Spec BPI Karaikudi
Spec BPI Karaikudi
Spec BPI Karaikudi
TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
SECTION - 1
1.1 SCOPE
This technical specification covers the requirements of design, manufacture, testing at works,
packing and dispatch of 420 kV and 145 kV Insulators to site.
This section covers the scope and quantities of 420 kV & 145 kV Insulators. The Specific
Technical Requirements for the above item as specified by the customer (POWERGRID) are
given in Section-2. The offered equipment shall also comply with the General Technical
Requirements for the project as detailed under section-3 of this specification.
In case of any discrepancies between the requirements mentioned under Section-1/Section-2 and
those specified in the Section-3, the specifications given under Section-1/Section-2 shall prevail
and shall be treated as binding requirements.
All equipments shall perform satisfactorily under various other electrical, electromechanical and
meteorological conditions of the site of installation.
All equipment shall be able to withstand all external and internal mechanical, thermal and
electromechanical forces due to various factors like wind load, temperature variation, ice
& snow, (wherever applicable) short circuit etc for the equipment.
Sl.
Technical Parameters 420kV 145kV
No.
1 Type Solid core
2 Voltage class (kV) 420 145
3 Impulse withstand voltage (dry & wet) (kVp) ± 1425 ±650
Switching surge withstand voltage (dry and
4 ± 1050 NA
wet) (kVp)
Power frequency withstand voltage (dry &
5 680 275
wet) (kVrms)
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Page 1 of 4
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
1) For insulators for isolators- bottom PCD 325mm and for bus post insulators-bottom
PCD 300mm
2) ** 25mm/kV for Karaikudi, Pagular & Abhishekpatty station and 31mm/kV for
Kalivanthapattu station.
Insulators shall also meet requirement of IEC-60815 for 420 kV and 145 kV
systems, as applicable having alternate long & short sheds. Insulator shall be
type and routine tested as per IEC-60168.
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Page 2 of 4
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
Kalivan-
Sl. Karaikud Abhishek
Description Unit Pugalur thapatt
No i -patty
u
420 kV,8kN Solid Core Post
Insulators as Bus Post
1 Nos. 20 20 20 07
Insulator complete in all
respects (with corona ring)
420 kV,8kN Solid Core Post
Insulators as Support Post
2 Insulator for wave traps Nos. 24 24 24 06
complete in all respects
(without corona ring)
420 kV,10kN Solid Core
Post Insulators as Support
3 Post Insulator for Isolators Nos. 144 162 162 54
complete in all respects
(without corona ring)
145 kV, 6kN Solid Core Post
Insulators as Bus Post
4 Insulator complete in all Nos. ---- 02 02 ----
respects
145 kV,6kN Solid Core Post
Insulators as Support Post
5 Nos. ---- 06 06 ----
Insulator for Isolators
complete in all respects
Mandatory Spares (listed in
6 Lot 1 1 1 1
clause 1.3.2)
NOTE:
Post insulator shall be supplied complete with Hot Dip Galvanised hardware for inter unit
joining and fixing to structure (both top & bottom).
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Page 3 of 4
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
Bidder shall submit valid type test reports (as per relevant IEC/IS Standard) for approval. The
type test reports submitted shall be of tests conducted within last 10 years prior to the date of bid
opening i.e. 17.05.13. The bidder should have conducted type test on identical or similar
equipment/ components to those offered. In case type test reports are found to be technically
unacceptable to BHEL/PGCIL, the type test shall be conducted without cost and delivery
implication to BHEL.
QUALITY PLAN
Bidder to follow valid PGCIL approved Quality Plan as per PGCIL procedure. In case the bidder
don’t have PGCIL approved QP, it will be the bidder’s responsibility to get its QP approved
directly from the ultimate customer.
1.5 NOTE:-
1) All switchgears/ equipments, insulator strings, bushings, BPIs shall be designed for
minimum creepage distance of 31mm/kV instead of 25mm/kV for other three stations.
2) The rate of zinc coating for galvanized lattice and pipe structures (excluding foundation
bolts and fasteners) shall not be less than 900gm/sq. m instead of 610gm/sq. m for other
three stations.
3) Outdoor atmosphere around the substation is highly polluted coupled with coastal
pollution. Suitable paint and corresponding primers etc. as recommended by paint
manufacturer shall be used to withstand the outdoor atmospheric condition.
4) Kalivanthapattu substation falls under high wind zone and basic wind speed shall be
considered as 50m/sec.
--xx--
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Page 4 of 4
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
SECTION – 2
STANDARD SPECIFICATION
2.0 GENERAL
This section covers the standard technical specification for Bus Post Insulator.
The post insulators shall conform in general to latest IS: 2544, IEC-60168, IEC-60273
and IEC-60815.
2.3.1 Post type insulators shall consist of a porcelain part permanently secured in a metal
base to be mounted on the supporting structures. They shall be capable of being
mounted upright. They shall be designed to withstand any shocks to which they may
be subjected to by the operation of the associated equipment. Only solid core
insulators will be acceptable.
2.3.2 Porcelain used shall be homogeneous, free from lamination, cavities and other flaws or
imperfections that might affect the mechanical or dielectric quality and shall be
thoroughly verified, tough and impervious to moisture.
2.3.3 Glazing of the porcelain shall be of uniform brown in color, free from blisters, burrs
and other similar defects.
2.3.4 The insulator shall have alternate long and short sheds with aerodynamic profile, The
shed profile shall also meet the requirements of IEC-815 for the specified pollution
level.
2.3.5 When operating at rated voltage there shall be no electric discharge between conductor
and insulators which would cause corrosion or injury to conductors or insulators by the
formation of substance produced by chemical action.
2.3.6 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulators shall not lead to deterioration.
2.3.7 All ferrous parts shall be hot dip galvanized in accordance with the latest edition of IS:
2633, IS: 2629 & IS: 4579. The zinc used for galvanizing shall be grade Zn 99.95 as
per IS: 209. The Zinc coating shall be uniform, adherent smooth, reasonably bright,
continuous and free from imperfections such as flux ash, rust stains bulky white
Section - 2 Page 1 of 5
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
deposits and blisters. The metal parts shall not produce any noise generating corona
under the operating conditions.
2.3.8 a) Every bolt shall be provided with a steel washer under the nut so that part of
the threaded portion of the bolts is within the thickness of the parts bolted
together.
b) Flat washer shall be circular of a diameter 2.5 times that of bolt and of suitable
thickness. Where bolts heads/nuts bear upon the beveled surfaces they shall be
provided with square tapered washers of suitable thickness to afford a seating
square with the axis of the bolt.
c) All bolts and nuts shall be of steel with well formed hexagonal heads forged
from the solid and shall be hot dip galvanized. The nuts shall be good fit on the
bolts and two clear threads shall show through the nut when it has been finally
tightened up.
Bidder shall make available data on all the essential features of design including the
method of assembly of shells and metals parts, number of shells per insulator, the
manner in which mechanical stresses are transmitted through shells to adjacent parts,
provision for meeting expansion stresses, results of corona and thermal shock tests,
recommended working strength and any special design or arrangement employed to
increase life under service conditions.
2.3 Tests
The post insulators shall be subject to type, acceptance, sample and routine tests as per
IS: 2544 and IEC-168
2.3.1 Type test reports shall be furnished for the following type tests for approval and
waiver.
a) Power frequency withstand test (dry & wet)
b) Lighting impulse test (dry)
c) Switching Impulse test (wet) (for 420 kV insulator only)
d) Test for deflection under load
e) Test for mechanical strength
f) Measurement of RIV (dry) and Corona extinction voltage test (dry). The test
procedure for same is given in Appendix-1
However, bidder shall also indicate the test charge for conducting these tests in the
offer, in case the owner desires to get these tests carried out.
2.3.2 In addition to acceptance/sample/routine tests as per IS: 2544 and IEC-168, the
following tests shall also be carried out.
a) Ultrasonic test as an acceptance test
b) Soundness test, metallurgical tests and magnetic test on MCI caps and pedestal
tests as acceptance test.
Section - 2 Page 2 of 5
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
c) All hot dip galvanized components shall be subject to check for uniformity of
thickness and weight of zinc coating on sample basis.
d) The bending test shall be carried out at 50% minimum failing loads in four
directions as a routine test and at 100% minimum failing load in four directions
as an acceptance test.
e) Acceptance norms for visual defects allowed at site and also at works shall be
agreed in the quality plan
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Section - 2 Page 3 of 5
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
APPENDIX - A
1.0 General:
Unless otherwise stipulated, all equipment together with its associated connectors, where
applicable, shall be tested for external corona both by observing the voltage level for the
extinction of visible corona under failing power frequency voltage and by measurement of
radio interference voltage (RIV).
3.2 Alternatively, RIV tests shall be in accordance with NEMA standard Publication No. 107-
1964, except otherwise noted herein.
3.3 Temporary additional external corona shielding may be provided in measurement of RIV.
Only standard fittings of identical type supplied with the equipment and a simulation of the
connections as used in the actual installation will be permitted within 3.5 meters of terminals.
3.4 Ambient noise shall be measured before and after each series of tests to ensure that there is no
variation in ambient noise level. If variation is present, the lowest ambient noise level will
form basis for the measurements. RIV levels shall be measured at increasing and decreasing
voltages of 85%, 100%, 115% and 130% of the specified RIV test voltage for all equipment
unless otherwise specified. The specified RIV test voltage for 400 kV and 220 kV is listed in
Section -1/ Section -2 of the specification together with maximum permissible RIV level in
micro-volts.
3.5 The measuring instruments shall be as per CISPR recommendation or equivalent device so
long as it has been used by other testing authorities.
3.6 The RIV measurement may be made with a noise meter. A calibration procedure of the
frequency to which noise meter shall be tuned shall establish the ratio of voltage at the high
voltage terminal to voltage read by noises meter.
Section - 2 Page 4 of 5
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
disappears. The procedure shall be repeated at least four times with corona inception and
extinction voltage recorded each time. The corona extinction voltage for purpose of
determining compliance with the specification shall be the lowest of the four values at which
visible corona (negative or positive polarity) disappears. Photographs with laboratory in
complete darkness shall be taken under test conditions, at all voltage steps i.e. 85%, 100%,
115% and 130%. Additional photographs shall be taken at corona inception and extinction
voltages. At least two views shall The photographed in each case using Panchromatic film
with an ASA daylight rating of 400 with an exposure of two minutes at a lens aperture of f/5.6
or equivalent. The photographic process shall be such that prints are available for inspection
and comparison with conditions as determined from direct observation. Photographs shall be
taken from above and below the level of connector so as to show corona on bushing, insulators
and all parts of energised connectors. The photographs shall be framed such that test object
essentially, fills the frame with no cut-off.
The test shall be recorded on each photograph. Additional photographs shall be taken from
each camera position with lights on to show the relative position of test object to facilitate
precise corona location from the photographic evidence.
In addition to photographs of the test object, at least four photographs shall be taken of the
complete test assembly showing relative positions of all the test equipment and test objects.
These four photographs shall be taken from four points equally spaced around the test
arrangement to show its features from all sides. Drawings of the laboratory and test set up
locations shall be provided to indicate camera positions and angles. The precise location of
camera shall be approved by Purchaser's inspector, after determining the best camera locations
by that energisation of test object at a voltage which results in corona.
The test to determine the visible corona extinction voltage need not be carried out
simultaneously with test to determine RIV levels.
However, both tests shall be carried out with the same test set up and as little time duration
between tests as possible. No modification on treatment of the sample between tests will be
allowed. Simultaneous RIV and visible corona extinction voltage testing may be permitted at
the discretion of Purchaser's inspector if, in his opinion, it will not prejudice other test.
In addition to the information previously mentioned and the requirements specified as per
CISPR or NEMA 107-1964 the following data shall be included in test report:
a) Background noise before and after test.
b) Detailed procedure of application of test voltage.
c) Measurements of RIV levels expressed in microvolts at each level.
d) Results and observations with regard to location and type of interference sources
detected at each step.
e) Test voltage shall be recorded when measured RIV passes through 100 microvolts in
each direction.
Onset and extinction of visual corona for each of the four tests required shall be recorded.
Section - 2 Page 5 of 5
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
SECTION-3
Particular Details
a) Customer Power Grid Corporation of India Limited
a) Altitude above sea Less than Less than Less than Less than
level 1000m 1000m 1000m 1000m
b) Ambient air temp.
50°C 50°C 50°C 50°C
(Max)
c) Special corrosion Yes
conditions No No See note No
below
d) Snow fall Nil Nil Nil Nil
e) Seismic zone As per IS 1893
f) Wind zone As per IS 875 (also see note below)
g) Pollution Severity High High Very High High
Pollution Pollution Pollution Pollution
level level level level
(25mm/kV) (25mm/kV) (31mm/kV) (25mm/kV)
Note:-
Following additional requirements shall be met for Kalivanthapattu substion
extension:
1) All switchgears/ equipments, insulator strings, bushings, BPIs shall be designed for
minimum creepage distance of 31mm/kV instead of 25mm/kV for other three
stations.
2) The rate of zinc coating for galvanized lattice and pipe structures (excluding
foundation bolts and fasteners) shall not be less than 900gm/sq. m instead of
610gm/sq. m for other three stations.
3) Outdoor atmosphere around the substation is highly polluted coupled with coastal
pollution. Suitable paint and corresponding primers etc. as recommended by paint
manufacturer shall be used to withstand the outdoor atmospheric condition.
4) Kalivanthapattu substation falls under high wind zone and basic wind speed shall
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Section 3 Page 1 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
be considered as 50m/sec.
1.0 GENERAL
f) The Bidder shall clearly indicate in the bid, the specific standards in
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Section 3 Page 2 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
g) The equipment must be new, of highest grade, the best quality of their
kind, to best engineering practice and latest state of art, and in accordance
with purpose for which they are intended and ensure satisfactory
performance throughout the service life.
h) All similar parts of the equipment shall be made to gauge and shall be
interchangeable with and shall be made of same materials and
workmanship as the corresponding parts of the equipment. Where
feasible, common components, units shall be employed in different pieces
of equipment in order to optimize the spare part stock-up and utilization.
a) The equipment furnished under this specification shall perform all its
functions and operate satisfactorily without showing undue strain, restrike
etc.
b) The equipment shall be able to withstand forces due to wind load, short
circuit, system over voltages, fluctuations, frequency variations etc., all
forces considered together.
a) The support structures should be hot dip galvanised with minimum 610
gram/m2 net of zinc.
4.0 STANDARDS
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Section 3 Page 3 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
5.1 The furnishing of engineering data by the Contractor shall be in accordance with
the Schedule for each set of equipment as specified in this Technical
Specification and the data furnished under the Schedule of Data Requirements
(DRS). The review of these data by the Employer will cover only general
conformance of the data to the specifications and documents, interfaces with the
equipment provided under the specifications, external connections and of the
dimensions which might affect overall layout. This review by the Employer may
not indicate a thorough review of all dimensions, quantities and details of the
equipment, materials, any devices or items indicated or the accuracy of the
information submitted. This review and/or approval by the Employer shall not be
considered by the Contractor, as limiting any of his responsibilities and liabilities
for mistakes and deviations from the requirements, specified under these
specifications and documents.
5.2 All engineering data submitted by the Contractor after final process including
review and approval by the Employer shall form part of the Contract Document
and the entire works performed under these specifications shall be performed in
strict conformity, unless otherwise explicitly requested by the Employer in Writing.
b) The reports for all type tests and additional type tests as per technical
specification shall be furnished by the Contractor alongwith equipment /
material drawings. The type tests conducted earlier should have either been
conducted in accredited laboratory (accredited based on ISO / IEC Guide 25
/ 17025 or EN 45001 by the national accredition body of the country where
laboratory is located ) or witnessed by the representative(s) of
POWERGRID or Utility. The test reports submitted shall be of the tests
conducted within last 5 (five) years prior to the date of bid opening. In case
the test reports are of the test conducted earlier than 5 (five) years prior to
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Section 3 Page 4 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
the date of bid opening, the contractor shall repeat these test(s) at no extra
cost to the purchaser.
In the event of any discrepancy in the test reports i.e. any test report
not acceptable due to any design / manufacturing changes (including
substitution of components) or due to non-compliance with the requirement
stipulated in the Technical Specification or any/all additional type tests not
carried out, same shall be carried out without any additional cost implication
to the Purchaser.
c) The Purchaser intends to repeat the type tests and additional type tests on
Capacitors for which test charges shall be payable as per provision of
contract. The price of conducting type tests and additional type tests shall
be included in Bid price and break up of these shall be given in the relevant
schedule of Bid Proposal Sheets. These Type test charges would be
considered in bid evaluation. In case Bidder does not indicate charges for
any of the type tests or does not mention the name of any test in the price
schedules, it will be presumed that the particular test has been offered free
of charge. Further, in case any Bidder indicates that he shall not carry out a
particular test, his offer shall be considered incomplete and shall be liable to
be rejected.
d) Four (4) copies of all test reports shall be submitted for approval before
shipment of equipment. The reports shall indicate clearly the standard
values specified for each test, to facilitate checking of the test reports. Six
(6) bound copies of test reports shall be submitted after approval of test
results.
f) 1 RTF and 8 copies of all drawings for each substation plus 6 copies and
one RTF of each drawing for corporate office shall be furnished after
approval of drgs. 6 copies of instruction/operation manuals for each
substation and corporate centre shall also be furnished after approval of
manuals.
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Section 3 Page 5 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
NOTE : The contractor may please note that all resubmissions must
incorporate all comments given in the prior submission by the
Employer failing which the submission of documents is likely to be
returned.
i) All exposed ferrous parts shall be hot dip galvanised as per IS : 2633 & IS :
4579.
j) All current making and breaking contact surfaces shall preferably be silver
plated.
l) Each drawing submitted by the Contractor shall be clearly marked with the
name of the Employer, the unit designation, the specifications title, the
specification number and the name of the Project. If standard catalogue
pages are submitted, the applicable items shall be indicated therein. All
titles, notings, markings and writings on the drawing shall be in English.
All the dimensions should be in metric units.
SYSTEM PARAMETERS
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Section 3 Page 6 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
6.1 The Employer or the Contractor may propose changes in the specification of the
equipment or quality thereof and if the parties agree upon any such changes,
the specification shall be modified accordingly.
6.2 The Bidder should however note that changes proposed by him will have to be
supported with applicable type test reports.
6.3 If any such agreed change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any change in
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Section 3 Page 7 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
the price and/or schedule of completion before the Contractor proceeds with the
change. Following such agreement, the provision thereof, shall be deemed to
have been amended accordingly.
7.1 To ensure that the equipment and services under the scope of this Contract
whether manufactured or performed within the Contractor’s Works or at his Sub-
contractor’s premises or at the Employer’s site or at any other place of Work are in
accordance with the specifications, the Contractor shall adopt suitable quality
assurance programme to control such activities at all points necessary. Such
programme shall be outlined by the Contractor and shall be finally accepted by
the Employer after discussions before the award of Contract. A quality
assurance programme of the contractor shall generally cover the following :
g) Inspection and test procedure both for manufacture and field activities.
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Section 3 Page 8 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
n) A quality plan detailing out the specific quality control measures and
procedure adopted for controlling the quality characteristics relevant to
each item of equipment furnished and /or service rendered.
o) System for various field activities i.e. unloading, receipt at site, proper
storage, erection, testing and commissioning of various equipment and
maintenance of records”. In this regard, the Employer has already prepared
Standard Field Quality Plan for Switchyard Civil Works Document Code No.
CC/QA&I/SFQP/SS/03/970905/Rev.1 which is required to be followed for
associated civil works. Field Quality Plan pertaining to receipt, storage,
erection, testing and commissioning shall be mutually discussed and agreed
upon before placement of order.
The Employer or his duly authorised representative reserves the right to
carry out quality audit and quality surveillance of the system and
procedure of the Contractor/his vendor’s quality management and control
activities.
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Section 3 Page 9 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
8.1 The Employer, his duly authorised representative and/or outside inspection
agency acting on behalf of the Employer shall have at all reasonable times
access to the Contractor’s premises or Works and shall have the power at all
reasonable times to inspect and examine the materials and workmanship of the
Works during its manufacture or erection and if part of the Works is being
manufactured or assembled at other premises or works, the Contractor shall
obtain for the Employer and for his duly authorised representative permission to
inspect as if the works were manufactured or assembled on the Contractor’s own
premises or works. The equipment if found unsatisfactory as to workmanship or
material is liable to be rejected.
8.2 The Employer reserves the right to witness any or all type, acceptance and
routine tests specified for which at least 30 days notice in advance shall be given
by the Contractor. Contractor shall ensure before giving notice for type test
that all drawings and quality plans have been got approved. The equipment shall
be dispatched to site only after approval of Routine and Acceptance test
results and Issuance of Dispatch Clearance in writing by the Employer.
8.3 The Contractor shall give the Employer/Inspector Twenty one (21) days written
notice of any material being ready for testing far each stage of testing as identified
in the approved quality plan as customer inspection point. Such tests shall be to
the Contractor’s account except for the expenses of the Inspector. The
Employer/inspector, unless witnessing of the tests is waived, will attend such
tests within Twenty one (21) days of the date of which the equipment is notified
as being ready for test/inspection, failing which the Contractor may proceed with
the test which shall be deemed to have been made in the Inspector’s presence and
he shall forthwith forward to the Inspector six copies of tests, duly certified.
8.4 The Employer or Inspector shall, within Twenty (21) days from the date of
inspection as defined herein give notice in writing to the Contractor, of any
objection to any drawings and all or any equipment and workmanship which in
his opinion is not in accordance with the Contract. The Contractor shall give
due consideration to such objections and shall either make the modifications that
may be necessary to meet the said objections or shall confirm in writing to the
Employer/Inspector giving reasons therein, that no modifications are necessary to
comply with the Contract.
8.5 When the factory tests have been completed at the Contractor’s or Sub-
Contractor’s works, the Employer/Inspector shall issue a certificate to this effect
within fifteen (15) days after completion of tests but if the tests are not witnessed
by the Employer/Inspector, the certificate shall be issued within fifteen (15) days
of receipt of the Contractor’s Test certificate by the Employer/Inspector.
Failure of the Employer/Inspector to issue such a certificate shall not prevent the
Contractor from proceeding with the Works. The completion of these tests or the
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Section 3 Page 10 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
issue of the certificate shall not bind the Employer to accept the equipment should,
it, on further tests after erection, be found not to comply with the Contract.
8.6 In all cases where the Contract provides for tests whether at the premises or
works of the Contractor or of any Sub- Contractor, the Contractor except where
otherwise specified shall provide free of charge such items as labour, materials,
electricity, fuel, water, stores, apparatus and instruments as may be reasonably
demanded by the Employer/Inspector or his authorised representative to carry
out effectively such tests of the equipment in accordance with the Contract and
shall give facilities to the Employer/Inspector or to his authorised representative
to accomplish testing.
8.7 The inspection and acceptance by Employer and issue of Inspection Certificate
thereon shall in no way limit the liabilities and responsibilities of the Contractor in
respect of the agreed quality assurance programme forming a part of the
Contract, or if such equipment is found to be defective at a later stage.
8.8 Material Inspection clearance certificate (MICC) shall be issued by the Employer
after inspection of the equipment. Employer may waive off the presence of
Employer’s inspecting engineer. In that case test will be carried out as per
approved QP and test certificate will be furnished by the supplier for approval.
MICC will be issued only after review and approval of the test reports.
8.9 The Employer will have the right of having at his own expenses any other test(s)
of reasonable nature carried out at Contractor’s premises or at site or in any other
place in addition of aforesaid type and routine tests, to satisfy that the material
comply with the specification.
8.10 The Employer reserves the right for getting any field tests conducted on the
completely assembled equipment at site.
b) The work shall be performed under the direction and supervision of the
Engineer. The scope of the duties of the Engineer, pursuant to the
contract, will include but not be limited to the following :
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Section 3 Page 11 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
iv) Inspect, accept or reject any equipment, material and work under
the Contract ;
10.0 TESTS
10.1 Charging
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Section 3 Page 12 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
b) Any special equipment, tools and tackles required for the successful
completion of the Commissioning Tests shall be provided by the
Contractor, free of cost.
The provisions outlines in the IS & IEC codes or other international and Indian
approved equivalents shall generally be used as a guide for all the above test
procedures unless otherwise specified in the Technical Specifications.
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Section 3 Page 13 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
i) Exposed live parts shall be placed high enough above ground to meet
the requirements of electrical and other statutory safety codes.
Bidder shall confirm in their technical offer that all clearances and spacing
as stated above will invariably be provided. Even though phase to earth
clearance under normal conditions will be as above at certain points
where there can be bird faults (i.e. a bird sitting on the earthed metal part
coming in contact with the HT terminal) adequate clearance as required
shall be provided between the HT terminal and nearest grounded metal
part.
13.0 PROTECTION
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Section 3 Page 14 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
All coated surfaces shall be protected against abrasion, impact, discoloration and
any other damages. All exposed threaded portions shall be suitably protected
with protecting device. All ends of equipment connections shall be properly
sealed with suitable devices to protect them from damage. The parts which are
likely to get rusted, due to exposure to weather should also be properly treated
and protected in a suitable manner.
14.1 All exposed metallic surfaces subject to corrosion shall be protected by shop
application of suitable coatings. All surfaces which will not be easily accessible
after the shop assembly, shall beforehand be treated and protected for the life
of the equipment. All surfaces shall be thoroughly cleaned of all mill scale, oxide
and other coatings and prepared in the shop. The surfaces that are to be finish
painted after installation or require corrosion protection until installation, shall be
shop painted with at least two coats of primer. Transformers and other
electrical equipment, if included shall be shop finished with one or more coats of
primer and two coats of high grade resistance enamel. The finished colours
shall be selected and specified by the Employer at a later date.
14.2 Shop primer for all steel surfaces which will be exposed to operating temperature
below 95 deg.C. shall be selected by the Contractor, after obtaining specific
approval of the Employer regarding the quality of primer proposed to be applied.
Special high temperature primer shall be used on surfaces exposed to
temperatures higher than 95 deg.C. and such primers shall also be subject to the
approval of the Employer.
14.3 All other steel surfaces which are not to be painted shall be coated with suitable
dust preventive compound subject to the approval of the Employer.
The Contractor shall be responsible for the selection and design of appropriate
equipment to provide the best coordinated performance of the entire system. The
basic design requirements are detailed out in this Technical Specification. The
design of various components, sub-assemblies and assemblies shall be so done
so that it facilitates easy field assembly and maintenance. All the rotating
components shall be so selected that the natural frequency of the complete unit is
not critical at or close to the operating range of the unit.
The Contractor will be called upon to attend design co-ordination meetings with
the Employer, other Contractor’s and the Consultants of the Employer during
the period of Contract. The Contractor shall attend such meetings at his own
cost at New Delhi or at mutually agreed venue as and when required and fully
cooperate with such persons and agencies involved during those discussions.
The post insulators shall conform in general to latest IS:2544, IEC-168 and IEC-
815.
CONSTRUCTIONAL FEATURES
18.1 Post type insulators shall consist of a porcelain part permanently secured in a metal
base to be mounted on the supporting structures. They shall be capable of being
mounted upright. They shall be designed to withstand any shocks to which they
may be subjected to by the operation of the associated equipment. Only solid core
insulators will be acceptable.
18.2 Porcelain used shall be homogeneous, free from lamination, cavities and other
flaws or imperfections that might affect the mechanical or dielectric quality and shall
be thoroughly vitrified, tough and impervious to moisture.
18.3 Glazing of the porcelain shall be of uniform brown in colour, free from blisters, burrs
and other similar defects.
18.4 The insulator shall have alternate long and short sheds with aerodynamic profile.
The shed profile shall also meet the requirements of IEC-815 for the specified
pollution level.
18.5 When operating at normal rated voltage there shall be no electric discharge
between conductor and insulators which would cause corrosion or injury to
conductors or insulators by the formation of substance produced by chemical
action.
18.6 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
18.7 All ferrous parts shall be hot dip galvanised in accordance with the latest edition of
IS:2633 and IS :4579. The zinc used for galvanising shall be grade Zn 99.95 as
per IS:209. The zinc coating shall be uniform, adherent, smooth, reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky white
deposits and blisters. The metal parts shall not produce any noise generating
corona under the operating conditions.
18.8 If corona extinction voltage is to be achieved with the help of corona ring or any
other similar device, the same shall be deemed to be included in the scope of the
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Section 3 Page 16 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
Contractor.
18.9 Tests
The post insulators shall be subject to type, acceptance, sample and routine tests
as per IS:2544 and IEC-168.
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Section 3 Page 17 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
c) Glazing of the porcelain shall be uniform brown in colour, free from blisters,
burrs and similar other defects.
g) All iron parts shall be hot dip galvanised and all joints shall be air tight.
Surface of joints shall be trued up porcelain parts by grinding and metal
parts by machining. Insulator/bushing design shall be such as to ensure a
uniform compressive pressure on the joints.
h) TESTS :
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Section 3 Page 18 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
d) Control cabinet/panels, junction boxes, marshaling box & terminal box shall
be provided with padlocking arrangements.
e) All doors, removable covers and plates shall be gasketed all around with
neoprene gaskets. The neoprene gasket shall be tested in the presence
of Employer’s representative.
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Section 3 Page 19 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
f) All sheet steel work shall be degreased, pickled, phosphated and then
applied with two coats of zinc chromate primer and two coats of finishing
synthetic enamel paint. The colour of finishing paint shall be light
admiralty grey in accordance with shade No. 697 of IS : 5 outside and
inside shall be glossy white.
i) Terminal Block :
The terminal shall be such that maximum contact area is achieved when
a cable is terminated. The terminal shall have a locking characteristic to
prevent cable from escaping from the terminal clamp unless it is done
intentionally. The terminal blocks shall be non- disconnecting stud type
equivalent to Elmex type CAT - M4/CST.
The terminal blocks shall have locking arrangement to prevent its escape
from the mounting rails.
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Section 3 Page 20 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
The terminal blocks shall be of 650 V grade and shall be rated to carry
continuously the maximum current that is expected to be carried by the
terminals.
The terminal blocks used for CT circuits shall be fully enclosed with
removable covers of transparent, non-deteriorating type plastic material.
Insulting barriers shall be provided between the terminal blocks. These
barriers shall not hinder the operator from carrying out the wiring without
removing the barriers.
The terminals shall be provided with the marking tags for wiring
identification.
All boxes shall be provided with 20 % spare terminals unless otherwise
specified.
j) There shall be a minimum clearance of 250 mm between the first row of
terminal block and the cable gland plate or side of the box. Also the
clearance between two rows of terminal blocks or side of the box shall be a
minimum of 150 mm.
l) Wiring :
All wiring shall be carried out with 650 V grade, stranded copper wires. The
minimum size of the stranded conductor used for internal wiring shall be as
follows :
i)All circuits except CT circuits – 1.5/ 0.75.00.4 sq.mm (depending on the
device current rating)
ii) CT circuits- 4sq mm; minimum no. of strands shall be 3 per conductor.
the addition of a red coloured unlettered ferrule. Number 6 & 9 shall not
be included for ferrule purposes.
All control switches shall be of rotary switch type or push button type and
toggle/piano switches shall not be accepted.
m) Earthing :
19.3 MOTORS :
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Section 3 Page 22 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 and 145kV Post Insulators
b) All castings shall be free from blow holes, surface blisters, cracks
and cavities. All sharp edges and corners shall be blurred and rounded
off.
d) All ferrous parts shall be hot dip galvanised conforming to IS: 2633.
The type test reports or the following tests on auxiliary switch shall be
furnished :
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Section 3 Page 23 of 23
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
SECTION - 4
Sl. Parameters
No.
1. Type
2. Voltage class (kV)
3. Dry and wet one minute power frequency
withstand voltage (kVp)
4. Dry lightning impulse withstand voltage (kVp)
5. Wet switching surge withstand voltage (kVp)
6. Max. RIV (in μV) at specified 50-Hz phase
to ground voltage in kV
7. Min. Corona extinction voltage (kV rms)
8. Total min. cantilever strength (kg)
9. Minimum torsional moment
10. Total height of insulator (mm)
11. P.C.D
a. Top (mm)
b. Bottom (mm)
12. No. of bolts
a. Top
b. Bottom
13. Diameter of bolt holes
a. Top (mm)
b. Bottom (mm)
14. Pollution level as per IEC-815
15. Min. total creepage distance (mm)
16. Hardware (Inter unit)
17. Hardware (for fixing to structure)
18. Applicable standard
NOTE: Bidder to submit GTP in separate sheet for each voltage class of Post Insulators.
____________________________________________________________________________________
Page 1 of 1
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
Technical Specification for POST INSULATOR
ANNEXURE - A
SCHEDULE OF TECHNICAL DEVIATIONS
Bidder shall list below all technical deviation clause wise w.r.t. tender specifications:
Any deviation not specifically brought out in this section shall not be admissible for any
commercial implication at later stage. Except to the technical deviations listed in this schedule,
bidder’s offer shall be considered in full compliance to the tender specifications
irrespective of any such deviation indicated / taken elsewhere in the submitted offer.
_____________________________________________________________________________________________________
Page 1 of 1
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
ANNEXURE-C
Put a tick mark on ‘YES’ if the specified requirement is met, or put a tick mark on ‘NO’
if the specified requirement is not met and give comments in the remark column.
1. TECHNICAL REQUIREMENTS
Page 1 of 4
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
2. TYPE TESTS
Whether Type test reports of the tests conducted earlier (not more than ___ years
earlier) on similar material submitted. YES/NO
If the valid type test reports are not available with the bidder then the following
tests shall be conducted by the bidder free of cost YES/NO
Page 2 of 4
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
Put a tick mark on ‘YES’ if the specified requirement is met, or put a tick mark on ‘NO’
if the specified requirement is not met and give comments in the remark column.
Page 3 of 4
Bharat Heavy Electricals Limited Doc No. TB-362-316-014
400kV Bay extension at Karaikudi, Pugalur, Kalivanthapattu Rev. 00
and Abhishekpatty substation
Technical Specification for 420 & 145 kV Post Insulators
2. TYPE TESTS
Whether Type test reports of the tests conducted earlier (not more than ___years
earlier) on similar material submitted. YES/NO
If the valid type test reports are not available with the bidder then the following
tests shall be conducted by the bidder free of cost YES/NO
Page 4 of 4