Line

27. IS 875 (Part 3) - 1987 Code of practice for design loads for

Building & Structures – Wind Load


Page | 390



28. ANSI 05.1 Standard Specification for Wood poles &

class of Poles

29. IS 6746 Polyester Resin System

30. BS EN 40-7:2002 Requirement for FRP Composites Lighting

column


Note: Only latest version of above standard shall be applicable. Any other

reputed International standard having performance equivalent to above shall

also be considered for acceptance.

22.9.2.2 System

FRP poles covered in this specification are required for the street and area

lighting purposes within thePMC-01 Project. The terrain is hilly and high speed

winds with salty environment are prevalent.

(g) The poles should give an attractive outlook as during the day, they serve

no other purpose. See BEAP for pole and lighting objectives.

(h) All the street and area lights shall be mounted on the top overhang and

shall be fed from a typical dedicated underground XLPE copper cable.

Contractor shall provide its arrangement for approval.

(i) As during an accident, a vehicle on road tends to move out of carriage way

and may hit the pole, accordingly the pole is proposed to be installed at a

distance not less than 1.5m from the edge of the carriage way.

(j) The width of carriage way is as per the road section provided, on which

these poles shall be installed for street light purposes.

(k) Each FRP pole shall have a 240V, 50Hz rated, single phase luminaire fitted

on the overhang. A 4 core three phase copper XLPE cable laid in an

underground duct shall enter into the pole up to junction box. There it shall

be looped out to next pole. An MCB shall be provided along with

disconnecting links for phase & neutral to isolate the supply to luminaire.

Isolating links shall also be provided to disconnect the power in the

incoming and outgoing cables so as to test the cables in case of fault

without disconnecting any cable from the terminals. There shall be a niche

for this purpose to house the above supply terminals, on a plate. This niche

shall be covered with removable cover, so as to give a uniform pole

appearance outside. Attaching any junction box to pole shall not be

acceptable.


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(l) Pole shall be tested with the niche cut in the pole with cover removed.

22.9.3 Calculations

22.9.3.1 Contractor shall submit the necessary calculations for the size of poles with bracket selected and the provision of terminal box inside the pole. considering the wind load as 50m/sec. for the site, as per latest IS-875-2015 Part 3.

22.9.3.2 The lux levels with computer generated charts indicating the lux levels for the fittings provided, at locations around the pole shall be provided.

22.9.3.3 The required FRP pole strength must exceed the factored load as indicated in subsequent clauses.

22.9.4 General Requirement

22.9.4.1 Street light pole height and spacing for different width of carriageway shall be as per latest National Electrical Code, SP-30: published by Bureau of Indian Standards. Non-street lighting for other open areas in the development shall be installed at locations and heights as suggested in the BEAP, or as required to maintain a pleasant and safe community.

Lighting for streets is classified into the following groups:

Group A – For main roads

Group B – For other main roads which do not require lighting up

to group A standard

Group C Lighting for residential and unclassified roads not

included in previous groups

Group D Lighting for bridges and flyovers if any

Group E Lighting for town and city centres

Group F Lighting for roads with special requirements, such as

roads near airfield, railway and docks

Corresponding to above the recommended pole heights as given in SP-30 shall

be adopted for the road width and types.

22.9.4.2 FRP poles shall consist of round conical tapered type poles having pleasant appearance with aluminum mast arms.

22.9.4.3 Pole should be designed to meet the testing requirements as are given for tabular poles in latest version of IS 2713.

22.9.4.4 Poles shall be hollow, tapered, non-conductive and chemically inert and shall conform to the requirements in "Standard Specifications for Structural Supports for


Page | 392


Signs, Luminaires, and Traffic Signals" published by AASHTO, and ANSI Standard: C136.20, "Fiberglass-Reinforced Plastic (FRP) Lighting Poles."

22.9.4.5 Pole shall not deform under impact.

22.9.4.6 Adverse climates at site such as sea winds, high humidity, saline environment, soil with salt, shall have no effect on the life and capability of pole.

22.9.4.7 It should have pleasant look with smooth surface and finish.

22.9.4.8 Poles shall be loaded 300 mm below the tip.

22.9.4.9 FRP pole shall have anchor base with high grade non-corrosive aluminum alloy anchor and base plate. These shall be painted with same paint as that of pole. Fixing of the same to the concrete foundation shall be with stainless steel bolts or of any other non-rusting material (GI bolts are not acceptable). Holes shall be provided in base plate to drain water if required.

22.9.5 Design and Standardisation

22.9.5.1 The pole shall be designed to ensure satisfactory operation of the lighting system, in which continuity of service is the first consideration and shall also be designed to with stand sudden variations due to short circuits and fault conditions. The design shall incorporate all reasonable precautions and shall have necessary provision for the safety of all those concerned in the operation and maintenance of the lighting system.

22.9.5.2 The design, materials, fabrication, inspection procedures, shipping and assembly procedures for the composite poles shall generally conform to latest best engineering practices. ASCE manual no. 104, “Recommended practice for Fiber-Reinforced Polymer Products for overhead utility line structures” may also be used as a general reference guide where appropriate.

22.9.5.3 To verify the ability of composite poles to meet given loading, deflection or other applicable requirements, structural analysis software, may be utilized to perform the analysis and overall structure stability (buckling) under combined loading.

22.9.5.4 The composite poles shall present the most pleasing appearance possible consistent with the strength, cost and serviceability requirements. The composite poles shall be symmetrical about the transverse and longitudinal axes, and any tapered filament-wound composite poles shall have a gradual and relatively constant taper rate from top to bottom.

22.9.5.5 The manufacturer shall certify that the composite poles meet or exceed the loading or other requirements, in accordance with applicable provisions of the Indian


Page | 393


Standard which are applicable to tubular poles or other relevant standards and as verified by design calculations and/or full-scale testing.

22.9.6 Drawings

The contractor is to submit drawings and instruction manuals after award of

contract.

However, after the award of contract the detailed drawings along with necessary

manuals are to be submitted (with any other particulars, the contractor may deem

necessary) for approval of Engineer. The poles shall be manufactured only after

the drawings submitted by contractor have been approved by Engineer in the

manner indicated therein, to incorporate the modifications suggested. The copies

of finally in-built approved drawings shall be furnished along with the delivery of

poles.


Page | 394


22.9.7 Quality Assurance

22.9.7.1 The manufacturer of FRP Poles shall have an approved testing and quality control program for fabrication of poles.

22.9.7.2 The manufacturer shall conform to ISO 9001:2008, a recognized quality assurance program.

22.9.7.3 The manufacturer shall afford the Engineer reasonable opportunity, without charge, to allow them to verify that the finished products and materials being furnished are in accordance with the requirements in this specification.

22.9.7.4 Composite samples and details regarding the quality with the type of glass fibers and resins used along with the manufacturing process shall be submitted by the manufacturer, before fabrication for approval of Engineer.

22.9.7.5 In general manufacturer shall submit its quality assurance plan (before fabrication) to be approved by Engineer

22.9.8 Material of Poles and Manufacturing

22.9.8.1 All material used shall be new and of best quality and of class, most suitable for working under the conditions specified herein without distortion or deterioration.

22.9.8.2 The polyester resin binders used in the manufacture of the composite poles shall be of the highest quality and the material properties shall be submitted. Thermoplastic resin binders are not acceptable for use in the composite poles.

22.9.8.3 The fiber reinforcement used in the manufacture of the composite poles shall be minimum “E-Glass” with acceptable forms being continuous strand and /or fabric.

22.9.8.4 Fabrication shall be performed in accordance with the composite pole detail drawings. Material substitutions or deviations from the approved drawings shall not be made without prior written approval by the Engineer.

22.9.8.5 The composite poles shall be produced by filament winding. For the poles manufactured using filament winding, the wind schedule will include both circumferential and axial fiber placement in the pole wall laminate.

22.9.8.6 When required drilling of holes shall be done in such a manner as to produce cylindrical holes perpendicular to the plane of the pole.

22.9.9 Technical Data

FRP poles shall meet the following minimum technical criteria.

Density : 1.5 to 1.9 gm/cm³

Minimum E-Glass Fiber : 65% (By Weight)

Water Absorption : ≤ 0.5%

Tensile Strength : 200 M Pa


Page | 395


Bending/Flexural Strength : 250 M Pa

Compression Strength : 200 M Pa

Impact Energy : >180 KJ/m²

Dielectric Strength : 35kV / 25.4 mm

Overall length : 2 to 12 m



Conicity (Slope to Determine bottom) : Approx. 10mm per

linear meter

Base Plate : Stainless Steel, with

GRP cover

22.9.10 Ultra Violet And Weathering Protection

22.9.10.1 General

The composite poles shall be manufactured with the best available protection

against UV degradation. The use of UV-stable “aliphatic” resins with pigment

additives is the preferred protection method. Resins enriched with UV inhibitors

and UV stable colour pigment additives are also acceptable. The use of standard

paint or coating for UV protection is not acceptable.

22.9.11 Mast Arms

Mast arms shall be aluminium alloy and shall conform to the requirements in

Aluminium Association Publication 30, “Specification for Aluminium Structures.”

The aluminium mast arm connected to the pole and with an approved luminaire

attached to it, shall withstand the vibrations as per the Standard.

22.9.12 Construction Detail

22.9.12.1 Poles shall be constructed from ultraviolet-resistant resin which shall be pigmented light gray and of uniform colour throughout the entire body of the poles. The poles shall be finished with polyurethane coating. The finish of poles shall be smooth.

22.9.12.2 Each pole shall have a niche to mount integral type junction box and the cover of niche shall bear the name of the owner. The box cover shall be securely attached to


Page | 396


the pole with tamper-resistant hardware. The junction box bottom shall be located at about 750mm from the ground.

22.9.12.3 The base shall be bonded to the pole with a suitable adhesive and coated with an aliphatic-type acrylic-modified polyurethane finish.

22.9.12.4 Poles shall have a grommeted conduit / conductor entrance and exit located 600 mm (±25 mm) below finished grade after installation. The entrance shall be located directly below the junction box.

22.9.12.5 Each pole shall be provided with a removable non-corrosive aluminum pole top cap.

22.9.13 Exterior Protection & Spare Paint

An aliphatic-type acrylic-modified polyurethane coating shall be applied to the

exterior of the fiberglass pole. The coating shall be semi-gloss, highly weather

resistant and light grey in color matching the color of the resin and shall have a

minimum 0.075mm dry film thickness. A one litre can of the coating matching the

poles shall be supplied with poles for site touching. The polyurethane coating

shall be tested for adhesion to the pole surface in conformance with the

requirements in ASTM: D 3359, Method A and shall have a scale rating of 5A.

The adhesion testing shall be conducted before and after the accelerated

weathering evaluation.

22.9.14 Marking

The pole shall be marked with designation, height, strength, manufacturer’s

identification, date of manufacture, pole length and name of Owner. This marking

shall be at about junction box niche location for ease in reading.

22.9.15 Design Safety Factor

FRP shall be designed considering the safety factor for failure against

(c) Bending

(d) Torsion

The safety factor in each case shall not be less than 2 though ASTM D4923

specifies it to be 1.5. For this the manufacturer shall submit the calculations

before fabrication.

22.9.16 Testing

22.9.16.1 Visual Inspection

Each component of the composite poles shall be inspected for conformance to

the approved manufacturing drawings and drill patterns. The inspection shall

include, but not be limited to:

(d) Dimensional check to verify manufacturing tolerances are being met.


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(e) Verification that drilled holes do not have ragged or tone edges; and

(f) Aesthetic appearance such as colour consistency and surface roughness.

22.9.16.2 Deflection

Tests shall be performed with reference to ASTM D 4923.

(c) Limits of Deflection

(iv) The pole deflection under dead loads, luminaire with arm load and

wind load, should not exceed 10% of the height of the pole through

ASTM D4923 permits 15% deflection.

(v) 30mm/m maximum slope at top of the pole under dead load from arm

and attachments (maximum slope).

(vi) Deflection of 5% of the pole height under a force of 890 N lateral top

load. This is to ensure that pole will not deflect excessively even if

ladders are used by workers to access attachments.

(d) Method

(v) The lateral deflection shall be measured from the deflected tip end of

the pole along a line at 90° to the longitudinal axis of the un deflected

pole.

(vi) The junction box niche on the FRP pole should be placed on the

compression side of the pole and the niche cover shall be removed

during testing

(vii) Deflection shall be recorded with each 223N load increment.

(viii) The maximum permanent deflection after testing should not exceed

2% of the maximum recorded deflection of the pole during test and

this deflection should be recorded 5 minutes after unloading.

22.9.16.3 Torsion Test

This test shall be done as per method in ASTM D4923, but with a load increment

of 223N, with deflection recorded at each load increment.

22.9.16.4 Fatigue Test

Bending or torsional fatigue loads applied to the pole correspond to an equivalent

pressure of 110Pa. The fatigue load shall be applied for 106 Cycles, per minute

with no more than 200 cycles per minute.

22.9.16.5 Destructive Testing

Destructive testing of the pole for bending and/or torsion strength should be

performed after application of fatigue loads.


Page | 398


22.9.16.6 Ultra Violet Weather Performance

The finished surface of the pole shall withstand a minimum of 2500 hours of

accelerated weathering when tested in conformance with requirements in ASTM

G154.

In this test Ultra Violet (UV) Bulb lamps with 313nm wave length and testing cycle

of 4 hours of UV exposure at 60°C and 4 hours of condensation at 40°C shall be

done. After testing the finished surface shall not exhibit fading, fiber exposure,

chalking, cracking or crazing as given below:

Fiber Exposure: None

Crazing: None

Chinks: None

Chalking: Very slight

Change in color: May dull slightly

22.9.16.7 Permanent Deflection

The pole with specified luminaire and mast arm installed, shall withstand the

bending strength test load with the maximum possible loading conditions as per

Indian Standard-IS 875. The pole shall not exceed a maximum deflection of 10

percent of the length of the pole above the ground line when subjected to

maximum wind load condition and not more than 1% permanent deflection.

22.9.16.8 Flame Resistance

FRP poles shall be flame resistant to prevent fire propagation due to short circuits

or oil spills. The specimen shall be tested as per ASTM D635 and fabricated with

the same material and process as that of poles.

The sample shall cease to burn before the gauge mask of 100mm is reached.

22.9.16.9 Dielectric Breakdown Voltage test shall be as per ASTM-D149.

22.9.16.10 Glass Content: Test as per ASTM D-2584-11.

22.9.16.11 Rejection of Material

Issues related to any material delivered under this specification, which as

mutually agreed by the manufacturer and the Engineer does not meet the

requirements set forth herein with regard to material, fabrication and testing the

poles shall be rejected without financial liability to the Owner under any

circumstances.


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22.9.17 Installation

22.9.17.1 Installation of FRP Poles shall be in conformance with the provisions for tubular steel poles, as per Indian Standard.

22.9.17.2 Cable Termination and Supply to Luminaire

(c) As indicated in specification, an integral type junction box is to be provided

in a niche in the FRP pole.

(d) The junction box shall have the following main items

(iv) Terminal box for looping in & looping out, 3 phase, 4 wire copper

cable size of which shall be worked out by contractor for approval.

(v) Single phase, 2 pole MCB of 2A, 10kA rating for luminaire.

(vi) 2.5mm², 3 core (3rd core for earth) copper connection to luminaire.

22.9.17.3 The junction box shall have a weather proof cover & to prevent entry of rain water in to junction box.

22.9.17.4 Provision for earthing terminal for the arm and associated LED fitting.

22.9.17.5 Cable Entry to FRP Pole

Main power cable for street light shall be laid in ducts both for entry to the pole

and exit from the pole. There shall be a small cable pulling box near the base of

the FRP pole.

In the concrete base of the FRP pole conduits shall be laid up to the niche in

FRP pole. So that the 4-core copper, loop in and loop out cables can be brought

in and taken out.

22.9.18 Bonding and Earthing

Each fiberglass-reinforced plastic lighting pole shall have its luminaire, mast arm,

and anchor bolts grounded in conformance with the earthing Specifications. A

separate bonding connection to the mast arm will not be required provided there

is a non-insulated contact between the luminaire and the mast arm.

22.9.19 Guarantee and Warranty

22.9.19.1 Guarantee

The composite poles shall be provided by a lifetime performance guarantee that

covers pole failure as a result of:

(e) The physical load of light fittings the weight of pole itself and the

attachment.


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(f) The direct force of wind from storm, tornadoes, hurricanes or blizzards that

has caused the failure of a composite pole mounted with fittings as per

designed wind load.

(g) A lightning strike on composite pole itself and/or an attachment.

(h) Damage to pole due to weather effects ultra violet radiation from sun light.

22.9.19.2 Warranty

The composite poles shall be covered by a minimum 25-year warranty against

manufacturing defects.

22.9.20 Packing, Shipping and Delivery

22.9.20.1 Each pole is spiral wrapped in its entirety with a weather proof wrap for protection during shipping at storage.

22.9.20.2 Reasonable care shall be taken to avoid damage to the composite poles during handling and transportation.

22.9.20.3 The manufacturer shall take all reasonable steps to ensure that the composite poles covered by this specification shall be delivered to the Owner’s designated storage facility during the period stated in the Contractor’s Proposal, or as previously agreed and detailed in the purchase order.

22.9.21 Lighting

22.9.21.1 Recommended Lux levels

Taking into account consideration of vision, criteria of quality, and characteristics

of sources and luminaries, table below gives the desirable level of recommended

illumination which is as per Institute of Urban Transport (IUT).

S. No. Particulars Required Illumination level

1 Main Roads 30 lux

2 Pedestrian Crossing 50 lux

3 Residential street lighting 1-10 lux

4 Cycle Track 20 lux

Table 25: Recommended Lux Levels

22.9.21.2 Lighting Fixtures with LED

LED type luminaries shall be used in the entire area. The following selection

criterial shall be used for selecting fixtures.


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(j) Luminaries selected shall be compatible to mast arm of the standard size.

(k) Luminaries shall pass the 3G vibration test as per ANSI C136.31.

(l) The housing shall be of non-corrosive material and the paint finish on the

same shall exceed the rating of six per ATSM D 1654 after 1000 hours of

salt spray testing in compliance to ASTM B 117. This is to ensure that finish

will not be dimmed in the coastal area.

(m) LED shall have colour temperature (Tc) of 4000k + 300k to provide a

“natural white” colour of light.

(n) Luminaires selected shall spread light downwards, producing zero light at

or above 90°. Lens shall be ultraviolet stabilised for high efficiency and

vandal resistance.

(o) The contractor shall provide lumens, efficiency, watts, Tc and Colour

Rendering Index (CRI) for prior approval. Lumens per watt shall be

maximum and the same shall be indicated in data sheet. Lumen/watt shall

be 110 or higher value shall be preferred.

(p) Luminaires shall be certified to be suitable for wet locations and

applications.

(q) LED lamps shall have minimum 5 years warranty.

(r) Electro Magnetic Interference (EMI) shall meet or exceed FCC 47 CFR part

15, Transient Voltage complies with ANSI C62.41 Cat C High. This is to

ensure that electronics in LED lamp will not interface with broadcast or

cable system.

22.9.21.3 Street And Area Lighting Arrangement

There will be main distribution board which will be dedicated to supply power for

street and area lighting feeder pillar. Each feeder pillar shall be capable to feed

supply 500 meter in either side. Not more than 1000W or 10 No. of light fixture

which one is earlier shall be kept on a single circuit. All the feeder pillar shall be

placed in such a location, which cannot be accessible to common public. All the

feeder pillar shall be IP-65 rated, dear front, front operated, form 4b type. Feeder

pillar construction shall be as per IEC-61439.

22.9.21.4 Lighting Management System

The lights shall be with astronomical clock device to automatically set the timings

for lights ON/OFF throughout the year.

Lighting management system shall be locally mounted in street light feeder

pillars.

Inefficient use of light may lead energy waste and create impact on burning hours

of luminary as well. To protect luminary from afore said point automatically light

control system is to be provided.


Page | 402


A centralized solution shall be adopted for intelligent operation such that if

required alternate light poles can be switch on/off. Hardware modules shall be

installed in control cabinet (Lighting feeder pillars) and shall enable

communication from the central server location to control cabinet via fiber optics

cable. All the data is to send to the central server, where it is stored and

accessible for reports, fault rectification, load balancing and emergencies such

as accident, flooding etc.

The system shall be consisting of following typical components & modules:

(h) System Central Processing Unit (CPU)

This is the central processing unit of the module system. This will be

equipped with microprocessor unit and run on linux/ MS Window. Direct

communication between modules take place by means of an A-bus

interface, which is based on industrially proven RS-485 technology. The

CPU module serves as a WAN communications and data concentrator

module. Two-way communication with the central server takes place via

Ethernet, GPRS or SMS. The module will have the ability to automatically

switch between different available communication carriers in order to

provide the stable and reliable communication. Data are either delivered to

the server immediately or stored locally in the built in flash memory of CPU

module until scheduled delivery. Software and configuration can be

updated remotely from the server and stored on the CPU module enabling

it to autonomously execute tasks e.g. turn the street light on/off or collect

meter reading based on the configuration set up by the user. Voltage value

on all three phases of the main supply shall also be monitored by the CPU

module.

(i) Battery Module

Battery module is the client module in the system. It is a backup / UPS

module which are used for supplying other modules with emergency power

in the event of the failure of supply. This system will incorporate an A-Bus

interface which is based on the industrially proven RS-485 technology. The

A-Bus interface is used for power supply and for direct communication

between modules. The battery will be recharged with the power as long as

the battery is supplied with 12V from A-Bus interface.

If main power fails, battery will instantaneously take over the supply of A-

Bus. This will enable the CPU module to store data and send main power

failure alarm to the central server before it is shut down safely.

(j) Switch Module

Switch module is a client interface module in the system. It will consist of

two individually controllable relays. These relays are isolated and are used

for switching minor loads on and off directly and three phase or larger loads

via an intermediate breaker.

(k) Current Module


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The current module is a client interface module in the system. It will detect

asymmetrical earth leakage in electrical system and for monitoring current

changes in each phase. For this purpose, one leakage transformer and two

three phase current transformer are connected to the module. Leakage and

current threshold value can easily be configured to fit specific needs in web

application that will run on a central server. Current module will be used for

wide range of monitoring purpose. Power failure, cable breakage, street

lamp failure, leakage etc. are immediately reported to the central server.

(l) M-Bus Module

M-bus module is designed for two-way communication with M-Bus

compatible equipment from various manufacturers. It is used for two-way

communication with M-Bus compatible electricity meter. The M-module will

collect data reading and other data from the meters and subsequently

transfer these data to CPU module that act as a data concentrator. The

CPU module delivers the data to the central server when required. Direct

communication and power supply between M-Bus module and CPU

Module are handled by A-Bus interface which is based on RS-485

technology.

(m) Dimming Module

This module will allow increasing and decreasing the light and thereby

reduced electricity consumption. The light is dimmed from the control

cabinet, allowing making individual dimming setting for each sector. This is

useful in energy saving. Dimming shall be with Real Time Clock (RTC)

system.

(n) Fault Monitoring

When a fault is detected, an alarm is sent to the web platform, where all

faults are monitored and reported real time.

Typical faults that can be monitored are as given below:

(xii) Under / over voltage detection

(xiii) Main Breaker error

(xiv) Contactor fault

(xv) Circuit Breaker off

(xvi) Main Power failure

(xvii) Leakage to ground

(xviii) Manual switch activated

(xix) Phase current out of range

(xx) Feeder pillars door open

(xxi) Flashing bulbs

(xxii) Bulb failures


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22.9.21.5 POWER DISTRIBTUION FOR STREET LIGHTING

There will be installed a main distribution board which will be dedicated to supply power

for street lighting feeder pillar. Each feeder pillar shall be capable to feed supply 500

meter in either side. Not more than 1000 W load of all LED bulbs or 10 No. of light

fixtures, either of which is achievable shall be kept on a single circuit. All feeder pillars

shall be IP-65 degree of protection and front operated. Feeder pillar construction shall

be as per IEC-61439.

(b) ed pole.

22.9.21.6 415 V OUT DOOR LIGHTING CONTROL PANEL

(s) SCOPE

This section covers the detailed requirements for design, supply, installation, testing and

commissioning of 415 Volts, 3 phase, 50 Hz 4 wire system, street/ road light feeder panel

for road lights to switching ON/ OFF function.

(t) TYPE OF BOARD

The medium voltage panel shall comprise of the following type of switchgears as

specified. The panel shall be capable of fault withstand capacity of 31 MVA for duration

of one second up to 200 Amp rating.

The Panel shall be metal enclosed, outdoor type having incoming, sectionalisation and

outgoing switchgears as specified. The design shall be cubicle type. The degree of

protection for enclosure shall be IP 55.

(u) GENERAL CONSTRUCTION

The Panel shall be floor/ foundation mounted freestanding totally enclosed and non-

extensible type. The switchboard shall be dust & vermin proof with lockable

arrangement with degree of protection IP55 as per IS 2147 and shall be suitable for the

climate conditions as specified. The design shall include all provisions for safety of

operating and maintenance personnel. The general construction shall conform to IS:

8623 for factory assembled switchboard.

The panel shall be equipped with space heater with thermostat. Along with lamp for

lighting of panel controlled by door switch & MCB and also 6/16 A socket & switch

(v) CUBICLE TYPE PANEL

Outdoor type panel of approximate dimension 1200 mm (W) x 350 mm (D) x 1475 mm

(H) shall be fabricated out of CRCA sheet steel 2.5 mm thick (Load bearing Main Frame)


Page | 405


with double door arrangement out of 2.0 mm thick. Sheet and canopy on all four sides.

Wherever necessary, such sheet steel member shall be stiffened by angle iron

framework. The general arrangement shall be got approved before fabrication. Cable

entries for various feeders shall be from the bottom. All cable entries shall be through

gland plates of 3 mm thick. There shall be separate gland plate for each cable entry so

that there will not be dislocation of already wired circuit when new feeders are added.

Cable entry plates shall therefore be sectionalized. The panel will be provided with 75x40

mm base channel to be painted in black to facilitate mounting on concrete platform

(w) INDICATOR LAMPS

On the incomer of L.T Panel, ON phase indicator neon type lamps shall be provided

suitable for operation on AC 230 Volts supply. Necessary filter G/Y/R/A shall be provided

depending upon the function. All lamps shall be protected by proper HRC fuses. Where

phase indicator lamps are provided, these shall be associated with necessary ON/OFF

toggle switch.

(x) SMALL WIRING

All small wiring controls, indication etc. shall be with suitable stranded copper conductor

cables PVC insulated conforming to IS: 1554 Part 1. Wiring shall be suitably protected

within the switchboard. Runs of wires shall be neatly bunched and suitably supported

and clamped. Means shall be provided for easy identification of the wires. Where wires

are drawn through PVC conduits, the works shall conform to IS 732. Identification

ferrules shall be used at both ends of the wires. All control wiring meant for external

connection is to be brought out on terminal block. All wiring shall be minimum 1.5 sq.

mm and for CT. Circuits it shall be 4.00 sq. mm. Brass/ copper thimbles, insulation tape

etc. shall be provided at joints and terminations as required.

(y) BUS BAR & BUS BAR CHAMBERS

Bus Bar and Connections

The bus bar shall be high conductivity copper alloy of E 91 grade and of adequate

section having current density not less than 1.0 Amp. / Sq. mm. Set of copper bus bar

shall be completed shrouded with acrylic sheet to avoid accidental touch. All connections

to individual circuits from the bus bar shall be with solid connections in case current

exceeds 63 Amp. All bus bars and connections shall be suitably sleeved with PVC or

suitably insulated in an approved manner. The bus bar temperature should not exceed

85 degree C i.e. 35 degree C temperature rise over 50 degree C ambient. The

calculation for temperature rise and bus bar sizing should be furnished along with shop

drawing for approval.

(z) BUS BAR SUPPORT AND ARRANGEMENTS

Supports


Page | 406


Bus bar shall be firmly fixed on supports constructed from SMC (glass fiber reinforced

thermosetting plastic). The supports shall be sufficiently robust to effectively withstand

electro-mechanical stresses produced in the event of short circuit.

Connections to Bus Bars

The bolts and nuts used for connections to bus bars shall be of copper, alloy, and tinned

forged brass or galvanized iron. Suitable precaution shall be taken against heating due

to bi-metallic contact.

Further for tapping off connections from bus bars, VIR/PVC insulated wire may be used

up to current capacities up to 63 amps and for higher current capacities solid conductors/

strips suitably be insulated with PVC sleeves / tape as per requirement.

Clearances

The minimum clearances to be maintained for open and closed indoor air insulated bus

bars/ electrically non-exposed and working at system voltages up to 600 volts shall be

as follows:

Between ……………………………………………. Minimum Clearances

Phase to Earth………………………………………. 22 mm

Phase to Phase ……………………………………… 32 mm

Bus Bar Markings

The colours and letters (or symbols) for bus bars: -

Main bus bar connections and auxiliary wiring etc. shall conform to relevant Indian

Standard. A brief from IS 375-1963 (revised) is given below: -

For AC bus bars and Main connections:

S.No. Bus Bar & Main Connection Colour Letter/ Symbol

1 Three Phase

Red

R, Y, B Yellow

Blue

2 Single Phase Red R

3 Neutral Connection White N

4 Connection to earth Green G

(aa) PHASE SEQUENCE AND POLARITY


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Bus bars and main connections, when marked shall be marked in accordance with the

following table to indicate the order in which the voltage in phases reach their maximum

values.

System As indicated by colour or letters Phase sequence as indicated vector ally

Three Phase Red, Yellow, Blue R, Y, B

Two Phase Red, Blue R, B

(bb) ARRANGEMENT OF BUS BAR & MAIN CONNECTIONS:

Bus bars and main connections, which are substantially in one plane, shall be arranged

in order given as follows: -

(cc) A.C SYSTEM

The order of phase connections shall be Red, Yellow and Blue.

When the run of the conductors is horizontal, the red shall be on the top or on the left or

farthest away as viewed from the front.

When the run of the conductor is vertical, the red shall be on the left or farthest away as

viewed from the front.

When the system has a neutral connection in the same plane as the phase connections,

the neutral shall occupy an outer position.

Unless the neutral connections can be readily distinguished from the phase connections,

the order shall be red, yellow, blue and black.

(dd) TERMINATIONS

Incomer terminals shall be suitable for receiving cables.

(ee) MOULDED CASE CIRCUIT BREAKERS

Moulded case circuit breakers shall comply with IEC 60947.2 & 13947 part 2. They shall

have the voltage and current ratings of 440 Volt & 200 Amp respectively whereas short

circuit breaking capacity and rated short – time withstand current should be as indicated

below.

The breaking capacity performance certificates shall be available for category A to the

above-mentioned standards. The test shall be carried out under the breaking

performance during the ultimate breaking capacity (Icu), Ics rating=100% Icu. Certificate

for all the sequences (Sequence 1 mandatory) should be available.’

MCCB’s shall be of the independent manual closing air-break type, rated for an

uninterrupted duty.

Auxiliary facilities, including power closing and under voltage releases, shall be provided

as indicated.


Page | 408


Each MCCB shall have a facility for padlocking in the “OFF” position.

Necessary set of CT’s together with an ammeter and selector switch as specified.

Necessary inter-connections to bus bars.

Necessary isolating plugs and sockets for front operated switches to enable withdrawing

the entire unit and replacing with another unit disconnecting the cable for maintenance

operation.

Each MCCB shall provide with a rotary operating mechanism.

(ff) CONTACTOR

3 Pole contactor of 60 Amp rating type AC-1 should conform to IEC 60947-4-1, IS 13947

Various parameters shall be as under: -

Insulation voltage—690 V

Impulse withstand voltage (Uimp)—8 KV

Shock resistance 10/5 gn

Shock pick up @85—110% of control voltage

Should drop @30—60% of control voltage

Operating time—15 to 35 ms

(gg) CURRENT TRANSFORMERS

Cast Resin current transformer shall be provided for main distribution boards carrying

current in excess of 60 amps wherever shown in drawing. All phases shall be provided

with current transformers of accuracy 0.5 and suitable VA burden to operate associated

metering.

Current transformers shall be in accordance with IS 2705.

(hh) EARTHING

All components, frame etc. shall be properly earthed.

GI earth bars of 25 x 5 mm shall be provided for the LT panel for the full length of the

panel and connected to the framework. Provisions shall be made for connection from

this earth bar to the main earthing bar on both sides of LT panel.

The Streetlight Control System will be auto controlled with a solar based real time clock

/Timer with the following features.


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The system should have a provision for remote and local operation with a three-way

selector switch.

Street/Road Light Control Panel shall be equipped with the following: -

Sr. no.

Description Quantity

1 200 Amp. TPN insulated copper Bus Bar 1 set


1 no.


1 no.

4 24 Hours& 7days (Real Time Clock) digital Timer make 1 no.

5 415 V, TPN 200 Amp, service cutout 1 nos.

6 RYB indicating LED lamps with fuses & 1 set of ON/ OFF LED lamp make

1 set each (5 nos.)

7 Ammeter with selector switch 1 no.

8 3-pole contactor of 60 Amp. Rating with prescribed heavy duty, type AC-1 with 240 V AC coil

4 nos.

9

220 V AC, 2 Amps. 2 Pole MCB of 9 KA short ckt. Breaking capacity

1 no.

10

3 positions AUTO/ OFF/ Manual selector switch of suitable rating.

1 no.

11 Elmex make bolted type Bus Bar Terminals type CBT—100

24 nos.

12 Set of CTs (Cast Resin, Class 0.5, 200/5) – 3 Nos. 1 no.

13 100A TP strip fuse way with size - 00 'DIN' type 63A HRC Fuses make

4 nos.

14 Door switch (Snap action with push rod) make Kaycee / any reputed

1 no.

15 Push button make Telemecanique 2 no.

16 240V AC, power socket make Legrand/ any reputed 1 no.

17 240V AC, 60W bulkhead light make Reputed 1 no.

18 32A, 1P isolatable fuse carrier make – any reputed 4A, 10x38 Distribution fuse, Type gl-gg

4 nos.

19 4A, 10x38 Distribution fuse, Type gl-gg make any reputed

4 nos.

20 0-5 A Static/ Electronic KWH meter with set of CT’s 1 set

21 63A, 10KA TP MCB make – any reputed make 6 nos.

(ii) PAINTING

All sheet steel shall undergo a process of degreasing, pickling in acid, cold rinsing,

phosphating, passivating and then sprayed with a high corrosive resistant primer. The

primer shall be baked in an oven. The finishing treatment shall be by application of two

coats of epoxy paint of approved colour and stoved.

(jj) TESTS AT MANUFACTURERS WORK


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All routine tests specified in IS: 8623:1977 shall be carried out and test certificates

produced to the Engineer-in-charge. Typical type test certificate shall be furnished.

22.9.21.7 INSTALLATIONS AND COMMISSIONING OF STREET LIGHT CONTROL PANEL

The installation work shall cover assembly of various sections of the panels, lining up,

grounding the units etc. In the case of multiple panel switchboards after connecting up

the bus bars etc. all joints shall be protected with necessary insulated shrouding. A

common earth bar as per IS specifications shall be run at the back of switch board

connecting all the sections for connection to frame earth system. All protections and

other small wirings for indication etc. shall be completed before calibration and

commissioning checks are commended. All equipment, meters etc. shall be mounted

and connected with appropriate wiring.

Testing and Commissioning

Commissioning checks and tests shall include all wiring checks and checking up of

connections. Primary/ Secondary injection tests for the relay adjustment/ setting shall

be done before commissioning in addition to routine meggar test. Checks and tests shall


Operation checks and lubrication of all moving parts.

Interlock function checks.

Continuity checks of wiring, fuses etc. as required.

Insulation test: when measured with 500 V megger the insulation resistance shall not be

less than 100 mega ohms.

Trip test and protection gear test.

MAJOR COMPONENTS

The major components of the system have been summarized below with some brief

specification.

(o) Feeder Pillar: Feeder pillar shall be installed for distribution of power to

different light poles. Ref drawing no. GA& SLD of lighting control panel

(p) Power Factor correction: A poor power factor is a major (and avoidable) cost

factor. As such light fitting with in-built capacitor has been considered to

improve the system power factor to 0.90 lagging or better.

(q) Surge Protector: Surge protector shall be installed for individual lights or for

lighting circuit as per the design.

(r) Earthing: All light poles, feeder pillar and junction boxes shall be earthed as

per standards.


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22.10 CONTRACTOR’S REQUIREMENT

(d) Contractor should get Inspected all the works involved in the project, from the

CEI Govt. of Uttar Pradesh, duly paying the necessary requisite fees and

submitting the Certificate-Unless and until such clearance are obtained, the

commissioning activities will not be considered as completed.

(e) It is obligatory on the part of contractor that the guaranteed technical

particulars of all the equipment ordered on the vendors will be got approved

from the owner / DVVNL before effecting their purchase.

(f) The Contractor shall provide necessary drawings and documents required by

statutory authorities and obtain approval before taking up erection.

22.11 INSPECTION

All the bought-out items/ equipment/ panels will be got inspected at Vendor’s

premises from the owner before it is transported at the site failing which it will be

treated as breach of contract.

22.12 DRAWINGS

The contractor will furnish three sets of all the drawings required for execution of

work after detailed design and engineering on the basis of SLD for approval to

the owner at the earliest but not later than one month after award of contract.

The owner/ consultant will approve the drawings within 15 days after receipt and

these approved drawings will be considered as GFC for execution at site.

Similarly all the drawings in respect of equipment to be purchased from approved

Vendors shall be submitted to owner/ consultant for approval and these

drawings. It shall also be approved within 15 days after receipt. Any equipment

purchased by the contractor without the approved drawing will be treated as a

breach of contract.

22.13 STATUTORY APPROVAL

Obtaining Approvals & Consents from relevant authorities like Chief Electrical

Inspectorate, State Electricity Board, PTCC, all statutory agencies etc like PWD

, NHA etc. However, any statutory fees paid by the contractor shall be

reimbursed against sub-mission of documentary proof.

22.14 SAFETY

Work is to be done on substations in operation; therefore, the following factors

are of paramount importance:

(s) Minimization of outage time

(t) Adaptation to operational constraints. All the work shall be conducted in

adhere to all instructions and safety rules approved by the DVVNL/Aligarh

Smart City Engineer –in- Charge.


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22.15 SPARES

Recommended spares: The Tenderer shall furnish in his offer a list of

recommended spares with unit rates for each set of equipment that may be

necessary for satisfactory operation and maintenance of circuit breaker and

Isolators for a period of 5 years.

The purchaser reserves right of selection of items and quantities of these spares

to be ordered. The cost of such spares shall not be considered for tender

evaluation.

22.16 TOOLS

The Tenderer shall submit a list and unit rates of all the special tools, equipment

and instruments required for erection, testing, commissioning and maintenance

of all electrical equipment. The purchaser shall decide the quantity of tools to be

ordered. Prices of these tools shall not be considered for tender evaluation.

However, the list of necessary tools/equipment which will be supplied free of cost

with each equipment may be furnished separately.

22.17 TRAINING

Provide training on CSS/ SCADA, telecommunications equipment to the

operation and maintenance staff of DVVNL/ Client.

22.18 CONSTRUCTION, ERECTION, TESTING AND COMMISSIONING

22.18.1 GENERAL

The Tenderer shall keep a competent Technical Person experienced in similar

works as Project-Manager and shall remain as overall in charge of Tenderer’s

work-site and also remain answerable to the Owner for all activities of the

Tenderer at site. Before his placement at site, the Tenderer shall submit his

resume to the Owner for his approval.

The Project-Manager shall supervise the work of all technical and specialized

staff including all section in-charge who is associated with work at site and or at

some outside place of fabrication for associated items; etc. He shall work in

complete harmony and co-operation with Owner’s engineers and manufacturer’s

engineers working at site. All statutory rules and labour laws prevailing in the

area must be observed by the Tenderer. All safety measures against occurrence

of accidents must be taken effectively. Project Manager shall not be withdrawn

without written permission of the Owner. If any of the Tenderer’s personnel is

found unsuitable for the job, the Tenderer shall remove him forthwith and a

suitable replacement shall be posted at site within a reasonable time without any

suffering to work. No compensation for withdrawal of unsuitable or unqualified


Page | 413


person(s) from site or for posting suitable persons(s) to site at any stage of the

project shall be allowed by the Engineer - In - Charge.

• The Tenderer shall execute the works in a professional manner so as to achieve

the target schedule without any sacrifice on quality and maintaining highest

standards of safety and cleanliness.

• The Tenderer shall co-operate with the Owner and any other

Contractors’/Agencies working at site and arrange to perform his work in a

manner so as to minimize interference with other Contractors’/Agencies works.

The Engineer - In - Charge shall be notified promptly of any defect in other

Contractor’s /Agencies works that could affect the Tenderer’s work. If

rescheduling of Tenderer’s work is requested by the Engineer in the interest of

overall site activities, the Tenderer shall comply the same with. In all cases of

controversy, the decision of the Engineer - In - Charge shall be final and binding

on the Tenderer without any commercial implication.

• The Engineer - In - Charge may hold meetings of all the Tenderers /Agencies

working at Site at a time and a place to be decided by the Engineer - In - Charge.

The Tenderer shall attend such meetings if called upon to do so, take note of the

decisions of the Engineer - In - Charge and shall strictly adhere to those

decisions in performing his Work.

• The Tenderer shall be responsible for performance of his Work in accordance

with the specified construction schedule. If at any time the tenderer is falling

behind the schedule, he shall take necessary action to make good such delays

by or otherwise accelerate the progress of the work to comply with the schedule

and shall communicate such action in writing to the Engineer - In - Charge,

satisfying that his action will compensate for the delay. The Tenderer shall not

be allowed any extra compensation for such action.

• The works under execution shall be open to inspection and supervision by the

Engineer - In - Charge at all times. The Tenderer shall give reasonable notice to

the Engineer - In - Charge before covering up or otherwise placing beyond the

reach of inspection any work in order that same may be verified, if so desired by

the Engineer - In - Charge.

• The Tenderer shall comply with all the rules and regulations of the local

authorities, all statutory laws including Minimum Wages, Workmen

Compensation etc. All registration and statutory inspection fees, if any, in respect

of the work executed by the Tenderer shall be to Tenderer’s account.

• All the works such as cleaning, checking, levelling, aligning, assembling,

temporary erection, opening, dismantling, surface and edge preparation,

fabrication, machining, chipping, scraping, fitting-up, bolting / welding, etc., as

may be applicable in such erection and are necessary to complete the work

satisfactorily, are to be treated as incidental and the same shall be carried out by

the Tenderer as part of the work.


Page | 414


• Equipment and material, which are wrongly installed, shall be removed and

reinstalled to comply with the design requirement at the Tenderer’s expense, to

the satisfaction of the Engineer - In - Charge.

• Throughout the period of construction of the Works the Tenderer shall maintain

the whole area of his operations in a clean, tidy and safe condition and shall

arrange his materials in an orderly manner, all the satisfaction of the Engineer.

• All rubbish, wooden planks, cable’s scrap, empty cable drums etc. shall be

systematically cleared from the working areas and, if not removed directly from

the Site, shall be deposited at general collecting points provided by the Tenderer

and agreed with the Engineer - In - Charge, pending removal from the Site.

Where practicable, screening shall be provided to prevent the ingress of dust

and dirt to any part of the Works. The Tenderer shall clearly state, in the

appropriate schedule, what provision is being made for disposal of waste

materials both on and off-site.

• The Tenderer shall not cause pollution of the Site land drainage system or any

water course by waste products from any source whatsoever. Whenever any

pollution is attributable to any act or omission on the part of the Tenderer, the

Tenderer shall clear the pollution as soon as possible and make early

arrangements to remedy the cause.

• The Tenderer shall make himself familiar with all statutory requirements relating

to the discharge of effluent from the Plant and shall take all steps to ensure that

these are not contravened by the disposal of effluent from the site. No dangerous

or noxious waste products, chemicals or materials shall be disposed of, on or off

the Site without proper treatment to make the quality comply with environmental

regulation.

• The Tenderer shall take all necessary measures to ensure the safe collection

and disposal of waste oils pertaining to those Works or plant for which he has

responsibility and to ensure the prohibition of any discharge of waste oils into

surface waters, ground waters or drainage systems of any kind and any deposit

and/or discharge of waste oils on to the ground or floors of buildings and any

uncontrolled discharge of residues resulting from the processing of waste oils or

the cleaning of oil contaminated surfaces with solvents.

• In the event that the Tenderer fails to comply with the above, the Owner reserves

the right to carry out such work on his behalf and to recharge accordingly.

• Damage to Public or Existing Site Roads

• The Tenderer shall carry out all repairs to damage to roads, drains, footways,

paved areas, boundary walls and fences etc. and clean all fouled roads and

paving etc., whether public or existing at site, caused by or in any way attributable

to the handling/transport of plant or materials by the Tenderer or any Sub-

contractor and indemnify the Employer against loss damage or claims by the


Page | 415


Local Authority or others for damage to or fouling of roads, paving etc., by reason

of unusual traffic or other causes.

• Cleanliness of Public or Existing Site Roads. The Tenderer shall at all times

ensure that the public roads, giving access to site, are kept clean of any materials

deposited by traffic from the Tenderer or his subcontractors. The tenderer shall

also ensure dust suppression of site roads.

• The tenderer shall be responsible for the Watch and ward to ensure security and

safety of materials under the Tenderer’s custody.

22.19 ERECTION, TESTING & COMMISSIONING

22.19.1 GENERAL

The tenderer shall furnish all labour, supervision, consumable materials, tools and

tackle and services necessary for receiving, unloading and storing, transportation

pre-assembly at site, if required, complete erection, testing and commissioning of

all items included to complete the plant unit as specified in the specification.

Omission of any specific reference to any method, parts, accessories or materials

required for proper and efficient execution of the work shall not, in any way relieve

the Tenderer from his responsibilities from providing such facilities and performing

the complete erection, testing and commissioning at no extra cost to the Owner &

without any time over-run.

22.19.2 EQUIPMENT, MATERIAL & SERVICES TO BE PROVIDED BY THE TENDERER

xiii. Receiving of materials.

xiv. Unloading of materials from ships, rails and other means of surface or air,

transport carriages, clearing from ports and customs.

xv. Transportation / shifting of unloaded material to storage area.

xvi. Proper stacking and storing of materials under Tenderer’s custody.

xvii. Checking of all materials with shipment list/consignment note, reporting for

missing or damaged items, repairing damages and cleaning before

erection, claiming from insurance agencies etc. Preservation of plant &

equipment at storage area/ site.

xviii. Maintaining proper record of the materials and place of storage for quick

identification as and when required.

xix. Issue of materials from stores and maintaining detail account of the same

as required.

xx. Transportation / shifting of material from stores to erection site.


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xxi. Final adjustment of foundation levels by chipping and dressing, checking

location, elevation etc. of anchor bolts and grouting of anchor bolts and

base- plates.

xxii. Pre-assembly at site after proper checking / overhauling as required.

xxiii. Erection and subsequent cleaning/flushing as required, re-commissioning

check to ensure correctness of erection.

xxiv. Testing and commissioning services as required.

22.19.3 MAN / MATERIAL SUPPLY

The Tenderer shall furnish all labour (supervisory, skilled, unskilled and

administrative), all consumable materials, transport vehicles, mobile cranes, other

lifting devices, hydraulic jacks, all erection tools, tackles and equipment, precision

levels including micro levels, dial and other gauges, surface plates, straight edges,

special tools like hydraulic crimping tools, blowers, cable rollers, jack all other

necessary implements such as shuttering materials in sufficient numbers as may

be required for timely and efficient execution of the contract. The materials

supplied shall be of the best quality, the specification and quality of which have to

be as per agreement and or otherwise added by the Engineer - In - Charge.

22.19.4 SUPERVISION DURING ERECTION

The Tenderer shall be required to provide, at proper time, the necessary

supervisory engineers, supervisors and other supervisory personnel duly qualified

and in sufficient number for transportation, erection, pre-commissioning and post

commissioning check-up, start-up, trail operation, testing and commissioning of

yard / plants and equipment.

22.19.5 SEQUENCE OF ERECTION WORK

All packing cases and packages shall be opened in presence of the Engineer -

In - Charge or his authorized representative. Timber packing cases shall be

carefully opened to avoid damage to materials or timber. Nails and packing strips

should be pulled out with suitable appliances and kept separately in a container

and not thrown away at random. All timber of packing cases shall have to be sorted

out and stored properly at a suitable place as directed by the Engineer - In -

Charge. From time to time packing materials, timber, nails and strips shall be

delivered back to the Engineer - In - Charge or otherwise disposed of as directed

by the Engineer - In - Charge. The timber reclaimed from the packing cases or any

other material shall not be used by Tenderer for rendering facility in the erection

work or any other job without prior permission of the Engineer - In - Charge.

All timber and packing materials shall remain the property of the Engineer - In -

Charge.


Page | 417


Each material after stripping from boxes or received loose, shall be carefully

inspected, checked with shipping list and identified with erection drawing if

necessary. The Tenderer shall be completely responsible to make all necessary

arrangements, application and follow procedure to process claim on underwriters,

obtain replacement/repair/rectify and modify as required of all such

damaged/defective/lost equipment and material at no extra cost to the Engineer -

In - Charge in order to execute the work in satisfaction to the Engineer - In - Charge

within the stipulated contract time.

Once the materials are inspected, the same shall be preserved properly and

adequately protected from theft and deterioration or damage due to rain, storm,

dust, and water, tampering by causal visitors or workers. The Tenderer shall

prepare and maintain stores, ledgers and bin cards for all materials in his custody.

Carrying out all repairs to damages that might have occurred during transit and in

subsequent storage or handling and modifications and rectification work and

replacement of all lost parts, are under the Tenderer’s Scope. All modifications and

rectification work and replacement shall be carried out in the presence of Engineer

- In - Charge.

22.19.6 ERECTION

k. Erection work shall be carried out in the manner and sequence as may be directed

by respective equipment manufacturer’s supervisory engineers and the Engineer -

In - Charge. The work shall be carried out as per applicable specifications, codes of

practice including drawings and instructions of Engineer - In - Charge where

applicable.

l. As erection proceeds each assembled part before being boxed up with a view to

erecting it finally shall be inspected and approved by the concerned supervisor.

Should any defect be found out during such inspection, the Tenderer shall make it

good as per directives from Engineer - In - Charge.

m. The equipment shall be placed on respective foundation or support, levelled and

aligned with precision measuring instruments, checked for proper clearance

between moving and stationary parts wherever applicable and grouted on the

foundation.

n. All fabrication and engineering work incidents to erection like scaffoldings, structural

forming for pre-assembly, transport and erection etc. shall have to be done by the

Tenderer at his own cost. The structural steel required for such work shall be

arranged by the tenderer. Also, any fabrication work like cutting, grinding, welding,

fitting up etc. which in the opinion of the Owner are incidental to the erection at site

shall have to be done by the tenderer. Any defect in the fabrication shall have to be

rectified by the Tenderer at his cost without any commercial/contractual implication.


Page | 418


o. Particular attention shall be given towards removal of buckles and other forms of

distortion.

p. Holes in plate work to assist in erection should be avoided. Lugs required for

erection shall be removed and projections of weld shall be chipped and ground flush.

q. All equipment shall be safe guarded from wind or other external causes by providing

suitable steel cables/guys until completion of erection.

r. Welding sequence shall be adopted in such a way so as to minimize distortion due

to weld shrinkage and shall be got approved from the owner prior to commencement

of work.

s. Welding shall not be carried out on wet surfaces and shall be protected from high

winds/rains water.

t. All materials such as electrodes, gaskets, bolts, nuts, etc. shall be of reputed make

and conforming to relevant Indian Standards. Prior approval of Engineer - In -

Charge shall have to be obtained before commencement of work. Manufacturer’s

test certificate shall have to be provided when called for.

22.19.7 EQUIPMENT INSTALLATION & WORKMANSHIP

The equipment installation and workmanship shall be as follows:

22.19.7.1 ASSEMBLY OF EQUIPMENT

iv. Units, which due to weight, size or other consideration arrive in a disassembled

state, shall be assembled at site.

v. Protection of equipment from damage, dust and exposure to corrosive factors

shall be a prime consideration throughout the period of installation,

commissioning and final handling over to Engineer - In - Charge.

vi. Prior to installing equipment, related work of other trades shall be inspected to

ensure that anchor bolts, inserts, sleeves, openings, foundations etc. are

provided at the proper time and in the correct locations and at the correct level.

22.19.8 LUBRICATION

v. The Tenderer shall be responsible for the lubrication requirements of all

equipment from the initial run to final lubrication before handing over to Engineer

- In - Charge. All lubrications shall be supplied by the tenderer for the equipment

supplied by them.

vi. Equipment shall be lubricated in accordance with manufacturer’s

recommendation.

vii. Bearings for driving and driving and driven equipment shall be checked and

lubricated in accordance with the manufacturer’s instructions.


Page | 419


viii. All packing, glands and flange joints shall be checked and tightened as

necessary during trial runs and commissioning. Should any packing or gasket or

gland require renewal or replacement during the period, such renewals shall be

made by the Tenderer from the materials to be supplied by him.

22.20 SAFETY REGULATIONS

k. Only scaffolds which meet the requirements of any governing laws shall be used

in the projects.

l. All burning and welding equipment shall conform to, and be used in accordance

with, regulations governing such equipment. No burning or welding shall be done

at any place on the site until location where such work is to be done is approved.

Welding near/at/in hazardous areas (like gas/oil etc.) shall be done only after

having all the fire protection/fighting equipment at hand.

m. Adequate fire protection shall be available before work shall proceed.

n. All warning signs shall be observed.

o. Use of explosives shall comply with all regulations.

p. Tenderer shall require his employees/staff/ workers to wear hard hats of ISI mark

at all times at the site of work.

q. Goggles shall be worn whenever there is a possibility of flying particles or

splashing corrosive fluid and during the gas cutting and welding.

r. Safety belts shall be used by men working in high places (above 3mtrs high).

s. Any loose materials like cotton/jute/oiled clothes etc. shall not be thrown hither

and hither and thither but dispose to safe places to avoid any accident/fire etc.

t. Tenderer shall be solely responsible for the dissemination of all safety

regulations including those written here, those promulgated by Owner and those

dictated by good practice, and shall ensure that all his employees and those of

his subcontractors and conversant with same.

22.21 INSPECTION

iv. All works to be carried out by the Tenderer shall be subjected to inspection by

the Engineer - In - Charge as well as statutory authorities. The Tenderer shall

provide necessary facilities, instruments, personnel etc. for carrying out the

inspection as above the shall comply with the instructions given.

v. After completion of erection and/or installation and before start-up, each item and

equipment and all its appurtenances shall be thoroughly cleaned and then,

inspected in the presence of Engineer - In - Charge for correctness, soundness

and completeness of installation and acceptability for start-up.

vi. A checklist in triplicate shall be furnished for the approval of Engineer in-charge

wherein all items to be checked and necessary instructions shall be listed.

Inspection and checking shall strictly follow this checklist. On conclusion of the


Page | 420


Joint Inspection and checking (2) copies of the inspection report shall have to be

handed over to the Engineer - In - Charge. The report shall have to be jointly

signed by the Tenderer’s supervisor and the Engineer - In - Charge to ensure

that all inspection and checking have been properly carried out. However, such

endorsement by Engineer - In - Charge shall not relieve the tenderer from the

responsibility in ensuring proper erection/installation.

22.22 PRE-COMMISSIONING TEST

iv. After verification of correct installation, Plant/ equipment material shall be subject

to a program of pre-commissioning tests. All equipment including tools, tackles,

instruments, test kits etc. and required manpower shall be made available by the

tenderer. Pre-commissioning tests shall include operational and functional tests,

measurement of parameters such as IR values/ Earthing resistance etc, relay/

meter calibration, high voltage tests etc. the list of pre-commissioning tests shall

be prepared by tenderer and got approved by Engineer - In - Charge.

v. The tenderer shall prepare test records for each equipment and after conclusion

of tests, it shall be his responsibility to prepare required copies of test records

and get them counter signed by the Engineer - In - Charge.

vi. Any defects brought to light during these tests shall be recorded in the test

records and Tenderer shall rectify the same.

22.23 START- UP (PRE- COMMISSIONING)

iii. On completion of erection of the equipment material and before the start-up,

equipment shall be inspected by the Engineer - In - Charge and the Tenderer for

correctness and completeness of installation and acceptability of start-up,

tending to initial pre-commissioning tests at site. The list of pre-commissioning

tests to be performed shall be as mutually agreed and included in the Tender’s

quality assurance programme.

iv. The Tenderer’s Engineers for commissioning and start-up specifically identified

shall carryout all the pre-commissioning tests at site. On completion of

inspection, checking and after the pre-commissioning tests are satisfactorily

over, the complete equipment shall be placed on initial operation during which

period the complete equipment shall be operated integral with sub-systems and

supporting equipment on no load, on successful completion of which the Owner

will issue Preliminary Acceptance Certificate.

22.24 COMMISSIONING

vi. The electrical equipment shall be energised after rectification of all defects

noticed during the site inspection/ Pre-commissioning tests and after tenderer

has obtained approval from statutory bodies for the installation, If required, the

system may be energised in parts and for short duration of time to establish the

correctness/ healthiness of the equipment material. These shall be deemed as

trial runs of the equipment.


Page | 421


vii. The complete installation shall be deemed to have been commissioned

successfully if the entire installation operates without any defect for a continuous

period of 72 hours over any period of 6 (Six) days. Any defects brought to light

during the test run of 72 hours shall be rectified by the tenderer.

viii. The tenderer shall maintain records of the measurements, minor repairs carried

out the trial run of the Plant/ continuous test run of the plant and get the same

certified by Owner. Required copies of these tests-records shall be submitted by

the tenderer.

ix. After successful commissioning including of defects, submission of test reports/

records, submission of O&M manuals etc., the plant system/ work will be taken

over by the Engineer - In - Charge and will operated by the Engineer - In - Charge

expect otherwise mentioned in the project B.O.Q. and or in other conditions.

x. Final Acceptance Certificate will be issued by the Engineer - In - Charge on

successful commissioning and after the tenderer has completed all his

obligations.

22.25 ENGINEERING SERVICES

22.25.1 GENERAL

The Tenderer shall be responsible for providing all equipment, material and

services including design and construction of all works specified or otherwise

which are required for a complete project as per agreement meeting the intent of

this specification, ensuring high degree of reliability, availability, operability and

maintainability. The equipment, system/sub-systems and components shall

conform in all respects to high standards of engineering, design and workmanship

and shall be capable of performing in continuous commercial operation in a

manner acceptable to the Owner and shall also be in line with the current practices

for reliable and efficient functioning of plants of similar size and rating.

The Tenderer shall render complete engineering services for the project including

complete detailed engineering, design submission and documentation as specified

and as required for a good design and installation ensuring efficiency, operability,

availability, maintainability and reliability of the plant and efficient archiving of plant

documentation for future reference. As part of the overall project management

activity, the Tenderer shall be responsible for proper engineering, co-ordination

and management during various phases of execution of the contract.

At any stage during the performance of the work, the Owner may require up-

gradation/improvements in the Contracted Plant and consequent modification in

the equipment/system designs in view of additional information available at a later

date(s) or feedback(s) received during execution / operation of similar units. If so

desired by the Owner, the Tenderer shall make the necessary design modifications

and carry out the up-gradation/improvements in the Plant. Commercial and time


Page | 422


implications of such action shall be mutually agreed between the Owner and the

Tenderer.

It is not the intent to give details of every single task to be carried out by Tenderer.

However, all engineering, supply and erection of plant and equipment work

required for the satisfactory completion of the plant / systems as specified shall be

carried out by the Tenderer. Broadly, the following are the minimum requirements

in respect of scope of major items of work.

xiii) Tenderer shall submit design calculations, criteria for selection and

sizing of equipment and systems, for approval by the Owner/Consultant.

xiv) Interface engineering and complete coordination work among various sub-

vendors of equipment / packages included in the Tender’s scope.

xv) Preparation of detailed technical specifications including data sheets, tender

drawings and bill of material for all bought out items, as also finalization of

corresponding sub-contractors.

xvi) Review of sub-contractors data, drawings, design calculations, schedules, bill of

materials, instruction manuals etc., for all equipment, before forwarding them of

Owner/consultant for approval.

xvii) Preparation of civil construction drawings for all works including if any buildings

and equipment showing foundation details and full details regarding equipment

loads, floor openings, details of embodiments etc. these documents shall be

preceded by appropriate design calculations, static and dynamic analysis as

necessary.

xviii) Preparation of consolidated schedules and bill of materials.

xix) Sizing of all equipment as per the stipulated design criteria to meet the

requirements.

xx) Final revision of all documents.

xxi) Preparation and compilation of operating Manuals and Maintenance Instructions.

xxii) Preparation and submission of certified final as-built drawings and documents.

xxiii) Preparation and submission of all erection and assembly drawing schedules and

instructions, which may be required at, site.

xxiv) Preparation and submission of procedure strategy for erection of major

equipment taking into consideration the layout of plant and auxiliaries.

Electrical Drawing / design data

xxiv) Levels of different voltage grade, Transformer details, metering and protection

with CT / PT cores / ratio / burden / accuracy class.

xxv) Complete BOQ of the project with technical details.

xxvi) Single Line Diagram of 415 V AC Distribution board


Page | 423


xxvii) Single Line Diagram of 11KV distribution system

xxviii) Overall Site Layout Plan

xxix) Maximum & Minimum fault level calculation

xxx) Insulation coordination.

xxxi) Switchgear/Control building layout – Plan.

xxxii) Cable duct routing, layout Plan & Section – outdoor.

xxxiii) Cable duct layout Plan & Section – Indoor.

xxxiv) Sizing calculation of HV& LV Cables

xxxv) Power cable & Control cable schedules.

xxxvi) Cable tag marking concept.

xxxvii) Earth design calculation based on actual site soil investigation.

xxxviii) Outdoor equipment grounding arrangement and details.

xxxix) Outdoor Illumination system design Calculation.

xl) Drawing of Outdoor Illumination with erection details.

xli) Cabling, earthing & lightning concept

xlii) CSS, Lighting pole, Feeder Pillar, Transformer foundation details

xliii) Relay setting with calculations.

xliv) Material inspection report

xlv) Pre commissioning / commissioning reports of all equipment

xlvi) As built documentation of the drawing / documents

Minimum three sets of drawings / documents are to be submitted unless specified otherwise.

22.26 QUALITY MONITORING AND ASSURANCES

22.26.1 GENERAL:

All materials, components and equipment covered under the technical

specification for this Project shall be procured, manufactured, tested, erected and

commissioned as per a comprehensive Quality Assurance Programme. It shall be

the primary responsibility of the Tenderer to draw up and implement such a

programme, which shall be duly, approved by the Engineer - In -


The detailed Quality Assurance Plan (QAP) for manufacturing and testing of

equipment shall be prepared by the Tenderer and submitted for approval by the

Engineer - In - Charge/Authorised Inspection Agency.


Page | 424


22.26.2 INSPECTION AND TESTING

The material shall be inspected by the Engineer - In - Charge/Authorised

Inspection Agency at manufacturer’s works prior to dispatch. The material will be

inspected as per the tests pre-identified in the approved QAP to ensure conformity

of the same with relevant approved drawings, data sheets, technical specification,

National / International Standard.

• The Tenderer shall furnish all relevant documents and test Certificates as

required by the Inspection Agency during inspection.

• The Inspection Agency shall have the right to demand for re-testing of

any material / re-calibration of the instrument and testing machine & the

charges for the above will be borne by the Tenderer.

• Performance tests of any particular equipment which cannot be

conducted / demonstrated either partially or wholly at the manufacturer’s

works, shall be conducted after erection at site in presence of Engineer -

In - Charge/Authorised Inspection Agency. In such cases, prior approval

of the Engineer - In - Charge shall be obtained.

• No equipment shall be dispatched before inspection and issue of

Inspection Certificate and dispatch clearance from the Engineer - In -


• The issue of Inspection Certificate / Waiver Certificate for any material or

part thereof does not absolve the Tendered from his contractual

obligations towards subsequent satisfactory performance of the

equipment at site. Should any equipment be found defective, in whole or

part thereof after receipt at site or during erection / commissioning and

testing shall be made good by the Tenderer at free of cost.

22.26.3 OPERATING MANUALS AND MAINTENANCE INSTRUCTIONS

xi. The Tenderer shall submit to the Owner, instruction manuals for all equipment

/ system / material covered under the contract at least thirty (30) days before

the first dispatch of the equipment.

xii. The operating manuals and maintenance instructions shall be in sufficient detail

to enable the Owner to operate, maintain, dismantle, re-assemble, adjust or

replace all equipment and components during the life time of the plant. The

manuals shall be specifically prepared for the contracted plant. Only a collection

of manufacturer’s standard leaflets shall not be acceptable as the manuals.

xiii. The operating manuals and maintenance instructions manual shall be

submitted in the form of one (1) reproducible original and two (2) copies.

xiv. The information provided shall include:


Page | 425


xv. A complete inventory of all items of plant, with identification details; procedure

for ordering spares.

xvi. Service manuals for equipment giving full descriptions, drawings and

specifications of the main items and auxiliary items.

xvii. A schedule of recommendations of routine maintenance of all electrical

equipment, recommended inspection point, information on detection, cause

and rectification of troubles and faults

xviii. Manufacturer’s literature.

xix. The instruction manuals shall be subject to the approval of Owner.

xx. If after the commissioning and the initial operation of the plant, the instruction

manuals require modifications/additions, the same shall be incorporated by the

Tenderer and the updated final version of the manuals shall be submitted

22.26.4 “AS- BUILT” DOCUMENT

The Tenderer shall provide and keep up to date “As built drawings” of all works

including civil and structural works constructed and all equipment and accessories

and miscellaneous metal works erected or installed. These drawings shall show

all changes and revisions from the original drawings and specifications, including

the exact “As-built” locations, sizes and kinds of equipment and accessories,

miscellaneous metal works, embedded piping and electrical systems and other

concealed items of work. These drawings shall be kept in Tender’s field office but

shall be made available at all times for review of the Engineer. At the end of every

work, all entries, changes or revisions made in the drawings by the Tenderer shall

be checked and approved by the Engineer. One soft copy of all

“Drawings in CD”s and Reproducible prints with requisite copies of all “As-built”

drawings shall be progressively handed over to the Owner after taking over of the

plant by the Owner.

22.26.5 PROJECT HANDBOOK

The Tenderer shall submit to the Owner, a project handbook which shall contain

all approved design basis and design calculations, the design and performance

data of various plant, equipment and systems covering the complete project

including single line diagrams, etc. prior to handing over the plant.

The project handbook shall be submitted in three (3) copies in original and Compact Disks

(CDs).

22.27 LIST OF PREFERRED MANUFACTURERS

The list of “Preferred Equipment Manufacturers” is as given below:


Page | 426



1. 33/11kV Transformer Schneider / BHEL / ABB / Bharat

Bijlee / EMCO / Toshiba

2. 33kV & 11kV Gas Insulated

Switchgear


3. 11/0.4kV Distribution

Transformer (As part of


BHEL / Crompton / ABB / GE/

Voltamp

4. SF6 gas insulated RMU (As

part of packaged RMU

substation

BHEL / ABB / Siemens / Schneider

5. Enclosure (as part of


Schneider / Siemens / ABB / BHEL

6. LT Switch Board (As part of



7. CTs and PTs AE / Kappa / Siemens / Crompton /

ABB / Schneider/ Gilbert & Maxwell/

Pragati

8. Insulators BHEL / Jai Shree / WSI

9. Protective Relays (for

Packaged substation)

Alstom / Siemens / ABB / Schneider

10. DC batteries / POWER

PACK

Exide / Amar-Raja / HBL

11. Battery Chargers Amar-Raja / Exide / AE /HBL

12. H.T. Cables CCI / Universal / RPG / KEI / Finolex

/ CMI

13. L.T. & Control Cables CCI / Universal / RPG / KEI / Finolex/

CMI

14. Lighting Cables Kalinga / Delton / Finolex / Havells /

KEI

15. Lighting Fixtures Phillips / GEC / Bajaj / Crompton /

Wipro

16. H.T. & L.T. termination kits Raychem / CCI / M-

SEAL/Denson/Birla-3M

17. Light Poles Bajaj / Valmont / Sumip


Page | 427



18. Smart Energy Meters ABB / Schneider / L&T / Secure

Meters / Automatic Electric

19. HV and LV bushings BHEL / Jayshree / WSI / CGL / SSB

21. Cable Glands HMI / Gripwel / Comet/ Baliga

Lighting/ Cosmos / Dowells

22. Cable lugs Dowells / AMP (Tyco Electronics) /

Comet / Cosmos / Hax Brass

(Copper alloy India)

23. PVC terminals & terminal

blocks

ELMEX / ESSEN / Phonix / Connect

Well / Wago

24. Semaphore Alstom / ABB / Siemens / Schneider

25. Modular type switches Wipro North West / MK / MDS /

Schneider / Legrand/ ABB Lumina

26. Indicating meters AE/ Schneider/ABB/ Secure

27. Pushing button & indicating

light

L&T / BCH / Siemens / C&S/ Altos /

Schneider Electric / Siemens /

Teknik

28. Selector & Control Switches Alstom / Siemens / Kaycee / Salzer

(L&T) / Schneider

29. MCB, MCCB & LT Breaker Legrand / Siemens / ABB /

Schneider / Mitsubishi

30. Switch Sockets & Modular

type receptacles

BCH / Crompton / Schneider / ABB

Lumina / Wipro North west/ Legrand

31. MCB distribution board Siemens / ALSTOM / Schneider/

ABB / Legrand /Mitsubishi

32. Lighting panels Siemens / Schneider /ABB OR Their

authorized system integrator

33. Indicating Lamps Siemens / BCH / Tecnic / Schneider

/ Altos

34. Contactors L&T / Siemens / ALSTOM /

Schneider / ABB

35. Portable Fire Extinguishers Minimax / Mather Platt / Ceasefire

36. SCADA including

Communication equipment

ALSTOM / Schneider / ABB /

Siemens


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37. DG Set with AMF Panel Cater Pillar / Kirloskar / Sudhir /

Cummins / Sterling Generators

38. Underground HDPE Ducts Duraline, Bajaj, Reliance

39. Feeder Pillar Schneider, Vidhyut, Siemens, ABB,

C&S

40. 11/3.3kV Transformer BHEL / Crompton / ABB / GE/

Voltamp

41 11kV RMU Siemens / ABB / Schneider

42 Fire Alarm System Edward EST3 / Honeywell-XLS

Series / Siemens Fire Finds Series /

Simplex / Notifier

43 Fire Suppression Novac / Inergen / Ansul

44. UPS Socomac / Mitsubhishi / Emerson

Network Power / ETON

45. Cable Tray RMCON / Profab / OBO Bellerman

46 GIS Panels Termination Nexans / NKT Cables / Raychem /

Sudkabel / Pfisteres

47 Earthing Erico/Terrect/Jef echo safe

48 MCC/LT Panels/PDB /

ACDB / DCDB

ABB/ Schneider/Siemens / Sterling

Generator OR their Authorised

System Integrator

49 Conduit AKG/BEC/Polycab/Polypack

Table 51: Preferred List of Manufacturers / Vendors

22.28 Storm Water Drainage - SPECIFICATION

22.28.1 General

Design and Construction of storm water Drainage includes Construction of

RCC channels for conveyance and disposal of storm water from the proposed

sites including catch basins/pits, road crossing works by box culvert or RCC

NP3 pipes and outfall control structures (prior to dumping into outfall, main

drainage channels, creeks or harbour)


Page | 429


22.28.2 Scope of Work

The detailed scope of work is given below. The work under the contract shall

include but not limited to the following:

(a) Design and Constructing Reinforced Concrete – M30 grade RCC Road

drains with covers for drain with width of drains shall be provided as

per the CPHEEO manual and shall be open for width above 2 m with

handrails and guide chains in roads at edge of carriage way including

road gully chambers/catch basins Steel Grates, with gratings including

dressing of sides and ramming of bottoms, getting out the excavated

soil and returning the suitable soil as required as per defined in concept

design basis/ parameters requirement, specifications, concept

drawing, applicable codes and as employer requirement/ it’s accepting

officer.

(b) Connection between road gully/catch pit chambers and RCC storm

water drain, with RCC pipe or uPVC pipes as per specifications.

(c) Construction of various components and appurtenant structures.

(d) Submission of As-built drawing, including L-section and cross-section.

The scope also covers associated civil works such as encasing of pipes at road

crossing points. All work shall be done as per the specifications. The

Contractor/s shall prepare the Detail Design calculation, sizing coordination

with other utilities and work plan before starting the work. The Contractor/s

should note that the indicative concept provided as in the tender drawings

are given to serve as a brief concept /indicative guidance purpose only.

contractor shall carry out site investigation and studies required including

verification of existing storm water drains and condition assessment prior

to commencement. The Contractor/s should execute the works as per these

specifications, bill of quantities and drawings for various items of Works. The

works under the project will have interfaces with other project components,

which will be implemented through other packages under the direction of

the Engineer.

22.28.3 Design Requirement:

(a) Culverts

Storm water drains shall cross the road by suitable pipe culverts or box

culverts. Material of construction of culverts shall be as below:

Pipe culverts : RCC pipe class NP3 as per IS :458 (collar)


Page | 430


Box culverts : RCC M30 to carry superimposed loads of applicable

Traffic loading

(b) SFRC Covers and Catch pits

These covers shall be placed on the newly created structures i.e.:

drainage channel.

The frame and cover shall be of Medium Duty (MD10) / Heavy Duty

(HD20) /Extra Heavy Duty (EHD 35) grade as per applicable loading

condition. Covers and frame in the carriage shall be EHD class.

S. No. Items Details

1 Material of

Construction SFRC rectangular or circular

2 Specification Load designation conforming to IS:

12592-2002 are from 10 T to 35 T.

3 Size of

Catchpit

450 mm x 450 mm x 450 mm deep, 600

mm x 600 mm x 750 mm deep

4 Special

features

• Water Proof and Weather Proof.

• Non-corrosive.

• Temperature resistance

• Logo embossing option.

• Life span (+) 30 years.

Table 7B509.3:

SFRC Covers and Catch Pits

Catch pits: The storm water catch pits are to be placed at an interval of

10 to 15 m c/c on both the sides of the road, low points, curves and

other area such as parking, landscape, parks, playground, open areas

etc. for efficient collection.

(c) Storm water Channels

(i) Earth Work

After construction, the contractor shall carry out backfilling/sand

filling in the trench in layers not exceeding 300 mm, For channels,

the constructed pit is to be kept in working condition till the storm

water drain coming and leaving the channel are constructed in


Page | 431


position and tested and then a connection between channel and

storm water drain is made. Backfilling for the channel is carried

out in layers not exceeding 300 mm with approved backfilling

material.

(ii) RCC Concrete

Storm water drain is to be constructed of Reinforced Concrete of

M30 grade in Channels, walls, slabs, and foundations etc.

including shuttering, handling of concrete, curing etc. as per

specifications.

Dimensions: W mm x D mm (depth) clear interval

Minimum Size: 450 mm x 450 mm (clear internal dimensions)

Base: 100 mm thick minimum PCC M10 (thickness as per

Structural details)

Depth of Channels will be measured as the distance from top of

Channels to the invert level. The Channels are composite

members consisting of Cast-in-situ Raft on top of PCC bedding,

walls and a precast cover and frame resting on the cast-in-situ

walls, to be fixed in line and level as per the adjacent top finished

level. The Shuttering required is to be fabricated from steel or wall

forms. The contractor shall fabricate the shuttering with all the

cutouts/openings as required, after obtaining approval for the

complete shuttering scheme from the Engineer-in-charge.

Adequate numbers of shuttering Sets are to be mobilized to

complete the works in stipulated time frame.

The cutouts/reservations/openings of various diameters pipe

with margin can be kept in Steel or Plywood as directed by the

Engineer.

(iii) Connection between Storm water Catch-Pits and Channels:

RCC NP-3 pipes of 150/200 mm (typical) diameters shall be used

for the connection between catch pits and storm water drain.

The cut-outs /reservations /openings of various diameters pipe

with margin can be kept in Steel or Plywood as directed by the

Engineer.

22.28.4 Civil Works

(a) Site clearance and rough grading


Page | 432


Before the start of the works, the entire site shall be cleared of all

bushes, shrubs, jungle and unwanted vegetation growth etc., and made

clean. The rubbish shall be disposed off, as directed by the Engineer.

After the site is cleared, it shall be roughly graded to even out any

undulations or ditches present therein.

(b) Materials

All materials used in the work shall be subjected to mandatory tests in

accordance with relevant IS codes and as specified in respective clause.

Before incorporating the materials in the permanent Works, test

reports shall be submitted to the Engineer-in-charge for seeking his

permission.

(c) Formwork

Formwork, shuttering, centering, scaffolding etc. shall be of steel or

plywood, lined with MS-sheets and, for scaffolding steel tubular shall

be used. Joints should be sufficiently tied to prevent loss of cement

slurry from the concrete. All forms, shuttering shall be levelled, aligned,

and thoroughly cleaned, before they are used for concreting.

Formwork shall be removed after specified days of curing with the

prior written permission of the Engineer-in-charge. The surface of RCC

after removal of formwork / shuttering shall be smooth, even and

without honeycombing or undulations.

(d) Reinforced Cement Concrete (RCC)

All concrete shall be “Controlled Concrete” as defined in IS: 456 and SP:

23, Handbook for Design Mix Concrete. Minimum cement content shall

be taken 10% more than that specified in IS Code.

Sulphate Resistant Portland cement shall be used as per the Standard

Specifications and conforming to IS: 12330 and as directed by the

Engineer. Unless and otherwise specified, 43 Grade of S R Cement shall

only be used for the construction work. All reinforcement used shall be

of Tor steel (Fe 415) ISI mark , and shall be clean and free from loose

mill scales, rust and coating of oil or other coatings which may destroy

or reduce bond. Minimum size of reinforcement bars shall be of 8 mm.

Where steel shuttering shall be used, the shuttering shall be new, or in

a good condition without holes or dents. It has to be approved by the

Engineer-. The construction joints should be minimum and, these have

to be executed with utmost care. Before concreting on contact joint,

loose material has to be removed, and they have to be cleaned properly.


Page | 433


Honeycombing has to be avoided by suitable fixing of shuttering and

proper use of vibrators.

The exposed surfaces of concrete shall be kept continuously in a wet

condition by ponding or covering with a layer of sackings, canvas,

hessian or similar materials and kept continuously wet for at least 21

days from the date of placing of concrete. RCC grade shall be as

specified in the Drawings or, Bill of Quantities. In case of any difference

in the two, Engineer-in-charge’s decision will be final.

(e) Portland Cement Concrete (P.C.C )

Portland Cement Concrete shall be as per the Standard Specifications

for Procurement of Project Works.

(f) Final Finishing

The contractor will ensure that the entire structure along with all its

installations is in a finished, and in new and fully operative condition,

when handed over. He shall have repaired and removed all signs of

damage that might have been done during the course of construction

of channels and pipelines.

He shall also see that the entire exterior has been finished properly and

the entire site is cleared of all extra construction material, debris, and

excavated soil. This shall be done to the satisfaction of the Engineer.

(g) Flood Protection Structures

The flood protection structures e.g. retaining wall, bunds, gabions, etc.

but not limited to shall be constructed wherever applicable in Package

conforming relevant Indian standard.

22.28.5 As Built Drawings

The contractor shall submit to the Engineer-, “Completion” Drawings as

specified below and operation and maintenance instructions for the whole

of the Works. These Drawings shall be accurate and correct in all respects

and shall be submitted to, and approved by, the Engineer:

(a) Plan and sections of Under Ground Drainage system showing pipe work

in package area on scale, as specified by Engineer-, showing

appurtenances, sizes and material of pipe.

(b) Structural Drawing showing reinforcement details of all the

components covered under this contract, as specified by Engineer-.


Page | 434


22.28.6 Applicable Codes

S. No. Code Description

1 IS.269 Specification for 33 grade ordinary Portland

cement

2 IS:8112 Specification for 43 grade ordinary Portland

cement

3 IS:12330 Specification for sulphate resisting Portland

cement

4 IS:383 Specification for coarse and fine aggregates from

natural sources for concrete

5 IS:432

Specification for mild steel and medium (tensile

steel bars and hard-drawn steel) wires for

concrete reinforcement. (Part 1 and 2)

6 IS:1786 Specification for high strength deformed steel

bars and wires for concrete reinforcement

7 IS:1566 Specification for hard-drawn steel wire fabric for

concrete reinforcement

8 IS:456 RCC works

9 IS:458 RCC pipeworks

10 IS:2645 Specification for integral cement water- proofing

compounds

Table 7B509.6: Applicable Codes

22.28.7 Design Guidelines


1 Type and material RCC Rectangular drain

2 Construction As per scope, Civil specification

3 Minimum velocity 0.6 m/sec


Page | 435



4 Maximum velocity 3.0 m/sec

5 Minimum depth 450 mm

6 Minimum rectangular

drain width 450 mm

7 Free board 150 mm minimum or matching with

ground level

Table 7B509.7: Design Guidelines

22.28.8 Samples and Tests

The Contractor shall be responsible for developing a Quality Management

Plan (QMP) which implements a quality control program and to provide all

necessary materials, apparatus, instruments, equipment, facilities and

qualified staff for sampling, testing and quality control of the materials and

the works under the Contractor.

22.28.9 Protection of Utilities

The Contractor is required to carefully examine the location of the Works

and their alignments and, to make special enquiries with all authorities,

concerning all existing utility lines such as water supply, sewers, gas pipe,

telephone (underground and/or overhead) lines, electric cable

(underground and/or overhead) etc.

Contractor should also determine and verify to his own satisfaction the

character, sizes, position and lengths of such utilities from authentic records.

The Contractor shall be wholly responsible for the protection and/or

facilitating relocation of such utilities as may be required, and shall not make

any claim for extra work or extra time that may be required to protect or

facilitate relocating such utilities.

22.28.10 Tests During Construction

For ensuring the requisite quality of construction and as per the contractor’s

QMP, the Materials and Works shall be subject to the quality control tests, as

described in Standard Specifications as applicable and as directed by the

Engineer. The testing frequencies set forth are desirable minimum and the

Engineer shall have full authority to get the additional tests carried out by

the Contractor, as frequently as he may deem necessary, to satisfy himself


Page | 436


that the Materials and Works comply with the appropriate Specifications.

Where no specific testing procedure is mentioned, the tests shall be carried

out as per the prevalent and accepted in practice, to the directions of the

Engineer.

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