Technical Specifications 11kv

Technical Specifications
TECHNICAL SPECIFICATIONS
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GENERAL CONSTRUCTION PRACTICES

CONSTRUCTION PRACTICES FOR 11 KV SUB-TRANSMISSION LINES 1. SURVEY AND MARKING: The preliminary survey of the line will be done jointly by CSEB and Contractors authorised representative. The survey done should be plotted on the map and submitted to CSEB Engineer-InCharge of the work. During preliminary survey crossings/proximity to buildings and to all categories of power lines as well as telecom lines under P&T Deptt. should be clearly indicated in the route map. The detailed survey should be under taken only after the route alignment submitted is approved. The pit marking is then done at the locations. Any likely discrepancy in respect of ground/building clearance is sorted out first then the work shall be started. In case of erection to be carried out across power line, telegraph, telephone lines and public roads, the engineer in charge shall however furnish the required drawings of the crossings for the purpose. All necessary care should be taken by the contractor to avoid damage to crops and trees and properties while executing the work. 2. EXCAVATING PITS FOR ERECTION OF POLES: After the pit locations are located & peg marked on the ground, the pole pit of size 600x900x1500mm be dug. The base padding of 200mm thick with 1:3:6 cement concrete be done before erection of pole. The earthing coil should also be grounded 800mm below ground level by digging a separate pit & filling the pit with soil. The earthing coil is jointed with the earth wire provided in the base of the PCC pole and metallic fittings should be earthed with the embedded wire in the PCC pole at the top. The pole in the pole pit be erected in truly vertical position and the pit should be filled with boulders for line poles and PCC poles of DPS be concreted 0.3 Cmt. per pole. The pit is filled with 1:3:6 cement concrete mixture for size 450x600x1500mm. The poles should be erected with maximum span of 100 meters. In case of Rail Pole/H Beam the earthing coil is bolted with the same. . The pole in the pole pit be erected in truly vertical position and the Rail Pole/H Beam and poles for DPs and tangent locations should be concreted 0.5 Cmt. per pole with 1:3:6 cement concrete mixture for size 450x600x1500mm. The poles should be erected with maximum span of 100 meters. 3. FIXING OF V CROSS ARM, TOP CLAMPS, DC CHANNELS etc. ON THE POLES: The fitting such as V cross arm, top clamps, D.C. channel etc. should be fixed on poles as per standard practice adopted in CSEB. The fabrication of above fittings should also be got done as per standard drawing available in the CSEB. The general specification of steel sections are given below: i. V Cross arm should be made out of M.S. Angle of size 65x65x6mm. The weight of one V cross arm is approximately 10.45 Kg/Cross Arm. ii. Top clamp should be made of M.S. Angle of size 65x65x6mm. The weight of clamp should be approximate 3.48 Kg/Top clamp. iii. D.C. cross arm 4 centre should be made out of the M.S. channel of size 100x50x6 mm. The weight of one DC cross arm comes out 46.00 Kg D.C. and length 2370 mm. iv. Other special fittings if required may be got fabricated as per the standard drawings of CSEB. The clamps for holdings the fittings should be fabricated out of M.S. flat 65x8 mm size as per the standard drawings of CSEB weight 3.5 Kg/Pair clamp. All nuts & bolts used shall be of M.S. with combination of plain and spring washer and machine made. 4. FIXATION OF INSULATORS AND HARDWARE OF PINS: Insulator shall be handled carefully in all stages of loading and the individually checked for cracks, damages, loss of glaze etc. before assembling and erection of at site. a) The 11KV galvanized steel pins made by process of forging suitable for 11KV pin insulators having maximum failing load of 5 K.N. with small steel head as per fig IB of IS 2486 (ii)/1974 shall be used. The dimension of pin shall conform to ref L-306N fig 69IS-2486 (ii)/1974. The pin shall be provided with nut (hot dip galvanized) one plain washer and one spring washer (electro galvanized). b) The disc insulators should be fitted with 11KV Hardware for tensioning the conductor 11KV hardware should be fixed in the disc insulators as per the standard practice and in the correct position to bear the
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tension of conductor. The 11KV strain hardware fitting of aluminium alloy suitable for required size of Conductor (ACSR) should be used conforming to IS-2486 (Part-II) 1989. The 4 feet centre DP are to be erected at the pre-decided location and six stays should be provided on the DP. The location of pit for embedding the anchor plate and stay rod shall carefully be determined either in true alignment. The overhead line or at angle locations as per the requirement of the case. The pit 0.4x0.6x1.6 mtr. shall be excavated and anchor plate with stay rod shall be suitably aligned in such a manner that the stay wire when binded with anchor rod & stay clamp at pole, the same should make an angle of 30 degree to 45 degree from the pole in the tightened position. Cement concrete mix 1:3:6 shall be poured 0.2 cmt. in the pit, well packed with ramming adequately & cured properly. The stay clamp shall be located near and below the DC Cross arm to counter balance the tensile load of the line conductor. Stay wire shall be bound at both ends i.e. at the box and the stay rod. Fly guy/storm guy, as per the site conditions should be used after getting approval from CSEB. The stay set consisting of Anchor Rod, Anchor plate, turn buckle bow, thimble should be used at the tension locations. The conductor shall be laid out in such a way that there is no damage to conductor. Reels of conductor should be handled carefully so that no damage to conductor strands occur. 5. STRINGING OF CONDUCTOR: Conductor should be laid out from a rotating wheel supported on jacks for easy unwinding of the conductor snatch blocks shall be used for stringing the conductor and shall have groves of a shape and size to allow early flow of conductor and ensure damage free operation. Come along clamps should be used to grip the conductor at the time of stringing. 6. SAGGING OF CONDUCTOR: All conductors sagging shall be preferred in accordance with the sag and tension tables. After the conductors have been pulled to the required sag, intermediate spans shall be checked to determine the correct sag. The conductor shall be installed on insulators secured to it by means of 6 SWG aluminium binding wire. The jumpers at the tension locations should also be bound by 6 SWG aluminium binding wire. Before fixing the conductor on insulator and strain hardware, aluminium tape should be wrapped on the conductor. 7. GUARDING: The 11KV guarding cross arm is to be fitted on the pole as per the drawing available in the CSEB for guarding the line with 8 SWG GI wire as guard wire and 10 SWG GI wire for lacing. Guarding cross arm made of 75x40x6 mm angle 5 feet long should be clamped at 300mm below the bottom arm of V cross arm. 8. ANTI-CLIMBING DEVICE: Barbed wire weighing 3.5 Kg per pole should be wrapped at a height of 3000 mm above ground level stretching in 900 mm length. Both ends of barbed should be clamped suitably to avoid coming down from its location. 9. DANGER BOARD: Danger Board for 11KV voltage and danger mark conforming to IS:2551-1963 should be fixed on each location.
SPECIFICATION FOR LT LINE ON 140 Kg. 8 METER LONG PCC POLE 1. SCOPE: Planning, supply, installation, testing and commissioning of 415 Volt over-head low tension line on 140 Kg. 8 meter long PCC Pole and necessary iron fitting etc. complete. All relevant supports fittings and fixtures, conductors shall conform to their respective IS specifications. The physical layout of the work has to be got approved by the concerned competent office of CSEB before start of work. 2. POLE: The overhead LT line shall be supported on 140 Kg. 8 meter long PCC pole as specified in the schedule of item conforming to ISS. Normally one sixth of the pole length shall be buried in the ground. The supports shall suitable be spaced depending on the number and size of the conductors, number of in between plots, road crossings etc. in general, the spacing of supports shall be approximately 50-60 meters depending upon road crossing, telephone crossing etc, and in no case the inter-distance between two consecutive support shall exceed 65 meters as per rule 85 of the Indian Electricity Rules, 1956. For erection of pole, a pit size of 600x900x1500 mm should be done and base padding of 200mm thick should provided and back filling of pole pit with boulders. Suitable time of atleast seven days shall be allowed for
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setting the base concrete with proper curing etc. Then the pole shall be laid in the center of the pit and tied with ropes of adequate strength on four sides of the poles by means of suitable clamps each fixed at right angle to its other two adjacent side clamps. Loose ends of two sides of ropes forming a straight line shall be tied firmly with deep driver iron pigs located equi-distance from the corner of the pole pit. One of the two ends of remaining ropes shall be connected to turner and the opposite rope shall be kept loose and ready to be tied on deep driver iron pig when the pole attains vertical position. To avoid any chance of injury or damage to labours and technicians working at site the remaining portion of earth pit shall then be refilled with excavated soil and well consolidated. 3. CROSS ARMS AND BRACKETS: The LT cross arm shall be made up of M.S. Angle as follows: i) LT 3 Pin Cross Arm: 50x50x6 mm size 4.5 Kg/meter, 680 mm long ii) LT 4 Pin Cross Arm: 50x50x6 mm size 4.5 Kg/meter, 980 mm long The minimum clearance between holes for U clamps shall be 300mm. A minimum space of 40mm along the length of the bracket shall be kept spare from top hole and bottom hole of the bracket the length of cross arm and bracket shall be suitable for spacing of conductors earth wire and guarding in accordance with the minimum spacing specified in relevant ISS and in accordance to Indian Electricity Rules. The width of the bracket shall be not less than 50 Cms. 4. INSULATORS: L.T. Porcelain shackle insulators of size 90x75mm conforming to IS: 1445-1977 shall be provided and fixed in U clamps for holding the conductors. LT shackle hardware galvanizing shall conform to ISL 2633-1964 for 4 dip tests. For holding neutral conductor Aluminium bobbin insulators of size 60x50mm size with nuts bolts shall be provided. 5. CONDUCTORS: For single phase three wire line ACSR 20 Sqmm Cu.Eq. (Weasel) conductor will be used for phase and 13 Sqmm Cu.Eq. Squirrel for neutral. Similarly for three phase four wire line ACSR 20 Sqmm Cu.Eq. (Weasel) conductor will be used for phase and 13 Sqmm Cu.Eq. Squirrel for neutral. Also for three phase four wire line ACSR 30 Sqmm Cu.Eq. (Rabbitl) conductor will be used for phase and 20 Sqmm Cu.Eq Weasel for neutral in some of the locations. The conductors shall be laid out in such a manner that there is no damage to the conductors in any form. While stringing overhead conductors, there should not be any kinking. Reels of conductor should be handled carefully, so that there is no cutting, nicking or fraying of the conductor strands. Conductor should be laid out from a rotating wheel supported on jacks for easy unwinding of the conductor. The conductor shall be binded to its respective shackle insulator by means of binding wire at one of the terminal end of span. The nuts shall be unscrewed in such a manner that top of nut gets flushed with bolts surface, so as to enable the U clamp to be at maximum distance from the brackets. Aluminium sheaves fitted with ball bearing should be used at all points of conductor support for easy pulling and to ensure uniform tension throughout the conductor length. The conductor should be pulled with a proper come along clamps. Conductor shall be pulled upto a proper sag in span at or near the dead end section of the line and then binds with the shackle insulator by means of adequate size of binding wire. The tension should then be adjusted threading of nut of MS U clamp until correct sages chained in spacing near the pulling end. The conductor shall then be binded with the shackle insulators of mid span poles maintaining proper sag and tension. The overhead line shall be correctly aligned. Where there is any deviation more than 30-Degree from straight line the overhead conductor shall be shackled of at the support. Similarly terminal and function poles shall also be provided with shackle insulators. D loops shall be provided on each conductor on both sides of each LT pole and all jumpers of LT line and service line shall be done on these loops only. The size of D loop shall generally be 200mm wide, 100mm high with 150mm additional length on both sides for binding. The cross sectional area of conductor of D loop shall be the same as that of conductor to which it is being binded. Aluminium tape shall be used for each contact/jumpers on lines. Binding at all places shall be done neatly by Aluminium binding wire of size 8 SWG. 6. CLAMPS: Back clamps and stay clamps for LT line should be made up of 50x6mm MS flats. 7. GUARDING: Suitable guarding shall be provided as per provision of Rules 88 of Indian Electricity Rules. The spacing between the outermost conductor and the guard wires shall not be less than 30 Cm. both vertically and horizontally. Diamond guarding shall be provided at a distance of 4 feet min. from the pole on its each side.
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Any other type of guardings shall be done with the permission of the Engineer-In-Charge. The guard wire shall be GI and shall in no case be less than 8 SWG in size and shall have a breaking strength of not less than 635 Kg. 8. EARTHING OF PCC POLE: i) 11KV Every pole should be earthed by earthing coil at the bottom and fittings at the top. ii) LT Every third pole should be earthed by earthing coil at the bottom and fittings at the top. CONSTRUCTION PRACTICE OF ADDITIONAL BAY AT 33/11 KV SUB-STATION 1. GANTRY: a. A gantry shall mean a group of two RS joists /or H Beam of required equal sections and equal lengths joined together along their toe of both flanges, with webs of both joints facing each other, shim welded throughout the length on both sides of flange and re strengthening of joints by MS flats of 50 mm x 6 mm thick as desired and directed by Engineer-in-Charge. The RS joists shall be 175 mm x 85 mm corresponding to ISMB 175 of required length.and H Beam shall be 152x152 mm ,37.1 Kg /meter b. Installation: The physical layout of entire sub-station with positions of equipment, bus bar structures and outgoing feeders shall be marked at site and has to be got approved by the concerned competent officer of CSEB before start of works, support required to be erected shall be painted on 1/6th of its length with approved type of anticorrosive paint. For erection of bus bar structure supports, normally one sixth of the support shall be buried in ground. A pit of size 0.6 Mtr. x 0.9 Mtr. of required 1.5 Mtr. depth shall be excavated. A layer of 20 cm thick of 1:3:6 cement concrete poured for base pad concreting of post is to be done by 1:3:6 ratio cement concrete of size 0.45 M x 0.60 M x 1.5 M. Suitable time shall be allowed for setting the cement concrete before removal of holding ropes. Proper curing of cement concrete by means of wet gunny bag for at least seven days shall be done. All precautions shall be taken to avoid any chance of injury or damage to labors working at site. c. Erection of structure & Equipments: After the columns/supporting structures are erected respective equipments of 33/11 KV are to be erected carefully by suitable crane. The breaker and isolators are to be erected as 3 phase unit basis and other item like 11 KV CT, PT, LA PI etc. are to be erected on Iphase unit basis and rigidly mounted on the supporting structures. Control relay panels are to be mounted inside the control room in the same order as in the switchyard. After the earth mat design is finalized, the earth mat with 50x6 mm GI flat are to be put for each equipment. Then flats are to be interconnected with each other. The bus bars are to be strung after all the columns and beams are fitted. Both the bus shall be of single bus type with suitable tension insulators and 11 KV Auxiliary bus are also to be strung. Control and power cables should be laid in consultation with Engineer-in-Charge for safe and easy maintenance. All the equipments of each 33/11 KV bays are to be connected by suitable jumpers and clamps.
d. Muffing: A layer of 1:3:6 mix cement concrete 45 cm x 45 cm on all sides of the pole upto a height of 45 cm and tapered on top shall be coasted and adequately cured for seven days. One finishing coat of cement paste shall be applied on outer surfaces of the muffing. e. MS Iron Fittings: All channels used shall not be less than 100x50x 6 mm. All angle used shall not be less than 65 x 65 x 8 mm corresponding to ISI 6565. MS flats used shall be of sections as directed by Engineer-in-Charge.All nut-bolts used shall be MS with a combination of plain and spring washer. Wherever required use of lock nuts shall be made without any extra cost. 2. CONDUCTORS: Aluminum conductor steel reinforced of size 100 Sqmm having approximate ultimate tensile strength of 3299 Kg. and 0.27450 Ohm/Km resistance at 20 deg. C. conforming to IS: 398-1961 as specified in the schedule of item and directed by Engineer-in-Charge shall be used for 3 phase 3 wire 33 KV or 11 KV over head bus bars. The conductors shall be laid down in such a manner that there is no damage to
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the conductor in any form. While stringing of conductors there should not be any kinking. Conductor should be pulled upto a proper sag as directed by Engineer-in-Charge. Tension should then be adjusted until correct sag is obtained in spacing near the pulling end. Stringing chart should be used for proper stretching of conductor. The sag shall then be checked either by sighting method or by stopwatch reflected method. The conductor shall be installed on insulators secured to it by means of 6 SWG aluminium binding wire and aluminum tape on it maintaining proper tension and sag. 3. PAINTING OF POLE: - All steel poles, brackets, cross arms and all steel fittings shall be first painted with two coat of red oxide paint. The portion of the pole to be buried inside the ground shall be painted with two coats of bitumen tar. After erection of pole, the external surface of pole and all steel items shall be painted with two coats of aluminium paint in an approved manner. GUYS AND STRUTS: a. GUYS: The guys shall consist of anchor plate, stay rod with bow and ratchet assembly, thimbles stay wires, stay grips and stay clamps. All iron fittings of stay shall be painted with Red Oxide paint. The minimum size of stay wire shall be 7/4.0 mm with and ultimate breaking strength of 6450 Kg. The stay rod shall be 20 mm dia 2 meters long fitted with bow and ratchets assembly having ultimate tensile strength of 8000 Kg. The anchor plate shall not be less than 300 x 300 x 6 mm size made up of mild steel. Turnbuckles with 20 mm dia. screw shall have ultimate breaking strength of 8000 kg. b. CHAIN LINK FENCING: The outdoor switchyard shall be enclosed by GI wire mesh chain link fencing. The fencing shall be supported by adequate angle iron frame work of minimum size 50 x 50 x 6 mm and shall have iron bracings of the angle iron frames. The upper parts shall be bent to the required degree and shall have four lines GI barbed wires. Framework of gates of the switchyard shall be made up of M.S. flate and (n.b) M.S. bars. The gates shall have a locking arrangement with providing 7 layers "Godrej" make lock. The gate is to be fabricated as per drawing & design provided by the Engineer-inCharge. The minimum height of fencing post is 2.4 meters above level and 0.5 meter below ground level. The distance between angle iron supports is minimum 2.0 meter and one angle iron should be provided on top of chain link fencing around the switchyard and one angle iron (50x50x6mm) just touching the ground level around the switchyard. The complete chain link fencing work shall be painted with two coats of primer and two coats of suitable weatherproof paint.
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5. CABLE AND EARTHING: a. Cables: The cables shall be supplied, inspected, laid tested and commissioned in accordance with drawings, specifications relevant standard specifications and cable manufacturer's instructions. The MV cable shall be PVC insulated PVC sheathed alluminium conductor armoured cable of 1100 volts grade. All cable shall be inspected upon receipt at site and checked for any damage during transit by the Engineer-in-Charge before it laid down to trenches, walls etc. b. Laying of Cables: Cables shall be laid by skilled and experienced workman using adequate rollers to minimise stretching of the cable. Great care shall be exercised in laying cables to avoid forming kinks. The relative position of cables shall be first marked to avoid the cables crossing each other. At all points of changes in direction in horizontal as well as in and vertical planes, the cables shall be bent smooth with a radius of bend not less than 12 times the diameter of the cables. For laying cables under-ground a trench of atleast 750 mm deep of required width shall be excavated for entire length of cable route. The trench shall be brick masonry made. A bed of fine sand of 100mm thickness shall be dressed and well dressed. The cable shall be laid on the bed of sand with full precautions to avoid any kinking, twisting and damage of cable. Fine sand shall be spread over the cable and shall be flushed with top surface RCC Slab are to be placed at suitable size to cover cable trenches. For cables to run along the wall proper and accurate verticality shall be maintained. Before fixing the cables on walls vertical plumbed arcing shall first be made. Parallel cables shall be spaced atleast 50 mm apart maintaining their relative position over the entire length. Saddles for gripping the
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cables shall be spaced not more than 1 meter apart in order to avoid undue stress on the cables due to its own weight. c. Earthing: All the non-current carrying metal parts of electrical installation shall be earthed properly. All metal conduits trucking, cable sheaths, switch gear, distribution fuse boards, light fittings and all other parts made of metal shall be banded together and connected by means of specified earthing conductors to an efficient earthing system. All earthing shall be in conformity with the Indian Electricity Rules and in accordance to IS: 3043-1987.
d. Earthing Conductors: All earthing conductors shall be of GI plate, GI pipe or earthing coil of specified size and shall be protected against mechanical injury or corrosion. e. Sizing of Earthing Conductor: Under no circumstances the cross sectional area of earthing conductor shall be less than half of the largest current carrying conductor subject to an upper limit of 80 Sqmm. If the area of the largest current carrying conductor or bus bar exceeds 160 Sqmm. then two or more earthing conductor shall be used in parallel to provide at least half one cross sectional area of the largest current carrying conductor. 6. TYPE OF EARTH ELECTRODE: a. Plate Electrode: Plate electrode forming a grid shall be used for earthing stations around substations. Required numbers of earth electrodes directed by Engineer-in-Charge should be provided for substation earthing. All electrodes shall be inter connected to form a grid. The substation equipments the structures shall be earthed in manner as approved and directed by Engineer-in-Charge. b. Connections to Earth: All sub station equipment shall be earthed on a grid system. The grid around the substation connecting earthing stations shall be of bare GI conductor of size not less than 7/3.15mm. The transformer neutral shall be connected. To the grid with two separate and independent bare GI conductor. All other sub station equipment shall be earthed with separate and independent GI strip of required section or bare GI conductor of size 6 SWG connected to grid. The earthing conductors inside the buildings shall be properly supported with clamps and brass screws. GI strips outside the building shall be laid atleast 450 mm below the finished ground level. Over lapping in strips at joints where required shall be minimum 75 mm. The joints shall be reverted with rivets and brazed in approved manner. Sheathed lugs of adequate capacity and size shall be used for all termination of connection. Lugs shall be fitted to the equipment body to be earthed after the metal is cleaned of paint and other oily substance and properly tinned. SITE TESTING AND PRE-COMMISSIONING CHECKS: An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the Field Quality Plan / instructions of the equipments manufacturer or owner without any extra cost to the Owner. The Contractor shall arrange all instruments required for conducting these tests alongwith calibration certificates and shall furnish the list of instruments to the Owner for approval. Detailed test certificates duly signed by CSEB representative & agency representative of tests jointly carried out at site before putting the equipments in use, shall be submitted by the contractor in three copies as per following distribution: o/o the Executive Engineer, Officer in Charge GENERAL CHECKS: Check for physical damages. Visual examination of zinc coating/ painting. Check from name plate that all items are as per order/ specification. Check tightness of all bolts, clamps and connecting terminals using toque wrenches. For oil filled equipments check for oil leakage, if any. Also check oil level and top up. Check ground connections for quality of weld and application of zinc rich paint over welded joints of galvanized surfaces. Check cleanliness of insulator and bushings.
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A. B. 8.
All checks and tests specified by the manufacturers in their drawings and manuals as well as tests specified in the relevant code of erection.
SPECIFICATION FOR 11/0.4KV 63/100 KVA TRANSFORMER DP STRUCTURE 1. SCOPE: Design, planning, supply, installation, testing for commissioning of double pole structure (D.P. structure) for pole mounting transformer Sub-station with all allied equipments etc. complete. The Sub-station plan shall be got approved by the concerned competent office of Chief Engineer (Electrical Safety) cum Chief Electrical Advisor to Government of C.G. and concerned competent office of C.G. Electricity Board prior to erection work. 2. SUPPORTS: The D.P. structure shall have two numbers 140 Kg. 8 meter long PCC Pole for 63 & 100 KVA Sub-station as specified in the schedule of items. Normally one sixth of the pole shall be buried in the ground. The support shall be placed at a distance of 2400 mm. For erection of pole, a pit digging of size 600x900x1500 mm should be done and base padding of 200 mm thick should be provided and concreting with 0.3 Cmt per pole with 1:3:6 cement concrete mixture for size 450x600x1500 mm. Suitable time for atleast seven days shall be allowed for setting the base concrete with proper curing etc. the pole shall than be laid in the center of the pit and tied with ropes of adequate strength of four side of the pole by means of suitable clamps fixed at right angles to each other. Loose ends of two sides of ropes forming a straight line shall be tied firmly with deep driven iron pigs located equidistant from the center of the pole pit. One of the remaining two ends of remaining ropes shall be connected to turfer and the end of opposite rope shall be kept loose and ready to be tied with deep driven iron pigs shall be manned by skilled worker to control the unwanted deflection of pole while pulling it by turfer. The pole shall then be pulled by turfer and correctly aligned to its truly vertical position and then set in 1:3:6 cement concrete poured upto ground level. Suitable time shall be allowed for setting the cement concrete before removing the ropes. Proper curing of cement concrete for atleast seven days shall be done. All precautions shall be taken to avoid any chance of injury or damage to labour and technicians working at site. 3. FITTINGS: 11KV V cross arms shall be made up of MS Channel 65x65x6 mm size having phase to phase clearance of 1070 mm. 11KV top clamps shall be made up of MS angle 65x65x6 mm size 405 mm long. DC cross arms, single pole cut point DC, transformer mounting DC, AB Switch mounting DC, DO and LA mounting channel shall be made up of MS Channel 100x50x6 mm size of required length. Back clamps and stay clamps shall be made up of 65x8 mm size. MS Nut and Bolts conforming to IS: 1363-1902 shall be used of 5/8 (16mm) for fitting works and for earthing arrangements GI nut-bolts must be used. 4. AB Switch :
AB switches and DO Fuses should be supplied with base steel structure, terminal bi-metallic connectors / PG clamps / earth connector. They should be checked for proper alignment and free & smooth operation. The insulators should be cleaned before commissioning. The linkage of contacts should be checked for free and adequate grip. The AB switch should be checked for fully OPEN/CLOSED positions. Contact between two movable points should be checked and recorded. The contacts should be adequately lubricated before commissioning. Connection of terminal connectors shall be checked for proper tightness. Operating handle should be separately grounded. Equipments should be supplied with detail technical specifications enclosed. The associated mounting / connection accessories items shall not be considered for measurement under any head of Price Schedule even if they happen to be appearing in Price Schedule.
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4. LIGHTENING ARRESTOR: The 11KV lightening arrestor shall be valve type arrestor consisting of an outer ceramic body containing 9 Set of resistance (Valves) and spark gaps in series. The resistance shall be made of special silicon carbide ceramic, which offer high resistance to power frequency voltages and low resistance to surge voltages. Arrestor should be installed as close as possible, to the HT line. The arrestor should be solidly earthed. The lightening arrestor shall be mounted on 100x50x6 mm MS Channel fixed approximately 1500mm below the 11KV tapping point. 5. D.O. FUSE UNIT: The 11KV drop out fuse unit shall have current carrying capacity of 200 Amps having 2 Nos 11KV post insulators fitted on bakelite base with fuse barrel as per BSS-1314. The DO fuse should be got checked and test certificate from CPRI Bangalore/Bhopal as per IS: 5792-1970 should be obtained and produced. 6. TRANSFORMERS: The 11/0.4KVstep-down distribution transformer shall be supplied and installed as per the specifications mentioned in the Transformer Section. 7. DISTRIBUTION BOX: The distribution box suitable for 63/100 KVA transformer with isolator on incoming side and SPMCCB on out going side will be used. All sheet steel work shall undergo a process of digressing, pickling in acid, cold rinsing, phosphating, possivating and then sprayed with a high corrosive resistant primer and then backed in oven. The finishing treatment shall be by application of two coats of synthetic enamel gray paint in an approved manner. 8. DANGER CAUTION BOARDS: The danger of caution boards shall have to be displayed on pole, Transformer and LT distribution panel. The danger signboards should conform to IS: 2551-1963. 9. ANTI-CLIMBING DEVICE: Anti-climbing device consisting of barbed wire extending to a minimum length of 900mm shall be provided on poles. Both ends of the barbed wire shall be secured to poles by means of suitable iron clamps as per the direction of Engineer-In-Charge. 10. PAINTING OF DP STRUCTURES: All metallic parts except transformer and LT distribution box of D.P. structure and PCC Pole shall be painted in an approved manner. 11. EARTHING OF SUB-STATION: Three numbers pipe earthing with 2.5 meter long GI Pipe 40mm dia used connecting pipe earthing with 4mm GI wire with LA transformer neutral, transformer body, DO earthing, Channel earthing. Pole pit is filled with soil. EQUIPMENT ERECTION NOTES All support insulators; circuit breaker and other fragile equipment shall preferably be handled with cranes with suitable booms and handling capacity. The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing, scratching by sling ropes etc. For cleaning the inside and outside of Hollow insulators only muslin of leather cloth shall be used. Handling equipment, sling ropes etc. Should be tested before erection and periodically for strength. Bending of compressed air piping should be done by a bending machine and through clod bending only. Bending shall be such that inner diameter of pipe is not reduced. Cutting of the pipes wherever required shall be such as-to avoid flaring of the ends, and only a proper pipecutting tool shall be used. Hacksaw shall be used. Hacksaw shall not be used. The Contractor shall arrange at site all the equipments, instruments and auxiliaries required for testing and commissioning of equipment.
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STORAGE OF EQUIPMENTS The Contractor shall provide and construct adequate storage shed for proper storage of equipments. Weather sensitive equipment shall be stored indoor. All equipments during storage shall be protected against damage due to acts of nature of accidents. The storage instruction of the equipment manufacturer/Owner shall be strictly adhered to. HELICALLY FORMED FITTINGS:
Pin insulator ties:
Helically formed insulator ties shall be suitable for specified conductor size, Helically formed ties used for holding the conductor on the pin insulator shall be made of aluminum allow or aluminized steel or aluminumclad steel wire and shall conform to the requirement of IS: 12048-1987. The ties shall be suitably for pin insulator dimensions and conductor sizes to be specified by specified by the owner. Elastomer pad for insulator shall be used with the ties to avoid abrasion of the conductor coming into direct contact with the insulator. Test : The ties shall be subjected to the tests specified in IS: 12048-1987.
Fittings for Strain Insulators: The Fittings shall consist of the following components: . Cross arm strap conforming to IS:2486(Part-II)-1989. . Aluminum alloy die cast thimble-clevis for attaching to the tongue of Strain insulator on one end for accommodating the loop of the helically formed dead-end fitting at the other end in its smooth internal contour. The thimble shall be suitable for all sizes of conduct ors ranging from 7/2. 11mm to 7/3.35 mm AAAC. The thimble clevis shall be attached to the insulator by a steel cutter pin used with a non-ferrous split pin of brass or stainless steel. The thimble shall have clevis dimensions as per IS:2486(Part-II)1989. .Helically formed dead-end grip having a prefabricated loop to fir into the grooved contour of the thimble on one end for application over the conductor at the other end. The formed fitting shall conform to the requirement of IS:12048-1987. Tests: The helically formed fittings for strain insulators shall be subjected to tests as per IS:12048-1987. The other hardware fittings shall be tested as per IS: 2486(Part-I).
The scope of work is as under:Erection and commissioning of following :(I) single circuit 11 KV line on PCC poles 140 Kg/8.0 meter long with maximum span 100 mtr. using Rabbit/Weasel ACSR conductor, (II) 11KV line on 60 Kg / meter 9 meter long Rail Pole or 37.1 Kg / meter 9 meter long H Beam with Rabbit conductor, (III) LT line single phase three wire & 3 phase 4 wire using weasel & squirrel ACSR conductor for phase & neutral respectively on 140 Kg. 8.0 meter long PCC pole, (IV) LT line single phase three wire & 3 phase 4 wire using Rabbit and weasel ACSR conductor for phase & neutral respectively on 140 Kg. 8.0 meter long PCC pole, (V) 11/0.4 KV pole mounted Sub-station on 140 Kg 8.0 meter long PCC pole alongwith steel structure with Transformer/without Transformer including supplying, installation & commissioning of 11 KV line/LT line and pole mounted Sub-station in the Rural area anywhere in Chhattisgarh State on turnkey basis. a) b) DPs on PCC poles 140 Kg/8.0 meter long shall be erected with every 1.6 Km of line in the rural area of Chhattisgarh State. Survey & approach clearance.
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c)
Pits digging for supports and stays & supply and erection of PCC poles /Rail Pole/ H Beam and grouting of stays.
d) i. Supply and fixing of top clamp, V Cross Arms, D.C. channels, Disc & Hardware, Pin & Pin Insulator. ii. Supply & fixing of LT 3 Pin cross arm, LT hardware nut bolt shackle insulator & earth knob. iii. Supply & fixing of LT 4 Pin cross arm, LT hardware nut bolt shackle insulator & earth knob. iv. Supply & fixing of DC cross arm, transformer mounting channel, DO and LA mounting channel, DO set, lightening arrestor, distribution box, cable & transformer. e) i. Supply and stringing of 11 KV lines with Rabbit/Weasel ACSR conductor. ii) Supply and stringing of LT line single phase three wire using weasel (20 Sqmm Cu Eq) (13 Sqmm Cu Eq) ACSR conductor for phase and neutral. iv). v). f) g) & Squirrel
Supply and stringing of LT line three phase four wire using weasel (20 Sqmm Cu Eq) & Squirrel (13 Sqmm Cu Eq) ACSR conductor for phase and neutral. Supply and stringing of LT line three phase four wire using Rabbit (30 Sqmm Cu Eq) & Weasel (20 Sqmm Cu Eq) ACSR conductor for phase and neutral
Supply and providing guarding on the line. i. ii. iii. Testing & energisation of single circuit 11 KV line. Testing & energisation of single circuit LT line. Testing & energisation of pole mounted Sub-station.
h) The minimum length of 11 KV line, which will be given for execution on contract or turnkey basis shall be about 1.0 Km combine together 11KV and LT line as one job. However, if the contractor agrees, the smaller work may also be awarded. i) There are some works where PCC poles are erected. If contractors agrees, these incomplete works may also be awarded for completion of balance works. Detailed drawing of fabricated materials may be seen at the office, if required.
SPECIFICATION FOR CONSTRUCTION OF 33 KV LINE 1. SURVEY AND MARKING: The preliminary survey of the line should be done and plotted on the map and submitted to CSEB Engineer in charge of the work. During preliminary survey crossings/proximity to buildings and to all categories of power lines as well as telecom lines under P&T Deptt. Should be clearly indicated in the route map. The detailed survey should be under taken only after the route alignment submitted is approved. The pit marking is then done at the locations. Any likely discrepancy in respect of ground/building clearance is sorted out first then the work shall be started. In case of erection to be carried out across power line, telegraph, telephone lines and public roads, the engineer in charge shall however furnish the required drawings of the crossings for the purpose. All necessary care should be taken by the contractor to avoid damage to crops and trees and properties while executing the work. 2. EXCAVATING PITS FOR ERECTION OF POLES: After the pit locations are located & peg marked on the ground, the pole pit of size 600x900x1500mm be dug. The base padding of 200mm thick with 1:3:6 cement concrete be done before erection of pole. The earthing coil should also be grounded 800mm below ground level by digging a separate pit & filling the pit with soil. The earthing coil is jointed with the earth wire provided in the base of the PCC pole and metallic fittings should be earthed with the embedded wire in the PCC pole at the top. In case of Rail Pole/H Beam the earthing coil is bolted with the same. The pole in the pole pit be erected in truly
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vertical position and the PCC pole should be filled with boulders and PCC poles of DPS be concreted 0.5 Cmt. per pole. The pit is filled with 1:3:6 cement concrete mixture for size 450x600x1500mm. The poles should be erected with maximum span of 100 meters. 3. FIXING OF V CROSS ARM, TOP CLAMPS, DC CHANNELS etc. ON THE POLES: The fitting such as V cross arm, top clamps, D.C. channel etc. should be fixed on poles as per standard practice adopted in CSEB. The fabrication of above fittings should also be got done as per standard drawing available in the CSEB. The general specification of steel sections is given below: v. V Cross arm should be made out 9 M.S. Angle of size 75x75x6mm. The weight of one V cross arm is approximately 25.70 Kg/Cross Arm. vi. Top clamp should be made of M.S. Angle of size 75x75x6mm. The weight of clamp should be approximate 4.08 Kg/Top clamp. vii. D.C. cross arm 5 centre should be made out of the M.S. channel of size 100x50x6.0 mm. The weight of one DC cross arm comes out 62.3 Kg D.C. and length 3245 mm. viii. Other special fittings if required may be got fabricated as per the standard drawings of CSEB. The clamps for holdings the fittings should be fabricated out of M.S. flat 65x8 mm size as per the standard drawings of CSEB weight 3.5 Kg/Pair clamp. All nuts & bolts used shall be of M.S. with combination of plain and spring washer and machine made. 4. FIXATION OF INSULATORS AND HARDWARE OF PINS: Insulator shall be handled carefully in all stages of loading and the individually checked for cracks, damages, loss of glaze etc. before assembling and erection of at site. c) The 33KV galvanized steel pins made by process of forging suitable for 33KV pin insulators having maximum failing load of 10 K.N. with small steel head as per fig IB of IS 2486 (ii)/1974 shall be used. The dimension of pin shall conform to ref L-306N fig 69IS-2486 (ii)/1974. The pin shall be provided with nut (hot dip galvanized) one plain washer and one spring washer (electro galvanized). d) The disc insulators should be fitted with 33KV Hardware for tensioning the conductor 33KV hardware should be fixed in the disc insulators as per the standard practice and in the correct position to bear the tension of conductor. The 33KV strain hardware fitting of aluminium alloy suitable for Dog Conductor (ACSR) should be used conforming to IS-2486 (Part-II) 1989. The 5 feet centre DP are to be erected at the pre-decided location and six stays should be provided on the DP. The location of pit for embedding the anchor plate and stay rod shall carefully be determined either in true alignment. The overhead line or at angle locations as per the requirement of the case. The pit 0.4x0.6x1.6 mtr. shall be excavated and anchor plate with stay rod shall be suitably aligned in such a manner that the stay wire when binded with anchor rod & stay clamp at pole, the same should make an angle of 30 degree to 45 degree from the pole in the tightened position. Cement concrete mix 1:3:6 shall be poured 0.3 cmt. in the pit, well packed with ramming adequately & cured properly. The stay clamp shall be located near and below the DC Cross arm to counter balance the tensile load of the line conductor. Stay wire shall be bound at both ends i.e. at the box and the stay rod. Fly guy/storm guy, as per the site conditions should be used after getting approval from CSEB. The stay set consisting of Anchor Rod, Anchor plate, turn buckle bow, thimble should be used at the tension locations. The conductor shall be laid out in such a way that there is no damage to conductor. Reels of conductor should be handled carefully so that no damage to conductor strands occur. 5. STRINGING OF CONDUCTOR: Conductor should be laid out from a rotating wheel supported on jacks for easy unwinding of the conductor snatch blocks shall be used for stringing the conductor and shall have groves of a shape and size to allow early flow of conductor and ensure damage free operation. Come along clamps should be used to grip the conductor at the time of stringing. 6. SAGGING OF CONDUCTOR: All conductors sagging shall be preferred in accordance with the sag and tension tables. After the conductors have been pulled to the required sag, intermediate spans shall be checked to determine the correct sag. The conductor shall be installed on insulators secured to it by means of 6 SWG aluminium binding wire. The jumpers at the tension locations should also be bound by 6 SWG aluminium binding wire. Before fixing the conductor on insulator and strain hardware, aluminium tape should be wrapped on the conductor.
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7. GUARDING: The 33KV guarding cross arm is to be fitted on the pole as per the drawing available in the CSEB for guarding the line with 6 SWG GI wire as guard wire and 8 SWG GI wire for lacing. Guarding cross arm made of 75x75x6 mm angle 8 feet long should be clamped at 300mm below the bottom arm of V cross arm. 8. ANTI-CLIMBING DEVICE: Barbed wire weighing 35 Kg per pole should be wrapped at a height of 3000 mm above ground level stretching in 900 mm length. Both ends of barbed should be clamped suitably to avoid coming down from its location. 9. DANGER BOARD: Danger Board for 33KV voltage and danger mark conforming to IS: 2551-1963 should be fixed on each location. IMPORTANT INSTRUCTIONS BEFORE FILLING UP THE PRICE BID Rates entered against each items shall deemed to have included the following works: 1. All nuts, bolts and screw etc. of required size. Measurement and payment of nut bolts screw etc. shall not be made with the items of iron/steel hardware. Nuts and bolts should be machine made only of renamed makes. 2. All mechanical works e.g. fabrication, cutting, drilling, welding, grinding, painting and blacksmith works etc. 3. Cable and overhead conductors terminations, crimping of lugs with crimping tools and cost of appropriate size of lugs, cable glands etc. 4. Providing and applying sealing compounds, insulating toughness compound wherever required and directed. 5. Touching up all damaged paint with one coat of red oxide primer and two finishing coats of approved synthetic enamel paint. 6. All fixing accessories such as saddles, brass screws, lug plugs etc. 7. Cutting chases, holes and making good the same wherever required. 8. All lead and lift, transportation of materials at site, loading unloading and all labour required completing the job. 9. The items are complete in itself and any allied work or equipments not mentioned in the nomenclature of item but forming part of the system shall in all respect deemed to be included within the meaning of the execution of the said item and shall not be paid extra than the tendered rates until and unless specified. The tenderer are therefore advised to have clear under-standing of the 33 KV sub station and 33 & 11 KV & LT KV line work before filling in the rates. 10. Each and every item shall be reading continuation with its respective specification for work and specific requirements of relevant Indian Standard Specification and local Electricity Authority before filling up the rates. 11. Drilling and cutting holes in brick/RCC walls for clamping cables, earth leads, earth strips, GI pipes or whatever it may be including cost of clamping device.
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Technical Specification of Items
TECHNICAL SPECIFICATION OF 11 & 33 KV PIN INSULATOR - 14 -
1.
SCOPE:This specification covers the design, manufacture, testing, supply and delivery of 11 KV and 33 KV Porcelain Pin Insulators for use on 11 KV and 33 KV overhead Power Lines. 2. STANDAND:Except where they conflict with specific requirement in the specification, the Pin Insulators shall comply with the Indian Standard Specification IS:731-1971 and its amendments from time to time. The insulator conforming to any other internationally accepted standard which ensures equal or better quality than the standard mentioned above would also be acceptable. Where the material is offered according to the international standards, an English version of the specifications shall be attached with the tender. 3. ATMOSPHERIC CONDITIONS:3.1 The material offered shall be suitable for operation under the climatic conditions indicated in Clause 31 of Annexure II General Terms and Conditions of purchase appended with this Tender Specification. 3.2 Reference atmospheric conditions at which insulators characteristics shall be expressed for the purpose of comparison shall:Ambient Temperature Barometric Pressure Absolute Humidity -20 Degree Centigrade - 1013 Milli bars -11 gms of water per cubic meter corresponding to 63 percent relative humidity at 20 Degree Centrigrade
Note:- A pressure of 1013 millibars is equivalent to a pressure of 750 mm of Mercury at 0 degree centigrade. 3.3 Tests for the purpose of this standard shall preferably be carried out under conditions of temperature and humidity specified in IS:196-1966(i.e. at a temperature of 27+ 2 degree centigrade and relative humidity of 66+2 percent) and at the prevailing atmospheric pressure. When this is not possible, test may be carried out under conditions naturally obtained at the time of the test. The barometric pressure, air temperature and humidity shall be recorded for the purpose of correction. Corrections of test voltage for atmospheric conditions is given in Appendix A of IS:731-1971. 4. The Thimble for 11 KV Pin Insulator should be suitable for use with Galvanised Steel Pins conforming to reference S-165 of IS:2486 (Part-II) of 1974 with shank length 150 mm which is provided with a small steel head. Similarly, the thimble of 33 KVPin Insulator should be suitable for use with 33 KV Galvanised steel Pins conforming to reference I-300-N of fig. 6 with shank length of 150 mm and with large head of ISS-2486 (Part-II) of 1974. 5. INSULATOR CHARACTERISTICS:The insulator shall have the electrical and mechanical characteristics which are given below:The test voltage of insulator shall be as under:11KV PIN INSULATOR 1. 2. 3. 4. 5. 33KV PIN INSULATOR
Highest system voltage 12KV (rms) 36 KV (rms) Wet Power frequency 35 KV (rms) 75 KV(rms) withstand voltage test for one minute Visible discharge voltage 9 KV (rms) 27 KV (rms) Power frequency puncture 105 KV (rms) 180 KV (rms) withstand voltage Impulse withstand voltage 75 KV(peak) 170 KV (peak)
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(In the above standards, power frequency voltage is expressed as peak values divided by 2 and impulse voltage is expressed as peak value) 6. The withstand and flash over voltage are referred to the reference atmospheric conditions. 7. Mechanical Loads Minimum Failing Loads i. 11 KV Pin Insulator 5 KN ii. 33 KV Pin Insulator 10 KN 8. DIMENSIONS AND CREEPAGE DISTANCE:The insulators shall have the following dimensions and minimum creepage distance for a moderately polluted atmosphere:Particulars 11 KV Pin Insulator 33 KV Pin Insulator
(A) Dimensions i. Height 130 MM 210 MM ii. Diameter 125 MM 275 MM (B) Creepage Distance 230 MM 580 MM 9. TESTS:- The insulator shall comply with the following tests as per IS-731-1971. 9.1 TYPE TESTS:The following constitute the type tests :a. Visual examination b. Verification of dimensions c. Visible discharge test d. Impulse withstand voltage test e. Wet power frequency withstand voltage test f. Temperature cycle test g. Mechanical failing load test h. Puncture test i. Porosity test j. Galvanising test. Type test certificate from recognized Govt. lab for the tests carried out on prototype of same specifications shall be enclosed with the tender. The type test certificates shall not be more then 5 years old from the date of opening of tender. 9.2 ROUTINE TESTS:The following shall be carried out as the routine tests:a. Visual examination b. Electrical Routine tests c. Mechanical Routine tests 9.3 ACCEPTANCE TESTS:The test samples after having withstood the routine tests shall be subjected to the following acceptance tests in the order indicated below:a. Verification of dimensions b. Temperature cycle test c. Mechanical failing load test d. Puncture test e. Porosity test f. Galvanising test 9.4 Tolerance in insulator dimensions shall be as per the relevant Indian Standard i.e. (0.04d+1.5) mm when d 300 mm and where d is the dimension in mm. 10. MARKING:Each insulator shall be legibly and indelibly marked to show the followings:a. Name and trade mark of manufacturer b. Month and year of manufacture c. Minimum failing load in newtons d. Country of manufacture
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Marking on porcelain shall be printed/engraved and shall be applied before firing.
11.
PACKING:All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport. 12. STANDARDISATION OF DIMENSIONS OF TOP AND NECK OF 11 KV PIN INSULATOR Please note that now-a-days Board is using preformed ties for binding conductor with the Pin Insulator instead of conventional method of binding by aluminium binding wire and tape. The design of the preformed ties depends upon the dimensions of top and neck of 11 KV Pin Insulator. For proper gripping of the conductor with the help of preformed fittings it has become necessary to standardise the dimensions of the insulator top and neck. Accordingly, a drawing 051-32/CSEB/1 dt.1.9.2001, which indicates the standardised dimensions of top and neck of 11 KV Pin Insulator is enclosed with Tender Specification. This drawing has been approved by REC, New Delhi, therefore, the tenderers are advised to offer material based on this drawing. TECHNICAL PARTICULARS FOR 11KV PIN INSULATORS --------------------------------------------------------------------------------------------------------------. Sno. Particulars 11KV Pin Insulator --------------------------------------------------------------------------------------------------------------. 1. Makers name & Country 2. Electrical Characteristics a. Nominal system voltage b. Highest system voltage c. Visible discharge voltage d. Dry one minute power frequency withstand voltage e. Wet one minute power frequency withstand voltage f. Power frequency puncture g. Impulse (1/50 micro second wave) Voltage h. Impulse flashover (1/50 micro second wave) voltage negative i. Impulse flashover (1/50 micro second wave) voltage negative j. Dry flashover voltage k. Wet flashover voltage 3. Mechanical characteristics: a. Minimum falling load b. Minimum creepage distance Colour of glaze Size of insulators: a. Height b. Diameter Standard according to which
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11 KV (rms) 12 KV (rms) 9 KV (rms) 55 KV (rms) 35 KV (rms) 105 KV (rms) 75 KVP 108 KVP 124 KVP 60 KV 40 KV 5 KN 230 mm Brown 130 mm 125 mm As per IS:
4. 5.
6.
porcelain insulator shall be manufactured and tested 7. 8. Tolerance in dimensions if any
731/1971 As per ISS
Weight per unit of a. Porcelain Part To be indicated b. Thimble To be indicated ----------------------------------------------------------------------------------------------------------------.

TECHNICAL SPECIFICATION OF 33 KV GS PINS
1. SCOPE : The specification provides for manufacture & testing of 33 KV GS Pins suitable for Pin Insulators, complying with Indian Standard Specification No.IS:2486 (Part-I) 1971, IS:2486 (Part-II & III) 1974 and the latest version thereof. 2. GENERAL REQUIREMENTS FOR 33 KV GS PINS :-
2.1 The Pins shall be a single piece obtained by the process of forging. They shall not be made by jointing / welding / Shrink fitting of any other process from more than one piece of materials. They shall be of good finish free from flaws and other defects. The finish of the collar shall be such that a sharp angle / edges between the collar and the shank is avoided and the collar or the seating surface shall be down correctly on to the cross arm when fixed to that through a hole the diameter of which is 2 mm greater than the diameter of the shank. 2.2 All ferrous pins & nuts shall be galvanized by the hot dip process. Other fittings i.e. flat washers and spring washers may be electro galvanized as per Clause.5.2.3 of IS: 2486 (Part-I) & subsequent amendments, if any, and should satisfy the tests as per IS: 1573 of 1986 and subsequent amendments (if any). The threads of nuts and taped holes when cut after galvanizing shall be well oiled or greased. 2.3 The Pins shall be as per relevant figure indicated in IS: 2486 (Part-II) with small / large steel heads and shall match with the Pin type insulators with cemented zinc thimble having similar threads. 3. MARKING :
Each and every material shall be legibly and indelibly and marked with NAME OR TRADE MARK of the manufacturer and suitable identification mark like property marking CSEB should be engraved / embossed. 4. TEST & TEST CERTIFICATES:
TYPE TEST CERTIFICATE: Notarized type test certificate giving the results of samples tested for the tests, as per Clause-4.3.1 of IS:2486 (Part-I) 1971 for the item quoted, shall compulsorily be enclosed by the tenderer alongwith their offer in support of evidence of compliance of the specifications and guaranteed particulars. TYPE TEST : a) Freedom from defects, b) Verification of dimensions, c) Galvanising test (both uniformity of Zn.coating and Wt.of Zn.coating). d) Mechanical tests, e) Chemical composition test, Type test shall be made and certified by any Govt. recognized authority. 5. ROUTINE TEST: The test certificate of the lot giving the results of routine tests as per requirement of Clause4.3.3 of IS:2486 (Part-I) 1971 shall have to be submitted invariably by the firms alongwith the offers of materials being made by them for pre-despatch inspection of the materials.
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6.
ACCEPTANCE TEST: (Test to be carried-out during pre-dispatch inspection) (i) The dimensional requirement of 33 KV GS Pins offered for pre-despatch inspection shall be checked and verified as per IS:2486 (Part-II)/1974 and the following tests shall be carried-out and witnessed by the Inspecting Officer during inspection of the material as per requirement of the IS:2486 (Part-I) 1974. (ii) Checking of threads on heads: The dimensions of the threads on the heads of Pins shall be checked and verified by means of gauges (Ref.IS:2486 (Part-II)/1974. (iii) Galvanizing Test: The uniformity of Zinc coating and Wt. of Zinc coating for Pins and Nuts shall be verified as per requirements of IS:2633/1972. (iv) Mechanical test: This test shall be conducted in accordance with the Clause-4.6 of IS:2486 (Part-I) 1971. (v) Visual Examination Test:- All the pins shall be checked visually for its good workmanship and finishing. All the relevant Indian Standard Specifications (ISS) shall be made available by the firms invariably to the inspecting officer for reference while carrying out the pre-despatch inspection of the lot. The Technical Particulars of 33 KV GS Pins are indicated in the Schedule-I B enclosed and these shall be required to be met out on inspection of the material.
7.
LOT :All the GS Pins of same type and design manufactured under similar conditions of production offered for acceptance, a lot may consist of whole or part of the quantity offered. A lot shall consist of only one type of fittings manufactured essentially from the same raw material and under identical conditions.
8. 9.
PACKING : The materials are to be packed in gunny bags, each bag containing 25 nos. of 33 KV Pins. DRAWING :Two sets of detailed drawing (s) of the products(s) shall have to be submitted along with offer and again two sets along with acceptance letter on issue of LOI for approval before issue of detailed order. TOLERANCE: All applicable as per latest edition / amendments of IS:2486 (Part-I).
10.
TECHNICAL REQUIREMENTS S.N. 1. I II III PARTICULARS Dimensions Pins & Studs Nuts REQUIREMENT OF 33 KV GS PINS Shall conform strictly to reference L-300-N of Figure-6 of IS:2486 (Part-II) 1974. The forged pins & studs shall be of steel complying with class:2 of IS:2004/1962. The nuts shall be made of material conforming to property class 4.8 of IS:1367/1983(Part-xiii) with regard to its mechanical properties.
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IV V
Steel Head Nuts, Flat & spring washers
VI VII
Failing load Drawing ref.of IS:2486 (Part-II)
This shall be as per Fig.1-B (large steel head) of IS:2486 (Part-II/1974 suitable for use with indigenous 33 KV Pin Insulators a) Nuts shall be hot dip galvanized, b) One flat washer & spring washer shall be provided with each pin. Both these washers shall be electro galv. as per Clause- 5.2.3 of IS:2486 (Part-I). Minimum 1080 kg.(10 KN) i) Fig.No.6, ref. No. L-300N ii) Fig.No.1 (B) 33 KV GS Pins 300 mm 44 mm 27 mm 150 mm 24 mm 100 mm 47 mm 6.00 mm 67 mm i. No negative tolerance is permissible for Dip test & Mass of Zinc coating, ii. +/- 5% (Plus Minus five percent) shall be allowed in all the dimensions except in thickness of collar and threaded portion of stalk. As per IS:2633/1972 (Hot dip for both 11 KV & 33 KV Galvanizing GS Pins) FOR GS PINS FOR GI NUTS 4 dips of 1 minute each 4 dips of 1 minute each 300 gms/m2 (Minimum) 300 gms/m2 (minimum) The mass of zinc coating on Pins shall be as per Clause-4 of IS:4759-1979 and in case of Nuts shall be as per Clause No.4 of IS:1367 (Part-XIII)-1983. The above tests shall invariably be conducted during all routine inspection of material (S.No.I,II & III). IS:2486 (Part-II) of 1974. IS:2486 (Part-I) of 1971, IS:4759-1979 and IS:1367 (Part-XIII)-1983 IS:2633-1972 IS:2004-1962
2 I II. III IV V. VI VII VIII IX X
Dimensional Requirements Length of stalk Bottom diameter of stalk Top diameter of stalk Length of shank Diameter of shank Length of threaded portion in the shank Length of threaded portion of stalk Thickness of collar Diameter of collar Tolerance
3 I ii.
Method of Galvanizing TESTS Dip test Mass of zinc coating
Applicable specifications: (with latest amendments, if any)
TECHNICAL PARTICULARS FOR GS PINS Sno. 1. 2. 3. 4. Particulars Dimensions Pins & Studs Nuts Steel Head Requirement of 11 KV GS Pins Shall conform strictly to reference S-165-P of Figure-5 of IS: 2486 (Part-II) of 1974. The forged pins and studs shall be of steel complying with clause: 2 of IS: 2004/1962. The nuts shall be made of material conforming to property clause 4.8 of IS: 1367/1983 (Part-xiii) with regard to its mechanical properties. This shall be as per Figure 1-A (small steel head) of IS: 2486 (Part- 20 -
5.
6 7. 8. I. II. III. IV. V. VI. VII. VIII. IX. X.
9. I. II.
10.
II) 1974 suitable for use with indigenous 11KV pin insulator. a) Nuts shall be not dip galvanised. b) One flat washer & spring washer shall be provided with each pin. Both these washers shall be electro galvanised as per clause-5.2.3 of IS: 2486(Part-I) Mounting arrangements Shall be suitable for mounting on 75x100mm M.S.Channel Falling load Minimum 540 Kg. (5 KN) Dimensional Requirements 11 KV GS Pins Length of stalk 165 mm Bottom diameter of stalk 25 mm Top diameter of stalk 24 mm Length of shank 150 mm Diameter of shank 20 mm Length of threaded portion in 100 mm the shank Length of threaded portion of 44 mm stalk Thickness of collar 5.00 mm Diameter of collar 40 mm 67 mm Tolerance i) No negative tolerance is permissible for Dip test & Mass of Zinc coating. ii) 5% (Plus minus five percent) shall be allowed in all the dimensions except in thickness of collar and threaded portion of stalk. Method of Galvanising As per IS: 2633/1972 (Hot dip for both 11KV Galvanising GS Pins) TESTS FOR GS PINS FOR GI NUTS Dip Test 4 dips of 1 minute each 4 dips of 1 minute each Mass of zinc coating 300 gms/m2 (Minimum) 300 gms/m2 (Minimum) The mass of zinc coating on Pins shall be as per Clause-4 of IS:4759-1979 and in case of Nuts shall be as per Clause No. 4 of IS: 1367 (Part-XIII)-1983. The above tests shall invariably be conducted during all routine inspection of material (S.No. I, II & III). Applicable specifications: (with IS: 2486 (Part-II) of 1974 latest amendments, if any). IS: 2486 (Part-I) of 1971, IS: 4759 1979 and IS: 1367 (Part-XIII) 1983. IS: 2633 1972 IS: 2004 - 1962 Nuts, Flat & Spring Washers
TECHICAL SPECIFICATION OF11KV DISC INSULATOR
1.
SCOPE:This specification covers the design, manufacture, testing, supply and delivery of porcelain Disc Insulator for use on 11 KV and 33 KV overhead power lines. 2. STANDARD:Except where they conflict with specific requirement in the specification, the Disc Insulator shall comply with the Indian Standard Specification IS:731/1971 and its amendment from time to time. The insulator conforming to any other internationally accepted standard which ensures equal or better quality than the above standard would also be acceptable. Where the material is offered according to the international standards, an English version of the specification shall be attached with the tender. 3. ATMOSPHERIC CONDITIONS:3.1 The material offered shall be suitable for operation under the climatic conditions indicated in Clause 31 of Annexure-II General Terms and Conditions of purchase appended with this tender specification.
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3.2 Reference atmospheric conditions at which insulator characteristics shall be expressed for the purpose of comparison shall be:Ambient Temperature Barometric Pressure Absolute Humidity 20 Degree Centigrade 1013 millibars 11 gms of water per cubic Meter corresponding to 63% Relative humidity at 20 Degree Centigrade A pressure of 1013 millibars is equivalent to a pressure of 750 mm of Mercury at 0 degree centigrade. -
Note:-
3.3 Tests for the purpose of this standard shall preferably be carried out under conditions of temperature and humidity specified in IS:196-1966 (i.e. at a temperature of 27+2 degree centigrade and relative humidity of 66+2 percent) and at the prevailing atmospheric pressure. When this is not possible, test may be carried out under conditions naturally obtained at the time of the test. The barometric pressure, air temperature and humidity shall be recorded for the purpose of correction. Corrections of test voltage for atmospheric conditions is given in Appendix A of IS:731-1971. 4. GENERAL REQUIREMENTS:The porcelain shall be sound free from defects, thoroughly vitrified and smoothly glazed.
4.1 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain parts of the insulator except those areas which serve as supports during firing or are left unglazed for the purpose of assembly. 4.2 The design of insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal. 4.3 Cement used in the construction of the insulator shall not cause fracture by expansion or lossening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as unifom as possible. 5. TYPE OF INSULATOR:The insulator shall be of type B according to its construction which is defined hereunder:Type B:-An insulator or an insulator unit in which the length of the shortest puncture path through solid insulating material is less than half the length of the shortest flash over path through air outside the insulator. 6. 6.1 INSULATOR CHARACTERISTICS:The insulator shall have the electrical and mechanical characteristics which are given below:The test voltage of insulator shall be as under:1. 2. 3. 4. 5. 6.2 6.3 6.4 7. 7.1 Disc Insulator Highest system voltage 12 KV (rms) Wet power frequency withstand 35 KV (rms) voltage for one minute Visible discharge voltage 9 KV(rms) Power frequency puncture withstand voltage 105 KV (rms) Impulse withstand voltage 75 KV(peak) In this standard, power frequency voltage are expressed as peak values divided by 2 and impulse voltage are expressed as peak value. The withstand and flash over voltage are referred to the reference atmospheric conditions. Minimum Failing Load 45 KN DIMENSIONS:The insulator shall have the following dimensions:Diameter - 254 mm Height -146 mm (Hole to Hole)
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7.2 8. 8.1
CREEPAGE DISTANCE:The insulator shall have minimum 320 mm creepage distance for a heavily polluted atmosphere. TESTS:The insulators shall comply with the following tests as per IS:731-1971 with its latest amendments. TYPE TESTS:- The following constitute the type tests : a. Visual examination b. Verification of dimensions c. Visible discharge test d. Impulse voltage withstand test e. Wet power frequency withstand voltage test f. Temperature cycle test g. Electro-Mechanical failing load test h. Puncture test i. Porosity test j. Galvanizing test. Type test certificate from recognized Govt. lab for the tests carried out on prototype of same specifications shall be enclosed with the tender for each type test failing which the tenders are liable for rejection. The type test certificates shall not be more than 5 years old from the date of opening of tender. ROUTINE TESTS:The following shall be carried out as the routine tests:a. Visual examination b. Electrical Routine tests c. Mechanical Routine tests
8.2
8.3
ACCEPTANCE TESTS:Acceptance of samples after having withstood the routine tests shall be subjected to the following acceptance tests in the order indicated below:a. b. c. d. e. f. Verification of dimensions Temperature cycle test Electro Mechanical failing load test Puncture test Porosity test Galvanizing test
8.4 Tolerance in insulator dimensions shall be as per the relevant Indian Standard, i.e. (o.04d+1.5)mm when d300 mm and where d is the dimension in mm. 9. MARKING:Each insulator shall be legibly and indelibly marked to show the followings:a. b. c. d. Name and trade mark of manufacturer Month and year of manufacture Minimum failing load in new tons Country of manufacture
Marking of porcelain shall be printed/engraved and shall be applied before firing. 10. PACKING:All insulator shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport. TECHNICAL PARTICULARS OF 11 KV DISC INSULATORS
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1. Makers name & country 2. Type of Insulator 3. Electrical Characteristics: a. b. c. d. e. f. g. h. i. j. k. l. Nominal system voltage Highest system voltage Visible discharge voltage Dry one minute power frequency withstand voltage Wet one minute power frequency withstand voltage Power frequency juncture withstand voltage Impulse withstand (1.2/50 microsecond wave) voltage positive Impulse withstand (1.2/50 microsecond wave)voltage negative Impulse flash over (1.2/50 microsecond wave)voltage positive Impulse flash over (1.2/50 microsecond wave)voltage negative Dry flash over voltage Wet flash over voltage :
: 11 KV (RMS) : 12 KV (RMS) : 9 KV (RMS) : 70 KV (RMS) : 40 KV (RMS) : 110 KV (RMS) : 100 KVP : 100 KVP : 105 KVP : 110 KVP : 75 KV (RMS) : 45 KV (RMS) : 320 mm : 45 KNK : Brown : 255 mm : 145 mm : 4.5 Kg. (Approx) : IS 731/1971
4. a. Minimum creepage distance b. Minimum failing load 5. Colour of glaze 6. Size of Insulator a. Outer diameter b. Spacing 7. Net weight 8. Standard according to which porcelain insulator shall be manufactured and tested 9. Tolerance in dimensions, if any
: As per ISS
TECHNICAL SPECIFICATION FOR STRAIN HARDWARE FITTINGS FOR 11 KV & 33 KV LINES SUITABLE FOR USE WITH TONGUE AND CLEVIS DISC INSULATORS (CONVENTIONAL TYPE FITTINGS)
1. SCOPE : This specification provides for manufacturers, testing before dispatch and delivery of materials listed in Schedule-I at the specified destination. 2. (a) (b) (c) (d) (e) TEST CERTIFICATE: The following shall constitute the type tests for clamps: Visual examination, Verification of dimensions, Slip strength tests, Ultimate strength tests, Galvanizing / Electroplating tests.
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The type tests are intended to prove the general qualities and design of a given type of 33 KV & 11 KV Hardware fittings. These tests should not have been conducted earlier, than 5 years from the date of opening of tender. One copy of same should be submitted alongwith the offer otherwise the offer is liable to be rejected. ii) ACCEPTANCE TESTS: The following shall constitute the acceptance tests : a) b) c) d) e) Visual examination tests, Verification of dimensions, Galvanizing / electroplating test, Mechanical tests, Ultimate strength test,
The acceptance tests shall be carried out on all the samples taken from a lot for the purpose of acceptance of lot. iii) ROUTINE TESTS: The following shall constitute the routine test, a) b) Visual examination tests, Mechanical routine tests on Conductor Tension clamp only.
The routine tests will be carried out on each of insulator fittings to check requirement, which are likely to vary during production. All the above three tests have been described in IS:2486 (Part-I) 1993. Galvanizing tests for Hot Dip Ferrous material shall be carried-out in accordance with IS-2633/1986 and satisfy the requirements in IS:4759/1984. Electro-galvanized ferrous fittings shall be checked in accordance with IS:1573/1986. However, one sample from each lot will be tested as per IS:4759/1984. 11 KV STRAIN HARDWARE FITTINGS (T&C) TYPE : Each Hardware fittings of the Strain Insulators shall comprise of :i) Hot dip galvanized cross arms and straps properly profiled suitable for use on 75/100 mm channel cross arms with 16 mm dia, hot dip galvanized Bolts, Nuts spring washers, Plain washer and 4 mm dia split pin as per figures 26 of IS:2486 (Part-II) 1989 and its latest amendments: Snail type clamp with clevis eye suitable for 11 KV System for following sizes of Conductors :ACSR:Item Stranding & Wire dia meter (Aluminum + Steel) (6+1/2. 11 mm) (6+1/2.509 mm) (6+1/3.35 mm) Nominal Aluminum Area
ii) (A) S.N.
i. ii. iii. (B) S.N.
ACSR Conductor (Squirrel) ACSR Conductor (Weasel) ACSR Conductor(Rabbit) AAAC:Item
20 mm2 30 mm2 50 mm2
Stranding & wire dia of Actual Area AA Alloy

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i. ii. iii.
AAA Conductor (Squirrel) AAA Conductor (Weasel) AAA Conductor (Rabbi)
(7/2.00 mm) (7/2.50 mm) (7/3.15 mm)
22 mm2 34 mm2 55 mm2
The ultimate strength of the clamp should not be less than 3000 kg. The clamp shall be made by process of Die casting. The clamp with process of sand casting shall not be accepted. All dimensions of clevis and tongue connections shall be as per figure-25 of the IS:2486 (Part-II) 1989 and its latest amendments. 5. GENERAL REQUIREMENTS: (A) All fittings of same type and design manufactured under similar conditions of productions. (B) All forging and castings shall be of good finish and free from f laws and other defects. The edges on the outside of fittings, such as the eye, clevis and holes , Shall be rounded.. The clamp shall be manufactured by the process of die casting or pressure die casting and shall be free from blow holes and other defects. (C) All ferrous fittings and the part other than those of stainless steel shall be galvanized by the Hot Dip process. Only small fittings like, plain & spring washers, nuts may be electroplated galvanized. (D) (E) The nuts shall conform to property 4.8 of IS:1367 (Part-6) 1980. The cotter pins shall be provided with Galvanized Mild Steel Flat Washers in addition to split pins.
(F) The split pin to be used on the cotter Pin shall be of phosphor bronze conforming to IS:7814/ 1975 or Stainless Steel conforming to IS:5577/1992 or brass conforming to IS:410/1977 with a minimum hardness of 160 HV. 6. MARKING ON CLAMPS : The clamps shall have the following markings for their identification as per IS: i) Trade Mark of manufacturer. Please note that the marking should be legible and permanent (preferable die casted). 7. PACKING : Strain clamps and related hardware shall be packed in double gunny bags or wooden cases if deemed necessary. The gross weight of the packing shall not exceed 50 kg. Different fittings shall be packed in different bags or cases and shall be complete with minor accessories fitted in place. All the nuts shall be hand tightened over the bolt and screwed up to the farthest point with split pin in position. The packing shall be fit to withstand rough handling during transit and storage at destination.
TECHNICAL SPECIFICATION FOR MS STAY SETS 16mm DIA
16 MM DIA BLACK STAY SETS FOR LT LINES (NON GALVANIZED, 1. The stay sets (Line Guy set) will consist of the following components:-
NOT-PAINTED):
i) Anchor rod with one washer and nuts: Overall length of rod should be 1800mm to be made out of 16mm MS rod, one end threaded upto 40mm length with pitch of 5 threads per cm and provided with one square MS washer of size 40x40x1.6mm and one MS Hexagonal nut conforming to IS:1367/1967 and IS:1363/1967. Both washer and nut to suit the threaded rod of 16mm dia. The other end of rod to be made into a round are having an inner dia of 40mm with best quality welding. Dimensional and other details are indicated in the enclosed drawing No.1 and details of welding are indicated below and also shown in the enclosed drawing No.4.
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ii) Anchor Plate Size 200x200x6mm: To be made out of MS plate of 6mm thickness. The Anchor plate should have at its center 18mm dia hole. iii) Turn Buckle : (a) Eye bolt with 2 nuts: To be made of 16mm dia MS Rod having an overall length of 450mm. One end of rod to be threaded upto 300mm length of pitch of 5 threads per cm and provided with two MS Hexagonal nuts of suitable size conforming to IS:1637/1967 & IS:1363/1967. The other end of rod shall be rounded into a circular eye of 40 mm inner dia with proper and good quality welding as described below and also shown in enclosed drawing No.4. (b) Bow with welded angle: To be made out of 16mm dia MS Rod. The finished bow shall have an overall length of 995mm and height of 450mm as shown in the enclosed drawing No.1. The apex or top of the bow shall be bent at an angle of 10 R. The other end shall be welded with proper and good quality welding to a MS angle 130mm long having a dimension of 50x50x6mm. The angle shall have 3 holes of 18mm dia each as per drawing No.1 enclosed herewith. Details of welding are indicated below and also shown in the enclosed drawing No.4. iv) Thimble: To be made on 1.5mm thick MS sheet into a size of 75x22x40mm and shape as per details given in attached drawing No.1. 2. WELDING: The minimum strength of welding provided on various components of 16mm dia stay sets shall be 3100Kgs. Minimum 6mm fillet weld or its equivalent weld area should be deposited in all positions of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS:823/1964 or its latest amendment. Minimum length of weld to be provided at various places in the stay sets shall be as shown in the enclosed drawing No.4. Welding if found short in lengths or not done properly as required shall be rejected. 3. THREADING: The threads on the Anchor Rod, Eye Bolt and Nuts shall be as per specifications IS:4218/1967 (ISO Metric Screw Threads). The nuts shall be conforming to the requirement of IS:1367/1967 & have dimensions as per IS:1363/1967. The mechanical property requirement of fasteners shall conform to property clause 4.6 each for Anchor Rod & Eye Bolt and property clause 4 for nuts as per IS:1367/1967. AVERAGE WEIGHT OF FINISHED STAY SETS: 7.702 Kg. (Minimum) (EXCLUDING NUTS, THIMBLES & WASHERS): 8.445 Kg. (Maximum) i) Anchor rod with one washer and nuts: Overall length of rod should be 1800mm to be made out of 16mm MS rod one end threaded upto 40mm length with pitch of 5 threads per cm and provided with one square MS washer of size 40x40x1.6mm and one MS Hexagonal nut conforming to IS:1367/1967 and IS:1363/1967. Both washer and nut to suit the threaded rod of 16mm dia. The other end of rod to be made into a round are having an inner dia of 40mm with best quality welding. Dimensional and other details are indicated in the enclosed drawing No.2 and details of welding are indicated below and also shown in the enclosed drawing No.4. ii) Anchor Plate Size 200x200x6mm: To be made out of MS plate of 6mm thickness. The Anchor plate should have at its center 18mm dia hole. iii) Turn Buckle : (a) Eye bolt with 2 nuts: To be made of 16mm dia MS Rod having an overall length of 450mm. One end of rod to be threaded upto 300mm length of pitch of 5 threads per cm and provided with two MS Hexagonal nuts of suitable size conforming to IS:1637/1967 & IS:1363/1967. The other end of rod shall be rounded into a circular eye of 40 mm inner dia with proper and good quality welding. Welding details are specified below and also shown in enclosed drawing No.4. (b) Bow with welded angle: To be made out of 16mm dia MS Rod. The finished bow shall have an overall length of 995mm and height of 450mm as shown in the enclosed drawing No.2. The apex or top of the bow shall be bent at an angle of 10 R. The other end shall be welded with proper and good quality welding to a MS angle 180mm long having a dimension of 65x65x6mm. The angle shall have 3 holes of 18mm dia each as per drawing No.2 enclosed herewith. Details of welding are indicated below and also shown in the enclosed drawing No.4. iv) Thimble: To be made on 1.5mm thick MS sheet into a size of 75x22x40mm and shape as per details given in attached drawing No.2.
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II. TOLERANCES: The tolerances for various components of the stay sets are indicated below subject to the condition that the average weight of finished stay sets of 16 mm and 20mm dia excluding nuts & thimbles and washers shall not be less than the weight specified above:-----------------------------------------------------------------------------------------------------------------------------. SNo. Item Section Fabrication Material Tolerances Tolerances ----------------------------------------------------------------------------------------------------------------------------. 1. Anchor Plate 6mm thick +12.5% 200x200 mm MS plate 6mm - 5% + 1% Thick 8mm thick +12.5% 300x300 mm MS plate 8mm - 5% + 1% Thick 2. Anchor Rod 16mm dia + 5% Length 1800mm - 3% + 0.5% MS Round 16mm dia Round Eye 40mm MS Round 16mm inside dia + 3% dia Threading 40 mm + 11% - 5% 20mm dia + 3% Length 1800mm MS Round 20mm - 2% + 0.5% dia Round Eye 40mm inside dia + 3% Threading 40mm + 11% - 5%
3. Turn Buckle Bow
16mm dia + 5% Length 995mm MS Round 16mm - 3% +1% 16mm dia dia Length 180mm MS angle +1% 50x50x6mm Length 180mm MS Angle +1% 65x65x6mm Channel length MS Channel 200 mm + 1% 100x50x4.7mm Length 450mm MS Round 16mm +1% dia Threading 300mm +1% Round Eye 40mm inside dia +3%. 20mm dia + 3% Length 450mm MS Round 20mm - 2% +1% dia Threading 300mm +1% Round Eye 40mm inside dia +3%.
4. Eye Bolt Rod 16mm dia + 5% - 3%
---------------------------------------------------------------------------------------------------------------------------.
TECHNICAL SPECIFICATION: 20 MM DIA BLACK STAY SETS FOR 33 KV LINES (NON GALVANIZED, NOT-PAINTED):
AVERAGE WEIGHT OF FINISHED STAY SETS: 7.922 Kg. (Minimum) (EXCLUDING NUTS, THIMBLES & WASHERS): 8.699 Kg. (Maximum) 1. The stay sets (Line Guy set) will consist of the following components:i) Anchor rod with one washer and nuts: Overall length of rod should be 1800mm to be made out of 20mm MS rod, one end threaded upto 40mm length with pitch of 4 threads per cm and provided with one square MS
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washer of size 50x50x1.6mm and one MS Hexagonal nut conforming to IS:1367/1967 and IS:1363/1967. Both washer and nut to suit the threaded rod of 20mm dia. The other end of rod to be made into a round are having an inner dia of 40mm with best quality welding. Dimensional and other details are indicated in the enclosed drawing No.3 and details of welding are indicated below and also shown in the enclosed drawing No.4. ii) Anchor Plate Size 300x300x8mm: To be made out of MS plate of 8mm thickness. The Anchor plate should have at its center 22mm dia hole. iii) Turn Buckle : (a)Eye bolt with 2 nuts: To be made of 20mm dia MS Rod having an overall length of 450mm. One end of rod to be threaded upto 300mm length of pitch of 4 threads per cm. The 20mm dia bolt so made shall be provided with two MS Hexagonal nuts of suitable size conforming to IS:1637/1967 & IS:1363/1967. The other end of rod shall be rounded into a circular eye of 40 mm inner dia with proper and good quality welding. Welding details are specified below and also shown in enclosed drawing No.4. (b) Bow with welded angle: To be made out of 20mm dia MS Rod. The finished bow shall have an overall length of 995mm and height of 450mm as shown in the enclosed drawing No.3. The apex or top of the bow shall be bent at an angle of 10 R. The other end shall be welded with proper and good quality welding to a MS Channel 200mm long having a dimension of 100x50x4.7mm. The channel shall have 2 holes of 18mm dia and 1.22mm dia hole at its centre as per drawing No.3 enclosed herewith. Details of welding are indicated below and also shown in the enclosed drawing No.4. iv) Thimble: 2 Nos To be made on 1.5mm thick MS sheet into a size of 75x22x40mm and shape as per details given in attached drawing No.3. 2. WELDING: The minimum strength of welding provided on various components of 20mm dia stay sets shall be 4900Kgs. Minimum 6mm fillet weld or its equivalent weld area should be deposited in all positions of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS:823/1964 or its latest amendment. Minimum length of weld to be provided at various places in the stay sets shall be as shown in the enclosed drawing No.4. Welding if found short in lengths or not done properly as required shall be rejected. 3. THREADING: The threads on the Anchor Rod, Eye Bolt and Nuts shall be as per specifications IS:4218/1967 (ISO Metric Screw Threads). The nuts shall be conforming to the requirement of IS:1367/1967 & have dimensions as per IS:1363/1967. The mechanical property requirement of fasteners shall conform to property clause 4.6 each for Anchor Rod & Eye Bolt and property clause 4 for nuts as per IS:1367/1967. AVERAGE WEIGHT OF FINISHED STAY SETS: 14.523 Kg. (Minimum) (EXCLUDING NUTS, THIMBLES & WASHERS): 15.569 Kg. (Maximum) III. TEST CERTIFICATE: The supplier shall be required to furnish the test certificates from Govt./Recognized testing laboratory giving result of following tests alongwith the inspection report of material of first lot in individual size separately. Tensile load of 3100Kg/4900Kg applied for one minute on the welding & maintained for one minute for 16 mm & 20 mm dia Stay Sets respectively. In view of non-submission of above test certificates inspection report shall not be acceptable. IV. IDENTIFICATION MARK: All stay sets should carry the identification mark of the manufacturer. For this, the firm must engrave identification mark of about 3 capital letters as advised in the order. This should be engraved on the stay plate and possible on stay rods to ensure proper identification of the material. On account of this, no extra charges will be paid. V. The nuts should be a size compatible with the threaded portion of rods and there should be no play or slippage of nuts. VI. Welding wherever required should be perfect and should not give way after erection. NOTE:
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1. Please see attached drawing Nos 1,2,3, & 4 for details of components and welding. 2. No assistance will be given in arranging the raw material by the Board. II. TOLERANCES: The tolerances for various components of the stay sets are indicated below subject to the condition that the average weight of finished stay sets of 16 mm and 20mm dia excluding nuts & thimbles and washers shall not be less than the weight specified above:-----------------------------------------------------------------------------------------------------------------------------. SNo. Item Section Fabrication Material Tolerances Tolerances ----------------------------------------------------------------------------------------------------------------------------. 1. Anchor Plate 6mm thick +12.5% 200x200 mm MS plate 6mm - 5% + 1% Thick 8mm thick +12.5% 300x300 mm MS plate 8mm - 5% + 1% Thick 2. Anchor Rod 16mm dia + 5% Length 1800mm - 3% + 0.5% MS Round 16mm dia Round Eye 40mm MS Round 16mm inside dia + 3% dia Threading 40 mm + 11% - 5% 20mm dia + 3% Length 1800mm MS Round 20mm - 2% + 0.5% dia Round Eye 40mm inside dia + 3% Threading 40mm + 11% - 5%
3. Turn Buckle Bow
16mm dia + 5% Length 995mm MS Round 16mm - 3% +1% 16mm dia dia Length 180mm MS angle +1% 50x50x6mm Length 180mm MS Angle +1% 65x65x6mm Channel length MS Channel 200 mm + 1% 100x50x4.7mm
4. Eye Bolt Rod 16mm dia + 5% - 3%
Length 450mm MS Round 16mm +1% dia Threading 300mm +1% Round Eye 40mm inside dia +3%. 20mm dia + 3% Length 450mm MS Round 20mm - 2% +1% dia Threading 300mm +1% Round Eye 40mm inside dia +3%.
---------------------------------------------------------------------------------------------------------------------------.
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TECHNICAL SPECIFICATION FOR HOT DIP GALVANISED MS STRANDED WIRE
The hot dip galvanised MS stranded wire of sizes 7/4 mm & 7/3.15 mm should conform to the below specifications : 1. MATERIAL: a) MS WIRE: Used for each strands shall have the chemical composition maximum sulpher & Phosphorus-0.055% each, Carbon-0.25%. b) Zinc shall conform to grade Zn 98 specified IS:209-1966 & IS:4926-1979 with upto date amendments. 2. ZINC COATING: Shall be in accordance with IS:4826-1979 (heavily coated hard quality grade 4 as per table) with up-to-date amendments. 3. GALVANISING: Shall be as per IS:2629-1966, IS:4826-1979 with up-to-date amendments. 4. UNIFORMITY OF ZINC COATING: Shall be as per IS:2633-1972 (Col.4.2.1 to 4.2.3) with up-to-date amendments. 5. TENSILE PROFERTIES: Of each strand ensuring MS wire Mechanical properties as per IS-280-1972 Cl.8.1 to 8.3 and after galvanising each wire shall be of tensile strength minimum 700 N/mm2 (71 kgs/mm2). Tensile strength, breaking load, lay & elongation of each wire and full stand shall conform to IS:21411968, IS:2141-1979 in the tensile grade given above. 6. CONSTRUCTION: Shall be as per IS:2141-1968. 7. FREEDOM FROM FEFECTS: Be ensured as per IS:2141-1968, 1975 Clause 4.1 & 6 respectively. 8. TEST ON WIRE BEFORE MANUFACTURE: As per IS:2141-1979 (Cl.7.1 to 7.2.2) shall be done. 9. TEST ON COMPLETED STRAND: In accordance to IS:2141-1979 and tests as per schedule-II (B) enclosed herewith shall be performed in presence of Boards representative deputed for this at your works & cost. 10. PACKING: Each coil shall be between 50-100 kgs. packed as per IS:2141-1968 (Col. 9.10 6594-1979) & 2141-1979 (Col.11). 11. MARKING: as per IS:2141-1968 (Col.8.1 & 8.1.1), IS:2141-1979 (Col.10 & 10.1) is required. -------------------------------------------------------------------------------------------------------------------------. S.No. Particulars 7/4 mm 7/3.15 mm --------------------------------------------------------------------------------------------------------------------------. 1. Number of wire in strand 7 mm 7 mm 2. Nominal diameter of each wire 3. Tolerance in diameter 4. Sectional Area of each wire +/- 2.5% 12.56 4 mm +/- 2.5% 7.789 700N/mm2 (71.4 kgf/mm2) 556 10% 3.15 mm
5. Min. tensile strength of each wire before 700N/mm2 stranding corresponding to grade-4 (71.4 kgf/mm2) 6. Minimum breaking load of each wire 897
7. Elongation test: The elongation shall be 10% subject to a reduction of not more than
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8. Weight of zinc coating gms./mm2 of each wire tested. i) Before stranding ii) After stranding 9. Type of coating of each wire 10. Variety of each wire
260 247 Heavy Hard
240 208 Heavy Hard
11. Ductibility test (wrap test of each wire before manufacture) a) Complete turns of wrap b) Dia menorel on which to be wrapped 4 mm 12. Min. braking load after stranding 13. Elongation test (Min. % elongation corresponding to Grade-4) 14. Length of lay of strand -Minimum Maximum
8 3.15 mm 5962 kgf 10% 144 mm 216 mm
8 3698 Kgf 10% 113.4 mm 170.1 mm
15. Number of dips the opating each strand at 18 +/- 2oC a) Before stranding b) After stranding 16. Freedom from defects 17. Chemical composition. The MS wire used shall not exceed a) Sulpher - 0.055% b) Phosphorus - 0.055% c) Carbon - 0.25%
--------3 dips of 1 minute------------------2 dips of 1 minute----------each dip & 1 dip of 1/2 minute As per IS:2141-1968, 1979 Clause 4.1 & 6 respectively
TECHNICAL SPECIFICATION FOR HOT DIP GALVANISED MS SOLID WIRE
The hot dip galvanised MS solid wire of sizes 5 mm, 4 mm and 3.15 mm diameters shall conform to the relevant ISS specification briefed here below: 1. MATERIAL: a) This Mild Steel wire shall have the chemical composition maximum sulpher - 0.055%. Phosphorus 0.055%, Carbon - 0.25%. b) Zinc shall conform to grade Zn 98 specified IS: 209-1966 & IS: 4926-1979 with upto date amendments. 2. ZINC COATING: Shall be in accordance with IS: 4826-1979 (col.4.2.1) for heavily coated hard quality. 3. GALVANISING: Shall be as per IS: 2629-1966, IS: 4826-1979 with up-to-date amendments. 4. UNIFORMITY OF ZINC COATING: Shall be as per IS: 2633-1972 (Col.4.2.1 to 4.2.30 with up-to-date amendments. 5. TENSILE PROFERTIES: The tensile strength of the wire after galvanizing shall be between 55-95 kg/mm (heavily coated Hard as per IS: 4826-1979 Table-1) ensuring MS wire Mechanical properties as per IS-280-1972 8.1 to 8.3.
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6. FREEDOM FROM FEFECTS: As per IS: 2629-1966 (Cl.6.1) & 4826-1979 (Col.4.3) & with up-to-date amendments, be ensured. 7. TESTS: During the process of manufacture/fabrication and finish all tests for chemical, mechanical, galvanizing tests as per IS: 280-1978, IS: 1521-1972, IS: 755-1961, IS: 6745-1972 & 4826-1979 be ensured. Test Certificate towards chemical composition (as per sno. 1 above) shall be submitted for each lot offered for inspection. The below said tests shall be conducted in presence of Boards representative deputed at your works & cost. a) b) c) d) Visual physical inspection and measurement of specified dimensions. Coating test as per IS:1755-1961, IS:2629-1966, IS:2633-1972, IS:4826-1968 & 1979, IS:6745-1972. Adhesion test as per IS:1755-1961, IS:2629-1966, IS:2633-1972, IS:4826-1968 & 1979, IS:6745-1972. Tensile strength and breaking load and elongation determined as per IS:1521-1972 with up-to-date amendments.
8. PACKING: Shall be as per IS:280-1972 (Col.13.1) and each coil between 50-100 Kgs. 9. MARKING: As per IS:280-1972 (Col. 14.1) is required. SPECIFICATION OF GALVANISED SOLID WIRE ---------------------------------------------------------------------------------------------------------------. S.No. Particulars 3 mm 4 mm ---------------------------------------------------------------------------------------------------------------. 1. Nominal diameter of wire 5 mm 4 mm 3.15 mm 2. Tolerance in diameter 3. Sectional Area in Sq.mm 4. Tensile strength (a) Minimum (Kg/mm2) (b) Maximum (Kgs./mm2) 5. Minimum breaking load (kgf.) 6. Type of coating Heavy/Medium light 7. Variety Hard/Soft 8. Weight of zinc coating (gms/sq.mtr) 9. No.of dips the coating is able to withstand at 18 +/- 2o C Hard 275 +/- 2.5% 19.625 55 95 +/- 2.5% +/- 2.5% 12.56 55 95 690.0 Heavy Hard 260 240 3 dips of 1 min. each 428.4 Heavy Hard Heavy 7.789 55
3.15 mm
95 1079.5
3 dips 3 dips of 1 min. of 1 min. & 1 dip each of 1/2 min.
10. Adhesion test (warp test at 1 turn per second coiling tensile strength not exceeding 2% nominal tensile strength: a) Min. complete turn of wrap 10 10 b) Dia of mandrels on which (6 time of d) wrapped 30.0 mm 24 mm 11. Send test: a) Angle bend b) Dia round & former to be bend 90 10 mm
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10 (4 time of d) 12.6 mm N.A. N.A N.A.
N.A.
12. Freedom from defect 13. Chemical composition
As per schedule II (A) page 10.1, S.No.6
The MS wire used shall not exceed Sulpher - 0.055% Phosphorus - 0.055% Carbon - 0.25%
TECHINCAL SPECIFICATION FOR DISTRIBUTION TRANSFORMERS
01. Scope The specification covers the design, manufacture, testing and inspection before dispatch and delivery at places anywhere in Chhattisgarh of the distribution transformers listed in Annexure-C. The specification covers oil immersed, naturally air cooled (type ONAN), outdoor type, three phase, 50 Hz, 11/0.433 KV step down distribution transformers of capacities 63, 100, 200 and 315 kVA. 02. Applicable Standards Unless otherwise modified in the specification, the transformers shall comply with the requirement of IS: 1180 (latest version), 2026 (latest version), IS: 2099 (latest version) and REC specification No. 2/1978. The bushings used shall conform to IS: 2099 & 3347 (latest version) except as modified herein. 03. Type i) The transformers shall be double wound, three phase oil immersed, oil natural air natural cooled (type ONAN), core type suitable for outdoor installation in tropical climate and shall be insulated with DPC insulation on HV & LV windings. Insulation should be of temperature class as per temperature rise stipulated in this specification. (ii) The neutral point of the secondary (LV winding) is intended for solidly earthed system and should be brought out to a separate insulated terminal, enabling external insertion of a current transformer in the earth lead to be connected wherever required. 04. Climatic Conditions (i) Peak Outdoor temperature : 50 0 C Minimum (50 0 C+50 0 C) (ii) Maximum oil temperature : (50 0 C+45 0 C) 950C under max. temperature & max load condition attainable. (iii) (iv) (v) (vi) (vii) (viii) Maximum relative humidity : point). Minimum relative humidity : Average No. of thunderstorm days per annum. Average number of rainy days: Number of months of tropical monsoon conditions. Average annual rainfall 95% (sometime approaches saturation 10% : 40 days
90 days : 3 months : 125 cm.
(ix) Wing pressure : 100 Kg/m2 (x) Altitudes not exceeding : 1000 meters. 05. Ratings Primary voltage : 11 KV Secondary voltage : 0.433 KV The windings of the transformers shall be connected in delta on primary side and star on the secondary side. The neutral of the LT winding shall be brought out to a separate terminal. The vector group shall be Dy-11. 06. Temperature rise Temperature rise for top oil over an ambient of 500C should be 450C Max. (measured by thermometer as per IS:2026). Temperature rise for windings over an ambient of 500C should be 500C Max (measured by resistance in accordance with IS:2026). 07. No load voltage rating
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The No-load voltage ratio shall be 11000/433-250 volts for all capacities. Taps No tapings shall be provided for transformers upto 100kVA rating. For ratings of 200 to 315kVA, tapings shall be provided on the higher voltage (HV) winding for variation of HV voltage within range of +3% to (-) 9% in the steps of 3%. Tap changing shall be carried out by means of an externally operated self-position switch and when the transformer is in de-energized condition. Switch position No.1 shall correspond to the maximum plus tapping. Each tap change shall result in variation of 3% in voltage. Provision shall be made for locking the tapping switch handle in Position. Suitable Aluminium anodised plate shall be fixed for tap changing switch to know the position of tap (i.e. tap no.). 09. Design and Construction A. Core: (a) Material: CRGO Sheet of M4 Grade shall be used for Core. (b) The core shall be of high grade cold rolled grain oriented M4 Gr. annealed steel laminations having low loss and good grain properties, coated with hot oil proof insulation, bolted together and to the frames firmly to prevent vibration or noise. All core clamping bolts shall be effectively insulated by Zinc chromate and paper. The complete design of core must ensure permanency of the core losses with continuous working of the transformer. The value of the flux density allowed in the design and grade of lamination used shall be clearly stated. (c) The transformer core shall not be saturated for any value of v/f ratio to the extent of 112.5% of the rated value of V/f ratio (i.e. 11 KV/50 due to combined effect of voltage and frequency) upto 12.5% on any tapping without injurious heating at full load condition and should not get saturated. The supplier shall furnish necessary design data in support of this situation. (d) Flux density at rated voltage and frequency shall not exceed 1.55 Webers per sq. meter. No load current at rated voltage and at 112.5% of rated voltage shall not exceed the % (percentage) values given below :KVA Rating Percentage of rated full load current At 100 percent Rated Voltage At 112.5 percent Rated voltage 63 3 6 100 2.5 5 200 2 4 315 2 4 Test for magnetic balance by connecting the LV phase by phase to rated phase voltage and measurement of an, bn, cn voltages will be carried out. (e) Details of Core: SN Particulars Rating in KVA 63 100 200 315 i) No. of steps (Min) 5 5 7 7 ii) Diameter of Core (Min) in mm. 100 115 155 170 iii) Effective core area 70 92 169 200 in Sq. Cm. iv) Core Clamping (1) Channel size 75x40 mm 100x50mm 125x65mm (2) Bolt dia. in mm/ Nos. (High 12mm/2 Nos. (at each end) 16 mm/2 Nos. in Parallel (at tensile bolts shall be used) each end) (3) Tie bolts of MS Rod 12/4 16/8 of high tensile steel (dia/nos.) (4) Core bolts and tie rods to be painted with Zinc chromate and effectively insulated. 08. (5) Top & Bottom yoke should be constructed in single piece of CRGO laminations. (6) The top yoke channels to be reinforced by M.S. Flat of 50x6 mm at equal distance, if holes cutting is done for LT Lead-so as to avoid bending of channel (7) Core Base and bottom yoke shall be supported with 75mmx40mm MS Channel properly bolted together. In no case, Flat or cut channels shall be accepted. (8) All Channels, top and bottom yoke, Nut Bolts and Tie rods shall be painted with oil and corrosion resistant paint before use
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(9) Core should be properly earthed through copper strip. One end of copper strip should be inserted deeply into core laminations and other end bolted with the core-clamping channel.
B. Windings: a. Materials: Double paper covered (DPC) Aluminium Conductor shall be used for ratings upto 200kVA. For ratings above 200kVA, double paper covered electrolytic copper shall be used. b. Current Density for HV & LV should not be more than 2.8 Ampere/Sq. mm. for copper and 1.6 Ampere/Sq. mm for Aluminium Conductor. c. HV Cross section shall not be less than: i) 63 KVA 1.39 SQ. MM ii) 100 KVA - 2.27 SQ. MM iii) 200 KVA - 3.79 SQ. MM iv) 315 KVA 3.40 SQ. MM d. LV Cross Section shall not be less than: i) 63 KVA 52.5 SQ. MM ii) 100 KVA 86.0 SQ. MM iii) 200 KVA 168.0 SQ. MM iv) 315 KVA 156.0 SQ. MM NOTE: LV Winding shall be in even layers so that neutral formation will be at top. e. HV winding resistance at room temperature of 200C with 5% tolerance should not be more than: i) 200 KVA 14.52 Ohms. ii) 315 KVA 7.07 Ohms. f. LV winding resistance at room temperature of 200C with 5% tolerance should not be more than: i) 200 KVA 0.00456 Ohms. ii) 315 KVA 0.00278 Ohms. C. Losses and Impedance: The losses and impedance for various ratings of transformers should be as shown below subject to tolerance as per ISS:1180 and 2026 and shall be calculated at 750C as per limits specified. However, no tolerance shall be permissible on No Load and Load losses for 63 to 100kVA ratings. SN i) ii) iii) iv) D. No load loss (Watts) 63 kVA 180 100kVA 260 200kVA 500 315kVA 580 Insulation material and clearance: Rating in KVA Load loss at 750C (Watts) 1235 1760 3000 4200 Impedance (%) 4.5 4.5 5.0 5.0
(a) Material: Electrical grade, insulating craft paper of Triveni/Ballarpur Make, press Board of Senapaty, Whitelay or Raman make shall be used. Permawood or Haldiwood blocks shall be used for top and bottom yoke insulation. (b) Radial clearance of LV coil to core (bare conductor) shall not be less than: i) 63 kVA : 3.5 mm ii) 100 kVA : 4.0 mm iii) 200 kVA : 4.0 mm iv) 315 kVA : 4.5 mm (c) Radial clearance between HV & LV shall not be less than 11 mm for ratings from 63kVA to 315kVA. (d) Phase to phase clearance between HV conductors shall not be less then 10 mm with minimum of 2x1 mm pressboard to cover the rods. (e) The minimum electrical clearance between the winding and body of the tank (between inside surface of the tank and outside edge of the windings) should be 30 mm. (f) Minimum end insulation to earth shall be 25 mm. (g) No. of coils for HV/Phase (minimum) (i) For 63 & 100 kVA : 04 Nos. (ii) For 200 & 315 kVA : 06 Nos. (h) Thickness of locking spacers between HV coils 10 mm (minimum).
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(i)
No. of axial wedges between LV and HV winding, equi-spaced around LV 6 for 63kVA, 7 for 100 & 200kVA & 12 for 315kVA. (j) Minimum external clearance of Bushing terminals: Phase to Phase Phase to earth HV 255 mm 140 mm LV 75 mm 40 mm E. Tank: The transformer tank shall be of robust construction and shall be built from electrically welded MS Plates. All joints of tank and fittings shall be oil tight and no bulging shall occur during service. The tank design shall be such that the core and windings can be lifted freely. The tank plate shall be of such strength that the complete transformer when filled with oil may be lifted easily by means of the lifting lugs provided. Tank inside shall be painted by varnish/zinc chromate. Top cover shall be slightly sloping (difference of heights should be 20 mm+10%) towards H.V. bushing and cover the top with end walls. Shape of the tank shall be rectangular only. No other shape will be accepted. The tank shall be fabricated by welding at corners. No Horizontal or vertical joints in tank side and its bottom or top cover will be allowed. Details of the tank are shown below: (a) (i) Side wall plate thickness : 3.15 mm upto 100kVA 4.00 mm above 100kVA (ii) Top and bottom plate : 5.0 mm upto 100kVA thickness 6.0 mm above 100kVA (b) Reinforcing shall be done by welded angle of size 50x50x6 mm on all the outside walls on the edge of tank to form two equal compartments in case of transformers up-to 100kVA rating and three equal compartments for above 100kVA rating. One face of reinforcement angle should be continuously welded with the tank surface so that other side of the angle forms inverted L and the permanent deflection is not more than 5 mm up to 750 mm length & 6 mm up to 1250 mm length, when transformers tank without oil is subjected to a vacuum of 760 mm of mercury. (c) Lifting lungs: 2 Nos. welded heavy duty lifting lugs of 8 mm thick MS Plate suitably reinforced by vertical supporting flat, welded edgewise below the lug on the side wall up-to the reinforcing angle, for transformers up-to 100kVA rating. For transformers of 200kVA rating and above, 4 no. lugs should be provided. (d) Pulling Lug: 4 Nos. of welded heavy duty pulling lugs of 8 mm thick MS Plate shall be provided on width side to pull the transformers horizontally up-to 100kVA and on length side for above 100kVA. (e) Top Cover Gasket & Bolts: (i) The Gasket provided in between Top Cover Plate and Tank shall be of 5 mm and 6 mm thick Neoprene Rubberized cork sheets confirming to IS:4352, Part-II for ratings up-to 100 and above 100kVA ratings respectively. (ii) G.I. Nut Bolts shall be of size 3/8 x 1.5 with one plain and one spring washer suitably spaced to press the cover for ratings up-to 100kVA. For ratings above 100kVA, GI Nut bolts of dia with one plain washer shall be used for fixing of top cover spaced at 4 apart. (iii) The height of the tank shall be such that the minimum clear height up-to the Top Cover Plate of 120 mm is achieved from the Top Yoke in case of transformers up-to 100kVA. The above clearance is achieved from the live part of the tap changer in case of transformers above 100kVA. F. Heat Dissipation: 1. Heat dissipation by tank walls excluding top and bottom should be 500 W/m2. 2. Heat Dissipation by fin type radiators of 1.25 mm thickness will be worked out on the basis of manufacturers datasheet. Supplier should submit the calculation sheet. 3. For 63 and 100kVA transformer, 2 Nos. Radiators shall be provided only on LV Side and shall be of fin type. They should be fixed at right angle to the sides and not diagonally. For transformers above 100kVA, radiators shall be provided on both sides. 4. Arrangement for studs provided for fixing of HV bushings shall be in diamond shape, so that the arcing horns are positioned vertically. G. Volume Of Oil (Total minimum):
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SN 01. 02. 03. 04.
KVA Rating Oil in Liters (inclusive of oil Absorbed in core Permissible coil Assembly.) (Ltrs.) 63kVA 155 100kVA 190 200kVA 400 315kVA 500
oil absorption 6 7 15 19
Note: If the absorption of oil in core and winding Assembly is more than permissible value, first filling of oil volume should be increased accordingly. Calculation details of oil absorption should be submitted. H. Conservator: 1) The total volume of conservator shall be such as to contain 10% quantity of the oil. Normally 3% quantity of the total oil will be contained in the conservator. Dimension of the conservator shall be indicated in General arrangement drawing. 2) Die cast Oil level indicator shall be provided on the side of conservator which will be with fully covered detachable flange with single gasket and tightened with MS Nut/Bolt and will be fixed on the side of rating plate and drain valve. 3) The pipe from the conservator tank connecting to main tank shall be of 30 mm. internal dia. and shall have a slopping plate so that the oil falling from the pipe shall not fall directly on the active job and shall fall on the side walls only. The pipe should project in the conservator so that its end is approximately 20 mm. above the bottom of the conservator. Thus slopping plate should be fitted such that clearance from the yoke/live part of the tap changer is maintained as prescribed i.e. 120 mm. The conservator shall be provided with a filling hole, with cover. In addition the cover of the main tank shall be provided with an air release plug. I. Breather: Breather joints will be screwed type. It shall have die-cast Aluminium body. Make of breathers shall be subject to purchasers approval. Volume of breather shall be suitable for 500 gm. of silica gel for transformers upto 200kVA and 1 Kg for transformers above 200kVA. J. Terminals (Studs): 1) Brass rods of 12 mm dia for H.T. and L.T. with necessary nuts, check nuts and plain thick tinned washers for 63kVA ratings. 2) Brass rods of 12 mm dia for HT with necessary Nuts, Check nuts and plain thick tinned washers and Brass rods of 20 mm dia OR Copper rods of 12 mm dia for LT with necessary Nuts, check nuts and plain thick tinned washers for 100kVA ratings. 3) Brass rods of 12 mm dia for HT and Brass rods of 20 mm dia in one piece with homogeneous mass as per drawing enclosed i.e. one side threaded and other side flat with vertical orientation in bushing for LT with necessary nuts, check nuts & plain thick washers suitable for HT & LT for 200kVA rating. 4) Copper rod of 12 mm dia for H.T. and copper rod of 20 mm dia in one piece with homogeneous mass as per drawing enclosed i.e. one side threaded and other side flat with vertical orientation in bushing for LT with necessary nuts, check nuts & plain thick washers suitable for HT & LT for 315kVA rating. 5) HT/LT bimetallic connectors shall be provided with transformer for all ratings. K. Bushings: 1) For 11 KV side- 12 KV bushing and for 433 volts side 1.1 KV terminal bushing will be used. Bushings of the same voltage class shall be interchangeable. Bushings with plain sheds as per IS:3347 shall be mounted on side of the tank and not on the top cover. Only continuous sheet metal pocket shall be provided for mounting of all H.V/L.V. bushings and the same shall not be fixed on pipes. Sheet metal pocket shall be designed in such a way that all HT bushings shall remain parallel and equidistance all through. The inside connections of windings to bushings shall remain within the pocket. Bushings having type tested as per IS:3347 shall only be acceptable. 2) Internal Connections: In case of HV winding, all jumpers from windings to bushing shall have cross section larger than the winding conductor (normally 1.5 times). For copper winding, joints will be made by using silver brazing alloy. For Aluminium winding L&T, Alkapee Aluminium brazing rods with suitable flux will be used or alternatively joints will be made by using tubular connectors properly crimped at three spots. Aluminium brazing rods to be used for ring forming on other end and nut bolting on HV bushing stud. LT Star connection will be made by using Aluminium/Copper Flat as per winding material and properly brazed or bolted with the crimped lugs on windings by means of plain or spring washers and lock nuts to the flat. Other end of the conductor is brazed on L shape Aluminium/copper flat and flat nut bolted with neutral bushing stud. ALTERNATIVELY, for 63 & 100kVA ratings all the three terminals of LV windings together with terminals for neutral bushing shall be properly brazed and then covered with Aluminium tubular sleeve of suitable length and
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cross sectional area duly crimped in order to provide sufficient strength to the joint. The star connection should be wrapped with cotton/paper tape. Firm connection for LV windings to bushings shall be made by brazing with adequate size of L shape flat nut bolted with LV Bushing stud. For delta formation on HV side, copper wire having cross sectional area 1.5 times the winding area should be used. SRBP tube/insulation paper should be used for delta connection and on the portion of HV winding joining to HV bushing. L. Explosion vent: Explosion vent shall be provided in transformers of 200kVA rating and above only. M. Tank Base Channel: Tank base channels to be fitted across the length of the transformer as follows: (a) For 63 and 100kVA Transformer - Two channels of 75x40 mm of length 460 mm. (b) For 200 & 315kVA Transformer - Two channels of 100x50 mm of length 635 mm for 200kVA & 760 mm for 315kVA transformer. N. Terminal Marking plates and Rating Plates: The transformers shall be provided with a plate showing the relative physical position of the terminal and their markings engraved on it. The transformers shall be provided with non-detachable rating plate of Aluminium anodized material fitted in a visible position, furnishing the information as specified in IS:2026. The rating plate shall be embossed/ engraved type but not printed type. The relative position of tapping switch and corresponding voltages may also be shown on the rating plate. Further, MS plate of size 125x125 mm be got welded on width side of the transformer on stiffener angle. On this plate Name of firm, order No. & Date, Rating, serial number and Date of dispatch should be engraved. O. Fittings: The fittings on the transformers shall be as under: (i) Rating and diagram plate : 1 No. (ii) Earthing terminals with lugs : 2 Nos. (iii) Lifting lugs 8 mm thick : 2 Nos. upto 100kVA and 4 Nos. above 100kVA. (iv) Oil filling hole with cap on : 1 No conservator. (v) Drain cum sampling valve : 1 No. of 32 mm dia for 200kVA and above only. (It shall be covered with metallic cover by spot welding). (vi) Conservator : 1 No. (vii) Thermometer pocket : 1 No. (viii) Aluminium die cast silica gal : 1 No. breather 500 gms. Capacity upto 200kVA and 1000 gms for 315 KVA) (ix) Platform mounting channel : 2 Nos. for transformers of all rating. (x) Oil level gauge indicating : three position of oil marked as below:Minimum (-) 50C, 300C Maximum 980C (xi) Bushings : H.T. 3 Nos. L.T. 4 Nos. Each bushing should be provided with 3 Nos. of brass nuts and 2 plain brass washers of 2 mm thick for connecting terminal. (xii) Radiator : Details shall be given as per drawing (to be provided on L.V. side upto 100kVA) (xiii) Pulling Lugs: 4 nos. of 8mm thickness (xiv) Explosion vent in case of transformers : 1 No. of 200kVA and above. (xv) Filter valve 32mm dia for 200kVA : 1 No. and above. (xvi) Off circuit tap changing switch with : 1 No.
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indicator, handle and locking device with tap ranging from (+) 3% to (-) 9% in step of 3% on HV side for HV variation (Direction of rotation to be marked) in 200kVA & above only. (xvii) Top cover lifting lugs (xviii) Bimetallic connectors to be fitted on the stud:
2 Nos.
HV for all ratings : 3 Nos. LV for 63kVA & 100kVA : 4 Nos. for LV on 200 & 315kVA : Please refer para No. J (3) & (4). P. Transformer Oil: The transformer shall be supplied complete with first filling of oil and the same shall comply with IS: 335-1983 with latest version thereof with ageing characteristics specified. These characteristics are shown in ScheduleII(B). Type tests certificate of oil being used shall be produced at the time of inspection. Q. Finishings: The exterior of the transformer and other ferrous fittings shall be thoroughly cleaned, scrubbed and given primary coat and two finishing coats of durable oil and weather resistant paint of enamel. The color of finishing coats shall be DARK GREEN confirming to IS: 5 of 1961 (colors for ready mixed paints) with conservator painted with white color. 10. Tests & Test Certificates The following routine tests and type tests are required to be carried out on the transformers. (a) Routine Tests: Before dispatch, each of completely assembled transformer shall be subjected at the manufacturers works to the following routine tests in accordance with the details specified in IS: 2026: Measurement of winding resistances. Ratio, polarity and phase relationships. Impedance voltage. No load losses and no load current. Load losses. Insulation resistance. Separate source voltages withstand. Induced over voltage withstand. Vacuum test. (b) Type Test: In addition to the routine tests as above the following type tests shall be carried out on the transformers in accordance with IS: 2026/1977 as amended from time to time: Lightening impulse tests. Temperature rise test. Short circuit test. The suppliers may carefully note following specific requirements of short circuit, impulse voltage and temperature rise tests: The Board intents to procure transformers designed and successfully tested for short circuit and impulse test. It may also be noted that the Board reserves the right to conduct any of the above type tests in accordance with the IS, afresh on each ordered rating at Boards cost, even if the transformers of the same rating and similar design are already tested. This test shall be carried out on a transformer to be selected by the Board either at their works - when they are offered in a lot for supplies or random sample unit from the supplies already made to Boards Area Stores. After conducting short circuit test, healthiness of active parts shall be checked by un-tanking the transformer. The findings and conclusion of these tests shall be binding on the supplier. In case the transformer does not pass in either of the tests and if the active part details are not found to be in line with the design tested and approved, the following punitive measures shall be taken: (i) 5% payment of the bill for the supplies already made will be recovered by the Board. (ii) For transformers already supplied, the guarantee period shall stand twice the normal guarantee period. The period of performance Security Deposit shall be suitably extended to cover the extended guarantee period. (iii) Further, supply of balance quantity of transformers will not be accepted by the Board, till another transformer from the manufactured batch is satisfactorily tested (OR transformers are modified according to the tested design) for both tests at your cost and consequent to this, if there is any delay in executing the order, the same shall be to your account. Board reserves the right to take action as per terms and conditions of the order.
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(iv) The test charges shall be borne by the firm. Please note that if the terms and conditions detailed above regarding short circuit withstand test & impulse voltage test on transformers and procedure for these tests are not accepted by you in full, action will be taken as deemed fit as per the terms of the order. (c) Acceptance test: The following tests shall be witnessed by the Purchaser through his representative at the firms works: (i) All the routine tests as mentioned above shall be performed on minimum 10% quantity of offered lot. (ii) Heat run test (Temperature rise test): Heat run test shall have to be conducted at suppliers cost on one transformer of each rating in any offered lot during the course of supplies. In case of transformers with tap changer, test shall be conducted on the lowest tap feeding corresponding losses at 750C. To facilitate conduction of heat run test on any unit in any lot at any point of time during the supplies, the manufacturers will provide a thermometer pocket, which gets immersed in oil on the side of the transformer in all the transformers. This pocket shall also be used for connecting thermal sensing device to monitor the variations in temperature and whenever required to operate the protective devices. The Sensor pocket shall be of 12 mm diameter with blanking screwed cap, removable at site. The depth of the projecting stem of this pocket inside the transformer will be below oil level. It shall not infringe with electrical clearances nor obstruct the un-tanking of the active part. (iii) Verification of active parts on one unit of each rating of ordered quantity along-with weighing of unit. (iv) Unbalanced current test: The value of zero sequence current in the star winding shall not be more than 2% of the full load current. (v) Transformer shall be subjected to test for over fluxing of core, wherever required by the Boards inspecting officer. Further, the purchasers Inspector reserves the right to get the Spill Current Measurement Test and also the Pressure Test performed on any tank during their inspection. (a) Air pressure test: The tank shall be fixed with a dummy cover with all fittings including bushings in position and be subjected to 0.8 Kg per cm sq. above atmosphere pressure for 30 minutes and the vacuum corresponding to (-) 0.7Kg per cm. Sq. for 30 minutes, permanent deflection for flat plate, after pressure has been released shall not exceed the values given below: Length of plate Deflection Upto 750 mm 5mm 751 to 1250 mm 6 mm 1251 to 1750 mm 8mm (b) Test for Spill Current in neutral: The test will comprise of measuring current between shorted secondary phases and neutral on applying impedance voltage at primary winding. The value should not exceed 2% of full load current. 11. Testing facilities The tenderer should have adequate testing facilities for all routine and acceptance tests and also arrangement for measurement of losses, resistance etc. 12. Inspection (A) To ensure about the quality of transformers, the inspection shall be carried out by the Boards representative or by third party at following two stages: (i) Stage Inspection will be done when the raw material is received, and the assembly is in progress in the shop floor. After the main raw-materials i.e. core and coil materials and tanks are arranged and transformers are taken for production on shop floor and a few assembly have been completed, the firm shall intimate the O/o the CE(S&P), in this regard, so that an inspecting officer for carrying out such inspection could be deputed, as far as possible within fifteen days from the date of intimation. During the stage inspection, a few assembled cores shall be dismantled to ensure that the CRGO laminations of M4 Grade used are of good quality. (ii) Final Inspection will be carried out at finished stage i.e. transformers are fully assembled and are ready for dispatch. As and when the transformers are ready for dispatch, an offer intimating about the readiness of transformers, for final inspection for carrying out tests as per relevant IS and as in Clause 10 above, shall be sent by the firm along with Routine Test Certificates. The Board shall normally arrange the inspection at the earliest after receipt of offer for pre-delivery inspection. (C) In case of any defect/defective workmanship observed at any stage by the Inspecting Officer, the same shall be pointed out to the firm in writing for taking remedial measures. Further processing should only be done after clearance from the Inspecting Officer/ this office. (D) All tests and inspection shall be carried out at the place of manufacture unless otherwise specifically agreed upon by the manufacturer and purchaser at the time of purchase. The manufacture shall offer the Inspector representing the Purchaser all reasonable facilities, without charges, to satisfy him that the material is
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being supplied in accordance with this specification. This will include Stage Inspection during manufacturing stage as well as Active Part Inspection during Acceptance Tests. (E) Random sample checking and testing of the transformer selected at random from the supplies made to the Area Stores shall be done for verification of technical details, design and losses as per approved G.T.P. drawings and technical specification of the order. In case of variations, the lot shall be rejected. (F) The purchaser has all the rights to conduct the test including type tests, at his own cost by an independent agency whenever there is dispute regarding the quality of supply or interpretation of test results. In the event of failure of transformers in such tests, the expenses incurred in testing shall be to the suppliers account as already mentioned above in case of random testing. (G) Test reports on the analysis of raw materials: The supplier shall furnish details of source(s) of rawmaterials, test certificates and report on the analysis of electrolytic copper//Aluminium used for the winding and the steel used for core, insulation material and also other bought out items form Sub-suppliers. 13. Inspection & Testing of Transformer Oil To ascertain the quality of the transformer oil, the original manufacturers tests report should be submitted at the time of inspection. Also arrangements should be made for testing of transformer oil, after taking out the sample from the manufactured transformers and tested in the presence of purchasers representative. 14. Loading of Transformers Transformer loading should be complied with IS:6600. 15. Drawings The dimensional drawing and internal construction drawing of each transformer shall be submitted. Guaranteed and other technical particulars of the transformers should also be submitted in A-4 size for our approval.
TECHNICAL SPECIFICATION OF EARTHING COILS
(MADE OF HOT DIP GALVANISED SOFT QUALITY MILD STEEL WIRE 4 MM DIA)
1. Earthing coils shall be fabricated from soft GI Wire Hot Dip Galvanized. The Hot dip galvanized wire shall have clean surface and shall be free from paint enamel or any other poor conducting materials. The coil shall be made as per REC constructions standard J-1 (drawing enclosed). The Hot Dip Galvanizing shall conform to IS: 2629/1966, 2633/1972 and 4826/1979 with latest amendments, galvanizing should be heavily coated and should stand for the following tests :I. GALVANISING TESTS : (i) Minimum Mass of Zinc :(a) ON GI Wire used 280 gm/m2 (b) After Coiling 266 gm/m2. The certificate from recognized laboratory should be submitted towards mass of zinc. (ii) Dip test :- Shall stand 3 dips of 1 minute and one dip of minute before coiling and 3 dips of 1 minute after coiling as per IS:4826/ 1979. 2. THE DIMENSIONAL REQUIREMENT SHALL BE AS FOLLOWS: (a) Nominal dia of GI Wire 4 mm (Tolerance + (-) 2.5%) (b) Minimum number of turns 115 nos. (c) External dia of Coil ( Min.) 50 mm, (d) Length of Coil (Min) 460 mm (e) Free length of GI Wire at one end coil (Min)- 2500 mm. 3. THE TURNS SHOULD BE CLOSELY BOUND. 4. WEIGHT OF ONE FINISHED EARTHING COILS (MIN.) 1.850 kg. 5. ADHESION TEST: As per ISS 4826-1979
TECHNICAL SPECIFICATION OF 11 KV DO FUSE UNITS
1. SCOPE: - This specification provides for manufacture testing at works before dispatch. This covers out door open drop-out expulsion type fuses suitable for installation in 50 Hz 11KV distribution system. 2. APPLICATION:- The D.O. fuses are intended for use on Distribution transformers for protection/ isolation of the same during overload or fault conditions. 3. APPLICABLE STANDARD: - Unless otherwise modified in this specification, the drop out fuse shall confirm to IS: 9385 (Part-I to III) as amended from time to time.
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4. CLIMATIC CONDITIONS: - The climatic conditions at site under which the equipment shall operate satisfactorily, are as follows:(i) Peak Ambient temperature in shade (ii) Maximum average ambient temperature in 24 hours period in shade. (iii) Minimum ambient temperature (iv) Maximum relative humidity : 48 deg.c : 45 deg.c : 4 deg.c : 95 % (Some time approaches saturation point) : 40 days
(v) Average number of thunder storm days per annum. (vi) Average number of rainy days per annum : 90 days (vii) Average annual rainfall : 124 cm (viii) Number of months of tropical monsoon : 3 conditions.
For the purpose of specifications, the reference ambient temperature shall be 40 deg. C. 5. DROP OUT FUSES:- The drop-out fuses shall be expulsion type. This shall be 'D' type and out-door lift off type suitable for manual operation by an operating rod from the ground level. The drop out operation will be angular in vertical plan. 5.1 5.2 The equipment offered by the tenderer shall be suitable for 11KV three phase 50 C/S solidly grounded earthed neutral systems. It shall be designed for a normal current rating of 200 Amps. The drops out fuses are required with Post Insulators. These shall be suitable for mounting on the structure. The bracket/Channel hardware for DO Fuses shall be provided with adequate sizes of nuts, bolts and washer for mounting on the structures of the purchaser.
6. POST INSULATORS: - Each 11KV DO Fuse shall have two nos 11KV Post Insulators. The insulators shall conform to IS: 2544 of 1973 with latest amendment. The porcelain used for manufacture of DO fuse shall be homogeneous, free from flaws or imperfections that might affect the mechanical or dielectric strength. They shall be thoroughly vitrified tough and impervious to moisture. The glazing of the porcelain shall be of uniform brown colour free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through range of temperature variation shall not loosen parts or create undue internal stresses which may effect the electrical or mechanical strength and rigidity. Each cap and base pin shall be high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized. The cap and base shall be properly cemented with insulators to give perfect grip. Excess use of cement shall be avoided. The tenderers shall invariably enclose with the offer, the type test certificate of CSEB design DO Fuses alongwith certified copy of the drawing and other relevant technical guaranteed particulars. Please note that offers without type test certificates will not be entertained and without the type test reports, offers may be rejected. 6.2 Each 11KV Post Insulators should have technical particulars as detailed below: 11 12 35 1.3 times the actual dry flashover voltage. 75 9
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(i) Nominal system voltage KV (rms) (ii) Highest system voltage KV (rms) (iii) Dry Power Frequency one KV (rms) minute withstand voltage. (iv) Power Frequency puncture KV (rms) voltage. (v) Impulse withstand voltage KV (rms) (vi) Visible discharge voltage KV (rms)
(vii) Creepage distance in mm (minimum) (viii) Cantilever strength (KN)
320 6.60
7. As stated above unless otherwise modified in this specification the drop out shall conform to ISI: 9385 (Part-I to III) and as amended from time to time. 7.1 7.2 7.3 RATED VOLTAGE:- The rated voltage shall be 11KV. RATED CURRENT:- The rated current shall be 200 Amp. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE VALUES FOR THE FUSE BASE:The rated lightning impulse withstand voltage both for positive and negative polarities shall be as given below:To earth and between poles Across the isolating distance of fuse base 75KV peak 85KV Peak
a. b. 7.4
RATED ONE MINUTE POWER FREQUENCY WITHSTAND VOLTAGE (DRY AND WET) VALUES FOR THE FUSE BASE: A. B. To earth and between poles. Across the isolating distance of fuse base 28KV Peak 32KV Peak
7.5 TEMPERATURE RISE LIMIT IN AIR ABOVE AMBIENT TEMPERATURE: A. B. C. Brass contacts silver faced Terminals. Metal parts acting as spring : 65 deg.c : 50 deg.c : The temperature shall not reach such a value that elasticity of the metal is changed
7.6
RATED BREAKING CAPACITY:- The rated breaking capacity shall be 8 KA (Asymmetrical). Submission of Type Test Certificate of rated breaking capacity is very essential (otherwise offers may be rejected)
8. MAIN CONTACTS: - The main contacts of the DO Fuse shall be suitable for heavy duty, properly aligned, made from Brass material. These shall have good finish and smooth surface and shall be silver-plated. All the sharp edges shall be rounded off. These contacts shall be so designed to withstand highest short circuit breaking current that may be encountered during service in nut-shell the contact assembly shall ensure:(i) Electrodynamic withstand ability during short circuit without any risk of repulsion of contact. (ii) Thermal withstand ability during short circuits. (iii) Constant contact pressure even when the lower parts of the insulator stacks are subjects to tensile stresses due to linear expansion of connected bus bar or flexible conductors either because of temperature variation of strong winds. (iv) Proper alignment to ensure smooth operation of D.O. Fuse without adjustment. 9. CONNECTORS:- The connectors shall be made from Brass suitable for ACSR Squirrel/Weasel & Rabbit and Raccoon. The connectors should be bolted type having 4 bolts & groove to hold the conductor. All brass parts should be silver plated for corrosion resistance and efficient current flow. All ferrous parts should be Hot dip galvanized as per the latest version of IS: 2633. Nuts and bolts shall conform to IS:1364 and should be hot dip galvanized. Spring washer should be electro galvanized. 10. FLY NUTS:- These shall be provided at both the ends of SRBP tube for tightening the fuse elements. The nut shall be provided with one flat washer of 25 mm Dia. The arrangement shall be made to ensure that the fuse wire runs centrally inside the SRBP tube after tightening. 11. SPRING STRIPS:-The spring strips shall be of phosphors bronze multilane brush type having a high pressure contacts and should retain its tension under minimum continuous service current of 200 Amps.
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12. OPERATING HOOKS:- The brass operating hook shall be fixed over the SRBP tube in such a way that the barrel can be removed for replacing the fuse element by operating rod from the ground level. The drop put fuse units shall operate efficiently, speed of operation shall not depend on the inclination of the fuse. However, the inclination of the fuse barrel shall be adjusted in such a way that the barrel does not drop by gravitational force. 13. D.O.BARRELS:- The D.O. Fuse Barrels shall be made from SRBP and shall confirm to BSS:1314. The supplier shall furnish the test certificate for the fuse barrels offered for use in the drop out fuses alongwith each lot offered for inspection. The test certificates of SRBP barrel should indicate the following test minutes:(i) Dimension:(a) External dia : (b) Wall thickness : (c) Internal dia : (ii) Max. wrapping in 12" length of the tube (iii) Axial electric strength (Proof test in oil at 900C at 25KV rms 50 C/s. (iv) Radial electric strength (Proof test in oil at 900C at 19 KV rms 50 C/s. : : The barrel should withstand this test satisfactorily for one minute. : The barrel should withstand this test satisfactorily for one minute. : The barrel should withstand this test satisfactory for one minute.
(v) Surface electric strength (Proof test in air at room temp.(320C) at 14KV rms at 50 C/s. (vi) Water absorption in 14 hours. (vii) Resistance to Hot oil. (viii) Cohesion between layers (proof test) (ix) Machineability : :
: :
13.1 The tenderers should indicate the name of manufacturers of SRBP tubes from where they will purchase the Barrels to make available the above test certificate. The barrels should have the properly to resist fire whenever the fuse is blown off. It should not catch fire easily during blowing off of fuse element inside the barrel, which causes short time high temperature. 14. DESIGN, MATERIALS AND WORKMANSHIP:- The successful tenderers shall assume full responsibility for co-ordination and adequate design. All materials used in the construction of the equipment shall be of the impropriate claims, well finished and of approved design and material. All similar parts should be accurately finished and interchangeable. The connecting of cap and pin with insulator should be perfect to avoid any kind of loosening. After cementing the insulator should be cured adequately in water to attain good gripping. 15. GUARANTEED DATA AND OTHER TECHNICAL PARTICULARS:- Guaranteed data and other technical particulars of the D.O. Fuse should be given in Schedule enclosed herewith. Any other particulars considered necessary by the supplier may also be given in addition to those listed in the schedule. 16. TESTS:- Each D.O. Fuse shall strictly comply with the requirement of all the type tests and shall be subjected to all routine tests stipulated in the relevant standard. All tests shall be made prior to despatch in the presence of the representative of the purchaser. No material should be despatched without prior approval of the tests certificate by the purchaser. The tenderer should note that alongwith the tender, the following type test certificate as per ISS:9385 PartII - 1980 (with latest amendment) must be furnished on CSEB design D.O. fuses. The type test should not be older than 5 (five) years from the date of opening of tender and should be performed in the Govt. recognized Lab. (i) Impulse voltage withstand test,
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(ii) H.V. Power Frequency dry/wet withstand test. (iii) Temperature rise test. (iv) Breaking Current test. Alongwith the inspection report of D.O. Fuse Units, the supplier should invariably furnished, Routine test certificates of DO Fuse barrels & Post Insulator of their manufacturers. 17. IMPORTANT REQUIREMENTS TO BE NOTED BY THE TENDERER:- The tenderer should carefully note the following requirements otherwise their offer shall be rejected. (i) (ii) All the accessories of D.O. Fuse Unit should be listed out clearly. Technical particulars of D.O. Fuse Units should be given as desired in the enclosed schedule.
18. Each D.O. Fuse shall be provided with name plate of size 2"x1" on steel strip and shall be either reverted bolted or pasted. The following shall be indicated on the plate:Name of manufacturer Order No & date Sl. No of the equipment Rating.............. Amps...........volts Name of purchaser viz made for CSEB Please note paper should not be used for name plate. The material should be packed in wooden cartoons. 19. DIMENSION:---------------------------------------------------------------------------------------------------------------------------. Sno. Particulars DIMENSION OF D.O.FUSE UNIT IN MM ---------------------------------------------------------------------------------------------------------------------------. 1. Drawing No. EB/P6/CSEB/5/(revised) dt. 14.1.88 2. M.S. Flat 3. M.S. Channel 4. Fuse Barrels 5. Lower Contact Hinge of Barrel: (i) Connectors (ii) Hinge Contact Length (iii) -doWidth (iv) Thickness of Hinge Outer Inner 6. Barrel take out hook: (i) Width (ii) Thickness (iii) Length (iv) Inner dia meter (v) Thickness between inner Outer dia. 7. Operating Hook (i) Width (ii) Thickness (iii) Inner Radius (iv) Outer Radius ---330 x 25 x 14 60 x 60 x 6 95 85 5 4 25 4 30 25 3 mm 18 3 19 22.5
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245 x 25 x 6
8. Female Contact (i) Main contact width (ii) Strip thickness (iii) Strip length (iv) Width (v) Female contact height 9. Female Contact Holder:(i) Length (ii) Upper Width (iii) Lower Width
65 1.5 100 20 75 74 34 40
10. Creepage of insulator 320 --------------------------------------------------------------------------------------------------------------------------.
TECHNICAL PARTICULARS OFFERED FOR 9KV GAP TYPE LIGHTNING ARRESTERS EFFECTIVELY GROUNDED NEUTRAL SYSTEM
1. Name of manufacturer 2. Type 3. Model 4. No.of Units 5. Rated Voltage (KV) 6. Normal discharge current (Amp) : : :
: SDV-5 : Single : 9KV (RMS)
5KVA (5000 A) : : : : 24 KV (RMS) -58 KV (Peak) 65 KV (Peak)
7. Power frequency spark over voltage (Min) 8. Switching surge spark over voltage (Max) 9. Impulse spark over voltage 1/50 Micro second wave (KV peak) 10 Maximum limit of wave impulse spark over voltage(KV peak) 11. Virtual steepness for front of wave for above (KV Microsecond) 12. Protective ratio crest arrester voltage during discharge total of maximum line to ground voltage. : :
75 KV/Microsecond 6.60
13. Maximum residual voltage for discharge current of B/20 micro-second wave (KV Peak): i. 1500 Amps. : ii. 2500 Amps. : iii. 5000 Amps. : iv. 10000 Amps. :
-42 KV (Peak) 46 KV (Peak) 52 KV (Peak)

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14. High current 4/10 Micro second test value (KA) 15. Long duration current: i. Current peak (KA) ii. Virtual duration (Micro second) iii. Weight of complete unit (kg) 16. Height of complete unit from base to the line side 17. Minimum recommended spacing between arresters center to center (mm)
65 KA (65000 A)
: :
75 Amp. 1000 Microsecond : 4 Kgs. : : 390 mm Not Applicable
18. Clearance required from ground equipment at various heights of arrestor unit (mm) 19. Earthing arrangement provided for earthing sides of arrestors (mm) 20. Mounting flange/bracket dimensional details :
Not Applicable
As per Drawing
To be furnished by the manufacturer.
TECHNICAL PARTICULARS OF LT SHACKLE INSULATORS SIZE 90x75 mm AND 65x50 mm
(i) White glazed Porcelain Shackle Insulators without Hardware Fittings suitable for low tension 660 Volts grade overhead Power Lines. The Insulators should be of size 90x75 mm with a central hole of minimum 15mm dia and shall conform to Shackle Insulator type-I of IS:1445/1977. (ii) Drawing and Dimensions: As per enclosed at Page No. 48 Permissible Tolerances in sizes are as under (All Dimensions are in mm) S.No. Net permissible size Plus(+) Minus(-) Max. Min. 1. A 90 5.1 5.1 95.1 84.9 2. B 75 4.5 4.5 79.5 70.5 3. C 85 4.9 4.9 89.9 80.1 4. D 50 3.5 3.5 53.5 46.5 5. E 40 3.1 3.1 43.1 36.9 6. F 15 2.1 2.1 17.1 12.9 7. G 10 1.9 Zero 11.9 10.0 TYPE TEST CERTIFICATE:The supplier shall be required to furnish with their offer, type test certificate from Govt./recognized testing laboratory giving results of following tests as per IS:1445/1977 for LT Shackle Insulators with latest amendments:i. Visual Examination ii. Verification of dimensions iii. Dry Power frequency voltage withstand test. iv. Wet power frequency voltage withstand test. v. Temperature Cycle Test. vi. Mechanical Failing Load Test. vii. Power frequency Puncture withstand test. viii. Porosity Test.
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Particulars
Size Specified
Permissible Tolerance
Acceptance Tests and Routine Tests shall be as per IS:1445/1977 with latest amendments. ---------------------------------------------------------------------------------------------------------------. Sno Particulars 90x75 mm 65x50 mm_____ Prescribed/offered Prescribed/offered ---------------------------------------------------------------------------------------------------------------. 01. Standard Specification the IS-1445/1977 with IS-1445/1977 with insulator shall confirm latest amendments. latest amendments. 02. 03. 04. Dimensions Hole Diameter Tolerance in various dimensions 90 x 75 mm 15 mm 65 x 50 mm 13 mm
(0.04d + 1.5)mm (0.04d + 1.5) mm (Where d-dimensions (Where d-dimensions in mm) in mm) White glazed White glazed
05. 06. 07. 08. 09. 10. 11.
Colour Dry Flashover Voltage Wet Flashover Voltage Dry one minute power frequency withstand voltage. Wet one minute power frequency withstand voltage. Power frequency puncture withstand voltage. Minimum Mechanical failing load
As per latest IS As per latest IS Specifications Specifications As per latest IS As per latest IS Specifications Specifications 23 KV Rms 10 KV Rms 23 KV Rms 10 KV Rms
1.3 x the actual 1.3 x the actual Dry flashover voltage Dry flashover voltage 11.5 KN 11.5 KN
TEST CERTIFICATE: The supplier shall be required to furnish with their offer, for first lot for pre-delivery inspection, test certificate from Govt./Recognised testing laboratory giving results of following tests as per IS: 1445-1977 with latest amendments:i) Visual examination. ii) Verification of dimensions. iii) Dry power frequency voltage withstand test. iv) Wet power frequency voltage withstand test. v) Temperature cycle test. vi) Mechanical failing load test. vii) Power frequency puncture withstand test. viii) Porosity test.
TECHNICAL SPECIFICATION FOR HOT DIP GALVANISED HARDWARE FITTINGS SUITABLE FOR LT SHACKLE INSULATORS OF SIZE 90 X 75 MM
ITEM: SIZE: VARIETY:
M.S. HARDWARE FITTING SUITABLE FOR LT SHACKLE INSULATORS 90 X75 MM HOT DIP GALVANISED
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The Mild Steel Hardware fittings will consist of the following components and should confirm to figure 3 of IS: 7935/1975 in respect of dimension: DESCRIPTION: 1 Strap 2 nos. 1. Made out of black mild stell 2. Over all project ional length of strap 185 mm 3. Width of strap 30 mm 4.Thickness of Strap 3 mm Both the Strap as per IS: 7935 should have a bend at two places as shown in Fig.3 of IS-7935 and as per drawing enclosed herewith. The Strap should be of proper shape each having two number holes of 14 mm dia at a distance of 20 mm from hole center to edges.
Nuts & Bolts 2 Nos. with one Spring Each bolt to be made of 12 mm dia Black MS Rod Washer with each bolt having an over-all length of 115 mm. The bolt should conform to IS-1363/ 1967. The bolt should be threaded upto 65 mm length with a pitch of 1.75 mm and provided with the Spring Washer of 3 mm thickness and one MS Hexagonal Nut of suitable size. As per Clause-3.1.3 of Is:7935/1975. The nut shall be made of material conforming to Clause 4.8 of IS: 1363/1967 with regard to its mechanical properties. Threads of the nuts and tapped holes shall be well oiled or greased. Galvanising All the above components shall be hot dip Galvanized conforming to IS:2629/1966 and 4759/1979 in all respect. However, the small fittings like Spring Washers, Nuts etc. may be electro-galvanized. As per Clause 3.1.4 of IS:7935/1975, zinc conforming to Grade Zn.98 of IS:209:1966 shall be used for galvanizing purposes so as to withstand 4 dip test as per IS:2633/1972. It should be ensured before galvanizing that the components are free from paint grease, enamel and other poor conducting material and galvanizing (except electro galvanizing) is done by hot process only. The weight of zinc coating shall not be less than 460 grams per Square meters for straps and 300 gm/m for Bolts. 249 gms 255 gms
3.
4.
II
Finished Products: (a) Weight of 2 Straps size 185x30x3 mm having 2 holes of 14 mm dia duty galvanised (b) Weight of 2 nos. Bolts having dia 12 mm and length 115, threaded portion 65 mm with suitable Nuts as per IS:1363/1967 and Spring Washer thickness 3 mm all duly galvanized. (c) Total weight of one set of Hardware Fitting complete Average weight of 10 Sets (finished Products) subject to the following rolling tolerances as per IS:1852 Clauses 9.1, 9.2, 9.3 for HR Sheets being used for Manufacturing of
504 grms. kg (+) 5%
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i ii iii iv v vi vii vii
Straps and Rolling tolerance for rounds in case of bolts vide Clause 5.11 of IS-1852 Length of Strap Width of Strap Thickness of strap Diameter of bolts Length of Bolt Thickness of Bolts head Thickness of Nut Thickness of Spring washer
() 10 mm () 1.0 mm () 0.22 mm () 0.5 mm () 3 mm () 0.45 mm () 0.45mm () 0.15 mm
All part shall have good finish and free from flaws and other defects. The edges on the out-sides of fittings and at the holes etc. shall be rounded. 1 2 3 4 5 6 7 8 9 10 11 (a) (b) (c) Size of Straps Diametre of Bolts Diametre of Bolts head Length of Bolts Thickness of Bolts head Thickness of Nuts Shape of bolts head and nuts Galvanising test for straps 4 bolts Weight of zinc of strap Weight of zinc for bolts The material should conform: Test as per IS:7935/1975 Galvanizing tests as per relevant IS:6745/1972 & IS:2633/1972 Mechanical Property requirement tests for Bolts and Nuts as per IS:1367/1972 (Required 185 x 30 x 3 mm) 12 mm 20.88 mm across corner 115 mm 8 mm 10 mm Hexagonal 4 Dip each of one minute 460 Grams per meter sq. Offered
300 grams per sq. meter
TECHNICAL PARTICULARS OF EHV GRADE-I NEW INSULATING TRANSFORMER OIL
Insulating oil for transformers and switchgears shall be as per ISS:335(1993) incorporating latest amendments and additional characteristic as incorporate below. It will be pure hydrocarbon mineral oil, clean and sufficiently free from moisture and other foreign materials likely to impair its properties. The test results for the
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characteristic of the oil when tested in accordance with ISS:335-1993 (4th revision) incorporating upto date and additional characteristic required by us shall be as hereunder. SN 1 2 3. 4. 5. 6. 7. 8. 9. CHARACTERSTICS Appearance Density at 29.5 C Kinematic viscosity at 27 C Interfacial tension at 27 C Flash Point Pour Point Neutralisation value acidity Corrosive sulphur Electric Strength (Breakdown Voltage) a. New unifiltered oil (as received in condition). b. After filtration Dieletric disppipation factor (Tan Delta) at 90 C. SK Value Water Content Specific resistances a. At 90 C b. At 27 C Oxidaation stability: a. Neutralisation value after Oxidation b. Total sludge after oxidation Ageing charaacterstics after Accelerated Ageing Test. a. Resistivity at 27 C b. Resistivity at 90 C c. Dielectric loss factor (tan Delta) at 90C d. Total acidity e. Sludge content after ageing Presence of Oxidation inhibitor shall not be present. TECHNICAL REQUIREMENT Oil should be clear, transparent and free from suspended matter or sediments. 0.89 G/Cm3 (Max.) 27 CST. 0.04 N/m (Min) 140 C (Min) - 10 C (Max) 0.01 mg KOH/q (Max) Non Corrosive 40 KV (rms) (min) 60 KV (rms) (min) 0.002 (max) 6% (Max.) 30 PPM (as received) (Max) 100x1012 Ohm. (Ohm.Cm.) (Min) 1500x1012 (Ohm.Cm) (Min) 0.2 mg/KOH/gm (Max) 0.05% by weight (Max) 2.5x1012 Ohm.Cm.(Min) 0.20x1012 Ohm. Cm. (Min) 0.15 (Max) 0.05 mg/KOH/gm 0.05% (Max) by weight Yes
10. 11. 12. 13 14. 15.
16.
CHARACTERISTICS OF OIL IN THE TRANSFORMERS SN 1 2 3 4 5 6 7 8 S.No. CHARACTERSTICS Electric Strength (Breakdown voltage KV) TECHNICAL REQUIREMENT 60 KV Min.(Prior to energisation) 40 KV Min.(After energisation) 25 PPM (Max)
Water contents (PPM) Specific Resistance (Resistivity) Ohm-cu at 90 Dec. C 20 x 1012Ohm-Cm (Min) Dielectric dissipation factor (Tan delta) at 90 Deg.C 0.01 (Max) Netralisation valve (Total acidity) 0.2 mg KOH/gm (Max) Sediment and/or precipitable sludge Absent Flash Point 140 Deg. C (Min) Interfacial tension at 27 Deg. C 0.030 N/m (Min) SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS OF EHV GRADE-I OIL Characteristics of oil
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Requirement
1 2 A B 3 4 A B 5 6 A B 7 A B C 8 A B C D 9 A B C D E F G
Flash point Pensky Martein (closed) 140 Neutralization value Total acidity, max 0.03 mg KOH/gm Inorganic acidity / alkalinity Nil Crrosive Sulphur Non corrosive Electric strength (breakdown voltage) min. New unfiltered oil 30 KV rms New oil after filtration 60 KV rms Dielectric dissiplation factor (tan delta) at 90c 0.002 Specific resistance (resistively) At 90c min. 35 x 10 ohm-cm At 27c min. 1500 x 10 ohm-cm Oxidation stability Neutralization value after oxidation (max) 0.40 mg KOH/gm Total sludge after oxidation (max) 0.1% by weight SK value 4% to 8% Ageing characteristic Ageing characteristics after accelerated ageing (open beaker method with copper catalyst) i) At 27c min. 2.5 x 10 ohm-cm (min) ii) At 90c min. 0.2 x 10 ohm-cm (min) Dielectric dissipation factor (tan delta) 0.20 max. Total acidity in mg KHO/gm 0.05 max. Total sludge value 0.05% by weight Characteristic of the oil in the transformer the Important characteristic of the transformer ol after it is filled in the transformer (within 3 months of filling) shall be as below :Electric strength (breakdown voltage)min. 40 KV (min) Dielectric disiipation factor (tan delta) at 90c. 0.01 max. Specific resistance (resistivity) at 27c 10 x 10 ohm-cm Flash point PM (closed) 140c min. Interfacial tension at 27c 0.03 N/m min. Neutralization value (total acidity). 0.05 mg KOH per gm Water content 35ppm (max.)
TECHNICAL SPECIFICATIN OF LT DISTRIBUTION BOXES
(A) DISTRIBUTION BOXES (SHEET METAL) Particulars S. N. 1. 63 kVA SCOPE Manufacture & testing of LT distribution Boxes AC 3 Phase 4 Wire 50 C/S. RATINGS 100 kVA Manufacture & testing of L.T. distribution Boxes AC 3 Phase Wire 50 C/S. 200kVA Manufacture & testing of L.T. distribution Boxes AC 3 Phase 4 Wire 50 C/S. 315 kVA Manufacture & testing of L.T. distribution Boxes AC 3 Phase 4 Wire 50 C/S.
2. 3.
SYSTEM
MATERIAL SHOULD BE SUITABLE IN THE WEATHER CONDITIONS AS BELOW 0o to 50oC (a) Temperature 20% to
0o to 50oC 20% to Max.100%

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0o to 50oC 20% to
0o to 50oC 20% to
Range Max.100% (b) Relative 0 to 1000 Meters Humidity (c) Altitude 4. SYSTEM DETAILS (a)kVA. Suitable for use with 63 kVA Distribution Xmer 415 VAC 50 C/S 100 A 2 Nos.
0 to 1000 Meters
Max.100% 0 to 1000 Meters
Max.100% 0 to 1000 Meters
Suitable for use with 100 kVA Distribution Xmer 415 VAC 50 C/S 140 A 2 Nos.
(b)Voltage (c)Frequency (d)Approximate full load current. (e) No. of Outgoing Circuit per phase 5. APPLICABLE STANDARDS (WITH LATEST AMENDMENTS) (a) MCCBs (b) Enclosure Box (c) General Requirement (d) Porcelain Fuse Unit (d)LT Switchgear used in Box 6. MANUFACTURIN G/ CONSTRUCTION AL DETAILS
IS:13947(PII)/1993 IS:2147/1962 IS:4237/1982 IS: 20861973/1993 IS:8623(PI)/1993 IS:13947(PI)/1993 One Triple Pole Moulded Case Circuit Breaker (MCCB) (Frame size 200A, O/L Current setting at 150A) on Incoming side and total 6 nos. Porcelain Fuse Units of rating of 100A on outgoing side for two circuits alongwith necessary interconnection with busbar & links with other components as per drawings enclosed.
IS:13947(P-II)/1993 IS:2147/1962 IS:4237/1982 IS: 20861973/1993 IS:8623(P-I)/1993 IS:13947(P-I)/1993
IS:13947(PII)/1993 IS:2147/1962 IS:4237/1982 IS: 20861973/1993 IS:8623(PI)/1993 IS:13947(PI)/1993 One Triple Pole Moulded Case Circuit Breaker (MCCB) (Frame size 400A, O/L Current setting at 375 A) on Incoming side and total 6 nos. Porcelain Fuse Units of rating of 300A on outgoing side for two circuits alongwith necessary interconnection with busbar & links with other components as per drawings enclosed.
IS:13947(PII)/1993 IS:2147/1962 IS:4237/1982 IS: 20861973/1993 IS:8623(P-I)/1993 IS:13947(PI)/1993
One Triple Pole Moulded Case Circuit Breaker (MCCB) (Frame size 200A, O/L Current setting at 200A) on Incoming side and total 6 nos. Porcelain Fuse Units of rating of 200A on outgoing side for two circuits alongwith necessary interconnection with busbar & links with other components as per drawings enclosed.
One Triple Pole Moulded Case Circuit Breaker (MCCB) (Frame size 630A, O/L Current setting at 575 A) on Incoming side and total 9 nos. Porcelain Fuse Units of rating of 300 A on outgoing side for total three circuits alongwith necessary interconnection with busbar & links with other components as per drawings enclosed.
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7.
DETAILS OF INCOMING CURCUIT WITH TRIPLE POLE MOULDED CASE CIRCUIT BREAKER WITH SWITCH (MCCB)
MCCB MCCB shall conform IS:13947:1993. MCCB of reputed makes like Siemens, L&T, ABB, GE Power, Schnider-France, Spaceage-Hyundai, Havells etc. shall be acceptable. The offered make of the MCCB shall require approval of the CSEB. Type tests reports of the MCCB required to be submitted with the offer. The MCCB shall not cause any nuisance tripping due to dead load charging current or switching current of motor and capacitor load. The tripping of MCCB should be independent of the position of knob and it shall have quick make, quick break mechanism. The Switch of the MCCB should be capable of onload operation specially for making, carrying and breaking currents under normal circuit conditions which may include specified operating overload conditions and also carrying for a specified time current characteristics under specified abnormal circuit conditions such as those of short circuit.
(a) Rated Insulation VAC Voltage (b) Rated Operating Voltage (c) Rated Impulse withstand voltage(kV) (d) Operating Current (Frame size) (e) Overload Currents setting (Fixed over load) (f) No. of pole (g) Rated Short circuit breaking capacity in kA (Icu) as per IS:13947 (Part-III)/1993 (h) Rated Service Short circuit breaking capacity in kA (Ics) as per IS:13947 (PartIII)/1993 (i) The sequence of operation for MCCB (j Utilization category (k) Power factor for short CKT Test (l) Arrangement of terminal strip of MCCB (m) Projections of terminal strips of MCCB on:-
should be more than 660 V 415 V 6 200 Amps 150 Amps Three Pole 10 kA at 0.4 PF (LAG)
50% of Icu
50% of Icu
50% of Icu
50% of Icu
As per clause 8.3.4 of IS: 13947 (PII) (A) 0.4 (LAG) (As per drawing) TinnedElectrolyti c Copper 60 mm
As per clause 8.3.4 of IS: 13947 (PII) (A) 0.4 (LAG) (As per drawing) TinnedElectrolytic Copper 60mm
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As per clause 8.3.4 of IS: 13947 (P (A) 0.4 (LAG) (As per drawing) TinnedElectrolyti c Copper 60mm
As per clause 8.3.4 of IS: 13947 (PII) (A) 0.4 (LAG) (As per drawing) TinnedElectrolytic Copper 60mm
[i] Incoming side [ii] Busbar side [iii] Size of terminal strips (n) Material of the busbar strips (o) Details of Type tests for MCCB (p) Type of MCCBs to be used (q) Other (r )GUARANTEE (s) THE TRIPLE POLE MCCB SHALL HAVE THE TIME CURRENT CHARACTERISTI CS AS INDICATED BELOW:-
60 mm 30 x 5 Sqmm
60 mm 30 x 5 Sqmm
60 mm 50x6 Sqmm
60 mm 50x10 Sqmm
Continuous tinned copper strip from the point of contact. MCCB to be used in the distbn. Box must be type tested for Seq-I, Seq-II &Seq-III as per IS:13947 (Pt-II)/1993 Hydro-magnetic / Thermo-magnetic ---Being main equipment of Distribution Box, MCCB shall be guaranteed for 18 months. Bidders should furnish a Backup Guarantee of Manufacturer in prescribed proforma as per Annexure-II Multiple of Tripping Time normal current setting (O/L)of MCCB
8.
More than 2.5 Hrs. More than10 Minutes & less than 2 Hrs. Less than 30 Minutes Less than 10 Minutes Less than 1 Minute Not less than 2 seconds Less than 5 seconds Instantaneous (less than 40 Milliseconds) For the above time - current characteristics the reference calibration temperature of the breaker should be 50o C. Deration, if any, upto 60o C ambient temperature, shall not exceed 10% of the current setting indicated above. OUTGOING CURCUIT DETAILS PORCELAIN FUSE UNIT SHALL BE PROVIDED AS PER DETAILS GIVEN BELOW :(a) No. of CKTs on 2 Nos/phase 2 Nos/phase 2 Nos/phase 3 Nos/phase Out-going side per phase. (b) Current Rating 100 Amps 200 Amps 300 Amps 300 Amp (c) Base Size of PF 190 x 65 mm 200 x 80 mm 235 x 80 mm 235 x 80 mm Unit (d) Details of Type PF Units to be used in the Dist. Box must be type tested for Mechanical test tests for PF Unit sequence (i to v), Electrical test sequence (i to iv) and of material properties (i to iii) as per IS:2086-1993. The bidder should furnish attested copies of type test certificates. (e) Others The rewirable PF-Units shall be as per drawing enclosed and conforming to IS:2086:1993. However, there shall be minor modification in the drawing of 300 Amp. fuse units so that fuse wire can be used in place of HRC link. For it, carrier should have a middle projection and fuse wire tightening arrangement as given in the drawing of 200 Amp. units. HRC fuse links are not to be supplied with the
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1.05 1.2 1.3 1.4 2.5 4 6 12
boxes. 9 DETAILS OF BUSBAR & LINKS:A. Material Electrolytic tinned copper (All bus bar should be made of single strip without joint burrs and properly drilled) 30 x 5 Sqmm B. Size of main Busbar C. Size inter-link 30 x 3 Sqmm (As per drawing) PVC insulation of standard colour code i.e. Red, Yellow, Blue for D. Insulations over R, Y & B Phase the As per drawing & Bus-bar & links other clea-rance as per IS:4237 amended upto date
Electrolytic tinned Electrolytic tinned Electrolytic copper (All bus bar tinned copper copper (As per should be made of (As per drawing) drawing) single strip without joint burrs and properly drilled) 30 x 5 Sqmm 50 x 6 Sqmm 30 x 3 Sqmm (As per drawing) PVC insulation of standard colour code i.e. Red, Yellow, Blue for R, Y & B Phase 30 x 5 Sqmm (As per drawing) PVC insulation of standard colour code i.e. Red, Yellow, Blue for R, Y & B Phase 50 x 10 Sqmm 30 x 5 Sqmm (As per drawing) PVCinsulation of standard colour code i.e. Red, Yellow, Blue for R, Y & B Phase As per drawing & other clea-rance as per IS:4237 amended upto date
As per drawing & other clea-rance as As per drawing & per IS:4237 other clea-rance amended upto date as per IS:4237 amended upto date
10
E. Minimum Clearance between Busbar, Box and terminals of MCCB & PF Unit ENCLOSURES (i) Size (900 x 950 x 325) mm (outer) As per drawing(inner) CR/MS Sheet 2 (ii) Material mm (iii) Thickness L-drop should be (iv) Arrangement welded on the for door for closing Pad lock the door as well as for padlocking. Slopping with 5 degree on back side (v) Slopping of A Magnetic Catcher should Roof provided in such a way that when doors are (vii) Magnetic pushed to closed Catcher condition, both
(900 x 950 x 325) mm (outer) As per drawing (inner) CR/MS Sheet 2 mm L-drop should be welded on the door for closing the door as well as for padlocking. Slopping with 5 degree on back side A Magnetic Catcher should provided in such a way that when doors are pushed to closed condition, both the doors can
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(1050 x 1000 x 325) mm (outer) As per drawing (inner) CR/MS Sheet 2 mm L-drop should be welded on the door for closing the door as well as for padlocking. Slopping with 5 degree on back side A Magnetic Catcher should provided in such a way that when doors are pushed to closed condition, both
(1250 x 1200 x 480) mm (outer) As per drawing (inner) CR/MS Sheet 2 mm L-drop should be welded on both doors for closing the door as well as for padlocking. As per drawing A Magnetic Catcher should provided in such a way that when doors are pushed to closed condition, both the doors can be
11
the doors can be kept in closed condition due to magnet. Size of Bottom As per drawing plate perforated. 2mm (i) Thickness of Bottom Plate Perforated MS (ii) Material of the sheet. Bottom Plate Should be (iii) Fixing Arrange- detachable. ment of the Bottom 3 Nos with PVC Plate glands suitable (iv) Knock out for the required Holes size of cable and in the Bottom additional 2mm plate thick sheet of suitable width to be provided to hold the cable glands. 2mm thick perforated sheet
be kept in closed the doors can be condition due to kept in closed magnet. condition due to magnet. As per drawing As per drawing 2mm 2mm Perforated sheet. Should detachable.
kept in closed condition due to magnet. As per drawing 2mm MS be
Perforated MS Perforated MS sheet. sheet. Should be Should be detachable. detachable.
3 Nos with PVC glands suitable for the required size of cable and additional 2mm thick sheet of suitable width to be provided to hold the cable glands. 2mm thick 2mm thick perforated sheet perforated sheet 3 Nos with PVC glands suitable for the required size of cable and additional 2mm thick sheet of suitable width to be provided to hold the cable glands.
4 Nos with PVC glands suitable for the required size of cable and additional 2mm thick sheet of suitable width to be provided to hold the cable glands. 2mm thick perforated sheet
(v) Additional Supports of the Bottom Plate (vi) Bottom M.S. Channels of 75x40x3 mm size are to be provided below the box on both Supports of side as shown in the drawings, so that box does not come in direct contact with Box ground when stored. Both side louvers with wire mesh should be provided for vermin proof ventilation. (vii) Air Circulation & Creepage should be as per IS:4237 clearance in the Box (viii)Clearance Instructions printed in Hindi to be provided as per drawing in side each box between the terminals To be provided as per drawing and each box must have identification plate on the of front cover. bus bar, a) Name of the firm MCCB and b) Rating Box PF Unit c) Serial No. (ix) Instructions to d) Order No. & date Lineman As per drawing. (x) Danger Board Identification Plate All Nuts, Bolts & Washers used in current carrying parts should be of good quality stainless steel. Petroleum Jelly should be provided in a small pack of polythene with each box which can be used by on nuts & bolts by the linemen.
(xi) Hinges
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(xii) Other parts such as Nuts and Bolts Washers etc. 12 EARGHING STUDS (a) Required No. (b) Fixing Two studs(one on each side) of galvanized MS 50x12 mm for external earth & internal neutral connections. Earthing Studs should be welded at middle with the Box & tightened with neutral bus-bar inside the box. As per drawing One set of one spring washer, two plain washers & one nut should be provided on earthing stud inside the box and another set outside the box.
13
(c) Size (d) Others PAINTING & FIXING ARRANGEMENT FOR BOX Electrostati-cally (a) Process charged technique alongwith oven curing process Powder Coating (b) Painting paint of good quality. Brown Suitable arrangement on (c) Colour (d) Fixing a double pole structure as per Arrangement drawing. for Box
Electrostatically charged tech-nique alongwith oven curing process Powder Coating paint of good quality. Green Suitable arrangement on a double pole structure as per drawing.
Electrostati-cally charged technique alongwith oven curing process Powder Coating paint of good quality. Grey Suitable arrangement on a double pole structure as per drawing.
Electrostati-cally charged technique alongwith oven curing process Powder Coat-ing paint of good quality. Grey Suitable arrangement on a double pole structure as per drawing.
14
NEUTRAL BUSBAR (a) Size (b) Fixing
Neutral bus-bar should be continuous throughout the width of the box and connected to earthing studs on bothsides as shown in the drawing. 30 x 5 Sqmm or 30 x 5 Sqmm or 50 x 6 Sqmm or 50 x 6 Sqmm or equivalent equivalent equivalent equivalent As per drawing As per drawing As per drawing As per drawing
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15
LUGS ON INCOMING AND OUTGOING TERMINALS
Bimetallic lugs on incoming terminals of Cables to MCCB and outgoing side from PF Unit should be provided as per drawing suitable for the required size of 3-1/2 core Cable. The bimetallic lugs should conform to IS:8337 (e.g. clause 4.1.1, Clause 4.1.3 and Clause 4.2). 150 Sqmm 31/2 with suitable double holes lug.
(a) Size of Incoming side cable & lugs.
Bimetallic lugs on incoming terminals of Cables to MCCB and outgoing side from PF Unit should be provided as per drawing suitable for the required size of 3-1/2 core Cable. The bimetallic lugs should conform to IS:8337 (e.g. clause 4.1.1, Clause 4.1.3 and Clause 4.2). 300 Sqmm 3150 Sqmm 3- 1/2 with suitable 1/2 with suitable double holes lug. double holes lug. 70 Sqmm 3-1/2 150 Sqmm 3Core size Cable 1/2 Core size suitable double 70 Sqmm 3-1/2 Cable hole lugs. Core size Cable suitabledouble suitable double hole lugs. hole lugs.
Bimetallic lugs on incoming terminals of Cables to MCCB and outgoing side from PF Unit should be provided as per drawing suitable for the required size of 31/2 core Cable. The bimetallic lugs should conform to IS:8337 (e.g. clause 4.1.1, Clause 4.1.3 and Clause 4.2).
Bimetallic lugs on incoming terminals of Cables to MCCB and outgoing side from PF Unit should be provided as per drawing suitable for the required size of 3-1/2 core Cable. The bimetallic lugs should con-form to IS: 8337 (e.g. clause 4.1.1, Clause 4.1.3 and clause 4.2). 300 Sqmm 31/2 with suitable double holes lug. 150 Sqmm 31/2 Core size Cable suitable double hole lugs.
(b) Size of Outgoing cable & lugs.
16
CABLE HOLDING CLAMP
17
OTHER REQUIREMENTS
18
APPLICABLE STANDARDS FOR
Cable holding clamp be made of 2mm thick strip with 4 mm base to be provided on incoming side and outgoing side as per drawing. There should be free circulation of Air between MCCB, bus-bar & PF Units at back and front so that the inside temp. does not exceed beyond per-missible limit IP-34 as per
Cable holding clamp be made of 2mm thick strip with 4 mm base to be provided on incoming side and outgoing side as per drawing. There should be free circulation of Air between MCCB, bus-bar & PF Units at back and front so that the inside temp. does not exceed beyond per-missible limits. IP-34 as per
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Cable holding clamp be made of 2mm thick strip with 4 mm base to be provided on incoming side and outgoing side as per drawing. There should be free circulation of Air between MCCB, bus-bar & PF Units at back and front so that the inside temp. does not exceed beyond per-missible limit IP-34 as per
Cable holding clamp be made of 2mm thick strip with 4 mm base to be provided on incoming side and outgoing side as per drawing. There should be free circulation of Air between MCCB, bus-bar & PF Units at back and front so that the inside temp. does not exceed beyond permissible limits. IP-34 as per
19
DEGREE OF PROTECTION TEST & TEST CERTIFICATE (I) TYPE TESTS i) Temperature rise test ii) High Voltage Test
IS:13947(P-I) 1993
IS:13947(P-I) 1993
IS:13947(P-I) 1993
IS:13947(P-I) 1993
iii) Short time withstand current test
iv) Degree of protection
v) Time/Current Characteristics
Temperature rise test as per IS:8623/Pt-I/93 High Voltage Test should be done at 3.00 kV for one minute. Short time withstand current test on Distribution Box. For short time current test the box should be subjected to a current of 10 kA for 1 Sec. for all the Ckt. Independently after by-passing the MCCBs. Degree of protection for IP34 on complete unit as per IS:13947 or latest version thereof Time/Current Characteristics test should be done at 1.05 &1.2 times of O/L current setting and should pass the requirement given in clause7(s) All type test as per IS 2086-1993 as amended upto date
Temperature rise Temperature rise test as per test as per IS:8623/Pt-I/93 IS:8623/Pt-I/93 High Voltage High Voltage Test Test should be should be done at done at 3.00 kV 3.00 kV for one for one minute. minute. Short time withstand current Short time test on withstand current Distribution Box. test on Distribution For short time Box. For short time current test the current test the box box should be should be subjected to a subjected to a current of 20 current of 10 kA kA for 1 Sec. for for 1 Sec. for all the all the Ckt. Ckt. Independently, Independently, after by-passing after by-passing the MCCBs. the MCCBs. Degree of protection for IP34 on complete Degree of unit as per protection for IP-34 IS:13947 or on complete unit latest version as per IS:13947 or thereof latest version Time/Current thereof Characteristics test should be Time/Current done at 1.05 Characteristics test &1.2 times of O/L should be done at current setting 1.05 &1.2 times of and should pass O/L current setting the requirement and should pass given in clausethe requirement 7(s) given in clause-7(s) All type test as per IS 2086-1993 All type test as per as amended upto IS 2086-1993 as date amended upto date
Temperature rise test as per IS:8623/Pt-I/93 High Voltage Test should be done at 3.00kV for one minute. Short time withstand current test on Distribution Box. For short time current test the box should be subjected to a current of 35 kA for 1 Sec. for all the Ckt. Independently, after by-pass-ing the MCCBs Degree of protection for IP34 on complete unit as per IS:13947 or latest version thereof Time/Current Characteristics test should be done at 1.05 &1.2 times of O/L current setting and should pass the requirement given in clause7(s) All type test as per IS 2086-1993 as amended upto date
vi) PORCELAIN FUSE UNIT (II) ROUTINE TEST

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CERTIFICATE Each Distbn. Box should be tested for the routine test as indicated. The routine test report indicating Sc. No. must be submitted with the offer at the time of inspection of the material.
A. Over all dimension B. Insulation Resistance Test. C. H.V. withstand test for 3.0 kV for one minute. D. Operation test on MCCB Temperature rise test: For this test, the box should be kept in an enclosure such that the temp. outside the box/MCCB shall be maintained at 50oC and the full load current of MCCB sett-ing i.e. 150A is passed in all circuit and maintained till the temp. is stabilized and max. temp. rise is recorded. (These test should be carried on box and MCCB separately.
A. Over all dimension B. Insulation Resistance Test. C. H.V. withstand test for 3.0kV for one minute. D. Operation test on MCCB Temperature rise test: For this test, the box should be kept in an enclosure such that the temp. outside the box/MCCB shall be maintained at 50oC and the full load current of MCCB setting i.e. 575A is passed in all circuit and maintained till the temp. is stabilized and max. temp. rise is recorded. (These test should be carried on box and MCCB separately.
(III) ACCEPTANCE TESTS ON COMPLETE BOX These tests should be carried out as acceptance test in addition to routine test on one random sample in each rating out of the lot offered for inspection.
Time/current charactreristic test: With the stabilized temperature rise as above the MCCB should be
Time/current charactreristic test: With the stabili-zed tempera-ture rise as above the MCCB should be tested for time current
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Time/current charactreristic test: With the stabilized temperature rise as above the Distribution Box MCCB should be
Time/current charactreristic test: With the stabilized temperature rise as above the Distribution Box MCCB should be
tested for time current characteristic at 1.05 and 1.2 times of over load release current setting and should pass the requirement given in Clause7(s) (B) S. N. 1 SMC DISTRIBUTION BOX : Particulars ENCLOSURE (i) Size (ii) Material
characteristic at 1.05 and 1.2 times of over load release current setting and should pass the requirement given in Clause-7(s)
tested for time current characteristic at 1.05 and 1.2 times of over load release current setting and it should pass the requirement given as per Clause-7(s)
tested for time current characteristic at 1.05 and 1.2 times of over load release current setting and it should pass the requirement given as per Clause-7(s)
63 kVA / 100 kVA RATINGS
Size should be nearer to size specified for Sheet Metal but should not be more than Sheet Metal Boxes. Size will subject to approval as per sample. Drawing is also to be submitted for approval with the offer. Thermosetting plastic (glass fibre reinforced polyester Sheet Moulding Compound (SMC) conforming to IS 13410-1992. The SMC Meter Box shall have light grey colour. 3 mm (back, load-bearing side) 2 mm (other sides)
(iii) Thickness (iv) Construction
Properties material enclosure Sheet Moulding Compound (SMC)
The enclosure shall complied with the requirement IP-34 as per IS:13947 alongwith latest amendments thereof. Access to the equipments like MCCB and PF-Units housed inside, shall be available only after the enclosure door is opened. Enclosure made out of thermosetting plastic i.e. glass reinforced polyester sheet molding compound (SMC) conforming ISI 13410 -1992 as per requirement of this specification. The enclosure shall have two doors. The base and door of enclosure shall be individual in one piece except for fixing of the accessories like hinges clamps, mounting Clamps, Bolts etc. The box and door shall have thickness as mentioned above. The collars of base and door shall overlap by 10 mm. Four hinges of each side shall be fitted from inside of the box to fix the doors. Hinges shall be 50 mm in length and made from 2mm thick MS sheet. Hinge pin diameter shall be 4 mm. Doors shall be fixed with minimum 3 screws in each hinge. The hinges shall be visible from outside. On closing of doors right door shall rest on the left door. All other details of the construction and installation of accessories and equipments like MCCB, PF-Units, Bus-bar arrangements, pad-locking arrangement, magnetic catcher etc. shall be same as given for Sheet Metal Boxes. The entire construction shall be subject to approval as per sample and drawing submitted with the offer. of S.N Test details Reference Standard of 1 Flammability (Vo) UL 94 or IS: 11731(Pt.II) 2 3 4 5 6 Heat deflection temperature (min.150o C) Glow wire test Ball pressure test Water absorption Mechanical Strength IS:13411 IEC 695 2-1 IS:11000(Pt.2/sec.1) IEC:335 IS:14772 IS:14772 or
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7 8 9
Marking Dimensions and construction Spirit burner test Melting point (to test up to 400oC)
IS:14772 IS :4249 IS:13360
The metal parts such as Nuts, Bolts & Washers etc. used in the Distribution Boxes shall be treated Electro galvanizing of Zinc except for bus bar and links. Additional Type tests are to be performed on material of distribution box in a Govt. approved Type test for Laboratory. Notarised photocopies of these type test should be submitted with the SMC material. tender otherwise offer will be liable for rejection. (i) Test for water absorption (As per IS:13411:1992) (ii) Glass content percent test by mass(As per IS:13410,13411:1992) (iii) IZOD Impact Strength Test (As per IS:13410,13411:1992) (iv) Heat Distortion Temperature Test (As per IS:13410,13411:1992) (for 1500 C minimum) (v) Surface Resistivity Test (As per IS:13410:13396) (vi) Volume Resistivity Test (As per IS:13410:13396) Acceptance (i) Marking IS:14772 tests (ii) Protection against electric shock IS:14772 (iii) Provision for earthing IS:14772 (iv) Tests for dimensions IS:14772 (v) Construction IS:14772 (vi) Mechanical Strength IS:14772 (vii) Spirit Burner Test IS:4249:1967 (Self extinguishing material)
TECHNICAL SPECIFICATION OF11 KV OUTDOOR EPOXY MOULDED MINIMUM OIL DESIGN & SELF OIL COOLED CURRENT TRANSFORMERS
1.
SCOPE: This specification covers design, manufacturing testing at manufacturers works, supply and delivery of 11 KV Out-door epoxy moulded minimum oil type current transformers for relaying (protection) and metering services in 11 KV Solidly grounded system. 2. GENERAL REQUIREMENT: 2.1 The current transformers shall be of outdoor, type epoxy moulded, single phase, 50 cycle, minimum oil design and self oil cooled suitable for operation in humid atmospheres and in the tropical direct sun light with temperature upto 50 degree centigrade. They should be suitable for use in areas subject to heavy lightning storms. The CTs should be suitable for operation under the climatic conditions, prevailing in the State of Chhattisgarh. 2.2 The CTs are required to be mounted on an out door structure in the switchyard. CTs will therefore, have suitable mounting holes at the base channel, for clamping it on the structure. This specification does not cover suppy of mounting structures for the CTs, which are being arranged by the purchaser, separately. 2.3 The current transformers shall have the following specification, i) Nominal system voltage : 11 KV ii) Highest system voltage : 12 KV iii) Frequency : 50 cycles, iv) Earthing of the system : Effectively grounded, v) Insulation level : 75 KV vi) Short circuit level : 250 MVA vii) Minimum one second short time : 13.1 KA current rating, viii) One Min. power frequency withstand : 28 KV voltage, ix) Minimum creepage distance : 300 mm x) Rated secondary current : 5 Amps. xi) No. of cores (with the following : 2 accuracies)
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S.No. 1 2 3 xii) xiii) 3.
Item Purpose Rated output Accuracy class Tank sheet thickness Transformation ratio
Core-I Relaying / Protection 15 VA 10 P 10 :
Core-II Metering 10 VA 0.5 1.0 Minimum 3 mm : 200-100/5-5 Amps., 300-150/5-5 Amps.
DESIGN: As stated, the 11 KV CTs shall be epoxy moulded minimum oil type. Thus, the CT cores after providing insulation shall be moulded in epoxy compound and thereafter shall be housed in the steel tank containing oil. Thickness of steel tank sheet shall be minimum 3 mm. Complete process of manufacturing shall be clearly described in the offer by the tenderers. 4. STANDARDS: The current transformers shall comply with the latest issue of Indian Standard 2705 (Part-I, II, III & IV) or IEC-185 with latest amendment thereof. 5. GENERAL: 5.1 The current transformers shall be outdoor single phase epoxy moulded and oil immersed and self cooled type suitable for the services indicated, complete in all respect conforming to the modern practices of design and manufacturing. 5.2 The core shall be of high grade, non-ageing electrical silicon laminated steel of low hysterisis loss and high permeability to ensure high accuracy at both normal and over currents. 5.3 Current transformers shall be sealed properly to eliminate and prevent air and moisture from entering the tank. 5.4 The maximum temperature attained by any part of the equipment, when in service, under continuous full load conditions and exposed to direct rays of sun, shall not exceed 45 degree centigrade above ambient. 5.5 The primary winding terminals terminal connectors etc. are required to be designed considering the continuous over loading of 25 percent. For the 25 percent continuous over- loading the ratio and phase angle error shall be maintained within the specified limit applicable for normal loading conditions. Further, temperature rise for 125 percent loading shall be within the permissible limits specified in the relevant IS. 6. WINDINGS: 6.1 The current transformer core to be used for metering and instrumentation shall be of accuracy class specified in the para 2.3 above. The primary winding shall be designed considering current density not exceeding 1.5 A/ Sq. mm. The saturation factor of this core shall be low enough not to cause any damage to measuring instruments in the event of maximum short circuit current. 6.2 Current transformers cores to be used for protective relaying purposes shall be of accuracy class specified or appropriate class suitable for over current protection. The cores shall be designed for a minimum saturation factor of 10 for the highest setting. The magnetization curves for these cores shall be furnished with the tender. 6.3 The rating of the secondary winding shall be 5 Amp. The secondary terminals shall be brought out in a compartment on side of current transformer for easy access. The secondary terminals shall be provided with short circuiting arrangement. The secondary taps shall be adequately re-enforced to withstand normal handling, without damage. 7. INSULATION: 7.1 The quantity of insulating oil for first filling of oil in each current transformer and the complete specification of the oil shall be stated in the tender. The oil should be EHV Grade one. 7.2 The current transformers shall be single phase, multicore, separately mounted, free standing type for outdoor installation.
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7.3 The insulators shall be prepared from wet process porcelain with arrangement for sealing hermetically the metallic tank containing the core and the secondary winding. 7.4 The primary terminals of current transformer shall be of non-ferrous corrosion-proof material and shall be provided with suitable terminals connectors to receive ACSR Dog conductors. The terminal connectors as per enclosed design are to be made of LM9 / LM25 composition of Aluminium Alloy and should be made by gravity die-casting process only. Sand casting shall not be allowed. The Drawing of terminal connector is enclosed. 7.5 The secondary terminals shall be brought to a suitable weather proof sheet metal terminals box for termination of multicore armoured cable (as per IS 2147). Secondary box should have two complete box size bakelite plate. Secondary screw (stud) shall be moulded on inner bakelite plate. Cork sheet should be used with inner bakelite plate for sealing. It may be noted that full secondary box size bakelite plates should be used.
7.6 The terminals of primary and secondary winding shall be clearly marked according to relevant standards. 8. INSULATION WITHSTAND CHARACTERISTICS:Insulation withstands characteristics shall be as per IS-2705 and as shown in the table below: Nominal system Highest system voltage Lightning impulse Power frequency withstand voltage withstand voltage voltage (for 1 min.) 11 KV (rms) 12 KV (rms) 75 KV (Peak) 28 KV (rms) All exposed ferrous parts shall be hot dip galvanized conforming to IS: 2633. For the secondary connections, threaded stud of minimum 6 mm diameter terminals shall be provided. Change in CT ratio will be obtained by providing tappings in the secondary windings, while the primary will have only one winding. The tenderer should note that CTs are required only of outdoor type having porcelain shell, duly epoxy moulded type. Compound filled CTs are not required. CTs with live tank design or inverted type are not acceptable. 9. 10. TYPE OF MOUNTING: The 11 KV CTs shall be mounted on CT bracket, provided on 11 KV Circuit breakers structure.
TERMINAL CONNECTORS: The terminal connectors suitable for ACSR Dog Conductor and for horizontal take off shall be supplied as per enclosed drawing. Suitable terminal earth connectors for earthing connections shall also be supplied. STUDS: Length of stud should invariably be more than the length of bushing. The connection of lower side of stud should not be done inside the bushing. Sufficient length of stud should be left on both sides of the bushing. Minimum 2 nuts with a check nut and washer should be provided on upper side of stud. The material and minimum size of stud should be 20 mm brass for 200-100/5-5 Amp. and 20 mm ETP grade copper for 300150/5-5 Amps. CTs. The stud should be of complete brass / ETP grade copper as specified and other connections such as cap etc. should also be of same material i.e. brass / copper only as specified before. It may be noted that no soldering shall be done for connection. Only brazing should be done and should be connected to stud through bolting arrangement. 12. BUSHING: The basic insulation level of the bushing shall be as specified and porcelain shall be homogeneous and free from cavities and other flaws. This shall be so designed to have ample insulation, Mechanical strength. All insulators of identical ratings shall be interchangeable. The insulators shall be type tested from any independent Govt. lab as per relevant standard.
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11.
Bushing should have grooves so that the stud is locked and it does not twist. The cap of the bushing (of same material as stud) should fit exactly on the bushing i.e. the cap should be manufactured of bushing size only. Any arbitrary size of cap will not be acceptable. 13. TESTS PARAMETERS: Short time current ratings: The outdoor type CTs shall comply with the following requirements in respect of short time current ratings:a. Thermal ratings: Short time thermal current rating assigned to the CTs for the rated time of 1 second shall be 13.1 KA. b. Dynamic Rating: Peak value of the rated dynamic current, which CT can withstand, without being damaged electrically or mechanically with the secondary winding short circuited, shall not be less than 2.5 times the rated short time thermal current. c. Temperature rise: Temperature rise of the CTs of Outdoor type when carrying a primary current equal to continuous thermal current, at a rated frequency and at a rated burden, shall not exceed 45 degree centigrade above ambient temperature. 14. TESTS: Outdoor type CTs shall be subjected to the following tests as per IS-2705 of 1992 with latest amendment thereof and the test certificates should be submitted for approval to the purchaser. A. Type test: a. Short time current tests, b. Temperature rise test, c. Lightning impulse test, d. High voltage power frequency wet withstand voltage tests, e. Determination of errors according to the requirements of the appropriate accuracy class, i) Copy of the notarized Test certificates for the above tests must be furnished alongwith drawings of type tested CTs duly signed by the type testing authority. ii) The type test certificates should be from independent Govt. lab.
iii) A firm will only eligible for opening of price bid, if it has type test on that rating & ratio. iv) The above tests must have been conducted on the CT earlier than 5 years from the date of opening of tender, v) In case of any change in design / type of CT already type tested and the one offered against this specification, the Company reserves the right to demand repetition of tests, without any extra cost. B. a) b) c) d) e) f) Routine test: The following shall constitute the routine tests: Verification of terminal markings and polarity, Power frequency dry withstand tests on primary windings, Power frequency dry withstand tests on sec. windings, Over-voltage inter-turn test, Determination of errors according to the requirements of the appropriate accuracy class, Partial discharge test,
Each current transformer shall be subjected to routine tests, as specified in Indian Standard 2705 in the presence of purchasers representative, if so, desired by the purchaser. All tests reports should be submitted and should be got approved from the purchaser before despatch of the equipment. 15. A detailed list of test facilities available at the suppliers works for routine tests may be furnished. 16. In case of any change in design purchaser, reserves the right to get one CT type tested at suppliers cost at any independent Govt. lab. 17. Any other design of CT such as polycrete type CTs will also be acceptable subject to meeting requirement of above technical specification. However, no price preference shall be given for it.
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TECHNICAL SPECIFICATION OF 11 & 33 KV AIR BREAK SWITCHES
1. SCOPE:- This specification provides for manufacture testing at works and delivery FOR destination of 11KV & 33KV switches. The 11KV & 33 KV AB Switches shall conform to IS:9920(Part- I to IV). 2. A.B. SWITCHES: The 11KV & 33 KV Air Break Switches are required with three poles in each phase. The AB Switches shall be supplied complete with phase coupling shaft, operation rod and operating handle. It shall be manually gang operated and verifiably break and horizontal mounting type. 3. The AB Switch shall be designed for a normal current rating of 400 Amps and for continuous service at the system voltage specified here as under:i) 11KV AB Switch: 11KV + 10% continuous 50 C/s solidly grounded earthed neutral system. ii) 33KV AB Switch: 33KV + 10% continuous 50 C/s solidly grounded earthed neutral system. The length of break in the air shall not be less than 400mm for 11KV AB Switches and 500 mm for 33KV AB switches. 4. The 11KV & 33KV AB Switches are required with post insulators. The AB switches should be suitable for mounting on the structure. The mounting structure will be arranged by the purchaser separately. However, the AB Switches shall be supplied with base channel for mounting on the structure, which will be provided by the purchaser. The phase-to-phase spacing shall be 750 mm in cash of 11KV AB Switches & 1200 mm in case of 33KV AB Switches. 5. POST INSULATORS: The complete set of three phase AB Switches shall have stacks of post insulators. 11KV AB Switches : 1 No. 11KV Post Insulator per stack. 33KV AB Switches : 1 No. 33KV Post Insulator per stack. The post insulators should conform to the latest applicable Indian Standards IS:2544 specification for Porcelain post Insulators. Creepage distance should be adequate for highly polluted outdoor atmosphere in open atmosphere. The porcelain used for manufacture of AB Switches should be homogeneous free from flaws or imperfections that might affect the mechanical dialectic quality. They shall be thoroughly vitrified. though and impervious to moisture. The glazing of the porcelain shall be of uniform brown in colour. free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts thought the range of temperature variation shall not loose the parts of create undue internal stresses which may affect the electrical or mechanical strength. Each cap and base of the insulators shall be interchangeable with each other. The cap and base shall be properly cemented with insulators to give perfect grip. Excess cement must be avoided. 6. Each 11KV & 33KV post Insulators should have technical particulars as detailed below: 11KV 33KV i) Nominal system voltage KV (rms) 11 33 ii) Highest system voltage KV (rms) 12 36 iii) Dry power Frequency one KV 35 75 minute withstand voltage(rms) iv) Wet power frequency one minute withstand voltage (rms) v) Power Frequency puncture voltage KV (rms) 1.3 times the actual dry flashover voltage vi) Impulse withstand voltage KV (Peak) 75 170 vii) Visible discharge voltage KV(rms) 9 27 viii) Creepage distance in mm (minimum) 320 580 7. The rated insulation level of the AB Switches shall not be lower than the values specified below: ---------------------------------------------------------------------------------------------------------------------------. Sno Standard Ratio voltage Standard impulse withstand One Minute power frequency
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voltage positive & negative withstand voltage KV (rms) polarity KV (Peak) ----------------------------------- ----------------------------------Across the To earth & Across the To earth & isolating between isolating between distance poles distance poles ---------------------------------------------------------------------------------------------------------------------------. i. 11KV 12KV 85 KV 75 KV 32 KV 28 KV ii. 33KV 36KV 195 KV 170 KV 80 KV 70 KV ---------------------------------------------------------------------------------------------------------------------------. 8. TEMPERATURE RISE: - The maximum temperature attained by any part of the equipment when in service at site under continuous full load conditions and exposed to the direct rays of sun shall not exceed 450 C above ambient. 9. MAIN CONTACTS: - AB Switches shall have heavy duty self aligned type contacts made of hard drawn electrolytic copper/brass. The various parts should be accordingly finished to ensure interchangeability of similar components. The moving contacts of the switch shall be made from Haro drawn electrolytic copper/brass. These contact shall have dimensions so as to withstand safely the highest short-circuit currents and over voltage that may be encountered during service. The surface of the contact shall be rounded smooth and silver-plated. In nut shall the male and female contacts assemblies shall ensure that:i) Electrodynamics withstand ability during short circuits without any risk of repulsion of contacts. ii) Thermal withstand ability during short circuits. iii) Constant contact pressure even when the lower parts of the insulators stacks are subjected to tensile stresses due to leaner expansion of connection bus bar of feasible conductors either because of temperature variations or strong winds. iv) Whipping action during closing and opening. v) Contact alignment assuring closing of the switch without minute adjustments. 10. CONNECTORS: The connectors shall be made of hard drawn electrolytic copper or brass suitable for raccoon/Dog ACSR conductor for both 11KV & 33 KV AB Switches. The connector should be 4 bolt type. 11. OPERATING MECHANISM: All A.B. Switches shall have separate independent manual operation. They should be provided with ON/OFF indicators and padlocking arrangements for locking in both the end positions to avoid unintentional operation. The isolating distances should also be visible for the A.B. Switches. The AB Switch will be supplied with following accessories: ---------------------------------------------------------------------------------------------------------------------------. Sno. Item Size of 11KV Size of 33 KV AB Switch AB Switch ---------------------------------------------------------------------------------------------------------------------------. i. Operating Rod (GI) Length 5.50 mtrs. Length 5.50 mts Dia: 25 mm Dia: 40 mm ii. Phase coupling square Rod (GI) Length 1800 mm Length 2700 mm size 25x25 mm Size 40x40mm
declared Voltage KV/RMS.
of the A.B. Switches
iii. Operating handle (GI) 1 No. 1 No. --------------------------------------------------------------------------------------------------------------------------. The A.B. Switches shall be capable to resist any chance of opening out when in closed position. The operating Mechanism should be of robust constructions, easy to operative by single person and to be located conveniently for local operation in the switchyard. The G.I. pipe shall conform to ISS:1239-68. The vertical down rod should be provided with adequate joint in the mid section to avoid bending or buckling. Additional leverage should be provided to maintain mechanical force with minimum efforts. All iron parts should be not dip galvanized. All brass parts should be silver-plated and all nuts and bolts should be hot dip galvanized.
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12. ARCING HORNS: It shall be simple and replaceable type. They should be capable of interrupting line charging current. They shall be of first made and after break type. 13. BUSH: The design and construction of bush shall embody all the features required to withstand climatic conditions specified so as to ensure dependable and effective operations specified even after long periods of inaction of these Air Break Switches. They shall be made from highly polished Bronze metal with adequate provision for periodic lubrication through nipples and vent. 14. DESIGN, MATERIALS AND WORKMANSHIP: The supplier shall assume full responsibility for co-ordination and adequate design. All materials used in the construction of equipment shall be of the appropriate class, well finished and of approved design and material. All similar parts should be accurately finished and interchangeable. Special attention shall be paid to tropical treatment all the equipment, as it will be subjected during service to extremely severe exposure to atmospheric moisture and to long period of high ambient temperature. All current carrying parts shall be of non-ferrous metal or alloys and shall be designed to limit sharp points/edges and similar sharp faces. 15. Dimension of 11KV & 33KV A.B. Switches in (Max.) tolerance 5% -----------------------------------------------------------------------------------------------------------------------------. Sno. Particulars 11KV AB Switch 33 KV AB Switch -----------------------------------------------------------------------------------------------------------------------------. i. Drawing No. EB/P6/MPEB/7 EB/P6/MPEB/8 (Revised) (Revised) dt. 1.5.88 dt. 1.5.88 ii. iii. iv. v. MS Channel Creepage distance of Post Insulator. Height it post shell Fixed contact assembly (a) Base (b) Contact (c) GI cover (d) Spring 16. Moving contact assembly (a) Base Assembly (b) Moving (c) Bush (d) Thickness of Groves Connectors: (Dimension of each pad) 450x75x40 320 mm (Min.) 254 mm 165x36x8 70x30x6 110x44 Bronze Metal 6 Nos 135x25x8 18x25x9 Bronze Metal 7 (Moving & fix both) 368 mm 165x36x8 70x30x6 140x44 Bronze Metal 6 Nos. 170x40x8 2900x25x14 Bronze Metal 7 (Moving & fix both) 675x100x50 580 mm(Min)
17.
18. ROUTINE TEST CERTIFICATE: The Routine Test Certificate should invariably be submitted in duplicate of each lot offered for inspection as per ISS:9920 (Part-I to IV). The offers received without Routine Test Certificate shall not be entertained. This may please be noted. 19. ACCEPTANCE TEST: At the time of inspection following tests shall be carried out:i) Physical verification and measurement of dimension. ii) Power frequency high voltage test. iii) Temperature rise test. iv) Mechanical endurance test/operation test. v) Milli volt drop test. vi) Galvanising test as per ISS:2633
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20. Name plate: The name plate in the schedule-II following design shall be fixed on each A.B. Switch:i) ii) iii) iv) v) Name of Supplier Name of Purchaser Order No. and date Rating Serial number of Units : : : : :
The size of name plate shall be 2"x1" for 11 KV and 2x2 for 33 KV A.B. Switch. TECHNICAL PARTICULARS FOR 11 KV & 33 KV A.B. SWITCHES Sno 01 02 03 04 05 Particulars 11KV AB Switch 33 KV AB Switch Type, make & country of origin Maximum permission continuous service 12 KV 36 KV voltage (KV) Length of the break/phase Not less than 400mm Not less than 500mm Phase to phase spacing 750 mm 1200 mm Power frequency withstand test voltage for completely assembled switches: (A) Against ground:(i) Dry KV 35 75 (ii) Wet KV 35 75 (B) Across open contact:(i) Dry KV 45 80 (ii) Wet KV 45 80 (C) Between phases:(i) Dry KV 35 70 35 70 (ii) Wet KV Impulse withstand test voltage of 75 170 completely assembled switch without arcing horns with 1.25/ 50 micro second impulse wave (KV Peak) 100 % impulse flashover voltage of 65 175 completely assembled switch with arcing horns with 1.2/50 micro-second impulse wave against ground (KV peak) Particulars of the main contacts i.e. fixed contacts and moving contacts: (a) Type Heavy duty self aligned Self aligning fully floating Jaw type fixed contact & type contact (Fixed & Gun type moving contact. Moving) (b) Material Brass Brass (c) Surface treatment & Silver plated 10/12 Silver coated 6 micron thickness of silver coating micron. (d) Contact pressure Approx. 25 kg. Approx. 25 kg. Continuous current rating (Amps) 400 Amp 400 Amp Short time current rating KA (rms) 16 16 Rated peak short circuit current (KA 40 KA. 40 KA. peak) No. of operations which the switch can 1000 Nos 1000 Nos withstand without deterioration of contacts. Type of mounting. Horizontal Horizontal Type of Material used in Connector Brass, four bolt type Brass, four bolt type Location and type of Bushing At Rocking base, Bronze At Rocking base, Bush metal ring type
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06
07
08
09 10 11 12 13 14 15
16
Particulars of post insulators i) Make ii) Type iii) Strength iv) Weight v) No. of units per stack vi) Height of stack mm vii) Creepage distance mm (Min. 320) viii) One minute dry withstand voltage KV (rms) Power frequency ix) Power frequency flashover voltage KV (rms) x) Impulse flashover voltage KV (Peak) xi) Impulse withstand voltage KV (Peak) xii) Puncture voltage (KV)
AC/IP/JSI/BHEL Post Cantilever upright 550 Kg compression 3500kg 5 kg One 254 330 70 110 110 75 180
AC/IP/JSI/BHEL Post 10 KN 10 kg One 368 580 95 100 +178/-188 +170/-175 180
Note:
Post Insulators of all standard makes will be used for manufacture of AB Switches.
PROPERTIES OF I.U. RAIL POLES:CHEMICAL COMPOSITION PERCENT
C 0.60 0.85 0.10 0.50
SI 0.55 0.055
S 0.055 0.80
MN
01.055 1.40
MECHANICAL PROPERTIES Tensile strength MPa Percentage Elongation -----------------------------------------------840 Min 10.00 Min. 840 Min. 10.00 Min -----------------------------------------------------------------------------------------.
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11 KV AND 33 KV VACUUM CIRCUIT BREAKERS/ CURRENT TRANSFORMERS AND CONTROL PANELS SCOPE This specification covers design, manufacturing, testing at manufactures works, supply of 11KV and 33 KV Vacuum Circuit Breakers complete with all accessories required for their satisfactory operation for the subtransmission system of CG State Electricity Board. The Breakers shall be used for Transformer protection or Feeder Control, in the system. TYPE AND RATING The circuit breakers shall be suitable for outdoor operation under the climatic conditions, as specified in Tender specification, without any protection from sun and rain. The circuit breakers shall have the following rating:S.No. i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) PARTICULARS Number of Poles Frequency Nominal System Voltage Highest System Voltage Interrupting Capacity at nominal system voltage Rated Continuous Current Short-time Current Rating for 3 Secs. Basic Insulation Level Power Frequency Withstand Voltage for one Minute Total Break-time for any Current up to the rated breaking current Control Circuit Voltage Operating duty for gang operation The VCBs shall be suitable for one reclosing followed by one delayed reclosing and lock out Minimum clearances a) b) c) Between Phases Between Live Parts & Ground Creepage Distance 430 mm 3700 mm 900 mm 280 mm 2750 mm 300 mm 33 KV 11 KV 3 Nos. 50 Cycles 33 KV 11 KV 36 KV 12 KV 1500 MVA 250 MVA 1250 Amps 630 Amps 25 KA 12.5 KA 170 KV 75 KV 70 KV 28 KV 5 cycles (max.) 30 Volt D.C. O 0.3 Sec CO 3 Min CO
The above are our minimum requirements. The suppliers may offer their standard design, keeping in view our minimum requirements. STANDARDS The circuit breakers shall comply with the requirements of IEC 56 or IS 13118 (1991) with latest amendment thereof, except wherein specified otherwise. Equipment, meeting any other authoritative standard, which ensures equal or better quality then the standard mentioned above, would also be acceptable. The bidders shall clearly indicate the applicable standards to which their equipments complies-with. A copy of such standard may also be enclosed. GENERAL The circuit breaker shall be of porcelain clad vacuum type. The breaker, complete in all respect, shall be supplied with all accessories in-place and all internal wiring installed and terminated in the mechanism housing and the equipment shall be complete in all respects.
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The circuit breakers shall provide rapid and smooth interruption of current under all conditions, completely suppressing all undesirable phenomena, even under the most severe and persistent short-circuit conditions or when interrupting small currents or leading/ lagging reactive currents. The details of any device incorporated to limit or control the rate of rise of Restriking voltage across the circuit breaker contacts shall be stated. The over voltage caused by the circuit breaker switching on inductive or capacitive load shall not exceed 3.2 times the normal phase to neutral voltage. The total break-time for the circuit breaker, throughout the range of breaker operating duty, shall be stated in the tender and shall be guaranteed. The breaker shall be fit for capacitor switching for 5 MVAr Bank. The breakers shall be provided with trip free mechanism. The circuit breakers shall be suitable for mounting on steel structures. The cost of necessary frames for mounting the circuit breakers shall be included in the offered prices. Strongly supported bracket or frame, for mounting associated 3 nos.11 KV / 33 KV CTs, shall also be provided. All the structures shall be hot dip galvanized with 3 dips. Please note that cantilever type supports for mechanism box are not acceptable. The mechanism box shall have firm supports from bottom. This is necessary to minimize vibration of mechanism box, which in turn may disturb various settings. The agency shall indicate clearly the vibration level of the breaker during fault / normal ON OFF operations in all three directions. The owner intends to operate 11 KV and 33 KV feeders with automatic reclosing scheme, the arrangement envisaged is as under:On the occurrence of a fault the concerned protective relay will open the circuit breaker as per its own characteristic. Thereafter, the breakers shall re-close but after pre-set time delay, which shall be adjustable (say range 4 10 sec. or near about). There shall be no further automatic reclosing. A simple type of reclosing relay (reputed make) for this purpose shall be provided under this kind of operation. It is also necessary that the breaker shall be suitable for this reclosing duty. The auto-recloser relay is to be installed in respective indoor control panels. SPECIFICATION FOR CIRCUIT BREAKERS The circuit breakers shall consist of three identical phase units with a common operating mechanism. While offering the circuit breaker, the following details should be confirmed and furnished with the tender:i) ii) iii) iv) Complete construction details of the equipment offered. It should be noted that the breakers should be suitable for out-door duty. Indoor breakers accommodated in out-door kiosks are not acceptable. Type, make & source of vacuum bottles with relevant details shall be indicated in the offer, clearly. The capacity of breaker to interrupt inductive and capacitive currents shall be indicated in the offer (rating of capacitor bank should be stated and type test report shall be furnished). Spare availability of vacuum interrupter should be confirmed by the bidder for the designed expected life of the breakers being offered.
Formatted: Bullets and Numbering
Formatted: Bullets and Numbering Formatted: Bullets and Numbering
VACUUM INTERRUPTER The design of the vacuum interrupter shall be such that it gives trouble free operation under normal load and fault conditions throughout the life of the equipment. As the efficiency of the breaker depends on the degree of vacuum inside the interrupter, manufacturer shall ensure that the same is maintained consistently during service. To know the residual life of vacuum interrupter, an indicator to indicate the status of contact erosion shall be provided. The insulating ceramic body of the interrupter should have high mechanical strength and it should be capable of withstanding high temperature without any significant deterioration in its mechanical and electrical properties
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The metal/ alloy used for the fixed and moving contacts shall have very low resistivity and low gas content. They should be resistant to arc erosion and the contact should have no tendency to get cold-welded under the high vacuum in the interrupter. The interrupter design should ensure rapid de-ionization of the gap so that normal electrical strength of the gap is restored instantaneously. The metallic bellow or any other similar vacuum sealing arrangement should be provided at the moving contact and should have a long fatigue life. Manufacturers catalogue on vacuum bottle, indicating all the details shall essentially be submitted with the tender. MOUNTING OF 11 KV / 33 KV CTs The offered steel structures for breakers to be supplied by the bidders should have provision and adequate strength to accommodate 3 nos. 11 KV / 33 KV CTs on it after provision of suitable supports from ground. TEMPERATURE RISE The maximum temperature attained by any part of the equipment, when in service at site, under continuous full load conditions, exposed to the direct rays of the sun, shall not exceed 45 Centigrade, above ambient temperature. The limits of temperature rise shall be as per relevant standards. The corrections proposed shall be stated in the tender and shall be subject to approval of the owner. INSULATION OF THE CIRCUIT BREAKER The insulation to ground, the insulation between open contacts and the insulation between phases of the completely assembled circuit breaker shall be capable of withstanding satisfactorily di-electric test voltage corresponding to specified basic insulation level in the standard. INSULATORS The basic insulation level of the Insulator and insulating porcelains shall be as specified and porcelain shall be homogenous and free from cavities and other flaws. They shall be designed to have ample insulation, mechanical strength and rigidity for satisfactory operation under conditions specified above. All insulators of identical ratings shall be inter-changeable. The puncture strength of the insulators shall be greater than the flash over value. The insulators shall be type tested from independent Govt. Laboratory as per relevant standards or at any recognized and reputed international laboratory or testing institutions. OPERATING MECHANISM The circuit breakers shall be designed for remote control from the control room and in addition there shall be provision for manual operation of circuit breakers during maintenance and for local tripping and closing by the normal means. The circuit breakers shall have operation control and mechanical open close indicator, in addition to facilities for remote electrical indication. The operating mechanism shall be of the spring charging type, by electric control under normal operation. The mechanism shall be trip free electrically and mechanically. The mechanism shall be capable of performing satisfactorily, the reclosing duty cycles indicated above, within the time specified. All working parts in the mechanism shall be of corrosion resistant material and all bearings, which require greasing, shall be equipped with pressured grease fittings. The mechanism shall be strong positive quick in action and shall be removable without disturbing the other parts of the circuit breaker. The mechanism and breaker shall be such that the failure of any spring will not prevent tripping and at the same time will not cause any false tripping or closing. The operating Mechanism should be motor operated spring charged type preferably without chain drive. The motor for spring charging shall be suitable to perform satisfactorily for input supply voltage of 230 Volt A.C. 50 Hz with a
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variation of plus 10 and minus 20 percent. The A.C. Motor should have overload protection. Provision should also be made for mounting of mechanism box at an adequate height and gear ratios shall be so chosen that one man should be able to charge the spring, without any additional efforts. CONTROL CUBICLE A common control cubicle shall be provided to house electrical, controls, monitoring devices and all other accessories, except those which must be located on individual poles. The cubicle shall be gasketed and shall have weather-proof construction, fabricated from sheet steel of minimum 2.5 mm thickness. The type test report on degree of protection test (IP-55) shall also be furnished. The cubicle shall have front access door with lock and keys, space heater, internal illumination lamp, 3 pins 5 Amp socket with individual ON-OFF switches shall be provided in the cubicle. For local operation following shall be provided:a) LOCAL / REMOTE selector switch b) TRIP / NORMAL / CLOSE control switches with pistol grip handle The control circuits shall be designed to operate on 30 Volt DC, as indicated in the schedule and it shall be possible to adopt to work on other voltages by simply changing the operating coils. The shunt tripping coils shall be designed to operate satisfactorily within 110% and 70% of the rated DC supply voltage and the shunt closing coils should operate up to 85% of the rated DC voltage. These checks shall be repeated during precommissioning checks at site before putting the breakers in service. AC Power supply for auxiliaries will be available at 230 Volt (+/- 10% variation) single phases 50 C/s at substation. The agency shall be required to extend this supply, using proper protection, to desired location through cable. Necessary double compression type cable glands for the cables of the operating mechanism shall be provided. The cables used for operation are all un-armoured 2.5 sq. mm copper control cables of 1100 V grade. The cable glands shall be suitable for 1 no. 8 core and 2 nos. 4 core cables and cables as per site requirements. The gland plate should be made of non-magnetic materials and suitably drilled at site to suit the cable entry. The Circuit breaker shall be provided with trip free Mechanism so that tripping instructions could over-ride the closing instructions. An additional tripping coil shall also be provided in the trip circuit. The second coil shall have separate tripping lever arrangements in the mechanism, so as to avail full advantage of second trip coil. Also the two trip coils shall have separate fuses in the DC circuit, so that in the event of any short circuit/damage in any one of the trip coils, the supply is available to the other one. The circuit diagram of Control circuit of VCB along with operating instructions (DOS/ DONT) shall be embossed on metallic plate duly laminated and the same shall be fixed on the rear door of the control cubicle from inside. WIRING Wiring shall be completed in all respects to ensure proper functioning of the control, protection, monitoring and interlocking schemes. All the wiring shall be carried out with 1100 V grade, PVC insulated stranded copper conductor of 2.5 sq. mm as per IS: 1554. Each wire shall be identified at both ends with permanent markers bearing wire numbers as per wiring diagram. Wire termination shall be done with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals. All spare contacts of auxiliary switches etc. shall be wired up to terminal blocks in the control cubicle.
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TERMINAL BLOCKS Terminal blocks shall be of 1100 V grade, box clamp type ELMEX 10 sq. mm or approved equivalent. Not more than two wires shall be connected to any terminal. Spare terminals, equal in number to 20% of active terminals, shall be provided. Terminal block shall be such located to allow easy access. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals. TERMINAL CONNECTORS 6 Nos. Terminal bi-metallic connector suitable for Dog conductors shall be supplied with each breaker. For ensuring quality and uniformity, the owner may decide to specify the design of terminal connector, the material of terminal connector and thickness of clamps. Further compliance of which will have to be done by the agency without any extra cost. Suitable earth connector for earthing connections shall also be supplied. The connector drawing shall be got approved from the owner. AUXILIARY CONTACTS Eight numbers each of auxiliary contacts both of the normally open and normally closed types shall be provided in each circuit breaker for use in the remote indication and control scheme of the circuit breaker and for providing safety interlocking. Special contacts for use with trip coils, which permit for relative adjustment with respect to the travel of the circuit breaker contact, shall also be provided, wherever required. There shall be provision to add more auxiliary contacts at a later date, if required. ACCESSORIES The vacuum circuit breaker shall be supplied as a complete unit with internal wiring installed and terminated in mechanism box and equipped with the following accessories :1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Motor operated spring charged mechanism (Motor voltage 230 V AC) Trip coil suitable for 30 V DC Closing Coil suitable for 30 V DC Pistol grip C.B. Control switch having Trip/ Normal/ Close position Local/ Remote selector switch Spring Charged indicator Manual operating handle for maintenance Facility for manual charging of spring Operation counter Auxiliary contacts (8 NO-8 NC) Anti pumping device suitable for 30 V DC Terminal connectors suitable for connecting Dog Conductor Cubicle illuminating lamp with cage and switch Spare terminals connectors Mechanical ON/OFF Indicator MCB for both AC and DC supply Space heater and ON-OFF switch in the mechanism box Power Type 3 Pin Socket with ON-OFF switch Earthing Terminals LED indicating lamps 1 No. 2 Nos. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 Set 1 No. 6 Nos. 1 No. 20% of Total Terminals 1 No. 1 No. each 1 No. 1 Set 2 Nos. Complete set
Other standard accessories which are not specifically mentioned above, but are required for efficient and trouble free operation of breaker, should also be provided, without any extra cost.
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Indicating Bulbs: The indicating lamps should be supplied with Low Voltage protection Circuit ( LVGP ) and surge suppressor circuit having LED indication. Lamp assembly should be of fire retardant glass epoxy PCB, industrial heat resistant, fire resistant, non- Hygroscopic DMC material , chrome plated corrosion resistant solid brass bezel , polycarbonate lens in desired colour shades of Red , Green, Amber, Yellow etc. the intensity of light should be minimum 100 mcd at 20 mA . Indication lamp should be suitable to operate on 30 V Direct Current supply source. Acceptable make are BINAY Opto Electronic Private Ltd. or equivalent. TYPE TESTS Type test certificates on VCB for the following tests, strictly as per IS 13118, with latest amendment thereof, from any of the independent Govt. Laboratory, or at any recognized and reputed international laboratory or testing institution, shall invariably furnished : Short Circuit Duty Tests Short Time Current Rating Tests Mechanical Endurance Test Temperature Rise Test Lightning Impulse Voltage withstand Test Capacitor Switching Duty Test for Single Bank of 5 MVAR capacity Power Frequency withstand Voltage Test dry & wet Degree of protection IP-55 for control cubicle
The above type test certificates must accompany drawing of type tested equipment, duly signed by type testing authority. The above tests must not have been conducted on the equipment earlier than 5 years from the date of opening of bids. In case of any change in design/type of Breaker already type tested and the one offered against this specification, the owner reserves the right to demand repetition of type tests, without any extra cost. ACCEPTANCE AND ROUTINE TESTS All acceptance and routine tests, as stipulated in relevant standards, shall be carried out by the supplier, in presence of owners representative. Immediately after finalization of the programme of type testing, the suppliers shall give, fifteen days advance intimation to the owner, to enable him depute his representative for witnessing the tests. RATING PLATES The detailed rating plate shall be as per IS and in addition, shall indicate serial number of the equipment, manufacturers name, our order number and date. 5.0 INDOOR CONTROL PANELS FOR 11 KV & 33 KV VCBs
SCOPE: This section contains the technical specification for the Indoor Control, indication, relay and metering panels associated with the outdoor switchgear for use at various sub-stations. The control and relay panels and other requirements specified under this section shall be complete in themselves with all main and auxiliary relays, fuses, links, switches, wiring, labels, terminals blocks, earthing terminals, foundation bolts, illumination, cable glands etc. PANEL FINISH AND COLOUR: The owner has standardized that the colour finish of control panel shall be opeline green as per colour no. 275 of BS: 381C (1948). Equivalent colour as per relevant Indian Standards or any other standard shall be acceptable. This colour finish shall be applied to all the exterior steel work of the panels. The exterior finish shall be semi-glossy only and shall not be fully glossy. The interior of the panels shall be painted with egg shell white.
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PROTECTIVE RELAYS AND INSTRUMENTS: The protective relays shall be manufactured, tested and supplied with the guaranteed particulars, as per following Indian Standard Specifications with latest amendment thereof :i ii iii iv v IS-3842 (Part-I) 1967 Application guide for electric relays for A.C. Systems overcurrent relays for Feeders and Transformers IS-3842 (Part-IV) 1967 Application guide for electric relays for A.C. System thermal protection relays IS-3231 (1965) Electric Relay for Power System Protection IS-1885 (Part-I & II) Electro-technical vocabulary Electrical Relays & Electrical Power System Protection All indicating instruments shall conform to IS-722 or BS-89
The equipment meeting any other authoritative standard which ensures equal or better quality than the standards mentioned above shall also be acceptable. Equipment for which Indian Standards are not available the relevant British Standards and IEC recommendations will be applicable. STATIC/ MICRO-PROCESSOR BASED OVER CURRENT & EARTH FAULT RELAY: Static/ Micro Processor based non-directional triple pole IDMT over current and earth fault relays with 2 over current and 1 earth fault elements. However for transformer protection control panel the relay shall have all the three over current elements. Relays shall be suitable for 5 Amp. C.T. secondary current and 30 Volts DC auxiliary supply with 1.3/0.6 seconds operating time at 10 times current setting and instantaneous cut off features with setting 4 to 10 times of rated current with arrangement to by pass the features, when not required. The relay shall conform to following specifications:CURRENT SETTING RANGE: 50% to 200% in seven equal steps of 25% for over current elements. 10% to 40% in seven equal steps of 5% for earth fault element. However, setting in more than seven steps will be preferred. Further, change of settings under load condition should be possible without interruption of feeder. Resetting Current: More than 90% of setting value.
Transient over reach less than 3% on maximum and 5% on minimum setting for primary source angle upto 75 degree. Time of operation 30 seconds at times setting. Over shoot time of maximum 80 secs. at 10 times current. Pick Up Current: 1.1 times the current rating. Operating Time: 1.3/0.6 secs. at 10 times current with time multiplier 1.0. The setting should be in 10 times more, fixed calibrated steps from 0.01 to 1.0 and in between variable separately for over current and earth fault relays. Resetting Current: More than 90% of setting value. Resetting Time: Less than 5 m sec. Burden: Less than 1 VA. Accuracy: Clause 5 Contacts :Two sets of NO contacts (for Trip and Annunciation) self rest type suitable for make and break having continuous rating 1250 W/VA and 30 W/VA respectively. Operational Indicator: following requirements: Should be provided by way of LED for, ON, O/C 1, O/C 2, E/F, and should fulfill the
Must give permanent visual signal after fault is cleared and relay has been reset. Should operate with pulse time of less than 20 m sec.. Should not give indication until the trip pulse is being executed.
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Other: Facility to re-set indicating lamp manually should be provided. During testing / calibration of relays, facility for blocking tripping should be provided. Facility for self monitoring / test should be provided, so that hardware and software are constantly monitored and irregularities are immediately detected and signaled. In case of non-draw out type relays test socket alongwith test prob should be provided, so that calibrated current and values are checked as also current can be injected through and adaptor. Since the static relay are being procured by us to replace existing Electro Mechanical relays the relays should be provided with a blanking plate of 18 SWB MS sheet having dimension of 550x250mm and duly painted with gray paint. TYPE TEST CERTIFICATES FOR RELAYS: The bidders should submit the following type test certificates in respect of relays offered by them for their control panels: i) 5 KV Impulse peak voltage test on the relays. This type test report is essential for over current and earth fault relays. ii) Type test report for vibration test to prove the stability of relays under vibration normally encountered and also vibration under abnormal conditions. iii) Type test report for overshoot time for IDMT relays. NOTE: Regarding testing of the relays, reference may please be made to BS - 142 - 19. The tenders not accompanied with the above type test reports shall be rejected. PANEL CUT OUT AND DIMENSIONS i) The panels shall be fabricated from 14 SWG steel sheets free from all surface defects. The panels shall have sufficient structural reinforcement to ensure a plain surface to limit vibration and to provide rigidity during despatch and installation. All control panels and switchgear cubicles shall be made absolutely vermin-proof and subjected to the approval of the owner. Pre-treatment & painting of panels shall be done as per the procedure detailed at Sr. No. 21 of this schedule. The panels shall have the following dimensions:Height Width Depth 1475 mm 700 mm 300 mm
ii)
No deviation in height/ depth will be permitted. However, width can be increased depending upon the actual requirement, which shall be subjected to approval from the owner. iii) iv) The preferred panel cut out dimensions for mounting of the relays shall be as per Indian Standard Specification IS-4483 (Part I & II). The design, material selection and workmanship shall be such as to present a neat appearance, outside and inside with no works of welds, rivets, screw or bolt heads apparent from the exterior surface of the Control Panels. PANEL LIGHTING a) For interior illumination, an incandescent lamp/ 2 feet fluorescent tube operating at 230 Volt 50 Hz with switch shall be provided in each panel. The lamp/ tube shall be located at the ceiling and guarded with protective cage. The switch shall be mounted on one of the side walls and shall be easily accessible. One 5 Amp. 3 Pin receiptable with plug, switch and fuse shall be provided in each control panel. AUXILIARY SUPPLY a) For each Control Panel, the owner will provide the following:- 80 -
b)
i) ii) b) c)
230 V plus 10% minus 20%, 50 Hz neutral grounded A.C. supply. 30 V 10% D.C. supply.
H.R.C. fuses shall be provided by the agency for both the A.C. and D.C. power supplies. All H.R.C. fuses and links shall be with holder. The base of fuse holder shall be mounted on slant support and with identification labels. CONTROL WIRING
a)
The agency shall provide complete wiring up to the terminal block for the equipment, instrument devices mounted in the control panel strictly according to the wiring diagram prepared by the bidder based on the owners information and schematic diagram and get approved from the owner. b) The wiring shall be completed in all respects so as to ensure proper functioning the control, protection and metering schemes. Agency shall supply, lay and terminate all the control cables between VCB panel, Control panel (Indoor) and CT.
c) d)
All spare contacts of relays and switches shall be wired up to the terminal block. The Control Panels shall be supplied completely wired ready for owners external connections at the terminal blocks. For CT circuits the wiring shall be carried out with 1100 V Grade PVC insulated stranded copper conductor of size 2.5 sq. mm. For PT circuits and also for control circuits, the wiring shall be carried out with 1100 Volt Grade PVC insulated stranded copper conductor of size 1.5 sq. mm. Colour coded wires should be used to facilitate easy tracing, as under:i) Three Phase A.C. Circuit:Red for R Phase Yellow for Y Phase Blue for B Phase Black for Neutral Single Phase A.C. Circuit:Red for Phase Green for Earthing Black for Neutral D.C. Circuit:Red for Positive Black for Negative Control Wiring:Gray for annunciation and other control circuits.
e)
ii)
iii)
iv) f)
Each wire shall be identified at both ends with wire designation number by plastic ferrules, as per wiring diagram based on latest revision of IS-375 to denote the different circuit functions. The agency shall take approval for the system of wire numbering. All wire termination shall be made with solderless compression type connectors. Wires shall not be tapped or spliced between terminal points. All wire shall have crimp type termination and direct connection at any place is not at all required. All series connected devices and equipment shall be wired-up in sequence. Loop-in/loop-out system of wiring shall be avoided, as far as possible and the common buses shall normally be made through the terminal block for better reliability of testing and maintenance.
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g)
h)
i) j)
Fuses and links shall be provided for isolation of individual circuit from the bus wires without disturbing the other circuits and equipments. The DC trip and DC voltage supplies and wiring to main protective gear shall be segregated from these for back up protection and also for protective apparatus for special purposes. Each such group shall be fed through separate fuses, either direct from main supply fuses or the bus wires. Since a number of wires will run from one point to another, it is desired that the support arrangement should be adequate and neat. The conventional method of bunching of wire should not be adopted, since the same may create problems in case any wire is required to be removed. The wires should be accommodated in plastic channel with sliding plastic cover mounted inside the panel, suitably. Inspection/removal of wires should be possible by sliding the covers. Blank plastic channels should be provided by the sides of the panel to accommodate the incoming cables from switchyard through the cable glands. The circuit diagram of control circuit along with operating instructions (DOS/DONTS) embossed on metallic plate duly laminated shall be provided on rear side of the door. TERMINAL BLOCKS
k)
l) m)
a)
Multi-way terminal blocks complete with necessary binding screws and washers for wire connections and marking strips for circuit identification shall be provided for terminating the panel wiring and outgoing cables. The terminal block shall be suitable for receiving atleast 27/0.737 mm stranded copper or aluminum conductor wire per terminal. Terminal blocks shall have shorting and disconnection facilities. The panel-side and outgoing wires should be dis-connectable just by opening the disconnecting links which slide up or down without dislodging the wires from their position. Asea-Kirloskar type sliding links shall be provided. However, dis-connectable type terminal connectors may be limited to CT & PT circuits only. The terminal blocks shall be grouped according to circuit functions and each terminal block group shall have at least 20% spare terminals. CABLE ENTRY
b)
c)
a)
The control panel shall have provision of cable entry from the bottom. One no. cable gland for 8 cores and 2 nos. for 4 core 2.5 sq mm un-armoured cables duly fitted in gland plate and covered shall also be provided. The agency will arrange for necessary floor opening, below the panels to suit the requirement. Agency shall also be responsible for laying of control cable in trench, floor opening below the panel, trench cutting and making the damages good as per the satisfaction of Engineer in charge inside the control room. The wiring through terminal blocks shall be such located so that it is convenient for floor opening. The control panel shall have provisions inside for fixing the multi-core cable glands which shall be included by the bidder in scope of supply. For fixing these cable glands, detachable gland plates of 4 mm thickness shall be mounted at least 200 mm above the floor level. The cable gland plate and rear door shall be properly gasketed. Rigid supports shall be provided along the terminal block for holding plastic channel. Suitable clamps may also be provided in plastic channel for holding cables. GROUNDING
b) c)
d) e)
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a)
25 mm 6 mm copper round bus shall be provided extending along with the entire length of the panel and effectively grounding all metal structures. The earth bus should be designed for suitable inter connection with adjacent control panel which are to be placed side by side in the control room. Each continuous length of ground bus shall have provision of two terminals at two separate points for connection to ground. Potential and Current transformer neutrals shall be grounded only at the terminal blocks where they enter the control panel from the transformer. Wherever a circuit is shown grounded in the drawings, a single wire for the circuit shall run independently to the ground bus and connected to it.
b) c) d) DOORS
Each panel shall be completed with end enclosing sheets on both sides and door in the rear. There shall be one door with handle and also turn twist locks at top and bottom. Proper gasketing shall be provided on the door. A type test report from the recognized Govt. Laboratory on degree of protection test (IP-55) shall also be furnished with the tender. The doors should be grounded with flexible braided copper conductor of 10 sq.mm. CONTROL AND RELAY PANELS The control panels required for installation at all the sub-stations shall be of simplex type. The control and indication apparatus, all meters and relays shall be mounted in the front. The instruments and relays shall be flush pattern. The labeling for the circuits shall be provided at the front control panel, as well as on the inside wall. All indicating instruments, meters and important components shall have identification labels from inside also, in addition to outside. The terminal block shall also have identification labels to them, clearly indicating phases identifications and also circuits and instruments identification. For example, the terminal connector shall have an identification indicating that CT circuit for metering, for protection etc. Labeling should be provided by using 2 mm thick aluminium strip embossed with desired information and fitted in the panel sheet by means of rivets. PROTECTION SCHEME The protection schemes to be supplied under this control shall cover the following equipments: a) b) Transformers Overhead sub-transmission lines
The protection schemes are described in the following clauses:Transformer Protection :Transformer Control Panel is required for control/ protection on both 33 KV and 11 KV sides of 33/ 11 KV transformers. This will be in the form of a relay set having 2 Nos. O/C and 1 No. E/F elements in 11 KV Control Panel. In 33 KV Control Panel the relay set shall have 3 Nos. O/C elements. The current settings of O/C relay elements shall be from 50 to 200% and of E/F relay element from 10 to 40%. They shall be suitable to work on 30 Volt D.C. supply. The secondary rating of C.T. shall be 5 Amps. The over current and earth fault relays shall have operating time of 1.3 sec. at 10 times of plug setting current. The relays shall be of draw out type with CT shorting facility. Further, the relays shall have self re-set contacts and hand re-set flag arrangement. Besides this provision for alarm and tripping due to Buchholtz relay operation, OTI and WTI may be kept in the panel. Tripping on OTI, WTI and Buchholtz operation is also needed for both 33 KV and 11 KV transformer breakers panels. Feeder Protection :- 83 -
a)
Feeder Control Panel is required for control/ protection of both 33 KV & 11 KV sub-transmission lines. This will be in the form of a relay having 2 Nos. O/C and 1 No. E/F elements. The current settings of O/C relay element shall be 50 to 200% and of E/F relay element 10 to 40%. They shall be suitable to work on 30 Volt D.C. supply. The secondary rating of C.T. shall be 5 Amps. The over current and earth fault relays shall have operating time of 0.6 sec. at 10 times of plug setting current (in case of 11 KV Control Panels) and 1.3 sec. at 10 times of plug setting current (in case of 33 KV Control Panels). In this case also, the relays shall be of draw out type with C.T. shorting facility. Further, the relays shall have self re-set contacts with hand reset flag arrangement. The feeder control panel shall also have auto re-closing scheme. The re-closing relay time shall be adjustable between 4 to 10 sec. or near about in case of 11 KV Control Panel. In case of 33 KV Control Panel the reclosing relay time shall be adjustable between 10 sec. to 60 sec. for 1st shot and 30 to 180 sec. for 2nd shot after the repeat of tripping pulse from the protective relay. Suitable adjustment knob for the same shall be provided on the front of the relay for this purpose. CONTROL AND INDICATING CIRCUITS The control and relay panels shall have the following instruments, relays and accessories:1 no. - 3 Pole static type / software based relay, flush pattern, having 3 Nos. O/C element (settings 50 to 200%), suitable for operation on 30 V DC and 5 Amp. CT secondary rating (for 33 KV Transformer Control Panel). The relay shall have operating time of 1.3 seconds at 10 times of plug setting current, as mentioned above. 1 no. - 3 Pole static type / software based relay, flush pattern, having 2 Nos. O/C element (settings 50 to 200%) and 1 No. E/F element (settings 10 to 40%), suitable for operation on 30 V DC and 5 Amp. CT secondary rating (for 33 KV Feeder Control Panel, 11 KV Feeder Control Panel and 11 KV Transformer Control Panel). The relay shall have operating time of 1.3/ 0.6 seconds at 10 times of plug setting current, as mentioned in above para. 1 Set provision for alarm and tripping due to Buchholtz relay operation, OTI and WTI may be kept in the 33 KV transformer control panel. 1 Set - Auto reclosing relay with adjustable time delay between 4 seconds to 10 seconds. (for 11 KV Feeder Control Panel only). 1 Set - Auto reclosing relay with adjustable time delay between 10 seconds to 60 seconds for 1st shot and 30 to 180 seconds for 2nd shot (for 33 KV Feeder Control Panel only). 1 no 1 no Relay for OTI, WTI and Buchholtz operation tripping both in 33 KV and 11 KV Transformer breaker panel. Fully static energy meter for incomer and outgoing feeders energy and system parameters indication and record.
b)
1 no. - Auto/ manual selector switch (for panels with auto reclosing relays). 1 no. - Circuit Breaker Control switch (Push Button type) having Trip/ Neutral/ Close positions. 4 nos. - Lamps for circuit breaker ON, OFF, TRIP CKT HEALTHY and AUTO TRIP indications. LED indicating lamp complete with static circuits and features should be supplied with Low voltage protection circuit (LVGP) and surge suppressor circuit having LED indication. Lamp assembly should be of fire retardant glass epoxy PCB , industrial heat resistant, fire resistant, non hygroscopic DMC material, chrome plated corrosion resistant solid brass bezel, polycarbonate lens in desired colour shades of Red, Green , Amber, Yellow etc. the intensity of light should be minimum 100 mcd at 20 mA . Indication lamp should be suitable to operate on 30 V direct current supply source. Acceptable make are BINAY Opto Electronic Private Ltd. or equipment.
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1 no. - Ammeter 96 sq. mm. Square MISC type flush pattern having class 1.0 accuracy. The ammeter shall have dual scale 0-200/100 Amps. or 0-300/150 Amps as per requirement. 1 no. - Ammeter selector switch to indicate current in three R, Y and B phases. 1 no. - Voltmeter 96 sq.mm. Square MISC type flush pattern having class 1.0 accuracy with selector switch (for Transformer Control Panel. (The range of Voltmeter shall be 0-15 KV for 11 KV Control Panel and 0-40 KV for 33 KV Control Panel). 1 no. - Alarm bell for circuit breaker trip alarm. 1 no. - Alarm cancellation relay for C.B. trip alarm 2 nos.- Push Buttons for alarm ACCEPT & RESET 1 no. - DC Failure Visual indication by way of providing a lamp. 2 nos.- Push Button for testing healthy condition of trip circuit. (Separate circuits for Supervision of healthiness of two trip coils are required. Accordingly, the DC circuit complete with fuses etc. shall be separate for the two trip coils). 1 no. - Illumination lamp with cage and switch. 1 no. - Space heater with associated ON-OFF switch. 1 no. - Power type 3 pin 5 Amps plug and socket with ON-OFF switch and fuse. A trip healthy lamp shall be provided for each circuit breaker and connected in such a way as to indicate the healthy condition of the trip circuit. The lamp should have the indication on demand when breaker is on. Such indication is also necessary when the breaker is off, but it should be possible to check the trip circuit condition before closing the circuit breaker. In brief, pre and post close trip supervision facility on demand is required and shall be included. The automatic tripping of the circuit breaker due to operation of protective relays shall be indicated by a common audible alarm. The audible alarm shall be cancelled by the flag cancellation of relay, in case of relays of handreset type. Space shall be provided for provision of KWH meter, with proper sealing. NOTE: - Any other indications which are required for proper protection/ operation of circuit breaker should be provided in control panel, without any extra cost. RELAYS All relays, except where otherwise approved, shall be capable of breaking the maximum current which shall not be affected by vibration or by external magnetic fields. The contacts shall be of silver, platinum or other approved materials and shall be capable of repeated operation, without deterioration. All relays, which are connected to complete the tripping circuit breaker coil of the auxiliary tripping relay shall be provided with approved flag indication, which whenever possible, shall be mechanically operated type. Indicators shall also be provided on such additional relay elements as it will enable the type and phase of the fault condition to be identified. Each indicator, whether of the electrically or mechanically operated type, shall be capable of being reset by hand, without opening the relay case. Each indicator shall be so designed that it cannot move before the relay has completed its operation. It shall not be possible to operate any relay by hand without opening case. All relays shall be so arranged that on opening the case it shall be impossible for any dust, which may have collected in or upon the case to fall on the relay mechanism.
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Over current relays shall be of static type / software based and shall have inverse definite minimum time limit characteristics with separately adjustable time and current settings. Unless otherwise approved, the definite minimum time shall be continuously variable from 0.2 seconds and current setting range shall be variable between 50% and 200% in six equal steps of 25% each. The relay rating shall be 5 Amps. All relays shall be of draw out type and also that O/C and E/F relays shall have characteristics 1.3 second for protection of transformer on both primary as well as on secondary sides and 0.6 second characteristics for protection of 11 KV feeders. In case of 33 KV feeder protection, the characteristics operating time shall be 1.3 seconds. Further, these relays shall have self re-set contacts with hand re-set DC operated flag arrangement. Type test certificates for relays shall be submitted.
INSTRUMENTS All indicating instruments shall conform to IS 1248 and shall be of types and sizes specified under Sr. No. 15 above. They shall be capable of carrying their full load currents continuously without heating. They shall have long clearly divided and indelibly marked scales of engraved or enameled metal and the pointers shall be of clean outline. The pointers and scales shall be subject to approval. The marking on the dials shall be restricted to the scale marking. All indicating instruments, shall be provided with non-reflecting glass type fronts. All indicating instruments shall be of class 1.0 accuracy. Type test certificate for Ammeter and Voltmeter shall be submitted. The following may be carefully noted :i) ii) The components of alarm scheme shall be strictly in accordance with tender specification and shall be explained very clearly. The alarm scheme is required with Transformer Control Panel only. The scheme incorporated should ensure that flag resetting of relay is self-hand operated type. Thus it should not be necessary to reset the flag at the time alarm/ annunciation is accepted in case of fault. It should be possible to separately reset the flag, after the fault is attended.
The automatic tripping of the circuit breakers due to operation of protective relays shall be indicated by audible alarm. The offered alarm scheme shall be complete in all respects including one DC bell for trip alarm with a connector/ auxiliary relay suitable to handle breaking of DC bell current. The contactor/ auxiliary relay will get energized through the self-reset alarm contact of protective relay and will remain actuated by its own seal-in contact. A push button shall be provided to accept the alarm by breaking the seal-in circuit. TESTS o Each control panel shall be completely assembled, wired, adjusted and tested at the factory prior to despatch. The tests shall include wiring continuity tests, insulation tests and functional tests to ensure operation of the control scheme and individual equipment. The test procedures shall have prior approval of the owner. All instruments, meters and relays shall be tested and calibrated in accordance with relevant standards.
- 86 Formatted: Bullets and Numbering
o o
Formatted: Bullets and Numbering Formatted: Bullets and Numbering
All auxiliary instrument transformers shall be tested in accordance with procedure as laid down in relevant standards.
TEST WITNESSING The tests shall be performed in presence of owners representative. The agency shall give atleast fifteen (15) days advance notice of the date when the tests are to be carried out. TEST CERTIFICATE Copies of test certificates for all routine and acceptance tests shall be furnished to the owner for approval before despatch of the equipment from the works. Test certificates for important components used shall also be furnished along with drawings. PRE-TREATMENT AND PAINTING PROCESS The control panel sheet steel shall be subjected to pre-treatment process before painting. The process shall be carried out as under. The procedure can broadly be divided as Metal Treatment and Painting. A. METAL TREATMENT i) DEGREASING
This can be achieved either by immersing in hot alkaline degreasing bath or in hot dry chlorothelene solution. In case, degreasing is done by alkaline bath, rinse with cold water thoroughly. ii) PICKLING
This is to remove rust and metal scales by immersing in diluted sulphuric acid (approximately 20%) at nearly 80C until scale and rust are totally removed. iii) iv) Rinse in cold water in two tanks to remove traces of acids.
Treat with phosphoric acid base neutralizer, for removal of chlorine from the above acid pickling and again wash with running water. v) PHOSPHATING
Immerse in grenadine Zinc phosphate solution for about 20 minutes at 80 to 90C. The uniform phosphate coating of 4 to 5 gms. per sq. meter shall be achieved. vi) vii) viii) ix) B. PAINTING i) Spray one coat wet on wet specially developed, High Lusture Zinc chromate primer and stove at 150 to 160C for 25 to 30 minutes. Alternatively, Red-oxide primer with chromate content may be used. However, former process is preferred.
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Swill in cold water. Rinse in decxy to bath at 70 to 80C to neutralize any traces of salts. Seal the above phosphate coating with hot dilute chromate solution. Dry with compressed air
ii)
Rubbing and putting :Apply putty to fill up the scar, if any, to present smooth surface and stove 15 to 20 minutes. Apply putty several times to get perfectly smooth finish. iii) Surfacing :-
Sand down with mechanical abrasive and stove for 20 minutes. iv) Primer :-
Spray second coat of primer as per(i) above or grey primer surface wet on wet and stove for 30 to 40 minutes at 150C. v) Finish Paint :-
Rub down dry and spray first coat of synthetic enamel finish paint wet on wet and stove for 30 minutes. vi) Surfacing :-
Sand down or rub dry to prepare for final finish. Spray 2 coats o synthetic enamel finish paint wet on wet and stove it at 150C for 30 minutes. NOTE :i) ii) iii) Necessary stiffness may be welded between large cut outs to provide rigidity before painting process. Painting process shall be done within 24 Hrs. of completion of metal treatment. Small coating shall be supplied along with equipment for touching up at site.
PRESTRESSED CEMENT CONCRETE POLES FOR 11 KV & L.T. LINES (8.0 m long / 140 kgs.)
1.1
SCOPE This specification covers PCC poles with an overall length of 8.0 meter suitable for use in overhead 11 KV and L.T. power lines and double pole structures for 11/0.4 KV substations. APPLICABLE STANDARDS Except when they conflict with specific requirements in this specification, the poles shall comply with the relevant provisions made in the following Indian Standard Specification. a) IS : 1678-1978, Specification for prestressed concrete poles for overhead power, traction and telecommunication lines. b) IS : 2905-1966. Methods of test for concrete poles for over-head power and telecommunication lines. c) IS : 7321-1974. Code of practice for selection, handling and erection of concrete poles for over-head power and telecommunication lines.
1.2
1.3 1.4 1.5
TERMINOLOGY For the purpose of this standard, the following definitions shall apply :AVERAGE PERMANENT LOAD That fraction of the working load, which may be considered or long duration over a period of one year. LOAD FACTOR The ratio of ultimate transverse load to the transverse load at first crack.
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1.6
TRANSVERSE The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a straight run, this will be normal to the run of the line. TRANSVERSE LOAD AT FIRST CRACK For design, the transverse load at first crack shall be taken as not less than the value of the working load. WORKING LOAD The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on the pole. This load is assumed to act at a pint 600 mm below the top with the but end of the pole planted to the required depth as intended in the design. ULTIMATE FAILURE The conditions existing when the pole ceases to sustain a load increment owing to either crushing of concrete, or snapping of the pre-stressing tendon or permanent stretching of the steel in any part of the pole. ULTIMATE TRANSVERSE LOAD The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the axis of the ole along the transverse direction with the but end of the pole planted to the required depth as intended in the design. APPLICATION These poles shall be used at tangent locations for 11 KV and LT lines in wind pressure zones of 50 kg./m2, 75 kg./m2, and 100 kg./m2 in accordance with REC construction standards referred to in the following table :Pole Length 8.0 M Line Description 11 KV Line Without Earth Wire LT Lines, Vertical Formation Ref. to REC Constn. Stds. A-4 B-6 & B-2
1.7
1.8
1.9
1.10
1.11
The adoptable spans shall be as per REC construction standards A-8 (for 11 kV lines) and B-8 (for L.T. lines) or as per the practice in force in MPPKVVCL. 1.12 CEMENT The cement used in the manufacture of pre stressed concrete poles shall be ordinary or rapid hardening Portland cement conforming to IS: 269-1976 (Specification for ordinary and low heat Portland cement) or IS: 8041 E 1978 (Specification for rapid hardening Portland cement). AGGREGATES Aggregates used for the manufacture of pro-stressed concrete poles shall conform to IS: 383-1970 (specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregate shall in no case exceed 12 mm. WATER Water should be free from chlorides, suiphates, other salts and organic matter. will be generally suitable. ADMIXTURES Admixtures should not contain calcium chloride or other chlorides and salts which are likely to promote corrosion of pre stressing steel. PRE STRESSING STEEL The pre stressing steel wires, including those used as un-tensioned wires, should conform to IS: 1785 (Part- I)- 1966 (Specification for plain hard-drawn steel wire for pre-stressed concrete. Part l cold
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1.13
1.14
Potable water
1.15
1.16
drawn stress relieved wire), IS: 1785 (Part Il) 1967 (Specification for plain hard-drawn steel wire)., or IS: 6003- 1970 (Specification for intended wire for pre-stressed concrete). 1.17 The concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS: 1343- 1980 (code of practice for pre stressed concrete) and IS: 456- 1978 (code of practice for plain and reinforced concrete), subject to the following special conditions; a) b) c) d) Minimum works cube strength at 28 days should be at least 420 kg/cm2. The concrete strength at transfer should be at least 210 kg! cm2. The mix should contain at least 380 kg. Of cement per cubic mater of concrete. The mix should contain as low water content as is consistent with adequate workability If it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ration is maintained.
1.18
DESIGN REQUIREMENTS The poles shall be designed for the following requirements: a) The poles shall be planted directly in the ground with a planting depth of 1.5 meters. b) The working load on the poles should correspond to those that are likely to come on the pole during their service life. Designs given in Annexure I are for 140 kg applied to 0.6 m from top. c) The factor of safety for all these poles shall not be less than 2. 5. d) The average permanent load should be 40 % ~f the working load. e) The F.O.S. against first crack load shall be 1.0. f) At average permanent load, permissible tensile stress in concrete shall be 30 kg. Cm2. g) At the design value of first crack load, the modules of rupture shall not exceed 55.2 kg./Cm.2 for M 420 concrete. h) The ultimate moment capacity in the longitudinal direction should be at least one fourth of that in the transverse direction. i) The maximum compressive stress in concrete at the time of transfer of pre stress should not exceed 0.8 times the cube strength. j) The concrete strength at transfer shall not be less than half the 28 days strength ensured in the design, i.e. 420 x 0.5 = 210 kg. /cm2 For model check calculations of the design of poles, referred to in Annexure I, a reference may be made to the REC Manual on Manufacturing of solid PCC poles, Part- I Design Aspects.
1.19
MANUFACTURE All pre stressing wires and reinforcements shall be accurately fixed as shown in the drawings and maintained in position during manufacture. The un-tensioned reinforcement, as indicated in the drawings, should be held in position by the use of stirrups, which should go round all the wires. All wires shall be accurately stretched with uniform pre stress in each wire. Each wire or group of wires shall be anchored positively during casting. Care shall be taken to see that the anchorages do not yield before the concrete attains the necessary strength.
1.20
COVER The cover of concrete measured from the outside of the pre stressing tendon shall be normally 20 mm. WELDING AND LAPPING OF STEEL The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire. COMPACTING Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means, Hand compaction shall not be permitted. CURING
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1.21
1.22
1.23
The concrete shall be covered with a layer of sacking, canvas, Hessian or similarabsorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of pre stress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit; the interval should depend on the atmospheric humidity and temperature. 1.24 DE-TENSIONING The pre stressing wires shall be de-tensioned only after the concrete has attained the specified strength at transfer (i.e. 210 kg/cm2). The cubes cast for the purpose of determining the strength at transfer should be cured, as far as possible, under conditions similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS: 1343-1960 (code of practice for pre stressed concrete). The manufacturer shall supply when required by the purchaser or his representative, result of compressive test conducted in accordance with IS: 456-1964 (code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. It the purchaser so desires, the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS: 456- 1964 (code of practice for plain and reinforced concrete). (i) The de-tensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the poles. The rate of de-tensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. The poles shall not be de-tensioned or released by cutting the pre stressing wires using flames or bar croppers while the wires are still under tension. Separate eye-hooks or holes shall be provided for handling and transport, one each at a distance of 0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided for lifting purposes, should be perpendicular to the board face of the pole. Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported of timber sleepers located at 0.15 times the overall length. measured from the end. The timber supports in the stack should be aligned in a vertical line. Poles should be transported with their broad faces placed vertically and in such a manner that shocks are avoided. Supports should be so arranged that they are located approx. at a distance equal to 0.15 times the overall length from the ends. The erections of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis. i.e. the rope used for hoisting the pole should be parallel to the broader face of the pole.
(ii) (iii)
(iv)
(v)
1.25
EARTHING Earthing shall be provided by having a length of a 8 SWG Gl wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 50 mm. at 250 mm. from top and 150 mm below ground level. GENERAL For further details on the process of manufacture, a reference may be made to REC Manual on Manufacturing of Solid FCC Poles Part II Manufacturing Aspects. TESTS
1.26
1.27
A. Transverse strength test Poles made from ordinary Portland cement shall be tested only on the completion of days and poles made from rapid-hardening cement only on the completion of 14 days, after the day of manufacture.
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(i)
(ii) (iii) (iv) (v)
The pole may be tested in either horizontal or vertical position. If tested in horizontal position, provisions shall be made to compensate for the overhanging weight of the pole, for this purpose the over-hanging portion of the pole may be supported on a movable trolley or similar device. The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting i.e. 1.5 M. Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to design value of the transverse load at first crack. The deflection at this load shall be measured. A pie stressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. The load shall then be reduced to zero and increased gradually to a load equal crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80% of the minimum ultimate transverse load and thereafter increased by 5 % of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes The load applied to pre stressed concrete pole at the point of failure shall be measured to the nearest five Kg.
1.28
MEASUREMENT OF COVER After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The cover of the pole shall be measured at 3 points, ~ne within 1.8 meters from the butt end of the pole, the second within 0.6 meter from the top and the third at an intermediate point and the mean value compared with the specified value. (i) (ii) The mean value of the measured cover should not differ by more than 21 mm from the specified cover. The individual values should not differ by more than (+) (-) mm from specified value. If these requirements are not met, the workmanship with reference to aligning end plates and prestressing wires and assembly of moulds should be improved and inspection at preproduction stage tightened suitably.
1.29
SAMPLING AND INSPECTION
A. Scale of sampling Lot: In any batch, all poles of the same class and same dimension shall be grouped together to constitute a lot. Sub-lott: If the numbers of poles in a lot exceed 500, the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise Of a sub-lot shall be determined on the basis of the performance of samples selected from it. The number of poles to be selected from a lost or a sub-lot shall depend upon its size and shall be in accordance with Col. I and 2 of the following table: SAMPLE SIZE AND CRITERION FOR CONFORMITY Dimensional Requirement Sample Size Permissible No. of Defective Samples 1 2 3 Up to 100 10 1 101 to 200 15 1 201 to 300 20 2 301 to 500 30 3 * The number of Poles to be tested shall be subject to the agreement between the Supplier. Size of lot or Sublot
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No. of Poles for Transverse Strength Test 4 * 3 4 5 Purchaser and
These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any ole may be included in the sample, being the integral part of N/n where N is the size of the lot or the sub-lot and n is the sample size. 1.30 NUMBER OF TESTS All the poles as selected in 9.1.2 shaU be tested for overall length, cross-section and tolerance shall be () (-) 15 mm on overall length, (+) (-) 3 mm on cross sectional dimensions and 0.5 % on uprightness. The number of poles to be tested for transverse strength test shall be accordance with col. 4 of the above table. These poles may be selected from those already tested. 1.31 CRITERIA FOR CONFORMITY A lot of sub-lot shall be considered as conforming to this specification if the conditions are satisfied. The number of poles which does not satisfy the requirements of overall length, cross- section and uprightness shall not exceed the corresponding number given in Col. 3 of Table in 9.1.2 if the number of such poles exceeds the corresponding number, all poles in the lot or sub-lot shall be tested for these requirements and those not satisfying the requirements shall be rejected. All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more poles fail, twice the number of poles originally tested shall be selected from those already selected and subjected to the test. If there is no failure these poles, the lot or the sub-lot shall be considered to have satisfied the requirement of this test. 1.32 Marking The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in. position. a) Month and year of manufacture. b) Transverse strength of pole in kg. c) Makers serial no. and mark.
SPECIFICATION FOR 280 Kg 9.1 meter LONG SOLID TYPE PCC POLE
Prestressed cement concrete poles with factor of safety 2.5 when planted 1/6th in the ground and load applied at 2 from the toe. The poles will conform to IS:1678/1960 as per size mentioned below. 9.1 meters long pole working load 280 Kg, tope dimension 130mmx150mm & bottom dimension 360x50 mm. Earthing: All poles will be embedded with a continuousi) Length of 8 SWG galvanised steel wire. The earth wire should be continuous & shall be embedded in pole with ends brought out. ii) Two fitting holes should be provided in each pole
45 KN DISC INSULATOR
3.1 3.2
SCOPE This specification covers Porcelain Disc Insulator for use on 11 KV overhead power lines. STANDARD Except where they conflict with specific requirement in the specifications the Disc Insulator shall comply with the Indian Standard Specification IS 731/1971 and its amendment from time to time. GENERAL REQUIREMENTS The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.
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3.3
(i) (ii) (iii)
Unless otherwise specified, the glaze shall be~ brown in colour. The glaze shall cover alt the porcelain parts of the insulator except those areas, which serve as supports during firing or are left unglazed for the purpose of assembly. The design Of insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal. Cement used in the construction of the insulator shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as uniform as possible.
3.4 3.5
TYPE OF INSULATOR The insulator shall be of type B according to its construction INSULATOR CHARACTERISTICS The insulator shall have the electrical and mechanical characteristics which are given below:No. 1. 2. 3. 4. 5. Particulars Highest system voltage Wet power frequency/withstand voltage for one minute Visible discharge voltage Power frequency puncture withstand voltage Impulse withstand voltage Disc Insulator 12 KV (rms) 35 KV (rms) 9 KV (rms) 105 KV (rms) 75 KV (peak)
3.6
The test voltage of insulator shall be as under :In this standard, power frequency voltages are expressed as peak values divide by and impulse voltages are expressed as peak values. The with-stand and flashover voltage are referred to the reference atmospheric conditions. Minimum Failing Load : 45 KN
The insulator shall have minimum 230 mm creepage distance for a moderately polluted atmosphere. 3.7 A. TESTS The insulators shall comply with the following tests as per IS 731-1971. Type tests: The following constitute the type tests 1. Visual examination 2. Verification of dimensions 3. Visible discharge test 4. Impulse voltage withstand test 5. Wet power frequency withstand test 6. Temperature cycle test 7. Electro-Mechanical failing load test 8. Puncture test 9. Porosity test 10. Galvanizing test The test certificates from recognized Govt. lab for the tests carried out on prototype of same specifications shall be enclosed with the tender. B. Routine tests: 1. Visual examination 2. Electrical Routine tests 3. Mechanical Routine tests
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C.
Acceptance tests: Acceptance of samples after having withstood the routine tests shall be subjected to the following acceptance tests in the order indicated below:1. Verification of dimensions 2. Temperature cycle test 3. Electro Mechanical failing load test 4. Puncture test 5. Porosity test 6. Galvanizing test Tolerance in insulator dimensions shall be as per the relevant Indian Standard.
3.8
MARKING Each insulator shall be legibly and indelibly marked to show the followings: Name and trade mark of manufacturer Month and year of manufacture Minimum failing load in Newton Country of manufacture Marking of porcelain shall be printed I engraved and shall be applied before firing. Disk insulator without above marking shall not be accept~
3.9
PACKING All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport.
POST INSULATOR
4.1
SCOPE The specification covers Porcelain Post Insulator shells with metallic cap and base. These shells will be used for manufacturing of 11 KV Single Phasing AB switches / 3 phase AB Switches or n other equipment in the system. STANDARDS Post Insulator should conform latest applicable Indian I IEC standards and in particular to the IS 2544 specification for Porcelain Post Insulators. Polygon or compact solids core or long rod insulator is also acceptable. Creepage distance should be adequate for highly polluted outdoor atmosphere in open execution. The porcelain used for manufacture of post insulator shall be homogeneous free from flaws or imperfections that might affect the mechanical or dielectric quality. They shall be thoroughly vitrified through and impervious to moisture. The glazing of the porcelain shall be of uniform brown colour, free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any technical expansion differential between the metal and porcelain parts through the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized. The cap and base of the insulator shall be Interchangeable with each other. The cap and base shall be properly cemented with insulators to give perfect grip. Excess cementing shall be avoided. TEMPERATURE RISE The maximum temperature attained by any part of the insulator when in service at site under continuous full load conditions and exposed to the direct rays of sun shall not exceed 45 degree centigrade above ambient temperature. The corrections proposed shall be stated in the tender and shall be subjected to approval of the Owner INSULATOR CHARACTERISTICS
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4.2
4.3
4.4
The insulator shall have the electrical and mechanical characteristics, which are given below Highest system voltage Dry one minute power frequency withstand voltage Wet one minute Power frequency with stand voltage Power frequency puncture with stand voltage Impulse voltage withstand voltage Visible discharge voltage 12 KV (rms) 35 KV (rms) 35 KV (rms) 1.3 times the actual dry flash over voltage of the unit 75 KV (peak) 9 KV (rms)
In this standard power frequency voltages are expressed as peak values divided by and impulse voltage is expressed as peak values. The with-stand and flashover voltage are referred to the reference climatic conditions. 4.5 4.6 MECHANICAL CHARACTERISTICS The insulators shall be suitable for the minimum failing load of 10 KN. Nature of load will be transverse. CREEP PAGE DISTANCE The minimum creep page distance of 11 KV Post Insulators shall be 320 mm for highest system voltage of 12 KV. PACKING All insulator shall be packed in wooden creates suitable for easy but rough handling and acceptable for rail and road transport. TEST The insulator shall comply with following tests as per IS 2544 (1973). Type tests Type tests are normally carried-out once and unless otherwise agreed to, test certificates giving the results of type tests, made on not less than 2 post insulators and post insulators unit identical in all essential details with those to be supplied are regarded as evidence of compliance. The tests should be carried out on two samples in the order mentioned below: (i) Test on both Insulators: 1. Visual examination 2. Verification of dimensions 3. Visible discharge test 4. Impulse voltage withstand test 5. Wet power frequency voltage withstand test 6. Dry power frequency voltage withstand test 7. Temperature cyclic test (ii) Test on first Insulators: 1. Mechanical strength test 2. Porosity test 3. Puncture test 4. Galvanizing test The contactor shall invariably enclose with offer; the type test certificates and guaranteed technical particulars. B. Routine tests: The following shall be carried out as routine tests: 1. Visual examination. 2. Electrical routine test
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4.7 4.8 4.9
C.
Acceptance test: The test samples after having withstand the routine test shall be subject to the following acceptance tests in the order indicated below: 1. Verification of dimensions 2. Temperature cyclic test 3. Mechanical strength test 4. Puncture test 5. Porosity test 6. Galvanizing test Tolerance in insulator dimensions shall be as per the relevant Indian Standards. MARKING Each insulator shall be legibly and indelibly marked to show the following: 1. Name and trade mark of the manufacturer 2. Month and year of manufacturing 3. Minimum failing load in KN 4. Country of manufacturing The above marking on porcelain shall be engraved and shall be applied before firing. Post insulator, without above markings shall not be accepted under any circumstances. DESIGN, MATERIALS AND WORKMANSHIP The successful tenderer shall assume full responsibility for co-ordination and adequate design. All materials used in the manufacturing of insulator shall be of the appropriate class well finished and of approved design and make. All similar parts should be accurately finished and interchangeable. All ferrous parts including bolts & nuts etc. used on the post insulators shall be heavily hot dip galvanized. Specific attention shall be paid to tropical treatment to the entire insulator, as it will be subject during service, to extremely severe exposure, to atmospheric moisture and to long period of high ambient temperature.
BOLTS AND NUT
4.9
4.10
5.1
lSl Marked bolts and nuts made of black mild steel shall conform to IS: 6639 and galvanized as per IS: 1367 Part 13)! lS-2629. All bolts and nuts shall have hexagonal heads, the heads being forged out of solid truly concentric, and square with the shank, which must be perfectly straight.. (i) Bolts up to M16 and having length up to 10 times the diameter of the bolt should be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. The shear strength of bolt for 5.6 grade should be 310 MPA minimum as per IS 12427. Bolts should be provided with washer face in accordance with IS: 1363 Part I to ensure proper bearing. Nuts should be double chamfered as per the requirement of IS: 1363 Part-III 1984. The manufacturer should ensure that nuts should not be over tapped beyond 0.4 mm oversize on effective diameter for size up to M16. Fully threaded bolts shall not be used The length of the bolt shall be such that the threaded portion shall not extend into the place of contact of the component parts. All bolts shall be threaded to take the full depth of the nuts and threaded ito permit the firm gripping of the component parts but no further. It shall be ensured that the threaded portion of the bolt protruded not less than 3 mm and not than 8 mm when fully tightened. All nuts shall fit and tight to the point where of the bolt connects to the head. Flat washers and spring washers shall be provided wherever necessary and shall be of positive lock type. Spring washers shall be electro-galvanised. The of washers shall conform to IS: 2016. The Bidder shalt furnish bolt schedules giving thickness of components connected the nut and the washer and the length of shank and the threaded portion of bolt and size of holes and any other special details of this nature. To obviate bending stress in bolt, it shall not connect aggregate thickness more than three time its diameter. Bolts at the joints shall be so staggered that nuts may be tightened with spanners without fouling.
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(ii) (iii) (iv)
(v) (vi) (vii)
(viii)
To ensure effective in-process quality control it is essential that the manufacturer should have all the testing facilities for tests like weight of zinc coating, shear strength, other testing facilities etc, in-house. The agency should also have proper Quality Assurance system which should be in line with the requirement of this Jon and IS 14000 services Quality System standard. Fasteners of grade higher than 8.8 is not to be used.
5.2 5.3
RAW MATERIALS MS round 16mm /12mm used shall be tested for quality as per IS: 2062 Gr. A. SPECIFICATION OF FINISHED PRODUCTS The bolts & Nuts shall be ISI Marked Mild Steel of Black Grade B and shall be round with hexagonal head. (i) (ii) The Bolts and Nuts shall be manufactured by Hot/Cold forging process neatly and cleanly finished and shall have metric threads as per IS : 4218/1967 with its latest amendments. The dimensions of the bolts & nuts and tolerances should conform to IS: 1363 with their latest amendments in all respect. The eccentricity and angular errors of various elements shall be within specified limits as per IS: 1367/1967 with its latest amendments the bolts & nuts shall be free from forging and threading defects such as cuts, spats. burns, bulging taper eccentricity, loose fill etc. which may affect their serviceability. The colt heads and nuts shall be chamfered on one face only and other face shall be machined made. Mechanical property requirement of tester shall conform to IS: 1367 (Part-III) 1979 property class 4.6 for bolts & property class-5 for nuts as per IS: 1367 (Part VI) 1980. The bolts & nuts shall be supplied in well-cleaned conditions and suitably protected against corrosion in individual bags of 50 kgs.
(iii) (iv) (v)
5.4
ACCEPTANCE TESTS The bidder should furnish test certificate from his awn/recognized Govt. Laboratory giving the results of tests as per IS: 1367 (Part-Ill) 1979 & IS: 1367 (Part-VI) 1980 withnessed by M,F,P.KV.V.C,L. Jabalpurs inspecting officer for each lot under inspection. The test certificate shall be in respect of the following for all sizes of both bolts & nuts as applicable given below:1. Dimensional particulars (Sampling Ifl accordance with IS: 2614 for both bolts & nuts (tolerance as per drawing). 2. Tensile strength test on full size (for bolts minimum 400 NI Sq.mm and for Nuts Proof Stress test Mm 610 N/Sq. mm). 3. Power load test on full size bolts and M-12-51400 N for 15 Sec. 4. Head soundness tests for bolts (no fracture). 5. Brinell hardness tests or Rockwell Hardness or Vickerss Hardness tests for bolts min-114 & max. 209 or mm. 67 & max. 95 or mm. 120 & max. 220 respectively. For nuts Vickerss Hardness mm. 130 & max. 302.
5.5
PRE-DESPATCH INSPECTION AND TEST The bidder shall arrange to carryout acceptance tests in presence of owners inspecting officer in his own laboratory. In case testing facilities are not available at works he will make necessary arrangements for carrying out these tests at a Govt. recognized lab at his own expense(s) and will provide all testing arrangement for Boards representative to witness the tests. MARKINGS On the bolt head, there shall be identification marking of the manufacturer as well as property class 4.6. If possible property class 5 shall be marked on Nuts also. Further ISI mark shall be marked on Sunny Bags for proper identification.
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5.6
TECHNICAL PARTICULARS FOR ACSR/AAA CONDUCTORS
1. SCOPE: This specification provides for the Manufacture , Testing before despatch , supply and delivery of ISI Marked Aluminium Conductors Galvanised Steel Reinforced (ACSR) and All Aluminium Alloy (AAA) conductors. 2. STANDARD: The conductor shall strictly comply with the Indian Standard Specification IS:398 (Part-1 & 2)/1996 & (Part-4)/1994 with the latest amendments unless otherwise stipulated in this specification , or any other International Standards which ensure equal or higher quality material and workmanship. 3. MATERIAL: 3.1. The conductors offered shall be of best quality and workmanship. The steel reinforced aluminium conductors shall be manufactured of hard drawn EC Grade aluminium wires and high tensile galvanised steel wires of the sizes as specified in Table-I and with mechanical and electrical properties as specified in Table-II . The coating on the galvanized steel wires may be applied by hot process or electrolytic process in accordance with IS:4826-1979(specifications for hot dipped galvanized coatings on round steel wires). AAA conductor shall however be constructed of heat treated aluminium magnesium silicon alloy wire . 3.2 The wires shall be smooth and free from all imperfections such as spills and splits and rolling and wire drawing defects etc., resulting in reduction in cross sectional area over the entire length . 4. TOLERANCE: The following tolerance shall be permitted:-
(i) Tolerance on Nominal diameter of Aluminium wires plus/minus 1%. (ii) Tolerance on Nominal diameter of High Tensile Galvanised Steel Wires plus / minus 2%. 5. MODULUS OF ELASTICITY AND CO-EFFICIENT OF LINEAR EXPANSION: The values of the final modulus of elasticity and co-efficient of linear expansion of ACSR/AAA conductor shall be as given hereunder:-
Item No. of wires Final modulus of elasticity GN/mm2(practical) Coefficient of linear expansion per 0 C Density at temp. of 20 0 C ACSR 6/1(Al./Steel) 79 19.1X10-6 for ACSR conductor 7.8gm/cm3 (Steel )2.703gm/cm3(Al.) ACSR 6/7(Al./Steel) 75 19.8X10-6 for ACSR conductor 7.8gm/cm3 (Steel)2.703gm/cm3 (Al.) AAAC 7 0.6324X106 kg/cm2 23.0X10-6 for Alu. Alloy 2.7 kg/dm3 (Al. Alloy) The wires of Aluminium Alloy conductor shall be of heat treated aluminium , magnesium , silicon alloy having composition appropriate to the technical and electrical properties as specified in Table_i of IS:398(Pt-4)/1994. 6. JOINTS IN WIRES: (a) No two joints shall be permitted in the aluminium strands closer than 15 metres. (b) No joints shall be permitted in galvanized steel wires. (c) In AAA conductors there shall be no joint in any wire/stranded conductor containing wires except those made in the base rod or wire before final drawing . 7. STRANDING:
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7.1 The wires used in the manufacturing of a stranded conductor before stranding satisfy all requirement of IS:398(Part-2 & 4)/1996 & 1994 with its latest amendments. The lay ratio of the layer shall be within the limit given under clause-8 below. 7.2 In all construction , the successive layers shall have opposite directions of lay . The outermost layer being right handed . The wires in each layer shall be evenly and closely stranded. 8. LAY RATIO: The lay ratio ( ratio of the axial length of a complete turn of the helix formed by an individual wire in a stranded conductor to the external diameter of the helix ) shall be within the limit given below :Item No. of wires Ratio ofAluminiumWire dia toSteel wire dia Lay ratio for Aluminium wire Alum-inum Steel Total Max. Min. ACSR Conductor 6 1 7 1 14 10 ACSR Conductor 6 7 13 3 14 10 AAA Conductor 7(Al.Alloy) NA 7(Al.Alloy) NA 14 10
9. PACKING AND MARKING: (A) The conductor shall be wound in non-returnable reels or drums conforming to IS:1778-1981 ( Specifications for reels and drums for bare wire ) or the latest version thereof . The drums shall be marked with the following details :(a) Manufacturers name (b) Trade Mark , if any (c) Drum No. & identification Number (d) Size of conductor (e) Number and lengths of pieces of conductor on each drum (f) Gross mass of the packing (g) Net mass of conductor (h) ISI or relevant international standard specification mark , if any (i) Name and address of the consignees. 10. PACKING CONDITION: 10.1 The reels/drums shall be of such constructions as to assure delivery of conductors free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that the conductor surface is not dented , scratched or damaged in any way during manufacture , transport and erection . The conductor shall be properly lagged on the drums. 10.2 The conductor drums should be suitable for wheel mounting . Before reeling , the cardboard or other suitable material shall be secured to the drum and inside flanges of the drums . After reeling the conductor , the exposed surface should be wrapped with suitable soft material e.g. polythene sheet etc. across the flanges to protect the conductor from dirt , grit and damage during transportation and handling and also prevent ingress of rain water during storage / transport. 10.3 All wooden components shall be manufactured out of seasoned wood of good quality free from defect that may materially weaken the component parts of the drums . Preservative treatment for anti-termite / antifungus shall be applied to the entire drum with preservatives of a quality which is not harmful to the conductor . 11. STANDARD LENGTH AND GROSS WEIGHT OF CONDUCTOR: The gross weight of each packing shall not exceed to the following limits subject to a tolerance of 10% . (i) For Steel Reinforced Aluminium Conductor of 20 mm2 and 30 mm2 Size ( & equivalent sizes of 22 mm2 & 34 mm2 of AAA Conductor) (Code word Squirrel & Weasel respectively .) (ii) For Steel Reinforced Aluminium Conductor of 50 mm2 and 80 mm2 Size ( & equivalent sizes of 55 mm2 & 80 mm2 of AAA Conductor) (Code word Rabbit & Raccoon respectively .) - 1000 Kg
- 1500 Kg
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The standard wire length for ACSR/AAA shall be 2 kms except for 80 mm2 of ACSR & equivalent size of AAA conductor (code word Raccoon) and 50mm2 of ACSR & equivalent size of AAA conductor (code word Rabbit) , for which it shall be 1.2 kms and 1.5 kms respectively . Longer lengths shall be acceptable . Short lengths of not less than 50% of the standard lengths , as indicated above , shall be acceptable to the maximum extent of 10% of the quantity ordered for each size. 12. TESTS: 12.1 Samples of individual aluminium , aluminium alloy and steel wires for tests shall be taken before stranding from not less than 10% of the spools/coils . If samples are taken after stranding, they shall be obtained by cutting 1.2 metres from the outer end of the finished conductor from not more than 10% of the reels . 12.2 The mechanical tests shall be carried out on single wires only and not on complete conductor .
12.3 The following tests shall be carried out on Aluminium wires as per detailed procedure given in IS:398(Part-II)/1996 and on Aluminium Alloy wires as per detailed procedure given in IS:398(Part-4)/1994 :(a) Breaking load test.((in both i.e. ACSR/AAA conductors) (b) Elongation test. (in case of AAA conductors only) (c) Wrapping test.(in case of ACSR conductors only) (d) Resistance test.( in both i.e. ACSR/AAA conductors) 12.4 The following tests shall be carried out on galvanized steel wire as per detailed procedure given in IS:398(Part-2)/1996 :(a) Breaking load test. (b) Ductility test (by either of the procedures viz. Torsion test or Elongation test) (c) Wrapping test. (d) Galvanising test.(the uniformity of Galvanising and the weight of coating shall be in accordance with IS:4826-1968) 12.5 The Rejection and Re-test procedure shall be followed as stipulated in IS:398(Part-2)/1996 and IS:398(Part-4)/1994. 13. CHECKING AND VERIFICATION OF LENGTH OF CONDUCTORS: The supplier/manufacturer of conductor should arrange for the inspection by the representative of the purchaser specially authorised for this purpose . At least 5% of the total number of drums of conductors taken at random should be checked to ascertain the lengths of conductor adopting either of the following two methods :(a)The drum alongwith the conductor should be weighed and six empty drums alongwith protective laggings & studs etc. normally used for winding the conductor should also be weighed . Net weight of the conductor should be calculated by subtracting the average weight of the six empty drums from the gross weight of the conductor and drums . Having known the weight of the conductor , the length of the conductor can be computed. In case of empty conductor drums , a check weighment of every one in ten empty drums shall also be done before the conductors are wound on the drums . (b)Arrangements should be made available in the works of the manufacturer for transferring the conductor from one reel to another at the same time measuring the length of the conductor so transferred by means of a meter . Percentage shortage , if any , in the length thus obtained and as declared by the supplier in the packing list shall be applied to all the drums . 14. CHECK MEASUREMENT: Where length of conductor is verified by weighment basis , the determining factor will be length/weight ratio of the sample drums verified at the firms premises of the lot of which the drum under measurement at the consignees end forms a part .
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(i) Wherever at the end of the consignee , length measurement machines are available , conductors shall be accepted by verification of lengths only and where the length measurement machines are not available , conductor shall be accepted on weighment basis . (ii) In case , where the recorded weight on the drum tallies with the measured weight at consignees end , then the conductor length shall be accepted as recorded on the drum . In other cases , the determining factor will be wight/lenth ratio of the sample(s) inspected at the firms premises of the lot of which the drum under measurement at the consignees end , forms a part . The factors of weight/length ratio shall however be made available to the consignees in the despatch instructions itself . If such factors are not available due to some reasons , actual measurement of diameter shall be made and weight/length ratio shall be obtained for the purpose of computing length .
TECHNICAL SPECIFICATION FOR, R.S.JOIST.
a. MICRO ALLOYING ELEMENTS:Elements, such as niobium, vanadium and titanium, added singly or in combination to obtain higher strength levels combined with better formability, weld ability and toughness as compared with non alloyed steel produced to equivalent strength levels. b. WELDABILITY:A metallic substance is considered to be weldable by a given process and for the given purpose, when metallic continuity to a stated degree can be obtained by welding using a suitable procedure, so that the joints comply with the requirements specified in regard to both their local properties and their influence on the construction of which they form a part. 3) 4) SUPPLY OF MATERIALS:General requirements relating to supply of weldable structural steel shall confirm to IS 8910. GRADE OF MATERIAL:The material shall be of Grade A. Other details shall be as mentioned in IS 2062:1999 and its latest amendments. FREEDOM FROM DEFECTS:ii) All finished steel shall be well and cleanly rolled to the dimensions, sections and masses specified. The finished material shall be reasonably free from surface flaws, laminations, rough/jagged and imperfect edges and all other harmful defects. iii) Minor surface defects may be removed by the manufacturer by grinding provided the thickness is not reduced locally by more than 4 percent below the minimum specified thickness. Reduction in thickness by grinding greater than 4 percent, but not exceeding 7 percent may be allowed. CHEMICAL COMPOSITION:The ladle analysis of the steel, when carried out by the method specified in the relevant parts of IS 228 for the required materials shall be strictly as below:Designatio n Fe 410 WA Ladle analysis, percent, and max. Carbon Equivalent (CE) Max Si 0.40 0.42 Deoxidatio n mode Supply condition Semi killed or killed 9) SELECTION & PREPARATION OF TEST SAMPLES:The selection and preparation of samples for testing of the material should be done strictly as per the clause no. 9.1 to 9.9 of IS 2062 Part I/1999.
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7)
8)
Grade
C 0.23
Mn 1.50
S 0.05
P 0.05
As rolled
10)
TESTS:The following tests are to be conducted and required to confirm as per relevant test as specified in the IS 2062:1999 as below:S.No. 1. 2. 3. 4. Name of test Tensile test Bend test Impact test Y groove crack ability test Clause no. of IS 2062:1999 10 (10.1 to 10.3.2) 11 (11.1 to 11.3.1) 12 (12.1 to 12.4) 13
11) Grade: -
MECHANICAL PROPERTIES:A Fe 410 WA 410 MPa
Designation Minimum Tensile strength in MPa: Minimum Yield Stress in MPa: <20 mm 20 40 mm >40 mm Percent elongation at Gauge Length 5.65 So min. Internal diameter of Bend (Min.) Charpy Y-Notch Impact Energy J, Min 12) 13) 14)
250 Mpa 240 Mpa 230 Mpa
23 3t --
15)
DIMENSIONS:The nominal dimensions of R.S. Joist required in the table shown in the "SCOPE" of this schedule and shall be in accordance with the relevant IS as mentioned in table 4 of the IS 2062: 1999 at Page No. 6. TOLERANCES: The rolling and cutting tolerances for steel products conforming to IS 2062 : 1999 shall be those specified in IS 1852. The aforesaid tolerances shall be strictly followed. RETEST: Should any one of test pieces first selected fail to pass any of the tests specified in this standard, two further samples shall be selected for testing in respect of each failure. Should the test pieces from both these additional samples pass, the material represented by the test samples shall be deemed to comply with the requirements of that particular test. Should the test pieces from either or these additional samples fail, the material represented by the test samples shall be considered as not having complied with this standard. MARKING:a. Each products with the exception of round, square and hexagonal bars and flats, shall carry a tag or be marked with the manufacturer's name or trade mark. Bars and flats shall carry a tag bearing the manufacturer's name or trade mark. Designation of steel should also be similarly marked on the product or tag
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b. 16)
The ends of the rolled product shall be painted with Green colour.
BIS CERTIFICATION MARKING:The material may also be marked with Standard Mark according to Bureau of Indian Standards Act 1986 and the rules and regulations made there under. CHEMICAL COMPOSITION AND PHYSICAL PROPERTIES OF STEEL SECTIONS CONFORMING TO IS-2062/84 AND ITS SUBSEQUENT AMENDED CHEMICAL COMPOSITION FOR FE 10 WP GRADE 0.23% 1.5% 0.050% 0.50% 0.40% 0.42% MAX. MAX. MAX. MAX. MAX. MAX.
1. 2. 3. 4. 5. 6.
C Mn. S P SI CE
Carbon Equivalent MECHANICAL PROPERTIES 1. Tensile strength kgf/mm2 Min - 42, N/Min. - 410 2. Yield stress Min. for thickness/diameter < 20mm - 26 Kgf/mm2 OR 250N/mm2 20-40mm - 24 Kgf/mm2 OR 240N/mm2 > 40mm - 23 Kgf/mm2 OR 230N/mm2 3. Elongation % - 23 Min. 4. End test (Internal Dia) Min 3-t (t is the thickness of the material)
TECHNICAL SPECIFICATION OF DIFFERENT STEEL SECTION
1) Scope: This tender is floated for the purchase of 948 MT M.S. H Beam 37.1 kg/metre152 x 152 mm length 11 mtr. The specifications with quantity conforming to relevant IS nos. are as below:S. No. 1 2) 3) Relevant IS to which it shall conform IS 2062: 1999 and latest amendment Material Particulars Gr. A
The above material is required IS mark and of standard quality conforming to the following important technical point along with relevant IS. The steel products conforming to the requirement of this specification can be rolled from the cast billet ingots, billets, blooms, slabs and continuously cast billets, blooms or slabs conforming to IS 2830:1992 "Carbon steel cast billet ingots, billets, blooms and slabs for re-rolling in to steel for general structural purposes (second revision)".
TECHNICAL SPECIFICATION FOR, H-BEAM
a. MICRO ALLOYING ELEMENTS:Elements, such as niobium, vanadium and titanium, added singly or in combination to obtain higher strength levels combined with better formability, weld ability and toughness as compared with non alloyed steel produced to equivalent strength levels. b. WELDABILITY:A metallic substance is considered to be weldable by a given process and for the given purpose, when metallic continuity to a stated degree can be obtained by welding using a
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suitable procedure, so that the joints comply with the requirements specified in regard to both their local properties and their influence on the construction of which they form a part. 4) 5) SUPPLY OF MATERIALS:General requirements relating to supply of weldable structural steel shall confirm to IS 8910. GRADE OF MATERIAL:The material shall be of Grade A. Other details shall be as mentioned in IS 2062:1999 and its latest amendments. FREEDOM FROM DEFECTS:iv) All finished steel shall be well and cleanly rolled to the dimensions, sections and masses specified. The finished material shall be reasonably free from surface flaws, laminations, rough/jagged and imperfect edges and all other harmful defects. v) Minor surface defects may be removed by the manufacturer by grinding provided the thickness is not reduced locally by more than 4 percent below the minimum specified thickness. Reduction in thickness by grinding greater than 4 percent, but not exceeding 7 percent may be allowed. CHEMICAL COMPOSITION:The ladle analysis of the steel, when carried out by the method specified in the relevant parts of IS 228 for the required materials at S.No. 1 to 40 shall be strictly as below:Designatio n Fe 410 WA Ladle analysis, percent, and max. Carbon Equivalent (CE) Max Si 0.40 0.42 Deoxidatio n mode Supply condition Semi killed or killed 18) 19) SELECTION & PREPARATION OF TEST SAMPLES:The selection and preparation of samples for testing of the material should be done strictly as per the clause no. 9.1 to 9.9 of IS 2062 Part I/1999. TESTS:The following tests are to be conducted and required to confirm as per relevant test as specified in the IS 2062:1999 as below:S.No. 1. 2. 3. 4. Name of test Tensile test Bend test Impact test Y groove crack ability test Clause no. of IS 2062:1999 10 (10.1 to 10.3.2) 11 (11.1 to 11.3.1) 12 (12.1 to 12.4) 13 As rolled
7)
17)
Grade
C 0.23
Mn 1.50
S 0.05
P 0.05
20)
MECHANICAL PROPERTIES:Grade: Designation

- 105 -
A Fe 410 WA
Minimum Tensile strength in MPa: Minimum Yield Stress in MPa: <20 mm 20 40 mm >40 mm Percent elongation at Gauge Length 5.65 So min. Internal diameter of Bend (Min.) Charpy Y-Notch Impact Energy J, Min 21)
410 MPa
250 Mpa 240 Mpa 230 Mpa
23 3t --
22) 23)
24)
25)
DIMENSIONS:The nominal dimensions of Angle, Joists, Channel, Plates, rounds, Flats, Tor-steel, I.U.M.S. Rail, Hbeams etc. are required as per S.No. 1 to 43 of the table shown in the "SCOPE" of this schedule and shall be in accordance with the relevant IS as mentioned in table 4 of the IS 2062: 1999 at Page No. 6. TOLERANCES: The rolling and cutting tolerances for steel products conforming to IS 2062 : 1999 shall be those specified in IS 1852. The aforesaid tolerances shall be strictly followed. RETEST: Should any one of test pieces first selected fail to pass any of the tests specified in this standard, two further samples shall be selected for testing in respect of each failure. Should the test pieces from both these additional samples pass, the material represented by the test samples shall be deemed to comply with the requirements of that particular test. Should the test pieces from either or these additional samples fail, the material represented by the test samples shall be considered as not having complied with this standard. MARKING:a. Each products with the exception of round, square and hexagonal bars and flats, shall carry a tag or be marked with the manufacturer's name or trade mark. Bars and flats shall carry a tag bearing the manufacturer's name or trade mark. Designation of steel should also be similarly marked on the product or tag b. The ends of the rolled product shall be painted with Green color. BIS CERTIFICATION MARKING:The material may also be marked with Standard Mark according to Bureau of Indian Standards Act 1986 and the rules and regulations made there under.
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Technical Specifications 11kv

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Technical Specifications

GENERAL CONSTRUCTION PRACTICES

Pin insulator ties:

Technical Specification of Items

TECHNICAL SPECIFICATION OF 11 & 33 KV PIN INSULATOR - 14 -

Marking on porcelain shall be printed/engraved and shall be applied before firing.

porcelain insulator shall be manufactured and tested 7. 8. Tolerance in dimensions if any

731/1971 As per ISS

Weight per unit of a. Porcelain Part To be indicated b. Thimble To be indicated ----------------------------------------------------------------------------------------------------------------.

Steel Head Nuts, Flat & spring washers

Failing load Drawing ref.of IS:2486 (Part-II)

2 I II. III IV V. VI VII VIII IX X

Method of Galvanizing TESTS Dip test Mass of zinc coating

Applicable specifications: (with latest amendments, if any)

6 7. 8. I. II. III. IV. V. VI. VII. VIII. IX. X.

TECHICAL SPECIFICATION OF11KV DISC INSULATOR

ii) (A) S.N.

i. ii. iii. (B) S.N.

ACSR Conductor (Squirrel) ACSR Conductor (Weasel) ACSR Conductor(Rabbit) AAAC:Item

20 mm2 30 mm2 50 mm2

Stranding & wire dia of Actual Area AA Alloy

AAA Conductor (Squirrel) AAA Conductor (Weasel) AAA Conductor (Rabbi)

(7/2.00 mm) (7/2.50 mm) (7/3.15 mm)

22 mm2 34 mm2 55 mm2

3. Turn Buckle Bow

4. Eye Bolt Rod 16mm dia + 5% - 3%

3. Turn Buckle Bow

4. Eye Bolt Rod 16mm dia + 5% - 3%

TECHNICAL SPECIFICATION FOR HOT DIP GALVANISED MS STRANDED WIRE

260 247 Heavy Hard

240 208 Heavy Hard

8 3.15 mm 5962 kgf 10% 144 mm 216 mm

8 3698 Kgf 10% 113.4 mm 170.1 mm

TECHNICAL SPECIFICATION FOR HOT DIP GALVANISED MS SOLID WIRE

3 dips 3 dips of 1 min. of 1 min. & 1 dip each of 1/2 min.

10 (4 time of d) 12.6 mm N.A. N.A N.A.

12. Freedom from defect 13. Chemical composition

As per schedule II (A) page 10.1, S.No.6

90 days : 3 months : 125 cm.

SN 01. 02. 03. 04.

TECHNICAL SPECIFICATION OF EARTHING COILS

(vii) Creepage distance in mm (minimum) (viii) Cantilever strength (KN)

10. Creepage of insulator 320 --------------------------------------------------------------------------------------------------------------------------.

: SDV-5 : Single : 9KV (RMS)

5KVA (5000 A) : : : : 24 KV (RMS) -58 KV (Peak) 65 KV (Peak)

-42 KV (Peak) 46 KV (Peak) 52 KV (Peak)

75 Amp. 1000 Microsecond : 4 Kgs. : : 390 mm Not Applicable

To be furnished by the manufacturer.

TECHNICAL PARTICULARS OF LT SHACKLE INSULATORS SIZE 90x75 mm AND 65x50 mm

05. 06. 07. 08. 09. 10. 11.

ITEM: SIZE: VARIETY:

504 grms. kg (+) 5%

i ii iii iv v vi vii vii

() 10 mm () 1.0 mm () 0.22 mm () 0.5 mm () 3 mm () 0.45 mm () 0.45mm () 0.15 mm

300 grams per sq. meter