EHV Specification

TECHNICAL SPECIFICATION

FOR

RENOVATION OF 220 kV SWITCHYARD AND C&R PANEL

PACKAGE STAGE-I (2X120 MW)

VOL. II

PART- A & B

CONSULTANT

NTPC Limited (A Government of India Enterprise )

CORPORATE ENGINEERING DIVISION ENGINEERING OFFICE COMPLEX

SECTOR-24,NOIDA-201301 BID DOCUMENT NO.: CW-APDP-R&M-9259-BOP-T-0011-R0

FINAL JULY 2007

TECHNICAL SPECIFICATION

FOR

RENOVATION OF 220 KV SWITCHYARD AND C&R PANEL – STAGE-I

VOLUME – II

PART – A & B

CONTENTS

Clause No. Description Page No.

PART – A

SCOPE OF WORK & SERVICES

1.00.00 INTENT OF SPECIFICATION 1

2.00.00 PROJECT INFORMATION 3

3.00.00 SCOPE OF WORK 3

4.00.00 SPARES

14

5.00.00 TYPE TEST, ROUTINE AND ACCEPTANCE TESTS

16

6.00.00 REQUIREMENTS IN RESPECT OF SUPPLY ITEMS 16

7.00.00 BILL OF QUANTITIES FOR MAIN EQUIPMENT ANNEXURE – I

18

8.00.00 BILL OF QUANTITIES FOR MANDATORY SPARES ANNEXURE-II

26

9.00.00 TENDER DRAWINGS ANNEXURE-III 29

TECHNICAL DETAILS FOR 220 KV CTs FOR 2X120 MW UNITS GANDHINAGAR TPS

30

PART- B

SECTION-I : ELECTRICAL

E-01 CONTROL, RELAY AND PROTECTION

E-02 ISOLATORS AND OPERATING BOXES

E-03 LT POWER CABLES

E-04 LT CONTROL CABLES

E-05 SWITCHYARD AUXILIARY ITEMS

E-06 LIGHTING

Clause No. Description Page No.

E-07 CABLING AND EARTHING

E-08 L.T. PANEL

PART-B SECTION – II : CIVIL

C-0 SWITCHYARD CIVIL WORKS

C-01 GEOTECHNICAL INVESTIGATION & FOUNDATION SYSTEM

ANNEXURE-C1

SOIL DATA

PART-B SECTION – III : MECHANICAL

M-1 FIRE DETECTION SYSTEM

M-2 PACKAGE AIR CONDITIONER

PART-B SECTION – IV : QUALITY ASSURANCE

PART-C GENERAL TECHNICAL CONDITIONS (GTC)

PART-D ERECTION CONDITION OF CONTRACT (ECC)

Separate Book

PART-E TECHNICAL DATA SHEET Separate Book

Note : Part-C : General Technical Condition and, Part-D : Erection Condition of Contract (ECC) are separately bounded.

GANDHINAGAR THERMAL POWER STATION (2 X 120 MW)

BIDDING DO. NO.: CS-APDP-R&M-9259-BOP-T-0011-R0

TECHNICAL SPECIFICATIONS FOR

RENOVATION OF 220 kV SWITCHYARD AND C&R PANEL-STAGE-I

PART – A

SECTION GENERAL

CLAUSE NO. SCOPE OF WORK & SERVICES


BIDDING DOC. NO.: CW-APDP-R&M-9259-BOP-T-0011-R0

TECHNICAL SPECIFICATION FOR


PART-A SECTION-GENERAL

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1.00.00 INTENT OF SPECIFICATION 1.01.00 This specification intends to cover the following activities, services and works in

respect of replacement of existing 220 kV 6 (six) nos. Lines bays & 1 (one) no. Bus coupler bay Control, Relay & Protection panels, metering panels with new Control, Relay & Protection panels having numerical relays and relocation of existing Bus Bar protection, ABT metering, transducer panels presently installed at main plant control room, replacement of isolators, conductors & hardware etc. and associated works and construction of new switchyard control room building to accommodate stage-I switchyard control, relay and associated panels etc. for Gandhinagar Thermal Power Station of Gujarat state Electricity Corporation limited (GSECL) located at a distance of 35 Km from the textile city of Ahmedabad, in the state of Gujarat. The total installed capacity of the power station is 870MW consisting of two units of 120 MW (Stage-I) two units of 210MW (Stage-II)

(i) Complete design and engineering of all the systems, sub-systems,

equipment, material and services. (ii) Providing engineering data, drawings, and O&M manuals for Owner’s review,

approval and records. (iii) Packing, transportation and insurance from the manufacturer’s work to the

site including port and customs clearance, if required. (iv) Receipt, storage, insurance, preservation and conservation of equipment at

the site. (v) All civil works as required. (vi) Erection, testing and putting into satisfactory operation of all the

equipment/material including successful commissioning. (vii) Relocation of the panels. (viii) Furnishing of spares on FOR site basis. (ix) Satisfactory conclusion of the contract.

The scope of work shall be on the basis of single point responsibility, completely

covering the following activities and services in respect of all the equipment & works specified and covered under the specifications and read in conjunction with “Scope of Supply & services” elaborated in this chapter.

The detailed scope of work under this package is listed at clause 3.00.00 1.02.00 In addition to the requirements indicated in this section (Technical specifications), all

the requirements as stated in other sections shall also be considered as a part of this specification as if completely bound herewith.

1.03.00 The Bidder shall be responsible for providing all material, equipment and services

specified or otherwise which are required to fulfill the intent of ensuring operability, maintainability and the reliability of the complete work covered under this specification.







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1.04.00 It is not the intent to specify all aspects of design and construction of equipment mentioned herein. The systems, sub-systems and equipment shall conform in all respect to high standards of engineering, design and workmanship, and shall be capable of performing in continuous commercial operation.

1.05.00 whenever a material or article is specified or described by the name of a particular

brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and quality desired. Products of other manufacturers may also be considered, provided sufficient information is furnished so as to enable the Owner to determine that the products are equivalent to those named.

1.06.00 Bidder is requested to carefully examine and understand the specifications and seek

clarifications, if required, to ensure that they have understood the specifications. Such clarifications should be sought at least 15 days before the scheduled date of the opening of the bids. The bid should not include any sections like clarifications, interpretations and/or assumptions. If the Bidder feels that, in his opinion, certain features brought out in his offer are superior to what has been specified, these may be highlighted separately.

1.07.00 The Bidder may also make alternative offers provided such offers are superior in his

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

1.08.00 Any deviation or variation from the scope requirement and / or intent of this

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

1.09.00 The drawings enclosed with this specification and forming a part of the specification

shall supplement the requirements specified herein. The scope and terminal points for the equipment to be furnished under this contract are also identified in these drawings and are to be read in conjunction with the text of the specifications. These are preliminary drawings for bidding purpose only and are subject to changes that may be necessary during detailed engineering after award, keeping the basic parameters as specified.

1.10.00 The Bidder is advised to visit the plant/site and familiarize himself with the existing

system, plant, equipment and layout etc. before quoting against this specification. The Employer will provide all cooperation to the Bidder in familiarizing him during their visit to site.







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1.11.00 In the event of conflict between requirements of any two clauses of specification documents, the more stringent requirements shall apply unless otherwise confirmed by the Employer in writing before the award of this contract, based on a written request from the Contractor for such clarification.

1.12.00 It shall be the responsibility of the Contractor to coordinate with Employer and offer

Control and Relaying System to meet the actual requirements of the plant and furnish a complete system and also to coordinate with Employer / other system vendors for proper interfacing of equipment and system supplied under this package with all other related equipment and systems.

2.00.00 PROJECT INFORMATION 2.01.00 Gandhinagar Thermal Power Station of Gujarat state Electricity Corporation

limited(GSECL) is located at a distance of 35 Km from the textile city of Ahmedabad, in the state of Gujarat. The total installed capacity is 870 MW consisting of two units of 120MW (stage-I) two units of 210MW (Stage-II) and one unit of 210MW in stage III. The 120 MW unit # 2 of GTPS commissioned in April 1977, has been generating around 90-95 MW. The switchyard employs two mains bus scheme.

2.02.00 Bay details for existing switchyard is indicated in the “KEY SINGLE LINE DIAGRAM

(220 kV SWITCHYARD)” Drg. No. 9259-ES-01, R-0. 2.02.00 In addition to this if any further information is required by the bidder, to assess the

existing plant/equipment condition, the bidder is advised to visit the plant/site and collect the information as required, before quoting, against this specification. The owner will provide all co-operations to the representative of the bidder in obtaining the required information during their visit to site. Bidder shall assess the work area, details existing foundations, equipment connections, control & protection schemes, etc. as required for the scope of the package. No deviation on this account shall be accepted during execution stage and work shall be executed in accordance with the specification.

3.00.00 SCOPE OF WORK The scope of work under Renovation and Modernization of Control, Relay &

Protection panels for 220 kV system and replacement of isolators, conductors, hardware etc. and associated works shall be on turnkey basis and shall comprise to the design, engineering. manufacture, testing and inspection at manufacture’s works, packing., supply, transportation, transit insurance, delivery to site, unloading, storage and equipment erection including associated air conditioning, fire detection system, civil works and dismantling of panels/cables etc. shall includes but not limited to the following:-

3.01.00 Control, Relay & Protection panels 3.01.01 Existing Control, Relay & Protection panels of generator # 1 & 2, Station

transformer, 220 kV Lines (6 bays) & Bus coupler (1 bay) are installed in the main plant control room. Control, Relay & Protection panels for Generator # 1 & 2, Station transformer are being replaced under separate R&M contract by M/s BHEL. The balance Control, Relay & Protection panels for 220 kV Lines (6 bays) & Bus coupler (1 bay), and other associated panels are to be replaced with new panels having numerical relays and necessary equipment / components.







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(a) 220 kV Control, Relay, protection and metering equipment panels including, energy meters, other associated panels etc. for the following 220 kV switchyard bays.

(i) CHHATRAL Line # 1 (ii) CHHATRAL Line # 2 (iii) SOJA Line # 1 (iv) SOJA Line # 2 (v) RANASAN Line # 1 (vi) RANASAN Line # 2 (vii) Bus coupler bay

(b) Digital Fault & Disturbance Recording System. (c) Event Logger (EL). (d) Time Synchronization Equipment. (e) Relay Test Kit. (f) Energy meter panels. (g) Panel mounted numerical protective relays (including specified DR) for the

lines and B/C bays with the relays networked to a common centralized operator workstation.

(h) The existing Bus bar protection panels of syage -I, 2 nos. transducer panels

and 3 nos. ABT metering panels presently installed in stage-1 main plant control room are to be relocated and installed in new control room building including erection, testing and commissioning at new location. Scope shall also include disconnection, dismantling, re-terminations of existing cables, supply of all required cables and cabling & terminations etc.

(i) Relay setting calculations shall be submitted by the Contractor and approved

by Owner. (j) The basic design shall include, but not limited to, the following:

� Development of detailed layout (plan & section/elevation) drawings. � Development of single line diagram with parameters of equipment

and details of protection. � Protection and control philosophy and selection of protection, control

and annunciation schemes and its integration with existing systems. � Development of interlocking schemes.







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� Development of power & control cable laying and termination schedules including changes in the existing scheme as required.

� Contractor shall furnish detailed drawings for the various equipments

covered in their scope for Owner’s approval. The equipment shall conform to type tests requirements as specified elsewhere in the specification.

(k) One no. 415 AC power supply distribution boards for distributing unregulated

power supply for bays control & isolators etc. The AC board shall have the following feeders.

(i) 2 (two) nos. 250 A SFUs as incomers. (ii) 24 (twenty four) nos. 32 A SFUs as outgoings. (iii) 1 (one) no. 160 A SFU bus coupler. (iv) Set of voltmeters, ammeters and indicating lamps.

(l) One no 415 AC power supply distribution boards for air conditioning heating, ventilation and lighting etc. The AC board shall have the following feeders.

(i) 2 (two) nos. 250 A SFUs as incomers. (ii) 2 (two) 63 A SFUs as outgoings for Lighting transformers. (iii) 2 (two) nos. 50 KVA, 415/415 V. delta/star lighting transformers. (iv) 2 (two) 63 A SFUs for A/Cs. (v) 1 (one) no.160 A SFU bus coupler. (vi) Set of voltmeters, ammeters and indicating lamps.

(m) The existing DC power supply source installed at main plant shall be retained.and brought up to the DCDB to be installed in the new control room with required size of the cables. DCDB shall have the following feeders.

(i) 2 (two) nos. 250 A SFUs incomers. (ii) 24 (twenty four) nos. 16 A SFUs as outgoings. (iii) 1 no. (one) 250 A feeder to take power from battery (for future use). (iv) The DCDB shall have two bus A & B with bus coupler of 160 A SFU

and equipped with voltmeter and under/over voltage relays.

Scope also includes all incoming & outgoing power supply cables, cabling, termination etc.for AC and DC boards above.







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(n) Supply of LT power and control cables shall be in the bidder’s scope. (o) Construction of new cables trench with covers. About 60 metes length having

size of 1.5 m (W) X 1.0 m (D) is required with galvanized cable trays of 300 mm wide in 3 rows on both side of the cables trech including supports for interconnection from existing trench to the new control room. Pre cast cables trench covers of suitable size shall be in the bidder’s scope.

(p) Technical details of CTs are attached at ANNEXURE-X for reference.

3.01.02 Switchyard Civil & Architectural work

(a) Construction of new control room building to accommodate new panels and other associated equipment as above including provision for 10 nos. of 220 kV feeder panels (6 nos. of 220 KV feeders of stage -1 viz. Chhatral - 1 & 2, Soja 1 & 2, Ranasan 1 & 2 and 4 Nos.of 220 KV feeders viz. Mehsana 1 & 2 and Jamla 1 & 2 feeders of stage-2, which are presently installed in Jamla Control Room), bus bar protection panels and other associated panels of stage-I.

(b) The scope include the design, engineering and construction including anti-

termite treatment of Buildings including sanitary, water supply, internal electrification etc. The building shall be of RCC framed structure of concrete grade M25.

(c) The tentative requirement of Control Room Building has been given in the

tender drawing. The scope also includes space for Electronic Lab, Store, Miscellaneous rooms like Pantry, Toilet (Both Gents & Ladies), room space for water cooler, Stair, fire escape Stair case ramp etc. shall be provided as per requirement.

(d) Civil works for Air conditioning system of the new control room building.

(e) Civil works for Fire detection system air conditioning system.

(f) Construction of cable trench including covers of suitable size and

interconnection from existing trench to the new Control room building.

(g) Internal lighting for the new switch yard control room building under bidder’s scope.

(h) Anti-weeding treatment of the switchyard of stage-I.

(i) Relocation of 15 meters existing fencing ans storm water drain (size- 30 m

(L) X 0.5 m (W) X 1.0 m (D)

3.01.03 Cabling, Earthing and Lightning Protection

(a) Cabling, earthing & lightening protection - All galvanized cable trays & cable tray’s covers and supporting arrangement including clamps, hardware etc. as per the requirement necessary for entire scope of work. Installation / erection of cables covered under this specification including power supply cables, control cables etc. Scope includes all (inter-panel wiring / cabling),







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terminations/jointing, cables accessories necessary for cabling such as glands, lugs, clamps for cables, ferrules, cable ties, etc.

(b) Development of cable trench layout and sections, and construction drawings

(c) Fire proof penetration sealing material including installations.

3.01.04 Switchyard Miscellaneous work

a. Replacement of the following existing main bus 1 & 2 ACSR moose conductors, jumpers, connectors, insulator strings, hardware etc.

(i) Replacement of existing twin conductor (ACSR Moose) of Bus - 1 and

2 of stage-1.(6 Nos. bus sections) with new ACSR Moose conductor. (ii) Replacement of existing single conductor (ACSR Moose) of fly over

bus of 10 Nos. of bays by new ACSR Moose conductor. (iii) Replacement of existing disc insulators by 120 /160KN Anti fog

insulators of Bus – 1 and 2 and fly over bus of 10 Nos. of bays of stage-1. (Total 84 Nos. double strings (32 Nos. in one string) of tension points, Total 129 Nos.(111 + 18 L) single string (16 Nos. in one string) of tension points and Total 51 Nos. of single suspension string (16 Nos. in one string).

(iv) Providing dead end compressed type joints on tension points. (v) Replacement of double tension and single tension hard wares. (vi) Replacement of existing bolted type Tee connectors by bolt less FCI

fire wedge connectors suitable for ACSR Moose conductor. (vii) Replacement of existing bolted type palm connectors for jumpers of

220 KV CTs/ Breakers/Isolators/ LAs./ wave trap/ CVT etc. by compressed type Aluminum palm connectors suitable for ACSR Moose conductor.

(viii) Providing double jumpers for bus isolators (Only bus side) (ix) Replacement of jumpers/droppers by new one. (x) Work includes dismantling of existing old conductor of twin bus/flyover

bus and jumpers

b. Replacement and retrofitting of existing pneumatically operated 220 kV Isolators with Electrically Operated Mechanism for Isolator.

(i) These isolators are to be made electrically operated by providing

motor operated mechanism boxes. (ii) The provision shall be made to operate these isolators from local as

well as remote control room.







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(iii) Existing structures are to be retained. (iv) Modification for mounting of existing structures of isolators (if

required). (v) Provision for double jumpers shall be made for all the isolators.

(vi) Compression type aluminium palm connector’s suitable ACSR Moose

conductors for jumpers. (double palm connectors arrangement and double palm compression type connectors shall be supplied with all the isolators)

(vii) Power and control cables including termination.

c. Constructions of new additional 44 nos. Earth pit stations including connection with existing grid and complete grounding and equipment earthing system for the equipment under bidder’s scope along with its interconnection to the nearest owner’s earth grid at two points.

3.01.05 Air conditioning system

Air conditioning system of the new control room building by providing 2 nos. (2 x 100% capacity) of air-cooled Package Air Conditioning (PAC) units, each of capacity 25 TR. The Condensing unit shall be placed on the roof (2nd floor) of the building while Evaporating unit/ Air Handling unit shall be located at ground floor in AHU room. The cooled air shall be supplied through insulated duct work to the control room on first floor.

3.01.06 Air conditioning system and protection system

Fire detection and protection system for new control room, consisting of Muti-sensor detectors, Photo-electric detectors, microprocessor based analogue addressable fire alarm panel and Portable Extinguishers.

3.01.07 The intent of the specifications for various services, electrical equipments etc. shall

also cover the following scope:

(a) Erection, supervision of erection, site testing, inspection, commissioning and handing over including association of sub vendors if any in the erection, supervision, site testing, inspection and commissioning of complete system.

(b) Contractor’s scope of work shall also include dismantling of existing

equipment / cabinets / control desk / control panel / terminal block which are to be replaced / modified or rendered surplus due to R&M, by the contractor and handing over the dismantled material at the Employer's designated place. This will also include disconnection / dismantling of the existing pipes, cables, cable trays, supports etc. as applicable and supplying, laying & termination of the new pipes, cables, trays, supports etc. and cables under the contractor’s scope of supply as per the requirement of these specifications.

(c) Any items though not specifically mentioned but which are required to make

the switchyard complete in all respects for its safe, efficient, reliable and







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trouble free operation shall also be deemed to be included and the same shall be supplied and erected by the Contractor, unless they are specifically excluded in the text of exclusions given in Clause-3.05.00 of this section.

(d) The schedule of the work shall be discussed and finalized with the site in

charge by the successful Bidder so as to carry out the work with the minimum shut down period.

(e) Contractor shall be responsible for design and engineering of overall system

/ station, and all elements, systems, sub-systems, facilities, equipments, material, etc.. The Contractor shall submit design calculations, drawings, codes, codes of practices, construction drawings, etc. for Owner’s approval.

(f) Contractor shall furnish design calculations and construction drawings for all

civil works showing details of pockets to be left in foundations and embedment to be provided in cable trenches.

(g) Contractor shall furnish the schematics, general arrangement drawings,

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

(h) Exposed live parts shall be placed high enough above ground to meet the

requirements of Indian Electricity Rules and other statutory codes. (i) All responsibilities regarding co-ordination with Electrical Inspection Agencies

and obtaining clearance certificate from them rests with the Contractor. (j) The terminal pads shall preferably be capable of taking the required

conductor span under normal, short circuit and meteorological conditions, without effecting the performance of the equipment.

(k) All equipment shall be suitable for hot line washing. (l) The Contractor shall cooperate in all respects and exchange the necessary

technical data / drawings with other agencies and Owner’s other Contractors under intimation to Owner to ensure proper coordination and completion of work in time.

3.02.01 Services and Items

The scope also includes but not limited to the following services/items described

herein and elsewhere in specification:

(a) System design and engineering (b) Supply of equipment and material (c) Civil works (d) Structural works (e) Erection works







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(f) Project management and site supervision (g) Testing and commissioning (h) Performance testing (i) Clearances from statutory authorities (j) Interface coordination

3.03.01 System Design and Engineering

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

(b) Contractor shall provide complete engineering data, drawings, reports,

manuals, etc. for Owner’s review, approval and records. (c) The scope shall also include the design and engineering as per details

elaborated elsewhere in this specification. 3.03.02 Supply of Equipment and Material

(a) The Contractor shall be responsible for design, engineering, manufacture, testing & inspection at manufacturer’s works, supply, transportation, insurance, delivery at site, unloading, storage, in plant transportation at site, complete erection & supervision, site testing & inspection, and successful commissioning of all the equipment and material listed at `Bill of Quantities’ to this Part-I of the specification,

(b) The quantities of equipment/materials indicated in `Bill of Material’ indicated

at Part-I are for the purpose of bidding only. The Contractor shall, however, supply and erect/construct as per the quantities finalized during/after detailed engineering/execution of works, and shall be paid accordingly. There shall be no lower/upper limit on the initially ordered quantities; however the percentage change in the contract price shall be limited to �20% during the execution of the contract for changes in quantities/scope variation. All consumables, wastages and damages shall be to the account of Contractor. The payments for miscellaneous items and civil works shall be regularized only after completion of works and joint verification of site in charge and contractor.

3.03.03 Civil Works

The scope of civil works shall include design, engineering & construction of all Civil, structural & architectural works including supply of all materials complete for 220 kV switchyard new control room building. (a) The nature of work shall generally include leveling / dressing, earthwork in

excavation and filling in all types of soils, dressing to the required profiles,







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de-watering till the structures are constructed / erected up to the required level or as directed by the Engineer, shoring, backfilling around the completed structure and plinth filling, disposal of surplus earth, concreting (including reinforcement and formwork), cable tray supports miscellaneous structural steel (i.e. cable tray supports, galvanized bolts etc), breaking of concrete / brick works/roads. R.C.C. trench & trench covers, gravel filling, pre-cast covers, drainage and connecting them to nearest disposal point drain, fencing, gates, pre-cast R.C.C. pipe / slab culverts at road crossing drains, soil sterilization /anti weed treatments, gravel filling, final grading and site clearance before handing over, painting and ancillary items of works etc., and any other work required for completion and proper functioning of the switchyard equipment.

(b) The scope of work described below is general in nature. The Bidder shall

provide all structures / facilities required for the effective functioning, whether or not they are specifically mentioned. Design, engineering, supply, fabrication, erection and construction for all the civil work required for completing the project work is in the scope of the bidder. The scope of Bidder for Civil, Structural & architectural works shall include but not limited to the following:

i) Detailed design criteria including basis of design shall be prepared by

the bidder based on various requirements specified elsewhere in the specifications. All the above documents shall be finalized after owner’s approval and the same shall form the basis of Detailed Engineering Work. The design and drawing shall be prepared by contractor and approved by the owner.

ii) Civil and structural work associated with switchyard NEW CONTROL

ROOM BUILDING as required. iii) Civil and structural work in switchyard shall include leveling/dressing,

RCC foundations, RCC equipment foundations, duct bank for cables, constructions of RCC cable trench with all embedded parts/inserts/lugs etc., burying of pipes/cables, construction of storm water drains and connection to nearby disposal point, cable duct /culverts at the crossing of cable trenches with roads/drains, site preparation, soil sterilization/anti weed treatment including gravel filling etc. and all associated civil works etc.

iv) Civil works for providing chain link fencing with gate around new

switchyard control room building as required and all associated works etc.

v) Any other facility / structure that would be required as per system

requirements, vi) All protection measures to prevent any damage to the adjoining

structures / facilities. vii) Geotechnical investigation report conducted by GSECL is enclosed

for reference.







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viii) The cement, reinforcement steel, structural steel and all embedment required for the work shall be arranged by the contractor.

3.03.05 Erection Works

(a) The contractor shall construct, erect and install all equipment and material of switchyard covered under the project. He shall be responsible for provision of all labor, tools and plant, and supervisory staff for safe, reliable, proper and correct erection of project components.

(b) The tools and plant shall include, but not limited to special hoisting

equipment, cranes, stringing equipment, slings, consumables and all other articles and supplies as required.

(c) The Contractor shall ensure periodic cleaning of work sites and removal of all

waste material, packing material, surplus earth and left-over and their proper disposal.

(d) As the work is to be carried out in the existing charged switchyard/units, the

contractor has to employ suitable manpower and supervision personnel. The contractor is solely and fully responsible for the safety of personnel and materials. Any damages to the existing equipments shall be made good by the contractor as directed by the engineer-in- charge at no extra cost to the Owner. The contractor shall coordinate with site personnel for arranging shut down for interconnections with the existing systems.

3.03.06 Project Management and Site Supervision

(a) The Contractor shall be responsible for the overall management and supervision of works. He shall provide experienced, skilled, knowledgeable and competent personnel for all phases of the project, so as to provide the Owner with a high quality system.

(b) The Contractor’s supervisory personnel shall provide operation and

maintenance assistance during the warranty period. (c) A project execution schedule called Master Network (MNW) in the form of

PERT chart/network and based on `Work break down structure’ shall be prepared by the Contractor for Owner’s approval. The MNW shall identify milestones of key events for each work/component in the areas of engineering, procurement, manufacture, dispatch, erection and commissioning. It shall also indicate interfaces and inputs required to be given by Owner.

3.03.07 Testing and Commissioning

(a) The scope includes testing and commissioning of all equipment, sub-systems and systems of the project and putting them into successful commercial operation. The scope shall include but not limited to the requirements given elsewhere in the specification.







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(b) The Contractor shall be responsible to provide all necessary testing and commissioning personnel, tools and plant, test equipment, etc.

3.03.08 Interface Coordination

(a) The contractor shall be responsible for collecting all the information/data of existing equipments/material/systems. The Owner shall only assist the contractor wherever possible to provide information/data.

(b) The Contractor shall identify all interface issues with Owner and other

agencies, and shall be responsible for such interfacing, coordination and exchange of all necessary information.

3.04.00 Terminal Points 3.04.01 The following are the project terminal points for the purposes of the scope of this

contract as indicated in the single line diagram:

(a) 220 kV switchyard Stage-II (b) 220 Volts DC and 415 Volts auxiliary power and control power supplies from

respective boards. (c) PLCC equipment

3.05.00 Exclusions

(a) The supply, erection and commissioning of PLCC equipment, HF cable and telemetry equipment are excluded from the scope of Contractor under this contract.

(b) Outdoor yard lighting. (c) DC system (Battery) (d) Switchyard equipment – 220 kV CB, CT, CVT, BPI and LA. (e) Switchyard Structural work. (f) 220 kV C&R panels of generator # 1 & 2 and station transformer bays.

3.06.00 Inputs by Owner

(a) Potable water at one point (free of cost) in plant area. The Employer shall provide the following feeders :

(b) 240V, single phase, 50 Hz feeder for meeting the unregulated AC power

supply requirement for illumination, heating, ventilation, and utility outlets, etc. at Employer”s MCC/switchgear/Lighting Board.

(c) Electrical Power Supply







PAGE 0 OF 30

The following power supplies shall be available at the plant. ----------------------------------------------------------------------------------------------------------------

Nominal Variation Frequency Phase Neutral Voltage in voltage (Hz) connection (Volt) --------------------------------------------------------------------------------------------------------------- 415V AC ± 10% 50 3 solidly earthed 240V AC ± 10% 50 1 solidly earthed 220V DC 190 to DC (Isolated - 240 2 wire system) --------------------------------------------------------------------------------------------------------------- Variation of frequency shall be +3% to -5% and combined variation of frequency and

voltage shall be ± 10%. Fault level for 415V AC power distribution system of the Employer shall be 45 KA.

3.07.00 Arrangement by the Contractor 3.07.01 Contractor shall make his own necessary arrangements for the following and for

those not listed anywhere else:

1 Construction power supply at all works areas. 2 Construction water. 3 Construction office and store (open & covered). 4 Construction workshop and material/field testing laboratory. 5 Boarding & lodging arrangement for their personnel. 6 Fire protection and security arrangements during construction stage.

4.00.00 SPARES 4.01.00 The Bidder shall include in his scope of supply all commissioning spares. List of

such spares along with the quantities shall be indicated in the bid. 4.02.00 All spares supplied under this contract shall be strictly interchangeable with the parts

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

4.03.00 Each spare part shall be clearly marked and labeled on the outside of the packing

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







PAGE 0 OF 30

4.04.00 Commissioning Spares 4.04.01 Commissioning spares are those spares which may be required during the start-up

and commissioning of the equipment/system. All spares used till the plant is handed over to the owner shall come under this category. The Contractor shall provide for an adequate stock of such start up and commissioning spares to be brought by him to the site for the plant erection and commissioning. They must be available at site before the equipments are energized. The unused spares, if any, should be removed from there only after the issue of Taking Over certificate. All start up spares which remain unused at the time shall remain the property of the Contractor.

4.04.02 No mandatory or recommended spares will be used during the commissioning of the

equipment/plant before take over by the Owner. 4.05.00 Mandatory Spares and Maintenance Equipment 4.05.01 The mandatory spares as listed at relevant annexure to this chapter are those

spares and maintenance equipments which are considered essential by the Owner. The Owner reserves the right to buy any or all of these spares. The Bidder shall furnish the itemized and total prices for these spares in the offer.

4.05.02 In compliance with the requirements of tender documents, the prices for mandatory

spares must be given separately, and shall be used for bid evaluation purposes. All mandatory spares shall be delivered at site.

4.06.00 Recommended Spares 4.06.01 In addition to the mandatory spares, the Contractor shall also provide a list of

recommended spares giving unit prices and total prices for 3 years of normal operation of equipment in the relevant schedule. This list shall take into consideration the specified mandatory spares and should be a separate list. The Owner reserves the right to buy any or all the recommended spares. The recommended spares parts shall be delivered at the site. The list of recommended spares to be furnished by the Bidder should also contain the following:

(a) Population of each item installed along with reference drawing number. (b) Service life expectancy of each item. (c) Offer validity period

4.06.02 Price of recommended spares will not be used for evaluation of bids. The prices of

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

4.07.00 Tools & Tackles

The Contractor shall also supply at site one set of all special tool & tackles, etc. which are required by the Owner’s maintenance staff to maintain the works







PAGE 0 OF 30

successfully at no extra cost. The list of such tools and tackles shall be enclosed with the offer.

5.00.00 TYPE TEST, ROUTINE AND ACCEPTANCE TESTS 5.01.00 All equipment with their terminal connectors, control cabinets, main protective relays,

etc. as well as insulators, insulator strings with hardware, clamps and connectors, marshalling boxes, etc., shall conform to type tests and shall be subjected to routine and acceptance tests in accordance with the requirements stipulated under respective equipment sections.

5.02.00 Contractor shall submit all type test reports/certificates according to the relevant

standards and/or specification for all the equipment/material for Owner’s review as a proof of their conformity to type tests along with a certificate regarding conformity of equipment to be supplied with the type test.

5.03.00 The test reports submitted shall be of the tests conducted within 5 years prior to the

date of bid opening. In case the test reports are of the tests conducted earlier than 5 years prior to the date of bid opening, or they do not meet the requirements of the specification/relevant standards, or they are not available, the Contractor shall conduct these type test(s) under this contract at no extra cost to the Owner.

5.04.00 The Owner will have the right of getting any test of reasonable nature carried out on

any component or completely assembled equipment at Contractor’s premises or at site or in any other place in addition to the aforesaid type and routine tests, to satisfy that the materials/equipment comply with the specification.

5.05.00 Failure of any equipment to meet the specified requirements of tests carried out at

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

6.00.00 REQUIREMENTS IN RESPECT OF SUPPLY ITEMS 6.01.00 All the major equipments to be supplied for the project shall meet the following

requirements: (I) PROTECTION RELAYS - The Protection Relays including energy metering

System offered should be from manufacturer(s) who have manufactured and supplied respective equipment (excluding the requirement of IEC 61850), which must have been in successful operation in a 120 MW or above unit / 220 kV class or above Substation/Switchyard for a minimum period of one (1) year as on the date of bid opening.

6.02.00 For other items of supply the Bidder shall supply equipment/accessories from the

manufacturer who has designed, manufactured, type tested and supplied similar items and these should have been in successful operation.

6.03.00 The Bidder must enclose the type test reports for the substation equipment and

accessories, main protective relays and tariff meters along with the offer.







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6.04.00 The Bidder shall clearly and unambiguously identify and name the proposed sub-Vendors for various equipment and enclose detailed documents for each proposed sub-vendor with the bid to establish that such sub-vendors meet the above stipulated requirements. Any vague statements like ‘make or equivalent’ shall not be accepted.

6.05.00 Any Bidder who fails to comply with the above clause 6.01.00 to 6.04.00 is liable to

be disqualified and his bid is liable to be rejected. 7.00.00 Bill of Quantities for main equipment shall be as per Annexure-I 8.00.00 Bill of Quantities mandatory spares shall be as per Annexure-II 9.00.00 List of tender drawings shall be as per Annexure-III







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ANNEXURE-I

BOQ FOR 220 KV MAIN EQUIPMENT, C&R PANELS AND OTHER ITEMS (Design, Engineering, Supply, Erection, Testing & Commissioning)

Sl. No.

DESCRIPTION QTY.

A 220 kV CONTROL & RELAY PANELS 1. Control Panels for : a) 220 kV Control and other associated panels etc. for the

following 220 kV bays 1. CHHATRAL Line # 1 2. CHHATRAL Line # 2 3. SOJA Line # 1 4. SOJA Line # 2 5. RANASAN Line # 1 6. RANASAN Line # 2 7. Bus coupler bay

1 set. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set.

2. Relay, Protection and metering Panels for: a) 220 kV Control, Relay, protection and metering equipment

panels including, other associated panels etc. for the following 220 bays 1. CHHATRAL Line # 1 2. CHHATRAL Line # 2 3. SOJA Line # 1 4. SOJA Line # 2 5. RANASAN Line # 1 6. RANASAN Line # 2 7. Bus coupler bay

1set. 1set. 1set. 1set. 1set. 1set. 1set.

3 Digital Fault & Disturbance Recording System 1 set.

4 Event logger panel 1 set

5 Time synchronizing Equipment 1 set

6 Dynamic Relay test kit 1 set

7 Metering and other panels 1 set







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8 415 AC power supply distribution boards for distributing unregulated power supply for bays control & isolators etc. The AC board shall have the following

� 2 (two) nos. 400 A SFUs as incomers

� 24 (twenty four) nos. 32 A SFUs as outgoings

� 250 A SFU bus coupler

� Set of voltmeters, ammeters and indicating lamps

1 set

9 415 AC power supply distribution boards for air conditioning

heating, ventilation and lighting etc. The AC board shall have the following

� 2 (two) nos. 250 A SFUs as incomers.

� 2 (two) 100 A SFUs as outgoings for Lighting transformers.

� 2 (two) nos. 50 KVA, 415/415 V. delta/star lighting transformers.

� 2 (two) 100 A SFUs for A/Cs.

� 100 A SFU bus coupler.

� Set of voltmeters, ammeters and indicating lamps.

10 The existing DC power supply source installed at main plant

shall be retained.and brought up to the DCDB to be installed in the new control room with required size of the cables. DCDB shall have the following

� 2 (two) nos. 250 A SFUs incomers.

� 24 (twenty four) nos. 16 A SFUs as outgoings.

� 1 no. (one) 250 A feeder to take power from battery (for future use).

� The DCDB shall have two buses A & B with bus coupler of 160 A SFU and equipped with voltmeter and under/over voltage relays.

1 set.

B 220 kV ISOLATORS Replacement of complete isolator on existing insulators, 40

KA / 3 sec. , HCB isolators including motorized operating boxes. 1. Isolators with E/S, 2000A, 220 kV.

6 nos.







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2. Isolators without E/S, 2000A, 220 kV. 3 Isolators without E/S, 2500A, 220 kV.

33 nos. 2 nos.

C ELECTRICAL MISCELLANEOUS ITEMS

1. ACSR Moose conductor 54/7/3.53 mm. Diameter - 7/3.53 mm. 8550 m.

2. 245 KV Double Tension string insulator (120 kN) assembly with

32 Nos. anti-fog type disc insulators per string with all hardware accessories including arcing horn and tension clamp for single moose ACSR conductor with one side turn buckle.

84 nos.

3. 245 KV Single Tension string insulator (120 kN) assembly with

16 Nos. anti-fog type disc insulators per string with all hardware accessories including arcing horn and tension clamp for single moose ACSR conductor with one side turn buckle.

129 nos.

4. 245 KV Single Suspension string insulator (120 kN) assembly

with 16 nos. anti-fog type disc insulators with all hardware accessories including arcing horn suitable for single moose ACSR conductor.

51 nos.

5. FCI /TYCO or Equivalent make power connectors (Boltless)

type Ampact fired C wedge connector for ACSR moose conductor 31.77 mm. outer diameter, Rated voltage 220 Kv, Rated normal current 1600 Amps. Short circuit rating 40 KA rms for 3 sec.,

550 nos.

6. Spacer clamps for twin ACSR moose conductor 230 nos.

7. Compressed type palm connector for ACSR moose conductor

31.77 mm. outer diameter Size of palm – 100X110X20 mm Size of sleeve length – 140 mm ID of sleeve – 33 mm. OD of sleeve – 52 mm. Grade of material – EC Aluminium Rated voltage 220 kv.

540 nos.







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8. G.I. pipes including bends for cabling (Medium class as per IS: 1239 (Part-I) & IS: 4736 (i) 50 mm nominal dia. (ii) 100 mm nominal dia.

125 m. 50 m.

9. Phase markers and identification for bays 24 nos.

10. Grounding/Earthing materials including supply, erection, civil

works, welding, laying, connection, all associated accessories like U-clamp, etc. a. Earth Electrodes (pipe type) b. 75 X 8 mm GI Flat for main earth grid including riser and

connection to the equipment and structure

44 nos.

100 m.

11. Galvanized cable trays & cable tray’s covers and galvanized supporting arrangement including clamps, hardware etc. c. 600 mm wide perforated type trays d. 450 mm wide perforated type trays e. 100 mm wide perforated type trays

500 m. 100 m. 50 m.

12. Supply of 1.1 kV grade Power and Control cables including

laying, supply of cable glands, cable lugs and termination, etc. (m)

12..1 LT Control Cables f. 5C x 2.5 mm2 CU PVC (Armoured) 3000 m. g. 7C x 2.5 mm2 CU PVC (Armoured) 3750 m. h. 10C x 2.5 mm2 CU PVC (Armoured) 14000 m. i. 14C x 2.5 mm2 CU PVC (Armoured) 7500 m. j. 19C x 2.5 mm2 CU PVC (Armoured) 8500 m. k. 4 C x 6 mm2 AL PVC (Armoured) 2250 m.

l. 7C x 4 mm2 CU PVC (Armoured) 3500 m. m. 12C x 4 mm2 CU PVC (Armoured) 3000 m.

n. 12C x 1.5 mm2 CU PVC (Armoured) 3000 m. o. 4C x 1.5 mm2 CU PVC (Armoured) 3000 m.

12.2 LT Power Cables

a. 1 C x 300 mm2 AL XLPE (Armoured) 800 m b. 1 C x 150 mm2 AL XLPE (Armoured) 800 m c. 2C x 120 mm2 AL PVC (Armoured) 400 m. d. 31/2 C x 70 mm2 AL PVC (Armoured) 500 m e. 31/2 C x 25mm2 AL PVC (Armoured) 1000 m







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f. 4C x 16 mm2 AL PVC (Armoured) 1250 m. g. 2C x 6 mm2 AL PVC (Armoured) 1250 m.

D SWITCHYARD CONTROL ROOM LIGHTING ITEMS 1 Twin 36 W mirror optics anti glare type fluorescent fixture

comprising CRCA sheet steel housing powder coated, high purity aluminium parabolic reflectors, etc. fitted with lamp, electronic ballast, etc. and with Anti glare louvers.

20 nos.

2 Twin 36 watts fluorescent fixture, totally enclosed, corrosion

proof, comprising fibre glass reinforced polyester Canopy, CRCA sheet steel gear tray finished stove enameled white, clear acrylic cover, stainless steel toggle clips & neoprene/ synthetic rubber gasket lining, fitted with lamp, electronic ballast, etc. complying to IP 52 class of protection.

25 nos.

3 Single 36 watts rail type, fluorescent fixture comprising CRCA

channel powder coated, CRCA cover plate powder coated, fitted with lamp, electronic ballast, etc.

20 nos.

4 100W incandescent industrial bulk head fixtures comprising die

cast aluminum body finished powder coated, heat resistant glass, neoprene/ synthetic gasket, MS powder coated wire guard, lamp, etc. complying to IP 54 class of protection.

5 nos.

5 100 W incandescent down light fixtures, electrochemically

brightened, anodised, high purity aluminium reflector comprising of lamp, galvanised mounting bracket, etc.

5 nos.

6 100 W incandescent well glass fixtures comprising die cast

housing finished powdercoated, heat resistant glass, MS powder coated wire guard, neoprene/ synthetic gasket, lamp, etc. complying to IP 65 class of protection.

6 nos.

7 Self contained emergency lighting fixture with 2x10W

Fluorescent lamp with nickel cadmium battery, charger etc. 4 nos.

8 LP-1 LIGHTING BOARD 2 Nos.

9 63 A receptacle 2 nos.

10 Junction box with one row of 16 nos. 63A terminals suitable to receive conductor upto 16 sq. mm.

2 nos.







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11 5/15 A combined receptacles 15 nos.

12 GI Conduits 5 km

13 Wires 1.5 sq. mm. 15 km.

14 1200 mm sweep fans 8 nos.

15 Exhaust Fans 4 nos.

16 GI wires 5000 m.

17 Other items for complete lighting of control room Note: 1 Dismantling of the existing equipments, conductors, panels, cables,

etc. are also included in the scope. 2 All the electrical miscellaneous items required for entire scope of work

described in scope including those required for completion of scope shall be in the contractor’s scope.

E BILL OF QUANTITY

Civil & Structural Works (Design, Engineering, Supply)

Sl. No.

DESCRIPTION Qty.

(1) (2) (3) 1 Civil, Structural and Architectural works associated with

220 kV Substation Control Room Building as per Tender drawings and Technical Specifications complete

1 lot

2 Anti weeding treatment of switchyard SQ MM 3 Construction of new cables trench with covers. About 60

metes length having size of 1.5 m (W) X 1.0 m (D) is required with galvanized cable trays of 300 mm wide in 3 rows on both side of the cables trech including supports for interconnection from existing trench to the new control room. Pre cast cables trench covers of suitable size shall be in the bidder’s scope.

1 lot

Note- (Design and Construction Drawings to be prepared by the Contractor and approved by Owner)







PAGE 0 OF 30

F

BILL OF QUANTITY AIR CONDITIONING SYSTEM FOR SWITCHYARD CONTROL ROOM

(Design, Engineering, Supply, Erection, Testing & Commissioning)

Sl. No

Item Capacity Quantity

1. Air cooled packaged type condensing unit, mainly comprising of reciprocating / scroll compressor with motor, condenser, evaporator, interconnected refrigerant piping, controls, instruments, base frame, etc.

25 TR

2 Nos.

2. Built-up double skin Air Handling units (AHU) complete with centrifugal fan, drive motor, pre-filters at inlet and fine filter at outlet, heater section, dampers and other accessories.

22,000 m3/hr

at 60 mmWC

2 Nos.

3. Fresh air fan assembly with drive motor along with pre filter and other accessories

2,000 m3/hr

at 15 mmWC

1 No.

4. Ductwork complete with 50 mm thick insulation, supports, grilles, diffusers and accessories

lot 1

5 Pan humidifier 1 No.

6. Solenoid operated Fire dampers of 1.5 hour rating

i) Area of dampers

ii) No. of solenoids

i) 1.8 sq. m.

ii) 2 nos.

G BILL OF QUANTITY

FIRE DETECTION AND PROTECTION SYSTEM (Design, Engineering, Supply, Erection, Testing & Commissioning)

1 Multi-sensor type (MSD) smoke detector 12 nos 2 Photoelectric type(PSD) smoke detector 12 nos. 3 Microprocessor based analog addressable fire panel 1 no. 4 Analog addressable Manual Pull station 1 no. 5 Analog addressable hooter with Strobe 1 no. 6 Cabling 1 Lot







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H RELOCATION WORKS

1 Relocation of busbar protection panels 5 set

2 Relocation of transducer panels 2 nos.

3 Relocation of ABT metering panels 3 nos.

4 Relocation of 15 meters existing fencing ans storm water drain (size- 30 m (L) X 0.5 m (W) X 1.0 m (D)

15 m.







PAGE 0 OF 30

ANNEXURE-II

BILL OF QUANTITY

FOR MANDATORY SPARES – ELECTRICAL ITEMS (Design, Engineering, Supply)

Sl. No.

DESCRIPTION Qty.

(1) (2) (3) I ISOLATORS

1 One complete pole of HCB isolator with 2 E/S alongwith

operating mechanism. 1 set.

2 Copper contact fingers for female contacts 10 nos. 3 Male contact assembly 10 nos. 4 Relay, power contactors, switch fuses for electrical control

circuit (one no. of each type and rating) 1 set

5 Rotary bearings for isolator 3 nos. 6 Limit switch & aux. switch 3 nos. 7 Terminal connectors 1 no. of each

type

II CONTROL & RELAY PANELS 1. Numerical Distance Protection Scheme for 220 KV Line

(one of each type) 1 Set

2 High speed trip relay 1 no. 3. Breaker failure protection relay (In case of standalone) 1 no. 4 Trip Circuit supervision scheme (In case of standalone) 1 5. Bus Bar trip relay 1 no. 6 Aux. Flag relay 2 no. III METERS AND RECORDERS 1 Voltmeter 3 nos. 2 Ammeter 3 nos. 3 MW meter 3 nos. 4 MVAR meter 3 nos.







PAGE 0 OF 30

5 Voltage transducer (suitable for “1” above)

1 no.

6. Current transducer (suitable for “2” above)

1 no.

7 MW transducer (suitable for “3” above)

1 no.

8. MVAR transducer (suitable for “4” above)

1 no.

9 Energy meter-(ABT type), class 0.2 1 no. IV OTHERS 1 Control Switches 2 sets 2 Semaphore indicators 2 sets 3 Push Buttons 2 sets 4 Lamps & Indicators 2 sets 5 Annunciation system 1 set

V AIR CONDITIONING SYSTEM

1 COMPRESSOR UNIT

a. Compressor shaft seal assembly

b. V-belt for compressor 1 Set

c. Set of ‘O’ ring and oil seal – each type 1 Set

d. Suction filter elements 1 Set

e. Bearings 2 sets

f. Gasket 1 Set

g. Complete set of suction valve 1 Set

h. Complete set of discharge valve 1 Set

2. CONDENSER FAN

a. V-belts for Fan 1 Set

b. Fan bearing 1 Set

c. Blower motor bearing 1 Set

3 AHU FAN

a. V-belts for AHU Blower 1 Set

b. AHU Blower bearing 1 Set

c. Blower motor bearing 1 Set







PAGE 0 OF 30

d. Filters at suction and discharge of all AHUs 25% of installed population

VI Mandatory Spares

Fire Detection and Protection System

(Design, Engineering, Supply)

I. Multi-sensor type (MSD) smoke detector 1 no.

II. Photoelectric type(PSD) smoke detector 1 no.

III. Fire Alarm Panel (Addressable)

1. Fuses 100% of population

2. Indicating lamps 100% of population

3. Push Button 5 nos. of each type and rating

4. Power supply modules 1 no. of each type & rating

5. All PCB assembly cards, loop cards including mother board, isolator cards etc. of each type

10% of population with min. one of each type, whichever is more.

6. LCD display of each type unit of panel

1 No.

7. Interface unit / modules for non-addressable devices, auxiliary / output relay modules, control modules, supervisory control modules.

10% of population with min. one of each type whichever is more.

8. i) LED’s of each type 100% of population.

ii) Power supervision relay 4 nos. of each type.







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ANNEXURE-III

A:- TENDER DRAWINGS

S. NO.

TITLE DRAWING NO.

1. KEY SINGLE LINE DIAGRAM 9259-230-UOE-A-001

2. SWITCHYARD CONTROL ROOM BUILDING (PROPOSED)

PLAN, ELEVATION, SECTION

9259-230-UOE-A-002







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Annexure-IV

TECHNICAL DETAILS FOR 220 KV CTs FOR 2X120 MW UNITS

GANDHINAGAR TPS

CTs HAVING RATIO 500-1000-1500/1 A

Core No

Application Current Ratio (A)

Output Burden (VA)

Accuracy Class as per IEC 185

Min. Knee Point Voltage (volts)

1 Metering 500/1 1000/1-1500/1

40 40 40

0.2S 0.2S 0.2S

- - -

2 Metering 500/1 1000/1-1500/1

40 40 40

0.2S 0.2S 0.2S

- - -

3 Backup Protection Transf. /Line

500/1 1000/1-1500/1

40 40 40

5P20 5P20 5P20

4 Transf. Diffl. / Line protection

500/1 1000/1-1500/1

- PS PS PS

200 400 600

5 Bus Differential main

500/1 1000/1-1500/1

- PS PS PS

200 400 600

CTs HAVING RATIO 100-200-1-1-1-1 A AND 1500/1 A : 3 NOS

Core No

Application Current Ratio (A)

Output Burden (VA)

Accuracy Class as per IEC 185

Min. Knee Point Voltage (volts)

1 Metering 100/1 200/1

40 40 40

0.2S 0.2S 0.2S

- - -

2 Metering 100/1 200/1

40 40 40

0.2S 0.2S 0.2S

- - -

3 Backup Protection Transf. /Line

100/1 200/1

40 40 40

5P20 5P20 5P20

4 Transf. Diffl. / Line protection

100/1 200/1

- PS PS PS

200 400 600

5 Bus Differential main

1500/1 - PS PS PS

200 400 600





PART – B


E-01 : CONTROL, RELAY AND PROTECTION

CLAUSE NO. TECHNICAL REQUIREMENTS





PART-B SECTION-I:E-01

CONTROL RELAY AND PROTECTION

PAGE 0 OF 23

CONTROL, RELAY AND PROTECTION

1.00.00 CODES AND STANDARDS

• IS:3231, IS:8686, IEC:60255, IEC:801, IS:9000, IEC:61000,

• IEEE/ANSI:037.901 (1989), ENV50140CLASSIII, ENV50204, IEC:60068

2.00.00 GENERAL REQUIREMENTS FOR PROTECTIONS

Relays/Energy meters shall be flush mounted on the front with connections at the rear Shall be draw-out or plug-in type/modular case with proper testing facilities. Provision shall be made for easy isolation of trip circuits for testing and maintenance.

3.00.00 OPERATIONAL REQUIREMENTS FOR NUMERICAL RELAYS AND AUXILIARY RELAYS

3.01.00 All protection relays to be used for EHV switchyard shall be Numerical type.

3.02.00 All the Distance protection , differential and multifunction over-current and earth fault protection relays offered shall support the Standard Open Protocol such as IEC 61850 protocol.

3.03.00 All numerical relays, auxiliary relays and devices shall be of reputed make & types proven for the application satisfying requirement covered elsewhere and shall be subject to Owner’s approval. Relays and timers shall have appropriate setting ranges, accuracy, resetting ratio, transient overreach and other characteristics to provide required sensitivity to the satisfaction of the Owner.

3.04.00 Numerical relays shall be suitable for efficient and reliable operation of the protection scheme. Necessary auxiliary relays, timers, trip relays, etc. required for complete scheme, interlocking, alarm, logging, etc. shall be provided. No control relay, which shall trip the circuit breaker when relay is de-energized, shall be employed in the circuits.

3.05.00 Relays shall be provided with self-reset contacts except for the trip lockout relays, which shall have manual reset facility.

3.06.00 Suitable measures shall be provided to ensure that transients present in CT & VT connections due to extraneous sources in EHV system do not cause damage to the numerical and other relays. CT saturation shall not cause mal-operation of numerical relays.

3.07.00 Only DC/DC converters shall be provided in the solid state devices / numerical relays wherever necessary to provide a stable auxiliary supply for relay operation. In case SMPS systems are provided. Bidder shall furnish all details to confirm that the noise-generated by SMPS systems shall not affect the relay functioning.

3.08.00 DC batteries in protective relays and timers necessary for relay operation shall not be acceptable. Equipment shall be protected against voltage spikes in auxiliary DC supply.








PAGE 0 OF 23

3.09.00 The numerical protection shall have continuous self-monitoring & cyclical test facilities. The internal clock of the system shall be synchronized through the GPS Time Synchronizing System to be supplied under this contract.

3.10.00 Each numerical relay shall have a serial interface on the front for local communication through PC & Printer. At least one more RS485 serial port, working on standard open protocol such as IEC61850, shall be provided for remote communication, data transfer etc.

3.11.00 Facilities shall be provided to access each discrete protection function including modification in the relay settings and monitoring of the relays through a local HMI (located on the front of the relay and comprises of LEDs , back lit LCD screen, keypads etc) and a Workstation located on the operators table. Necessary licensed software(latest version)[two copies] and hardware including PC(latest configuration), printer, cabling (fiber optic cable to be used if the distance is more than 100 meters) and furniture one set for SWYD CR, for the above purpose shall be in the scope of the bidder. A print out of all settings, scheme logic, event records etc. shall be accessible through Local HMI and the Workstation. Display of various measured parameters during normal as well as fault condition on segregated phase basis shall be provided. Local HMI shall also provide visual indication and display of messages related to major trips / alarms. Necessary multilevel password protection shall be provided.

3.12.00 The sampling rate of analog inputs, the processing speed and processing cycle of digital values shall be selected so as to achieve the operating times of various protection functions specified. In case Bidder does not have all the protections specified, as a part of the standard numerical relay, separate discreet numerical relays can be provided for such protection. The reasons for providing the same shall be clearly brought out in the bid.

3.13.00 The protection system shall be arranged to provide two independent, high performance and reliable systems with separate monitored DC supplies, separate CT/VT cores, separate cables and trip relays to obtain 100% redundancy. Associated trip relays of the two systems shall be separate, having sufficient number of contacts for all the functions. Each protection shall energize both trip coils of the circuit breakers to be tripped.

3.14.00 The numerical relays shall be provided with built-in disturbance recorder. The data from DR function shall be available in IEEE/COMTRADE format and compatible with the dynamic relay test system being supplied in this contract.

3.15.00 Complete C&R schemes shall be prepared / got reviewed by the main relay manufacturer. The main relay manufacturer shall carryout all commissioning activities including configuration of relays, testing & demonstration of relay functioning to the satisfaction of NTPC site engineers.

3.16.00 The numerical relays offered shall have self-diagnostic features to reduce the down time of the relay and provide useful diagnostic information on detection of an internal fault to speed up the maintenance. Necessary support documentation explaining the self-diagnostic features of the numerical relays in detail shall be furnished for owner’s use.








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3.17.00 The total critical fault clearance time from fault initiation in any part of the system shall be 80 m sec for phase to phase and phase to earth faults in the EHV system inter-connection.

3.18.00 Bidder shall include in his bid a list of installations wherever the relays/other devices of identical type designations are under successful operation at EHV systems 220 KV and above for at least one (1) year as on the date of bid opening.

4.00.00 PROTECTIONS AND METERING FOR EHV SYSTEM

4.01.00 The transmission line parameters shall be furnish by Owner during detailed design stage. Bus Switching Scheme: Main Bus – I and Main Bus – II for 220 kV system. Transmission system is effectively earthed.

4.01.01 The minimum fault current could be as low as 20% of the rated current. The characteristics shall be such as to provide satisfactory operation under such extremely varying conditions

4.02.00 Total critical fault clearing time including CB operating time from fault initiation in any part of the 220KV systems under all conditions shall not be more than 80 ms for faults within zone-I reach (i.e. up to 80% of line length) and 100 ms for end zone faults including carrier transmission time of 20ms.

4.03.00 The protection and control equipment and circuitry, shall be arranged to provide two independent, high performance and reliable protection systems with separate DC supplies, separate CT/VT cores and separate cables and self reset (single phase) hand reset (three phase) trip relays to obtain 100% reliability. The DC supplies to these protections shall be monitored.

4.04.00 Associated trip relays of the two systems shall be separate having sufficient number of contacts for all the functions.

4.05.00 Each protection system shall energize both trip coils of the circuit breaker.

4.06.00 The SIR values to be considered for operating time of relays shall be from 4 to 15. Rated break time for EHV breaker as offered shall be considered for the purpose of operating time. Bidder shall furnish the operating time curves at various SIR values for all types of faults.

4.07.00 EHV LINE PROTECTION

4.07.01 Each line of 220kV shall be provided with the following:

Main-I : Numerical Distance protection scheme suitable for carrier aided protection scheme.

Main-II : Numerical Distance protection scheme suitable for carrier aided protection scheme with a hardware platform different from that of Main – I Protection.








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4.07.02 Both Main-I and Main-II Numerical Distance protection schemes shall preferably be provided with following built in features.

i) Over voltage protection

ii) Open jumper protection

iii) Auto Re-closing with check synchronizing & dead line charging features.

iv) Fuse-failure protection

v) Power swing blocking protection.

vi) Disturbance recording function

4.08.00 NUMERICAL DISTANCE PROTECTION

4.08.01 Shall be modular in construction.

4.08.02 The reach of the relay for zones 1,2 & 3 should be able to cover line lengths associated with the project.

4.08.03 It shall have stepped time-distance characteristics and shall have at least two directional and one non-directional independently variable time graded distance protection zones. Additional protection zones required to achieve the complete functionality described in this specification shall be included.

4.08.04 Relay shall have two independent continuously variable time setting range of 0-3 seconds for zone-2 and 0-5 seconds for zone-3.

4.08.05 The relay shall have an adjustable characteristic angle setting range of at least 45 degrees to 85 degrees.

4.08.06 It shall have a full scheme design, i.e. shall have six measuring systems for each distance zone.

4.08.07 Tripping characteristics shall be polygonal and/or mho circle with and without offset and with independently adjustable reactive and resistive reaches separately for each zone. Tripping characteristics shall be user selectable.

4.08.08 It shall operate correctly for a close-up 3-phase fault and other adverse conditions. It shall operate instantaneously when circuit breaker is closed to a zero-volt, 3-phase fault.

4.08.09 It shall be suitable for single & three phase tripping.

4.08.10 Relay shall have a maximum resetting time of 60 milliseconds.

4.08.11 It shall have facilities for offset features with adjustable 10-20% of zone – 3 setting.

4.08.12 It shall have residual compensation variable from 30-150%.








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4.08.13 The setting/reach should not be affected by mutual coupling effect of D/C line or nearby parallel circuits.

4.08.14 It shall have a continuous current rating of two times rated current. The voltage circuit shall be capable to continuously withstand 1.2 times rated voltage. The relay shall also be capable of carrying a high short time current of 70 times the rated current without damage during a period of 1.0 sec

4.08.15 It shall Include Power Swing Blocking protection which shall:

i) Be of triple pole type.

ii) Block / unblock tripping during power swing conditions, separately for each zone.

iii) Have a continuously adjustable time delay on pick-up of setting range 0-2 seconds.

iv) Be in service during dead time of single pole re-closing cycle.

v) Have user configurable unblocking criteria in case of fault detection during a power swing.

4.08.16 It shall Include Fuse Failure protection, which shall

i) Monitor all the three fuses of C.V.T and associated cable against open circuit.

ii) Inhibit trip circuits on operation and initiate annunciation.

iii) Have an operating time less than 7.0 milliseconds.

iv) Remain inoperative for system earth faults.

4.08.17 It shall have user configurable scheme logics such as permissive under-reach (PUTT), Permissive over-reach (POTT), Direct Transfer Trip, Blocking scheme etc. using communication channels. The scheme shall be complete so that user can select any option at site without any modification. Non – carrier aided schemes such as Zone – 1 extension, loss of load etc shall be provided to ensure high speed clearance during channel failure.

4.08.18 It shall be able to distinguish between short circuit & heavy load condition.

4.08.19 It shall have features to ensure correct tripping during condition of weak end in feed & current reversal.

4.08.20 It shall have emergency back up Over Current and Earth Fault protection, which gets activated by fuse-failure protection.

4.08.21 It shall have built in Auto-Reclosing scheme, which shall:

i) Be provided for each main breaker of EHV lines.








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ii) Be of single shot type

iii) Have single phase and/or three phase reclosing facilities. It shall have user-selectable option of single phase, three phase, single & three phase reclosing or non-auto reclosure mode.

iv) Incorporate normal / delayed auto reclosure option with a time range of 2 -30 sec.

v) Have a continuously variable single phase and three-phase dead time of 0.1-2 sec.

vi) Have a continuously variable reclaim time of 5-25 sec.

vii) Have facilities for selecting check synchronizing or dead line charging features. User shall have an option to change the required feature.

In case the Auto-Reclose scheme is not an in-built feature of the numerical distance relay, the standalone relay provided shall meet all the requirements specified here.

How ever for tie breaker, stand alone autoreclose scheme shall be provided meeting the above requirements.

4.08.22 It shall have a built-in Open Jumper Protection function, which shall operate on detecting negative sequence current and provide alarm. Standalone open jumper protection based on this principle is also acceptable.

4.08.23 It shall have built-in Check Synchronizing Feature, which shall

i) have a phase angle setting not exceeding 35 degs.

ii) have a voltage difference setting not exceeding 10%.

iii) have a time setting continuously variable between 0.5-5 secs. with a facility of additional 10 secs.

iv) have a response time within 200ms with the timer disconnected.

4.08.24 It shall have built-in Dead Line Charging Feature, which shall have minimum and maximum voltage settings possible. Necessary auxiliary relays and timers shall be provided for a comprehensive scheme.

4.08.25 Over Voltage Protection Scheme

Have built-in over-voltage protection function. The over voltage function shall have adjustable voltage and time settings. It shall monitor all phases and be tuned to system frequency. Stand-alone over voltage protection relay having two independent over voltage and time stages is also acceptable.

4.08.26 It shall have multiple settings group feature. It shall be possible to switch the various available setting groups when the relay is in service.








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4.08.27 The numerical distance relays shall have built in disturbance recording function. The DR functions of both the distance relays shall be mutually triggerable.

4.08.28 The protection shall include the following additional functions:

• Weak-infeed tripping

• Echo function

• Current reversal guard

• Switch onto fault logic

4.08.29 It shall be suitable for Series compensated lines.

4.09.00 Digital Fault & Disturbance Recording System

A Digital Fault Recorder shall be provided for each 220kV line. The Digital Fault Recorder shall meet the following requirements:

a) Shall be used to record the graphic form of the instantaneous values of analog inputs such as voltages and currents in all the three phases, open delta voltage and neutral current in the primary circuits and digital inputs such as protection relays status and breaker auxiliary contacts, in the case of a short circuit (fault) and a disturbance in the Power System, as per the required technical parameters.

b) Shall be provided with a self-monitoring facility.

c) Fault / disturbance logs shall be clearly identified by Fault ID, Fault date and time (hour, minutes, seconds and ms). Time stampings on fault records shall be synchronized with a GPS clock.

d) The disturbance recorder shall comprise distributed individual acquisition units, one for each feeder and an evaluation unit which is common for the entire substation in the present scope. The acquisition units shall acquire the disturbance data for the pre-fault, fault and post-fault periods and transfer them to the evaluation unit automatically for storage on a mass storage device. The acquisition unit shall be suitable for inputs from current transformers with 1 A rated secondaries and capacitive voltage transformers with 63.5 V (phase-to-neutral voltage) rated secondaries.

e) Shall have Scan rate of 1000 Hz or better for sampling each of the analog channels having a fundamental frequency of 50 HZ. The frequency response for these channels shall be DC on the lower side to 500 HZ or better on the upper side. Any interposing devices provided with the DFR system shall not compromise this frequency response.

f) Shall be provided with sensors based on threshold values of voltage, current and frequency and rate of change of system frequency. The triggering sensors of the DFR shall pick-up and preserve the disturbance/fault data on the non-volatile solid state memory of the acquisition unit. The setting of the








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triggering sensors shall be flexible, and shall have reasonable range/steps. The settings of the triggering sensors shall be field programmable.

g) The fault data from the Digital Fault Recording feature shall be available in IEEE / COMTRADE format. The data format shall be compatible for dynamic protection relay testing with the relay test kit to be supplied by the Bidder. The necessary equipment for interfacing and transfer of data shall also be supplied by the Bidder.

h) All the fault records shall be transferred to the Protection / DR Workstation automatically or on request for further detailed analysis. The software for analyzing the fault data shall be available at the Protection / DR Workstation, which shall be provided by the bidder. The software shall be capable of the complete analysis of fault data, including the display of RMS/Peak envelop of any voltage / current, fundamental power frequency deviation, display of instantaneous values of Real Power (computed value), Reactive Power (computed value), power factor angle etc. A facility to edit the fault data shall also be provided.

i) Two copies of licensed software of the DFR system shall be provided.

j) Following analog values shall be recorded - Currents (R-phase, Y-phase, B-phase and Neutral), Voltages (VRY, VYB, VRB, Open Delta).

k) The pre-fault recording time shall be at least 200 ms and the post-fault recording time shall be at least 5.0secs.

l) The DR shall have:

- 8 nos Analog channels (IR,IY,IB,IN,VRY,VYB,VBR & Open Delta)

- 16 nos Digital Channels.

- Amplitude Resolution of Analog channels (minimum): 16 bit

- Event Resolution of Digital Channel (minimum): 1ms

m) The DFR system offered shall also have Distance-to-Fault Locator Function. This function shall be an on-line function and shall be suitable for circuit-breaker operating times of 2 cycles. The computed distance-to-fault shall be available as a percentage of line length or kilometers without requiring any further calculations. It shall have a provision for mutual zero sequence compensation. It shall have an accuracy of 3% or better for all types of faults and fault levels. This accuracy shall not be impaired under following conditions:

- Presence of remote end in-feed

- Predominant DC component in fault current

- High fault arc resistance








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- Severe CVT transients

- Mutual zero sequence coupling between adjacent lines.

The above Digital Fault recorder can be provided as a standalone unit or as in-built feature of numerical relays if it meets all the above requirements

4.10.00 EHV Circuit Breaker Protection

4.10.01 Each EHV circuit breaker shall be provided with following protections/functions:

a) Local breaker back-up protection (50Z)

b) Pole discrepancy protection

c) Trip circuit supervision for each trip coil.

d) DC supply monitoring

e) EHV disconnecting switch interlocking

f) Monitoring of various alarm/trip/lockout conditions of EHV breakers to be provided.

g) High speed trip relays as per scheme requirement.

h) For Bus Coupler bay, back-up over current and Earth Fault protection also to be provided.

4.10.02 Local Breaker Back-up Protection (50 LBB)

LBB protection function shall be provided for each circuit breaker in the 220 kV switchyard Relay shall:

a) Be triple pole type having three single phase units

b) Shall operate for stuck breaker conditions.

c) Have an operating/resetting time each of less than 15 ms.

d) The relay DC circuit shall be initiated by trip relay contacts and after set time delay shall energise the trip bus in bus bar protection scheme on which the stuck breaker is connected for tripping of all breakers connected to the particular bus.

e) Have a setting range of 5-80% of rated current.

f) Have a continuous thermal withstand of two times rated current irrespective of the setting.

g) Have a separate timer with a continuously adjustable setting range of 0.1-1 sec.








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h) Have necessary elements to make a individual phase comprehensive scheme.

i) Shall not operate during single phase auto-reclosing period

In case the LBB protection is provided as a built-in feature of numerical distance protection scheme, it shall meet the requirements specified above in this clause and shall be duplicated for 220kV circuit breakers

4.10.02 Trip circuit supervision relay

a) Shall be provided for each lock-out trip relay and EHV circuit breaker trip coils.

b) Shall monitor the healthiness of each phase trip coil and associated circuit of breaker during ‘on’ and ‘off’ conditions.

c) Shall have adequate contacts for providing connection to alarm .

d) Shall have time delay on drop-off of not less than 200 ms. and provided with operation indications for each phase.

Trip Circuit Supervision feature as a built in feature of Numerical Distance Protection is also acceptable, provided it meets the above specified requirements.

4.10.03 High Speed Trip Relay

The relay shall be:

a) With operating time of less than 10ms.

b) With reset time of less than 20ms.

c) Provided with operation indicator for each element/coil.

d) Have adequate contacts to meet the requirements of trip, interlock, LBB, auto-reclose, DR, fault locator, etc.

e) Hand reset or self reset, depending on the application

f) Interface with Existing Bus Bar protection

4.11.00 The bidder shall provide all interfacing requirements with the existing 220 kV bus bar protection scheme on ac/dc circuits including the supply of any hardware, separate high speed trip relays, CT Switching relays, etc for all the bays in bidder’s scope.

4.12.00 EVENT LOGGER (EL)

4.12.01 The EL shall be provided to cover the requirements of 220 kV bays under the scope of supply, and shall be used to record the state of 220 kV Switchyard equipments, relays & alarms. The equipments shall be designed with objectives of flexibility, reliability & simplicity for maintenance, repairs and suitability for hostile electrical environment.








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4.12.02 The EL shall meet the following requirements.

a) Record all changes of alarms and state (plant state) of switchyard equipment with alpha-numeric display of not less than 60 characters per event.

b) The date and time of all alarms and plant state changes of switchyard equipment to the nearest one ms.

c) Have facilities to commit 200 points of sequential memory or 100% of alarms, whichever is greater in rolling buffer mode.

d) Cope with upto 40 changes in any one 10 milli sec interval.

e) Cope with 500 alarms and changes of state of EHV switchyard equipment.

f) On receipt of an alarm the equipment must

i) Print out a message on the printer

ii) Set off an audible alarm and beacon.

g) Allow normal inputs of

i) Accept

ii) Alarm demand log.

iii) Plant state demand log.

iv) Date & Time.

h) Events occurring whilst a previous event is in process of the being printed are to be stored after time stamping to await printing. Over 100 such events must be stored.

i) Input point shall be field programmable through use of EEPROM.

j) The system shall have its own time generator, which will be synchronized with the time generator from time synchronization system to be supplied under the contract. The clock of time generator shall have a drift limited to +/- 0.5 sec per day when allowed to operate without synchronization from external source.

k) The complete system with all auxiliaries shall work from the switchyard DC supply only. Invertors shall be provided wherever necessary.

l) The system shall be fully type tested to the relevant international standards such as IEC: 60801 and 60255. One copy of the type test report shall be submitted alongwith the bid.

Bidder shall furnish a typical print out on the original paper in two copies for simulated conditions with his bid.








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4.13.00 TIME SYNCHRONIZATION EQUIPMENT

4.13.01 Shall be located in Switchyard Control Room. Shall receive Coordinated Universal Time (UTC) transmitted through Geo Positioning Satellite (GPS) for time synchronization of Line DRs, static energy meters, Numerical protections etc.

4.13.02 Shall be complete in all respects including antenna, all cables, processing equipment, etc.

4.13.03 All auxiliary systems and special cables required for synchronization of the various equipment shall be supplied and commissioned by the bidder.

4.13.04 Shall work from the plant UPS (240V AC) system or from DC supplies only and the Bidder to clarify if any built in battery back up is provided, in which case, same shall be of long life lithium batteries.

4.13.05 Shall be located in switchyard control room and as such shall be immune to hostile electrical environment. Suitable protections are to be provided against lightning surges and over voltages in power supply systems.

4.13.06 The synchronization shall have one millisec. accuracy. Shall give real time corresponding to IST (taking into consideration all factors like voltage, temperature variations, propagation and processing delays, etc.)

4.13.07 The system should be able to track the satellites to ensure no interruptions of synchronization signals.

4.13.08 The output signal from each port shall be programmable at site for either hour, half hour, minute or second pulse as per requirements. The equipment offered shall have minimum six (6) output ports. Various combination of output ports shall be from the following:

i) Voltage signal : 3 - 5 V continuously variable, with 50ms minimum pulse duration

ii) Potential free contact (minimum pulse duration of 50ms)

iii) IRIG B

iv) RS232C / RS 485

4.13.09 These output ports shall be compatible with the requirement of the equipment to be synchronized i.e. numerical relays & DFR.

4.13.10 The equipment should have a periodic time correction facility of one sec. periodicity. The equipment shall also have real time display in hour, minute, second (24 hour mode) and have a separate time display unit to be mounted on top of control panel, having display size of approx. 144mm height.

4.14.00 RELAY TEST KIT

4.14.01 Shall comprise the following:








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4.14.02 One dynamic portable relay test system based on type Multi-Amp. PULSAR Cat. 10 E3T3N or Omicron make type 256 or equivalent with 3 current and 3 voltage modules allowing dynamic and steady state testing capabilities. The DR recording of the line/generator in standard IEEE COMTRADE or EMTP simulations shall be compatible for transient testing of protections with this test system. Required software for steady state/dynamic testing of the protection relays, energy meters and transducers, alongwith a Lap top PC shall also be supplied.

4.14.03 Auxiliary items like phantom loads, etc. shall also be supplied as required for protection relay testing.

4.14.04 Test plugs for modular protections and two relay tool kits.

4.14.05 All commissioning tests on protection relays, energy meters and transducers shall be carried out with the relay test kit being supplied under this contract and the test reports shall be maintained as per agreed protocols.

4.15.00 CONTROL AND RELAY PANELS FOR EHV SWITCHYARD.

Control Panels shall be provided for EHV feeders and shall comprise of minimum of the equipments as listed below:

4.15.01 For each EHV Line

a) One Watt meter with transducer.

b) One VAR meter with transducer.

c) Three Ammeters with transducers.

d) One voltmeter with selector switch and transducer.

e) Control switches having red & green indication lamp for each EHV breaker and disconnecting switches and one synchronization switch

f) Semaphore indicators for all earth switches.

g) DC fail lamp

h) W & VAR transducers for tele-metering (Remote control room and ULDC)

i) Mimic

j) Synchronizing sockets and switches

k) Annunciation windows with test, accept and reset push buttons.

4.15.02 For Bus Coupler Bay

a) Control switches having red & green indication lamp for each EHV breaker and disconnecting switches & one synchronisation switch

b) Semaphore indicators for all earth switches








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c) DC fail lamp

d) Annunciation windows with test, accept and reset push button

e) Mimic

f) Synchronizing sockets and switches

4.15.03 Annunciation System

The annunciation system shall be either relay based or based on state of the art static system of proven design. The annunciation facia shall be at least of 35mm x 50mm size for each point. The system shall have accept, reset and test facilities for alarms in each control panel. Annunciation alarm shall be provided for failure of annunciation dc supply by means of separate AC supply. No of annunciation windows per control panel shall be decided during detailed engineering.

4.15.04 Energy Meters

a. One no. class 0.2 accuracy energy meter suitable for ABT requirement as specified in the specification on the 220 kV Line feeder on the position as indicated on the Protection Single Line Diagram.

b. A common evaluation unit/Work-Station along with Printer, networking hardware, optical fiber cables, furniture etc shall be supplied by the Bidder which shall have installed Protection System Software as detailed in clause 3.10.00, DR evaluation software as detailed in clause 4.09.00 and energy metering software as detailed in clause 4.19.00 of the specification. A lap-top shall also be supplied by the bidder, which shall contain all the above software and the interfacing hardware & software required for communicating with Protection System, DR and Energy meters.

4.16.00 CONSTRUCTIONAL FEATURES

4.16.01 Panels:

a) Shall be free standing, floor mounting type and completely metal enclosed. Cable entries shall be from bottom. Sheet steel of thickness not less than 3 mm for weight bearing members of the panels such as base frame, front sheet and door frames and 2.0 mm for sides, door, top and bottom portions. Cable entries shall be from bottom.

b) Shall have removable gland plates with glands made of brass and suitable for armoured cables

c) All sheet steel work shall be pretreated, in tanks, in accordance with IS : 6005. Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline hot water and dried. The phosphate coating shall be "Class-C " as specified in IS : 6005. The phosphated surfaces shall be rinsed and passivated prior to application of stoved lead oxide primer coating. After primer application, Electrostatic Powder Painting shall be used. Finishing paint shade for complete panels








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excluding end covers shall be RAL9002 & RAL5012 for extreme end covers of all boards, unless required otherwise by the Owner. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peelable compound by spraying method to protect the finished surfaces from scratches, grease, dirt and oil spots during testing, transportation, handling and erection.

d) The dimensions of control / relay panel shall be matching with the existing panels at site, details of which shall be furnished during the detailed engineering.

e) Shall be supplied complete with interconnecting wiring between all devices mounted therein.

f) All equipment mounted on front and rear side of the panels shall have individual name plates with equipment designation engraved. Each panel shall also have circuit/feeder designation name plate.

g) Each panel shall be provided with a 240V AC fluorescent lighting fixture controlled by door switch as well as a 5A, 240V AC switch-socket unit.

h) Shall be provided with necessary arrangements for receiving, distributing, isolating and fusing of AC & DC supplies for various circuits for control, signaling, lighting, interlocking, etc. Selection of main and sub-circuit fuse rating shall ensure selective clearance of the sub-circuit faults.

i) Voltage circuits for protection and metering shall be protected by fuses. Suitable fuse failure relays shall be provided to give an alarm for voltage circuits of protection/metering. Voltage selection scheme based on relays shall be provided for meters wherever possible.

j) The DC supplies at the individual relay and protection panels shall be monitored by suitable relays and failure of DC supplies shall be annunciated.

4.16.02 Earthing

a) The panels shall be equipped with an earth bus of at least 50x6 mm. galvanised steel flat or equivalent copper.

b) Earth buses of adjoining panels shall be connected for continuity. The continuous earthbus so formed shall be connected to main earth grid at both ends.

c) All metallic cases of the mounted equipment shall be connected to the earthbus by 2.5 sq.mm. copper wire.

d) One breach in such earthing shall not cause loss of earthing of any equipment. CT/VT neutral secondary shall only be earthed at the terminal block of the panel through links, such that earthing of one group may be removed without disturbing others.








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4.16.03 Wiring

a) Internal wiring to be connected to external equipment shall terminate on terminal blocks.

b) The terminal blocks for CTs and VTs shall be provided with test links and isolating facilities. The CT terminal blocks shall be provided with short circuiting and earthing facilities.

c) Shall have 20% terminals as spare terminals in each panel.

d) All equipment mounted on front and rear side of the panels shall have individual name-plates with equipment designation engraved. Each panel shall also have circuit/feeder designation name plate.

e) All wiring shall be with 660V grade, single core, PVC insulated stranded copper conductor.

f) Wires shall be vermin proof. Minimum size of conductor shall be 1.5 sq.mm. in general, but for CT & VT circuits it shall be 2.5 sq.mm. Minimum number of strands shall be three.

g) Bidder shall be solely responsible for completeness and correctness of all the wiring, and for proper functioning of the connected equipment.

4.16.04 Colour Mimic

Colour mimic diagram showing the exact representation of the system shall be provided in front of the control panel. Mimic colour shall be matching with that of the existing 220 kV /132 kV control panels and the details shall be furnished by the Owner during detailed engineering.

4.17.00 Auxiliary Equipments

a) All control and instrumentation switches shall be rotary operated type with escutcheon plate showing the operating position and circuit designation. All switches shall be flush mounted. Handles of different shapes shall be provided as approved by Owner. Control switches for breaker or disconnecting switch shall be of spring return to neutral type, while all other shall be stay-put type all the synchronising switches shall have a removable common handle, removable only in off-position. Lockable type switches shall be provided for same application as specified by the Owner. The contact combination and their operation shall ensure completeness of the scheme function and interlock requirements. Contact ratings of the switches shall be as per relevant standards. Contacts shall be spring assisted and contact faces shall be made pure silver.

b) Cluster type LED-indicating lamps shall be provided.

c) Position indicators for the earth switches of semaphore type shall be provided as specified in the mimic diagram. It shall be suitable for dc operation.








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4.18.00 Technical Requirements of Energy Meters for Tariff Requirement

a) Shall be microprocessor-based conforming to IEC: 687.

b) Shall carry out measurement of active energy (both import and export) and reactive energy (both import and export) by 3 phase, 4 wire principle suitable for balanced/ unbalanced 3 phase load.

c) Shall have an accuracy of energy measurement of at least Class 0.2 for active energy and at least Class 0.5 for reactive energy according to IEC 60687, and shall be connected to Class 0.2 CT cores and Class 0.2 VT windings.

d) The active and reactive energy shall be directly computed in CT & VT primary ratings. The active energy shall be stored for each metering interval in two different registers as MWh (Export) and MWh (Import), along with a plus (+) sign for export and minus (-) sign for import. The reactive energy shall be stored for each metering interval in four different registers as MVARh (lag) when active export, MVARh (Lag) when active import, MVARh (lead) when active export, MVARh (Lead) when active import. In addition, two more registers shall be provided to record MVARH when system voltage is >103% and when system voltage is < 97%.

e) Shall accumulate the net MWh and MVARh during each successive 15-minute block metering interval and store in the registers in non-volatile memory.

f) Shall continuously integrate the energy readings of each register up to the previous metering interval.

g) Each energy meter shall have a display unit. It shall display the net MWh and MVARh during the previous metering interval; peak MWh demand since the last demand reset; accumulated total MWh and MVARh; date and time; and instantaneous current and voltages on each phase.

h) All the registers shall be stored in a non-volatile memory. Meter registers for each metering interval, as well as accumulated totals, shall be downloadable.

i) At least last 40 days of data shall be stored before being over-written.

j) Shall have a built in clock and calendar with an accuracy of less than 15 seconds per month drift without assistance of external time synchronizing pulse.

k) Date/time shall be displayed on demand. The clock shall be synchronized by GPS time synchronization equipment being supplied by the bidder.

l) The voltage monitoring of all the three voltages shall be provided and alarm contacts provided to signal failures as well as to indicate meter healthy status. The meter shall normally operate with power drawn from the VT supplies. The burden of the meters shall be less than 2 VA.








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m) The power supply to the meter shall be healthy even with a single-phase VT supply. An automatic backup, in the event of non-availability of voltage in all the phases, shall be provided by a built in long life battery and shall not need replacement for at least 10 years with a continuous VT interruption of at least 2 years. Date and time of VT interruption and restoration shall be automatically stored in a non-volatile memory.

n) Shall have an optical port on the front of the meter for data collection from either a hand held meter reading instrument (MRI) having a display for energy readings (to be supplied by the bidder), or from a notebook computer with suitable software (to be supplied by the bidder). The MRI and/or notebook shall be complete with optical interface unit required.

o) The stored data shall be continuously transferred through necessary serial/parallel ports to a local IBM compatible PC to be supplied by the Bidder ( as detailed in clause 4.16.05 of the specification). Necessary hardware and software shall be provided for downloading data on the local PC for display and printing. The printer shall be supplied by the Bidder.

p) The software shall provide, on demand, the net energy (Active and Reactive) sent out of the station bus bars during a specified period.

q) The necessary software shall be provided to accept the data on line and store in memory and on a floppy diskette and also to print the same. The data format for printing shall be finalized during detailed engineering

r) The meter shall have means to test MWh and MVARh accuracy and calibration at site in-situ and test terminal blocks shall be provided for the same.

s) Two copies of licensed software of the metering system i.e MRI/notebook computer & PC software shall be supplied by the bidder.

4.19.00 INDICATING INSTRUMENTS

a) Shall conform to IS:1248

b) Shall be suitable for the instrument transformers as indicated in the drawings enclosed and shall be calibrated to read directly the primary quantities.

c) Shall be calibrated and adjusted at works and shall also be tested and calibrated at site before commissioning. All these instruments shall be flush mounted.

d) Shall be transducer operated, having 240 deg. scale and a dial of 96x96 mm, have an accuracy of 1.5 class and resolution of at least 50% of accuracy class

e) Current coils shall be 120% of rated current and 10 times for 0.5 sec. without loosing accuracy.








PAGE 0 OF 23

4.20.00 TRANSDUCERS

a) Shall conform to IEC: 688-1

b) The output of the transducers shall be 4-20mAdc as necessary for the instruments.

c) Accuracy class shall be 0.5 or better except for frequency transducer, which shall have an accuracy of 0.2.

d) Summation transducer shall be suitable for taking multiple inputs from individual MW/MVAR transducers.

e) Shall have dual output. One output shall be used for the indicating instrument/recorder provided and other shall be wired upto terminal block of the panel for Owner's use in future.

f) Energy transducers shall be suitable for 3 phase, 4 wire connection.

4.21.00 CONTROL CABLING PHILOSOPHY

a) Each secondary core of each phase CT/CVT shall be brought to the equipment marshalling box through independent cables.

b) Each three phase secondary core of CT/CVT shall be brought to the associated control/relay panel from the equipment marshalling box through independent cables.

c) Duplicated cores with at least 4 sq. mm. equivalent core cross-sectional area per connection shall be used for connection of all CT/CVT circuits.

d) VT leads used for tariff metering shall have an equivalent core cross-sectional area of at least 10 sq. mm. per phase/neutral connection.

e) Duplicate channels of protection shall have independent cables for tripping, DC supply, etc.

f) For the following applications multiple cores with at least 4 sq. mm. equivalent core cross - sectional area per connection shall be used.

1) DC supply to Bay Marshalling box

2) DC supply to circuit breaker cubicle

3) DC looping for closing and tripping circuits of circuit breaker

g) Bidder may use lesser cores with lesser cross- sectional areas, provided bidder fully justifies the selection by means of calculations of voltage drop.

h) Bidder shall justify the exact requirement of cores to be used by way of calculations with regards to voltage drop considerations.








PAGE 0 OF 23

i) Spare cores shall be provided as per following norms

• Up to 3 core cable Nil

• 5 Core Cable Min. 1 core

• 7 to 14 core cable Min. 2 cores

• More than 14 cores Min. 3 cores

5.00.00 TYPE TESTS FOR NUMERICAL RELAYS/ DEVICES

Type test report for the following tests for all the numerical relays, energy meter and other devices like E/L, DR, Time Synchronizing Equipment, etc covered in this chapter shall be submitted for owner’s approval as specified elsewhere in this specification.

Type Tests on Numerical Relays:

a. Insulation Tests:

Sl. No.

Description Standard

1. Dielectric Withstand Tests

IEC 60255-5

2kV rms for 1 minute between all case terminals connected together and the case earth.

2kV rms for 1 minute between all terminals of independent circuits with terminals on each independent circuit connected together.

ANSI/IEEE C37.90-1989

1kV rms for 1 minute across the open contacts of the watchdog relays.

1kV rms for 1 minute across open contacts of changeover output relays.

1.5kV rms for 1 minute across open contacts of normally open output relays.

2. High Voltage Impulse Test, class III

IEC 60255-5

5 kV peak; 1.2/50 μsec; 0.5 J; 3 positive and 3 negative shots at intervals of 5 sec








PAGE 0 OF 23

b. Electrical Environment Tests:

Sl. No.


1. DC Supply Interruption

IEC 60255-11

The unit will withstand a 20ms interruption in the auxiliary supply, in its quiescent state,

Without de-energizing.

2. AC Ripple on DC supply

IEC 60255-11

The unit will withstand a 12% ac ripple on the dc supply.

3. AC voltage dips and short Interruptions

IEC 61000-4-11

20ms interruptions/dips.

4. High Frequency Disturbance

IEC 60255–22–1, class III

At 1MHz, for 2s with 200 ohms source impedance:

2.5 kV peak; 1 MHz; T = 15 μsec; 220 shots/sec; duration 2 sec between independent circuits and independent circuits and case earth. 1.0kV peak across terminals of the same circuit.

5. Fast Transient Disturbance

IEC 60255-22-4, class IV

4kV, 2.5kHz applied directly to auxiliary supply

4kV, 2.5kHz applied to all inputs.

6. Surge Withstand Capability

IEEE/ANSI C37.90.1 (1989)

4kV fast transient and 2.5kV oscillatory applied directly across each output contact, optically isolated input and power supply circuit.

7. Radiated Immunity

C37.90.2: 1995

25MHz to 1000MHz, zero and 100% square wave modulated. Field strength of 35V/m.

8. Electrostatic Discharge

IEC 60255-22-2 Class 4 15kV discharge in air to user interface, display and exposed metal work.

IEC 60255-22-2 Class 3 8kV discharge in air to all communication ports. 6kV point contact discharge to any part of the front of the product.








PAGE 0 OF 23

Sl. No.


9. Surge Immunity

IEC 61000-4-5: 1995 Level 4

4kV peak, 1.2/50ms between all groups and case earth.

2kV peak, 1.2/50ms between terminals of each group.

10. Capacitor Discharge

No change of state or any operation shall occur when a capacitor of capacitance shown below, charged to 1,5 × Vn volts, is connected between any combination of terminals and any combination of terminals and ground.

Master trip circuits - 10 μF

Other protection & control circuits - 2 μF

Carrier/channel interface - 0,2 μF

c. EMC Tests:

1. Radio-Frequency Electromagnetic Field, Non-Modulated

IEC 60255–22–2, class III

10 V/m; 27 MHz to 500 MHz

2. Radio-Frequency Electromagnetic Field, Amplitude Modulated

ENV 50140, class III

10 V/m; 80 MHz to 1000 MHz; 80% AM;

1 kHz

3. Radio-Frequency Electromagnetic Field, Pulse Modulated

ENV 50140/ENV 50204

10 V/m; 900 MHz; repetition frequency 200 Hz; duty cycle 50 %

4. Disturbances Induced by Radio Frequency fields, Amplitude Modulated

ENV 50141, class III

5. Power Frequency Magnetic Field

EN 61000-4-8, class IV

30 A/m continuous; 300 A/m for 3 sec;

50 Hz

6. Interference Voltage, Aux. Voltage

EN 50081-*

150 kHz to 30 MHz

7. Interference Field Strength

EN 50081-*

30 MHz to 1000 MHz








PAGE 0 OF 23

d. Atmospheric Environment Tests:

1. Temperature

IEC 60255-6

Operating –25�C to +55�C

Storage and transit –25�C to +70�C

IEC 60068-2-1 for Cold

IEC 60068-2-2 for Dry heat

2. Humidity

IEC 60068-2-3

56 days at 93% RH and +40�C

e. Mechanical Stress Tests:

1. Vibration (during Operation and Transportation)

IEC 255-21-1; IEC 68-2-6

Response Class 2

Endurance Class 2

2. Shock (during Operation and Transportation)

IEC 255-21-2, class 1, IEC 68-2-27

Shock response Class 2

Shock withstand Class 1

Bump Class 1

3. Seismic Vibration (during Operation)

IEC 60255-21-3 Class 2

4. Continuous Shock (during Transportation)

IEC 255-21-2, class 1, IEC 68-2-27

f. Functional Tests:

All functions of the Numerical protection relays shall be tested for the functions as specified in NTPC technical specifications. In case of Numerical Distance Protection, dynamic tests shall be carried out and ascertain the operating time under different system/fault conditions.





PART – B


E-02 : ISOLATORS AND OPERATING BOXES






PART-B

SECTION-I:E-02 ISOLATORS

PAGE 0 OF 7

ISOLATORS

1.00.00 GENERAL

1.01.00 The isolators and accessories shall conform in general to IEC 62271-102 (or equivalent Indian Standard) except to the extent explicitly modified in specification.

1.02.00 Earth switches shall be provided on isolators wherever called for.

1.03.00 The isolators and earth switches shall be motor operated.

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

2.00.00 DUTY REQUIREMENTS

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

2.02.00 In addition to the constructional interlock, isolator and earth switches shall have provision to prevent their electrical and manual operation unless the associated and other interlocking conditions are met. All these interlocks shall be of fail safe type. Suitable individual interlocking coil arrangements shall be provided. The interlocking coil shall be suitable for continuous operation from DC supply and within a variation range as stipulated in relevant section. The interlock coil shall be provided with adequate contacts for facilitating permissive logic for ‘DC’ control scheme of the isolator as well as for AC circuit of the motor to prevent opening or closing of isolators when the interlocking coil is not energised.

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

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


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

3.02.00 The isolator shall be provided with a galvanised steel base provided with holes and designed for mounting on a lattice/pipe support structure. The base shall be rigid and self-supporting. The position of movable contact system (main blades) of each






PART-B


PAGE 0 OF 7

of the isolator and earthing switch shall be indicated by a mechanical indicator at the lower end of the vertical rod of shaft for the isolator and earthing switch. The indicator shall be of metal and shall be visible from operating level. Mechanical stoppers shall be provided for over travel of isolator and earth switch.

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

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

3.05.00 The insulator of the isolator shall conform to the requirements stipulated under Indian Standard Specification and shall have a min. cantilever strength of 500 kg. Pressure due to the contact shall not be transferred to the insulators after the main blades full close. The insulators shall be so arranged that leakage current will pass to earth and not between terminals of the same pole or between phases.

3.06.00 The terminal connectors shall confirm to requirements stipulated elswhere in the specification.

4.00.00 EARTHING SWITCHES

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

5.00.00 OPERATING MECHANISM AND CONTROL

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

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

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

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






PART-B


PAGE 0 OF 7

5.05.00 The isolator and earth switch shall be provided with mechanical stopper to avoid over travel.

6.00.00 OPERATION

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

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

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

7.00.00 TESTS

7.01.00 The isolator along with operating mechanism shall conform to the type tests and shall be subjected to routine tests and acceptance tests in accordance with IEC62271-102.

7.02.00 The insulator shall conform to all the type tests as per IEC 60168. In addition to all type, routine and acceptance tests, as per IEC-60168, the following additional routine/ acceptance tests shall also be carried out:

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

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

(c) Torsional test on sample insulator of a lot.

8.00.00 PARAMETERS

8.01.00 General

a) Type of isolator Outdoor type

b) Rated frequency 50 Hz

c) Number of poles Three (3)

d) Operating time Not more then 12 sec.

e) Control voltage 220V DC

f) Auxiliary contacts on Isolator

Total 8NO and 8NC contacts per isolator. The contacts shall have continuous rating of 10A and breaking capacity of 2A with circuit time constant of minimum 20 millisecond at 250V DC. Additionally MBB contacts as required shall also be provided.






PART-B


PAGE 0 OF 7

g) Auxiliary contacts on earth switch

Total 6NO and 6NC

h) Rated mechanical terminal load

As per IEC 62271-102

i) Temperature rise over ambient

As per IEC 62271-102

j) Rated ambient temperature 50 degree Celsius

k) System neutral earthing Effectively earthed

l) Seismic acceleration 0.3 g horizontal

m) Support structure height Adequate so that lowest part of support insulator of equipment is minimum 2550 mm from ground or plinth level

n) Rated mechanical terminal Load

As per IEC62271-102

o) Operating mechanism of Isolator and Earth Switch

A.C. Motor operated

p) Temperature rise As per table V of IEC 60694 for an ambient of 50 deg. C.

8.03.00 220 kV ISOLATORS:

a) Normal system voltage 220 kV

b) Highest system voltage 245 Kv

c) Rated current at 500 C ambient Temperature

As per BOQ

d) Rated short time withstand Current of isolator and earth switch

40 kA for 1 sec

e) Rated dynamic short circuit withstand Current of isolator and earth switch

80 kA (Peak)

f) Rated insulation levels:

(i) Rated one minute power frequency withstand voltage

(a) ±460kV(rms)- Between live terminals to earth

(b) ±460 kV (rms) - Across isolating distance






PART-B


PAGE 0 OF 7

(ii) Rated lightning impulse- withstand voltage

(a) ±1050 kVp - Between live terminals to earth

(b) +/-1050kV (peak) – impulse on one terminal and 240 kVp power freq. voltage of opposite polarity on other terminal (across isolating distance)

g) Max. Radio interference voltage

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






PART-B


PAGE 0 OF 7

OPERATING BOXES

FOR ISOLATORS / DISCONNECTING SWITCHES AND EARTH SWITCHES

1.00.00 GENERAL:

The operating mechanism boxes of the 220 kV isolators and earth switches are to be replaced with AC motor operated mechanism boxes. The modifications in the mounting arrangements including supply of angles/brackets etc. for mounting the boxes shall also be carried out by the Contractor.

2.00.00 OPERATIONAL REQUIREMENTS

Arrangement for adjustment of length of operating rods by means of screw thread and lockable with locknut shall be provided.

2.01.00 Local / remote selector switch along with open/close push buttons shall be provided in the box for operation. Provision shall also be made for disconnecting power supply.

2.01.01 Signaling of closed position shall not take place unless it is certain that the movable contacts have reached a position in which switch current ratings can be met. Signaling of open position shall not take place unless movable contacts have reached a position such that clearance between contacts is at least 80% of the isolating distance.

2.01.02 Each operating mechanism shall be provided with local manual operation facility with interlock to disconnect motors. For this purpose a handle shall be provided suitably mounted inside the box. The mechanism shall be located so that it is accessible to a man standing on ground.

2.01.03 Motors shall meet requirements as specified in the relevant chapters.

2.01.04 Suitable reduction gear of non-rusting forged material shall be provided between motor and switch drive shaft. The mechanism shall stop rapidly on switching off power supply to motor. If necessary, a quick electro-mechanical break shall be fitted on higher speed shaft for rapid breaking.

2.01.05 Main blades and earth-switches shall be provided with interlocking coils suitable for continuous operation to prevent their electrical and manual operation unless associated and other interlocking conditions are met. The interlocking coils shall be provided with adequate contacts to facilitate permissive logic for DC control scheme as well as motor supply circuit to prevent operation of switches when coil is not energised.

2.01.06 All the interlocks shall be fail safe type. Suitable interlocking coil arrangement shall be provided. The interlock coil shall be suitable for continuous operation for DC supply with adequate contacts to facilitate permissive logic for DC control scheme and AC scheme for motors.

2.01.07 The design of mechanism shall be such so as to prevent over-travel of contacts when operated manually or electrically. Mechanical stoppers for the same shall be provided. The operating rods/pipes shall preferably be provided with universal couplings to account for angular misalignment.






PART-B


PAGE 0 OF 7

2.01.08 Limit switches shall be mounted on operating shaft and shall be of cam type.

2.01.09 Position of blades for both disconnecting and earth switches shall be indicated by a mechanical indicator mounted on the operating shaft. This mechanical indicator should be visible from ground.

2.01.10 It shall be ensured that blade shall be locked in open/closed position in case operating shaft gets disconnected. Further, they shall not be dislodged from their open or closed positions by short circuit forces, gravity, wind pressure, vibrations, shocks or accidental touching of connecting rods.

2.01.11 Earth switches shall be only locally motor-operated. The plane of movement and final position of blades shall ensure adequate electrical clearance from adjacent live parts.

2.01.12 Each switch shall have flexible copper or aluminium braids for connection to earth terminal having specified short time current rating. Transfer of fault current through swivel connection will not be accepted.

2.01.13 Disconnecting switch design shall permit additional/location of earth switches on either side of the pole at site.

3.00.00 PARAMETERS

a. Type of Isolator HCB/Double break as existing.

b. No. of poles Three (3) individual pole/ three pole operated

c. Operating time Not more than 12 second

d. Auxiliary contacts As required plus

10NO and 10NC as spare for isolator.

6NO and 6 NC as spare for earth switch.

Additionally MBB contacts as required shall also be provided.

e. Degree of protection of box

IP-55





PART – B


E-03 : L.T. POWER CABLES






PART-B

SECTION-I:E-03 LT POWER CABLES

PAGE 0 OF 5

LT POWER CABLES

1.00.00 CODES & STANDARDS

1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes:

IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V.

IS : 3961 Recommended current ratings for cables

IS : 3975 Low carbon galvanised steel wires, formed wires and tapes for armouring of cables.

IS : 5831 PVC insulation and sheath of electrical cables.

IS:7098 (Part -I) Cross linked polyethylene insulated PVC sheathed cables for working voltages upto and including 1100V.

IS : 8130 Conductors for insulated electrical cables and flexible cords.

IS : 10418 Specification for drums for electric cables.

IS : 10810 Methods of tests for cables.

ASTM-D -2843 Standard test method for density of smoke from the burning or decomposition of plastics.

IEC-754 (Part-I)

Tests on gases evolved during combustion of electric cables.

IEC-332 Tests on electric cables under fire conditions. Part-3: Tests on bunched wires or cables (Category-B).

2.00.00 TECHNICAL REQUIREMENTS

2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground buried installation with chances of flooding by water.

2.02.00 Cables shall be flame retardant, low smoke (FRLS) type designed to withstand all mechanical, electrical and thermal stresses developed under steady state and transient operating conditions as specified elsewhere in this specification.

2.03.00 Aluminium conductor used in power cables shall have tensile strength of more than 100 N/ sq.mm. Conductors shall be stranded.






PART-B


PAGE 0 OF 5

2.04.00 XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg. C and short circuit conductor temperature of 250 deg C. PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and short circuit conductor temperature of 160 deg. C.

2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831.

2.06.00 For single core armoured cables, armouring shall be of aluminium wires/ formed wires. For multicore armoured cables, armouring shall be of galvanised steel as follows :

Calculated nominal dia. of cable under armour

Size and Type of armour

Upto 13 mm 1.4mm dia GS wire

Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia GS wire

Above 25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire

Above 40 & upto 55mm 1.4 mm thick GS formed wire /2.5mm dia GS wire

Above 55 & upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia GS wire

Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire

2.06.01 The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of aluminium armouring shall be same as indicated above for galvanized steel.

2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. 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 / formed wire. Zinc rich paint shall be applied on armour joint surface of G.S.wire/ formed wire.

2.07.00 Outer sheath shall be of PVC as per IS: 5831 & black in colour. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables shall have the following FRLS properties.

(a.) Oxygen index of min. 29 (as per IS 10810 Part-58).

(b.) Acid gas emission of max. 20% (as per IEC-754-I).

(c.) Smoke density rating shall not be more than 60 % (as per ASTMD-2843).






PART-B


PAGE 0 OF 5

2.08.00 Cores of the cables shall be identified by colouring of insulation. Following colour scheme shall be adopted:

1 core - Red, Black, Yellow or Blue

2 core - Red & Black

3 core - Red, Yellow & Blue

4 core - Red, Yellow, Blue and Black

2.09.00 For reduced neutral conductors, the core shall be black.

2.10.00 In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath.

(a.) Cable size and voltage grade - To be embossed

(b.) Word 'FRLS' at every 5 metre - To be embossed

(c.) Sequential marking of length of the cable in metres at every one metre -To be embossed / printed

The embossing shall be progressive, automatic, in line and marking shall be legible and indelible.

2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part-3.

2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum, over the declared value in the technical data sheets.

2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable.


(a.) 1.1 KV grade XLPE power cables shall have compacted aluminium conductor, XLPE insulated, PVC inner sheathed (as applicable), armoured/ unarmoured, FRLS PVC outer sheathed conforming to IS:7098. (Part-I).

(b.) 1.1KV grade PVC power cables shall have aluminium conductor (compacted type for sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed, armoured / unarmoured, FRLS PVC outer sheathed conforming to IS:1554 (Part-I).

4.00.00 CABLE DRUMS

(a) Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof cover. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to






PART-B


PAGE 0 OF 5

eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS: 10418.

(b) Each drum shall carry manufacturer's name, purchaser’s name, address and contract number, item number and type, size and length of cable and net gross weight stencilled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.

(c) The standard drum length for power cables shall not be less than 500 meters. The length per drum shall be subjected to a maximum tolerance of +/- 5% of the standard drum length. The Employer shall have the option of rejecting cable drum with shorter lengths. For each size, the variance of total quantity, adding all the supplied drum lengths, from the ordered quantity, shall not exceed +/- 2%.

5.00.00 TESTS

5.01.00 Type Tests

5.01.01 The reports for the following type tests shall be submitted for one size each of LT XLPE/PVC Power cables:

S.No. Type test Remarks

For Conductor

1. Resistance test

2. Tensile test For circular non-compacted conductors only

3. Wrapping test For circular non- compacted conductors only

For Armour Wires/ Formed Wires

4. Measurement of Dimensions

5. Tensile Test

6. Elongation test

7. Torsion test For round wires only

8. Wrapping test For aluminium wires / formed wires only.

9. Resistance test

10(a) Mass of zinc coating test For GS Formed wires/wires only

10(b) Uniformity of zinc coating For GS Formed wires /wires only






PART-B


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11. Adhesion test For GS Formed wires/wires only

For PVC/XLPE insulation & PVC Sheath

12. Test for thickness

13. Tensile strength & elongation tests before ageing and after ageing

14. Ageing in air oven

15. Loss of mass test For PVC insulation and sheath only

16. Hot deformation test For PVC insulation and sheath only

17. Heat shock test For PVC insulation and sheath only

18. Shrinkage test

19. Thermal stability test For PVC insulation and sheath only

20. Hot set test For XLPE insulation only

21. Water absorption test For XLPE insulation only

22. Oxygen index test For outer sheath only

23. Smoke density test For outer sheath only

24. Acid gas generation test For outer sheath only

For completed cables

25. Insulation resistance test

(Volume resistivity method)

26. High voltage test

27. Flammability test as per IEC-332 Part-3 (Category-B)

5.02.00 Indicative list of tests/checks, Routine and Acceptance tests shall be as per Quality Assurance & Inspection table of LT power cables enclosed with this chapter.





PART – B


E-04 : L.T. CONTROL CABLES






PART-B

SECTION-I:E-04 CONTROL CABLES

PAGE 0 OF 5

CONTROL CABLES


1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes:

IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V.

IS : 3961 Recommended current ratings for cables

IS : 3975 Low carbon galvanised steel wires, formed wires and tapes for armouring of cables.

IS : 5831 PVC insulation and sheath of electrical cables.

IS : 8130 Conductors for insulated electrical cables and flexible cords.

IS : 10418 Specification for drums for electric cables.

IS : 10810 Methods of tests for cables.

ASTM-D –2843 Standard test method for density of smoke from the burning or decomposition of plastics.

IEC-754 (Part-I)

Tests on gases evolved during combustion of electric cables.

IEC-332 Tests on electric cables under fire conditions. Part-3: Tests on bunched wires or cables (Category-B).

2.00.00 TECHNICAL REQUIREMENTS

2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground buried installation with chances of flooding by water.

2.02.00 Cables shall be flame retardant, low smoke (FRLS) type designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions as specified elsewhere in this specification.

2.03.00 Conductor of control cables shall be made of stranded, plain annealed copper.

2.04.00 PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and short circuit conductor temperature of 160 deg. C.






PART-B


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2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS: 5831.

2.06.00 For multicore armoured cables, the armouring shall be of galvanised steel as follows:

Calculated nominal dia of cable under armour

Size and Type of armour

Upto 13 mm 1.4mm dia GS wire

Above 13 upto 25 mm 0.8 mm thick GS formed wire / 1.6 mm dia GS wire

Above 25 upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire

Above 40 upto 55mm 1.4 mm thick GS formed wire/2.5mm dia GS wire

Above 55 upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia GS wire

Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire

The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. 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 / formed wire. Zinc rich paint shall be applied on armour joint surface.

2.07.00 Outer sheath shall be of PVC as per IS: 5831 and grey in colour. In addition to meeting all the requirements of Indian Standards referred to, outer sheath of all the cables shall have the following FRLS properties.

(a.) Oxygen index of min. 29. (As per IS 10810 Part-58)

(b.) Acid gas emission of max. 20% (As per IEC-754-I)

(c.) Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843.

2.08.00 Cores of the cables of upto 5 cores shall be identified by colouring of insulation. Following colour scheme shall be adopted.

1 core - Red, Black, Yellow or Blue

2 core - Red & Black

3 core - Red, Yellow & Blue

4 core - Red, Yellow, Blue and Black

5 core - Red, Yellow, Blue, Black and Grey






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2.09.00 For cables having more than 5 cores, core identification shall be done by numbering the insulation of cores 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 number shall be printed in Hindu-Arabic numerals on the outer surfaces of the cores. All the numbers shall be of the same colour, which shall contrast with the colour of insulation. The colour of insulation for all the cores shall be grey only. 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 the 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.

2.10.00 In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath:

(a.) Cable size and voltage grade - To be embossed

(b.) Word 'FRLS' at every 5 metre - To be embossed

(c.) Sequential marking of length of the cable in metres at every one metre - To be embossed / printed.

The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible.

2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC-332 Part-3.

2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum over the declared value in the technical data sheets.

2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable.


3.01.00 1.1 KV Grade Control Cables shall have stranded copper conductor and shall be multicore PVC insulated, PVC inner sheathed, armoured / unarmoured, FRLS PVC outer sheathed conforming to IS: 1554. (Part-I).

4.00.00 CABLE DRUMS

(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof cover. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS: 10418.






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(b.) Each drum shall carry manufacturer's name, purchaser’s name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both the sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.

(c.) The standard drum length for control cables shall not be less than 1000 metres. The length per drum shall be subjected to a maximum tolerance of +/- 5% of the standard drum length. The Employer shall have the option of rejecting cable drums with shorter lengths. For each size, the variance of total quantity, adding all the supplied drum lengths, from the ordered quantity, shall not exceed +/- 2%.

5.00.00 TESTS

5.01.00 TYPE TESTS

5.01.01 The reports for the following type tests shall be submitted for one size of control cables :

S. No. Type Test Remarks

For Conductor

1. Resistance test

For Armour Wires / Formed Wires (If applicable)

2. Measurement of Dimensions

3. Tensile Test

4. Elongation test

5. Torsion test For round wire only

6. Wrapping test For aluminium wires / formed wires only.

7. Resistance test

8(a). Mass of zinc Coating test For GS wires/formed wires only

8(b). Uniformity of zinc coating For GS wires/formed wires only

9. Adhesion test For GS wires/formed wires only

For PVC insulation & PVC Sheath

10. Test for thickness






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11. Tensile strength and elongation test

before ageing and after ageing

12. Ageing in air oven

13. Loss of mass test For PVC insulation and sheath only

14. Hot deformation test For PVC insulation and sheath only

15. Heat shock test For PVC insulation and sheath only

16. Shrinkage test

17. Thermal stability test For PVC insulation and sheath only

18. Oxygen index test For outer sheath only

19. Smoke density test For outer sheath only

20. Acid gas generation test For outer sheath only

For completed cables

21. Insulation resistance test (Volume resistivity method)

22. High voltage test

23. Flammability test as per IEC-332 Part-3 (Category-B)

5.02.00 Indicative list of tests/checks, Routine and Acceptance tests shall be as per Quality Assurance & Inspection table of Control Cables enclosed with this chapter.





PART – B


E-05 : SWITCHYARD AUXILIARY ITEMS






PART-B

SECTION-I:E-05 SWITCHYARD

AUXILIARY ITEMS

PAGE 0 OF 8

SWITCHYARD - AUXILIARY ITEMS

1.00.00 ACSR CONDUCTOR

1. Code and standard IS 398

2. Name MOOSE ACSR

3. Overall diameter 31.77 mm

4. Weight 2004 kg/km

5. Ultimate tensile strength 161.2 kN minimum

6. Strands and wire diameter of

- Aluminium - 54 / 3.53 mm and Steel - 7 / 3.53 mm

2.00.00 INSULATOR STRING HARDWARE

2.01.00 The insulator hardware shall be of bolted type and shall be of forged steel except for insulator cap, which can be of malleable cast iron. It shall also generally meet the requirements of clamps and connectors as specified above. In one span, Tension string assembly at one end shall be supplied with suitable turn buckle.

Disc Insulator

The disc insulator shall meet the following parameters:

a. Type : Antifog type insulator

b. Size of insulator : 255x145

c. Electro mechanical strength : 120kN

d. Leakage distance (mm) : 430mm minimum or as required to meet the total creepage.

e. Power frequency withstand : 85 kV (dry), 50kV (wet) voltage

SPACERS

Spacers shall conform to IS:10162. They shall be of non-magnetic material except nuts and bolts, which shall be of hot dip galvanised mild steel.

Spacers shall generally meet the requirements of clamps and connectors as specified above. Its design shall take care of fixing and removing during installation and maintenance.






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In addition to the type tests as per IS:10162, clamp slip test should have been conducted. In this test the sample shall be installed on test span of twin/quad bundle string at a tension of 44.2 kN (4500 kg). One of the clamps when subjected to a longitudinal pull of 2.5 kN (250 kg) parallel to the axis of conductor shall not slip, i.e. permanent displacement between conductor and clamp after the test shall not exceed 1.0 mm. This test should have been performed on all other clamps of the sample.

3.00.00 EARTHING CONDUCTOR

3.01.00 The main conductor buried in earth shall be 40mm dia rod for main and auxiliary mat. The earthing conductors over the ground shall be of 75x12 mm GS flat. The earthing leads for columns and auxiliary structures, cable trenches shall be of 75x12 mm GS flat. The earthing of the lighting fixtures shall be carried out by 16 SWG wire.

3.02.00 All conductors above the ground level shall be galvanised steel.

3.03.03 Earthwire for lightning protection

1. Number of strands 7 of steel

2. Strand diameter 3.66 mm

3. Overall diameter 10.98 mm

4. Weight 583 kg/km approx.

5. Ultimate tensile strength 68.4 kN minimum

6. Total cross-sectional area 73.65 sq.mm.

7. Calculated d.c. resistance 2.5 ohms/km at 20 deg.C.

8. Direction of lay of outer layer Right hand

9. Protective coating for storage Boiled linseed oil to avoid wet storage stains (white rust)

4.00.00 BUSHINGS, HOLLOW COLUMN INSULATORS, SUPPORT INSULATORS AND DISC INSULATORS

The bidder may offer to supply porcelain or fibreglass reinforced polymer based composite insulator with silicone shed profile. The Requirements for Porcelain Insulators are given in the subsequent clauses.

4.01.00 Bushings shall be manufactured and tested in accordance with IS:2099 & IEC:60137 while hollow column insulators shall be manufactured and tested in accordance with IEC 60233/IS 5284. The support insulators shall be manufactured and tested as per IS:2544 / IEC 60168/IEC 60273. The insulators shall also conform to IEC 815 as applicable. Support insulators/ bushings/ hollow column insulators shall be designed






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to have ample insulation, mechanical strength and rigidity for the conditions under which they will be used.

4.02.00 Porcelain used shall be homogenous, free from laminations, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. Hollow porcelain should be in one integral piece in green & fired stage.

4.03.00 Glazing of the porcelain shall be uniform brown in colour, free form blisters, burns and other similar defects.

4.04.00 When operating at normal rated voltage there shall be no electric discharge between conductor and insulators which would cause corrosion or injury to conductors or when operating at normal rated voltage.

4.05.00 The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall be lead to deterioration. All ferrous parts shall be hot dip galvanised.

4.06.00 Contractor shall make available data on all the essential features of design including the4method of assembly of shells and metal parts, number of shells per insulator, the manner in which mechanical stresses are transmitted through shells to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions.

4.07.00 Post type insulators shall consist of a porcelain part permanently secured in metal base to be mounted on supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand all shocks to which they may be subjected to during operation of the associated equipment.

4.08.00 Bushing porcelain shall be robust and capable of withstanding the internal pressures likely to occur in service. The design and location of clamps, the shape and the strength of the porcelain flange securing the bushing to the tank shall be such that there is no risk of fracture. All portions of the assembled porcelain enclosures and supports other than gaskets, which may in any way be exposed to the atmosphere shall be composed of completely non hygroscopic material such as metal or glazed porcelain.

4.09.00 All iron parts shall be hot dip galvanised and all joints shall be air tight. Surface of joints shall be trued, porcelain parts by grinding and metal parts by machining. Insulator/ bushing design shall be such as to ensure a uniform compressive pressure on the joints.

4.10.00 In accordance with the requirements stipulated elsewhere, bushings, hollow column insulators and support insulators shall conform to type tests and shall be subjected to routine tests and acceptance test/ sample test in accordance with relevant standards.






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4.11.00 The parameters of bushings/ Hollow column insulators/ support insulators are given in section E0. Insulator shall also meet requirement of IEC - 815 as applicable, having alternate long & short shed profile.

5.00.00 CABINETS, BOXES, KIOSKS, PANELS, ETC.

5.01.00 All types of control cabinets, junction boxes, marshaling boxes, lighting panels, terminal boxes, operating mechanism boxes, etc. shall generally conform to IS:5039, IS:8623 and IEC:439 as applicable.

5.02.00 They shall be of painted sheet steel or aluminium. The thickness of sheet steel shall be 2mm cold rolled or 2.5mm hot rolled. The thickness of aluminium shall be 3mm and shall provide rigidity. Top of the boxes shall be sloped towards rear of the box. The paint shall be of grey shade 697 of IS:5 on the outside and glossy white inside. However, the junction and switch boxes shall be of hot dip galvanised sheet steel of 1.6mm thickness.

5.03.00 The cabinets/boxes/kiosks/panels shall be free standing or wall mounting or pedestal mounting type. They shall have hinged doors with padlocking arrangement. All doors, removable covers and plates shall be gasketed all around with neoprene gaskets.

5.04.00 The degree of protection of of all the outdoor boxes shall not be less than IP 55 as per IS 2147.

5.05.00 The cable entry shall be from bottom, for which removable gasketed cable gland plates shall be provided.

5.06.00 Suitable 240V, single phase, 50Hz ac heaters with thermostats controlled by switch and fuse shall be provided to maintain inside temperature 10deg. above the ambient.

5.07.00 The size of enclosure and the layout of equipment inside shall provide generous clearances. Each cabinet/box/kiosk/panel shall be provided with a 15A, 240V ac, 2 pole, 3 pin industrial grade receptacle with switch. For incoming supply, MCB of suitable rating shall be provided. Illumination of each compartment shall be with door operated incandescent lamp. All control switches shall be of rotary switch type.

5.08.00 Each cabinet/box/kiosk/panel shall be provided with two earthing pads to receive 75mmx12mm GS flat. The connection shall be bolted type with two bolts per pad. The hinged door shall be connected to body using flexible wire. The cabinets/boxes/kiosks/panels shall also be provided with danger plate, and internal wiring diagram pasted on inside of the door. The front label shall be on a 3mm thick plastic plate with white letters engraved on black background.

5.09.00 Each bay of the switchyard shall be provided with a Bay Marshaling Box (BMB) located at a convenient location to receive and distribute cables within the bay. It shall receive two incoming three phase AC(63A) supplies controlled by MCBs with auto changeover provision and distribute five (5) three phase (16A) and ten (10)single phase ac (10A) supplies controlled by MCBs. BMB shall also be provided with 63 A, 3 phase 4 pin industrial grade receptacle with rotary switch. 120 number






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of terminal blocks shall be provided in separate compartment in BMB for interlocking facility.

6.00.00 BAY MARSHALLING BOX

6.01.00 Each bay of the switchyard shall be provided with a Bay Marshaling Box located at a convenient location to receive and distribute cables within the bay. It shall meet all the requirements as specified for cabinets/boxes above.

6.02.00 It shall have three separate distinct compartments for following purposes:

1. To receive two incoming 415V, three phase, AC supplies controlled by 100A four pole MCBs with auto changeover provision, and to distribute five (5) three phase ac supplies controlled by 32A four pole MCBs. It shall also be provided with 63A, 3 phase 4 pin industrial grade receptacle with rotary switch.

2. To receive three phase incoming from first compartment and to distribute ten (10) single phase ac supplies controlled by 16A two pole MCBs.

3. 120 nos. terminal blocks in vertical formation for interlocking facility.

7.00.00 TERMINAL BLOCKS

7.01.00 They shall be non-disconnecting stud type of extensible design equivalent to Elmex type CAT-M4.

7.02.00 The terminal blocks shall be of 650V grade, and rated to continuously carry maximum expected current. The conducting part shall be tinned or silver plated.

7.03.00 They shall be of moulded, non-inflammable thermosetting plastic. The material shall not deteriorate with varied conditions of temperature and humidity. The terminal blocks shall be fully enclosed with removable covers of transparent, non-deteriorating plastic material. Insulating barriers shall be provided between the terminal blocks so that the barriers do not hinder the wiring operation without removing the barriers.

7.04.00 The terminals shall be provided with marking tags for wiring identification. Unless otherwise required (expected current rating) or specified, terminal blocks shall be suitable for connecting the following conductors on each side:

• All CT & VT circuits - Min. four 2.5 sq. mm. copper flexible conductor

• AC & DC power supply Circuits - Two 16 sq. mm. aluminium conductor

• Other control circuits - Min. two 2.5 sq. mm. copper flexible conductor






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• The terminal blocks for CT and VT secondary leads shall be provided with test links and isolating facilities. CT secondary leads shall also be provided with short circuiting and earthing facilities.

8.00.00 WIRING

8.01.00 All wiring shall be carried out with 1100 V grade stranded copper wires. The minimum size of the stranded conductor used for internal wiring shall be as follows :

1. All circuits except CT circuits 2.5 sq.mm

2. CT circuits 4 sq. mm (minimum number of strands shall be 3 per conductor).

8.02.00 All internal wiring shall be securely supported, neatly arranged readily accessible and connected to equipment terminals and terminal blocks.

8.03.00 Wire terminations shall be made with solderless crimping type of tinned copper lugs which firmly grip the conductor and insulation. Insulated sleeves shall be provided at all the wire terminations. Engraved core identification plastic ferrules marked to correspond with the wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wires shall not fall off when the wires and shall not fall off when the wire is disconnected from terminal blocks.

8.04.00 All wires directly connected to trip circuit breaker shall be distinguished by the addition of a red coloured unlettered ferrule. Number 6 & 9 shall not be included for ferrules purposes.

8.05.00 All terminals including spare terminals of auxiliary equipment shall be wired upto terminal blocks. Each equipment shall have its own central control cabinet in which all contacts including spare contacts from all poles shall be wired out. Interpole cabling for all equipment’s shall be carried out by the Contractor.

9.00.00 CABLE GLANDS AND LUGS

9.01.00 Cable glands shall be Double compression type, tinned/Nicked plated (coating thickness not less than 20 microns in case of tin and 10 to 15 microns in case of nickel) brass cable glands for all power and control cables. They shall provide dust and weather proof terminations. They shall comprise of heavy duty brass casting, machine finished and tinned to avoid corrosion and oxidation. Rubber components used in cable glands shall be neoprene and off tested quality. Required number of packing glands to close unused openings in gland plates shall also be provided.

9.02.00 The cable glands shall be tested as per BS:6121. The cable glands shall also be duly tested for dust proof and weather proof termination.

9.03.00 Cables lugs shall be tinned copper solder less crimping type conforming to IS:8309 and 8394 suitable for aluminum or copper conductor (as applicable). The cable lugs shall suit the type of terminals provided. The cable lugs shall be of Dowell make or equivalent.






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10.00.00 CONDUITS, PIPES AND ACCESSORIES

10.01.00 The Contractor shall supply and install all rigid conduits, mild steel pipes, flexible conduits, hume pipes, etc. including all necessary sundry materials, such as tees, elbows, check nuts, bushing reduces, enlargers, wooden plugs, coupling caps, nipples, gland sealing fittings, pull boxes, etc.

10.02.00 Rigid conduits shall be flow-coat metal conduits of Nagarjuna Coated Tubes or equivalent make. The outer surface of the conduits shall be coated with hot-dip zinc and chromate conversion coatings. The inner surface shall have silicone epoxy ester coating for easy cable pulling. Mild steel pipes shall be hot-dip galvanised. All rigid conduits/ pipes shall be of a reputed make.

10.03.00 Flexible conduits shall be heat-resistant lead coated steel, water-leak, fire and rust proof, and be of PLICA make or equivalent.

11.00.00 MOTORS

11.01.00 Motors shall be “Squirrel Cage” three phase induction motors of sufficient size capable of satisfactory operation for the application and duty as required for the driven equipment and shall conform to type tests and shall be subjected to routine tests as per applicable standards.

11.02.00 Enclosures

1. For motors to be installed outdoor, the motor enclosure shall have degree of protection IP:55. For motors to be installed indoor, i.e. inside a box, the motor enclosure shall be dust proof equivalent to IP:44.

2. Two independent earthing points shall be provided on opposite sides of the motor for bolted connection of earthing conductor.

3. Motors shall have drain plugs so located that they will drain water resulting condensation or other causes from all pockets in the motor casing.

11.03.00 Operational Features :

1. Continuous motor ratings (name plate rating) shall be at least suitable for the driven equipment at design duty operating point of driven equipment that will arise in service.

2. Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously in the given system.

11.04.00 Starting Requirements

1. All induction motors shall be suitable for full voltage direct on-line starting. These shall be capable of starting and accelerating to the rated speed alongwith the driven equipment without exceeding the acceptable winding temperature even when the supply voltage drops.






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2. Motors shall be capable of withstanding the electrodynamic stresses and heating imposed if it is started at a voltage of 110% of the rated value.

3. The locked rotor current shall not exceed six(6) times the rated full load current for all motors subject to tolerance given in IS:325.

4. Motors when started with driven equipment imposing full staring torque and supply voltage conditions specified shall be capable of withstanding at least two successive starts from cold condition at room temperature and one start from hot condition without injurious heating of winding. The motors shall also be suitable for three equally spread starts per hour under the above referred supply condition.

5. The locked rotor withstand time under hot condition at 110% of rated voltage shall be more than starting time with the driven equipment of minimum permissible voltage by a least two seconds or 15% of the accelerating time whichever is greater. In case it is not possible to meet the above requirement, the Contractor shall offer centrifugal type speed switch mounted on the motor shaft which shall remain closed for speeds lower than 20% and open for speeds above 20% of the rated. The speed switch shall be capable of withstanding 120% of the rated speed in either directions of rotation.

11.05.00 The maximum permissible temperature rise over the ambient temperature shall be within the limits specified in IS:325 (for 3 phase induction motors) after adjustment due to increased ambient temperature specified.

11.06.00 The double amplitude of motor vibration shall be within the limits specified in IS:729. Vibration shall also be within the limits specified by the relevant standard for the driven equipment when measured at the motor bearings.

11.07.00 All the induction motors shall be capable of running at 80% of rated voltage for a period of 5 minutes.

12.00.00 AUXILIARY SWITCH

The auxiliary switch shall conform of following type tests:

1. Electrical endurance test - A minimum of 1000 operations for 2A. D.C. with a time constant greater than or equal to 20 milliseconds with a subsequent examination of mV drop/ visual defects/ temperature rise test.

2. Mechanical endurance test - A minimum of 5000 operations with a subsequent checking of contact pressure test/ visual examination

3. Heat run test on contacts

4. IR/HV test, etc.





PART – B


E-06 : LIGHTING







LIGHTING

PAGE 0 OF 3

LIGHTING

1.00.00 GENERAL 1.01.00 The lighting system and its accessories shall confirm in general to the relevant

standards except to the extent explicitly modified in the specification and shall be in accordance with the requirement specified under part-I.

1.02.00 Supply, storage and installation of various lighting fixtures complete with lamps and

accessories on the gantries and lightning masts. 1.03.00 Supply, storage and installation of lighting panels, including their cable terminations

from switchyard MCC/switchgear. 1.04.00 Supply, storage and installation of fixture supports, complete with all accessories

including junction boxes. 1.05.00 All the civil works like fixing of anchor bolts, erection of lighting panels etc. shall be

carried out by the contractor. Hardwares for fixing of fixtures etc. are also included in the erection component of the items.

1.06.000 Laying and termination of 415 V PVC armoured power cables of 2Cx6 mm2 Al. from

lighting panel to the junction box at the bottom of the gantry for the lighting fixture and looping from one gantry to the other shall be carried out by the contractor.

1.07.00 Laying and termination of 415 V PVC armoured power cables of 3 ½ Cx 35 mm2 Al.

from MCC to the marshalling box and looping from one box to the other shall be carried out by the contractor.

1.08.00 Power supply shall be fed from 415/240V normal ac power supply through suitable

number of conveniently located lighting panels (LPs). 1.09.00 Lighting panels, fixtures, masts, distribution boards, switchboxes, conduits, junction

boxes, etc. shall be properly installed and earthed as per relevant IE rules. 1.10.00 All outdoor fixtures shall be weather proof type (IP 55 as per IS 2147). Fluorescent

fixtures shall be provided with electronic ballasts. 1.11.00 All luminaires and their accessories and components shall be of the type readily

replaceable by the available Indian makes. All fixtures and accessories shall of reputed make and non-corrosive type. Acrylic covers/louvers shall be of non-yellowing type.

1.12.00 The constructional features of lighting distribution boards shall be similar to AC/DC

distribution boards described elsewhere. Outgoing circuits in LPs shall be provided with MCBs of adequate ratings.

1.13.00 Wiring shall be by multi-stranded PVC insulated colour coded wires laid in GI

conduits. Minimum size of the wire shall not be less than 1.5 sq.mm. copper or 4 sq.mm. aluminium. Wires shall conform to IS:694 and wiring installation shall be as per IS:732.







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1.14.00 Conduits shall be of heavy duty type, hot dip galvanised steel conforming to IS:9537. In corrosive areas, conduits shall have additional suitable epoxy coating.

1.15.00 All outdoor lighting systems shall be automatically controlled by synchronous timer

or photocell. Arrangement shall be provided in the panel to bypass the timer/photocell for manual control.

2.00.00 LIGHTING FIXTURES AND ACCESSORIES 2.01.00 General 2.01.01 All lighting fixtures and accessories shall be designed for continuos operation under

atmospheric conditions existing at site, without reduction in the life or without deterioration of materials and wiring etc.

2.01.02 Lighting fixtures shall be as given below or as specified in part – I. 1x400W weather proof miniature flood lighting with aluminium housing polished

inside and stove enameled grey outside suitable to Bajaj type BHEF 21-S or Crompton type FBD-14 or Philips type SVF -12.. All the fixtures shall be supplied with matching lamps.

2.02.00 Lighting fixtures 2.02.01 The lighting fixtures and accessories shall be designed to operate at 240V AC 50Hz

with supply voltage variation of ± 10%, frequency variation of ± 5%and combined voltage and frequency variation of ± 10%.

2.02.02 All fixtures shall be complete with accessories like ballasts, igniters, power factor

improvement capacitors etc. These shall be mounted inside the fixtures as far as possible. If these cannot be accommodated inside, then a separate metal enclosed weather proof box shall be included to accommodate these. The starting time of these lamps to attain full light output shall be minimum. Each fixture shall have terminals suitable for 2.5 sq.mm stranded flexible copper conductor.

2.02.03 The mounting facility and conduit knockouts for the fixtures shall be as required and

shall be suitable for cable/conduit entry. 2.02.04 On completion of the manufacture, all surfaces of the fixtures shall be thoroughly

cleaned and degreased. The fixtures shall be free from scale, rust, sharp edges and burns.

2.02.05 All enamel finishing shall have a minimum thickness of 2 mils for outside surface and

1.5 mils for inside surface. The finish shall be non porous and free from blemishes, blisters and fading.

2.02.06 The housing shall be stove enamelled or vitreous enamelled or anodised aluminium

as relevant for the type of fixtures. 2.03.00 Lamps 2.03.01 Sodium vapour lamps shall be color corrected type with screw caps.







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2.03.02 The contractor shall furnish typical wiring diagram for HPSV fitting including all accessories. The diagram shall include all technical details of accessories i.e. starters, chokes, capacitors and igniters etc.

3.00.00 LIGHTING PANELS 3.01.00 Each panel shall be provided with one incoming triple pole switch-fuse unit with

neutral link and outgoing MCB’s as specified. 3.02.00 The panel shall have degree of protection of IP55 as per IS 2147. The panel shall be

single front construction, front hinged and front connected, suitable for floor mounting.

3.03.00 The panel shall be provided with a circuit directory plate (of anodized aluminium with

the inscriptions indelibly etched on the plate) which is fitted on the inside of the door. 3.04.00 Each panel shall be provided with one no. ON indicating lamp for each phase. 3.05.00 The main busbars of the panel shall be of aluminium alloy with adequate cross

section to carry rated and short circuit currents. The maximum temperature of the busbars shall not exceed 85 degree C. The busbars shall be able to withstand a fault level of 20kA for 1 sec.

3.06.00 Switches shall be hand operated air break type, heavy duty confirming to IS 4064.

The fuses shall be of class 3 type (20kA prospective breaking current). 3.07.00 The MCB’s shall in general conform to IS 8828. The rating shall be well coordinated

with the corresponding circuits and shall be ‘Morarajee Dorman’ or ‘Standard’ make or its equivalent.

3.08.00 The contactors shall be of full voltage, direct on line air break, single throw,

electromagnetic type. They shall be provided with atleast 2 NO and 2 NC type auxiliary contacts.

3.09.00 The panels shall be provided with proper identification labels for the panel, incoming

and outgoing circuits etc. 4.00.00 ILLUMINATION LEVELS AND TYPE OF FIXTURES AND LUMINAIRES

Location Average Illumination Type of Fixture level (lux) Switchyard 20 (general) HPSV flood light, weather proof

50 (on strategic equipment) HPSV flood light, weather proof





PART – B


E-07 : CABLING AND EARTHING






PART-B

SECTION-I:E-07 CABLING AND

EARTHING

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CABLING AND EARTHING


1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards, etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards/ codes as applicable.

IS:513 Cold rolled low carbon steel sheets and strips.

IS:802 Code of practice for the use of Structural Steel in Overhead Transmission Line Towers.

IS:1079 Hot Rolled carbon steel sheet & strips

IS:1239 Mild steel tubes, tubulars and other wrought steel fIttings

IS:1255 Code of practice for installation and maintenance of power cables upto and including 33 KV rating

IS:1367 Part-13

Technical supply conditions for threaded Steel fasteners. (Hot dip galvanized coatings on threaded fasteners).

IS:2147 Degree of protection provided by enclosures for low voltage switchgear and control gear

IS:2309 Code of Practice for the protection of building and allied structures against lightning.

IS:2629 Recommended practice for hot dip galvanising of iron & steel

IS:2633 Method for testing uniformity of coating on zinc coated articles.

IS:3043 Code of practice for Earthing

IS:3063 Fasteners single coil rectangular section spring washers.

IS:6745 Methods for determination of mass of zinc coating on zinc coated iron & steel articles.

IS:8308 Compression type tubular inline connectors for aluminium conductors of insulated cables

IS:8309 Compression type tubular terminal ends for aluminium conductors of insulated cables.

IS:9537 Conduits for electrical installation.

IS:9595 Metal – arc welding of carbon and carbon manganese steels - recommendations.






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IS:13573 Joints and terminations for polymeric cables for working voltages from 6.6 kV upto and including 33 kV performance requirements and type tests.

BS:476 Fire tests on building materials and structures

IEEE:80 IEEE guide for safety in AC substation grounding

IEEE:142 Grounding of Industrial & commercial power systems

DIN 46267

(Part-II)

Non tension proof compression joints for Aluminium conductors.

DIN 46329

Cable lugs for compression connections, ring type ,for Aluminium conductors

VDE 0278

Tests on cable terminations and straight through joints

BS:6121 Specification for mechanical Cable glands for elastomers and plastic insulated cables.

Indian Electricity Act and Indian Electricity Rules.

1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, DIN, USA, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison.

2.00.00 EQUIPMENT DESCRIPTION

2.01.00 Cable trays, Fittings & Accessories

2.01.01 Cable trays shall be ladder/perforated type as specified complete with matching fittings (like brackets, elbows, bends, reducers, tees, crosses, etc.) accessories (like side coupler plates, etc. and hardware (like bolts, nuts, washers, G.I. strap, hook etc.) as required. Cable tray shall be ladder type for power & control cables and perforated for instrumentation cables.

2.01.02 Cable trays, fittings and accessories shall be fabricated out of rolled mild steel sheets free from flaws such as laminations, rolling marks, pitting etc. These (including hardware) shall be hot dip galvanized as per relevant IS.

2.01.03 Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard lengths of 2.5 metre. Minimum thickness of mild steel sheets used for fabrication of






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cable trays and fittings shall be 2 mm. The thickness of side coupler plates shall be minimum 3 mm and of tray cover shall be minimum 1.6 mm.

2.01.04 Cable troughs shall be required for branching out few cables from main cable route. These shall be U-shaped, fabricated of mild steel sheets of minimum thickness 2 mm and shall be hot dip galvanised as per relevant IS. Troughs shall be standard width of 50 mm & 75 mm with depth of 25 mm

2.02.00 SUPPORT SYSTEM FOR CABLE TRAYS

2.02.01 Cable tray, racks, their supports shall be pre-fabricated out of sheet steel and fully galvanized having rigidity to withstand the maximum possible loads including those applied during cable installation.

2.03.00 Pipes, Fittings & Accessories

2.03.01 Pipes offered shall be complete with fittings and accessories (like tees, elbows, bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.) The size of the pipe shall be selected on the basis of maximum 40% fill criteria

2.03.02 GI Pipes shall be of medium duty as per IS:1239

2.03.03 Duct banks shall be High Density PE pipes encased in PCC (10% spare of each size, subject to minimum one) with suitable water-proof manholes.

2.04.00 Junction Boxes

2.04.01 Junction Boxes with IP:55 degree of protection, shall comprise of a case with hinged door constructed from cold rolled sheet steel of minimum thickness 2mm. Top of the boxes shall be arranged to slope towards rear of the box. Gland plate shall be 3mm thick sheet steel with neoprene/synthetic rubber gaskets. All junction boxes shall be of adequate strength and rigidity, hot dip galvanised as per relevant IS, and suitable for mounting on wall, columns, structures etc. The boxes shall include brackets, bolts, nuts, screws M8 earthing stud etc. required for installation

2.04.02 Terminal blocks shall be 650 volts grade, rated for 10 Amps and in one piece moulding. It shall be complete with insulating barriers, Klip-on-type terminals and identification strips. Marking on terminal strip shall correspond to the terminal numbering on wiring diagrams. It shall be Elmex type CSLT-1 with insulating material of Melamine conforming to ESI Standard 12.1 or equivalent. Terminal block shall be suitable for terminating 2 wires of 2.5 sq mm. on both sides arranged to facilitate easy termination

2.05.00 Cable glands

2.05.01 Cable shall be terminated using double compression type cable glands. Cable glands shall conform to BS:6121 and be of robust construction capable of clamping cable and cable armour (for armoured cables) firmly without injury to insulation. Cable glands shall be made of heavy duty brass machine finished and nickel chrome plated. Thickness of plating shall not be less than 10 micron. All washers and hardware shall also be made of brass with nickel chrome plating Rubber components shall be of neoprene and of tested quality.






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2.06.00 Cable lugs/ferrules

2.06.01 Cable lugs for power cables shall be Aluminium solderless crimping type conforming to IS:8309 suitable for aluminium compacted conductor cables. Cable lugs and ferrules for control cables shall be tinned copper conforming to IS:8309 . The cable lugs for control cables shall be provided with insulating sleeve and shall suit the type of terminals provided on the equipments.

2.07.00 Trefoil clamps

2.07.01 Trefoil clamps for single core cables shall be pressure die cast aluminum or fibre glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts, washers, etc. Trefoil clamps shall have adequate mechanical strength to withstand the forces generated by the system short circuit current of 105 KA peak.

2.08.00 Cable Clamps & Straps

2.08.01 The cable clamps required to clamp multicore cables on vertical run shall be made up of Aluminium strip of 25x3 mm size. For clamping the multicore cables, self-locking, de-interlocking type nylon clamps/straps shall be used. The clamps/straps shall have sufficient strength and shall not get affected by direct exposure to sun rays and outdoor environment.

2.09.00 Galvanising

2.09.01 Galvanising of steel components and accessories shall conform to IS:2629 & IS:2633. Additionally galvanising shall be uniform, clean smooth, continuous and free from acid spots

2.09.02 The amount of zinc deposit over threaded portion of bolts, nuts, screws and washers shall be as per IS:1367 . The removal of extra zinc on threaded portion of components shall be carefully done to ensure that the threads shall have the required zinc coating on them as specified

2.10.00 Welding

2.10.01 The welding shall be carried out in accordance with IS:9595. All welding procedures and welders qualification shall also be followed strictly in line with IS:9595

3.00.00 INSTALLATION

3.01.00 Cable tray and Support System Installation

3.01.01 Cables shall run in cable trays mounted horizontally or vertically on cable tray support system which in turn shall be supported from floor, ceiling, overhead structures, trestles, pipe racks, trenches or other building structures. All cable trays shall be in vertical configuration in boiler & ESP areas.

3.01.02 Horizontally running cable trays shall be clamped by bolting to cantilever arms and vertically running cable trays shall be bolted to main support channel by suitable bracket/clamps on both top and bottom side rails at an interval of 2000 mm. For vertical cable risers/shafts cable trays shall be supported at an interval of 1000mm.






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Fixing of cable trays to cantilever arms or main support channel by welding shall not be accepted.

3.01.03 The cantilever arms shall be positioned on the main support channel with a minimum vertical spacing of 300 mm unless otherwise indicated in the relevant tray layout drawings

3.01.04 All cable way sections shall have identification, designations as per cable way layout drawings and painted/stenciled at each end of cable way and where there is a branch connection to another cable way. Minimum height of letter shall be not less than 75 mm. For long lengths of trays, the identification shall be painted at every 10 meter. Risers shall additionally be painted / stenciled with identification numbers at every floor.

3.01.05 In certain cases it may be necessary to site fabricate portions of trays, supports and other non standard bends where the normal prefabricated trays, supports and accessories may not be suitable. In such cases the Contractor shall fabricate at site suitable sections of trays, supports and accessories to make the installation complete for the specific purpose after obtaining Project Manager's prior approval, which shall be neat in appearance and shall match with the prefabricated sections in the dimensions. They shall be applied with one coat of red lead primer, one coat of oil primer followed by two finishing coats of aluminium paint.

3.02.00 Conduits/Pipes/Ducts Installation

3.02.01 The Contractor shall be fully responsible for properly embedding conduit pipe sleeves wherever necessary for cabling work. All openings in the floor/roof/wall / cable tunnel/cable trenches made for conduit installation shall be sealed and made water proof by the Contractor.

3.02.02 GI pull wire of adequate size shall be laid in all conduits before installation. Metallic conduit runs at termination shall have two lock nuts wherever required for junction boxes etc.

3.02.03 Conduit runs/sleeves shall be provided with PVC bushings having round edge at each end. All conduits/pipes shall have their ends closed by caps until cables are pulled. After cables are pulled, the ends of coundits/pipes shall be sealed with Glasswool/Cement Mortar/Putty to prevent entrance of moisture and foreign material

3.02.04 Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or by other approved means. Conduits /pipe support shall be installed square and true to line and grade with an average spacing between the supports as given below, unless specified otherwise

Conduit /pipe size (dia). Spacing

Upto 40 mm 1 M

50 mm 2.0 M

65-85 mm 2.5 M

100 mm 3.0 M






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3.02.05 For bending of conduits, bending machine shall be arranged at site by the contractor to facilitate cold bending. The bends formed shall be smooth.

3.03.00 Junction Boxes Installation

3.03.01 Junction boxes shall be mounted at a height of 1200mm above floor level or as specified in the drawings or as decided by Project Manager and shall be adequately supported/mounted on masonry wall by means of anchor fasteners/ expandable bolts or shall be mounted on an angle, plate or other structural supports fixed to floor, wall, ceiling or equipment foundations.

3.04.00 Cable Installation

3.04.01 Cable installation shall be carried out as per IS:1255 and other applicable standards. Cable drums shall be unloaded, handled and stored in an approved manner on hard and well drained surface so that they may not sink. In no case shall be drum be stored flat i.e. with flange horizontal. Rolling of drums shall be avoided as far as possible. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In absence of any indication, the drums may be rolled in the same direction as it was rolled during taking up the cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on cable wheels and shall be rolled slowly so that cable comes out over the drum and not from below. All possible care shall be taken during unreeling and laying to avoid damage due to twist, kink or sharp bends. Cable ends shall be provided with sealed plastic caps to prevent damage and ingress of moisture.

3.04.02 While laying cable, ground rollers shall be used at every 2 metre interval to avoid cable touching ground. The cables shall be pushed over the rollers by a gang of people positioned in between the rollers. Cables shall not be pulled from the end without having intermediate pushing arrangements. Pulling tension shall not exceed the values recommended by cable manufacturer. Selection of cable drums for each run shall be so planned so as to avoid using straight through joints. Care should be taken while laying the cables so as to avoid damage to cables. If any particular cable is damaged, the same shall be repaired or changed to the satisfaction of Project Manager.

3.04.03 Cables shall be laid on cable trays strictly in line with cable schedule furnished. Where specific cable layouts are not shown on drawings, Contractor shall route these as directed by the Project Manager

3.04.04 Power and control cables shall be laid on spearate tiers. The laying of different voltage grade cables shall be on different tiers according to the voltage grade of the cables. In horizontal tray stacks, H.T. cables shall be laid on topmost tier and cables of subsequent lower voltage grades on lower tiers of trays. Single core cable in trefoil formation shall be laid with a distance of four times the diameter of cable between trefoil center lines and clamped at every two metre. All multicore cables shall be laid in touching formation. Power and control cables shall be secured fixed to trays/support with self locking type nylon cable straps with de-interlocking facilities. For horizontal trays arrangements, multicore power cables and control cables shall be secured at every five meter interval. For vertical tray arrangement, individual multicore power cables and control cables shall be secured at every one






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meter by nylon cable strap. After completion of cable laying work in the particular vertical tray, all the control cables shall be binded to trays/supports by aluminium strips at every five meter interval and at every bend.

3.04.05 Bending radii for cables shall be as per manufacturer’s recommendations and IS:1255.

3.04.06 Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/PVC pipe.

3.04.07 Joints for less than 250 Meters run of cable shall not be permitted.

3.04.08 In each cable run some extra length shall be kept at suitable point to enable one LT/two HT straight through joints to made, should the cable develop fault at a later stage. Control cable termination inside equipment enclosure shall have sufficient lengths so that shifting of termination in terminal blocks can be done without requiring any splicing

3.04.09 Wherever few cables are branching out from main trunk route troughs shall be used.

3.04.10 The installation work shall be carried out in a neat workman like manner & areas of work shall be cleaned of all scraps, water, etc. after the completion of work in each area every day. Contractor shall replace RCC/Steel trench covers after the Installation work in that particular area is completed or when further work is not likely to be taken up for some time.

3.04.11 Separation

At least 300mm clearance shall be provided between :

- HT power & LT power cables,

- LT power & LT control/instrumentation cables,

3.04.12 Segregation

1) Segregation means physical isolation to prevent fire jumping.

2) All cables associated with the unit shall be segregated from cables of other units.

3) Interplant cables of station auxiliaries and unit critical drives shall be segregated in such a way that not more than half of the drives are lost in case of single incident of fire. Power and control cables for AC drives and corresponding emergency AC or DC drives shall be laid in segregated routes. Cable routes for one set of auxiliaries of same unit shall be segregated from the other set.

4) In switchyard, control cables of each bay shall be laid on separate racks/trays.






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3.04.13 Minimum number of spare cores required to be left for interconnection in control cables shall be as follows:

Minimum number of spare cores required to be left for interconnection in control cables shall be as follows:

No. of cores in cable No. of spare cores

2C,3C NIL

5C 1

7C-10C 2

3.04.14 Directly Buried Cables

a) Cable trenches shall be constructed for directly buried cables. Construction of cable trench for cables shall include excavation, preparation of sieved sand bedding, riddled soil cover, supply and installation of brick or concrete protective covers, back filling and compacting, supply and installation of route markers and joint markers. Laying of cables and providing protective covering shall be as per IS:1255 and the enclosed drawings showing cabling details.

b) RCC cable route and RCC joint markers shall be provided wherever required. The voltage grade of the higher voltage cables in route shall be engraved on the marker. Location of underground cable joints shall be indicated with cable marker with an additional inscription “Cable Joint”. The marker shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change in direction. They shall be located on both sides of road crossings and drain crossings. Top of cable marker/joint marker shall be sloped to avoid accumulation of water/dust on marker.

3.04.15 Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry, and at every 20 meters in cable tray/trench runs. Cable tags shall also be provided inside the switchgear, motor control centers, control and relay panels etc. where a number of cables enter together through a gland plate. Cable tag shall be of rectangular shape for power cables and control cables. Cable tag shall be of 2 mm thick aluminum with number punched on it and securely attached to the cable by not less than two turns of 20 SWG GI wire conforming to IS:280. Alternatively, the Contractor may also provide cable tags made of nylon, cable marking ties of ‘TY-CAB’ or equivalent type with cable number heat stamped on the cable tags

3.04.16 While crossing the floors, unarmoured cables shall be protected in conduits upto a height of 500 mm from floor level if not laid in tray.

3.05.00 Cable Terminations & Connections

3.05.01 The termination and connection of cables shall be done strictly in accordance with cable termination kit manufacturer’’ instructions, drawings and/or as directed by Project Manager. Cable jointer shall be qualified to carryout satisfactory cable






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jointing/termination. Contractor shall furnish for review documentary evidence/experience reports of the jointers to be deployed at site.

3.05.02 Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing, soldering, drilling, cutting, taping, preparation of cable end, crimping of lug, insulated sleeving over control cable lugs, heat shrinking (where applicable), connecting to cable terminal, shorting and grounding as required to complete the job to the satisfaction of the Project Manager.

3.05.03 The equipment will be generally provided with undrilled gland plates for cables/conduit entry. The Contractor shall be responsible for punching of gland plates, painting and touching up. Holes shall not be made by gas cutting . The holes shall be true in shape. All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively sealed by 2mm thick aluminium sheets.

3.05.04 Control cable cores entering control panel/ switchgear/ MCC/ miscellaneous panels shall be neatly bunched, clamped and tied with self locking type nylon cable ties with de interlocking facility to keep them in position.

3.05.05 The panels where a larger number of cables are to be terminated and cable identification may be difficult, each core ferrule shall include the complete cable number as per the drawings. The ferrules shall be indelible interlocking type and shall fit tightly on cores. Spare cores shall have similarly ferrules with a suffix letter ‘S’ alongwith cable numbers and coiled up after end sealing.

3.05.06 All cable terminations shall be appropriately tightened to ensure secure and reliable connections.

3.05.07 It is the responsibility of the Contractor to terminate the cables at motor terminals in correct phase sequence to ensure the proper direction of rotation.

4.00.00 EARTHING SYSTEM

4.01.00 Earthing system shall be in strict accordance with IS:3043 and Indian Electricity Rules/Acts.

4.02.00 The earth conductors shall be free from pitting, laminations, rust, scale and other electrical, mechanical defects.

4.03.00 The material of the earthing conductors shall be as follows :

1) Conductors above ground level and in built up

trenches.

- Galvanized steel

2) Conductors buried in earth - Mild steel

3) Earth electrodes - Mild steel rod






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4.04.00 The sizes of earthing conductors for various electrical equipments shall be as below:

Equipment Earth conductor buried in earth

Earth conductor above ground level & in built-up trenches

a) Main earth grid 40 mm dia.MS rod

65x8mm GS flat

b) 33KV/11KV swItchgear/equipment 415V switchgear

--- 65x8mm GS flat

c) 3.3 kV switchgear / 415 V MCC/ Distribution boards / Transformers

--- 50x6mm GS flat

d) LT Motors above 125 KW --- 50 x 6mm GS flat

25 KW to 125 KW --- 25 x 6mm GS flat

1KW to 25 KW --- 25 x 3mm GS flat

Fractional House power motor --- 8 SWG GS wire

e) Control panel & control desk --- 25 x 3 mm GS flat

f) Push button station / Junction Box

--- 8 SWG GI wire

g) Columns, structures, cable trays and busducts enclosures

--- 50x6mm GS flat

h) Crane, rails, rail tracks & other non-current carrying metal parts

25x6mm GS flat

4.05.00 Metallic frame of all electrical equipment shall be earthed by two separate and distinct connections to earthing system, each of 100% capacity, Crane rails, tracks, metal pipes and conduits shall also be effectively earthed at two points. Steel RCC columns, metallic stairs, and rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing ensured by bonding the different sections of hand rails and metallic stairs. Metallic sheaths/screens, and armour of multi-core cables shall be earthed at both ends. Metallic Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by the Employer. Every alternate post of the switchyard fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. Railway tracks within the plant area shall be bonded across fish plates and connected to earthing grid at several locations. Portable tools, appliances and welding equipment shall be earthed by flexible insulated cable.






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4.06.00 Each continuous laid lengths of cable tray shall be earthed at minimum two places by G.S. flats to earthing system, the distance between earthing points shall not exceed 30 metre. Wherever earth mat is not available Contractor shall do the necessary connections by driving an earth electrode in the ground.

4.07.00 Neutral connections and metallic conduits/pipes shall not be used for the equipment earthing. Lightning protection system down conductors shall not be connected to other earthing conductors above the ground level.

4.08.00 Connections between earth leads and equipment shall normally be of bolted type. Contact surfaces shall be thoroughly cleaned before connections. Equipment bolted connections after being tested and checked shall be painted with anti corrosive paint/compound.

4.09.00 Suitable earth risers as approved by Project Manager shall be provided above finished floor/ground level, if the equipment is not available at the time of laying of main earth conductor.

4.10.00 Connections between equipment earthing leads and between main earthing conductors shall be of welded type. For rust protection the welds should be treated with red lead compound and afterwards thickly coated with bitumen compound. All welded connections shall be made by electric arc welding.

4.11.00 Resistance of the joint shall not be more than the resistance of the equivalent length of conductors.

4.12.00 Earthing conductors along their run on columns, walls, etc. shall be supported by suitable welding / cleating at interval of 1000mm and 750mm respectively.

4.13.00 Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded below permanent moisture level. Minimum spacing between electrodes shall be 600mm. Earth pits shall be treated with salt and charcoal if average resistance of soil is more than 20 ohm metre.

4.14.00 Earthing conductor shall be buried at least 2000mm outside the fence of electrical installations. Every alternate post of the fences and all gates shall be connected to earthing grid by one lead.

5.00.00 QUALITY ASSURANCE PROGRAMME

5.01.00 Bidder shall furnish detailed Quality Assurance Programme and Quality Plans for all materials and accessories to be supplied and installed under the scope of the specification as per General Technical Conditions of technical specification. The Quality Plans shall include all tests/ checks as per relevant National/International Standards and the requirements of this specification including tests listed in this section.

6.00.00 TESTS

6.01.01 All equipment to be supplied shall be of type tested quality. The contractor shall submit for Owner's approval the reports of all the type tests as listed in this specification and carried out within last five years from the date of bid opening.






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These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.

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

6.01.03 All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price.

6.02.00 Routine/ Acceptance Tests

Following routine/acceptance tests shall be carried out on all the equipments, devices & materials supplied

6.02.01 Galvanizing Tests

The quality of galvanizing shall be inspected visually and shall be smooth, continuous, free from flux stains

In addition following tests shall be conducted :

i) Uniformity of coating – The coating of any article shall withstand four 1 minute dips in standard copper sulphate solution without the formation of an adherent red spot of metallic copper upon the basic metal.

ii) The quality of cadmium/zinc plating on items with screw threads shall be inspected visually and shall be free from visible defects such as unplated areas, blisters and modules.

iii) In addition, the plating thickness shall be determined microscopically/chemically or electronically.

6.02.02 Welding

The quality of welding shall be visually inspected, particular attention being paid to the following points.

1) The welded joints shall be continuous along its length on both sides and of uniform width and thickness. It should be free from blow holes.

2). The weld metal shall be properly fused with the parent metal without undercutting.

3) The outside surface of the weld shall be clean. All slag shall have been removed. All welding shall be regularly checked for cracking using magnetic particle inspection or their equivalent technique.






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6.02.03 Physical and dimensional checks for all items.

6.02.04 All conduits/pipes, etc. shall be routine/acceptance tested as per relevant standards.

6.02.05 All acceptance and routine tests on cable glands as for BS:6121. Additionally Proof torque test shall be carried out as acceptance on each body group of cable glands.

6.02.06 Deflection test cable trays.

6.02.07 All acceptance and routine tests on Junction boxes.

6.02.08 Following tests shall also be carried out on each type of equipments, devices and materials/items supplied:

1) Physical and Dimensional checks

2) Check/measurement of thickness for Nickel chrome plating for cable glands and tinning for cable lugs.

3) Check chemical composition of brass parts for cable glands.

4) Hardness check on gaskets.

5) Test for uniformity of galvanization.

7.00.00 COMMISSIONING

7.01.01 The Contractor shall carry out the following commissioning tests and checks after installation at site. In addition the Contractor shall carry out all other checks and tests as recommended by the Manufacturers.

7.01.02 Cables

a) Check for physical damage

b) Check for insulation resistance before and after termination/jointing.

c) HT cables shall be pressure tested( test voltage as per IS:7098) before commissioning.

d) Check of continuity of all cores of the cables.

e) Check for correctness of all connections as per relevant wiring diagrams. Any minor modification to the panel wiring like removing/inserting, shorting, change in terminal connections, etc., shall be carried out by the Contractor.

f) Check for correct polarity and phasing of cable connections.

g) Check for proper earth connections for cable glands, cable boxes, cable armour, screens, etc.






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h) Check for provision of correct cable tags, core ferrules, tightness of connections.

7.02.00 Cable trays / supports and accessories

1) Check for proper galvanizing/painting and identification number of the cable trays/supports and accessories.

2) Check for continuity of cable trays over the entire route.

3) Check that all sharp corners, burrs, and waste materials have been removed from the trays supports.

4) Check for earth continuity and earth connection of cable trays.

7.03.00 Earthing system

1) Earth continuity checks.

2) Earth resistance of the complete system as well as sub-system.





PART – B


E-08 : L.T. PANEL






PART-B

SECTION-I:E-08 LT PANEL

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1.00.00 TYPE

Circuit Breakers : Shall be air break, three pole, spring charged and horizontal draw out type, suitable for electrical operation.

Switchgear : Fully draw out type single front

MCC : Fully draw out type single front/Double front.

ACDB / DCDB

: Fixed type single front

2.00.00 SYSTEM PARAMETERS

415VAC +/- 10 % (Solidly Grounded)

50 Hz + 3% / - 5%

45KA RMS(105 KA Peak) / 1sec (Fault Level)

220 V DC Nominal (190V DC-240V DC) Isolated Type


All equipments shall, generally, comply with the updated issues of applicable Indian Standards

4.00.00 TECHNICAL REQUIREMENTS AND CONSTRUCTIONAL DETAIL

i) All switchboard frames and load bearing members shall be fabricated using suitable mild steel structural sections or pressed and shaped cold-rolled sheet steel of thickness not less than 2.0 mm. Frames shall be enclosed in cold-rolled sheet steel of thickness not less than 1.6 mm. Doors and covers shall also be of cold rolled sheet steel of thickness not less than 1.6 mm. Stiffeners shall be provided wherever necessary. The gland plate’s thickness shall be 3.0 mm (minimum) for hot / cold-rolled sheet steel and 4.0 mm (minimum) for non-magnetic material. The gland plate thickness 3.0 mm

ii) The panel shall be provided with doors on the front. The doors shall preferably be in two halves with hinges at the extreme ends and locking facility at the center.

iii) Suitable synthetic rubber gaskets shall be provided to make fuse boards completely dust and vermin-proof with a degree of protection of IP-52 for indoor and IP-54 for outdoor application, as per IS: 13947.

iv) Switchboard shall be of metal enclosed, indoor, floor-mounted, free standing, draw out type.

v) All panels edges and covers/ door edges shall be reinforced against distortion by rolling, bending or by the addition of welded re-enforced members. The top covers of the panel should be designed such that they do






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not permanently bulge, or bend by the weight of maintenance personnel working on it.

vi) All switchboard shall be of dust prove and vermin prove construction with a degree of protection of IP-52 as per IS-2147.

vii) All switchboard shall be of uniform height not exceeding 2450 mm.

viii) Switchboard shall be supplied with base frame made of structural steel section, along with all necessary mounting hardware required for welding down the base frame to the foundation. The base frame height shall be such that floor finishing (50mm thick) to be done by the owner after erection of the switchboard does not obstruct the movement of doors, covers, with drawable modules etc.

ix) The completely enclosed Busbar compartment shall be provide to the horizontal and vertical busbars and all joints for repair and maintenance shall be feasible without disturbing any feeder compartments. Auxiliary and power busbars shall be in separate compartments.

x) All equipments associated with an incomer or outgoing feeder shall be housed in a separate compartment of the vertical section. The compartment shall be sheet steel enclosed on all sides with the withdraw able units in position or removed. The front if the Compartment shall be provided with the hinged single leaf door with captive screw for positive closure.

xi) A full height vertical cable alley of min. 175mm shall be provided for power and control cables. Cable alley shall have no exposed live parts and shall have no communication with the bus bar compartment. Cable termination located in cable alley shall be suitably shrouded to prevent accidental contact by falling of tools etc. Cable alley doors shall be hinged. Provision should be there for top and bottom entry of the cables in cable alley. Final entry will be decided during detailed engineering.

xii) The minimum clearance in air between phases and between phases and earth for the entire run of horizontal and vertical busbars shall be 25 mm. For all other components the clearance between two live parts, live part and an earthed part shall be at least 10 mm through out. Wherever it is not possible to maintain these clearances, insulation shall be provided by sleeving or barriors. However for horizontal and vertical bus bars the clearances specified above should be maintained even when the bus bars are sleeved or insulated. All connections from the bus bars upto switch /fuses shall be fully shrouded/ insulated and securely bolted to minimize the risk of phase to phase and phase to earth short circuit.

4.01.00 Painting

All sheet steel work shall be pretreated, in tanks, in accordance with IS : 6005. Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline hot water and dried. The phosphate coating shall be "Class-C” as specified in IS: 6005. The phosphated surfaces shall be rinsed






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and passivated prior to application of stoved lead oxide primer coating. After primer application, Electrostatic Powder Painting shall be used. Finishing paint shade for complete panels excluding end covers shall be RAL9002 & RAL5012 for extreme end covers of all boards, unless required otherwise by the Owner. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peelable compound by spraying method to protect the finished surfaces from scratches, grease, dirt and oil spots during testing, transportation, handling and erection.

4.02.00 Name Plates & Labels

Each panel shall be identified by a name plate. Panel internal equipment shall be identified by paint marking. Nameplates shall be non rusting metal or 3-ply lamicoid, with engraved lettering and shall be subjected to Owner’s approval.

4.03.00 Wiring

i) All auxiliary wiring shall be carried out with 650 V grade, single core stranded copper conductor, colour coded, and PVC insulated wires. Conductor size shall be 1.5 mm sq. (min.) for control circuit wiring and 2.5 mm sq (min) for CT and space heater circuits.

ii) All internal wiring terminations shall be made with solderless crimping type tinned copper lugs, which shall firmly grip the conductor or an equally secure method. Similar lugs shall also be provided at both ends of component-to-component wiring. Insulating sleeves shall be provided over the exposed parts of lugs to the extent possible. Wago type terminal shall also be provided with lugs.

iii) Engraved core identification ferrules marked to correspond with panel wiring diagram shall be fitted at both ends of each wire. The ferrule shall be of self-locking type of 'Novoflex' or equivalent make. The wire identification marking shall be in accordance with IS: 375. Red Ferrules should be provided on trip circuit wiring.

4.04.00 Terminal Block

i) Control terminal blocks shall be of 650 Volts grade, rated for 10 Amps and in one-piece moulding. It shall be complete with insulating barriers, clipon type terminals and identification strips. Marking on terminal strip shall correspond to the terminal numbering on wiring diagrams. It shall be 'Klippon' type RSF-1 ('Elmex' type CSLT-1) with insulating material of Melamine conforming to ESI standard 12.1 or equivalent. Terminal blocks may alternatively be of CAGE clamp spring type

ii) At least 10% spare terminals for external connections shall be provided and these spare terminals shall be uniformly distributed on all terminal blocks.

iii) All terminal blocks shall be suitable for terminating on each side two (2) nos. stranded copper conductors of size upto 2.5 mm sq. each. However for DDCMIS terminals shall be suitable for 1.5 mm sq. cable.






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iv) All terminals shall be numbered for identification and grouped according to the function. Engraved white-in- black labels shall be provided on the terminal blocks.

4.05.00 Grounding

i) 25 x 3 mm copper ground bus to be provided for each panel

ii) A galvanized steel earthed shall be provided at the bottom of each panel and shall extend through the length of switch board. It shall be welded/ bolted to the frame work of each panel. Vertical earth bus shall be provided in each vertical section which shall in turn be bolted/welded to main horizontal earthed bus.

iii) Suitable arrangement shall be at each end of the horizontal earthed bus for bolting to owners earthing conductors. The horizontal earthing bus shall project out of the switch board ends and shall have pre drilled holes for this connections.

4.06.00 Space Heater

240V AC, single phase, thermostatically controlled space heaters to be provided.

4.07.00 Switches

i) Air break switches shall be of heavy duty, single throw, group operated, load break, fault make type when associated with fuses. All switches for motor circuits shall be of utilization category AC23 with 1NO+1Nc auxiliary contact. All switches for other outgoing shall be of utilization category AC22.

ii) The main switches shall be operable from outside the module door. The switch handle shall clearly indicate the position of switch. Switch handle shall be provided with padlocking facilities to lock them in OFF position.

4.08.00 Fuses

HRC cartridge with visual operation indicator.

4.09.00 Panel Lighting

Each free standing panel shall be provided with a door switch operated fluorescent lamp and a 240V AC plug point.

4.10.00 Degree of enclosure protection

For panels located in

i) Air conditioned areas : IP-32

ii) Other indoor areas : IP-52

iii) Outdoor areas : IP-55






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4.11.00 Meters/ Instruments

All meters/ instrument shall be flush mounted on front panel, at least 96 sq.mm. size with 90 degree linear scales and accuracy class of 2.0.

4.12.00 Current Transformers

Cast Resin Bar Primary Class of insulation E or better Accuracy class & burden - 5P-20,VA adequate for application subject to owner’s approval For protection Class 1.0, 7.5 VA (min) For metering

4.13.00 Voltage Transformers

Type - Cast Resin, Voltage Ratio-440/110 V , Rated Voltage factor -1.1 continuous, 1.5 for 30 sec. , Class of insulation - E or better

4.14.00 Contactors

i) Type Air break electro magnetic, Utilizing Category - AC 3 of IS: 13947 for non reversible AC-4 of IS:13947 for reversible drives

ii) Motors starters contactors shall be off air break, electro magnetic type rated for un-interrupted duty as per IS 13947, Part-4 Section-1.Operating coils of the contactors shall be of 240v AC. The contactors shall operate satisfactorily between 85 to 110% of the rated voltage. The contactors shall not drop at 70% of the rated voltage, but definitely drop out 20% of the rated voltage.

4.15.00 Relays

Power frequency withstands voltage-2.5KV for 1 sec. or 2.0 KV for 1 min.

4.16.00 Current Transducers

Input - 0-1 A (CT secondary), Rated frequency - 50HZ, Output - 4-20 mA (2 Nos. decoupled), Over current -Transducer for motor current ammeters shall be capable of withstanding min. 6 times CT sec. current of 1A for a min period of 30 seconds, Accuracy - 0.5%

4.17.00 Voltage Transducers

Input-110 V (VT secondary), 50 HZ, (for AC) / 250 V DC (for DC)

Output 4-20 mA (2 Nos. decoupled), Accuracy 0.5%

4.18.00 Gaskets

The gaskets, wherever specified, shall be of good quality synthetic rubber with good ageing, compression and oil resistance characteristics suitable for panel applications.






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4.19.00 Fuses

i) All fuses shall be of HRC cartridge fuse link type. Screw type fuses shall not be accepted. Fuses for AC circuits shall be rated for 80 KA rms (prospective) breaking capacity at 415 V AC and for DC circuits 20 KA rms breaking capacity at 250 V DC.

ii) Fuse shall have visible operation indicators. Insulating barriers shall be provided between individual power fuses.

iii) Fuse shall be mounted on insulated fuse carriers, which are mounted on fuse bases. Wherever it is not possible to mount fuses on carriers, fuses shall be directly mounted on plug-in type of bases. In such cases one set of insulated fuse pulling handles shall be supplied with each switchboard.

iv) Fuse ratings shall be selected to achieve class -II protection coordination and also to match the motor characteristics. Switch rating shall in no case be less than the fuse rating.

v) The Neutral links shall be mounted on fuse carriers, which shall be mounted on fuse bases.

4.20.00 Control Transformers

Type - Dry / Cast Resin, Voltage Ratio -415/110 with taps + 5% in Steps of 2.5%, Class of insulation - Class-B or better.

4.21.00 Control and Selector switch Ratings

The contact ratings shall be at least the following:

• Make and carry, continuously, 10 A at 250 V DC and 110 V AC

• Breaking current at 250 V DC, 1 A (inductive).

• Breaking current at 110 V AC and 0.3 lagging p.f., 5A

4.22.00 Instrument Transformers

i) All current and voltage transformers shall be completely encapsulated, cast resin insulated type suitable for continuous operation at the temperature prevailing inside the switchgear enclosure, when the switchboard is operating at its rated condition and the specified ambient temperature. The class of insulation shall be 'E' or better.

ii) All instrument transformers shall be able to withstand the thermal and mechanical stresses resulting from the maximum r.m.s. Short circuit breaking and peak making current ratings of the associated switchgear.

iii) All instrument transformers shall have clear indelible polarity markings. All secondary terminals shall be wired to separate terminals on an accessible terminal block where star point formation and earthing shall be done.






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iv) Current transformers may be multi or single-core type. All voltage transformers shall be single-phase type.

4.23.00 Indicating Lamps

Indicating lamps shall be of CLUSTER LED type. The lamps shall have escutcheon plates marked with its function, wherever necessary. Lamps shall have translucent lamp-covers of the following colors, as warranted by the application:

4.24.00 Temperature Rise

The temperature rise of the horizontal and vertical busbars and main bus links including all power drawout contacts when carrying 90% of the rated current along the full run shall in no case exceed 55 deg C with silver plated joints and 40 deg C with all other types of joints over an outside ambient temperature of 50 deg C.





PART – B

SECTION-II : CIVIL WORKS

C-0 : SWITCHYARD CIVIL WORKS






PART – B SECTION-II:C0

SWITCHYARD CIVIL WORKS

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CIVIL WORKS

1.00.00 GENERAL

The scope of civil works consists of Design, Engineering, construction of a Chlorine Evaporation Room, Control Room Building and chlorine leak absorption area. The building shall be of RCC framed structure, single storey with infill masonary walls and trenches, drains, foundations etc at GESCL, Gandhinagar with all associated civil works, flooring, finishing, painting, etc all complete with all materials, labour, equipments etc as per specification, drawings ,general requirements etc. The size of Chlorination Evaporation room and control room building shall be as per tender drawing. The chlorine leak absorption area is per tender drawing with PVC coated MS fencing and GI MS Steel gate.

2.00.00 GENERAL REQUIREMENTS AND SPECIFICATIONS

2.01.00 Description of various items of work under this specification and nature of work in detail are given hereinafter. The complete work under this scope is referred to as civil works

The work to be performed under this specification consists of design, engineering and providing all labour, materials, consumables, equipment, temporary works, temporary storage sheds, temporary labour and staff colony, temporary site offices, constructional plant, fuel supply, transportation and all incidental items not shown or specified but reasonably implied or necessary for the completion and proper functioning of the plant, all in strict accordance with the specifications and including revisions and amendments and IS Codes (Annexure-2 with this chapter ) thereto as may be required during the execution of the work.

All materials including cement, reinforcement steel and structural steel etc. shall be arranged by the Bidder.

The scope shall also include setting up by the Bidder a complete testing laboratory in the field to carry out all relevant tests required for the civil works for the project. Minimum facilities as specified in the enclosed Annexure-I to this section shall be provided by the Bidder in this laboratory.

The work shall be carried out according to the design/drawings to be developed by the Bidder and approved by the Owner. For all building & structures, foundation, etc. necessary layout and details are to be developed by the Bidder keeping in view the statutory & functional requirements of the plant & facilities and providing enough space & access for operation, use and maintenance.

The land will be given to the Bidder by the Owner. All survey works, and other related works shall be done by the Bidder.

The layout and levels of all structures shall be made by the Bidder at his own cost from the general grid of the plot and the nearest bench mark or other acceptable bench mark of GESCL as per the directions of the owner. The Bidder shall be solely responsible for the correctness of the layout and levels.








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All the quality standards, tolerances, welding standards and other technical requirements as covered in this specification shall be strictly adhered to by the Bidder.

The Bidder should fully appraise himself of the prevailing conditions at the proposed site, climatic conditions including monsoon pattern, local conditions and site specific parameters and shall include for all such conditions and contingent measures in the bid, including those which may not have been specifically brought out in the specifications.

3.00.00 SUBMISSIONS

3.01.00 The following documents are to be submitted for the approval of the Owner, prior to commencement of fabrication & erection/construction. All drawings shall be of standard sizes (Metric System) and shall be made on AUTOCAD (release 14). The list is not exhaustive but indicative only.

a) General layout drawing with coordinates of adjacent roads, boundary wall, buildings and facilities, piping/cable corridors, pipe and cable trestles, diversion drains, etc.

b) Architectural floor plans, elevations, cross-sections and perspective view in colour of all buildings

c) Basis of design of all buildings, facilities, services and structures.

d) Design calculations and drawings for foundations/sub-structure and superstructure of all buildings including pump houses and other structures.

e) Design calculations and drawings for all facilities and services , (to the extent included in the scope of this contract), trenches, ducts etc.

f) Drawings of all architectural works including finish schedule, colour scheme (both internal and external), doors & windows, flooring and false ceiling, etc.

g) Design calculations and drawings for plumbing and building drainage.

h) Design calculations and drawings for switchyard structure

i) Copy of all reports of studies/investigations carried out by the Bidder as per scope.

j) All construction drawings shall include/indicate total quantity of concrete (gradewise), reinfocement steel (diameterwise) and structural steel (sectionwise).

4.00.00 DESIGN CRITERIA

The proposed building shall have framed structure of RCC. The design of shall generally be carried out using limit state method of design as per ‘Code of practice for plain and reinforced concrete for general building construction’, IS : 456 ( latest ).








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Building structures shall be designed for the most critical combinations of dead loads, super-imposed loads, equipment loads, crane load, wind loads, seismic loads, and temperature loads.

Building structures shall be designed for the most critical combinations of dead loads, super-imposed loads, equipment loads, crane load, wind loads, seismic loads, and temperature loads.

Dead loads shall include the weight of structures complete with finishes, fixtures and partitions and should be taken as per IS : 1875.

Super-imposed loads in different areas shall include live loads, minor equipment load, cable trays, small pipe racks / hangers and erection, operation and maintenance loads. Equipment’s loads shall constitute, if applicable, all load of equipments to be supported on the building frame.

Seismic forces shall be considered as specified in in these documents

For temperature loading, the total temperature variation shall be considered as 2/3 of the average maximum annual variation in temperature. The average maximum annual variation in temperature for the purpose shall be taken as the difference between the mean of daily minimum ambient temperature during the coldest month of the year and mean of daily maximum ambient temperature during the hottest month of the year. The structure shall be designed to withstand stresses due to 50% of the total temperature variation.

Wind and Seismic forces shall not be considered to act simultaneously.

Floors / slabs shall be designed to carry loads imposed by equipment, cables piping travel of maintenance trucks and equipment and other loads associated with building. Floors shall be designed for live loads as per relevant IS. Cable and piping loads not less than 5 kN/sq.m hanging from the underside, shall also be considered additionally for floors where these loads are expected.

For consideration of loads on structures IS: 875, the following minimum superimposed live loads shall, however, be considered for the design.

a) Roofs 150 Kg / Sq.m (accessible /AC eqpt. load as per requirement)

b) Floors

i) Building floors 1000 Kg / Sq.m

c) Stairs and Balconies 500 Kg / Sq.m

d) Toilet rooms 200 Kg / Sq.m

e) Chequered plate floors / covers

400 Kg / Sq.m

f) Walkways 400 Kg / Sq.m








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g) Road Culverts and its supporting structures including RCC pipes in case of pipe culverts

Design for Class - ’AA’ loading ( wheeled and tracked both ) and check for Class - ’A’ loading as per IRC standard.

h) Underground structures such as channels, sumps, basement floors of pump houses, tanks, pits, trenches etc.

In addition to the earth pressure and ground water pressure, the surcharge of 2000 Kg / Sq.m shall also be taken into account.

i) Covers for channels and trenches crossings.

400 Kg / Sq.m ( General ) or a central load of 75 Kg and as per item ( h ) above for all road

4.01.00 Foundation System

General Requirements.

a) Bidder can either provide open foundations (isolated footing/raft) or pile foundations depending upon the results of the geotechnical investigations carried out by GESCL, report enclosed (Enclosed as Annexure-3 with this chapter ) ,(the report is of unit 3 & 4 areas but the same is valid for unit 1 & 2 also) any special requirements/remedial measures / treatment called for subsoil / foundations as approved by the Owner.

b) All foundations shall be designed in accordance with provisions of the relevant parts of the latest revisions of Indian standards.

c) No major foundation shall rest in the filled up ground/soil.

d) A combination of open and pile foundations shall not be permitted under the same structure.

e) Foundations shall be designed to resist loading derived from environmental loads including loads due to wave, current, wind or seismic, gravity loads, construction loads, static and moving loads and any other load as applicable and as specified elsewhere in the specification.

f) Foundation shall be designed for worst combination of loads as described elsewhere in the specification.

4.01.01 Open foundations

In case open foundations are adopted following shall be adhered to:

i) Minimum width of foundation shall be 1.0 m.

ii) Minimum depth of foundation shall be 1.0 m below NGL.








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iii) It shall be ensured that all foundations of a particular structure / building shall rest on one bearing stratum, i.e. either over burden or rock.

iv) Wherever the intended bearing structure is weathered rock but the actual stratum encountered during foundation excavation consists of both overburden soil and weathered rock at founding level, under such cases either the foundation shall be lowered completely into the weathered rock or the overburden soil upto the weathered rock level shall be removed and built up through PCC up to designed foundation level.

v) The net allowable bearing pressure values to be adopted for design upon Owner’s approval shall correspond to total permissible settlement as mentioned under para “permissible settlement of foundations” or the permissible settlement from functional requirement, which ever is more stringent.

vi) Permissible settlement of foundations.

The total permissible settlement and differential settlement shall be governed by IS:1904, IS:13063 and from functional requirements, whichever is more stringent. However, total settlement shall be restricted to the following.

a) i) Isolated/strip footing of width upto 6.0 m : 40 mm.

ii) Footings width greater than 6.0 m (raft) : 75 mm

b) Analysis and proportioning of footings to minimise differential settlements shall be carried out for all major foundations and the same shall be submitted for Owners approval.

5.00.00 ARCHITECTURAL CONCEPT

The CW Chlorination Plant building for new building of chlorinator cum evaporator room and Control Room, Ramp etc and associated pump and other foundations ,fencing, gates etc shall be architecturally treated in such a way that it retains a monumental scale, yet presents a pleasing composition of mass and void with suitable and functionally designed projections and recesses. The overall impact of the building shall be one of aesthetically unified architectural composition having a comprehensive scale, bending tonal values with the surroundings and taking full consideration of the climatic conditions and the building orientation. The over all composition may have straight or curvilinear profiles.








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The Buildings Shall Be Designed :

(1) To The Requirements of The National Building Code Of India, And The Standards Quoted There In

(2) To Adequately Suit The Requirements Of The Equipment And Apparatus Contained In The Buildings And In All Respects To Be Compatible With The Intended Use And Occupancy.

(3) With A Functional Space Arrangement.

(4) To Allow For Easy Access To Equipment And Maintenance Of The Equipment.

(5) With, Wherever Required, Fire Retarding Materials For Walls, Ceilings And Doors, Which Would Prevent Supporting Or Spreading Of Fire.

(6) With Materials Preventing Dust Accumulation

6.00.00 FINISHING SCHEDULE

This finishing schedule as given below shall be adhered to by the Bidder.

6.01.00 PLASTERING

Outer face (i.e., rough side) of all brick walls shall have 18 mm thick and inner face (i.e., smooth side) of all brick works shall have 12 mm thick cement sand plaster 1:6

Wherever specified the plaster of paris (Gypsum Anhydrous) conforming to IS: 2547 shall be used for plaster of paris punning. The finish surface shall be smooth and shall be of 2 mm nominal thickness.

All exposed faces of R.C.C. walls of buildings shall have minimum 12 mm thick cement sand plaster 1:6.

All RCC ceilings (except areas provided with false ceilings and cable vault ceiling) shall be provided with 6 mm thick cement sand plaster 1:4.

All plastering work shall conform to IS: 1661.

Parapets, chajjas, window / door heads, architectural facias, fins etc., shall be

i) Textured paint of approved colour (Sandtex mat or equivalent) shall be provided for the under mentioned areas. This combination shall generally be in the proportion of 3:1.

a) All buildings with RCC framework unless specified otherwise in this specification.

b) Projection and facias: RCC/Brick parapets.

c) Exterior brick walls.








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6.02.00 Interior finishes

i) Flooring

a) IPS (cement concrete flooring) with metallic hardner topping shall be provided for maintenance and unloading area, floors, operating floor of pump houses, MCC room, cable vault/cable spreader room.

b) Oil Resistant paint shall be provided for all areas with Indian patent stone cement concrete flooring which are likely to be subjected to regular oil spillage

c) In other areas ironite flooring will be done

ii) Interior wall/ceiling finish

a) For control room area Acrylic emulsion paint of approved make & shade over 2mm thick plaster of paris punning shall be provided.

b) For control room , Minimum 8.5mm thick vitrified ceramic tiles of approved make and shade with approved pattern shall be provided.

c) For other areas not specified above, oil bound distemper of approved shade over 2mm thick plaster of paris punning shall be provided

6.03.00 Exterior finish

i) Textured paint of approved colour (Sandtex mat or equivalent) with a combination of resin bonded granular finish (Vineratex or equivalent) shall be provided for the under mentioned areas. This combination shall generally be in the proportion of 3:1.

a) All buildings with RCC framework unless specified otherwise in this specification.

b) Projection and facias : RCC/Brick parapets.

c) Exterior brick walls.

7.00.00 FLOORING

7.01.00 The nominal total thickness of floor finish shall be 50mm i.e. underbed & topping. The floor shall be laid on an already laid and matured concrete base. The underbed for floors and similar horizontal surfaces shall consist of cement concrete (1 part cement, 2 part sand and 4 part stone chips by volume). Stone chips shall be 12.5 mm down well graded.

7.02.00 Wherever specified metallic hardener topping shall be 12mm thick using uniformly graded iron particles, properly treated.

7.03.00 Wherever specified vitrified ceramic tiles of size 600 x 600 x 8.5 mm thick (minimum) of reputed manufacturer (somany, or equivalent) of approved finish








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shade and colour to be used. The tiles shall have a scratch resistance ( EN 101 test method)greater than or equal to 6.0on Mohr's scale and shall have a MODULUS OF RUPTRE as( EN100 test method) greater than or equal to275 kg/sqcm .

1) PCC paving of nominal mix 1:2:4 (1 part element : 2 parts sand:4 parts aggregate), 100mm thick laid over 75 mm thick bed of dry brick aggreagate shall be provided for following areas:

750mm wide plinth protection around new buildings.

7.04.00 Plinth level of all buildings shall be kept at least 500mm above the finished grade/ formation level.

7.05.00 Roof of all buildings having RCC framework shall have cast -in-situ RCC slab.

7.05.01 For efficient disposal of rain water, the run off gradient for the roof shall not be less than 1:100. This gradient can be provided either in structure or subsequently by screed concrete 1:2:4 (using 12.5 mm coarse aggregate) and/or cement mortar (1:4). However, minimum 25mm thick cement mortar (1:4) shall be provided on top to achieve smooth surface.

7.05.02 Roof water proofing treatment shall be provided using high solid content liquid applied elastomeric water proofing Membrane with separate wearing course as per ASTM C-898. Thickness of the membrane shall be 1.5mm. This treatment shall include application of polymerised mastic over the roof to achieve smooth surface and primer coat. Wearing course on the top of membrane shall consist of 25mm thick PCC (1:2:4) cast in panels of maximum 1.2 x 1.2m size and reinforced with 0.56mm dia galvanised chicken wire mesh and sealing of joints using sealing compound/elstomeric water proofing membrane. 1000mm wide pathways for handling of materials and movement of personnel shall be provided with 22mm thick chequered cement concrete tiles as per IS:13801 in place of PCC. Slope of the roof shall not be less than 1 in 100.

7.05.03 Cast Iron rain water downcomers conforming to IS:1230 with water tight lead joints or medium class galvanised mild steel pipes conforming to IS:1239/IS3589 with welded joints shall be provided to drain off rain water from the roof. These shall be suitably concealed with masonry work, cement concrete, or sheeting work to match with the exterior finish. The number and size of downcomers shall be governed by IS:1742 and IS:2527. Roof drain level of all RCC framed buildings having cast-in-situ RCC roof shall be provided with 45x45cm size Khurras having minimum thickness of 30mm with 1:2:4 concrete over PVC sheet of 1m x 1m x 400 micron and finished with 12mm thick cement sand plaster 1:3.

7.05.04 Roof of all buildings shall be provided with access through staircase or ladder.

7.05.05 RCC parapet wall of minimum 900mm height for all accessible roofs and 600mm height for all non-accessible roofs shall be provided.

7.05.06 Fillets at junction of roof and vertical walls shall be provided with cast-in-situ cement concrete (1:2:4) nominal mix followed by 12mm thick 1:4 cement sand plaster.








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8.00.00 WALLS

a) All walls shall be non-load bearing infilled panel walls.

b) All internal walls shall be with brick masonry and all toilets shall be provided with minimum one brick thick masonry walls.

c) RCC Transoms & Mullions shall be provided wherever necessary to reinforce the brick work.

d) 50mm thick DPC in Cement concrete (1:1:5:3) with water proofing compound followed by two layers of bitumen coating 85/25 grade as per IS:702 @ 1.7 kg/sq.m. shall be provided at plinth level before starting the masonry work.

e) The bricks used shall be of minimum class designation 50 and above. The bricks shall be laid with cement mortar (1:6) for one brick thick walls and (1:4) for half brick thick walls. IS:1905, IS:2212 and SP-20 shall be followed for brick work design and construction.

9.00.00 FENCING

The fence around chlorine leak absorption area shall comprise of PVC coated G.I. chain link fencing of minimum 8 G (including PVC coating) of mesh size 75 mm & of height 2.4 m above the toe wall , such that total fence height of 2.4 m above the toe wall is achieved. The diameter of the steel wire for chain link fence (excluding PVC coating) shall not be less than 12 G.

The PVC coated chain link will be stretched by the clips at 0.5 m intervals to three strands of galvanised high tensile spring steel wire (HTSSW) of 12 G interwoven chain link wire mesh and kept under tension which in turn are attached to the fence post with security nuts and bolts. On every fourth post a clamping strip will be threaded through the links of chain link and bolted to the fence post with the help of security nuts and bolts.

All nuts, bolts, fasteners, clamping strips, clamps, clips, etc. shall be hot dip galvanised. Weight of zinc coating shall be at least 610 g/sqm.

All fence post including stay post & straining posts shall be of 75x75x6 MS. angles placed at 2.5 meter c/c. All corner posts will have two stay posts and every tenth post (straining post) will have transverse stay post. Suitable R.C.C. foundations for the post and stays shall be provided based on the prevailing soil conditions.

Toe walls either of brick masonry with bricks of minimum 50 kg/cm2 crushing strength or of hollow concrete block masonry shall be provided between the fence posts all along the run of the fence with suitable foundation. Toe wall shall be minimum 200 mm above formation level with 50mm thick P.C.C. coping (1:2:4) and shall extend minimum 300 mm below the formation level. Toe wall shall be plastered with cement sand mortar (1:6) on both sides and shall be painted with two coats of textured cement paint (Sandtex mat or equivalent) of approved colour and shade. Toe wall shall be provided with weep holes at appropriate spacings. All gates shall be of structural steel and shall be galvanised with minimum zinc coating of 610 gm/sqm.








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10.00.00 PAINTING

a) All painting on masonry or concrete surface shall preferably be applied by roller. If applied by brush then same shall be finished off with roller.

b) All paints shall be of approved make including chemical resistant chlorinated rubber paint.

c) Minimum two finishing coats of paint shall be applied over a coat of primer.

d) The thinner shall not be used with textured paint (Sandtex Matt or equivalent) finish.

e) Acrylic emulsion paint shall be as per IS:5411 (Part-I). Oil bound distemper shall be as per IS:428.

f) All fire exits shall be painted in post office red/signal red colour shade, which shall not be used anywhere else except to indicate emergency or safety measure.

g) For painting on concrete, masonry and plastered surface IS:2395 shall be followed. For painting on steel work and ferrous metals, IS:1477 shall be followed. for painting on wood work IS:2338 shall be followed.

11.00.00 DOORS & WINDOWS

a) Unless specified all doors, windows and ventilators areas, provided on the outer face of all buildings shall have, electro colour coated (anodised) aluminium framework with galzing. all doors of office and toilet areas shall be of factory made pre-laminated particle board (MDF exterior grade). All other doors (unless otherwise specified) shall be of steel.

b) All steel doors shall consist of double plate flush door shutters. The door shutter shall be 45mm thick with two outer sheets of 18 G rigidly connected with continuous vertical 20 G stiffeners at the rate of 150 mm centre to centre. Side, top and bottom edges of shutters shall be reinforced by continuous pressed steel channel with minimum 18G. The door shall be sound deadened by filling the inside void with mineral wool. Doors shall be complete with all hardware and fixtures like door closer, tower bolts, handles, stoppers, aldrops, etc.

c) Wherever functionally required Rolling shutters with suitable operating arrangement manual/Electric shall be provided to facilitate smooth operations. Rolling shutters shall conform to IS:6248.

d) Hollow extruded section of minimum 3 mm wall thickness as manufactured by INDAL or equivalent shall be used for all ALUMINIUM doors, windows & ventilators.

12.00.00 GLAZING

a) Double glazing will be provided in all windows, except in toilet, double glazing shall consist of two 6mm thick clear toughened safety glass








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conforming to IS:2553, hermetically sealed and separated by 12mm thick gap for thermal insulation.

b) For single glazed aluminium partitions and doors, Float glass or flat transparant sheet glass of minimum 5.5mm thickness shall be used.

c) All glazing work shall conform to IS:1083 and IS:3548.

13.00.00 MISCELLANEOUS SPECIFICATIONS

a) Expansion joints for all underground structures shall be made water tight by ribbed PVC water stops with central bulb or of kicker type. the thickness and width of PVC water stops shall be as per the requirement of design. However the minimum thickness and width shall be 6mm and 230mm respectively.

Two-part polysulphide sealant conforming to IS:12118 shall be used for sealing of joints.

b) Minimum 100mm thick lean concrete (1:3:6) shall be provided below all other underground structures, foundations, trenches etc. to provide a base for construction.

c) Doors and windows on external brick walls of buildings shall be provided with RCC sunshade over the opening extending 300mm on either side of the opening. Projection of sunshade from the wall shall be minimum 450mm over window openings and 750mm over door openings.

d) All stairs shall have a maximum riser height of 180 mm and a minimum tread width of 250 mm. Minimum clear width of stair shall be 1200 mm. Aluminium angle nosing with minimum 50x25x3 mm angle shall be provided for edge protection in RCC stairs.

e) In design of all buildings, fire safety requirements conforming to IS:1641 and IS:1642 shall be followed in addition to TAC

f) All drains inside the building shall have minimum 40mm thick grating covers. in areas where heavy equipment loads would be coming, precast RCC covers shall be provided in place of steel grating.

g) All drains outside building shall have perforated precast RCC covers of minimum 50mm thickness with provision of openable steel grating cover at about 4.0m interval. In areas where vehicular loads would be coming precast RCC covers of suitable thickness without perforations and designed for the vehicular loading shall be provided.

h) Anti termite chemical treatment shall be given to all vulnerable areas susceptible to termite including column pits, wall trenches, foundation of buildings, fillings below the floors etc. as per IS:6313 and other relevant Indian Standards.

i) All cable & pipe routing in outlying area shall be clubbed and shall run over ground on steel trestles or other supporting structures at a height of not less








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than 3000mm above grade for easy inspection & maintenance except in some localised area (approved by Owner) where the same can run in trenches. In case cable route is not envisaged in the area, pipe shall be routed on ground over RCC pedestals at height of not less than 500mm. All trenches INSIDE shall be of RCC with removable CHEQUERED PLATES 6MM TH covers. Trenches located outside buildings shall project atleast 200mm above the finished formation level so that no storm water shall enter into the trench. The bottom of the trench shall be provided with a slope of 1:500 for draining out the collected water into a sump pit to be provided at suitable location. The precast covers shall not be more than 300mm in width. Lifting hooks shall be provided in the precast covers. The trenches shall be given a slope of 1 in 200 in the direction perpendicular to the run of the trenches. PVC water stops shall be provided at all expansion joints of all trenches.

j) All steel platforms above grade shall be provided with kick plates at edge of platform to prevent tools or materials from filling off platform.

k) Unless specified all sand filling shall be compacted to minimum 75% of the relative density and backfilled earth shall be compacted to minimum 90% of the Standard proctor density at OMC.

However, the sub-grade for the roads and embankment filling shall be compacted to minimum 95% of the Standard Proctor density at Optimum moisture content (OMC).

l) Detailed scheme for dewatering shall be prepared before starting of deep excavation work. IS:9758 shall be followed as general guidance for dewatering.

m) Plywood formwork shall be used for all water retaining/conveying structures and for all overground concrete works. For all other areas steel/plywood formwork shall be used.

n) All buildings shall be provided with Brick / RCC peripheral (garland) drains by the side of plinth protection for catering the storm water from roofs and adjacent area.

o) Parapet, Chajjas over window and door heads, architectural facias, fins etc. shall be provided with drip course in cement sand mortar 1:3.

14.00.00 CONCRETE:

a) Concrete work shall be carried out as per IS:456. Mix design concrete shall be used for all areas other than lean concrete work and plain cement concrete where nominal/volume mix can be permitted. Design mix shall be carried out as per IS:10262.

b) Minimum grade of concrete for various structures/areas other than machine foundations shall be as follows:








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M-25 FOR ALL RCC WORK

1) Unless specified 20mm and down aggregates shall be used for all structural concrete works. However 40mm and down aggregates may also be used under special conditions for the mass concreting in foundation.

2) Special requirements for concreting of major equipment foundations shall be as given below.

i) Coarse Aggregates

Sound and durable crushed stone aggregates shall be used. All aggregates shall be tested for alkali aggregated reaction. Materials which contain high percentage of reactive silica shall not be used. In exceptional cases of high percentage of reactive silica content, aggregate may be allowed where low alkali content cement shall be used. Lime stone aggregate shall not generally be used for foundations which are subjected to high temperature and repeated temeperature cycles (like in the case of all machine foundations). However, in case other types of suitable aggregate is not available, the Engineer may allow the use of lime stone aggregate provided the Bidder gets the sample tested from a reputed testing laboratory for satisfactory performance under high temperature and repeated temeperature cycle. Unless otherwise specifically approved by the engineer, the tests shall be carried out for a temperature range from 10deg.C to 65 deg.C and for 60 (sixty) temperature cycles.

ii) Admixture

Plasticizer-cum retarder type admixture shall generally be added to the concrete for promoting workability in addition to retarding setting time, for mass concreting work. The slump shall generally be in the range given below:

Block foundation - 100mm to 150mm

Column - 100mm to 150mm

iii) Form work

Plywood formwork shall be used.

iv) Scheme for Concreting

Weigh Batching shall be done for all concrete works. Arrangements for stand-by Plant and Equipments shall also be made.

15.00.00 EXCAVATION

15.01.00 Excavation in Earth

Cutting shall be done from top to bottom. Under no circumstances undermining shall be allowed.








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If water is met during excavation in the form of ground water, seepage, rain or any other cause it shall be removed by suitable diversions or bailing out or pumping and the excavation kept dry.

15.02.00 Excavation in Rock

Excavation in rock shall be carried out by means of chemical grouting, chiselling or any other means approved by the

16.00.00 INSPECTION, TESTING AND QUALITY CONTROL FOR CIVIL WORKS

16.01.00 Sampling and testing for major items of civil works viz earthwork, concreting, structural steel, work (including welding), piling etc. shall be carried out in accordance with the requirements of this specification. Wherever nothing is specified relevant Indian Standards may be used, in absence of Indian Standards, equivalent International standards may be used.

The Bidder shall submit for Owner’s approval a detailed field Quality Assurance Programme for civil works before starting of the construction work. This shall include frequency of sampling and testing, nature/type of test, method of test, setting of a testing laboratory, arrangement of testing apparatus/equipment, deployment of qualified/experienced manpower, preparation of format for record, Field Quality Plan, etc. Tests shall be done in the field and/or at a laboratory approved by the Engineer and the Bidder shall submit to the Engineer, the test results in triplicate. In addition, the Bidder shall furnish the original test certificate from the manufacturer’s of various materials to be used in the construction.

16.02.00 Workmanship and dimensional tolerances shall be checked as stipulated below.

16.02.01 PERMISSIBLE TOLERANCE FOR CIVIL WORKS

i) Excavation and filling

Tolerance on finished levels for filling areas shall be as specified under the clause pertaining to “Site Levelling and Slope Protection Work”.

ii) Cast-in-situ concrete works

Description of Item Permissible Deviation in mm

structural element

The dimensions of concrete as cast when compared with those on the drawings shall be within the tolerances given below.

Faces of concrete in foundations and structural members against which backfill is placed +25 -10 Location of footing (for RCC framed structures only) +25 -25








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Ecentricity of footing 2% of footing width in Direction of misplacement but limiting to 50 mm. Top surfaces of slabs and of concrete to receive base plates to be grouted. +5 -5 Alignment of beams, lintels, columns, walls, slabs, and similar structural elements. +5 -5 Cross sectional dimensions of walls, slabs and similar structural elements +5 -5 Deviation from specified dimensions of cross-section of columns and beams. +12 -6 Alignment of holding down bolts without sleeves +1.5 -1.5 Alignment of holding down bolts with sleeves. +5 -5 Level of holding down bolt assemblies. +10 -10 Embedded parts (in any direction). +5 -5 Centres of pockets or holes with greatest lateral dimension not exceeding 150mm +10 -10 Variation in steps: Riser +1.5 -1.5 Tread +3.0 -3.0 Plumb 3mm for every metre subject to a maximum of 10 mm.

iii) Form work Levels and heights + 6 mm Plumb 3mm for every metre subject to a maximum of 10 mm.








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Unevenness of any surface + 3 mm Length or breadth + 12 mm Diagonals + 15 mm

In case of inclined surfaces like folded plates etc, the deviation in the alignment of inclined surfaces, shall not exceed 3 mm with reference to the theoretical alignment, for a length of 1000 mm measured vertically, subject to a maximum of 10 mm.

In addition to above, requirement of Item No. 23.02.00 shall be complied with, which shall be the final acceptance criteria of concrete work.

iv) Masonry

All masonry shall be built true and plumb within the tolerances prescribed as below. Care shall be taken to keep the perpends properly aligned.

a) Deviation in verticality in total height of any wall of a building more than one storey in height shall not exceed +/- 12.5mm.

b) Deviation from vertical within a storey shall not exceed +/- 6mm per 3 m height.

c) Deviation from the position shown on the plan of any brickwork more than one storey in height shall not exceed 12.5 mm.

d) Relative displacement between load bearing walls in adjacent storeys intended to be in vertical alignment shall not exceed 6mm.

e) Deviation of bed joint from horizontal in any length upto 12m shall not exceed 6mm, and in any length over 12m it shall not exceed 12.5mm total.

f) Deviation from the specified thickness of bed-joints or perpends shall not exceed +/-3 mm.

v) Plastering work

The finished plastered surface shall not show any deviation more than 4mm when checked with a straight edge of 2 metre length placed against the surface.

The thickness of the plaster shall be measured exclusive of the thickness of key i.e. grooves or open joints in brickwork. The average thickness of plaster shall not be less than the specified thickness. The minimum thickness over any portion of the surface shall not be less than the specified thickness by more than 3 mm for plaster thickness above 12mm and 1 mm for ceiling plaster. Extra thickness required in dubbing behind rounding of the corners at junctions of wall or in plastering of masonry cornices etc. shall be ignored.








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vi) Pre-cast concrete work

a) Length: +/-0.1 percent subject to minimum of -5 mm and maximum of + 10 mm.

b) Cross-sectional dimensions: +/-3 mm or +/- 0.1 per cent whichever is greater.

c) Straightness of Bow : 1/750 of the length subject to minimum of -5mm and maximum of + 10 mm.

d) Squareness: When considering the squareness of the corner, the length of the two adjacent sides being checked shall be taken as the base line. The shorter side shall not vary in length from the perpendicular by more than 5mm.

e) Flatness: The maximum deviation from a 1.5m straight edge placed in any position on a nominal plane surface shall not exceed 5mm.

vii) Reinforcement work Description of Item Permissible Deviation Structural element in mm (Max.) Placing of reinforcement

For effective depth 200 mm or less +10 -5 For effective depth more than 200 mm +15 -10 Cover to reinforcement - -5 Cutting of reinforcement When minimum length specified +75 - When maximum or minimum length not specified +75 -25

viii) Structural steel work Tolerances on dimensions for fabrication of steel structures shall be

according to IS:7215. Tolerances on dimensions for erection of steel structures shall be according

to IS:12843.

16.03.00 BIDDER SHALL PROVIDE MINIMUM FOLLOWING FACILITIES

IN THE FIELD LABORATORY FOR MATERIAL TESTING.

A. GENERAL EQUIPMENT :

1. Balances 10. Burette stand








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2. Drier 11. Pippette

3. Thermometer 12. Wooden mallet

4. Hydrometer 13. Hair Brush

5. Hand-scoop 14. Wire brush

6. Glass beakers 15. Buckets

7. Measuring Cylinder 16. Test Tubes

8. Desiccator 17. Working platforms

9. Burette

B. Testing Equipment for conducting the following tests on concrete samples :

i) Compressive strength of concrete

ii) Slump of concrete

iii) Specific gravity and absorption and bulking of fine aggregates.

iv) Sieve Analysis of fine aggregates and coarse aggregates.

C. Testing equipment for conducting the following tests on welds for fabricated structural steel members :

i) Dye penetration test

ii) Ultrasonic test.

17.00.00 MATERIALS

i) Cement

Fly ash based portland pozzolana cement conforming to IS:1489 (Part-1) shall be used for all areas other than for the critical structures identified below. However, Engineer may allow the use of other types of cement namely, ordinary portland cement & portland slag cement conforming to IS:259 and IS:455 respectively under special circumstances on specific request of the contractor and prior approval of the Engineer. Minimum grade of cement shall be Gr.33. Higher grade of portland ordinary cement namely Gr. 43 and Gr. 53 conforming to IS:8112 and IS:12269 respectively can also be used for specific application.

Structures requiring grade of concrete of M25 and above.

The cement type shall be as approved by the owner based on soil water chemical environment.

ii) Aggregates

a) Coarse aggregate - Coarse aggregate for concrete shall be chemically inert, hard, strong, durable against weathering, of limited








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porosity and free from deleterious materials. It shall be properly graded. It shall meet the requirements of IS:383.

b) Sand - Sand shall be hard, durable, clean and free from adherent coatings or organic matter and clay balls or pellets. Sand, when used as fine aggregate in concrete shall conform to IS:383. For plaster, it shall conform to IS:1542 and for masonry work to IS:2116.

iii) Reinforcment Steel

For underground structures the type of reinforcement steel used shall be as approved by the owner based on soil water chemical environment.

However, for superstructure, reinforcement steel shall be of high strength deformed steel bars of grade Fe-415 and/or Fe-500 and shall conform to IS:1566

Mild steel & medium tensile steel bars and hard drawn steel wire shall conform to grade-1 of IS:432 (Part-I). Welded wire fabric shall conform to IS:1566.

iv) Structural Steel

Structural steel (including embedded steel) shall be straight, sound, free from twists, cracks, flow, laminations and all other defects. Structural steel shall be of tested quality and shall be of Mild steel of Grade ‘A’ upto 20 mm thickness and of Grade ’B’ normalised for thickness above 20 mm and shall conform to IS:2062. High Strength low alloy steel (HSLA) conforming to IS:8500 may also be used in place of Mild steel. Chequered plate shall conform to IS:3502 and pipes for hand rail shall conform to medium grade of IS:1161. All gratings shall be pressure locked/electroforged.

v) Bricks

Class-II bricks only are available locally. Burnt clay bricks conforming to IS:1077 shall be used. Wherever possible fly ash lime bricks conforming to IS:12894 shall also be used. The crushing strength of bricks shall be minimum 50 Kg/sq.cm.

The bricks shall be well burnt, of uniform size, shape, having sharp edges and cherry red colour. These shall be free from cracks, flaws or nodules of free lime and shall emit clear ringing sound when struck. These should not absorb water more than 20% of their weight when completely immersed in water for 24 hours.

vi) Water

Water used for cement concrete, mortar, plaster, grout, curing, washing of coarse aggregate, soaking of bricks, etc. shall be clean and free from oil, acids, alkalis, organic matters or other harmful substances in such amounts that may impair the strength or durability of the structure. Potable water shall generally be considered satisfactory for all masonry and concrete works, including curing. The Bidder shall carry out necessary tests in








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advance to prove the suitability of the water proposed to be used. When water from the proposed source is used for making the concrete, the maximum permissible impurities, development of strength and initial setting time of concrete shall meet the requirements of IS:456.

18.00.00 STATUTORY REQUIREMENTS

18.01.00 Bidder shall comply with all the applicable statutory rules pertaining to Factories Act (as applicable for the state of Gujarat), Fire Safety Rules of Tariff Advisory Committee. Water Act for pollution control, Explosives Act. etc.

18.02.00 Provisions of safety. health and welfare according to Factories Act shall be complied with.

18.03.00 Provisions for fire proof doors. number of staircases, fire separation wall, lath plastering/encasing the structural members (in fire prone areas), type of glazing etc. shall be made according to the recommendations of Tarrif Advisory Committee.

18.04.00 Statutory clearances and norms of State Pollution Control Board shall be followed.

19.00.00 Bidder shall obtain approval of Civil/Architectural drawings from owner/consultant before taking up the construction work.








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ANNEXURE-1

CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT

All structures and equipment shall be designed for seismic forces adopting the information provided in this document and using the other provisions in accordance with IS:1893 (Part 1):2002. Pending finalisation of Parts 2 to 5 of IS:1893, provisions of part 1 shall be read along with the relevant clauses of IS:1893:1984, for structures other than the buildings.

Damping in Structures

The damping factor (as a percentage of critical damping) to be adopted shall not

a) Steel structures : 2%

b) M1 Concrete structures : 5%

Method of Analysis

Since most structures are irregular in shape and have irregular distribution of mass analysis should be such that the sum total of modal masses of all modes considered is at least 90 percent of the total seismic mass and shall also meet requirements of IS:1893 (Part 1). Modal combination of the peak response quantities shall be performed as per Complete Quadratic Combination (CQC) method or by an acceptable alternative as per IS:1893 (Part 1).

For building less than 12m in height, design seismic base shear and its distribution to different floor levels along the height of the building may be carried out as specified under clause 7.5, 7.6 & 7.7 of IS:1893 (Part 1).

Design/Detailing for Ductility

Structures shall be engineered and detailed in accordance with relevant








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ANNEXURE-2

CODES AND STANDARDS

1.01.00 All standards, specifications, acts and code of practice referred to herein shall be the latest editions including all applicable official amendments and revisions.

1.02.00 In case of conflict between this specification and those (IS standards, codes etc.) referred to here - in, the former shall prevail.

1.03.00 Some of the relevant Indian standards, Acts and Codes are referred to here below :

EXCAVATION AND FILLING

IS: 2720 ( Part - II, IV TO VIII, XIV, XXI, XXIII, XXIV, XXVII TO XXIX, XL )

Methods of test for soils - determination for water content etc.

IS: 4701 Code of practice for earth work on canals.

IS: 9758 Guide lines for Dewatering during construction

IS: 10379 Code of practice for field control of moisture and compaction of soils for embankment and sub - grade.

PROPERTIES, STORAGE AND HANDLING OF COMMON BUILDING MATERIALS

IS: 280 Specification for mild steel wire for general engineering purposes.

IS: 456 Code of practice for plain and reinforced concrete.

IS: 457 Code of practice for general construction of plain & reinforced concrete for dams & other massive structures.

IS: 516 Method of test for strength of concrete.

IS: 650 Specification for standard sand for testing of cement.

IS: 1199 Methods of sampling and analysis of concrete.

IS: 1791 General requirements for batch type concrete mixers.

IS: 1838 Specification for preformed fillers for expansion

(Part - I) Joints in concrete pavements and structures (non - extruding and resilient type ).

IS: 2438 Specification for roller pan mixer.

IS: 2502 Code of practice for bending and fixing of bars for concrete reinforcement.








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IS: 2505 General requirements for concrete vibrators, immersion type.

IS: 2506 General requirements for concrete vibrators, screed board type.

IS: 2514 Specification for concrete vibrating tables.

IS: 2645 Specification for Integral cement water proofing compounds.

IS: 2722 Specification for portable swing weigh batches for concrete. (single and double bucket type)

IS: 2750 Specification for Steel scaffolding.

IS: 2751 Code of practice for welding of mild steel plain and deformed bars for reinforced concrete construction.

IS: 3025 Methods of sampling and test waste water.

IS: 3366 Specification for Pan vibrators.

IS: 3370 (Part I to IV)

Code of practice for concrete structures for the storage of liquids.

IS: 3414 Code of practice for design and installation of joints in buildings.

IS: 3550 Methods of test for routine control for water used in industry.

IS: 3558 Code of practice for use of immersion vibrators for consolidating concrete.

IS: 4014 (Parts I & II)

Code of practice for steel tubular scaffolding.

IS: 4326 Code of practice for earthquake resistant design and construction of buildings.

IS: 4656 Specification for form vibrators for concrete.

IS: 4925 Specification for batching and mixing plant.

IS: 4990 Specification for plywood for concrete shuttering work.

IS: 5256 Code or practice for sealing joints in concrete lining on canals.

IS: 5525 Recommendations for detailing of reinforcement in reinforced concrete work.

IS: 5624 Specification for foundation bolts.








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IS: 6461 Glossary of terms relating to cement concrete.

IS: 6494 Code of practice for water proofing of underground water reservoirs and swimming pools.

IS: 6509 Code of practice for installation of joints in concrete pavements.

IS: 7861 Code of practice for extreme weather concreting. (Parts I & II)

IS: 9012 Recommended practice for shot concreting.

IS: 9103 Specification for admixtures for concrete.

IS: 9417 Recommendations for welding cold worked steel bars for reinforced concrete construction.

IS: 10262 Recommended guidelines for concrete mix design.

IS: 11384 Code of practice for composite construction in structural steel and concrete.

IS: 12118 Specification for two - parts poly sulphide.

IS: 12200 Code of practice for provision of water stops at transverse contraction joints in masonry and concrete dams.

IS: 13311 Method of non - destructive testing of concrete.

Part - 1 Ultrasonic pulse velocity.

Part - 2 Rebound hammer.

SP : 23 Handbook of concrete mixes

SP : 24 Explanatory Handbook on IS: 456 - 1978

SP : 34 Handbook on concrete reinforcement and detailing.

CAST - IN - SITU CONCRETE AND ALLIED WORKS

IS: 280 Specification for mild steel wire for general engineering purposes.

IS: 456 Code of practice for plain and reinforced concrete.

IS: 457 Code of practice for general construction of plain & reinforced concrete for dams & other massive structures.

IS: 516 Method of test for strength of concrete.

IS: 650 Specification for standard sand for testing of cement.








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IS: 1199 Methods of sampling and analysis of concrete.

IS: 1791 General requirements for batch type concrete mixers.

IS: 1838 Specification for preformed fillers for expansion

(Part - I) joints in concrete pavements and structures (non - extruding and resilient type).

IS: 2438 Specification for roller pan mixer.

IS: 2502 Code of practice for bending and fixing of bars for concrete reinforcement.

IS: 2505 General requirements for concrete vibrators, immersion type.

IS: 2506 General requirements for concrete vibrators, screed board type.

IS: 2514 Specification for concrete vibrating tables.

IS: 2645 Specification for Integral cement water proofing compounds.

IS: 2722 Specification for portable swing weigh batches for concrete. (single and double bucket type)

IS: 2750 Specification for Steel scaffolding.

IS: 2751 Code of practice for welding of mild steel plain and deformed bars for reinforced concrete construction.

IS: 3025 Methods of sampling and test waste water.

IS: 3366 Specification for Pan vibrators.


Code of practice for concrete structures for the storage of liquids.

IS: 3414 Code of practice for design and installation of joints in buildings.

IS: 3550 Methods of test for routine control for water used in industry.

IS: 3558 Code of practice for use of immersion vibrators for consolidating concrete.

IS: 4014 (Parts I & II)

Code of practice for steel tubular scaffolding.

IS: 4326 Code of practice for earthquake resistant design and construction of buildings.








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IS: 4656 Specification for form vibrators for concrete.

IS: 4925 Specification for batching and mixing plant.

IS: 4990 Specification for plywood for concrete shuttering work.

IS: 5256 Code or practice for sealing joints in concrete lining on canals.

IS: 5525 Recommendations for detailing of reinforcement in reinforced concrete work.

IS: 5624 Specification for foundation bolts.

IS: 6461 Glossary of terms relating to cement concrete.

IS: 6494 Code of practice for water proofing of underground water reservoirs and swimming pools.

IS: 6509 Code of practice for installation of joints in concrete pavements.

IS: 7861 Code of practice for extreme weather concreting. (Parts I & II)

IS: 9012 Recommended practice for shot concreting.

IS: 9103 Specification for admixtures for concrete.

IS: 9417 Recommendations for welding cold worked steel bars for reinforced concrete construction.

IS: 10262 Recommended guidelines for concrete mix design.

IS: 11384 Code of practice for composite construction in structural steel and concrete.

IS: 12118 Specification for two - parts poly sulphide.

IS: 12200 Code of practice for provision of water stops at transverse contraction joints in masonry and concrete dams.

IS: 13311 Method of non - destructive testing of concrete.

Part - 1 Ultrasonic pulse velocity.

Part - 2 Rebound hammer.

SP : 23 Handbook of concrete mixes

SP : 24 Explanatory Handbook on IS: 456 - 1978

SP : 34 Handbook on concrete reinforcement and detailing.








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PRECAST CONCRETE WORKS

SP : 7 (Part VI / Sec.7)

National Building Code - Structural design of prefabrication and systems building.

IS: 10297 Code of practice for design and construction of floors and roofs using precast reinforced / prestressed concrete ribbed or cored slab units.

IS: 10505 Code of practice for construction of floors and roofs using pre - cast reinforced concrete units.

MASONRY AND ALLIED WORKS

IS: 1905 Code of Practice for Structural Safety of Buildings - Masonry walls.

IS: 2212 Code of Practice for Brickwork.

IS: 2250 Code of Practice for Preparation and use of Masonry Mortar.

SP : 20 Explanatory hand book on masonry code.

SHEETING WORKS

IS: 277 Galvanised steel sheets (plain or corrugated).

IS: 459 Unreinforced corrugated and semi - corrugated asbestos cement sheets.

IS: 513 Cold - rolled carbon steel sheets.

IS: 730 Specification for fixing accessories for corrugated sheet roofing.

IS: 1626 Specification for Asbestos cement building pipes and pipe fittings, gutters and gutter fittings and roofing fittings.

IS: 2527 Code of practice for fixing rain water gutters and down pipe for roof drainage.

IS: 3007 Code of practice for laying of asbestos cement sheets.

IS: 5913 Methods of test for asbestos cement products.

IS: 7178 Technical supply conditions for tapping screw.

IS: 8183 Bonded mineral wool.

IS: 8869 Washers for corrugated sheet roofing.

IS: 12093 Code of practice for laying and fixing of sloped roof covering using plain and corrugated galvanised steel sheets.








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IS: 12866 Plastic translucent sheets made from thermosetting polyester resin (glass fibre reinforced).

IS: 14246 Specification for continuously pre - painted galvanised steel sheets and coils.

FABRICATION AND ERECTION OF STRUCTURAL STEEL WORK

IS: 2016 Specification for plain washers.

IS: 814 Specification for covered Electrodes for Metal Arc Welding for weld steel.

IS: 1852 Specification for Rolling and Cutting Tolerances for Hot rolled steel products.

IS: 3502 Specifications for chequered plate.

IS: 6911 Specification for stainless steel plate, sheet and strip.

IS: 3757 Specification for high strength structural bolts

IS: 3664 Code of practice for Ultra sonic Testing by pulse echo method.

IS: 3613 Acceptance tests for wire flux combination for submerged Arc Welding.

IS: 3658 Code of practice for Liquid penetrant Flaw Detection.

IS: 5334 Code of practice for Magnetic Particle Flaw Detection of Welds.

PLASTERING AND ALLIED WORKS

IS: 1635 Code of practice for field slaking of Building lime and preparation of putty.

IS: 1661 Application of cement and cement lime plaster finishes.

IS: 2333 Plaster - of - paris.

IS: 2402 Code of practice for external rendered finishes.

IS: 2547 Gypsum building plaster.

IS: 3150 Hexagonal wire netting for general purpose.

WATER SUPPLY, DRAINAGE AND SANITATION

IS: 458 Specification for concrete pipes.








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IS: 554 Dimensions for pipe threads, where pressure tight joints are made on thread.

IS: 651 Specification for salt glazed stoneware pipes.

IS: 774 Flushing cisterns for water closets and urinals.

IS: 775 Cast iron brackets and supports for wash basins and sinks.

IS: 778 Copper alloy gate, globe and check valves for water works purposes.

IS: 781 Cast copper alloy screw down bib taps and stop valves for water services.

IS: 782 Caulking lead.

IS: 783 Code of practice for laying of concrete pipes.

IS: 1172 Basic requirements for water supply, drainage and sanitation.

IS: 1230 Cast iron rain water pipes and fittings.

IS: 1239 Mild steel tubes, tubulars and other wrought steel fittings.

IS: 1536 Centrifugally cast ( Spun ) iron pressure pipes for water, gas and sewage.

IS: 1537 Vertically cast iron pressure pipes for water, gas and sewage.

IS: 1538 Cast iron fittings for pressure pipe for water, gas and sewage.

IS: 1703 Ball valves ( horizontal plunger type ) including float for water supply purposes.

IS: 1726 Cast iron manhole covers and frames.

IS: 1729 Sand cast iron spigot and socket, soil, water and ventilating pipes, fittings and accessories.

IS: 1742 Code of practice for building drainage.

IS: 1795 Pillar taps for water supply purposes.

IS: 1879 Malleable cast iron pipe fittings.

IS: 2064 Code of practice for selection, installation and maintenance of sanitary appliances.

IS: 2065 Code of practice for water supply in building.

IS: 2326 Automatic flushing cisterns for urinals.








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IS: 2470 (Part - I & II)

Code of practice for installation of septic tanks.

IS: 2501 Copper tubes for general engineering purposes.

IS: 2548 Plastic seat and cover for water - closets.

IS: 2556 (Part 1 to 15)

Vitreous sanitary appliances (vitreous china).

IS: 2963 Non - ferrous waste fittings for wash basins and sinks.

IS: 3114 Code of practice for laying of cast iron pipes.

IS: 3311 Waste plug and its accessories for sinks and wash basins.

IS: 3438 Silvered glass mirrors for general purposes.

IS: 3486 Cast iron spigot and socket drain pipes.

IS: 3589 Electrically welded steel pipes for water, gas and sewage (200mm to 2000mm nominal diameter).

IS: 3989 Centrifugally cast (Spun) iron spigot and socket soil, waste and ventilating pipes, fittings and accessories.


Code of practice for ancillary structure in sewerage system.

IS: 4127 Code of practice for laying of glazed stone - ware pipes.

IS: 4764 Tolerance limits for sewage effluents discharged into inland - surface waters.

IS: 4827 Electro plated coating of nickel and chromium on copper and copper alloys.

IS: 5329 Code of practice for sanitary pipe work above ground for buildings.

IS: 5382 Rubber sealing rings for gas mains, water mains and sewers.

IS: 5822 Code of practice for laying of welded steel pipes for water supply.

IS: 5961 Cast iron grating for drainage purpose.

IS: 7740 Code of practice for road gullies.

IS: 8931 Cast copper alloy fancy bib taps and stop valves for water services.








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IS: 8934 Cast copper alloy fancy pillar taps for water services.

IS: 9762 Polyethylene floats for ball valves.

IS: 10446 Glossary of terms for water supply and sanitation.

IS: 10592 Industrial emergency showers, eye and face fountains and combination units.

IS: 12592 Specification for precast concrete manhole covers and frames.

IS: 12701 Rotational moulded polyethylene water storage tanks.

SP : 35 Hand book on water supply and drainage.

- Manual on Sewerage and sewage treatment ( Published by CPH & EEO ) As updated.

PILING AND FOUNDATION

IS: 1080 Code of practice for design and construction of simple spread foundations.

IS: 1904 Code of practice for design and construction of foundations in Soils; General Requirements.

IS: 2950 (Part- I) Code of practice for designs and construction of Raft foundation.

IS: 2974 (Part - I TO V)

Code of practice for design and construction of machine foundations.

IS: 6403 Code of practice for determination of Allowable Bearing pressure on Shallow foundation.

IS: 8009 Code of practice for calculation of settlement of foundation subjected to symmetrical vertical loads.

Part - I Shallow foundations.

Part – II Deep foundations.

IS: 12070 Code of practice for design and construction of shallow foundations on rocks.

DIN : 4024 Flexible supporting structures for machines with rotating machines.

VDI : 2056 Criteria for assessing mechanical vibrations of machines.

VDI : 2060 Criteria for assessing rotating imbalances in machines.








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ROADS

IRC : 5 Standard specifications and Code of practice for road bridges, section - I general Features of Design.

IRC : 14 Recommended practice of 2cm thick bitumen and tar carpets.

IRC : 16 Specification for priming of base course with bituminous primers.

IRC : 19 Standard specifications and code of practice for water bound macadam.

IRC : 21 Standard specifications and Code of practice for road bridges, section - III - Cement concrete (plain and reinforced).

IRC : 37 Guidelines for the Design of flexible pavements.

IRC : 86 Geometric Design standards for urban roads in plains.

IRC : SP : 13 Guidelines for the design of small bridges & culverts.

IRC - Publication Ministry of Surface Transport ( Roads Wing ), Specifications for road and bridge works.

IS: 73 Specification for paving bitumen

LOADING

IS: 875 (Pt. I to V) Code of practice for design loads other than earthquake ) for buildings and structures.

IS: 1893 Criteria for earthquake resistant design of structures.

IS: 4091 Code of Practice for design and construction of foundation for transmission line towers & poles.

IRC : 6 Standard specifications & code of practice for road bridges, Section - II Loads and stresses.

M.O.T. Deptt. of railways Bridge Rules.

SAFETY

IS: 3696 (Part I & II)

Safety code for scaffolds and ladders.

IS: 3764 Safety code for excavation work.

IS: 4081 Safety code for blasting and related drilling operations.








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IS: 4130 Safety code for demolition of buildings.

IS: 5121 Safety code for piling and other deep foundations.

IS: 5916 Safety code for construction involving use of hot bituminous materials.

IS: 7205 Safety code for erection on structural steelwork.

IS: 7293 Safety code for working with construction machinery.

IS: 7969 Safety code for handling and storage of building materials

IS: 11769 Guidelines for safe use of products containing asbestos.

Indian Explosives Act. 1940 as updated.





PART – B

SECTION-III : MECHANICAL

M-01 : FIRE DETECTION SYSTEM






PART-B

SECTION-III:M-01 FIRE DETECTION

SYSTEM

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CONTROL AND INSTRUMENTATION FOR FIRE DETECTION SYSTEM


1.01.00 The design, manufacture, testing, performance, etc. of the various components of the analog addressable Fire Detection and Alarm System shall comply with all currently applicable statutes, 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.

1.02.00 Unless otherwise specified, the Fire Detection and Alarm System and the components shall conform to the latest applicable Indian or IEC Standards. Equipment complying with any other authoritative National Standards such as British, USA, VDE, etc. will also be considered, provided the parameters specified are equivalent or better than the corresponding IS.

1.03.00 Certified copies of test reports and approvals shall be furnished along with the Bid.

2.00.00 AVAILABLITY REQUIREMENTS

2.01.00 The equipment and system shall be designed for maximum reliability and availability and shall be of proven design using material with well established physical and chemical properties and as appropriate to the service intended.

2.02.00 Monitoring circuits shall be provided to check the proper functioning of all systems/sub-systems.

2.03.00 Components used shall be provided with adequate design margins to provide intended degree of availability of the system.

3.00.00 APPROVALS FOR SYSTEMS AND COMPONENTS

3.01.00 GENERAL

3.01.01 The Contractor shall be solely responsible for obtaining the required approval and clearance for the different components and systems of the Fire Detection and Alarm System from the following authorities, as applicable:

(a.) Department of Atomic Energy (Certification of safety from Radioactivity).

(b.) Central Building Research Institute, Roorkee.

(c.) Central Mining Research Station, Dhanbad.

(d.) Local Fire Authorities.

3.01.02 The equipment and the system shall be of types approved by any of the following bodies, as applicable:

(a.) Loss Prevention Council, (LPC), U.K.






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(b.) National Fire Protection Association, (NFPA), USA

(c.) Under-writers laboratories, (UL), USA

(d.) Factory mutual(FM)

Approval/clearance certificates from one of the above bodies shall be furnished by the Contractor. Further the system and its equipment shall have the approval of Tariff Advisory Committee (TAC), India.

3.01.03 All the Components shall be suitable for installation and satisfactory performance under the atmospheric conditions specified in this specification.

3.01.04 The components shall be suitable for satisfactory operation even when the auxiliary supply voltage falls to 70% of their rated voltage.

3.01.05 The components shall be free from false operation due to vibration and mechanical shocks. All electrical contact shall be platinum or silver or other suitable metal alloy and shall be capable of withstanding 10,000 operations

3.01.06 Fire detection and alarm circuits shall be of modular design using electronic printed plug-in card circuits to facilitate easy replacement of faulty circuits with spare cards. Electronic components and cards shall be compatible with non air-conditioned environment for satisfactory operation.

3.01.07 All components shall be clearly and unambiguously marked for proper identification which facilitates maintenance. The wires shall be colour coded.

3.01.08 Readily accessible and clearly marked test points shall be provided in all important modules and circuits.

3.01.09 The equipment shall be able to withstand any impulse arising from power source, batteries, etc. without being damaged.

3.01.10 As far as possible, test equipment shall be built into the equipment. Those that are not built-in shall be furnished as a test kit.

3.01.11 The printed circuit boards (PCBs) shall be of glass epoxy and not Bakelite sheets.

3.01.12 The PCB thickness shall be properly selected so that perfect contact is made between card and female connector. The solder shall not be applied on contacts of PCBs to increase the thickness.

3.01.13 The PCB layout shall be as per individual circuit connection requirement and wire jumpers shall be avoided for the interconnections.

3.01.14 Clips or channels shall be provided with latching facility for holding the PCBs in position.

3.01.15 The contacts for holding the PCBs shall be gold plated and not silver plated.






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3.01.16 Quality of soldering should be such that dry solders shall be avoided. The quality of soldering shall be comparable with machine soldering.

3.01.17 High heat dissipation components shall not be mounted on PCBs to avoid damage to PCB’s and loosening of solder connection due to heat.

4.00.00 DETECTION SYSTEM

4.01.00 General requirements for all types of Detectors

4.01.01 Detectors shall be housed or mounted in suitable enclosure in such a way that their performance is in no way affected. Special maintenance procedures if any required for the satisfactory operation of the detectors shall be clearly stated in the bid.

4.01.02 Necessary mounting accessories shall be provided for all the detectors.

4.01.03 In case the detectors are offered with their output (on sensing a fire) in the form of an electrical contact, it shall be noted that the contact shall be ‘NC’ type such that under fire conditions, this contact will open to initiate the fire alarm system.

4.01.04 Detectors shall preferably be designed as plug-in units, which fit into various bases according to place and type of mounting. This would also enable interchangeability.

4.01.05 Detectors shall be provided with the necessary compression type cable terminating glands for the incoming cables of flameproof type or PVC/metallic flexible/rigid conduits.

4.01.06 Depending upon the environmental conditions in which detectors are installed, chlorinated rubber based or epoxy or equivalent paint shall be used for finishing the surface of the enclosure.

4.01.07 The coverage or the zone of protection afforded by the detector and recommended height of mounting shall be furnished by the Bidder. The bidder shall furnish the test certificate in support of this.

4.01.08 Any metal parts used for detector construction shall be inherently resistant to corrosion or shall be plated or otherwise suitably treated to afford protection against corrosion. The plating or treatment shall in no way affect the detector performance.

4.01.09 Any plastic material or any sealing compound used in the detector shall be such as it will not deform or fail under the maximum temperature to be expected.

4.01.10 No detector shall contain any moving parts subject to wear and tear and must be able to operate afresh after each alarm release, without its exchange or adjustment.

4.01.11 The detector shall be located where the largest combustion gas concentration can be expected.

4.01.12 Adequate compensation and considerations shall be made for effects for wind velocities such as air-conditioning system and exhaust fans where dilution of particles of combustion is greater.






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4.01.13 The exact location of detectors shall be coordinated with other services like air-conditioning grills, light fittings, cable trays etc. to provide aesthetically pleasing appearance. The return air paths of air-conditioning shall be avoided for detector location.

4.01.14 The detectors shall not be affected by temperature, humidity; air flow or by drift failures and shall not give any false alarm due to above.

4.01.15 The detectors shall not be sensitive to vibrations. Any special mounting arrangements required to counteract vibration shall be included in the contractor scope.

4.01.16 The minimum number of detectors shall be as per the BOM. The quantity of smoke detectors in each zone indicated in BOM is based on a coverage factor of 25-sq. meter per detector. However the actual quantity of detectors required, taking into consideration obstructions due to floor beams, ventilation, doors, windows etc., shall be worked out and supplied (based on the actual layout) and installed by the contractor. Any increase in quantity of detectors over and above the quantity specified in BOM due to such layout aspects shall be paid to contractor.

4.01.17 The detectors shall not give false alarm due to high humidity, temperature, and velocity of air in the surroundings and static electricity conditions.

4.01.18 All detectors shall incorporate internal automatic temperature compensation to overcome the effects of either high or low ambient temperatures in the installed environment on the detector sensitivity.

4.01.19 Process actuated switch devices such as pressure switches, flow switches, level switches, etc. shall be provided with suitable individual addressable interface (local or remote) units or modules so that these devices are addressable from the panel.

4.02.00 Addressable Analog Intelligent Detectors

In addition to the features specified under the item General requirements for all types of Detectors, the Addressable Analog Intelligent Detectors shall be provided with the following features:

(a.) Detectors not specifically listed for sensitivity testing from the control panel are not acceptable due to the expense involved with manual testing as required by NFPA 72E.

(b.) The detector shall be suitable for two-wire operation and two-way communication on the intelligent analog signaling circuit.

(c.) The detector shall display a steady LED when in the Alarm State. The LED shall flash when in stand by or normal mode.

(d.) Address and sensivity assignments shall be set preferably electronically. However, dip switches / rotary switches for the same are acceptable. The detectors shall be assigned a sensitivity level based on environment, time of






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day or any programmable function as required by the system user, and shall respond at that level whether in the “on line” or “default” mode.

(e.) The detectors furnished shall be listed for use in environments as covered by Factory Mutual and UL and shall be installed according to the requirements of NFPA 72E for open area coverage.

4.03.00 Infra-red Detectors - NA

4.04.00 Linear Heat Sensor Cables - NA

4.05.00 Installation features for LHSC/IR detectors - NA

4.06.00 Smoke Detectors

4.06.01 The detectors shall be sensitive to very low smoke densities of the order of say 0.05 g/m3. Also it shall be possible to adjust this sensitivity on a step less basis over a range so that the optimum sensitivity could be selected at site to suit the conditions of installations. The coverage area of the smoke detection under standard NFPA test conditions shall not be less than 80-90m2.

i. The smoke detector shall be of Multisensor type and photoelectric type as required.

ii. The detectors shall be complete with a mounting base that includes a terminal box into which the detector can be plugged in. Terminals for looping of the cables shall be provided. The base shall be suitable for both multisensor and photoelectric type detectors.

iii. All detectors shall be provided with built-in response and indicating lamps which shall give local visual indication, when it has operated in dense smoke conditions. The failure of lamp shall not prevent the function of detector.

iv. In areas such as false ceiling where detectors themselves are not easily accessible, the remote response indicators outside the enclosed areas shall be provided to indicate the fire condition.

4.06.02 It shall be possible to replace any type of detector head by a different type detector without requiring change in cabling/panel wiring and condition of the zone, originally covered by the detector, thereby making it possible for a smoke detector to be replaced by either heat, flame detector or vice versa.

4.06.03 All types of smoke detectors shall be of analogue addressable type. Conventional detectors with interface modules are not acceptable. Each zone of LHSC detector and each IR detector shall be provided with interface module.

4.07.00 Multisensor

Multisensor detectors shall incorporate a heat detection element and a photoelectric detection element. Both the elements shall be incorporated in a






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single unit. Both the elements shall be operative at all times and the fire signal shall be available from any or both elements combined together.

5.00.00 SYSTEM CONFIGURATION

5.01.00 The detectors or other devices of any unit/area shall be addressable only from the respective Addressable Fire Alarm Panel, so that each of the Addressable Fire Alarm Panel is under the control of designated operating personnel at that location.

5.02.00 The Fire alarm panel shall be provided with necessary interface hardware and software for dual fibre optic connectivity & interconnection with station wide LAN (in employer’s scope) for two –way transfer of signals for the purposed of information sharing. The information shall be made available though on Ethernet link following TCP/IP standard. The system shall be OPC compliant. The exact data structure shall be as decided during detailed engg.

6.00.00 ANALOG ADDRESSABLE FIRE DETECTION AND ALARM SYSTEM

6.01.00 General Requirements

6.01.01 This specification in general covers the functional requirements, and general design aspects of Microprocessor based, Analog Addressable Fire Detection Alarm / Annunciation and Control System.

6.01.02 The following description intends to describe only the brief hardware and functional requirements, scope of hardware requirements etc. but the actual configuration of the system shall be in line with the prevalent normal practices in the industry and shall conform to latest product range of selected manufacturer.

6.01.03 The fire detection and control system offered shall be complete in all respects for the safe and reliable operation of the entire system. Any additional hardware/software than those mentioned herein required to make the system complete shall be included in the scope of the Bidder.

6.01.04 All the system and its equipment specifically detectors, interface modules, panels, power supply, battery chargers etc. shall be furnished from a single source and the same shall be new and latest state of the art products of manufacturer engaged in the manufacture of Integrated Microprocessor based Analog Addressable Fire Detection and Alarm System.

6.01.05 Complete system and all equipments such as detectors, panels etc shall be approved and listed by UL/FM/LPCB/VDS/TAC.

6.01.06 All the fire detection systems, process actuated switch devices such as pressure/flow/temperature switches and relays of control functions shall be hooked up with the analogue addressable fire detection and alarm system. Required addressable interface units shall be provided for various switch devices by the bidder to make them addressable.

6.01.07 The wiring shall be of Style 7 as per NFPA-72 with loop / short circuit isolators.






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6.01.08 Each of building / areas shall be considered as a zone and isolators shall be provided zone wise. Isolators shall be provided for every 20 devices in case of large building.

6.02.00 The complete system shall include, but not be limited to the following :

a) Analog addressable type smoke detectors.

b) Analog Addressable Fire Detection and Alarm System panels with master CPU, alarm modules, system supervisory control modules, auxiliary output control modules etc.

c) Printers (preferably inbuilt to Analog Addressable Fire Detection and Alarm System ) to print out the alarm/ trouble occurrences

d) Power supplies, batteries and battery chargers.

e) Software and hardware as required for complete operation of the system.

f) Complete Wiring/cabling including its conduits/trays/fixtures etc.

g) The software logic modules and system database shall be programmable using a MS - Windows compatible program (latest version) on PC and required hardware shall be included in scope of supply. The system software programme shall be password protected and shall include full upload and download capability. During program upload or download on the PC, the capability of alarm reporting shall be retained. The software shall be capable of being edited from PC based monitoring station.

h) The software shall enable Employer to add the spare loop provided in the fire alarm panels or addition of additional devices/detectors in any of the fire alarm panel.

i) The system shall support the use of Color Graphic display terminal for the display of information in an appropriate format.

j) System configuration shall be menu driven and capable of being operated by, a person with no previous computer programming experience.

6.03.00 System Functional Requirements

6.03.01 The fire alarm control panel shall function as a communication interface between central processing unit and sensors.

6.03.02 The CPU shall serve as the systems central processor. Software shall be designed specially for fire alarm annunciation system applications and shall monitor status of processing alarms according to priorities, controlling/processing communications and synchronising all system activities.

6.03.03 The system shall support the use of color interactive History Reporting video display terminal for the display of information in an appropriate format and shall include






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software for system data base, historical event log, logic, and operating system. The system shall require no manual input to initialise in the event of a complete power down condition. It shall return to an on line state as an operating system performing all programmed functions upon power restoration.

6.03.04 All Fire alarm panel shall be capable of being monitored by PC based central monitoring stations.

6.03.05 Each of the fire alarm control panel shall support analog addressable detectors of all types, non-addressable type detectors/devices along with its addressable interface units/modules, Video display units etc.

6.03.06 All devices shall be individually identifiable for its type, its zone location, alarm set value, alarm and trouble indication by an unique alpha numerical label.

6.03.07 Each of the devices and/or detectors shall be individually, uniquely and continuously addressable by the panel to which it is connected

6.03.08 This panel shall have facility to process the input signal and to control all the input data received from initiating and indicating devices

6.03.09 The system shall be able to recognize and indicate an alarm condition in a degrade mode of operation, in the event of processor failure or the loss of system communications to the circuit interface panels.

6.03.10 Detectors shall be interrogated for sensitivity settings from the control panel, logged for sensitivity changes indicating the requirement for cleaning and tested by a single technician using the field test routine.

6.03.11 The detectors shall be tested at a specified frequency by raising the detector sensitivity level to the alarm threshold, to check the operation of the detector without system alarming automatically by the control panel

6.03.12 Fire alarm control panel shall have filters to ignore false alarm and shall be capable of self-adjustment to compensate for the accumulation of contaminants that would change the detector sensitivity in either a more or less sensitive direction to prevent false indications or failure to alarm in the actual fire conditions.

6.03.13 The system shall annunciate a trouble condition when any analog addressable smoke detector reaches 80% of its alarm threshold due to gradual contamination, signaling the location of device requiring service.

6.03.14 The fire alarm panel shall evaluate the signals received from the detectors and shall handle the following functions:

1. System self monitoring and fault signaling.

2. Transmission of alarm and fault signals to the respective fire alarm panels and as well as in the repeater panel in fire station (in future). Further, the panel shall activate a hooter/sounds in each of the area locally provided with fire/smoke detection system. Further, the system shall enable operation of






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SYSTEM

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spray system from the panel through monitoring station when the system operation is selected under remote manual mode.

3. Initiate control functions like closure of fire doors, shutdown of draft fans, air-conditioning and ventilation plant/ equipment, opening smoke extraction vents, switching on smoke extraction equipment, emergency lighting etc.

4. Triggering stationary extinguishing systems such as clean agent system.

5. Supervising of unauthorised removal of a detector head from its base and giving a fault alarm on the control panel.

6. Supervising and monitoring the detection cabling, to indicate fault conditions in case of open/short circuit in the wiring.

7. Supervising by a separate annunciation window, changeover from mains supply to battery supply. “Mains On” indication shall be continuously on, as long as the main supply is available.

8. Facilitating simulation of fire conditions to enable the testing of circuits (without creating actual fire) under the test mode from the fire Alarm panel.

9. The control unit shall contain all the systems main switches lamps and fuses. Switches and lamps shall be easily identified even in closed casings.

10. All the circuits from the detectors to the panels and the circuits from panels to the actuating/operating devices of the respective extinguishing system shall be of closed loop type and shall be supervised for grounding, open-circuiting, and short-circuiting of cables. The cable fault shall be audio-visually annunciated on the panels. Separate hooters with different tones shall be provided for ‘fault’ alarms and ‘fire’ alarms.

11. Actuate solenoid valve in spray system in case of fire from respective fire alarm panel. For achieving this if any additional hardware is required like relays, power supply and cables, the same may be provided.

6.03.15 Activation of any fire alarm initiating device shall display (LCD alpha numeric display) message (describing the device originating the alarm condition) at the Central monitoring station, at alarm panel, and shall initiate the associated protection systems & other related control functions. Similarly activation of any supervisory circuit, (supervised valve closure, fire pump trouble, water pressure low, etc.) or receipt of trouble report (primary power loss, open or grounded initiating or signaling circuit wiring, battery disconnect etc) shall display at the fire alarm control panel the origin of supervisory condition or origin of trouble condition as the case may be. It shall also record the occurrence of the event, the time of occurrence and the device initiating the same.






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6.03.16 Panel Display Requirements.

System display shall consist of minimum 80 character back lighted alphanumeric LCD display readable at any angle. Thirty-two character customer defined custom messages shall describe the location of the active device. In addition to the above, the following features shall be available.

a. The system shall be capable of programming to allow troubles occurred and restored in the system to be automatically removed from the display queue, eliminating the necessity for individual acknowledging of these events. This feature shall not affect the historical logging of events as programmed.

b. As a minimum an LED display for “Alarm”, “Audible Silenced”, “Supervisory”, “Trouble”, “Security”, “Power On”, And “Partial System Disabled”.

c. Touch activated membrane switches for “Alarm Acknowledge”, “Audible Silence”, “Supervisory Acknowledge”, “Security Acknowledge”, “Reset”, “Display Hold”, And “Display Next”.

d. All membrane switches shall be tactile with audible feedback when pressed.

7.00.00 PC BASED MONITORING STATION - NA

8.00.00 SYSTEM SOFTWARE REQUIREMENTS

i) The software shall control the operation, function and display of the graphic system and provide for automatic boot up and run from the hard disk drive of the computer.

ii) All project specifics actuating device programming shall be capable of being carried out on site via password access.

iii) The system shall monitor all alarm, supervisory; trouble and security conditions detected by the fire alarm control panel and provide separate disk based files, for each condition. These logs may be enabled, disabled, or cleared with password access.

This log information is not to be lost upon power failure or fire alarm control panel reset. A utility file shall be provided to sort the log data by date or by device and display this information either on the screen or the system printer.

iv) Selective memory storage up to 800 events, shall be stored in flash memory and displayed, printed or downloaded by classification for selective event reports.

a. Software shall allow selection of events to be logged, including; inputs as alarms, troubles, supervisors, securities, status changes and device verification; out puts, as audible control and output activation; action, as reset, set sensitivity, arm/disarm, override, password, set time and acknowledge.






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b. Audible and visual indications shall be generated when memory is 80% and 90% full to allow downloading of data. The system shall be programmable circular logging, assuring that at least the last 400 events will always be stored in non-volatile memory.

v) Software has driven logic for adjusting the alarm threshold windows on detectors to compensate for accumulating contamination and keep detector response sensitivity constant. The software shall compensate for either over-sensitized or desensitized units, raising a system flag when a detector approaches the allowable limits of adjustment, indicating a requirement for cleaning.

a. Values shall be stored in non-volatile memory allowing activation of all tracking functions within 90 sec of system initiation from a "cold boot". During the boot sequence, alarms from detectors programmed with the feature shall be suppressed.

When the full data history is active all devices shall be checked and any active alarms displayed.

b. The control panel shall place each detector in the system in an alarm condition, transparent to the system user, every twenty-four hours as a dynamic check of the accuracy of the alarm threshold setting. Upon reception of the alarm report, the system detector shall be restored to its pretest state.

d. The system shall be capable of recognizing that a detector has been cleaned, initiating a series of tests to determine if the cleaning was successful and display a detector cleaned message, readjusting that detectors normal sensitivity setting reference.

vi) When an alarm or trouble is registered at the fire alarm control panel the graphics system shall display the first screen image for the first actuated device. The system shall be capable of zooming in for further information if required. At all times when in the alarm or trouble mode the fire control panel status i.e. number of current alarms and or troubles is to be displayed on the graphics screen.

9.00.00 SYSTEM TESTING /COMMISSIONING

The complete Fire Detection and Alarm System shall be tested so that each of the above mentioned functions are demonstrated to the satisfaction of the Employer. The Contractor shall make all equipment, instruments, tools and labour required to conduct the system tests available.

The complete performance testing procedure shall be drawn before the tests by the Contractor and shall be approved by the Employer.






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10.00.00 SERVICES

10.01.01 The contractor shall guarantee the entire system against mechanical and electrical defects for a period described in the Conditions of Contract.

10.01.02 The Contractor's scope of services shall also includes two inspections of the complete system including testing and repairs if any and system re-commissioning, in full compliance with the requirements of NFPA during guarantee period of the complete fire alarm and detection system.

10.01.03 The contractor performing the above mentioned contract services shall be qualified and listed to maintain ongoing certification of the completed system to the UL, (USA) for specific installed system listing.





PART – B

SECTION-III : MECHANICAL

M-02 : AIR CONDITIONING SYSTEM






PART-B

SECTION-III:M-02 AIR CONDITIONING

SYSTEM

PAGE 0 OF 16

AIR CONDITIONING SYSTEM

1.00.00 GENERAL

1.01.00 This section of specification covers details of system specifications, detailing the areas to be air-conditioned, basis of design, brief description of the system, equipment and services to be furnished by Contractor. The supply, delivery and erection of the entire equipment listed here shall be in Contractor's scope.

1.02.00 Description of Air Conditioning System scheme

1.02.01 The details of AC system is as

1.02.02 The Plant shall consist of two (2) numbers of air-cooled Condensing unit of capacity 25 TR each with all its accessories.

1.02.03 Air Handling units shall be located in AHU room at ground floor. The conditioned air shall be re-circulated through ducts/plenum and diffusers/grills.

1.02.04 Insulated chilled water pipes shall be routed to respective AHUs with proper water balancing.

1.03.00 Design Basis

1.03.01 The air conditioning system will be designed to provide specified environmental condition for equipment and/or personnel during all modes of plant operation. Filtering, cooling, heating, humidification/dehumidification of the supply air and its distribution shall be done to maintain the specified condition within the specified limits.

1.03.02 All air conditioned areas shall be maintained at 24 deg. C ± (plus or minus) 1 deg. C and relative humidity of 50% ± (plus or minus) 5%.

1.03.03 All the equipments of Air Conditioning system shall be designed for continuous duty.

1.03.04 The supply and return air ducts shall be provided with automatic motorized operated fire dampers at locations as specified for isolation and fire protection purpose. The operation of these automatic dampers shall be interlocked with the fire alarm system and shall also be possible to operate manually from the remote control panel. Required electrical contacts shall be provided in control panel of A/C plant by the Contractor for further wiring upto Fire alarm panels.

1.03.05 Coil face area of Air Handling units shall be designed considering a face velocity of not more than 2.5 m/sec.

1.03.06 Water piping shall be sized for a maximum velocity of 2.0 m/sec. However gravity flow / pump suction line shall be sized for a maximum water velocity of 1.5 m/sec.

1.03.07 The air distribution system shall be sized to have a constant frictional drop along its length and velocity through ducts shall not exceed 7.6 m/sec.






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1.03.08 Continuous Motor rating (at 50 deg.C ambient) for pumps shall be at least ten percent (10%) above the maximum load demand of the pump in the entire operating range.

1.03.09 For fans, compressors and blowers continuous Motor rating (at 50 deg.C ambient) shall be atleast ten percent (10%) above the maximum load demand of the Fan, compressors, blower at the design duty point.

1.03.10 Wherever belt drives are used the belts shall be sized for 150% of the rated power and there shall be minimum of two belts per drive.

1.03.11 Noise level within the air conditional space shall be restricted to 35-45 NC level with suitable acoustic attenuation/ duct silencers/ acoustic insulation, etc.

1.03.12 For calculating friction loss in piping system: WILLIAM & HAZEN formula shall be used with C value as 100.

2.00.00 EQUIPMENT DESCRIPTION – AIR CONDITIONING SYSTEM

The AC plant shall comprise of Refrigerant Compressor with drive motor, Condenser, Water Chiller/evaporator, Chilled water pumps, Condenser Cooling Water pumps, other accessories such as supporting structure, vibration isolators, insulation, piping, valves, instrumentation, microprocessor / PLC based Control panel, etc.

2.01.00 VAPOUR ABSORPTION MACHINE

2.01.01 NA

2.02.00 VAPOUR COMPRESSION TYPE MACHINES

2.02.01 The Reciprocating compressor type chilling unit to be supplied shall be ARI / Eurovent / Equivalent standard certified.

2.02.02 Condensing unit

Type Air-cooled type.

Vibration isolators : Steel spring/ Neoprene rubber cushy foot/ neoprene serrated rubber pad type with isolation efficiency not less than 85%.

Compressor

Type

:

Compressor shall be reciprocating / scroll type, serviceable, either open or semi-hermetic type with load, unload and automatic control facilities (minimum 3 steps) with maximum speed of 1500 rpm.

Type of drive : Motor driven, through direct/V-belt






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Refrigerant : The refrigerant shall be R-22/ R-123/ R-134a/ R-410A or any other environment friendly refrigerant.

Capacity : Minimum capacity shall be suitable for the identified/selected evaporating temperature and condensing temperature.

Motor rating : 10% more than the power required by the compressor at 50 deg. C design ambient condition

Condenser

Condensor coil : Seamless copper arranged in staggered rowsand mechanically expanded into super slit aluminium fins

Condenser fan : Propeller type driven by motor and positioned for vertical air discharge

Condenser fan motor : Totally enclosed squirell cage type with IP-55 protection and designed for outdoor operation in high ambient temperature

2.03.00 Air Handling Unit (AHU)

2.03.01 Each AHU shall consist of casing, fan impeller section, cooling coil section, damper section, steel frame with vibration isolators (minimum efficiency of 85%) for the complete AHU, isolation dampers at the suction and discharge of each AHU shall be provided in case return air duct is directly connected to AHU. However, in case AHU room is used for return air, isolation dampers are required to be provided only at AHU discharge of each AHU. Pre-filter at the suction and fine (micro-vee type) at the discharge of each individual AHU, and heater section in the common discharge of AHUs.

2.03.02 The casing of AHUs shall be of double skin construction. Double skin sandwich panels (inside and outside) shall be fabricated using minimum 0.63 mm (24g) galvanized steel sheet, with 25mm thick polyurethane foam insulation of minimum 38 Kg/Cum density in between. Suitable reinforcements shall be provided to give structural strength to prevent any deformation/buckling.

2.03.03 Cooling coil shall be of seamless copper tubes with aluminium fins and shall be provided with suitable drains and vents connections.

2.03.04 All filter plenum shall be provided with a walking platform inside the plenum chamber for filter cleaning purpose. Inspection door shall be provided at the plenum chamber and a removable type ladder shall be attached to plenum.

2.03.05 Fan impeller Section :

a) Fan impeller : Forward/ backward curved blade & centrifugal type.






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Material – MS with Spray Galvanisation.

b) Casing material : GI /Mild steel spray galvanized with minimum thickness of 3 mm.

c) Fan bearings : Self aligning type, permanently lubricated, heavy duty with a design life of 10,000 operating hours.

d) Critical speed : First critical speed of rotating assembly shall be at least 25% above the operating speed.

e) Drive : Motor driven with removable belt guard.

2.03.06 Pan humidifier with tank and header in common discharge plenum shall be provided. A make up water line with float valve shall be provided for Pan humidifier tank.

2.04.00 PACKAGED / SPLIT TYPE AIR CONDITIONERS

2.04.01 a) These shall in general consist of the following:

i) Casing

ii) Compressor

iii) Condenser

iv) Air Handling Fan

v) Cooling Coil

vi) Filters

vii) Piping, valves, refrigerant strainer etc.

viii) Controls, Instruments, control panel/starter panels.

ix) Vibration Isolator pads, Ducting (if applicable), diffusers, grills, etc. as required.

b) The compressor shall be scroll type and of hermetic type.

c) The condenser shall be air cooled.

d) The air-handling fan shall be centrifugal type with forward curve blade with variable speed pulley for adjusting the air flow.

e) Cooling coil shall be D-X type.

f) Vibration isolator pads shall be provided with isolation efficiency of minimum 85%.






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3.00.00 BALANCE EQUIPMENT SPECIFICATION

3.01.00 Centrifugal Pumps - NA

3.02.00 Material of Construction for Piping & Fittings

a) Piping for Chilled and Condenser water lines

: Heavy grade-IS:1239 or Equivalent upto150 NB and IS:3589 or Equivalent for pipes beyond 200 NB with a minimum thickness of 6 mm.

b) Drain piping : Same as (a) above & galvanized as per IS:4736.

c) Refrigerant piping : : Seamless steel tubes conforming heavy grade IS:1239 or copper tubes as per IS:2501 (copper material as per IS:191 hard copper grade).

d)

Fittings

: 1) The steel fittings shall conform to ASTM A234 Gr. WPB and dimensional standard to ANSI B 16.9/ANSI B16.11 / equivalent for sizes 65 NB and above.

2) For sizes 50 NB and below, the material shall conform to ASTM A-105.

3) All steel flanges shall be of slip on type and shall conform to ANSI B 16.5

4) For pipe sizes above 350 NB, fabricated fittings from sheets of adequate thickness may be used. The bend radius in case of mitre bends shall be minimum 1.5 times the nominal pipe diameter and angle between two adjacent sections shall not be more than 22.5 deg and shall be as per BS:2633/BS:534.

5) Fittings, flanges and pipe joints of refrigerant piping shall conform to ANSI B31.5

3.03.00 VALVES

i) Valves shall have full sizes port and suitable for horizontal and as well as vertical installation.

ii) Valves for regulating duty shall be of globe type suitable for controlling throughout its lift.

iii) Gate, Globe and stop check valves shall have bonnet back seat to facilitate easy replacement of packing with the valves in service.

iv) All safety /relief valves shall be so constructed that the failure of any part does not obstruct the free discharge.






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v) Manual gear operators be provided for valves of size 250 NB and above.

vi) All valves with rising stem shall have position indicators.

vii) All valves shall be provided with locking arrangement.

viii) The refrigerant line valves shall have steel or brass body with TEFLON gland packing. The construction of disc shall be either globe or angle type. The valve seat shall have white metal lining or equivalent.

ix) All water line valves shall be of Cast Iron body for sizes 65 NB and above conforming to IS: 780 and Gun Metal construction for sizes less than 65NB conforming to IS:778. Cast Iron parts shall conform to IS:210 Gr. FG 220.

3.04.00 AIR FILTERS

3.04.01 Pre Filter

1) Fabric Type

i) Filter medium shall be suitable fibrous material (e.g. choir, extruded sections of polyethylene, etc.) packaged into a frame of galvanized sheet steel of 20 gauge thickness. Filter element shall be felt filter fabric of suitable material recommended by the manufacturer.

ii) The filter shall be capable of being cleaned of the accumulated dust by tap water flushing. V-fold galvanized wire mesh inter spaced with a flat layer of galvanized wire mesh for Metallic type pre-filters.

2) Metallic Panel Type

Filter medium, aluminium alloy shall be supported on galvanized expanded metal casing. Frame shall be fabricated from aluminium alloy of minimum 16 gauge thickness conforming to IS:737 or 18 gauge.

3) Other requirements : (as applicable)

a) Suitable aluminium spacers be provided for uniform air flow;

b) Casing shall be provided with neoprene sponge rubber sealing.

c) Capable of being cleaned by water flushing.

d) Density of filter medium shall increase in the direction of air flow in case of metallic filter.

4) Efficiency :

Average arrestance of 65 - 80 % when tested in accordance with BS:6540/ASHRAE – 52 - 76.






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5) Minimum thickness : 50 mm

6) Face Velocity : Not more than 2.5 m/sec.

7) Pressure drop : Initial pressure drop - Not to exceed 5.0 mm WC at rated flow. Final pressure drop - Upto 7.5 mm WC.

8) Location : a) At the suction of each AHUs

: b) At the suction or discharge of each Fresh air fan

3.04.02 Fine Filters (Microvee type)

1) Construction : By pleating a continuous sheet of filter medium into closely spaced plates separated by heavy corrugated aluminium spacers.

2) Frame : Aluminium alloy of (minimum 16 gauge conforming to IS:737) with handles.

3) Other requirements :

a) A neoprene sponge rubber sealing shall be provided on either face of the filter frame.

b) Capable of being cleaned by air or water flushing.

4) Efficiency : Average arrestance of 80-90% when tested in accordance with BS:6540/ASHRAE–52-76.

5) Minimum thickness : 150 mm or 300 mm.

6) Face Velocity : Not more than 1.2 m/sec for 150 mm and not more than 2.4 m/sec. for 300 mm.

7) Pressure drop : Initial pressure drop - Not to exceed 10 mm WC at rated flow ; Final pressure drop-Up to 25 mm WC.

8) Location : i) At the discharge of each individual AHU.

ii) At the discharge of each Fresh air.

3.05.00 LOW PRESSURE AIR DISTRIBUTION SYSTEM

3.05.01 Material of air distribution system shall be through galvanized steel sheet (Conforming to Class 275 of IS :277) or Aluminium alloy (grade 19000 / SIC or 3100 / NS3 of IS:737)






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3.05.02 Thickness of rectangular ducts shall be as follows :

Larger Dimension of duct (mm) Thickness of GI sheet(mm)

Thickness of Aluminium sheet (mm)

up to 750 mm 0.63 (24 G) 0.80

751 to 1500 0.80 (22 G) 1.00

1501 to 2250 1.00 (20 G) 1.50

2251 & above 1.25 (18 G) 1.80

3.05.03 Thickness of round ducts shall be as follows :

Diameter of Round duct (mm)

Thickness of GI sheet(mm)

Thickness of Aluminium sheet (mm)

150 to 500 0.63 0.80

501 to 750 0.80 1.00

751 to 1000 0.80 1.00

1001 to 1250 1.00 1.50

1251 & above 1.25 1.80

3.05.04 Duct Fabrication and Supports:

a) Duct fabrication shall be as per the latest relevant BIS standard.

b) The ducts with larger side greater than 2250 mm shall be supported by 15mm MS rods and 50x50x3mm MS double Angles while those below 2250 mm shall be supported by 10mm MS Rods and 40x40x3 MS angles. The duct supports shall be at a distance of not more than 1200 mm. The MS rods shall be hung from building steel wherever available, with provision of necessary auxiliary or special steel members or by hooks or by dash fasteners fixed to the ceiling slab. All items of duct support including MS rods, MS angles and double angles, auxiliary or special steel members, hooks, dash fasteners coach screws and all other supporting material required shall be provided by Contractor.

c) Where ever ducts are running outside the building and or at locations where it is not possible to support the ducts from Employers ceiling/floor due to non-availability of the same, the base steel frame/truss work for supporting the ducts between two columns shall be provided by Employer. However all other auxiliary steel members, hooks, rods etc for supporting the duct work with the base frame/truss work shall be provided by the bidder.






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d) Where the sheet metal duct connects to the intake or discharge of fan units a flexible connection of at least 150 mm width shall be provided of closely woven, rubber impregnated double layer asbestos/canvas or neoprene coated fibre glass.

e) All curves, bends, off-sets and other transformations shall be made for easy and noiseless flow of air. The throat of every branch duct shall be sized to have the same velocity as in the main duct to which the branch duct is connected.

f) Wherever duct passes through a wall, the opening between masonry and duct work shall be neatly caulked or sealed to prevent movement of air from one space to the adjoining space.

g) Wherever pipe hangers or rods pass through the ducts, light and streamline easement around the same shall be provided to maintain smooth flow of air.

h) Access doors shall be provided in the duct work or casing on the both sides of the equipment to be serviced. All access doors shall be of adequate size and shall be lined with substantial felt edging to prevent air leakage. Access doors shall be of built up construction, structurally strong and each shall have at least two hinges. Access doors shall have two rust proof window sash of approved type. All doors shall be set so as to flush with insulation or plaster finish on the duct.

3.05.05 Splitters and dampers shall be provided for equipment/area isolation and for proportional volume control of system. The same shall be minimum 16 gauge GS sheet of quadrant type with suitable locking device, mounted outside of duct in accessible position.

3.06.00 Diffusers, Grills & Dampers :

i) Supply air diffusers/grills with volume control dampers be provided for all air-conditioned areas.

ii) Return air diffusers of air conditioned areas shall be without volume control dampers.

iii) The diffusers/grills shall be of extruded Aluminium of minimum 1.2 mm thick with powder coating. These grills may be in continuous formation.

iv) Supply air grills shall be of double deflection type and return air grills shall be of single deflection type.

v) All volume control (VC) damper shall be operated by a key from the front of the grills/diffusers and shall be GI sheet.

vi) The thickness of VC dampers shall be of minimum 20 gauge and thickness of louvers shall be of minimum 22 gauge.






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vii) Suitable vanes shall be provided in the duct collar to have uniform and proper air distribution. Bank of Baffles wherever required shall also be provided.

viii) Fire dampers shall be motor operated type and shall have fire rating of minimum 90 minutes.

ix) All plenum chambers of connections to fans, dampers etc shall be constructed in 18 gauge GS sheet and supported on MS angle frames,

x) All ducting surfaces coming in contact with corrosive fumes or gases shall be painted with three coats of epoxy paint over a coat of suitable primer.

3.07.00 Thermal And Acoustic Insulation

3.07.01 Application

(a.) All surfaces to be insulated both thermally and acoustically shall be thoroughly cleaned, dried and an adhesive (CPRX compound of Shalimar Tar Products or Equivalent) be applied @ 1.5 Kg /Sqm on the surface.

(b.) Insulation material (either expanded polystyrene foam or Glass Wool/ Glass fiber or Equivalent) shall be struck to the surface. All the joints shall be sealed with bitumen.

(c.) Insulation mass to be covered with 500 gauge polythene sheet with 50 mm overlaps and sealing all joints on hot side.

(d.) Insulation Finish of types specified under shall be provided thereafter.

3.07.02 Type of Insulation & Finish

Sl. No.

Surface Insulation Material Insulation Form

Thick

(mm)

Finish (mm)

1. Supply & return air

duct of AC System

Resin bonded glass wool

Roll /Slab 50 F-3

2 Refrigerant (Suction

and liquid lines)

Expanded Polystyrene or resin

bonded Mineral wool

Pipe sec. 75 F-1

3 AHU drain pipe

Expanded Polystyrene or resin

bonded Mineral wool or resin

bonded glass wool

Pipe sec. 25 F-1






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Sl. No.

Surface Insulation Material Insulation Form

Thick

(mm)

Finish (mm)

4 AHU condensate

pan (insulation if

required)

Expanded Polystyrene or

Mineral wool or resin bonded glass

wool

Slab 25 As per manufacturer

std.

5 Acoustic insulation of

duct

Resin bonded Glass wool

Slab 25 As per specifications

3.07.03 Specification for insulation shall be as follows : -

Insulation Material Code Thermal conductivity (mw/cm/oC

Density Kg/m3

Resin bonded glass wool IS:8183 0.49 at 50oC i) 4 (For thermal insulation)

ii) 48 (For acoustic insulation)

Mineral wool pipe section. Min.Gr.2

IS:9842 0.43 at 50oC 144

Expanded polystyrene IS:4671 0.39 at 50oC 20

Note : Expanded polystyrene shall be of self extinguishing type (Type 2 of IS:4671)

3.07.04 The specification for various finishes shall be as follows

a) Finish F-1

Step-1 Wrapping of Poly-Bonded Hessain (PBH – to act as vapour seal) on outer surface of insulation with 50 mm overlap stitching and sealing of overlap with synthetic adhesive like CPRX or Equivalent compound.

Step-2 The surface then shall be wrapped with 19 mm mesh 24 SWG GI wire netting, butting all the joints and laced down with 22 SWG lacing wire.

Step-3 Sand cement (4:1) plaster shall be applied in two layers totalling to 12.5 mm thick, the second layer being brought to a smooth finish. A






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water proofing compound shall be added to the cement before its application.

b) Finish F-2

Step-1 Insulation shall be covered with 500g polythene with 50mm overlap and sealing of overlap with synthetic adhesive like CPRX or Equivalent compound.

Step-2 Same as Step-2 of Finish F-1 above.


c) Finish F-3

Step-1 Same as Step-1 of Finish F-2 above

Step-2 The polythene shall be covered with 30 gauge Aluminium sheet and locking of joints with self-locking screws at a pitch of minimum 100 mm.

d) Finish F-4

Step-1 Same as Step-1 of Finish-1 above.



Step-4 Application of 3 mm thick coat of water proofing compound “SHALIKOTE 30“ or Equivalent and wrapped with fibre glass RP tissue followed by final coat of 3 mm thick water proofing compound “SHALIKOTE 30“ or Equivalent over the RP tissue.

Step-5 After the above treatment, 22G Aluminium sheet cladding, properly stiched at all joints shall be provided over the external surface.

3.07.05 For all inspection covers and hatches on equipment, pump casing, valve bodies and flanges (100 mm and above), insulation shall be applied so as to facilitate removal without minimum damage to the insulation by encasing the insulation in 22 gauge Aluminium sheet metal boxes which are bolted together around the equipment. However continuity of the vapour seal between the static and removable portions of the insulation is to be maintained.

3.07.06 ACOUSTIC INSULATION

(a.) All ducts up to a distance of 5 meters from AHU shall be acoustically lined from inside with 25 mm thick resin bonded glass wool of 48 Kg/Cu.M. density and 30 gauge perforated aluminium sheet having 5 mm dia perforation at 8 to 10 mm centre-to-centre distance. Insulation shall be fixed on wooden frame of 600 x 600 mm dimension.






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(b.) Fibre glass tissue sheet shall be applied over the outer surface of insulation before applying perforated aluminium sheet. Application of acoustic insulation shall be inline with the requirements specified above.

3.07.07 In case of all external/exposed insulation, Aluminium sheet (22 gauge) cladding, properly stitched all joints need to be provided over the external surface.

3.08.00 VENTILATION FANS

3.08.01 Axial Fans

a. These fans shall have single piece cast aluminium impeller with blades of aerofoil design.

b. The fan casing shall be of heavy gauge sheet steel construction and the same shall be spray or hot dip galvanised.

c. Necessary rain protection cowl, inlet and outlet cones, bird protection screen, adjustable damper, vibration isolators, back draft dampers etc. shall be provided.

d. The speed of the fan shall not exceed 960 rpm for fan with impeller diameter above 450 mm and 1400 rpm for fan with impeller diameter 450 mm or less. However for fans having static pressure of 30 mm WC or above the speed of the fan shall not exceed 1440 rpm for fan with impeller diameter of above 450 mm and 2800 rpm for fan with impeller diameter of 450 mm or less. The first critical speed of rotating assembly shall be atleast 25% above the operating speed.

e. All other accessories like supporting structure etc. as required shall be provided.

4.00.00 PLANT CONTROL

4.01.00 GENERAL

Brief scheme of controlling the operation is described below. Detailed description of the control system for safe and efficient operation of the plant shall be elaborated, got approved from Employer. The descriptions in the sub-sections of the Control & Instrument sections shall also be referred to.

4.02.00 Control Scheme of Air Conditioning System

4.02.01 The Air Conditioning System control system shall be PLC based. The PLC configuration and detailed specification of the same shall be as per Control & Instrumentation requirements specified elsewhere in the specification.

4.02.02 All the functional requirements specified below and general control logic specified under this section shall be implemented in the PLC.






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4.02.03 The basic function of the system shall be to closely control and monitor temperature and humidity conditions inside the air-conditioned spaces, to provide remote monitoring & control for various mechanical facilities including sequential start/stop of the AC System, automatically calculate and record the cooling load for each hour /day/season, to generate maintenance data & alarms, to maintain records of plant operation & energy consumption for varying loads, duty cycling to operate all the equipment including standby equipment for equal duration, automatic startup of standby equipment in case of failure of operating unit and displaying fault alarm status of the tripped unit, programmed startup/stop of individual AHU as per operating requirements and for maintaining the room temperature/ RH , humidified system and duct heater, etc.

4.02.04 The operation of each Air Conditioning system shall be done as described below: -

(a.) Microprocessor based dedicated controllers shall be provided for 2 numbers of Reciprocating / scroll compressor type condensing units with local start / stop and indications for main plant AC system.

(b.) PLC based Control panel with PC based operator work station shall be provided for performing all the functions such as auto/manual operation of pumps, drives, local remote selection of operation, status indication, interlock and protection of pumps, valves, fans etc. Operation of AC plant and auxiliaries shall be through PC based operator Work Stations

(c.) Remote control units housing I/O modules & GIU for processing inputs and outputs related to all the AHUs. Facility of operation of drives shall be provided on this unit. All the remote control units in the AHU's shall be connected in a network to the PLC of Air Conditioning System. Operation of all AHU's and related drives shall be possible through OWS of PLC also.

4.02.05 PLC provided for the Control of AC system shall suitably interface with Remote I/Os & GIUs at two locations and microprocessor based controls of PAC units.

4.03.00 Air Handling Unit

i) Control of the inside room temperature and humidity shall be by controlling the chilled water flow by means of motor operated three way modulating valve and the modulating valve shall get its signal from the modulating thermostat.

ii) Humidity sensor located in the return air duct shall actuate the humidifier pumps to obtain the desired degree of humidification.

iii) Separate humidity & temperature sensor shall be provided and interlocked in steps with winter heater / re-heater / strip heaters for monsoon and winter re-heating or heating as the case may be.

iv) Heater banks shall be interlocked with the running of AHU, temperature of return air, humidity of return air and safety thermostat (Geyserstat-located in front of the each heater in the supply air duct)






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v) AHU shall be started either locally or from the main control room of AC system by means of Remote / Manual selection facility.

vi) The closure of fire dampers, automatic tripping of AHU fans and fresh air fans shall be interlocked with Employer's fire Detection System.

vii) Each AHU shall be provided with temperature indictors and flow indicator in the chilled water piping inlet and outlet to monitor the air-conditioning load of each area.

4.04.00 Miscellaneous control requirements

i) Separate emergency local stop push button shall be provided for each pump, compressor, fans etc. of AC system.

ii) Status shall be provided of each pump, compressor, fans etc. of AC system on MMI system at control room.

iii) All the alarms related to failure of equipments, tripping of equipments, source of failure / reason due to which the equipment is stopped / tripped, low & high limits of parameters such as level, temperature, pressure drop, pressure etc shall be provided for each pump, fan, compressor, AHU, PAC etc.

5.00.00 PAINTING

5.01.00 All the Equipments shall be protected against external corrosion by providing suitable painting.

5.02.00 The surfaces of stainless steel, Galvanised steel, Gunmetal, brass, bronze and non-metallic components shall not be applied with any painting. The Contractor shall clean the external surfaces and internal surfaces before Erection by wire brushing and air blowing. The steel surface to be applied with painting shall be thoroughly cleaned before applying painting by brushing, shotblasting etc as per the agreed procedure.

5.03.00 For all the steel surfaces (external) exposed to atmosphere (outdoor installation), a coat of chlorinated rubber based zinc phosphate primer of minimum thickness DFT of 50 microns followed up with undercoat of chlorinated rubber paint of minimum DFT of 50 microns shall be applied. Then, intermediate coat consisting of one coat of chlorinated rubber based paint pigmented with Titanium di-oxide with minimum DFT of 50 microns and top coat consisting of two coats of chlorinated rubber paint of approved shade and colour with glossy finish and DFT of 100 microns shall be provided. Total DFT of paint system shall not be less than 250 microns.

5.04.00 For all the steel surfaces (external) inside the building (indoor installation), a coat of red oxide primer of minimum thickness of 50 microns followed up with undercoat of synthetic enamel paint of minimum thickness of 50 microns shall be applied. The topcoat shall consist of two coats each of minimum thickness of 50 microns of synthetic enamel paint and thus total thickness shall be minimum 200 micron.






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6.01.00 The design, manufacture and performance of equipment shall comply with all currently applicable statues, regulations and safety codes in the locality where the equipments are to be installed. Nothing in this specification shall be considered to relieve the bidder of this responsibility.

6.02.00 Unless otherwise specified, equipment shall conform to the latest applicable Indian or IEC standard. Equipment complying with other authoritative standards such as British, USA, ASHRAE etc. will also be considered if it ensures performance equivalent or superior to Indian Standard.





PART – B

QUALITY ASSURANCE

CLAUSE NO.

QUALITY ASSURANCE

GANDHINAGAR THERMAL POWER STATION (2X120 MW)

BIDDING DOC. NO.: CW-APDP-R&M-9259- BOP-T-0011-R0


RENOVATION OF 220KV SWITCHYARD AND

C&R PANEL-STAGE-I

PART-B SUB-SECTION-IV: QA

PAGE 0 OF 10

QUALITY ASSURANCE & INSPECTION MODULE NO. SQE-16 CABLING, EARTHING, LIGHTNING PROTECTION

ATTRIBUTES / CHARACTERISTICS

ITEMS/COMPONENTS / SUB SYSTEMS

Dim

ensi

on

Pai

nt s

hade

, pai

nt th

ickn

ess,

adh

esio

n

Pre

-trea

tmen

t of s

heet

IP p

rote

ctio

n

Pro

of lo

ad*

Sur

face

fini

sh

Def

lect

ion

test

*

HV

& IR

Gal

vani

se T

est (

If A

pplic

able

)

Func

tiona

l

Bou

ght o

ut it

ems/

Bill

of m

ater

ial

Rou

tine

test

s as

pe

r

rele

vant

st

anda

rd

&

spec

ifica

tion

Acc

epta

nce

test

s as

per

rel

evan

t st

anda

rd &

sp

ecifi

catio

n

Con

stru

ctio

nal f

eatu

re a

s pe

r NTP

C S

peci

ficat

ion

Wall Mounted-Lighting Panel (IS-513, IS:5, IS:2629, 2633, 6745)

Y Y Y Y Y Y Y Y Y Y Y Y

Switch box/junction box/ Receptacles Panel (IS-513, IS:5, IS:2629, 2633, 6745)


Cable glands(BS-6121) Y Y Cable lug(IS-8309) Y Y Lighting wire(IS-694) Y Y Flexible conduits Y Y Y Conduits (Galvanise & Epoxy) IS-9537 & IS-2629,2633 ,6745

Y Y Y Y Y

RCC Hume Pipe (IS-458) Y Cable termination & straight through joint (VDE-0278)

Y Y Y

Cable Trays, Flexible supports system & accessories IS-513, 2629,2633,6745

Y Y Y Y Y Y Y Y Y Y Y

Trefoil clamp Y Y GI flats for earthing & lighting protection (IS 2062, 2629, 6745,2633)

Y Y Y Y Y

GI wire (IS-280) Y Y Fire Sealing System ( BS –476) Y Y Y

Note: 1. This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan

indicating the practice and procedure along with relevant supporting documents.

2.* Deflection Test on cable trays and Proof Load test on cable trays support system will be as per details given in the NTPC technical specification & approved MQP. The above acceptance tests shall be done only on one sample from each size of offered lot.

3. Make of all items will be subject to NTPC approval.

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

CONTROL PANEL SQE_25 Attributes Characteristics Item Components Sub System Assembly

Ele

ctric

al P

rope

rties

Mec

hani

cal P

rope

rties

Che

mic

al P

rope

rties

Dim

ensi

ons

/ Fin

ish

Type

/ Rat

ing/

Func

tiona

l che

ck

H

V/IR

Rou

tine

test

as

per r

elev

ant

std

.

Con

stru

ctio

nal F

eatu

res

IS:6

005

,Sev

en ta

nk p

roce

ss

Pai

nt fi

nish

/ sha

de/th

ickn

ess

adhe

sion

Mou

ntin

gs /

BO

M/

Mak

e, C

ompl

eten

ess

/ W

iring

Inte

rlock

Fun

ctio

nal &

Ope

ratio

n Te

stin

g /

Sim

ulat

ion

chec

k

Deg

ree

of P

rote

ctio

n Te

st

Spe

cific

atio

n re

quire

men

t

Sheet Steel (IS-513) Y Y Y Aluminum / Copper Bus-bar (IS-5082/IS-613/IS-1987)

Y Y Y Y

Support Insulator (BS-2782/IEC-660/IS-10912)

Y Y Y Y

Control / Selector Switch(IS-6875) Y Y Y Contractor/ MCB (IS-13947) Y Y Y O/L Protection relays (IS-3231) Y Y C.T /V.T/ Indicating Meter(IS-2705/3156/1248)

Y Y Y

Fuse/ Fuse carrier (IS-13703) Y Y Y Terminals/lugs/pvc wires (IS-13947//IS-694)

Y Y Y Y Y

Timers (IS-3231) Y Y Y LVS, Mosaics Y Push Button/ Lamp/ (IS-6875) Y Y Y Control Transformer (IS-12021) Y Y Y Mimic, Annunciater Y Y GASKET(IS-11149) Y Y Y Y Y Fabrication Y Pretreatment & Painting Y Y Control panel Y Y Y Y Y

NOTE:

1. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.

2. All major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

ENERGY METER

Attributes / Characteristics Items / Components / Sub- assembly

Mak

e, M

odel

, Typ

e, R

atin

g &

Fin

ish

Con

form

to re

leva

nt S

tand

ard

& N

TPC

spe

c

Dim

ensi

onal

che

ck a

nd P

aint

sha

de,

thic

knes

s,

adhe

sion

& F

inis

h ch

ecks

Com

plet

e ph

ysic

al e

xam

inat

ion

for

cons

truct

iona

l fe

atur

es

as

per

NTP

C

appr

oved

dr

gs

&

spec

ifica

tion

Bur

n-In

Tes

t an

d E

leva

ted

Tem

pera

ture

Tes

t a

s pe

r sp

ecifi

catio

n

All

rout

ine

& ac

cept

ance

test

s as

per

IS 1

3779

Electronic Components Y Y

PCB for electronic cards Y

Electronic Cards Y Y Y Y

Terminal Blocks as per IS 13779 Y Y

Instrument Transformer CTs & PTs (IS : 2705 & IS 3156)

Y Y

Sheet Steel ( IS : 513 ) Y Y

Synthetic Rubber Gaskets

IS 11149

Y Y

Energy meter

IS 13779

Y Y Y Y Y

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan

indicating the practice and procedure along with relevant supporting documents. 2. Makes of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

L.T CONTROL CABLES (1.1 KV PVC CABLES)

Attributes / Characteristics Item / Components / Sub System Assembly

Mak

e, T

ype,

Rat

ing,

T.C

Dim

ensi

on/s

urfa

ce fi

nish

Mec

hani

cal P

rope

rties

Che

mic

al C

ompo

sitio

n

Ele

ctric

al P

rope

rties

Spa

rk T

est

Lay

leng

th/S

eque

nce

Arm

our

cove

rage

, cr

oss

over

, lo

osen

ess,

ga

p be

twee

n tw

o ar

mou

r wire

Seq

uent

ial m

arki

ng/s

urfa

ce fi

nish

/cab

le le

ngth

Tens

ile s

treng

th, e

long

atio

n be

fore

&

afte

r ag

eing

of

insu

latio

n &o

uter

she

ath

shea

th

Ther

mal

sta

bilit

y of

insu

latio

n an

d ou

ter s

heat

h

Ant

i ter

mite

trea

tmen

t on

woo

den

drum

s

Con

stru

ctio

nal f

eatu

re a

s pe

r NTP

C S

pec.

Rou

tine

& A

ccep

tanc

e te

st a

s pe

r re

leva

nt s

tand

ard

&

page

2 &

3 o

f thi

s ta

ble

FRLS

Tes

t

Copper Conductor (IS-8130) Y Y Y Y Y PVC Compound (IS-5831) Y Y Y Y FRLS PVC Compound IS-5831 ASTM-D-2843/ IS 10810 (Part-58) IEC-754 Part-1

Y Y Y Y

Armour wire/strip (IS-3975) Y Y Y Insulated Core Y Y Y Y Laid up core Y Y PVC Inner sheath Y Armouring Y Y Outer sheath Y Y Y Y Y Finish cable (IS-1554- 1) ASTM-D-2843/ IS 10810 (Part-58) IEC-754 Part-1 Swedish Chimney: SEN SS 424-1475(F3 category) Flammability test IEC-332 Part-3 Cat-B

Y Y Y Y Y Y Y Y Y

Wooden drum (IS : 10418) / Steel drum

Y Y

Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the

Practice and procedure along with relevant supporting documents.

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

CONTROL CABLE

ROUTINE TESTS

Routine tests shall be carried out on each drum of finished cables for all types & sizes.

Following shall constitute routine tests:

1) Conductor Resistance test

2) High voltage test at room temperature

ACCEPTANCE TESTS

Following Acceptance tests shall be carried out for each type and size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 1554 Part 1

A) For Conductor

1) Annealing test For copper conductor only

2) Resistance test

B) For Armour Wires / Formed Wires ( If applicable )

1) Measurement of Dimensions

2) Tensile Tests

3) Elongation Test

4) Torsion Test For Round wires only

5) Wrapping Test

6) Resistance Test

7) Mass of Zinc coating test For G S wires / Formed wires only

8) Uniformity of Zinc coating For G S wires / Formed wires only

9) Adhesion test For G S wires / Formed wires only

10) Freedom from defects

C) For PVC insulation & PVC Sheath

1) Test for thickness

2) Tensile strength & Elongation before ageing

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

D) For completed cables

1) Insulation resistance test ( Volume resistivity method )


E) Following tests shall be carried out and only one sample shall be taken from each offered lot of all sizes for these tests:-

1) Tensile strength & elongation after ageing on PVC insulation and PVC outer sheath

2) Thermal stability test on PVC insulation and outer sheath

3) Oxygen index test on outer sheath

4) Smoke density rating test on outer sheath as per ASTM –D 2843

5) Acid gas generation test on outer sheath as per IEC – 754 (Part 1)

6) Flammability test as per IEC-332 - Part- 3 (Category- B) on completed cable

7) Fire resistance test as per SS 4241475 (F3 Category) on completed cable

F) Following tests shall be carried on one length of each size of offered lot:

1) Surface finish, length measurement, sequence of cores, armour coverage, Gap between two consecutive armour wires / formed wires

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

L.T POWER CABLES (1.1 KV PVC & XLPE CABLES)

Attributes / Characteristics Item / Components / Sub System Assembly M

ake,

Rat

ing,

Typ

e &

TC

Dim

ensi

on/s

urfa

ce fi

nish

Mec

hani

cal P

rope

rties

Che

mic

al C

ompo

sitio

n

Ele

ctric

al P

rope

rties

Spa

rk T

est

Hot

set

test

(XLP

E)

Lay

leng

th /

Seq

uenc

e

Arm

our c

over

age,

Cro

ss o

ver,

loos

enes

s, G

ap

betw

een

two

arm

our w

ire/s

trip

Seq

uent

ial

mar

king

/sur

face

fin

ish

/cab

le

Tens

ile s

treng

th,

elon

gatio

n be

fore

&

afte

r ag

eing

of i

nsul

atio

n &

out

er s

heat

h

Ther

mal

S

tabi

lity

of

insu

latio

n an

d ou

ter

shea

th *

Ant

i ter

nite

trea

tmen

t on

woo

den

drum

s

Con

stru

ctio

nal

/ re

quire

men

t as

pe

r N

TPC

S

pec.

Rou

tine

and

acce

ptan

ce te

st a

s pe

r R

elev

ant S

tand

ard

and

NTP

C s

peci

ficat

ion

FRLS

Tes

t

Aluminum (IS-8130) Y Y Y Y Y

PVC Compound (IS-5831) Y Y Y Y

XLPE Compound (IS-7098 Part-I)

Y Y Y Y Y

FRLS PVC Compound (IS-5831) ASTM-D-2843/ ASTM-D-2863 IEC-754 Part-I

Y Y Y

Armour wire/strip (IS-3975) Y Y Y

Insulated Core Y Y Y Y

Laid up core Y Y

PVC Inner sheath Y

Armouring Y Y

Outer sheath Y Y Y Y Y

Finish cable (IS-1554 & 7098 – Part-1) ASTM-D-2843/ IS 10810 (Part- - 58 ) IEC-754 Part-I Swedish Chimney SS 4241475 for (F3 category)

Flammability test IEC-332 Part –3 Cat-B

Y Y Y Y Y Y Y

Y Y

Wooden drum (IS-10418) / Steel drum

Y Y

Note: 1. This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating

the practice and procedure along with relevant supporting documents. 2. Not applicable for XLPE insulation

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

ROUTINE TESTS

Routine tests shall be carried out on each drum of finished cables for all types & sizes.

Following shall constitute routine tests:

1) Conductor Resistance test


ACCEPTANCE TESTS

Following Acceptance tests shall be carried out for each type and size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 1554 Part 1 & IS 7098 Part-I

A) For Conductor

1) Annealing test For copper conductor only

2) Tensile test For aluminium conductor only

3) Wrapping test For aluminium conductor only

4) Resistance test

B) For Armour Wires / Formed Wires (If applicable)

1) Measurement of Dimensions

2) Tensile Tests

3) Elongation Test

4) Torsion Test For Round wires only

5) Wrapping Test

6) Resistance Test

7) Mass of Zinc coating test For G S wires / Formed wires only

8) Uniformity of Zinc coating For G S wires / Formed wires only

9) Adhesion test For G S wires / Formed wires only

10) Freedom from defects

C) For PVC / XLPE insulation & PVC Sheath

1) Test for thickness

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

2) Hot set test For XLPE insulation only

3) Tensile strength & Elongation before ageing

D) For completed cables

1) Insulation resistance test ( Volume resistivity method )


E) Following tests shall be carried out and only one sample shall be taken from each offered lot of all sizes for these tests:-

1) Tensile strength & elongation after ageing on PVC / XLPE insulation and PVC outer sheath

2) Thermal stability test on PVC insulation and outer sheath

3) Oxygen index test on outer sheath

4) Smoke density rating test on outer sheath as per ASTM –D 2843

5) Acid gas generation test on outer sheath as per IEC – 754 (Part 1)

6) Flammability test as per IEC-332 - Part- 3 (Category- B) on completed cable

7) Fire resistance test as per SS 4241475 (F3 Category) on completed cable

F) Following tests shall be carried on one length of each size of offered lot:

1) Surface finish, length measurement, sequence of cores, armour coverage, Gap between two consecutive armour wires / formed wires

CLAUSE NO.

QUALITY ASSURANCE





C&R PANEL-STAGE-I


PAGE 0 OF 10

STATION LIGHTING SQE_17

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice

and procedure along with relevant supporting documents. 2. Make of all major Bought Out Items will be subject to NTPC approval.

Item Components Sub System Assembly Attributes Characteristics M

ake,

Typ

e , R

atin

g/ T

C

Dim

ensi

on

Pre

-Tre

atm

ent o

f she

at

Pai

nt

Sha

de T

hick

ness

Adh

esio

n &

Fi

nish

Gal

vani

se T

est

IP T

est

Bou

ght O

ut It

ems/

Bill

of M

ater

ial

HV

& IR

Func

tiona

l Che

ck a

s pe

r spe

c.

Con

stru

ctio

nal

Feat

ure

as p

er N

TPC

sp

ec.

Rou

tine

Test

as

per

rele

vant

std

aad

sp

ec

Acc

epta

nce

Tes

t as

per

rel

evan

t st

d an

d sp

ec

Item

to c

onfo

rm to

rele

vant

sta

ndar

d

Luminaries (IS-10322 Part-5 Sec.1) Y Y Y Y Y

Electronic Ballast Y Y Y Y

Lighting Wire (IS-694) Y Y

Fans (IS-374) Y Y

Pole (IS-2713) Y Y Y Y Y

Lamps (IS-9800, IS-9974) Y Y Y

Lighting Mast (with raise & lower lantern type)

Y Y Y Y Y Y

Wall Mounted Lighting Panel (IS-513, IS-5)


Switch Box/ Junction Box/Receptacles/ Local Push Button Station, Lighting Panel (IS-513, 2629, 2633, 4759, 6745)


Cable Gland (BS-6121) Y Y Y

Cable Lug (IS-8309) Y Y Y

Flexible Conduit Y Y

Lighting Transformer (IS-1117) Y Y Y

Epoxy & Galvanised Conduit (IS-9537, 2629, 2633, 4759, 6745)

Y Y Y Y

(GANDHINAGAR THERMAL POWER STATION)

STAGE-I (2X120 MW)

TECHNICAL DATA SHEETS

FOR

RENOVATION OF 220 kV SWITCHYARD AND C&R PANEL

PACKAGE STAGE-I (2X120 MW)

CONSULTANT

NTPC Limited (A Government of India Enterprise )

CORPORATE ENGINEERING DIVISION ENGINEERING OFFICE COMPLEX

SECTOR-24,NOIDA-201301

BID DOCUMENT NO.: CW-APDP-R&M-9259-BOP-T-0011-R0





ELECTRICAL CONTROL BOARD / CONTROL PANELS

CLAUSE NO. TECHNICAL DATA SHEETS






PAGE 1 OF 3

ELECTRICAL CONTROL BOARD/ CONTROL PANELS

*Use separate sheets for each application 1.00.00 a) Application b) Overall dimensions 2.00.00 CONTROL SWITCH a) Manufacturer and country of manufacturer b) Type and designation c) Catalogue attached as Ann. No. 3.00.00 Annunciators a) Manufacturer b) Type and designation c) Solid state or electromechanical d) Catalogue attached as Ann. No. 4.00.00 Meter & Instruments a) Manufacturer b) Type and designation c) Catalogue attached as Ann. No. 5.00.00 Recording Meters a) Manufacturer b) Type and designation c) Catalogue attached as Ann. No. 6.00.00 Active Energy Meters a) Manufacturer b) Type and designation c) Catalogue attached as Ann. No.







PAGE 2 OF 3

7.00.00 Control Equipment a) Discrepancy type switches i) Manufacturer ii) Type and designation iii) Catalogue attached as Ann. No. b) Synchronising switch i) Manufacturer ii) Type and designation iii) Catalogue attached as Ann. No. 8.00.00 Indicating Lamps a) Manufacturer b) Type and designation c) Catalogue attached as Ann. No. 9.00.00 Push Buttons a) Manufacturer b) Type and designation c) Catalogue attached as Ann. No. 10.00.00 Auxiliary Instrument Transformer a) Manufacturer b) Type and designation c) Catalogue attached as Ann. No. 1100.00 Panels a) Manufacturer b) Type and designation c) Catalogue attached as Ann. No. 1200.00 CONTROL PANEL DETAILS a) Make of control panel







PAGE 3 OF 3

b) Manufacturer’s type designation c) Over all dimension of panel (W x D xH) mm d) Antivibration pad provided (Yes/No) e) Transportation size of panel f) Total weight of panel g) Operating device height (Minimum) h) Operating device height (Maximum) i) Panel IP protection j) Make, technical details and catalogue of air break switches, fuses, contactors, annunciators, MCBs, push buttons indicating lamps etc. providing in the panel.





CABLING SYSTEM






CABLING SYSTEM

PAGE 1 OF 3

CABLING SYSTEM 1.00.00 Cable Trays, Tray Covers & Accessories 1.01.00 Makers, Name, Country of ............................ ..................... manufacturer 1.02.00 Type of cable tray ............................ ..................... 1.03.00 Type of cable support system ............................ ..................... 1.04.00 Applicable standard ............................ ..................... 1.05.00 Catalogue and indicative ............................ ..................... sketch attached as annexure no. 2.00.00 Conduit Pipes & Accessories 2.01.00 Maker's Name and Country of ............................ ..................... manufacture 2.02.00 Material ............................ ..................... 2.03.00 Catalogue attached as annexure no. ............................ ..................... 2.04.00 Applicable Standard ............................ ..................... 3.00.00 Junction Boxes 3.01.00 Maker's Name and Country of manufacture ............................ ..................... 3.02.00 Material ............................ ..................... 3.03.00 Applicable Standard ............................ ..................... 4.00.00 Cable Glands 4.01.00 Maker's Name and Country of manufacture ............................ ..................... 4.02.00 Type of cable gland ............................ ..................... 4.03.00 Applicable Standard ............................ ..................... 5.00.00 Cable Jointing / Termination Kits 5.01.00 Maker's Name & Country of ............................ ..................... Manufacturer 5.02.00 Type of system ............................. ................... a) Termination ............................ ..................... b) Joints ............................ .....................






CABLING SYSTEM

PAGE 2 OF 3

5.03.00 Catalogue attached as annexure no. ............................ ..................... 5.04.00 Type test reports enclosed as annexure no. ............................ ..................... 5.05.00 Applicable Standard ............................ ..................... 6.00.00 Cable lugs & Terminals 6.01.00 Maker's Name & Country of ............................ ..................... Manufacturer 6.02.00 Applicable Standard 7.00.00 Earthing System a) Buried earthmat ............................ ..................... i) Material & size ............................ ..................... ii) Applicable standard ............................ ..................... for the system b) Equipment earthing i) Material .............................. ..................... ii) Size ............................ ..................... iii) Applicable Standard ............................ ..................... 8.00.00 Lightning Protection System i) Applicable Standard ............................ ..................... ii) Size & material for Air termi- ............................ ..................... nation and down conductor 9.00.00 Fire Sealing 9.01.00 Fire rating of the system a) Below CCR i) Type ............................ ..................... ii) Make ............................ ..................... iii) Catalogue of system ............................ ..................... attached as annexure no.






CABLING SYSTEM

PAGE 3 OF 3

b) Floor below Swgr/MCC i) Type ii) Make ............................ ..................... iii) Catalogue of system ............................ ..................... attached as annexure no. c) Other areas i) Type ............................ ..................... ii) Make ............................ ..................... iii) Catalogue attached as ............................ ..................... annexure no.





ISOLATORS / DIS-CONNECTORS /

EARTH SWITCHES







EARTH SWITCHES

PAGE 1 OF 7

ISOLATORS / DIS-CONNECTORS / EARTH SWITCHES (SEPARATE SHEET SHALL BE FILLED UP FOR DIFFERENT RATING) 1.00.00 General (a) Name of the Manufacturer ……………...................

(b) Country of Manufacture ………………............... (c) Manufacturer's type ...................................... designation (d) Standard Applicable for ...................................... disconnecting switches and earthing switches (e) Rated Voltage (KV) ...................................... (f) Rated Current (Amps) ..................................... (i) Under normal condition ...................................... (ii) Under site Conditions (Amps) at 50 deg.C. ambient ...................................... . (g) Rated frequency (HZ) (50 Hz) ...................................... (h) Number of poles ....................................... (i) Whether all 3 pole are ........................................ ganged mechanically (j) Pole to pole spacing ...................................... (k) Type of installation ....................................... 2.00.00 Guaranteed Ratings (a) Rated short time current of disconnecting switches ...................................... (i) for 1 Sec. (kA rms) ...................................... (ii) for 3 sec. (kA rms) ....................................... (iii) Dynamic current ........................................ (b) Opening time of dis- ........................................ connecting switch







EARTH SWITCHES

PAGE 2 OF 7

(c) Closing time of disconnecting switch ......................................... (d) Temperature rise over ......................................... 50 deg.C. ambient temperature continuous current (deg.C) 3.00.00 Dielectric Withstand Capacity ...................................... of completely assembled disconnecting switch and earth switch (a) One minute power freq. ........................................ withstand test voltage (kV rms) (i) against ground ........................................ - dry (kV rms) ......................................... - wet (kV rms) .......................................... (b) 1.2/50 micro second impulse ......................................... withstand test voltage (i) against ground ......................................... (kV peak) (ii) across open contacts .......................................... (kV peak) c) 250/2500 micro second impulse withstand test voltage (i) Between live terminals .............................................. and ground (kVp) (ii) Between terminals with .............................................. contacts open (kVp) (d) Corona extinction voltage (kV rms) .............................................. (e) Radio interference level .............................................. (in micro volts) at 156 kV (rms) (i) 0.5 MHz ............................................. (ii) 1.0 MHz .............................................. (iii) 1.5 MHz .............................................. (iv) 2.0 MHz ..............................................







EARTH SWITCHES

PAGE 3 OF 7

(f) Total creepage distance .............................................. to ground (mm) 4.00.00 Operating Mechanism (a) Type of motor operating .............................................. mechanism (b) Manufacturer's type .............................................. designation (c) Rated torque of the mechanism ............................................ (d) Type and Rating of motor ............................................. (e) Whether motor details ............................................. as per schedule filled in 4.01.00 Interlocking (a) Whether mechanical/ Yes/No

constructional interlock between disconnecting switch & earth switch provided (b) Details of electrical ............................................. interlock enclosed for (i) Disconnecting switch Yes/No (ii) Earth switch Yes/No (c) Arrangement provided to prevent electrical or manual operation unless interlock conditions are satisfied Yes/No (d) Whether interlock coil is continuously rated Yes/No (e) Rated D.C. control voltage and variation allowed ............................................. (f) Power consumption (Watts) ........................................... 4.02.00 Controls (a) Rated D.C. Control voltage (Volts) ...........................................







EARTH SWITCHES

PAGE 4 OF 7

(b) Limits of Voltage ........................................... (c) Power consumption of control coils (W) ........................................... 5.00.00 Constructional Features (a) Minimum clearance in air ........................................... (b) (i) Between phases (mm) ........................................... (ii) Between live parts to earth (mm) ........................................... iii) Distance between terminals of same phase ........................................... c) Whether position of earth switch can be interchanged at site to either side of pole Yes/No d) Minimum clearance between live part and earth switch blade throughout the entire operational arc of earth switch (mm) ........................................... e) Terminal pad details: i) Diameter & length ........................................... ii) Material of pad ........................................... f) Insulator data i) Height ........................................... ii) Type ........................................... g) Whether support insulator details as per schedule filled in Yes/No h) i) No. of insulator stacks/phase ........................................... ii) No. of insulators / stack ........................................... i) Main contacts i) Type of contacts ...........................................







EARTH SWITCHES

PAGE 5 OF 7

ii) Contact area (cm2) ........................................... iii) Material of contacts ...........................................

iv) Contact pressure (Kg/cm2) ........................................... v) Maximum current density under normal current carrying capacity (Amp/cm2) ........................................... vi) Thickness of silver plating ........................................... j) Auxiliary contacts on disconnecting switch/pole i) Total number ........................................... ii) NO ........................................... iii) NC ........................................... iv) Adjustable ........................................... v) Make before break ........................................... vi) Rated voltage (volts) ........................................... vii) Rated continuous current (Amps) ........................................... viii) Rated DC breaking current with 20 ms time constant (A) ........................................... k) Auxiliary contacts on earth switch i) Total ........................................... ii) NO ........................................... iii) NC ........................................... iv) Adjustable ........................................... v) Rated voltage (volts) ........................................... vi) Rated continuous current (Amps) ...........................................







EARTH SWITCHES

PAGE 6 OF 7

vii) Rated DC breaking current with 20 ms time constant (A) ........................................... l) Mounting dimensions of disconnecting switch ........................................... i) Distance between supports ........................................... ii) Top dimensions of support ........................................... m) Height from mounting plane to top of terminal stud ........................................... n) Whether cable glands required included in the scope Yes/No o) Whether counter balance springs provided for isolator and earth switch Yes/No p) Whether details of terminal connectors as per relevant schedule filled in Yes/No q) Whether details of controls cabinets as per relevant schedule filled in Yes/No 6.00.00 Literature Whether the following are enclosed a) Type test reports as per IEC-129 Yes/No b) OGA drawing for isolator with & without earth switches Yes/No c) Operation manual for isolators Yes/No d) Details of motor operating mechanism, Yes/No e) OGA drawing for terminal connectors Yes/No







EARTH SWITCHES

PAGE 7 OF 7

f) Recommended drawing for mounting details for isolator and drives Yes/No g) Leaflets & literature bringing out salient feature of equipment offered Yes/No h) Reference list of past, supplies in proforma enclosed Yes/No i) Reference list of past supplies made in case of gang operated isolator with a pole to pole spacing as per specification enclosed Yes/No j) Whether schematic drawing enclosed Yes/No k) Whether details of constructional interlock enclosed Yes/No





STATION LIGHTING






STATION LIGHTING

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STATION LIGHTING

1.00.00 Lighting distribution board a) Make ................................................. b) Applicable standard ................................................. c) Type of construction ................................................. d) Degree of protection ............................................... e) Catalogue attached as annexure no. ................................................. 2.00.00 Lighting Panel a) Make ............................................... b) Applicable standard ................................................ c) Enclosure ................................................ d) Degree of protection i) Indoor ................................................ ii) Outdoor ................................................. e) Catalogue attached as annexure no. ................................................ 3.00.00 Miniature Circuit Breaker a) Make ................................................ b) Type designation ................................................ c) Applicable standard ................................................ d) Rated current voltage ................................................ e) Breaking capacity of 0.6p.f. ................................................ f) Catalogue attached as annexure no. ................................................ 4.00.00 Isolator a) Make ................................................ b) Type designation ................................................ 5.00.00 Fuses a) Make ................................................






STATION LIGHTING

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b) Type ................................................ c) Applicable standard ................................................ 6.00.00 Contactor a) Make ................................................. b) Type & duty ................................................. c) Applicable standard ................................................ 7.00.00 Synchronous timer a) Make ................................................ b) Type ................................................ c) Applicable standard ................................................ 8.00.00 Lighting fixtures & Accessories a) Make of lighting fixture & ................................................ accessories b) Catalogue for each type of. ............................................... fixture attached as annexure no. c) Applicable Standard 9.00.00 Switches a) Make ................................................. b) Type ............................................... c) Catalogue attached as annexure no. ................................................. d) Applicable standard ................................................ 10.00.00 Receptacles/Sockets a) Make ................................................ b) Type ................................................ c) Applicable standard ................................................ 11.00.00 Junction Boxes a) Make ...............................................






STATION LIGHTING

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b) Type ............................................... c) Material ................................................ d) Applicable standard ................................................. 12.00.00 Terminal Blocks a) Make ................................................. b) Type ................................................. c) Rating ................................................. 13.00.00 Rigid steel Conduits/Fittings & accessories a) Make ................................................. b) Material ................................................. c) Applicable standard ................................................. 14.00.00 Hume Pipes a) Make ................................................. b) Applicable standard ................................................. 15.00.00 Flexible steel standard a) Make ................................................. b) Applicable standard ................................................. 16.00.00 Lighting Wires a) Make ................................................. b) Applicable standard ................................................. c) Voltage grade ................................................. d) Size ................................................. e) Conductor material ................................................ f) Insulation ................................................. 17.00.00 Lighting poles a) Make .................................................






STATION LIGHTING

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b) Applicable standard ................................................. c) Type ................................................. d) Pole height .................................................





POWER AND CONTROL CABLES







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POWER AND CONTROL CABLES (Use separate sheet for each type and size of cables) 1.00.00 Make ............................ ..................... 1.02.00 Country of Manufacturer ............................ ..................... 1.03.00 Type & designation ............................ ..................... 1.04.00 Applicable standard ............................ ..................... 1.05.00 Cable size & no. of cores ............................ ..................... 1.06.00 Rated voltage ............................ ..................... 1.07.00 Catalogue attached as Annexure No. ............................ ..................... 1.08.00 Continuous current rating ............................ ..................... for max. conductor temperature a) When laid in air at an ambient ............................ ..................... temperature of 50 deg. C b) When buried in soil having ............................ ..................... thermal resistivity of 150 deg.C cm/n at a depth of 1000 mm at ground ambient temperature of 40 deg. C 1.09.00 Short circuit withstand capacity and ............................ ..................... duration for a) Conductor ............................ ..................... b) Screen ............................ ..................... c) Armour ............................ ..................... 1.10.00 Conductor ............................ ..................... a) Material ............................ ..................... b) Nominal cross section ............................ ..................... area in sq. mm iii) Shape of conductor ............................ ..................... iv) DC resistance at 20oC ............................ ..................... 1.11.00 Insulation a) Material ............................ .....................







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b) Nominal thickness (in mm) ............................ ..................... c) Type of curing (for XLPE) ............................ ..................... 1.12.00 Metallic screen (wherever applicable) a) Material ............................ ..................... b) Type ........................... .................... c) Rating KA, Sec 1.13.00 Type of Inner sheath ............................ ..................... 1.14.00 Armour material ............................ ..................... 1.15.00 Outer sheath material ............................ ..................... 1.16.00 Over all dia cable (in mm) ............................ ..................... 1.17.00 Guarantee value of minimum ............................ ..................... oxygen index of outer sheath 1.18.00 Maximum acid-gas generation ............................ ..................... by weight (%) of outer sheath 1.19.00 Average light transmission ............................ ..................... 1.20.00 Type test report enclosed as annexure no. ............................ .....................





SWITCHYARD ANCILIARY ITEMS







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I. CLAMPS AND CONNECTORS 1.00.00 Manufacturer’s Name and .................... ................... Address 2.00.00 Applicable Standards .................... ................... 3.00.00 Application .................... ................... 4.00.00 Type .................... ................... 5.00.00 For connection to a) Conductor size and .................... ................... arrangement b) Equipment terminal .................... ................... size and arrangement 6.00.00 Material (state percentage .................... ................... composition of constitutents and impurities present) a) Clamp body .................... ................... b) Bolts and Nuts .................... ................... c) Spring washers .................... ................... d) Liners, if any .................... ................... 7.00.00 Rated Current (A) .................... ................... 8.00.00 Maximum temperature rise .................... ................... over reference ambient temperature specified of 50oC when carrying rated current (deg.C) 9.00.00 Rated terminal load (Kg) .................... ................... 10.00.00 Minimum thickness of any .................... ................... part (mm) 11.00.00 Weight of clamp complete .................... ................... with hardware (Kg) 12.00.00 Machine accuracy for mating .................... ................... surfaces







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13.00.00 Factor of safety .................... ................... 14.00.00 Short circuit current .................... ................... rating for 1 sec. (KA) 15.00.00 Radio interference .................... ................... voltage (Micro volts) at 1.1 time Vm/3 kV rms 16.00.00 Type test reports Yes/No Yes/No as per IS enclosed 17.00.00 General arrangement Yes/No Yes/No drawing with sections enclosed II. MARSHALLING KIOSK 1.00.00 Manufacturer’s Name and .................... ................... country 2.00.00 Indoor/Outdoor application .................... ................... 3.00.00 Design ambient air .................... ................... temperature (deg.C) 4.00.00 Thickness of sheet steel .................... ................... (mm) (Hot rolled/Cold rolled) 5.00.00 Degree of protection provided .................... ................... 6.00.00 Bill of material for all the equip- .................... ................... ment mounted in Marshalling Kiosks giving details a) Make and type .................... ................... b) Applicable standards .................... ................... c) Voltage rating .................... ................... d) Current rating .................... ................... e) Duty class, if applicable .................... ................... f) Manufacturer’s .................... ................... catalogue No. g) Total heat load of kiosk .................... ................... (for purpose of Ventilation requirement)







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7.00.00 Busbars a) Material .................... ................... b) Temperature rise at .................... ................... rated current over specified ambient (deg.C) c) Continuous current .................... ................... rating (A) d) Short circuit current .................... ................... rating for one sec. (kA) 8.00.00 Control Wiring a) Size of conductor (mm2) i) For CT circuits .................... ................... ii) For other circuits .................... ................... b) Conductor (solid/ .................... ................... stranded) 9.00.00 Space Heater Rating .................... ................... at 240V AC. 10.00.00 Marshalling Kiosk drawing enclosed showing the following a) Outline dimensions, Yes/No floor opening, floor/ wall/pedestal fixing arrangement, weight etc. b) Front view, and inside Yes/No view showing the mounting arrangement of various equipment 11.00.00 Schematic/wiring diagram Yes/No of marshalling kiosk enclosed 12.00.00 Interconnection drawing Yes/No showing external cable, connections to the marshalling kiosk enclosed 13.00.00 Type test report to verify Yes/No degree of protection enclosed







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14.00.00 Terminal Block a) Make, type & Cat. No. .................... ................... b) Current rating .................... ................... i) Power Terminals (A) .................... ................... ii) Other Terminals (A) .................... ................... 15.00.00 PAINTING Coat Primer Finish Coat a) Manufacturer’s Name and .................... ................... country b) Manufacturer’s type .................... ................... designation/brand name c) Shade .................... ................... i) Outside .................... ................... ii) Inside .................... ................... d) No. of Coats provided a) Fabricated steel .................... ................... b) Junction boxes .................... ................... e) Whether descriptive Yes/No pamphlet is enclosed 16.00.00 JUNCTION BOXES a) Manufacturer’s Name & .................... ................... Country b) Manufacturer’s type .................... ................... designation c) Material Specification .................... ................... d) Type of Enclosure with .................... ................... degree of protection e) Thickness of G.I. sheet .................... ................... 17.00.00 TERMINALS a) Make .................... ................... b) Current Rating (Amps) .................... ...................







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c) Voltage Rating (volts) .................... ................... d) Stud type Yes/No e) Complete with Yes/No insulated barriers f) Whether suitable for Yes/No 2 Nos. 2.5mm2 copper conductor g) Whether descriptive Yes/No pamphlet is enclosed? 18.00.00 COMPRESSION TYPE CABLE GLAND a) Manufacturer’s Name & .................... ................... Country b) Manufacturer’s type .................... ................... designation c) Material .................... ................... d) Whether passivated or not? Yes/No e) Whether descriptive pamphlet Yes/No & dimension drawing is enclosed 19.00.00 CABLE LUGS a) Manufacturer’s Name & .................... ................... Country b) Manufacturer’s type .................... ................... designation c) Current rating .................... ................... d) Material Specification .................... ................... e) Tinned Yes/No f) Solderless crimping type Yes/No g) Whether descriptive Yes/No Pamphlet is enclosed?







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20.00.00 STRAIGHT THROUGH JOINTS a) Manufacturer’s Name & .................... ................... Country b) Heat shrinkable type/taped .................... ................... type/premoulded type c) Whether bill of materials Yes/No of the kit furnished? d) Whether straight through joint Yes/No kit is complete with all accessories? e) Whether descriptive Yes/No pamphlet is enclosed? 21.00.00 CABLE CLAMPS (25 x 2.5mm Al Strip) a) Manufacturer’s Name & .................... ................... Country b) Material Specification size and type of clamps/cords i) For single core cables .................... ................... ii) for multi core cables .................... ................... iii) for cables in trefoil .................... ................... formation c) Whether descriptive pamphlet Yes/No and drawing showing general arrangement is furnished? 22.00.00 200mm DIA HUME PIPE a) Manufacturer’s Name & .................... ................... Country b) Manufacturer’s type .................... ................... designation c) Applicable Standard .................... ................... d) Material Specification .................... ................... e) Whether drawing/descriptive Yes/No pamphlet enclosed f) Wall thickness .................... ...................







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III. CONTROL CABINET (Bidder shall furnish this data for each equipment marshalling • box/operating mechanism box separately) 1.00.00 Manufacturer’s Name and country of origin .................... ................... 2.00.00 Indoor/Outdoor application .................... ................... 3.00.00 Design ambient air temperature (degree C) .................... ................... 4.00.00 Standards applicable .................... ................... 5.00.00 Thickness of sheet steel (mm) and whether cold rolled or hot rolled .................... ................... 6.00.00 Degree of protection provided .................... ................... 7.00.00 Bill of material for all the equipment mounted on control cabinet giving the following details: a) Make and type .................... ................... b) Applicable standard .................... ................... c) Voltage rating .................... ................... d) Current rating .................... ................... e) Duty class, if applicable .................... ................... f) Manufacturer’s catalogue No. .................... ................... g) Total heat load of cabinet (for purpose of ventilation requirement .................... ................... 8.00.00 Colour of finish paint IS:5 a) Outside .................... ................... b) Inside .................... ................... 9.00.00 Busbars a) Material .................... ...................







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b) Temperature rise at rated current over specified ambient (deg.C) .................... ................... c) Continuous current rating (A) .................... ................... d) One second current rating (kA) .................... ................... 10.00.00 Control Wiring a) Size of Conductor i) for CT circuits .................... ................... ii) for other circuits .................... ................... b) Conductor Solid/Stranded .................... ................... 11.00.00 Terminal Blocks a) Make & type .................... ................... b) Current rating .................... ................... i) Power terminals (A) .................... ................... ii) Other terminals (A) .................... ................... 12.00.00 Space Heater Rating at 240 V AC .................... ................... 13.00.00 Control cabinet drawing showing the following enclosed a) Outline dimensions, floor openings, floor/wall/pedestal fixing arrangments, weights etc. Yes/No b) Front view, inside view showing the mounting arrangement of various equipment Yes/No 14.00.00 Schematic/Wiring diagram of control cabinet enclosed Yes/No 15.00.00 Interconnection drawing showing external cable, connections to the control cabinet enclosed Yes/No







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16.00.00 Type test report to verify degree of protection enclosed Yes/No 17.00.00 Details of terminal rows: i) Wheather arranged vertical or horizontal .................... ................... ii) Clearance from adjacent components .................... ................... iii) Distance between rows .................... ................... iv) Whether transparent protection cover provided Yes/No 18.00.00 i) Rating of lamp provided in cabinet .................... ................... ii) Rating of plug & socket provided in cabinet .................... ................... IV. TERMINAL CLAMPS AND CONNECTORS (Bidder shall furnish this data for each Terminal Clamps and Connector separately for each equipment)” 1.00.00 Manufacturer’s Name and Address .................... ................... 2.00.00 Applicable standards .................... ................... 3.00.00 Type .................... ................... 4.00.00 Material (state percentage composition of constituents and impurities present) a) Clamp body .................... ................... b) Bolts & Nuts .................... ................... c) Spring washers .................... ................... 5.00.00 Bimetalic Liners if any and its thickness .................... ................... 6.00.00 Rated Current .................... ................... 7.00.00 a) Rated terminal load (kg) .................... ................... b) Factor of safety .................... ...................







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8.00.00 Minimum thickness of any part (mm) .................... ................... 9.00.00 Weight of clamp complete with hardware (kg) .................... ................... 10.00.00 RIV in micro volts and corresponding

voltage a) 0.5 MHz .................... ................... b) 1.0 MHz .................... ................... c) 1.5 MHz .................... ................... d) 2.0 MHz .................... ................... 11.00.00 Corona extinction voltage (kV rms) .................... ................... 12.00.00 Type test reports as per IS enclosed Yes/No 13.00.00 OGA drawing enclosed Yes/No 14.00.00 Maximum allowable span on .................... ................... equipment terminal pad and with specified fault current (rms) with specified phase to phase spacing for 4" IPS Al tube V. INSULATOR HARDWARE 1.00.00 Manufacturer ................... ................ 2.00.00 Applicable Standards ................... ................ 3.00.00 Material ................... ................ a) Ferrous Parts ................... ................ b) Nuts & Bolts ................... ................ c) Cotter Pins ................... ................ d) Split Pins ................... ................ e) Strain and Suspension ................... ................ clamps







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4.00.00 Ultimate Strengths a) Complete Assembly (Kg) ................... ................ b) Suspension clamp (Kg) ................... ................ c) Strain clamp (Kg) ................... ................ d) D-Shackle (Kg) ................... ................ e) Ball eye (Kg) ................... ................ f) Ball clevis (Kg) ................... ................ g) Clevis eye (Kg) ................... ................ h) Socket eye (Kg) ................... ................ i) Socket clevis (Kg) ................... ................ j) Yoke Plate (Kg) ................... ................ 5.00.00 Magnetic power loss of the ................... . ............... suspension clamp assembly at 600A 6.00.00 Magnetic power loss of the ................... ................ drop clamp assembly at 600A 7.00.00 Drawings of clamps Yes/No Yes/No enclosed 8.00.00 Type test reports as Yes/No Yes/No per I.S. enclosed

EHV Specification

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