Transformer Manual

MADHYA PRADESH POWER TRANSMISSION CO. LTD.
SHAKTI BHAWAN RAMPUR: JABALPUR
VOLUME II
PART-1
Technical Book Serial No.
MPPTCL/TECH/PROC/01/MAY13
TECHNICAL SPECIFICATION FOR SUPPLY

OF EHV EQUIPMENTS AND MATERIAL FOR
SUB-STATIONS AND FEEDER BAYS
O/o CHIEF ENGINEER (PROCUREMENT)

MPPTCL, JABALPUR
Volume-II contains four booklets as under:Section
Description
Technical Book
Serial No.
Part-1
TECHNICAL SPECIFICATION FOR MPPTCL/TECH/

SUPPLY
OF
132KV,
40MVA PROC/03/MAY13
POWER TRANSFORMERS
Part-2
Book I
of III

SUPPLY OF EHV EQUIPMENTS/ PROC/04/MAY13
MATERIALS
Part-2
Book II
of III

MATERIALS
Part-2
Book III SUPPLY OF EHV EQUIPMENTS/ PROC/06/MAY13
of III
MATERIALS
All the above four booklets are in the form of

separate books. This book refers to:-
PART-1
TECHNICAL SPECIFICATION FOR SUPPLY OF 132KV,
40MVA POWER TRANSFORMERS
Please note that the modifications in technical specifications
are indicated in Appendix-1, enclosed in Volume-I of the
Tender document.
Contents
Description of document
Technical specification for transformer
Page No.
1-66
Annexures and appendix for 132KV, 40MVA Power Transformer

Annexure I
Principal Technical particulars
67-69
Annexure II
List of Fittings and Accessories
70-73
Annexure III -
Test certificates to be furnished for

accessories
74-76
Annexure IV
Schedule of Inspection Windows
Annexure V
Schedule of Valves
Annexure VI(A)- Drawings & Data to be furnished

Annexure VI(B)- List of drawings
alongwith bid
Annexure VII
to be furnished
- Calculations required to be
furnished
77
78-79
80-82
83
84-87
Annexure VIII -
Details of Inspection Program
Annexure IX
List of Hand Tools and Jacks
93
Annexure X
Description of equipment for

schedule of rates & prices
94
Appendix I
Calculation for Hot Spot winding

temperature for EHV transformers
Appendix II
- Technical particulars to be filledin by bidder
List of abbreviations used in technical specification
88-92
95-96
97
98-99
VOLUME II, PART-1
TECHNICAL SPECIFICATION FOR 40 MVA ,

132/33 KVPOWER TRANSFORMERS
1.0
SCOPE
1.1
This specification covers design, engineering, manufacture,
assembly, stage inspections and testing before
supply
and delivery
including unloading on plinth at our substation sites of 132/33KV,40 MVA,
three phase transformers complete with all fittings, accessories, associated
equipment including oil for first filling including wastage & 10% extra of that
quantity specified herein which are required for efficient and trouble free
operation as specified hereunder. Scope of supply also includes services to
be provided by the supplier/Bidder for supervision of erection and supervision
of commissioning of each transformer unit at each project site anywhere in
MP.
1.2
It is not the intent to specify completely herein all the details of
the design and construction of equipment. However, the equipment shall
conform in all respects to high standards of engineering, design and
workmanship and shall be capable of performing the duties specified
herein. The offered transformers shall be complete with all components
necessary for their effective and trouble free operation. Such components
shall be deemed to be within the scope of Bidders supply irrespective of
whether those are specifically brought out in this specification or not. The
transformers should be free from Polychlorinated Biphenyls
(PVB/PCB).
1.3
The Purchaser will interpret the meanings of drawings and
specification and shall have the power to reject any work or material
which,
in
his judgment is not in accordance therewith. The offered
transformers shall be complete with all components necessary for their
effective and trouble free operation. Such, components shall be deemed to
be within the scope of Bidders supply irrespective of whether those are
specifically brought out in this specification and/or the commercial order or
not.
2.0
STANDARDS
2.1
The transformers and associated accessories shall conform to
the latest issues/amendments of standards as given below, except to the
extent explicitly modified in this specification. Transformers conforming to
any other authoritative standards meeting better quality and ensuring better
performance are also acceptable. Bidder shall specifically indicate deviations if
any from the INDIAN STANDARDS.
1 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
THE APPLICABLE INDIAN/INTERNATIONAL STANDARDS FOR POWER
TRANSFORMERS AND ASSOCIATED ACCESSORIES ETC.
INDIAN
STANDARD
NUMBER
TITLE
IS-2026
Power Transformers
(Part 1 to 5 )
CBIP PubliManual on Power Transformers
cation
No.295
IS-335
Insulating oil for transformers
IS1866Electrical maintenance and Supervision
2000
of mineral insulating oil in equipment.
IS-2099
Bushings for alternating Voltage above
1000V.
IS-2312
Fans (Cooler fans)
IS-2705.
Current Transformers.
IS-325.
Three phase Induction motors.
IS-375 &
Marking & arrangements for switch
IS-996
gear, bus bars, main connections &
auxiliary wiring.
IS-3407.
Gas & oil operated relays.
IS-10028
Code of practice for installation and
(Part 1to3)
maintenance of transformers.
IS-2147.
Degree of protection provided by
enclosures for low voltage switch gear
and control.
IS-5.
Colours for ready mix paints.
IS-6272
Industrial cooling fans.
DOC.ETD16
Draft standard by BIS for revision of IS(3703)
6600 for Guide for loading of oil
immersed transformers.
OLTC
IS 8478
Application Guide for OLTC
IS 10561
Application
Guide
for
Power
Transformer.
IS 13964
Method of measurement of Transformer
Sound levels.
IS 2071
Methods of High Voltage Testing
(Part 1 to 3)
IS 6209
Methods
for
Partial
Discharge
Measurements
IS 2165
Insulation Coordination
IS 5561
Terminal connectors
2 of 99
INTERNATIONAL
AND
INTERNATIONALLY
RECOGNISIED
STANDARD
IEC-60076(Part I to 5)
IEC-296,BS-148.
IEC-60137(2008)
IEC 60044
IEC-34.
IEC 60529,IEC60947
IEC 60354
IEC 60214
IEC 60542
IEC 60076-8
NEMA-TR1
IEC 60060
IEC 60270
IEC 60071
40 MVA TRANSFORMER
Volume-II, Part-1
INDIAN
STANDARD
NUMBER
IS-5553
IS:335
IS -1886
INTERNATIONAL
AND
INTERNATIONALLY
TITLE
RECOGNISIED
STANDARD
Short Circuit Current calculation of IEC 865(part I & II)
effects
Shunt
Reactors,
Neutral/Earthing IEC 60289
Reactor and Arc Suppression Coil
Insulating oils for transformers and IEC:60296, BS:223
switchgears
Code of practice for installation and
maintenance of transformers.
Supervision and Maintenance guide for
Mineral Insulating Oil in Electrical
Equipment
Method of Sampling of Liquid dielectrics
Guide for the Sampling of Gases and of
Oil from Oil-filled Electrical Equipment
for the Analysis of Free and Dissolved
Gases
Digital Recorders and Software for High
Voltage Impulse testing
Specification for radio disturbance and
immunity measuring apparatus
Guidelines for conducting design reviews
for transformers 100 MVA and 123 kV
and above.
Metal oxide surge arrestors without
gaps
Selection and application
recommendation
Indian Electricity Rule 1956
IEC 60422
IEC 60475
IEC 60567
IEC 61083
CISPR 16
Cigre Publication 202
IEC 99-4
IEC 99-5
2.2
In case equipment conforms to other International standards which
ensure equivalent or better performance than specified under cl 2.1 then
the English version of such standards or the relevant extracts of same shall
be forwarded with the bid and the salient features of comparison shall be
brought out separately.
2.3
The electrical installation shall meet requirements of Indian
Electricity Rules, 1956 and IS-1886,"Code of practice for installation &
maintenance of Transformers" as amended till date.
2.4
It has been experienced that the weight of core lamination, weight of
copper, weight of steel, weight of Transformer Tank along with Fittings and
Accessories and quantity of oil for first filling including wastage & 10% extra
3 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
of that quantity, total weight of core + winding after assembly and total
weight of transformer are indicated in the technical bid by the manufacturers
on tentative basis and at the time
of submission of drawing, wide
variations in these quantities take place. This is not in order and it will
be obligatory on the part of the Bidder to ensure that all these details are
worked out carefully and only correct figures after proper design are offered
in the technical bid. It may be noted that at the time of submission of final
drawings, variation in these weights beyond the limits of (+) 5% shall not be
permitted.
2.5
It will also be obligatory on the part of the manufacturer to furnish
details of calculations for quantity (weight & size) of core material, quantity
(weight & size) of copper material, calculations for thermal and dynamic
short
circuit withstand capability of transformer, calculations for pressure
relief valve, adequacy of size of AIRCELL Bag, volume of oil for adequate
cooling with calculations of size of conservator and other details as called
for in the specification. Furnishing of these calculations along-with technical
bid is a must. All the data should be supported with calculation details.
2.6
Interconnection : The transformers are meant for service as
interconnecting transformers and shall be capable of being energized either
from 132 KV side or 33 KV side. The power transformer shall be capable of
being loaded at rated power on the 132 KV and 33 KV sides at its full rating
(lagging or leading or mixed load). On Load Tap Changer shall be suitable for
such operation. The OLTC shall be suitable for bidirectional flow of power.
3.0
SERVICE CONDITIONS
3.1
Climatic Conditions : The transformers and its accessories to be
supplied against this specification shall be suitable
for satisfactory
continuous operation under the following tropical conditions.
1.
Location
2.
3.
4.
Max. Ambient air temp. (oC)

Min ambient air temp (oC)
Maximum daily average ambient air
temperature(oC)
Maximum yearly weighted average
temperature (oC)
Maximum Relative humidity (%)
5.
6.
7.
8.
9.
Average annual rainfall (cm)

Max. Wind pressure (Kg/sq.m.)
Max. Altitude above mean sea level
(Metres)
10. Isoceraunic level (Average number of
thunderstorm days per year)
11. Seismic level (horizontal acceleration)
4 of 99
At various substations within

the State of Madhya Pradesh
50
-5
40
32
95 (sometimes reaches
saturation.)
125
150
1000
50
0.3g
40 MVA TRANSFORMER
Volume-II, Part-1
Moderately hot and humid tropical climate, conducive to rust and
fungus growth. Tropical Protection Shall conform to IS:3202 titled climate
proofing of electrical equipments and BS: 1014 : titled protection of
electrical power equipments against the climatic condition. The transformer
tank fittings and radiators including all accessories shall be designed to
withstand seismic acceleration equivalent to 0.3 g. Special precautions shall
be taken to prevent mal-operation of Buchholz relay under such condition.
3.2
Auxiliary Power Supply : Auxiliary electrical equipment shall be
suitable for operation on the following supply system.
a.
Power Devices
(like drive motors)
433V, 3phase, 4wire 50Hz. neutral grounded AC

supply.
b.
DC
Alarm, 220V or 110volts DC, ungrounded
2wire
control
& (Substation wise exact details shall be furnished to
protective
the successful Bidder).
devices
c.
Lighting.
250V, single phase, 50Hz. AC supply.
Bidders scope include supply of interconnecting cables, terminal

boxes etc. The above supply voltage may vary as indicated below and all
devices shall be suitable for continuous operation over the entire range of
voltages.
+/- 4%
i)
AC supply
: Voltage Variation of 25% to +10%;Frequency
ii)
DC supply
: Voltage Variation of -20% to + 10%.
All accessories requiring AC or DC

satisfactorily for voltage variation as above.
4.0
GENERAL TECHNICAL REQUIREMENTS
4.1
Duty Requirements
a)
shall
perform
The transformers and all its accessories like CTs etc., shall
be designed to withstand without injury, the thermal and
mechanical effects of any external short circuit to earth and of
short circuits at the terminals considering infinite bus
arrangement of values specified as under :
132KV 33KV -
b)
supply
40KA for 3 secs.

31.5KA for 3 secs.
Over Loading : The transformer shall be capable of being

loaded in accordance with IS:6600. There shall be no limitation
imposed by windings, bushings, tap changer etc. of
transformer. Transformer & all its accessories shall be liberally
rated to allow 10% over loading at all taps on continuous
basis without exceeding the temperature limits specified in
clause 6.0.
5 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
The transformer shall be capable of being operated without
danger on each tapping at the rated KVA with specified voltage
variation corresponding to the voltage of that tapping with
normal temperature rise. The design adopted to achieve this
shall be indicated in detail in the Bid.
Transformer shall be capable of operating under the natural
cooled condition up to the specified load i.e. as ONAN rating.
The forced air cooling equipment shall come into operation by
pre-set contacts of winding temperature indicator and the
transformer shall operate as a forced air cooled unit i.e. as
ONAF. Cooling shall be so designed that during total failure of
power supply to cooling fans the transformer shall be able to
operate at full load for Ten(10) minutes without the calculated
winding hot spot temperature exceeding 140 deg.C. Also
stopping of two cooling fans should not have any effect on the
cooling system. Transformers fitted with two coolers (cooling
banks) each capable of dissipating 50 per cent of the loss at
continuous maximum rating shall be capable of operating for
20 minutes in the event of failure of the blowers associated
with one cooler, without the calculated winding hot spot
temperature exceeding 140oC at continuous maximum rating.
c)
Over Voltage : The transformers shall be capable of being

operated on continuous basis at 10% excess voltage than the
rated voltage specified at each tap.
4.2 Radio Interference & Noise Level

4.2.1
The transformers shall be designed with particular attention for
suppression of maximum harmonic voltage especially the third and fifth so as
to eliminate wave form distortion and minimize interference with
communication circuits.
4.2.2
The noise level, when energized at normal voltage and frequency
with fans running shall not exceed, when measured under standard
conditions, the values specified in NEMA,TR-I.
4.3
Stresses : Transformer shall be capable of withstanding Electrical,
thermal and mechanical stresses on any winding caused by forces due to
symmetrical or asymmetrical external fault.
4.4 Frequency & Magnetic Induction
4.4.1
The transformers shall be suitable for continuous operation for a
frequency variation of (+) plus (-) minus 4% from normal 50Hz without
exceeding the specified temperature rise. For considerations of over fluxing,
the transformer shall be suitable for continuous operation for values of over
fluxing factor up to 1.1.
V
FN
The over fluxing factor being { -x -- }
VN
F
6 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
4.4.2
The working flux density shall not exceed 1.65 Tesla for offered no
load losses and the maximum flux density in any part of core and yoke at
110% rated voltage combined with (-) 4% frequency variation shall preferably
not exceed the value of 1.90 Tesla as per CBIP manual no 295. For
manufacturing of Power transformer, core laminations of various specifications
are available and therefore while selecting the working flux density, the
Bidders will have to comply with the requirements of cl.4.4.1 & 4.4.3.
4.4.3
For the selected flux density, the transformer shall have minimum
of following over fluxing capabilities , such that while meeting the above
requirement saturation of transformer core shall not take place under any
circumstances. Transformer shall accept, without injurious heating, combined
voltage & frequency fluctuation, which produces the following over fluxing
conditions :
Over Fluxing Factor
1.50
1.40
1.25
1.10
Period
Less than 2 seconds
5.0 seconds
60 seconds
Continuous
The Bidder shall also indicate 160% & 170% over voltage/over
fluxing withstand capability period. Over fluxing withstand characteristics up
to 170% shall be submitted along with the bid.
4.4.4
Detailed calculations for maximum flux density and magnetizing
current for core material shall be furnished to substantiate the above
requirement. The manufacturer shall enclose details of Core Material with
thickness of lamination, type designation and source of raw material and its
characteristic curves. All characteristic curves of material including Voltage Vs
Flux Density and Loss per Kg Vs Flux Density are to be enclosed with Bid
clearly indicating Flux Density selected for calculation of core losses (No load
loss). On the basis of these data, for the Flux Density and core material
chosen verification of Saturation Flux Density shall be done by the purchaser,
to know the margin considered in operating Flux Density .
4.4.5
The maximum current density for design of power transformers
within specified limits of transformer losses shall not exceed the limits of 300
amps per sq.cm.
4.4.6
All other requirement of magnetic circuit shall be as per latest issue
of CBIP Manual no 295.
4.4.7
The transformers shall be either core type or shell type
construction, oil immersed, ONAN/ONAF with external heat exchangers and
shall be suitable for outdoor service as inter connecting and/or step-down
transformers suitable for parallel operation with the existing transformer
having tertiary winding already in service at the EHV substation where these
transformers are to be commissioned. The rating and electrical characteristics
of the transformers shall be strictly as specified in this specification. For
matching the parameters required for parallel operation with existing unit,
details shall be intimated to successful Bidder.
7 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
4.5
All the transformers shall be suitable for continuous operation with
frequency variation of +/- 4% from normal 50 Hz . Combined voltage &
frequency variation should not exceed the rated V/f ratio by 10 %.
5.
INSULATION
5.1
Impulse & Power Frequency Voltage Withstand Values : For
rated nominal system voltage of 33KV & 132KV following minimum power
frequency and impulse withstand voltage should be offered for the windings.
System
Voltage
Highest System
Voltage
Power Frequency
Withstand
Voltages
Impulse
Withstand
Voltage
33KV
36KV
95KV rms
250KVp
132KV
145KV
230KV rms
550KVp
5.2
The HV winding of the transformers shall have graded
insulation. The insulation class of the neutral end of the winding
shall be graded to 95 KV. The 33KV winding shall have full insulation
for 33KV i.e. 250 KVp impulse and 95KVrms power frequency.
6.0
TEMPERATURE RISE : Each transformer shall be capable of
operating continuously at its normal rating & 10% over load condition
without exceeding temperature limits as specified below. The maximum
ambient temperature shall be taken as 50 degree C and type of cooling be
suitably adopted to limit the temperature rise within the safe limit of
operation.
Type Of Cooling
Temperature-Rise
Windings
o
Oil
ONAN (Air natural).
50 C
45oC
ONAF (Air forced)
50oC
45oC.
7.0
FREQUENCY : All the transformers shall be suitable for continuous
operation with a frequency variation of + 4% to -4% from normal 50 Hz
without exceeding the specified temperature rise.
8.0
IMPEDANCE : The percentage impedance of the power transformer
shall be 10% on 40 MVA base. manufacturer shall indicate the guaranteed
impedance, tolerances and also the impedance on all taps for the offered
transformers. Impedance shall include positive and zero sequence and shall
be expressed in terms of the branches of the star connected equivalent
diagrams on all the specified MVA base and the range shall be given for each
branch of the equivalent circuit turn. It may be noted that if required the
percentage impedance should be designed identical to the existing
transformer of any make in case parallel operation is desired. The
IS
tolerance on all matching taps are acceptable. Confirmation regarding
requirement of parallel operation should be given in the Bid.
8 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
It may be noted by the manufacturer that for the purpose of
matching impedance of transformer, included in scope of this Bid,
between 132KV & 33KV windings, the Bidders are not permitted to use
reactor or reactor/capacitor assembly. The design of the main winding should
take care of the requirement of impedances as specified in this Bid
document and for this purpose, no reactor or reactor/capacitor should be
used.
9.0
MAXIMUM LOSSES:
9.1
Maximum Losses : While the Bidders may offer their own design, it
may be noted that the transformer losses at 75 deg. C. at rated Output.
Rated Voltage and rated frequency should not
exceed the following
maximum limits which include tolerances as per IS :
a)
No load losses (Iron losses).
20 KW
b) Load(Copper losses) + Auxiliary losses. : 100 KW

including stray loss in KW
9.2
The losses in kilowatts (including BIS tolerance) at rated voltage
and rated frequency and the total load losses in kilowatts at rated output,
rated voltage and rated frequency at 75oC shall be guaranteed by the
Bidder. It may be noted that the losses of the Transformer shall not exceed
during final testing of the transformer, if the same exceeds from the
maximum Ceiling limit of Transformer losses as detailed in 9.1 above the
Transformer shall not be accepted
9.3
Heat Run Test:
One 40 MVA 132 KV power transformer of each manufacturer (if

there are more than one manufacturer) shall be subject to heat run test
(Temperature rise test).
10.0
COOLING : The Bidder may offer ONAN / ONAF type of cooling
for these transformers. The ONAF rating for each transformer winding shall
be 125% of ONAN rating achieved by cooling. The ONAF cooling shall be in
two groups each of 50% capacity. Adequate no. of standby cooling fans
shall be provided for 20% additional cooling per bank, in line with requirement
indicated in clause 15.1 ( C ).
11.0
CONSTRUCTION DETAILS : The features and construction details
of power transformer shall be in accordance with the requirements stated
hereunder
11.1
Tank
(A) As required in CBIP specification, the tank shall be of Bell type
construction for 40 MVA transformers covered under this
specification. Top cover of Bell type construction shall be
welded to the tank body .
9 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(B) Tank shall be of welded construction and fabricated from
tested quality low carbon steel suitable for welding & of
following minimum sheet thickness.
Tank cover - 20 mm, Sides including inspection covers10 mm ,
Base - 20 mm.
(C) All seams and those joints not required to be opened at site
shall be factory welded and wherever possible they shall
be double welded. After completion of tank construction and
before painting, 'Dye Penetration Test' shall be carried out on
welded parts of jacking bosses, lifting lugs and all load
bearing members.
(D) Tank stiffeners shall be provided for general rigidity and these
shall be designed to prevent retention of water.
(E)
The tanks shall be designed to withstand the following

without permanent distortion.
(i)
Mechanical shocks during transportation.
(ii)
Vacuum filling of oil at 10 milli torr in transformer with

all fittings.
(iii) Continuous internal pressure of 35 kN/m2 over normal

hydrostatic pressure of oil.
(iv) Short circuit forces &
(v)
(F)
Under seismic condition /events both horizontal/vertical.
Where ever possible the transformer tank and its accessories

shall be designed without pockets wherein gas may collect.
Where pockets can not be avoided, pipes shall be provided to
vent the gas into the main expansion pipes if any.
(G) The shields shall be such that no magnetic fields shall exist
outside the tank. They shall be of magnetically permeable
material. If required impermeable shields shall be provided
at the coil ends. Tank shield shall not resonate when excited at
the natural frequency of the equipment.
(H) The tank shall be provided with :
(i)
Lifting lugs suitable for lifting the equipment complete

with oil.
(ii)
A minimum of four jacking pads in accessible position

at 500mm height to enable the transformer complete
with oil to be raised or lowered using hydraulic or screw
jacks. The location of jacking pads shall be such that
there should not be any interference with the civil
foundation of rails in either direction i.e. longitudinal or
transverse. A typical drawing no. MPPTCL/TR-57/
40MVA/01 for providing jacking pad is enclosed with the
Bid specification.
10 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(iii) Suitable haulage holes shall be provided.
(I)
(J)
(i)
Inspection cover/access windows & Manholes:

Suitable man-hole with a welded flange and a properly
gasketted bolted cover having of minimum thickness of
10 mm shall be provided on the tank cover, weight of
which shall not be more than 50Kg each. The manhole
shall be of sufficient size to offer easy access to the lower
ends of the bushings, terminal etc. The requirement of
inspection windows and manholes have been stipulated
in Annexure-IV & Bidders have to confirm compliance of
the same in their Bid.
(ii)
Space for free movement in Transformer Tank for

inspection:
Details of passage & free space provided inside the
main tank should be indicated in concerned drawing to
allow free movement of at-least two persons for
inspection of active parts etc. To be more specific it
may please be noted that minimum clearance from
outer most winding/connection leads to tank shall
not be less than 300 mm. on all 4 sides with
suitable platform on bottom of the tank to facilitate
free movement of person all around inside the tank.
All bolted connections to the tank shall be fitted with

suitable oil tight gaskets which shall give satisfactory service
under all operating conditions. Special attention shall be given
to the methods of making the hot oil tight joints between
the tank and the cover as also between the cover and the
bushings and all other outlets to ensure that the joints can be
remade satisfactorily and easily with the help of semi skilled
labour. Where
compressible gaskets are used, stoppers/
runners shall be provided to prevent over compression.
(K) Suitable guides shall be provided for positioning the various

parts during assembly or dismantling. Adequate space shall
be provided between the cores and windings assembly and
the bottom of the tank for collection of any sediment.
(L)
The design of the tank, lifting lugs shall be such that the
complete transformer assembly filled with oil can be lifted with
the use of these lugs without any damage or distortions.
(M) For the complete transformer we have clearly brought out our
requirement of various types of valves in Annexure V enclosed
brings out details of type, size and quantity of valves which are
to be provided at various locations. This requirement has to
be confirmed by the Bidders without any deviation.
(N) It may be noted that all gasketted joints shall be grooved one
using O rings of nitrile rubber or better, such as the joints
between bushing turret and bushing flange, inspection covers
of inspection windows and all other openings provided for the
11 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
purpose of inspection of internal parts of the transformer etc.
The main bell tank gasket between upper tank and bottom
tank shall be single piece O ring cord/gasket of nitrile rubber
or material of better quality. The gasketting arrangement shall
be grooved one with proper stopper to avoid over
compression.
(O) One detachable bolted type mild steel (MS) ladder with anticlimbing arrangement shall be provided. Ladder for climbing
up to & over top cover of power transformers shall be
mechanically sturdy enough to bear the load of healthy
maintenance staff without any shake/jerks. The arrangement
shall not be detached after erection and commissioning of the
unit, hence shall be provided with padlock locking arrangement
for anti-climbing device. On the upper top of the ladder,
provision for support shall be
made. However, the
arrangement of the ladder shall be to purchasers approval.
Collapsible ladder shall not be acceptable to us.
11.2
11.3
Tank Cover
(a)
The tank cover shall be sloped to prevent retention of rain

water and shall not distort when lifted.
(b)
Inspection cover/man holes shall be provided as per AnnexureIV.
(c)
The tank covers shall be fitted with pockets at the position of

maximum oil temperature of MCR (Maximum Continuous
Rating) for inserting bulbs of oil and winding temperature
indicators. It shall be possible to remove these bulbs without
lowering the oil in the tank.
(d)
Bushings, turrets, covers of inspection openings, thermometer,

pockets etc., shall be designed to prevent ingress of water into
or leakages of oil from the tank.
(e)
All bolted connections shall be fitted with weather-proof, hot oil

resistant gasket in between, for complete oil tightness. If
gasket is compressible, metallic stoppers shall be provided to
prevent over-compression.
(f)
A minimum of three nos. PRD shall be provided above

each phase winding.
Undercarriage
(a)
The transformer tank shall be supported on a structural steel

base equipped with forged steel or cast steel single flanged
wheels suitable for moving the transformer completely filled
with oil.
(b)
Jacking pads/steps shall be provided. It shall be possible to

change the direction of the wheels through 90 deg. when the
12 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
transformer is lifted on jacks to permit movement of the
transformer both in longitudinal and transverse direction.
11.4
11.5
(c)
The track/rail gauge shall be 1676 mm along the longer side,

as well as along the shorter axis. However Rails shall be placed
perpendicular to the bushing line.
(d)
Pulling eyes shall be provided to facilitate movement/pulling of

the transformers and these shall be suitably braced in a
vertical direction so that bending does not occur when the pull
has a vertical component.
Axles And Wheels

(a)
The transformers are to be provided with flanged bi-directional

wheels and axles. These shall be so designed as not to deflect
excessively to interfere with the movement of the transformer.
Wheels shall be provided with suitable bearings which shall be
rust and corrosion resistant. Fittings for lubrication shall also
be provided.
(b)
Suitable locking arrangement along-with foundation bolts shall

be provided for the wheels to prevent accidental movement of
transformer. The locking arrangement shall be such that it can
be locked with plinth of transformer. The length of the
arrangement should be adequate to cover height of the rail. No
floating type locking arrangement shall be accepted.
(c)
The wheels are required to swivel and they shall be arranged

so that they can be turned through an angle of 90 degrees
when the tank is jacked up to clear of rails. Means shall be
provided for locking the swivel movements in positions parallel
to and at right angles to the longitudinal axis of the tank (i.e.
longitudinal & transverse directions).
(d)
To facilitate uniform distribution of transformer weight two

nos. props each on front & rear side along longer axis to be
provided.
Anti Earthquake/Transport Clamping Device

(a)
To prevent transformer movement during earthquake,

clamping device shall be provided for fixing transformer to the
foundation. The Bidder shall supply necessary bolts for
embedding in the concrete foundation. The arrangements shall
be such that the transformer can be fixed to or unfastened
from these bolts as desired. The fixing of the transformers to
the foundations shall be designed to withstand seismic events
to the extent that a static co-efficient of 0.3g. applied in the
direction of least resistance to that loading will not cause the
transformer or clamping devices as well as bolts to be over
stressed..
(b)
Locking arrangement to eliminate relative movement between

top yoke/active parts with the transformer tank shall be sturdy
13 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
enough to bear transport hazards taking in to account the poor
road conditions and also considering that road transportation
of transformer will not be on hydraulic trailers
11.6
Conservator Tank
(a)
The conservator tank shall be of minimum thickness of 8 mm

and it shall have adequate capacity between highest and
lowest visible levels to meet the requirement of expansion of
the total cold oil volume in the transformer and cooling
equipment from minimum ambient temperature to 100oC.
(b)
The conservator tank shall be bolted into position so that it can

be removed for cleaning purposes.
(c)
Magnetic oil gauge (MOG) & prismatic oil level gauge

having three overlapped windows on one side of
conservator and on opposite side of conservator, plain oil
gauge with three overlapped windows shall be provided
to indicate oil level inside the conservator at each
location. Proper arrangement to ensure visibility of oil level
from ground be also ensured .
(d)
Conservator shall be provided in such a position as not to

obstruct the electrical connections to the transformer.
(e)
In order to avoid congestion and to facilitate operation and

maintenance activities, the main conservator and OLTC
conservator shall be provided on opposite sides of the main
tank. Further, there shall be adequate space for manual
operation of OLTC.
(f)
Separate conservator tank shall be provided for OLTC.
(g) The size of the conservator shall be so designed as to

accommodate approximately 10% volume of total quantity of
oil in the transformer.
(h)
Suitable arrangement shall be made for providing a foot rest

with
easy
&
access
arrangement
to
facilitate
maintenance/operation at top of the conservator, on magnetic
oil level gauge and buchholz relay.
(i)
The design of conservator shall be such that the air is not

trapped between air cell and main conservator.
11.7
Tank Earthing Arrangement : Two earthing pads complete with
two number tapped holes M10 bolts plain and spring washer suitable for
connection to 50X8 mm GI flat shall be provided each at position close to two
diagonally opposite bottom corners of tank. Earthing strips up to the ground
level and its connection with station earth pit shall be provided by the Bidder.
11.8
Pressure Relief Device : A minimum of 3 (three) number of
pressure relief devices of reputed make and reliable quality shall be
provided on each transformer and these shall be mounted preferably
14 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
on the tank cover above each phase winding. Bidders must submit
calculations to prove that the no and capacity of pressure relief device with
location of each PRV provided on the transformer will adequately meet our
requirement. The quantity of three numbers is on the basis that two numbers
will be required as per design calculation and one number additional PRD shall
be provided from the point of view of additional safety.
Constructional and design details of pressure relief device must be
furnished and it should be proved by calculation that the size and operating
pressure setting of pressure relief device is adequate, considering the rating
of the transformer and quantity of oil in the transformer. Furnishing of this
information is a must. These PRD's shall be of sufficient size for rapid release
of any pressure that may be generated in the tank and which may result in
damage to the equipment. The device shall operate at a static pressure of less
than the hydraulic test pressure of transformer tank. It shall be mounted
directly on the tank. One set of electrically insulated contacts shall be
provided for alarm & tripping along-with the recommendations.
11.9
Relays
11.9.1
Buchholz Relay : A double float type Buchholz relay along with
suitable moulded type cover to avoid ingress of moisture/ rain water shall be
provided. All the gases evolved in the transformer shall collect in this relay.
The relay shall be provided with a test cock suitable for a flexible pipe
connection for checking its operation and for taking gas sample. A copper or
stainless steel tube, shall be connected from the gas collector to a valve
located about 1200mm above ground level to facilitate sampling of gas while
the transformer is in service. The device shall be provided with two electrically
independent ungrounded contacts, one for alarm on gas accumulation and the
other for tripping on sudden rise of pressure. The contacts of relay shall be
properly housed, sealed and gasketted to make the arrangement water proof.
Entry of moisture/water in the contact chamber needs to be eliminated. Cable
entry to terminal box of buchholz relay should be made through bottom of
relay.
11.9.2
Oil Surge Relay (OSR) : From our past experience, it is found that
undesired tripping of Power Transformers is occurring on oil surge relay
(OSR)and Buchholz relay operation actuating due to accumulation of water
inside relay pockets. The water accumulation takes place through entry point
of cable gland. In view of above, the design and placement of Alarm & trip
contact assembly of OSR and Buchholz Relay should be improved to take care
of the following requirements:
(a)
The cable entry to terminal box of OSR should be made through bottom
of relay. Also the OSR relay should be protected from rain water by
providing proper cover on it.
(b)
In order to ensure exit/drainage of accumulated water from inside the

relay, a fine hole should be made in terminal box of relay.
15 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
Note : The Bidders shall ensure that the compartments housing relay
contacts of Pressure Relief Valve , Buchholz Relay and Oil Surge Relay are
made absolutely water and vermin proof. The compartment housing contacts
of OSR,PRV and Buchholz Relay shall be tested for water proof at the time of
inspection and effectiveness of water proofing shall be demonstrated at the
time of inspection. This should be noted carefully by the Bidder and
specifically confirmed in their bid.
11.10
Temperature Indicator
11.10.1 Oil Temperature Indicator (OTI) :Transformers shall be provided

with a 150mm dial type thermometer with maximum pointer for top oil
temperature indication. The thermometer shall have adjustable two
electrically isolated heavy duty alarm and trip contacts, maximum reading
pointer and resetting device mounted in the Fan control cubicle (FCC). A
temperature sensing element suitably located in a pocket on top oil shall be
provided. This shall be connected to the OTI by means of capillary tubing.
Accuracy class of OTI shall be plus or minus 1.0% or better. The OTI shall be
provided with anti vibration mounting .
11.10.2 Winding Temperature Indicator (WTI)
(a)
WTI for measuring the winding temperature of the windings

shall be provided. It shall comprise of the following
(i)
Temperature sensing element.
(ii)
Image coil.
(iii) Auxiliary CTs, if required, to match the image coil, shall

be provided.
(iv) 150mm dia local indicating instrument with maximum
reading pointer mounted in FCC/marshalling box and with
four adjustable electrically isolated heavy duty contacts
(two for control of cooling equipment, one for high
winding temperature alarm and other for trip) shall be
provided. The WTI shall be provided with anti vibration
mounting.
(v)
Calibration device.
(b)
In addition to the (a) above, repeater dial of WTI for each

winding shall be provided for Remote winding temperature
indication. It shall be suitable for flush mounting on RTCC
panel. A precision potentiometer mounted inside the case shall
function as a transmitter to operate a repeater for RWTI. The
transmitter shall be directly connected to the repeater.
(c)
Auxiliary supply, if required in RTCC panel for RWTI, shall be

220V or 110V DC only.
(d)
Accuracy class of WTI shall be plus or minus 1.0% or better.
(e)
Any special cables required for shielding purpose for

connection between cooler control cabinet and remote winding
temperature indicator control circuit shall be in Bidders scope
of work.
16 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(f)
Note
WTI CT ratio shall be embossed on secondary winding terminal

box.
Some of the manufacturers have a practice to directly install winding

temperature indicator (WTI) and oil temperature indicator (OTI) on
the body of the transformer in open. This is not acceptable & it is
obligatory on the part of the Bidders to enclose OTI & WTI and all
such accessories in a separate Fan Control Cubicle (FCC) cum
Marshalling Box .
11.11 Core
a)
The core shall be constructed from high grade, non- ageing,

low loss, Cold Rolled Super Grain oriented (CRGO) silicon steel
laminations of HI-B grade steel or better. All stipulations under
clause 4.4 should be considered while selecting material of
core. Interlamination resistance shall be as per BS601
Part 5 method of July 1973. The Bidder shall furnish the
details of steel laminations i.e. type alongwith hysterisis
loss curve (B-H curve) etc.
(b)
After being sheared, the laminations shall be treated to remove

all burrs and shall be re-annealed to remove all residual
stresses.
(c)
The design of the magnetic circuit shall be such as to avoid

static discharges, development of short circuit paths within
itself or to the earthed clamping structure and production of
flux component at right angles to the plane of laminations
which may cause local heating.
(d)
The core shall be provided with lugs suitable for lifting

complete core & coil assembly of transformer.
(e)
Core Belting : The core shall be rigidly clamped by belting to

ensure adequate mechanical strength. Core and winding shall
be capable of withstanding the vibrations & shock during
transport, installation, service and adequate provision shall be
made to prevent movement of core & winding relative to tank
during these conditions. The location, size and material of
belting shall be clearly indicated in drawing which shall be
submitted with Bid. Bolted type core construction shall not
be acceptable.
(f)
All steel sections used for supporting the core shall be

thoroughly sand blasted after cutting, drilling and welding.
(g)
Each core lamination shall be insulated with a material that will

not deteriorate due to pressure and hot oil.
(h)
The insulation of core to bolts and core to clamps plates

shall be able to withstand a voltage of 2KV RMS for one
minute.
(i)
The maximum flux density in any part of the core and yoke at
rated MVA, 110% voltage and (-) 4% frequency at any tap
shall not exceed 1.90 Tesla. The Bidder shall provide saturation
curve of the core material proposed to be used and
17 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
calculations to demonstrate that the core is not over fluxed
under stringent condition of transformer operation.
(j)
Bidder will offer the core for inspection & approval by

the purchaser during the manufacturing stage. Bidder's
call notice for this purpose should be accompanied with
the following documents, as applicable, as a proof
towards use of prime core material.
i)
Invoice of the supplier
ii) Mill's Test Certificate
iii) Packing List
iv) Bill of lading
v) Bill of entry certificate by customs.
(k)
Core material shall be directly procured either from the

manufacturer
or
through
their
accredited
marketing
organization of repute and not through any agent.
(l)
Bidder should have in-house Core Cutting facility for proper

monitoring & control on quality and also to avoid any
possibility of mixing of prime material with defective/second
grade material.
(m) Oil ducts shall be provided wherever necessary to ensure

adequate cooling. The winding structure and major insulation
shall not obstruct the free flow of oil through such ducts.
Where the magnetic circuit is divided into pockets by cooling
ducts parallel to the plane of laminations or by insulating
material above 0.254 mm. Thick, tinned copper strip bridging
pieces shall be inserted to maintain electrical continuity
between pockets. The design of the magnetic circuit shall be
such as to avoid static discharge development of short circuit
path within itself or to the earthed clamping structure and
production of flux components at right angles to the plane of
the laminations which may cause local heating.
(n)
11.12
Core shall not directly rest on the bottom metal sheet of

transformer tank. Around 3 mm or more free space for oil
insulation shall be made between the core and bottom sheet of
transformer tank. A 5 mm FRP Insulating sheet shall be
provided to take care of core earthing due to accidental
slippage of stampings. Also in addition to this extra
insulation thickness of 5 mm or more FRP sheet be
provided at the bottom of resting shoes of end frame
with proper fixing arrangement to avoid accidental
slippage, damages etc.
Windings
(a)
The Bidder shall ensure that windings of all transformers are

made in dust proof, conditioned atmosphere. The Bidder shall
furnish the facilities available at their works alongwith the bid.
(b)
The conductors shall be of electrolytic grade copper as per

relevant IS. The maximum current density for design of
18 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
transformers within specified limits of transformer losses shall
not exceed the limits of 300 amps per sq.cm.
(c)
The insulation of transformer windings and connections shall

be free from insulating compounds which are liable to soften,
ooze out, shrink or collapse or be catalytic and chemically
active in transformer oil during service.
(d)
Coil assembly and insulating spacers shall be so arranged as to

ensure free circulation of oil and to reduce the hot spot of the
winding. The conductor shall be transposed at sufficient
intervals in order to minimize eddy currents and equalize the
distribution of currents and temperature along the winding.
(e)
The LV winding should withstand short circuit faults/forces of

the transformer upto the prescribed fault levels on HV & LV
sides against mechanical and thermal stresses.
(f)
Best insulating material shall be used and compression of the

windings after drying out shall be carried out at a pressure
exceeding one and a half to twice the force which can occur in
the transformer; to impart greater mechanical strength to the
windings against heavy short circuit stresses.
(g)
The windings shall be so designed that all coil assemblies of

identical voltage ratings shall be interchangeable and field
repairs to the windings can be made readily without special
equipment. The coils shall be supported between adjacent
sections by insulating spacers, and the bracings and other
insulation used in the assembly of the winding shall be
arranged to ensure free circulation of the oil to reduce hot
spots in the windings.
(h) The coil insulation shall be treated with suitable insulating

varnish or equivalent compound wherever necessary to
develop the full electrical strength of the winding. All materials
used in the insulation and assembly of the winding shall be
insoluble, non-catalytic and chemically inactive in the hot
transformer oil and shall not soften or otherwise be adversely
affected under the operating conditions.
(i)
All threaded connections shall be provided with locking

facilities. All leads from the winding to the terminal connectors
and bushings shall be rigidly supported to prevent injury from
vibration. Guide tubes shall be used where practicable.
(j)
Windings shall be subjected to a shrinkage treatment before

final assembly so that no further shrinkage occurs during
service. Adjustable device shall be provided for taking up any
possible shrinkage of coils in service. After shrinkage process,
the windings shall be clamped securely in place so that they
will not be displaced or deformed during short circuits. The
assembled core and windings shall be vacuum-dried and
suitably impregnated before removal from the treating tank.
The copper conductors used in the coil structure shall be best
suited to the requirements and all permanent current carrying
19 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
joints in the windings and the leads shall be crimped or brazed
preferably by high frequency brazing system.
It is observed that many manufacturers are using sectored
clamping arrangement at top as well as bottom for clamping of
the windings. This type of arrangement is considered to be not
suitable for EHV grade power transformers. In this regard, it
may be noted that both top & bottom clamping rings to be
provided for clamping of windings shall be of one piece single
ring. The top & bottom clamping rings should be of
minimum thickness 60 mm thk with proper safety
margins based on design and shall be in one piece to
make the clamping arrangement sturdy. Sectored
pressure/clamping rings are not acceptable. The single
pressing/clamping ring shall be provided with adequate
number of pressure/jacking points as per design. Since
sectored ring arrangement shall not be accepted hence
bidder should ensure and confirm this specific
requirement in the technical questionnaire.
(k)
i)
Bidder will offer the Copper and insulating material for

windings for inspection & approval by the purchaser during the
manufacturing stage. Bidder's call notice for the purpose
should be accompanied with the following documents, as
applicable, as a proof towards use of prime Copper and
insulating material for windings .
ii) Mill's Test Certificate

iii) Packing List
iv) Bill of lading
v)
(l)
Bill of entry certificate by customs.
Core, Copper and insulating material for windings shall be

directly procured either from the manufacturer or through their
accredited marketing organisation of repute and not through
any agent.
20 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(m) Certificate : Supplier shall provide purchaser details of

procurement of raw materials i.e., core, insulation & copper.
Supplier shall also record a certificate as under :
" CERTIFICATE "

It is certified that the Transformer shall be
manufactured by --------- (Name of manufacturer) out of
the core, insulating and winding material procured as per
details indicated in specification. We are agreeable
to
undertake third party inspection of Transformer during its
manufacture or of raw materials, at the sole discretion of
MPPTCL without any extra cost.
If at any stage it is found that the transformer is not
manufactured
out
of the raw material
indicated
specification, the transformer shall be liable for rejection by
MPPTCL and transformer shall be replaced by (name of
manufacturer) at no extra cost to MPPTCL.
Signature of Authorised
Signatory with Seal of manufacturer
(o)
11.13
The Purchaser also reserves the right to carry out stage

inspections at other stages also, for which advance intimation
shall be given and all necessary cooperation shall be rendered
by the supplier.
Bushings
(a)
The electrical & mechanical characteristics of bushings shall be

in accordance with IS-3347 & IS-2099 ( latest version ) & IEC
60137(2008 or latest version).
(b)
The bushings shall have high factor of safety against leakage

to ground and shall be so located as to provide adequate
electrical clearances between bushings and also between the
bushings and grounded parts. Bushings of identical voltage
rating shall be inter changeable. All bushings shall be equipped
with suitable terminals of approved type and size and all
external current carrying contact surfaces shall be adequately
silver plated. The insulation class of the high voltage neutral
bushing shall be properly coordinated with the insulation class
of the neutral of the high voltage winding.
(c)
All main winding and neutral leads shall be brought out

through outdoor type bushings which shall be so located that
the full flashover strength will be utilized and the adequate
phase clearance shall be realized.
21 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(d)
Each bushing shall be so coordinated with the transformer

insulation that all flashovers will occur outside the tank.
(e)
All porcelain used in bushings shall be of the wet process,

homogeneous and free from cavities or other flaws. The
glazing shall be uniform in color and free from blisters, burns
and other defects.
(f)
(i)
(g)
All bushings shall have puncture strength greater than the dry
flashover value.
(h)
Main winding terminals shall be solder-less terminals and shall

be of the type and size specified.
(i)
The spacing between the bushings must be adequate to

prevent flashover between phases under all conditions of
operation. The clearances shall be as follows :
For 33KV winding & neutral , the bushing shall be of OIP

condenser of 72.5KV class of draw rod type/solid stem
type.
(ii) The bushings of 145 KV class shall be of OIP condenser of
draw rod type (DR) only.
(iii) Tan-delta of all bushings shall be 0.005 (max.)during testing at
manufacturers works.
S.
N
o
Nomin
al
Syste
m
Voltag
e
Voltage
Class
Of
Bushin
g
Curre
nt
Rating
Impulse
Withsta
nd
Voltage
(Kvp)
1
2
132KV
33KV
145KV
72.5KV
1250A
2000A
650
325
1min.Po
wer
Frequenc
y
withstand
Voltage
Kv(rms)
275
140
Creepa
ge
Distanc
e
in mm
3625
1813
Clearance
in mm
Ph
to
Ph.
Ph
to E
1430 1270
700
660
The Bidders are required to confirm clearances and no change/

reduction in clearances shall be acceptable. The clearances
shall be clear distances in air after accounting for
clamps/connectors dimensions to be mounted on the stud of
bushings.
(j)
Special adjustable arcing horns shall be provided for the HV

bushings. For 72.5KV class bushings, arcing horns are not
required.
(k)
The Bidder is requested to furnish the guaranteed withstand

voltage for the above and also furnish a calibration curve with
different settings of the coordination gap to the purchaser to
decide the actual gap setting. Bidder's recommendations are
also invited in this respect.
22 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(l)
The bushings shall be capable of withstanding without injury

the electrical, thermal and mechanical effects of external short
circuits. The 145 KV bushings shall be rated for short time
thermal current rating of 40 KA for 3 seconds and 72.5 KV
Bushings, for 31.5KA for 3 seconds.
(m) All the transformers covered under this specification shall be

utilized in heavily polluted atmosphere. In view of this the
Bidders while offering prices for the transformers against this
contract may please note that the offer should be made out
based on the creepage for the bushings @ 25mm per KV based
on the voltage of 72.5KV/145KV. Thus in the quoted prices of
transformer cost of bushings should be included based on a
creepage distance of 25mm per KV.
(n)
All O.I.P. Condenser bushings shall be provided with :

(i)
Oil level gauge.
(ii)
Oil filling plug and drain valve, if not hermetically sealed.
(iii) Tap for capacitance/tan delta test.

(o)
When bushings have an under-oil end of reentrant form, the

pull through lead shall be fitted with a gas bubble deflector.
(p)
The bushings with current transformers are specified, hence

the bushings shall be removable without disturbing the current
transformers.
(q)
Porcelain used in bushing manufacture shall be homogenous,

free from laminations, cavities and other flaws or imperfections
that might affect the mechanical or dielectric quality and shall
be thoroughly vitrified tough and impervious to moisture.
Glazing of porcelain and bushing shall be of uniform brown
color free from blisters and burrs.
(r)
Bushing turrets shall be provided with suitable vent pipes

which shall be connected to route any air/gas collection
through the Buchholz relay.
(s)
For Bushings of all voltage class, the arrangement for

connection of winding/neutral terminal shall be indicated .
(t)
From the end point of the condenser of the bushing which will
protrude inside the transformer OR the bottom termination
point of bushing, sufficient clearance should be available so
that in case any other make bushing is installed problem in this
regard may not arise. Maximum length of condenser portion,
which can be easily accommodated, should be clearly indicated
by the Bidder.
(u)
The LV take off arrangement within the transformer is of

utmost importance hence due care shall be taken while
providing this arrangement inside the transformer tank. The
connecting lug of LV winding with the bushing bottom terminal
pad should match with the current rating of the bushing. The
23 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
size of the LV winding lug shall be of suitable rating to match
with the maximum load current of the transformer to be fed
through extreme tap of OLTC meeting requirements of IS6600. In this regard, the clamping arrangement of LV
winding with two lugs having two holes with two hole
terminals on counter part of the bushing pad are not
acceptable. In case of such arrangement, it will have to
be ensured that the counter part of winding lead/lug i.e.
bushing terminal is with four holes or vice versa.
11.14
Bushing Current Transformers

(a)
Current transformers shall comply with IS:2705.
(b)
One no. bushing CT of Ratio 200/1 on each phase of HV

winding & one no. CT of Ratio 800/1 on each phase of LV
winding i.e 3 nos for HV & 3 nos for LV winding, one no.
bushing CT of Ratio 200/1 for HV neutral and 800/1 for LV
neutral shall be provided for each out door Transformer .
(c)
It shall be possible to remove turret mounted CTs from the

transformer tank without removing the tank cover. Necessary
precaution shall be taken to minimize the eddy currents and
local heat generated in the turret.
(d)
All secondary leads shall be brought to a terminal box near

each bushing. These terminals shall be wired out to cooler
control cabinet using separate cables for each core.
(e)
For the thermal image coil of winding temperature indicator,

CT with suitable ratio and class may be used.
11.15
Terminal Marking : The terminal marking and their physical
position shall be in accordance with IS:2026.
11.16
The positioning of HV & LV bushings shall be such that skew
jumpering is avoided. The middle phase primary & secondary bushing center
line shall be parallel to side axis of the transformer body.
12.0 EARTHING ARRANGEMENT
12.1 NEUTRAL EARTHING ARRANGEMENT: The neutral terminal of the
star connected HV / LV winding shall be brought up to the ground level
through two tinned copper flat strips of size 50x6mm which shall be supported
on transformer tank horizontal/vertical by porcelain insulators of adequate
voltage class. The number of insulators shall be sufficient to provide a
mechanically sturdy arrangement. Necessary mechanical supports on the tank
for mounting of the insulators shall be made. The KV class rating of insulators
shall commensurate with the rating /KV class of neutral design. It may be
ensured that connection of the neutral strips to neutral bushings at one end
shall be made using a terminal connector suitable for connection to the
neutral bushing terminal and to receive 2x50x6 mm tinned copper strips on
the other side. The connection between the bushing and transformers earth
pit shall be through 2x50x6 mm tinned copper strips single run without any
joint connection/brazing/ welding etc. The other end of the earth connection
24 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
to the earth pit shall also be through terminal connector suitable to receive
2x50x6 mm copper strips at one end and to receive MS flat and /or twin ACSR
zebra conductor on the other end. The length of the copper strips shall be
suitable for providing a joint less connection between transformer neutral and
earth pit and details in this regard shall be intimated to the successful bidder
based on transformer/substation layout design. A typical arrangement is
shown in drg. No: MPPTCL/TR-57/40MVA/02 of this specification for neutral
earthing.
12.2
CORE EARTHING ARRANGEMENT : The bidder should note our
requirement in this regard very clearly. It is required to bring out leads from
core, end frame and tank to the top of the transformer through only three
insulated bushings. The arrangement shall be housed in a box at the top cover
of transformer tank with provision for interconnection between the studs of
bushings. The bushing housing shall have a suitable cover with gasket to make
the arrangement waterproof. A clear marking (engraved/punched) shall be
made to indicate that the housing contains core/end frame/ tank earthing
arrangement. Please note that stickers/flags/tags/painted marking for
identification shall not be accepted. A typical sketch of general arrangement
needed by purchaser is shown in drawing no. MPPTCL/TR-57/40MVA/03 of this
specification. Arrangement shall be such that even after removal of
connections, oil shall not leak. Removable shorting strips between the three
bushing shall be provided. It may be noted that internal earthing of any nature
between core and End frame should not be provided. Earthing at site shall be
done by interconnecting the three bushings through shorting strips. This
arrangement is to facilitate checking of multiple core earthing in the
transformer.
It may be noted that :
a)
any alternative arrangement is not acceptable and therefore bidder

must confirm provision of three bushings as desired above.
b)
Once transformer reaches site, before unloading from the trailor the
position of core earthing shall be checked and in case any problem of
multiple core earthing is observed, delivery of Transformer will not be
taken.
The insulated cable to be used for core to Bushing connection & end
frame to Bushing connection should be of good quality with proper
grounding arrangement. The size and number of strands of cable shall
be subject to purchasers approval.
13.0
AUXILIARY POWER SUPPLY FOR OLTC, COOLER CONTROL

AND POWER CIRCUIT
13.1
Duplicate (Two) auxiliary power supplies of 433volt, three phase,
four(4) wire shall be provided by the purchaser at cooler control cabinet and
for OLTC drive.
13.2
All loads shall be fed by one of the two feeders through an
electrically interlocked automatic transfer switch housed in the cooler control
cabinet, for tap changer control and cooler control circuits.
25 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
13.3
Design features of the transfer switch shall include the following :

i)
Provision for the selection of one of the feeders as normal

source and other as standby.
ii)
Upon failure of the normal source, the loads shall be

automatically transferred after an adjustable time delay to the
standby source.
iii)
Indication to be provided at cooler control cabinet for failure of

normal source and for transfer to standby source and also for
failure to transfer.
iv)
Automatic re-transfers to normal source without any

intentional time delay following re-energisation on the normal
source.
v)
Both the transfer & re-transfer shall be dead transfers and AC

feeders shall not be paralleled at any time.
13.4
AC feeder shall be brought to the OLTC cabinet (Cooler Control
Cabinet) by the Bidder, after suitable selection at cooler control cabinet. The
Bidder shall derive AC power for control circuit from the AC feeder as
mentioned above by using appropriately rated dry type transformers. If the
control circuit is operated by DC supply then suitable converters to be
provided by the Bidder to be operated from AC Power source.
13.5
Necessary isolating switches and HRC fuses shall be provided at
suitable points as per approved scheme of purchaser.
14.0 TAP CHANGING EQUIPMENT
14.1: GENERAL REQUIREMENT
a) OLTC gear shall be motor operated for local as well as remote operation.
An external hand wheel/handle shall be provided for local manual
operation. This hand wheel/handle shall be easily operable by a man
standing at ground level.
(b) Arrangement shall be made for securing and padlocking the tap changer
wheel in any of the working positions and it shall not be possible for
setting or padlocking the wheel in any intermediate position. The
arrangement shall be such that no padlock key can be inserted unless all
contacts are correctly engaged and switch set in a position where no open
or short circuit is possible. An indicating device shall be provided to show
the tap in use.
(c) The design of OLTC shall be on the principle of Constant Flux Design
(CFVV) wherein HV (132KV ) voltage would be varied in the range of
(+)5 % to (-)15 % in steps of 1.25 % so as to provide constant voltage
of 33 KV on LV side. While through current rating of OLTC shall be based
on cl.2.3.2 of IS 8478,the purchaser desires to obtain OLTC with higher
voltage and current rating from the point of view of better performance.
In view of this, the bidder shall offer OLTC for 40 MVA transformer
suitable for rated voltage and rated current as mentioned in the following
table :
26 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
Rating of OLTC
Transformer
Rating
OLTC on
Winding
(HV)
Voltage
Rating
Minimum
Current
Rating
Tap Range
(In steps of
1.25%)
132 KV, 40
MVA
132KV
66KV/132KV*
300 Amp.
(+)5% to (-)15%
*Suitable for 132KV neutral end

d) The OLTC motor should be capable of smooth and trouble free operation
with supply voltage variation of 433 V +10% & -25%.
14.2 ON LOAD TAP CHANGING GEAR (OLTC)
(a) The details of the method of diversion of the load current during tap
changing, the mechanical construction of the gear and the control
features for OLTC gear alongwith detailed drawings on the inner view and
the arrangement of connections shall be submitted with the Bid.
Information regarding the service experience on the gear and a list of
important users shall also be furnished. The tap changer shall change the
effective transformation ratio without producing phase displacement.
(b) The current diverting contacts shall be housed in a separate oil chamber
not communicating with the oil in main tank of the transformer.
(c) The contacts shall be accessible for inspection without lowering oil level in
the main tank and the contact tips shall be replaceable.
(d) The Bidder shall indicate the safeguards employed to take care of harmful
arcing at the current diverting contacts in the event of operation of the
OLTC gear under overload conditions (overloading capability as per IS
6600) of the transformer. Necessary tools and tackles shall be provided
alongwith main supply for maintenance of OLTC gear.
(e) The OLTC oil chamber shall have oil filling and drain valves, oil sampling
valve, relief vent and oil level gauge/glass. It shall also be fitted with an
oil surge relay. For accommodating oil expansion of OLTC a separate
conservator tank shall be provided.
(f) The diverter switch or arcing switch shall be designed so as to ensure that
its operation once commenced shall be completed independently of the
control relays or switches, failure of auxiliary supplies etc. To meet any
contingency which may result in incomplete operation of the diverter
switch, adequate means shall be provided to safeguard the transformer
and its ancillary equipments.
(g) Drive mechanism chamber shall be mounted on the tank in accessible
position. It should be adequately ventilated and provided with anti
condensation metal clad heaters. All contactors, relay coils and other
27 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
parts shall be protected
condensation, fungi etc.
against
corrosion,
deterioration
due
to
(h) The control feature shall provide the following :

i)
LOCAL-REMOTE selector switch mounted in the local control cubicle

shall switch control of OLTC for lower/ raise functions in local or
remote mode as selected.
ii)
The LOCAL-REMOTE selector switch shall have at-least two spare

contacts per position which are closed in that position but open in
the other position.
iii)
A RAISE-LOWER CONTROL SWITCH shall be provided in the local

control cubicle. The switch shall be spring loaded to return to the
Centre "OFF" position and shall require movement to the RIGHT to
raise the voltage of the transformer. Movement to the left shall
lower the voltage. Alternatively push button type arrangement of
standard design may be provided.
iv)
An OFF-ON tap changer control switch shall be provided in the OLTC

local control cabinet of transformer. The tap changer shall be
inoperative in the OFF position. Also the OFF-ON switch shall have
atleast one spare contact per position which is closed in that position
but open in the other position.
v)
Operating mechanism for on load tap changer shall be designed to

go through one step or tap change per command. Subsequent tap
changes shall be initiated only by a new or a repeat command.
vi)
On load tap changer shall be equipped with a time delay in complete

STEP alarm consisting of a normally open contact which closes, if
the tap changer fails to make a complete tap change. The alarm
shall not operate for momentary loss of auxiliary power.
vii) The selsyn units or approved equivalents shall be installed in the

local OLTC control cabinet to provide tap position indication for the
transformer. Complete mounting details shall be included with
approved diagram.
viii) Transformer load tap changer shall be equipped with a fixed resistor
network capable of providing discrete voltage steps for input to the
supervisory system. Any other approved / established design for
remote indication of tap position shall also be acceptable.
(i) Limit switches shall be provided to prevent overrunning of the mechanism
and in addition, a mechanical stop shall be provided to prevent overrunning of the mechanism under any condition.
(j) Limit switches may be connected in the control circuit of the operating
motor provided that a mechanical-de-clutching mechanism is
incorporated.
(k) Thermal device or other means shall be provided to protect the motor
and control circuit. All relays, switches, fuses etc. shall be mounted in the
28 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
drive mechanism chamber and shall be clearly marked for the purpose of
identification.
(l) A permanently legible lubrication chart shall be fitted within the driving
mechanism chamber.
(m) Any "DROP DOWN" tank associated with the tap changing apparatus shall
be fitted with guide rod to control the movements during lifting or
lowering.
(n) A five digit counter shall be fitted to the tap changing equipment to
indicate the number of operations performed.
(o) All relays and operating devices shall operate correctly at any voltage
between the limits specified.
(p) It shall not be possible to operate the electric drive when the manual
operating gear is in use.
(q) It shall not be possible for any two controls to be in operation at the
same time.
(r) The equipment shall be suitable for supervisory control and indication
with make before break multi-way switch, having one potential free
contact for each tap position. This switch shall be provided in addition to
any other switch/switches which may be required for remote tap position.
(s) Operation from the local or remote control switch shall cause one tap
movement only until the control switch is returned to the off position
between successive operations.
(t) All electrical control switches and the local operating gear shall be clearly
labeled in a suitable manner to indicate the direction of tap changing.
(u) Transfer of source failure of one AC supply shall not affect tap changing
operation.
(v) For the purpose of operation of OLTC, based on design of manufacturer,
transition resistor could be used. However, no component of OLTC
including transition resistor shall be housed inside main transformer tank.
The design of the transition resisters should be liberal to ensure
suitability during tap change operation at rated current including over
loading capability and system short circuits.
(w) The location and design of OLTC shall be such that in the event of any
repair / maintenance , it should be possible to take out various parts
from the OLTC and other accessories and fittings mounted on the
transformer particularly equalizing pipes etc do not infringe /obstruct.
14.3 MANUAL CONTROL : The cranking device for manual operation of the
OLTC gear shall be removable and suitable for operation by a man standing
on ground level. The mechanism shall be complete with the following :
i)
Mechanical tap position indicator which shall be clearly visible to the

person operating tap changer manually at the transformer.
29 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ii)
A mechanical operation counter.
iii)
Mechanical stoppers to prevent over-cranking of the mechanism beyond

the extreme tap positions.
iv)
The manual control considered as back up to the motor operated load tap
changer control shall be interlocked with the motor to block motor startup during manual operation. The manual operating mechanism shall be
labeled to show the direction of operation for raising the voltage and
vice-versa.
14.4 ELECTRICAL CONTROL This includes Local Electrical control and

Electrical remote control from remote control panel. The control circuits shall
have the following features:
(i)
An interlock to cut off electrical control automatically upon recourse

being taken to the manual control in emergency.
(ii)
Reinforcement of the initiating impulse for a tap change, ensuring a

positive completion once initiated to the next (higher or lower) tap.
(iii) Step-by-step operation ensuring only one tap change from each tap
changing impulse and lock-out of the mechanism if the control switch (or
push button) remains in the "Operate Position".
(iv) An interlock to cut-out electrical control when it tends to operate the
gear beyond either of the extreme tap positions.
(v)
An electrical interlock to cut-off a counter impulse for reverse step

change being initiated during a progressing tap change and until the
mechanism comes to rest and resets circuits for a fresh position. Suitable
interlocks shall be provided to prevent operation of OLTC beyond
extreme tap with a mechanical/electrical lockable switch.
(vi) Protection apparatus, considered essential by the Bidder according to

specification.
14.5 REMOTE ELECTRICAL GROUP CONTROL The OLTC control scheme
offered shall have provision of remote electrical group control during parallel
operation of transformers. This is in addition to independent control of OLTC.
(i)
A four position selector switch having MASTER, FOLLOWER,

INDEPENDENT and OFF position shall be provided in the remote OLTC
control panel for each transformer. This shall be wired to enable operator
to select operation of OLTC in either Master, Follower or Independent
mode.
(ii)
Out of step relays with timer contacts shall also be provided to give
alarm and indication in case of tap positions in all the transformers under
group control being not in same position.
(iii) Master Position : If the selector switch is in MASTER position, it shall

be possible to control the OLTC units in the FOLLOWER mode by
operating the controls of the MASTER unit Independent operation of the
30 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
units under FOLLOWER mode shall have to be prevented. However, the
units under independent mode will be controlled independently.
(iv) Follower Position : If the selector switch is in FOLLOWER mode,
control of OLTC shall be possible only from MASTER panel.
(v)
Independent Position : In this position of Selector Switch, Control of

OLTC of individual unit only shall be possible.
14.6 LOCAL OLTC CONTROL CUBICLE The Auxiliary devices for electrical
control of the OLTC shall be housed in a weather proof cubicle. It shall be
complete with the following :
i)
A circuit breaker/contactor with thermal overload devices for

controlling the AC auxiliary supply to the OLTC motor.
ii) Cubicle light with door switch.

iii) Space heaters to prevent condensation of moisture.
iv) Padlocking arrangement for hinged door of cabinet.
v) Cable terminal glands for power and control cables to the OLTC gear.
14.7 REMOTE TAP CHANGER CONTROL PANEL (RTCC)
Remote tap changer control panel to be supplied by the Bidder shall consist
of :
i)
Actuating switch for electrical raise/lower control.
ii)
Remote tap position indicator.(preferred digital type)
iii) Signal lamps for Tap changer in progress and Tap changer out of
step.
iv) Auxiliary devices for remote electric group control of OLTC.
v)
Annunciation scheme with the following :

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
vi)
Fan fail (for all fans individual windows).

AC supply fail.
Stand by fan fail.
Stand by fan on.
OLTC motor over loaded.
OLTC control supply fail.
OLTC at extreme position i.e. lowest & highest voltage tap.
Two spare windows.
Indicating Devices : Following lamp indications shall be provided in

Remote tap changer control cubicle /panel
-
Fan "ON", Fan "OFF"

Cooling system "On Automatic Control".
Cooling system "On Manual".
31 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
-
Selector switch in auto or manual.

433volts cooler supply auto changeover.
Control supply failure main and standby.
one potential free initiating contact for all the above indications
shall be wired independently to the terminal blocks of cooler
control cabinet exclusively for owner's use.
vii) Remote OTI with repeater unit.

viii) WTI repeater unit.
ix) Voltmeter for indicating HV & LV voltage.
x) Schedule of equipments for RTCC panel shall be as under:
1.
Name plate remote OLTC and cooler control cubicle
2.
Indicating lamp-OLTC control supply on ( red)
3.
Indicating lamp-tap change in progress ( yellow)
4.
Indicating lamp-OLTC out of step ( red)
5.
Indicating lamp-OLTC motor trip ( red)
6.
Cooler mode selector (auto-off-on)
7.
OLTC sequence selector switch.(OFF-INT-FOLL-MAST.)
8.
Emergency stop push button for tap change operation. (red)
9.
Auxiliary contactor for OLTC out of step monitoring.
10.
Out of step timer.
11.
Voltmeter for HV. (0-150 KV)
12.
Remote oil temperature indicator.
13.
Voltmeter for LV. (0-40 KV)
14.
Terminal blocks.
15.
Cubicle lamp.
16.
Door switch.
17.
HRC cartridge fuse holder with link for cubicle illumination circuit.
18.
Neutral link.
19.
Earth bus.
20.
HRC cartridge fuse holder with link for HV volt meter.
21.
HRC cartridge fuse holder with link for LV volt meter..
22.
HRC cartridge fuse holder with link for RWTI and ROTI circuit.
23.
Selector switch for HV volt meter.
24.
Selector switch for LV volt meter.
25.
Remote winding temperature indicator.
26.
Ammeter for HV & LV winding current measurement.
32 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
27.
Selector switch for amp. meters
28.
OLTC control switch
29.
Tap position indicator (digital).
xi. a. HV digital Voltmeter of accuracy class 0.5 provided for indicating HV

voltage shall be scaled for voltage range 0-150 KV (phase to phase)
and shall be suitable for use with PT ratio 132KV/110 volt. The HV
digital voltmeter shall be precisely calibrated so as to indicate 132KV
Voltage on voltmeter scale corresponding to input voltage of 110 Volt
(phase to phase).
b. LV digital Voltmeter of accuracy class 0.5 provided for indicating LV
voltage shall be scaled for voltage range 0-40 KV (phase to phase)
and shall be suitable for use with PT ratio 33KV/110 volt. The LV
digital voltmeter shall be precisely calibrated so as to indicate 33KV
Voltage on voltmeter scale corresponding to input voltage of 110 Volt
(phase to phase).
xii. a.
HV digital Ampere meter of accuracy class 0.5 provided for

measurement of HV winding current shall be for use with 132KV CT
having CT ratio 200/1 with 20% over range reading scale. The HV
digital Ampere meter shall be precisely calibrated so as to read 200
HV side current in ampere on Ampere meter scales corresponding to
input current of 1 Amp. from 132KV CT.
b.
LV digital Ampere meter of accuracy class 0.5 provided for

measurement of LV winding current shall be for use with 33KV CT
having CT ratio 800/1 with 20% over range reading scale. The LV
digital Ampere meter shall be precisely calibrated so as to read 800
LV side current in ampere on Ampere meter scales corresponding to
input current of 1 Amp. from 33KV CT.
15.0
COOLING EQUIPMENT
15.1
The design shall take into account the following requirements

a)
The oil cooling system of transformer shall be designed using

2x50% radiator banks. The radiator banks shall be mounted on
two different sides of transformer tank. The arrangement shall
be subject to approval by the purchaser based on substation
layout and positioning of other neighboring switch yard
equipments. Coolers/radiators shall with stand pressure /
vacuum conditions specified for the tank. All coolers/ radiators
shall be attached on the transformer tank through header
having suitable expansion joints (flexible coupling) to
ensure adequate mechanical strength against vibration
etc. subject to specific approval from the purchaser. Radiators
directly mounted on transformer tank are not
acceptable.
b)
Each radiator bank / block shall have its own set of cooling
fans, shut off valves, lifting lugs, top and bottom oil filling
valves, air release plugs, drain valves and if considered
33 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
necessary based on design thermometer pocket fitted with
captive screw cap on the inlet and outlet, in line with valve
schedule as per Annexure-V.
15.2
c)
Each radiator bank shall be provided with at least 20%

standby (spare)cooling fans. These spare fans shall be duly
mounted and shall also be wired up complete with required
protective devices and be identified with each radiator bank.
While working out number of spare fan for 20% additional
cooling per bank, if 20% quantity works out in fraction , the
spare fans to be provided shall be next whole number.
d)
Cooling fans shall be designed

requirements as per clause 4.1 (b)
e)
The exhaust air flow from cooling fan shall not be directed
towards the main tank in any case.
f)
Cooling fans for each radiator bank shall be located so as to

prevent ingress of rain water. Each fan shall be suitably
protected by galvanised wire guard.
g)
The cooler and its accessories shall preferably be hot dipped

galvanised or corrosion resistant paint shall be applied to it.
h)
Each cooling fan shall be provided with starter thermal

overload and short circuit protection and also single phase
preventor.
i)
Each radiator shall be provided with suitable lifting lugs and

shut off/air release/sampling valves as per Annexure-V
j)
Expansion joints, one each on top and bottom cooler pipe

connections as per a above.
k)
Air release device/plug

connections.
l)
The cooling Fans shall be mounted on separate foundation at

bottom of externally mounted radiator Banks. Mounting of
Cooling fans directly on Radiators or on transformer tank is not
acceptable . The radiators mounting arrangement is to be
indicated by the Bidder in his Bid.
m)
Cooling fan support shall be of adequate strength to avoid

bending etc..
and
oil
to
drain
meet
plug
overloading
on
oil
pipe
Cooling Equipment Control (ONAN/ONAF Cooling)

a)
Automatic operation control (switching in and out) of fans shall

be provided (with temperature change) from contacts of
winding temperature indicator. The Bidder shall recommend
the setting of WTI for automatic change over of cooler control
from ONAN to ONAF. The setting shall be such that hunting i.e.
frequent start stop operations for small temperature difference
do not occur.
b)
Suitable manual control facility for cooler fans shall be

provided.
34 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
c)
15.3
Selector switches and push buttons, shall also be provided in

the cooler control to disconnect the automatic control and
start/stop the fans manually.
Indicating devices
Fan ON , Fan OFF
Cooling system on automatic control.
Cooling system on manual.
Selector switch in auto or manual for cooler.
A.C. auxiliary cooler supply auto change over.
Cooler supply failure for main /standby.
Cooling fan failure for each fan.
Control supply failure for main and standby.
One potential free initiating contact for all the above indications
shall be wired independently to the terminal block of cooler control
cabinet exclusively for purchasers use.
16.0
LOCAL OLTC CONTROL CABINET, COOLER CONTROL CABINET

& REMOTE TAP CHANGER CONTROL PANEL
a)
Each three phase transformer unit shall be provided with local

OLTC control cabinet, cooler control cabinet OR fan control
cubicle (FCC) and RTCC panel. The total height of RTCC panel
shall be 2250mm to match with the height of other control &
relay panels. Local OLTC control cabinet shall be mounted on
the transformer. The thickness of front panel, door frame etc.
shall be 3mm (10 SWG),while doors & side panels may be 2
mm (14 SWG).
b)
The cooler control cabinet or FCC shall not be mounted directly

on transformer tank .Please note that FCC shall be grouted
away from the main tank thus the length of capillary tubes of
all oil and winding temperature indicating meter shall be
sufficient to connect OTI and WTI meters in the FCC. The
cooler cabinet shall have all necessary devices meant for cooler
control and local temp. indicators. All the contacts of various
protective devices mounted on the transformer shall also be
wired up to the terminal Board in the cooler control cabinet. All
the secondary terminals of the bushing CT's shall also be wired
upto the terminal Board at the cooler control cabinet.
c)
The cooler control cabinet shall have two(2) sections. One

section shall have the control equipment exclusively meant for
cooler control. The other section shall house the temperature
indicators, aux. CT's and the terminal Boards meant for
termination of various alarm and trip contacts. Alternatively
the two sections may be provided as two separate panels
depending on the standard practices of the Bidder.
d)
The cooler control cabinet, Local OLTC cabinet and RTCC Panel
shall be provided with non disconnecting stud type terminal
blocks. Each of the terminal blocks in the above panels should
have 20% spare terminals exclusively for purchasers use. All
35 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
the necessary terminals for remote connection to purchasers
panel shall be wired upto the cooler control cabinet. Necessary
shorting of terminals shall be done at the cooler control
cabinet, local OLTC cabinet and remote OLTC panel. All the CT
secondary terminals in the cooler control cabinet shall have
provision for short circuiting to avoid CT open circuit while it is
not in use.
e)
The local OLTC control cabinet shall house all necessary

devices meant for OLTC control and indication.
f)
Following cabling are specifically excluded from the scope of

the Bidder. However, interconnection drawings for the same
are to be submitted by the Bidder.
i)
Cabling between Remote OLTC Panel to Cooler Control

Cabinet.
ii)
Cabling between Remote OLTC panel to Local OLTC

Cabinet.
iii)
Cabling between Remote OLTC to Purchaser's Panel.
iv)
Cabling between Cooler Control Cabinet to Purchaser's

Panel.
v)
Cabling between Local OLTC Cabinet to Purchaser's Panel.
16.1
The degree of protection shall be IP-55 in accordance with IS-2147.
16.2
The temperature indicators shall be so mounted that the dials are

not above 1600mm from ground level. Glazed door of suitable size
shall be provided for convenience of reading.
16.3
A space heater and cubicle lighting with ON-OFF switch shall be

provided.
16.4
Terminal Blocks
a)
The terminal blocks to be provided shall be fully enclosed with

removable covers and made of moulded, non inflammable
plastic material with block and barriers moulded integrally.
Such block shall have washer and binding screws for external
circuit wire connections, a white marking strip for circuit
identification and moulded plastic cover. All terminals shall be
clearly marked with identification numbers or letters to
facilitate connection to external wiring.
b)
All internal wiring to be connected to the external equipment

shall terminate on terminal blocks, preferably vertically
mounted on the side of each panel. The terminal blocks shall
be 1100 V grade and have 10 amps continuous rating,
moulded piece, complete with insulated barriers, nondisconnecting stud type terminals, washers, nuts and lock
nuts. Terminal block design shall include a white fiber marking
strip with clear plastic, slip-on/clip-on terminal cover. Markings
on the terminal strips shall correspond to wire number and
terminal numbers on the wiring diagrams.
36 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
c)
Terminal blocks for current transformer secondary leads shall

be provided with test links and isolating facilities. Also current
transformer secondary leads shall be provided with short
circuiting and earthing facilities.
d)
Unless otherwise specified, terminal blocks shall be suitable for

connecting the following conductors on each side.
For all circuits except current transformer circuits minimum of
two nos. 2.5 mm2 copper.
For all CT circuits minimum of four nos. 2.5 mm2 copper.
e)
There shall be a minimum edge to edge clearance of 250 mm

between the first row of terminal blocks and the associated
cable gland plate. Also the clearance between two rows of
terminal blocks shall be a minimum of 150 mm.
f)
Arrangement of the terminal block assemblies and the wiring

channel within the enclosure shall be such that a row of
terminal blocks is run parallel and in close proximity along
each side of the wiring duct to provide for convenient
attachment of internal panel wiring. The side of the terminal
block opposite the wiring duct shall be reserved for the owner's
external cable connection. All adjacent terminal blocks shall
also share this field wiring corridor. A steel strip shall be
connected between adjacent terminal block rows at 450mm
intervals for support of incoming cables.
g)
The number and sizes of the owner's multi core incoming cable
will be furnished to the successful Bidder.
16.5
One Cooler Control Cabinet and OLTC local control cabinet shall be
tested for IP-55 protection in accordance with IS-2147.
16.6
The gaskets shall be of neoprene rubber.
17.0
PAINTING
17.1
It has been observed that certain units received in the past
by us are not having good quality painting on inside & out side and
with passage of time peeling of flakes of paint takes place. In view of
this the Bidders are requested to furnish in a separate sheet painting
procedure adopted by them for internal & external surfaces of the
tank. This is an essential requirement and details should be confirmed
by the Bidders in their offer. The internal and external surfaces including
oil filled chambers and structural steel work to be painted shall be shot or
sand blasted to remove all rust and scale of foreign adhering matter or
grease. All steel surfaces in contact with insulating oil shall be painted with
two coats of heat resistant, oil insulating varnish.
17.2
All steel surfaces exposed to weather shall be given a primary coat
of zinc chromate, second coat of oil and weather resistant varnish of a colour
distinct from primary and final two coats of glossy oil and Epoxy light gray
37 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
paint in accordance with shade no.401 of IS-5.For each transformer oil paints
should be obtained from same source to ensure compatibility & proper finish.
17.3
All paints shall be carefully selected to withstand extremes of
weather. The paint shall not scale off or crinkle or be removed by abrasion
due to normal handling. The process of painting should be clearly described.
17.4
The minimum thickness of each coat of outside painting of tank
shall be 20 microns and the total thickness shall be minimum 80 microns.
17.5
Bolts & Nuts :All bolts and nuts exposed to weather shall be hot
dipped galvanised/cadmium plated.
18.0
WIRING & CABLING

(a)
All external cabling will be carried out by the purchaser based

on wiring diagram & interconnection schedule to be supplied by
the Bidder . Cable box/sealing end shall be suitable for
following types of cables :i)
POWER SUPPLY 433 VOLTS
ii) CONTROL CABLE
: 1100volts
grade
PVC
insulated
armoured
aluminum cable .
: 1100volts
grade
PVC
insulated
7/0.737mm
stranded
armoured copper
cable .
Size of the Purchasers cable will be intimated to

successful Bidder after detailed engineering.
the
(b)
Compression type cable connector shall

termination of power and control cables.
for
(c)
All controls, alarms, indicating and relaying

devices
provided with the transformer shall be wired upto the
terminal blocks inside the Cooler Control Cabinet.
(d)
All devices and terminal blocks with the Cooler Control

Cabinet shall be clearly identified by symbols corresponding to
those used on applicable schematic or wiring diagrams.
(e)
Not more than 2 wires shall be connected to one terminal.

Each terminal shall be suitable for connecting two 7/0.737mm
stranded copper conductors from each side.
(f)
All internal wiring shall be securely supported, neatly

arranged, readily accessible and connected to equipment
terminals and terminal blocks.
(g)
Engraved code identification plastic ferrules marked to

correspond with schematic diagrams shall be fitted at both
ends of wires. Ferrules shall fit tightly on wires and shall not
fall off when the wire is disconnected from terminal block.
(h)
The schematic diagrams of circuitry shall be available in the

respective cabinets (local OLTC control cabinet , local fan
38 of 99
be
provided
40 MVA TRANSFORMER
Volume-II, Part-1
control cubicle and RTCC panel). The diagrams shall be
mounted on the inner side of door of cubicle/cabinets. The
arrangements shall be such that it is not be possible to remove
the diagram from its place and diagrams are long lasting
(engraved type).
19.0
TERMINAL CONNECTORS
19.1
Terminal connectors for HV & LV side bushings shall be suitable
for single/double Zebra ACSR (28.62mm) conductor and suitable for
horizontal and /or vertical take off arrangement i.e. universal type.
19.2
Bushing terminals shall be provided with terminal connectors of
approved type and size for connection to external parts. Terminal connectors
offered must have been successfully type tested as per IS-5561.
19.3
All terminal connectors shall be manufactured out of gravity dye
casting process only and shall be free from blow holes, surface blisters,
cracks and cavities. All sharp edges and corners shall be blurred and
rounded off. The aluminum alloy castings, if used, shall conform to
relevant IS.
19.4
No part of the clamp shall be less than 12mm thickness.
19.5
All bolts, nuts and washers shall be of Hot Dip Galvanised.
19.6
For
bimetallic clamps , bimetallic strip of not less than 2 mm
thickness shall be provided.
19.7
sheets.
Flexible connectors, if provided shall be made from tinned copper
19.8
Size of terminal (bushing stud)/conductor ( ACSR Zebra ) for which
the clamp is designed and also rated current under site conditions shall be
embossed/ punched on each part of the clamp, except hardware.
19.9
All current carrying parts shall be designed and manufactured to
have minimum contact resistance.
Clamps shall be designed corona
controlled.
19.10
The nominal current rating and short time current rating of terminal
connectors shall match the corresponding rating of respective bushings.
20.0
INSULATING OIL REQUIRED FOR TRANSFORMERS
20.1
Transformer oil shall be supplied by the Bidder. The offered Price
of
transformers therefore, should
include first filling of oil( including
wastage) & 10% extra of that quantity. The quantity of oil for first filling
including wastage and 10% extra of that quantity should be indicated by the
Bidder in kilo-liters and in kg in the technical questionnaire. The design of
the transformer shall be based on the characteristic of EHV transformer oil as
per relevant IS.
39 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
20.2
Although oil for the transformer is included in the scope of supply,
but it may be noted that the transformer shall be supplied duly N2 gas filled
with suitable arrangement to ensure that the pressure of gas is regularly
maintained during transit and upto the date of filling of oil. For this
purpose, necessary gas cylinders with regulator shall be supplied on non
returnable basis. Additional gas cylinders required recouping and
maintaining of positive Nitrogen pressure upto filling of oil should be
supplied by the manufacturer of Transformers and the offered price
should take into account this requirement.
20.3
The quality of the oil supplied with transformer shall conform to the
oil parameters specified in this clause. No inhibitors shall be used in the oil.
The oil samples of transformer will be drawn for the oil used at factory &
site as follows.
i.
Prior to filling
ii.
Before and after heat run test / pre-commissioning test
iii. Before energizing.
samples.
All tests as per IS:335 (latest revision) shall be conducted on oil
20.4
Sufficient quantity of oil necessary for first filling of main tank,
coolers, radiators and conservators etc. upto the proper level plus anticipated
quantity of wastage of oil during first filling shall be supplied in tankers. Please
note, wastage means quantity of oil absorbed during initial filling at works for
testing. In addition to the oil needed for first filling, 10% extra quantity of oil
for topping up in future, shall be supplied in non-returnable containers
suitable for outdoor storage. Therefore, total quantity of oil required for first
filling shall be measured at works at the time of testing on unit subjected to
heat run test.
20.5
The supplier shall dispatch the transformer in an atmosphere of
pressurised Nitrogen.
In this case, necessary arrangement shall be ensured
by the supplier to take care of pressure drop of nitrogen during transit and
storage till completion of oil filling during erection. A gas pressure testing
valve with necessary pressure gauge and adapter valve shall be provided.
20.6
The supplier shall warrant and confirm that oil to be used for the
transformer testing at Works & oil to be supplied for the transformer is free
from Polychlorinated Biphenyls (PVB/PCB). The transformer oil to be used
and supplied by the bidder for first filling at site shall be new oil of EHV GradeI having technical specification mentioned hereunder . Hence Oil to be used
by the manufacturers at factory for the purpose of testing at their
works shall be of similar or better quality having parameters matching
with the parameters specified in the specification. Specific approval of
oil test results of oil proposed to be used for testing of transformer in
factory shall be obtained by the manufacturer from the purchaser
before first filling in the unit. MPPTCL shall not accept any other oil for
testing purposes having lower parameters than those specified in the
Bid. Bidders should specifically confirm this requirement in their offer.
40 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
Sl.
No
Characteristics
Requirement
Method of Test
1.
2.
3.
4.
1.
Appearance
The oil shall be clear

and transparent and
free from suspended
matter or sediment
A
representative
sample of oil shall be
examined in a 100
mm thick layer at
ambient
temperature.
2.
Density at 29.5oC
(maximum)
0.89 gm/cm3
IS:1448
3.
Kinematics viscosity at
27oC (minimum).
27 CST
IS:1448
4.
Interfacial tension at
27oC (minimum).
0.04 N/m
IS:6104
5.
Flashpoint Pensky
Marten (closed)
(minimum).
140oC
IS:1448
6.
Pour point. (maximum)
-6 oC
IS:1448
7.
Neutralization value
(Total acidity maximum)
0.01 mg KOH/g
IS:335 Appendix
À, IEC 62021
8.
Corrosive Sulphur
Non-corrosive
IS:335 Appendix `B
9.
Electric strength
(breakdown voltage)
Minimum.
a. New unfiltered oil (as 40 KV (rms)
received condition).
b. After filtration
60 KV (rms)
IS:6792
10.
Dielectric
dissipation 0.002
factor (tan delta) at
90oc Maximum.
IS:6262
11.
Specific resistance
(resistivity)
a. at 90oC Minimum.
b. at 27oC Minimum.
100x1012 ohm.cm
1500X1012 ohm.cm
IS:6103
12.
Oxidation stability
a. Neutralisation value 0.20 mg KOH/g
after
oxidation,
maximum.
0.02 percent by
b. Total sludge, after weight
oxidation Maximum
IS:335 Appendix `C
13.
Presence
inhibitor
IS:335
Appendix `D
of
oxidation The oil shall not

contain antioxidant
inhibitors .
41 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
Sl.
No
Characteristics
Requirement
Method of Test
1.
2.
3.
4.
14.
SK value
6% maximum
IS:335
15.
Water content,
maximum.
10 ppm
IS:2362,IS 13567
16.
Ageing
characteristics
after accelerated ageing
(open Breaker method
with copper catalyst)
a) Resistivity
i. 27oc
ii. 90oc
b) Tan delta at 90oc
c) Total acidity
d) Sludge content
by weight
17.
18
Oil sample taken from

the transformer after
the completion of site
processing and tested in
approved manner shall
have
the
following
values
before
commissioning of the
transformer.
i. Break down
strength
ii. Moisture content
iii. Resistivity at 90oc
minimum
iv. Interfacial Tension
at 27oc
v. Dielectric
dissipation factor at
90 oC
N-dm analysis
CA%
CN%
CP%
As per ASTM-D
1934, IS 12177,IEC
62021
2.5x1012 ohm.cm
(min.)
0.2x1012 ohm.cm
(min.)
0.15 (max.)
0.05 mg
KOH/gm(max.)
0.05% (max)
Minimum 70 KV
withstand
Maximum of 10 ppm
35x1012 ohm.cm
(min)
Tested in accordance
with IS :335
0.04 N/M (min)

0.002 (max.)
4 6%
40-43%
51-54%
20.7
AIR CELL : Our technical specification calls for supply of power
transformers with air cell type oil preservation system of PRONOL, FRANCE
make only. It is obligatory on the part of the Bidders to clearly submit
complete constructional and technical details of sealing arrangement, duly
supported with technical details, pamphlets and dimensional drawings.
42 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
While furnishing details for the above sealing arrangement the Bidders
must confirm clearly that the size and capacity of sealing arrangement is
adequate for the transformer and for the quantity of oil required for the
transformers. Necessary calculation/documentary proof shall be furnished.
20.8
Air cell type oil preservation system included with each transformer
shall ensure as under:
(a)
The air inlet of COPS (Conservator Oil preservation System)

shall be properly fitted on the conservator for leak proof
arrangement to ensure that the air does not come in contact
with oil under any circumstances.
(b)
The size and capacity of the COPS (Conservator Oil

preservation System) shall be selected to suit the design of
Conservator and to ensure proper operation for the quantity of
oil in the unit with the proper allowances. The COPS shall be of
reputed make, proven design and of established performance.
Details in this regard are to be submitted with the offer by the
Bidder for verification . The Bidder is required to submit
calculation with bid to prove adequacy of air cell & its size.
(c)
The Bidder shall clearly indicate in the manual the procedure

for installation of COPS and precautions to be taken at the
time of first oil filling under vacuum in the transformer.
20.9 THERMOSYPHON FILTER: Atleast two Nos. of Thermosyphon filter

arrangement each of capacity 1/5th of the total oil flow in the cooler shall be
provided with rigid support (i.e., slotted one not acceptable) on the
transformer along with connecting piping, isolating valves at either end, drain
plug shall be mounted on the transformer. It will have Alumina trap and will
be designed in such a way that 1/5th of the forced oil circulation passes
through it. The quantity of absorbent will be 0.25% of the total weight of total
oil in the transformer, cooler, conservator etc. Spare alumina for one time
replacement shall be also supplied by the supplier. The location of
Thermosyphon filter should be in such a way that same do not interfere with
any of the existing equipments. The Thermosyphon filter shall be located at
diagonally opposite points of transformer. The connecting pipes of
Thermosyphon filter to tank shall be provided with flexible couplings. It may
be noted that rigid supports shall be provided for thermosyphon filter i.e.,
slotted type of fixing arrangement is not acceptable.
20.10 SILICAGEL BREATHER : Minimum 2 nos. dehydrating filter Silica Gel
Breathers each of 100% breathing capacity are required and the same shall
be provided. Suitable arrangement for parallel mounting of breathers shall be
made for connecting both the Silica Gel Breather to the main conservator.
The passage of air should be through dual filter & Silica Gel. Silica Gel shall be
isolated from atmosphere by an oil seal.
The capacity of silicagel breather shall be adequate to ensure supply of dry air
only for the volumetric expansion/contraction of oil keeping in view the total
quantity of oil in the unit. The container of the breather shall be made of
metal with glass enclosure along its periphery to ensure that the transparency
43 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(to verify the colour of dehydrating agent) is maintained during operation
directly under sunlight (ultra violet rays) for long life. The quantity of the
dehydrating agent shall be sufficient keeping in view the climatic condition
specified and that the breather will be maintained generally two times in a
year. This applies to all the breathers provided with the transformer.
20.11 TRANSPORTATION CONFIGURATION OF POWER TRANSFORMER:
In order to conduct low voltage field testing on power transformers before
unloading/commissioning at site to determine the internal condition, the
transformer shall be transported with :
a) Small bushing (12 KV) may be installed on the bushing cover plate to
represent the actual bushing.
b) Winding leads may be routed, secured and electrically isolated from the
tank walls and active part.
c) Temporarily tests leads may be used to connect the winding leads by
the small bushings (which will be removed before erection of the main
bushings).
The details of arrangement for transport configuration of Power Transformer
(which shall be adopted by Manufacturer) shall be submitted by the
Manufacturer to the Purchaser for approval. The price quoted by the Bidder
should take into account this requirement.
21.0 FITTINGS & ACCESSORIES FOR THE POWER TRANSFORMERS
21.1
Only those offers will be considered for evaluation wherein the
Bidders submit a specific confirmation that the transformers will be supplied
complete with all fittings and accessories exactly in line with various
requirements indicated in Annexure II in this technical specification. The
basic offered cost must take into consideration cost of all fittings and
accessories as under and indicated elsewhere in this specification otherwise
the Bid will be treated as non responsive.
21.2
The
equipments and accessories furnished
with
the
transformer shall be suitably mounted on the transformer for ease of
operation, inspection and maintenance and the mounting details shall be
subject to the approval of the purchaser. All valves shall be provided either
with blind companion flanges or with pipe plugs for protection.
21.3
Indication, alarm and relay equipment shall have contacts suitable
for operation with 110V/220V DC supply. Any other accessories or
appliances
recommended by the
manufacturer
for
the satisfactory
operation of the transformer shall also have 110V/220V DC as input.
a)
OLTC
and its controls shall be as per clause 14.
b)
All
cabinets
& panels shall
stipulations under Clause-16 .
c)
All 145KV, 72.5KV phase and 72.5 KV neutral bushings shall be

of OIP condenser type and as per Clause 11.13 .
44 of 99
be
conforming
to
40 MVA TRANSFORMER
Volume-II, Part-1
21.4.
Equalizing pipes for maintaining equal pressure between main tank
and OLTC and at various other locations as per design shall be provided.
These equalizing pipes shall be routed such as not to create any obstruction.
21.5
Accessories, which are not included in the above schedule
but details of which are given in Bid specification and which are necessary for
satisfactory operation of Transformer shall be deemed to have been
included in the accepted price without any extra cost to the Purchaser.
21.6
It may be noted that all the name plates/rating plates/diagram
plates on transformer shall be engraved type/anodized type and shall be fixed
using rivets/spot welding method. The method of printing of letters on the
R&D plate shall be such that inscriptions shall not fade by ultra violet rays and
other adverse weather conditions under which the same is subject to during
service life of transformers.
(a)
Rating & Diagram Plate: In the R&D plate following additional

information over & above as specified in the IS/CBIP specification shall
be provided.
- Weight of the copper for windings
- Weight of the core laminations for core
- Weight of insulation
- Weight of steel
- Untanking weight (Core & Coil)
- Weight of Transformer Tank along with Fittings &
Accessories
- Percentage Impedance at all taps
- HV winding resistance of all phases at all taps
- LV winding resistance of all phases
- Weight of the oil for first filling in Kg/Liters
- Total quantity of oil (including wastage) and 10% extra
quantity in Kg/Liters
- If required two separate R & D plates may be used.
(b)
Valve Schedule Plate: In the valve schedule plate, at least two views
should be inscribed so that location of all the valves provided on the
transformer could be indicated/visualised. In the table of valve
schedule plate, details of valves viz. type of valve, material of valve,
size of valve & position of valve during transportation and after
commissioning shall be clearly indicated. The size of the letter shall be
such that the same be visible clearly to a person standing away at a
distance of one meter from the respective vertical face of the
transformer.
(c)
Instruction Plate For Oil Filling in the Conservator with Air Cell:
An instruction plate shall be provided for oil filling in the conservator
having air cell type breathing arrangement. In addition to the
instructions for oil filling on this plate, a diagram indicating mounting
details of MOLG, oil level gauges, air cell inside the conservator with a
pictorial view of conservator including make, type & size of air cell shall
also be inscribed. The location of plate should be such that same is
45 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
visible to operating personal from a distance as mentioned in (b)
above.
22.0 CENTRE OF GRAVITY : The centre of gravity of the assembled
transformer shall be low and as near to the vertical centre line as possible.
The transformer shall be stable with or without oil. If the centre of gravity is
eccentric relative to track gauge either with or without oil, its location shall
be shown on the outline drawing.
23.0
PACKING
23.1
The packing may be in accordance with the Bidder's standard
practice but Bidder should give full particulars of packing for the approval of
the purchaser. Special arrangements should be made to facilitate handling
and to protect the projecting connections for damage in transit.
23.2
The transformer shall be transported filled with inert gas preferably
Nitrogen gas. The Bidder shall ensure that adequate pressure of gas is
maintained inside the tank throughout during transportation by sending
escorts and required apparatus and equipment with the transformers.
23.3
All parts shall be adequately marked to facilitate field erection.
Boxes and crates shall be marked with the contract number and shall have
a packing list enclosed showing the parts contained therein. however the
verification of accessories shall be done in presence of suppliers
representative.
24.0
TESTS
24.1
The manufacturer shall carryout routine test ,additional routine
tests and type tests on the transformers as per the relevant Indian
Standard IS-2026 with latest amendments , IEC 60076,CBIP Publication No
295,IEEE or any equivalent International Standard .The details of tests are
specified hereunder. It should be specifically noted by the Bidder that testing
of each & every transformer included in this Bid specification shall be carried
out at the manufacturers works in fully assembled condition complete with all
fittings & accessories.
24.2 ROUTINE TESTS AND ADDITIONAL ROUTINE TESTS: All routine
tests and additional routine Tests detailed under clauses 24.2.1 & 24.2.2
herein under will be carried out on each transformer on "free of cost" basis, in
accordance with IS:2026 part-I.
24.2.1
ROUTINE TESTS
a)
Measurement of winding resistance as per cl.16.2 of IS 2026

Part I. The winding resistance shall be measured on all taps
and of all the three phases and values be recorded in
respective test certificates.
b)
Measurement of voltage ratio at all taps and checking of

voltage vector relationship as per cl.16.3 of IS 2026 Part I.
46 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
c)
Measurement of Impedance voltage/ short circuit impedance

(at all taps) & load loss (at principal tap & extreme taps) as
per cl.16.4 of IS 2026 Part I, IEC 60076.
d)
Measurement of no load loss at 90%,100%,110% of rated

voltage & no load current as per cl.16.5 of IS 2026 Part I.
e)
Measurement of insulation resistance as per cl. 16.6 of IS

2026 Part I.
f)
Dielectric tests as per cl.16.7 of IS 2026 Part I , IEC 60076 as

per latest version.
g)
All tests on OLTC as per cl.16.9 of IS 2026 Part I, IEC 60214.
h)
Measurement of Tan-Delta, Capacitance & IR values of HV,LV &

Neutral bushings before mounting on transformer, before &
after tests on transformer and after dismantling.
i)
Low voltage AC, magnetic balance and magnetizing current

three phase & single phase at normal tap for field reference.
Note : DGA test of oil of main tank of transformer before (initial)&

after completion of all testing shall be done and test results shall be
submitted to the purchaser .
24.2.2
ADDITIONAL ROUTINE TESTS

(A) Insulation
Resistance
: Insulation
Resistance
measurement shall be done for 15 Secs. , 60 secs. and 600
secs. Duration. Polarization Index (PI) shall be clearly
recorded on test report for 600 sec /60 sec values and D.A.R.
for 60 sec/15 sec values.
PI value : PI value (i.e. ratio of IR Values for 600 sec /
IR Values for 60 sec) for winding should be greater than
2.0. This requirement is to be confirmed specifically by
the Bidders in their offer.
(B) Magnetic Circuit Test :After assembly, core shall be tested
for 1 minute at 2000 volts AC between all bolts, side plates &
structural steel work. Immediately prior to the despatch of the
transformer from works of manufacturer, the magnetic
circuit shall be tested for one minute at 2 KV AC between the
Core & Earth and leakage current shall also be recorded.
(C) Oil Leakage Test on Tank : All Transformer tank with its
active part as assembled for type test (i.e. including pipe work
and cooling equipment and excluding PRV and conservator
when air cell is provided) shall
be subjected to a
pressure corresponding to twice the normal head of oil or to
normal pressure plus 35 kN/ m.sq. whichever is
lower
measured at the base of the tank and will be maintained
for 12 hours during which time no leakage shall occur. Before
conducting the pressure test, the following are to be taken
care of :
47 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(i)
Pressure relief valve are to be removed and the opening

blanked .
(ii) Transformer and tap changer conservators

disconnected.
(iii) Diverter switch
connected with
pressure on both
(iv)
Oil should be
released.
are
to
be
compartment of tap changer to be

transformer tank for equalising the
sides.
completely filled and all trapped air
(D) Capacitance & Tan-delta Test on winding: The

measurement of capacitance and tan delta to determine
capacitance between winding & earth shall be carried out
before and after series of dielectric tests by Ampere turn
method. For temperature correction factors IEEE C.57.90 shall
be referred.
The measured Tan delta values of winding shall not
exceed 0.45% at 200C (degree Centigrade) temperature.
In case Tan delta of transformers during testing at
works of manufacturer is measured above maximum
ceiling of 0.45% at 200C (degree Centigrade)
temperature, then MPPTCL reserves right not to accept
such of the transformer. This requirement is to be
confirmed specifically by the Bidders in their offer.
(E)
Test On Bushings: All tests as per IS 2099 & IEC 60137

including Capacitance, creepage distance, Dry/wet p.f. on
terminals
& tapping,
Partial Discharge test, Tan Delta
measurement and oil leakage shall be carried on each
bushing. Each Bushing shall be tested for oil leakage at a
pressure of 1.5 Kg/cm2 for 12 Hours period.
(F)
Test Results of calibration & measurement reports of WTI CT.
(G) Checking & recording of following:

a. IR values
i.
Between Core and End frame
ii.
Between Core and Tank
iii. Between End frame and main Tank.
The measured IR values should be more than 1000 M
Ohms. This requirement is to be confirmed
specifically by the Bidders in their offer.
b. Measurement and recording of currents with
application of 400 volts, 3phase, AC supply on HV
side with LV side shorted, as under
i.
Between Core and Tank.
ii.
Between Core and End frame
iii. Between End frame and Tank
iv. Between neutral and short circuited links with neutral
grounded and ungrounded conditions.
48 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
NOTE: The details of arrangements provided outside the main

tank for connecting core, end frame and main tank body shall be
indicated on a diagram , to be attached with the test reports.
(H) Magnetising current measured with LT supply.
No Particulars
a
b
With Single phase

supply
Volts.
Amps.
With Three phase

supply
Volts.
Amps.
On
HV
side
On LV side
(I)
Magnetic balance test on HV and LV side
(J)
Pressure Relief Device Test : All pressure relief devices

provided in each transformer shall be subject to test for its
successful operation. It shall operate before reaching the test
pressure specified in clause 24.3 (C) of this specification. The
device shall seal off after the excess pressure has been
relieved.
(K) Frequency
Response
Analysis
(SFRA)
Test
on
Transformer : The SFRA test shall be conducted by the
manufacturer at manufacturers works using his own SFRA test
set and also SFRA test shall be conducted by the manufacturer
at site using same SFRA test set at the time of erection &
commissioning of unit.
(L) Measurement of Dew point prior to despatch of the unit,
filled with N2 gas: Dew point is the temperature at which
water vapours present in the gas filled in the transformer
begins to condense. The transportation of transformer from the
factory of manufacturers works upto the purchasers site is
done with dry Nitrogen gas filled condition, due to weight
limitation. Positive gas pressure say 0.25 kg/cm2 is normally
maintained during transportation as well as during storage. In
case positive pressure is not maintained then due to
hygroscopic properties of insulation used in transformer
possibility of absorption of moisture in insulation can not be
overruled. Therefore to check the dryness of insulation,
measurement of dew point at factory prior to despatch and at
site prior to oil filling is necessary and to be carried out. It
may be noted that dew point shall be measured at factory prior
to despatch. Temperature, pressure and dew point at the time
of gas filling (reading taken after stabilisation) shall be taken
and painted on the transformer tank. The minimum
permissible value of dew point shall be ()25oC at normal
temperature and pressure.
49 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(M) Functional tests on auxiliary equipments i.e. OTI,WTI,

valves etc as per CBIP publication no 295.
24.3 TYPE TESTS : Following Type Tests shall be conducted on the
transformer as per IS:2026 Part I, IEC , CBIP publication no 295.
(A) Temperature Rise Test : This test as per cl. 16.8 of IS:2026(PartII) shall be conducted at the lowest voltage tap having maximum
current with 10% over load condition. The supplier before carrying
out such tests, shall submit detailed calculations showing the
alternatives possible, on various taps and for different ratings
(ONAN/ONAF), of the transformer and shall recommend the
combination that results in highest temperature rise, for the test.
Gas chromatographic analysis of oil shall be conducted before and
after heat run test and the values shall be recorded in the test
report. The sampling shall be in accordance with IEC-60567. For
the evaluation of the gas analysis in temperature
rise test, a
method will be proposed which is based on the rate of increase of
particular gases and the permissible limits of minimum detectable
value of gases and the maximum limit will be mutually discussed
and agreed upon between the Purchaser and Supplier. This shall be
treated as reference during maintenance of transformer in future.
The calibration of OTI and WTI shall be done by Transformer
Manufacturer and these calibrated OTI,WTI shall be used during
testing of transformer. The Sr.No. of WTI,OTI shall be recorded
during testing of transformer and these indicators only shall be
supplied with the transformer. During test the manufacturer
selects suitable tap from CT based on gradient between the reading
of WTI & OTI . This tap position is to be clearly recorded on test
report so that selection of correct tap could be done at site to avoid
discrepancy in temperature gradient recorded during factory test and
the value recorded at site.
(B) Impulse Test on line terminals as per IS 2026 part III, on one
transformer of Bid
(C) Tank tests : Following Vacuum and Pressure tests shall be carried
out on one transformer tank.
(a)
(b)
Vacuum Test (Fabrication stage) :

One transformer tank
of each design shall be subjected to the vacuum of 760 mm
of Hg. The tanks designed for full vacuum (760 mm of mercury
at sea level or the barometric reading at the location of test)
shall be tested
at a maximum internal pressure of 3.33
kN/m.sq. (25 mm of Hg) for one hour i.e. 760-25=735 mm of
Hg at sea level and (Barometric reading -25mm Hg) at other
location. The permanent deflection of flat plates after vacuum
has been released shall not exceed the values specified
below:
Pressure Test (Fabrication stage) : One transformer tank
of each design , its radiator, conservator vessel ,and other
50 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
fittings together or separately shall be
subjected
to a
pressure corresponding to twice the normal head of oil or to
normal pressure plus 35 kN/m2, whichever is lower, measured
at the base of the tank and will be maintained for 1 hour
during which time no leakage shall occur. The permanent
deflection of the flat plate after the excess pressure has been
released shall not exceed the figures specified above for
vacuum test as per clause 24.3(C)(a).
24.4
SPECIAL TESTS
: Following special tests other than type and
routine tests shall also be carried out as per IS:2026 Part-I
on one
transformer.
a) Measurement of zero seq. impedance as per CL.16.10 of IS:2026
Part-I.
b)
Measurement of acoustic noise level as per CL.16.12 of
IS:2026 Part-I,NEMA TR1 & IEC 60076-10. Detailed calculations &
conditions outlined in the IEEE standard C 57.12.12.90 shall be
followed.
c)
Measurement
IS:2026 Part-I.
of
power
taken by fans
as
per
cl.16.14
of
d)
Measurement of harmonic level of no load current and total
harmonic distortion of voltage & current as per CL.16.13 of IS:2026
Part-I. Details of rms voltage applied & print out of Harmonic Analyser
shall be enclosed with report.
e)
One Cooler Control Cabinet and OLTC cabinet of each type of
transformer shall be tested for IP:55 protection in accordance
with IS:2147.
f)
24.5
Test to prove over fluxing capability of transformer.

To summarize the requirement of tests for 132KV 40MVA
power transformers covered in this Bid specification, are as
under :
Number of
transformers to
be tested
1
2
3
24.2.1 Routine tests & On each unit
&
additional routine
24.2.2. tests
24.3
Type test:
(A) Temperature
On
Each
unit
rise test
included in Bid
(B) Impulse test
On One Unit of
Bid
(C) Vacuum and
On One unit of
Clause
No.
Nature of tests
51 of 99
Test charges
4
While offering for the Bid, cost
of all these tests for specified
no. of units as per column 3
should be included in the total
Bid price. Thus no additional
charges shall be payable for
any
of
the
tests
and
therefore, offered Bid price
should account for all the
40 MVA TRANSFORMER
Volume-II, Part-1
pressure test
24.4
Special tests
24.7
Tests at site
Bid
costs to be incurred for this

On One unit of purpose
Bid
On
each
unit
included in Bid
24.6
Oil to be used by manufacturers at factory for the purpose of
testing at their works shall be of similar or better quality having
parameters matching with the parameters specified in the
specification. Specific approval of oil test results of oil proposed to be
used for testing of transformer in factory shall be obtained by the
manufacturer from the purchaser before first filling in the unit.
MPPTCL shall not accept any other oil for testing purposes having
lower parameters than those specified in the Bid.
25. TESTS AT SITE :On delivery /receipt, after erection at site, the
transformer shall be subject to the following tests, in presence of supplier's
engineer.
(i)
Immediately upon receipt of transformer at site and before

unloading of transformer from trailer, core earthing , end
frame earthing & tank earthing shall be checked . Only after
satisfactory verification that there is no multiple core earthing
in transformer, unloading of transformer shall be undertaken.
ii)
Insulation resistance test and polarisation index.
iii)
Ratio and polarity test.
iv)
DGA of oil and Dielectric, Tan-Delta, resistivity & moisture

content test of oil.
v)
OLTC operational test at each tap for lower and raise operation
of tap changer.
vi)
Magnetic
current.
balance test and measurement of magnetizing
vii) Vector group test.

viii) Percentage Impedance test at all taps.
ix)
Short circuit current measurement at low voltage and at all

taps.
x)
Measurement of winding resistance at all taps.
xi)
Tangent Delta, capacitance and insulations resistance tests

of bushings.
xii) Leakage current between core & tank, core & end frame , end
frame & tank and between short circuited links & neutral in
grounded and un grounded conditions.
xiii) Dew point measurement & recording of pressure of Nitrogen
gas.
xiv) SFRA test
xv) After receipt of transformer at site physical inspection shall be
done for checking any physical damage to transformer tank &
52 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
accessories. Further data of Impact recorder shall be analysed
for any changes before unloading of transformer.
26.0 CHECKS & TESTS : Following checks & tests shall be carried out by
Manufacturer at different stages of manufacture & supply of transformer and
these reports shall be sent to the purchaser for records :
(i) Assembled Transformer:
a) Check completed transformer against approved out line drawing,
provision for all fittings, finish level etc.
b) Jacking test on the assembled Transformer.
c) Measurement and recording of temperature and drying time during
vacuum treatment.
d) Check for completeness of drying by measuring IR values & Tan Delta.
e) Certification of all test results.
(ii) Preshipment Checks at Manufacturer's Works:
a) Check for interchangeability of components of similar Transformers for
mounting dimensions.
b) Check for proper packing and preservation of accessories like
radiators, bushings, explosion vent, dehydrating breather, rollers,
buchholz relay, control cubicle, connecting pipes, conservator etc.
c) Check for proper provision of bracings to arrest the movement of core
and winding assembly inside the tank.
d) Gas tightness test to conform tightness.
e) Derivation of leakage rate and ensure adequate reserve gas capacity.
(iii) Commissioning Checks at site :
a) Check the colour of silicagel breather.
b) Check the oil level in the breather housing, conservator tank, cooling
system, condenser housing etc.
c) Check the bushings for conformity of connection to the line etc.
d) Check for correct operation of all protection and alarms.
i) Buchholz relay
ii) Excessive winding temperature
iii) Excessive oil temperature
iv) Low oil flow
v) Low oil level indication
e) Check for adequate protection on electric circuit supplying the
accessories.
f) Insulation resistance measurement
g) Check for cleanliness of the Transformer and the surroundings.
27.0 TEST REPORTS : After all tests have been completed seven certified
copies of each test report shall be furnished. Each report shall supply the
following information :i)
Complete identification data including serial number of the

transformer.
53 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ii)
Method of application, where applied, duration and

interpretation of results for each test. Complete diagram of
test circuits and details of test equipments including auxiliary
transformer, Instrument transformer shall be furnished.
iii)
Where ever applicable parameters to be corrected to 75 C

temperature.
iv)
Test certificates
inspections.
of
all
the
accessories
and
stage
28.0 TOOLS : The transformer shall be supplied with a full outfit of tools,
spanners, special tools for assembling and dismantling transformers with a
rack for holding them as per Annexure IX. All spanners shall be double ended
& case hardened. The quantity of each item of tools shall be indicated by the
Bidder in Bid.
29.0 DRAWINGS & INSTRUCTION MANUALS
29.1
SPECIFIC
REQUIREMENT
FOR
GENERAL
ARRANGEMENT
DRAWING: For our 132 KV switch yard, the bay width adopted is 9.6 metres.
Following points shall be kept in view while finalizing General Arrangement
drawing of the transformer.
i.
Along transverse direction (i.e. the parallel to the Bushing line)

spread of the transformer from one extreme end to the other
extreme end shall be limited to 9.6 meters. This spread shall be
distributed symmetrically with respect to the centre line of the
transformer ( i.e. 4.8 meters on either sides) This is an essential
requirement to avoid encroachment of the transformer body in the
adjoining bay.
ii.
Along the longitudinal direction the 132 KV lightning arrestor are

located at a distance of 6.0 meters & the 33 KV lightning arrestor
are located at a distance of 4.0 meters from centre line of the
transformers. While deciding arrangement of location of the
accessories, this requirement needs to be kept in view from
consideration of clearances.
29.2
The drawings for each items of transformer and its accessories are
to be submitted to MPPTCL at the time of obtaining approval of manufacturer.
29.3 As soon as possible after the award of the contract the manufacturer
shall supply Instruction Manual. This Instruction Manual shall be hard
bound manual shall contain set of all approved drawings, instruction books,
manufacturers catalogue of all bought items & fittings, operation &
maintenance manuals , spare part bulletin.
(a) Two copies of each drawing mentioned above and Instruction
Manual shall be sent along with the transformer & its accessories
to site. Further a CD containing soft copy of all drawings in
AutoCAD , instructions manuals and other relevant details in
54 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
acrobat or MS word shall be sent with transformer to site . This
CD shall contain AutoCAD software and acrobat reader software
also.
(b) Ten (10) sets of hard bound folders containing copies of approved
drawings, instruction manuals shall be sent to order placing
authority within a fortnight of approval of drawings. Further, Six
(6) CDs containing soft copy of all drawings in AutoCAD ,
instructions manuals and other relevant details in Acrobat or MS
word shall be sent to order placing authority. These CDs shall
contain AutoCAD software and acrobat reader software also.
30.0
The offered price shall include cost of drawing / manuals as
detailed out in Annexure VI(A).
31.0 DESIGN CALCULATIONS & DESIGN DATA TO BE ENCLOSED WITH
BID : All the important data of the transformer i.e. Net weight of bare copper
in each winding , Weight of core without clamping fixtures , Weight of core
and windings, Cross section of the core, Flux density calculations ,
Calculations for short circuit current and its duration , Current density during
short circuit , Calculations showing withstand capability of windings for
thermal & mechanical stresses during short circuit conditions , Mechanical
Design of transformer tank etc should be invariably submitted by the Bidder .
After placement of detailed contract the final design calculations shall be
submitted for our verification and records .
Submission of design calculations and data with technical bid is a
necessary requirement and those Bids will be rejected wherein these
data & calculations is not found . It may be noted by the Bidders that
no correspondence with the bidder in this regard shall be made after
opening of technical & commercial offer. All responsibility for
Submission of design calculations and data with the Bid is therefore of
the Bidder & non furnishing of same may run the risk of rejection
/non responsiveness of the Bid.
31.1 SHORT CIRCUIT WITHSTAND CAPABILITIES :
31.1.1 The calculations to prove dynamic and thermal short circuit withstand
capability of transformer shall be submitted by the Bidder for the fault level
indicated as under
132 KV - 40 KA for 3 secs.
33KV - 31.5KA for 3 secs.
It may be noted by the Bidders that calculations for short circuit withstand
capability for two winding transformer shall be submitted. Results of
calculations shall be submitted with the bid. The design of winding assembly,
which is to be furnished in the drawing as per Sr. No. (e) of Annexure VI(A)
should be commensurating with these calculations. The details of clamping
ring shall be indicated in the drawing .
55 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
31.1.2 Design of Tank : Complete mechanical design of transformer tank
including details of stiffeners shall be submitted . The tank shall be designed
to withstand the following without permanent distortion.
(i)
(ii)
Vacuum filling of oil at 10 milli torr in transformer with all fittings.
(iii) Continuous internal pressure of 35 kN/m2 over normal hydrostatic

pressure of oil.
(iv) Short circuit forces &
(v)
Under seismic condition /events both horizontal/vertical .
The calculations for tank stiffeners shall be submitted with the bid to prove
no. & size of stiffeners are adequate to withstand full vacuum & pressure.
Drawing of tank shall be submitted indicating stiffners .
31.1.3 Design of Static End Rings (SER) and Magnetic Shunts : Details
of Static End Rings (SER) and magnetic shunts, if provided, shall be submitted
with the bid with calculations. A drawing indicating locations, size, material of
SER and magnetic shunts shall be submitted with the Bid.
31.1.4 Overfluxing Capability: A curve to prove suitability of transformer to
withstand various Overfluxing conditions for the duration indicated in clause
4.4.1 to 4.4.3 without core saturation shall be furnished with the Bid .
31.1.5 Cooling Calculations: Calculations of tank surface for heat
dissipation, details of radiators, fans for ONAN & ONAF cooling shall be
provided with the bid.
31.2 DESIGN DATA : On the basis of offered flux density and current
density, the Bidder shall furnish following design calculations & data. :
31.2.1 Core Data: Details of core material i.e Name of Manufacturer,
Manufacturers type designation for core , thickness of core, curve for Loss Vs
Flux density, No of steps of Core & No of limbs, gross core area , stacking
factor , Net core area ,height & width of core window, center to center
distance of limb, voltage per turn, wt. of core material, working flux density ,
core loss in watts per kg marked on graph for grade of core material &
selected flux density, building factor and calculated no load loss in watts,
guaranteed no load loss.
Design data for core shall be submitted with the bid. A drawing indicating
details of core i.e. limbed construction, step width & thickness , core belting,
top & bottom yoke plate etc shall be submitted with the Bid .
31.2.2 Winding Data : wt. of copper for windings ie. for HV, LV, tap, cross
sectional area ,current density, type of coil, ID/OD/mean dia of coils, size of
winding conductor including parallels, no. of turns per phase, no of spacers,
length of mean turn, weight of copper without paper covering, resistance per
phase of winding at 75 deg C,I2R loss at 75 deg C & normal tap, eddy current
& stray loss at 75 deg C , total copper loss at 75 deg C , guaranteed
transformer losses at 75 deg C.
56 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
Complete details of Insulation components i.e. Top & Bottom clamping rings,
washers , Pressboard blocks & cylinders, Pressboard spacers & Phase barriers,
Pressboard segments etc shall be submitted indicating qty , thickness in mm,
width & height , wt. Design data for winding as per clause 31.2.2 shall be
submitted with the bid.
Dimensioned drawings indicating details of winding, ducts, insulation, take off
arrangement, clamping ring, pressure points etc shall be submitted with the
Bid .
31.3 QUANTITY OF OIL : Complete calculations of oil quantity to be utilized
in transformer for first filling shall be submitted. The calculations shall indicate
(i) Volume of tank including turrets, conservator main & OLTC ,volume
of headers & Radiators, oil quantity in OLTC & thermosyphon filter.
(ii) Oil displacement by Active parts i.e. core - coil assembly,
31.4 CAPACITY OF CONSERVATOR & SIZE OF AIR CELL : While furnishing
details of conservator & air cell type sealing arrangement, the Bidder shall
submit details & calculations for adequacy of size and capacity of Pronal
france make air cell for the rating of the power transformer and also for the
quantity of oil required. Catalogue of Pronal france should be enclosed with
the Bid clearly marking type designation of selected size of Air cell. A drawing
indicating complete details of conservator with Air cell shall be submitted .
31.5 CAPACITY OF PRESSURE RELIEF DEVICE : Our specification calls for
supply of pressure relief device for all power transformers. Bidders must
submit calculation with the bid to prove that the capacity/rating of pressure
relief device and locations of the same for the transformer will adequately
meet our requirement. Constructional and design details of pressure relief
device must be furnished and it should be proved by calculation that the size
and setting of pressure relief device is adequate considering the rating of the
transformer and quantity of oil in the transformer.
A drawing indicating complete details of PRDs & their locations on tank shall
be submitted .
31.6 LIMITS OF TEMPERATURE RISE & HOT SPOT WINDING
TEMPERATURE : The limits of temperature rise for windings, oil and hot spot
have been specified. Temperature rise calculations at rated full load, 110%
load and 125% load considering 100% cooler banks, 50% cooler banks and
without coolers shall be furnished as indicated below :
(a)
100 % Loading : (i) 20 minutes duration

(ii) 10 minutes duration
(b)
57 of 99
100 % cooler bank

50 % cooler bank
without cooler bank
100 % cooler bank
50 % cooler bank
without cooler bank
- 100 % cooler bank

- 50 % cooler bank
- without cooler bank
40 MVA TRANSFORMER
Volume-II, Part-1
(c)

100 % cooler bank

50 % cooler bank
without cooler bank
100 % cooler bank
50 % cooler bank
without cooler bank
100 % cooler bank
50 % cooler bank
without cooler bank
The calculations shall indicate temperature gradient (for all windings i.e.
HV,LV,tap), load losses at lowest tap for all windings , Eddy current & stray
losses, thermal Constant Value & calculations with parameters affecting the
values for above conditions for top oil temperature & winding hot spot
temperature .
The Calculations for Hot Spot winding Temperature and Calculations for
Temperature Rise shall be submitted with the bid.
31.7
CAPACITY OF FILTER & BREATHER :
31.7.1 NUMBER OF THERMOSYPHON FILTER AND CAPACITY OF EACH

THERMOSYPHON FILTER : The Bidder shall submit details & calculations
for adequacy of size and capacity of thermosyphon filter for
the oil
quantity in the power transformer . While furnishing details of thermosyphon
filter arrangements, the Bidder must confirm clearly the
number of
thermosyphon filter, its size and capacity is adequate for the rating of power
transformer. The Bidder shall submit details & calculation to prove for
adequacy of size and capacity of thermosyphon filter with the bid.
31.7.2 CAPACITY OF SILICA GEL BREATHER : The Bidder shall submit
details & calculations for adequacy of size and capacity of silica gel breather
for the oil quantity in the power transformer with the bid.
31.8 RATING OF ON LOAD TAP CHANGER (OLTC) : It has been our
experience that due to inadequate rating of
OLTC elements, the failure of
OLTC components or pitting of contacts have been observed before the
claimed period for maintenance. To verify the adequacy and suitability of the
OLTC components, it is necessary to furnish the calculations for selecting
the proper rating of transition resistance as well as the normal current
rating of OLTC. The calculations shall include the temperature rise of the
OLTC
diverter switch and also the short circuit current considered for
calculation of temperature rise.
Calculations shall be submitted to prove that the current rating of OLTC is
adequate for the rating of the transformer winding taking in to account the
over loading capability as per IS 6600 . The basis for selection of transition
resistance and its current carrying capacity shall also be submitted. In this
regard the circulating current in tap winding during tap change operation
through transition resistance shall be taken in to consideration. Adequacy of
insulation provided in the OLTC between various parts needs to be established
with specific reference to the voltage between two taps. Confirmation shall be
58 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
given that the OLTC is suitable for bidirectional flow of current. The through
current capacity shall be adequate to handle on continuous basis the winding
current including over loading as per IS 6600. The through current rating and
the rating of transition resistance shall take in to account the short time
current rating of the winding. Capability to handle short circuit current to be
established by calculations and also by test reports. The above Calculations
for OLTC shall be submitted with the bid.
31.9 Capacity of Nitrogen Cylinder, pressure in Nitrogen Cylinder to be used
during transportation of transformer shall be submitted with the bid.
31.10
The Bidder shall carry out optimization of Dielectric design of
insulation including electromagnetic design, overload & short circuit withstand
capabilities. During design , transformer modeling shall be done & finite
element software (FEM) may be used.
31.11
Please note that submission of above calculations with
technical bid is a must and in absence of the above, the Bid will
be treated as non responsive and rejected. It is assured that these data
will be kept strictly confidential by MPPTCL.
32.0 QUALITY ASSURANCE PROGRAMME : The Bidders must establish
that a proper quality assurance program is being followed by them for
manufacture of power transformers. In order to ensure this, suitable QAP
should form a part of the technical bid, which will be submitted
against this Bid specification. The quality Assurance Program must have
a structure as detailed in the following paragraphs.
32.1
Customers Specifications And Contract Review : The quality
assurance and failure prevention starts with careful study and scrutiny of
our technical specifications and requirements. The supplier shall carefully
study all the technical parameters and other particulars & the supplier shall
categorically give his confirmation that these requirements shall be met
in a satisfactory manner.
32.2
Design Control : The supplier shall furnish the checks
exercised in design calculations particularly in respect of short circuit
forces and method of clamping end coil to show the healthiness of the
design. The salient features of design together with the certificates of
design engineers will have to be made available to the Purchaser.
32.3
Engineering Documents :The supplier shall give complete
information regarding copper conductor, insulating paper, core materials,
tap changer, gaskets etc. bringing out
the
detailed description and
specification of these items with explanation as to how our requirements are
being met in this respect.
32.4 Procurement Document Control & Purchased Material &
Services : The supplier shall indicate the various sources of the items namely
copper conductor, insulating paper, core material, tap changer and other
items such as gaskets etc. are being procured. The type of checks,
quantum of checks and acceptance norms shall be intimated and random
59 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
test and check results should be made available for inspection whenever
so desired. The vendor list for various bought out items shall be submitted
with the Bid and the same shall be subject to purchasers approval. However,
no change in vendor list shall be acceptable after placement of order and list
of vendors shall be freezed at the time of placement of order. Furnishing
of following certificates is essential ;
i)
Certificate and proof in the form of bill of lading for

purchase of core material
either directly from abroad
manufacturers or their accredited selling agent.
ii)
Certificate and proof in the form of bill of lading for purchase

of EC grade copper from National & International reputed
manufacturers or from their accredited selling agents.
It will however be obligatory on the part of Bidder to allow third

party inspection of all important material e.g. copper, core material,
Insulating cylinder etc. Bidder shall furnish certificate that the transformer
shall be manufactured with the input material approved by the Purchaser
and in case during independent third party inspection any of the above
material is found different than from approved list of vendors, in that case
Purchaser reserves the right to summarily reject complete transformer
and the manufacturer has to replace complete unit made out from all input
material from the vendors approved by the Purchaser.
32.5
Programme Chart : Based on above QAP and offered delivery
schedule a tentative program chart indicating period for various
manufacturing/testing activities shall be submitted along with QAP . The
program chart should specify periods for various activities i.e. design,
ordering of new materials, assembly, testing etc.
It should be noted by the Bidders that submission of QAP with the Bid
is an essential requirement and such of the Bids wherein QAP is not
found shall be rejected by the Purchaser.
33.0
INSPECTION AND TESTING
33.1
Inspection
33.1.1
The Purchaser shall have access at all times to the works and all
other places of manufacture where the transformers are being manufactured
and the Bidder shall provide all facilities for unrestricted inspection of the
Bidders works, raw materials, manufacture of all the accessories and for
conducting necessary tests as detailed herein.
33.1.2
The successful Bidder shall keep the Purchaser informed in advance
of the time of starting and of the progress of manufacture of equipment
at its various stages of manufacturing, so that arrangements could be
made for inspection.
33.1.3
No material shall be dispatched from its point of manufacture
unless the material has been satisfactorily inspected and tested.
60 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
33.1.4
The acceptance of any quantity of Transformer & its accessories
shall in no way relieve the successful Bidder of his responsibility for
meeting all the requirement of this specification and shall not prevent
subsequent rejection if such equipments are later found to be defective.
Acceptance of condition regarding stage inspection at various stages which
will be intimated to successful Bidders shall be the essence of the contract to
be placed against this Bid.
33.2.
Inspection Programme :The Bidder shall chalk out a detailed
inspection and testing program for manufacturing activities for the various
components. An indicative program of inspection as envisaged by the
Purchaser is given in Annexure-VIII. The Purchaser reserves the right to get
carried out any tests by a third party. All Cost of inspection/tests shall be
borne by the Bidder.
33.3
Stage Inspections
33.3.1
The supplier shall indicate the inspections and checks carried out
at various stages of the manufacture of the transformers. A complete
record of stage inspection would be kept by the supplier and this record
should be made available for inspection by the representative of the
Purchaser. The supplier should indicate the manufacturing program and
the Purchaser will have a right to depute its inspecting officers during
the manufacture. Some of the inspecting stages are tank during fabrication,
coil winding , core building, assembly of coil on core, the condition of the coil
and core after the treatment in vacuum chamber, assembly within the
transformer tank together with application of tap changer.
33.3.2
It may be noted that stage inspection for first unit or all the units
,at our discretion , shall be done by us at the following stages.
(a)
Fabrication stage of tank: After fabrication, tank shall be inspected

for measurement of its dimensions, thickness of sheets used and
leakage test by applying requisite pressure/vaccum.
(b)
Building up of Core : After the core is built but before its

clamping, our representative will inspect the core to
take
complete weight of the core and also to measure approximate core
loss. If necessary, a small strip of core shall also be taken for
testing at CPRI, Banglore or at any other testing lab. of repute
(c)
Preparation of Winding : Once the coils are prepared but before

the same are fitted on to the core, stage inspection shall be done
to take various measurements and also for weighment of total weight
of coil of each voltage class. Measurement of resistance shall be taken
and for this purpose, a small piece of conductor for each type of
winding shall be made available by the manufacture.
(d)
Core Coil Assembly before & After VPD or Drying out

The Bidder has to submit with the Bid complete details of
Drying out process of transformer adopted in its works. The
details should include cycle, description , termination rate ,
process diagram , size of oven , measurement method of
61 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
moisture extracted etc . Failure of the Bidder to comply with
this requirement shall result in rejection of the Bid.
(e) Final Assembly of Transformer after boxing in of active material
Apart from the above, the Purchaser also reserves the right to carry out stage
inspections at
other stages also, for which advance intimation shall be
given and all necessary cooperation shall be rendered by the manufacturer.
33.4
Final Inspection and Testing
33.4.1
At the time of final inspection, the supplier shall identify each
and every item/accessories/fittings
of the particular transformer under
testing. Unless all the items are identified, the manufacture will not be
treated as complete. Serial number of bushings, serial number of tap changer
and other accessories shall be entered into the test report to ensure that the
same are supplied with the transformer. Various
tests
stipulated in IS
shall be performed in the presence of purchasers engineers or when the
inspection waiver has been given, in such a case, the testing shall be
done at the manufacturer's works as per IS stipulations and same should
be confirmed by documentary evidence by way of Test Certificate which
shall be got approved by the purchaser.
33.4.2 The WTI & OTI shall be calibrated during testing of transformer
and Serial Nos. of these instruments shall be recorded in test reports.
The WTI & OTI used during testing shall be dispatched with the transformer
so that installation of same OTI & WTI on transformer is done which are
utilized during testing of transformer at suppliers works. The Bushings
and Radiators on Transformer (if heat run test is conducted ) during testing
of transformer at manufacturers works are required to be supplied with the
same transformer to avoid any mismatch / misalignment etc. during
assembly of transformer. This should be noted for strict compliance and
confirmed specifically.
33.4.3
Whenever inspection call for a particular transformer is given, the
letter of inspection call will accompany the following:
a.
List of various fittings and accessories which are ready at the works
and will be offered for inspection. The Inspecting Officer will carry
the list and check the items declared to have been offered for
inspection
b.
It is expected that before a transformer is finally offered for

inspection,
internal testing of
the
transformer
for various
important parameters like winding
resistance, transformer
losses, IR values etc are already done. Routine test report for such
tests shall also accompany the letter of inspection call so that the
Inspecting Officer
at
the time of inspection may verify the
parameters brought out in the preliminary report. Details of all
tests should be clearly brought out.
c.
In case for any reasons inspection is not completed or

equipment is not found to be complete with all accessories as per
62 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
confirmation given with the
letter
of
inspection call,
the
Purchaser will reserve the right to recover the complete cost of
deputation of inspecting team to the works of the manufacturer.
34.0
STORAGE, HANDLING & SHIPPING :
When the transformer is declared ready, the manufacturer has

to identify each and every item associated with this unit and a `Complete
Packing List shall be prepared in advance. The equipments shall be stored
and handled properly in shipping depot, while the same is under process
of dispatch. The manufacturer should ensure dispatch of all the related items
and accessories with a particular unit of transformer along with tank.
Tap changer, bushing, radiators and other accessories of the
transformer should not be withheld for use subsequently on units for testing
purposes. If there are any items procured from sub-contractors which are to
be directly installed like instrumentation, panels, control gear etc. test and
inspection report for the same shall be kept separately and made available to
purchasers inspecting officers.
It may be noted that NO CHANGE in any accessory or
associated equipments after passing all the test successfully shall be
allowed and if this is subsequently detected it shall be binding on the Bidder
to replace with the same item with which the initial test were conducted at
his part failing which the entire test shall become null and void. The
Purchaser at his discretion may consider for rejection of the units thus
supplied. The entire cost, for replacement of such rejected units thus
supplied and for repeating acceptance test, shall be borne by the Bidder.
35.0
COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS
The Bidders must furnish the following information along with

technical bid.
35.1
A list of all the accessories which will be supplied with the
transformer should be furnished. This should be as per Annexure II & III.
While furnishing the list of accessories, items which will be manufactured by
the main manufacturer and balance items, which will be procured from subsuppliers should be clearly identified and intimated.
35.2
It is obligatory on the part of Bidder to ensure that supply of all
accessories as per Annexure-II are made alongwith Main Tank or prior to
delivery of Main Tank so that erection
and commissioning
work of
Transformer can be completed properly and uninterruptedly .The date of
supply of last accessory will be treated as date of delivery of transformer
and penalty shall be imposed upto a maximum of 10 % for delay in supply
and supply bills will be processed accordingly.
35.3
The responsibility for obtaining timely supplies of bought out
items will rest on the Bidder and only on this basis, delivery period will be
offered in the Bid.
63 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
35.4
It may be noted that in case of damages/shortages due to
improper packing or any other negligence ,replenishment shall be arranged
within 45 days of being noticed by the purchaser . If this is not done, date
of delivery of such accessory will be treated as date of delivery of main
equipment and full penalty shall be recoverable from the Bidder on total
cost of the equipment. This should be confirmed.
35.5
For bought out items, responsibility for guarantee and obtaining
immediate replacement in case any defects are noticed and in case defective
supply of any item is reported will rest on the Bidder.
35.6
In case for attending to defect in any accessory or inspection/
replacement of the accessory, which may be bought out item
for the
Bidder; services of engineer of original manufacturer is required, the same will
be organized on immediate basis by the Bidder at his cost.
35.7
The bidders are required to furnish in their bid, the following details
of packages for supply of complete quantity of materials/one complete
equipment:
i.
ii.
iii.
iv.
Total number of packages

Dimensional details of each package.
Weight of each package.
Nature of content (i.e. fragile or non-fragile)
In addition, the bidder from outside India offering CIF prices shall
also indicate the port of entry in India.
36.0
For all power transformer included in the
Bid specification ,
provisions and stipulations as per CBIP Manual on Transformers in regard to
the following except as modified in this document should be strictly adopted
a)
Design and standardisation.
b)
Galvanising.
c)
Labels.
d)
Nuts & bolts.
e)
Cleaning & Painting.
f)
Prevention of acidity.
g)
Continuous maximum rating & over loads.
h)
Duty under faults conditions for stabilizing windings.
i)
Flux density and magnetizing current.
j)
Vibration & noise.
k)
Suppressions of harmonics.
l)
Magnetic circuit and mechanical construction of cores.
m)
Constructional arrangements for winding.
n)
Earthing arrangements.
64 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
o)
Cooling plant for the transformers.
p)
Temperature indicating device and alarm.
q)
Gas actuated relays.
r)
Marshalling box/control cubicle, panel drives & Mechanism Box
s)
Control connection and instrument wiring.
t)
Drying out, transport and erection.
u)
Valves and air release plugs.
37.0 REQUIREMENT FOR TRANSPORTATION OF TRANSFORMERS:

The Bidders shall include charges for fitting atleast one Electronic
impact recorder (on returnable basis) during transportation of Transformers to
measure the magnitude and duration of the impact in all three directions. The
acceptance criteria and limits of impact in all three directions which can be
withstood by the equipment during transportation and handling shall be
submitted by the supplier during detailed engineering. The recording shall
commence in the factory before despatch and must continue till the unit is
installed on its foundation. The data of electronic impact recorder(s) shall be
down-loaded at site and a soft copy of it shall be handed over to Engineerincharge. Further, within three weeks the supplier shall communicate the
interpretation of the data. In the unlikely event of impact recorder output not
available at site, the equipment shall be thoroughly internally inspected by the
manufacturers representative before erection at site to ensure healthiness of
the equipment.
Further the supplier shall mount Vehicle tracking system (GPRS/ GPS/
GSM based) to track the exact position of the vehicle on which the power
transformer is being loaded for transportation and during detailed engineering
take approval for the equipment installed.
37.1 ESSENTIAL SPARE BUSHINGS TO BE SUPPLIED ALONGWITH
TRANSFORMER
The offered transformer should include following spare
bushings required for operation & maintenance of the transformer.
With each transformer, the spare bushings described below should be
supplied.
No. spare bushings to be supplied with each transformer
Quantity
1
145 KV bushing (Meeting technical specification stipulated in 1 No.
clause 11.13 of Section I, Part-1, Volume-II)
2
72.5 KV bushing (Meeting technical specification stipulated in 1 No.
clause 11.13 of Section I, Part-1, Volume-II)
37.2.4 TRAINING: Subsequent to delivery of above testing equipments,
demonstration & Training for 1 to 2 days period to a batch of our engineers
shall be provided by the supplier on free of cost basis for each Equipment
65 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
supplied
by
the
supplier.
The
training
shall
cover
operation,
evaluation/analysis of test results and general trouble shooting about the
equipment.
38.0
Please ensure the bid document containing number of pages
have been properly page numbered and each page is signed by the
Bidder. All bid documents including Annexures should be indexed
properly and Index of the document should be enclosed/placed at
the beginning of the bid document.
66 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE I
PRINCIPAL PARAMETERS FOR 132/33 KV, 40 MVA
POWER TRANSFORMER
The transformers shall conform to the following specific parameters described
here under :No.
1
2
DESCRIPTION
PARAMETERS
Type of power transformer/ Two winding, Three phase suitable for
installation
out door installation
Mounted on rails
Type of mounting
Centre to centre distance 1676 mm +
Rail width on both direction
i.e
longitudinal and transverse.
3
4
5
6
7
Suitable for system frequency

Rated voltage ratio: HV/LV
No. of phases
No. of windings
Type of cooling
50 Hz
132/33 KV
Three
Two
ONAN/ONAF
MVA Rating corresponding to

a. ONAN Cooling (80%)
b. ONAF Cooling (100%)
32 MVA
40 MVA
Method of connection
HV - Star
LV - Star
10
Connection Symbol (Vector

group)
Ynyno
11
System earthing
Solidly/ Effectively earthed
12
Percentage Impedances, Voltage

on normal tap and MVA base
corresponding
to
HV/LV
rating and
with
applicable tolerances as per IS
13
Ohmic value of HV/LV short

circuit
Impedance as viewed
from HV side
Supplier to furnish
a. Max. Voltage Tapping
b. Minimum Voltage Tapping
c. Normal Voltage Tapping
14
Anticipated continuous loading

HV and LV
15
Tap Changing gear

i.
Type
ii. Provided on
10%
Not to exceed 110% of its rated

capacity.
ON LOAD
Taps on HV for variation of HV
voltage to provide constant 33 KV
67 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
No.
iii.
iv.
v.
DESCRIPTION
Tap range
Tap step
Voltage and current rating
PARAMETERS
Voltage.
(-)15% to (+)5%.
1.25%
66KV/132 KV(Suitable for132KV
neutral end), 300Amp (min.).
16
Over voltage operating capability 110% rated voltage continuous,

and Duration
125% rated voltage for 60 seconds,
140% rated voltage for 5 seconds.
17
Minimum Air core reactance of 20%

HV Windings
18
Minimum knee point voltage
19
Flux Density
a.
Working Flux density in 1.65 Tesla
any part of core and yoke at
rated MVA,
frequency and
normal voltage .
1.90 Tesla
b. Maximum flux density in
any part
of core and yoke
at 110% voltage
and (-)
4% frequency variation shall
not exceed
20
Insulation levels for windings

a. 1.2/50 micro second wave
shape lightening impulse
withstand(kVp)
b. Power frequency voltage
withstand(KV rms)
21
Type of winding insulation

a. HV winding
b. LV winding
110% rated voltage
HV/LV
550/250
230/95
Graded
Full
22
System short circuit level and 40 KA for 3 sec. for 132KV

duration
for
which
the 31.5 kA for 3 sec for 33KV
transformer shall be able to
withstand thermal and dynamic
stresses (kA rms/sec)
23
Noise level when energized at As per NEMA-TR1 Standards

rated voltage and frequency but (Copy of NEMA-TR1 Standards to be
without load.
furnished)
Permissible temperature rise
Over ambient temp of 50 0C
i. of top oil measured by
45C
thermometer
50C
ii. of winding measured by
resistance
24
68 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
No.
25
26
27
28
29
30
DESCRIPTION
Minimum clearance in air (mm)
a. HV (132)
b. LV ( 33)
Terminals : (Bushings)
a. HV winding line end
b. HV/LV winding Neutral end
c. LV winding
Max. Radio Interference voltage
level at 1 MHz. & 266 kV rms
phase to ground voltage for HV
winding
Cooling Equipments :
a. Number of banks
b. Number of Fans
PARAMETERS
PHASE TO PHASE PHASE TO GROUND
1430
1270
700
600
145 KV OIP condenser
72.5KV OIP condenser
72.5KV OIP condenser
1000 micro volt
Two 50% cooler banks

Adequate number of Fans for ONAF
cooling and standby Fans for 20%
additional cooling, in each bank
Bushings :
a. Voltage Rating ( KVrms )
b Current Rating (Amps)
c. Insulation level
i. Lightning impulse
withstand(KVp)
ii. One minute power
frequency withstand
voltage (KV rms)
iii. Creepage distance (mm)
145KV/72.5KV
1250/1250A
650/325
275/140
3625/1813
HV
LV
a) Bushing Current Transformer
for purchasers use
Single phase ring type turret mounted
i. Type
200/1
800/1
ii. Current Ratio HV:LV(A/A)
3
nos
3 nos
iii. Quantity
1000V
1000V
iv. Knee point voltage (V)
PS
PS
v. Accuracy class
vi. Secondary resistance (Ohms) As per requirement or < one ohm
One
One
vii. No. of cores
HVN
LVN
b) Neutral
side
C.T.
for
Purchasers
use
(for
restricted E/F protection):
i. Type
Single phase outdoor mounted
ii. Quantity
1 no
1 no
iii. No. of cores
One
One
iv. Current Ratio (A/A)
200/1
800/1
v. Class of accuracy
PS
PS
vi. Max.
secondary
winding As per requirement or < 1.5 ohm
resistance
69 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE - II
LIST OF FITTINGS AND ACCESSORIES
TO BE PROVIDED WITH EACH POWER TRANSFORMER.
1.
Each transformer shall be provided with the following accessories.

i
One no. Dial type Thermometers for oil : A dial type

indicating thermometer with repeater of robust
pattern
mounted inside FCC at a convenient height to read the
temperature in the hottest part of the oil and fitted with alarm
and trip contacts. ROTI shall also be mounted on RTCC
panel.
ii
Three nos. WTI, two nos. for HV (on extreme phases) &
one no. for LV winding (on middle phase) :
These shall be indicating type, with repeater responsible to
the combination of top oil temperature and winding current,
calibrated to follow the hottest spot temperature of the
transformer winding. The winding temperature indicator shall
operate a remote alarm before the hottest spot temperature
approaches a dangerous value and
it shall automatically
actuate the cooling fan Motors.
iii
RWTI : These shall be as per cl. 11.10 of Section-I. A

precision potentiometer mounted inside the case shall function
as a transmitter to operate a repeater for RWTI. For HV
winding the transmitter shall be directly connected to the
repeater. For the LV winding the transmitter shall be
connected to a Resistance Transducer, which will supply DC
for operating repeater.
iv
One magnetic type oil level gauge with low level alarm
contacts and dial showing minimum, maximum and normal oil
levels.
One plain oil level gauge of over lapped type on either side of
the conservator shall also be provided.
vi
Valves (As Per Annexure V) In the Annexure-V of valve

schedule, 4 nos. valves are required to be provided in each
Thermosyphon filter. Out of 4 nos., 2 nos. shall be provided
for the purpose of disconnecting the oil flow between the main
tank and Thermosyphon filter and 2 nos. are to be provided
for the purpose of filtration of charge of the Thermosyphon
without disconnecting the Thermosyphon from body .
vii
Minimum 3 nos. pressure relief valves. The quantity of these

valves should commensurate with the quantity of oil in the
transformer and also location of valves should be properly
designed to adequately release the excessive pressure.
viii
A set of air release valves on the top and on the radiators and
also at appropriate places.
70 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ix
One thermometer
thermometer.
pocket
for
mercury
in
One double float gas detector relay(Buchholz relay) with alarm

and tripping contacts to detect accumulation of gas and
sudden changes of oil pressure, complete with shutoff valves
and flanges couplings to permit easy removal without lowering
oil level in the main tank, a blend valve for gas venting, and
test valve. Make of buchholz relay shall be as per our
discretion.
xi
Heat exchangers or radiators complete with shut of valves and

with facility for oil draining arrangement.
xii
a.
Two oil conservator, with required accessories, one for

main tank and other for OLTC. Two nos Silica gel
Breathers with main Conservator & one no. for OLTC
Conservator.
b.
Air cell type breathing arrangement with oil preserving

equipment complete in all respects of PRONOL make
only.
xiii
Eye bolts and lugs on all parts for easy handling.
xiv
Two grounding earthing terminals

corner of tank.
xv
One rating and diagram plate.
at
glass
diagonally
type
opposite
xvi
A set of minimum 4 nos. flanged bi-directional wheels for rail

mounting (for 1676 mm rail gauge.)
xvii
Set of fans required for ONAF cooling of the transformer with

following information
a.
Number of Radiator Banks.
b.
No. of BEE triple star rating cooling fans (Industrial

duty of adequate voltage & rpm) provided in each bank
to ensure 100% ONAF rating of the transformer. As per
our specification, for each bank one additional cooling fan
is to be included which will be duly wired-up.
xviii
Suitable jacking lugs and haulage holes.
xix
Inspection window & main holes with bolted cover

Annexure-IV.
xx
Adequate no of Thermosyphon filter assembly (minimum 2

nos) with suitable supports, valves and pumps for forced but
slow circulation of Transformer oil .
xxi
Lifting arrangement for the complete transformer, core

assembly and also tank.
xxii
One detachable bolted type MS ladder each on main tank and

conservator tank.
xxiii
For the purpose of taking earthing connection from the

neutral bushing, adequate number of brackets with small
71 of 99
as
per
coil
40 MVA TRANSFORMER
Volume-II, Part-1
support insulators shall be provided on the body of the tank
so that earthing could be arranged by Purchaser near the
earthing pit of transformer itself.
xxiv
A separate weather proof FCC (Fan/Cooler control) cubicle

containing dial type thermometer and winding temperature
indicator and terminals of dial type thermometer, winding
temperature indicator, buchholz relay, MOG, control of fans
etc.
Please note provision of separate Fan Control Cubicle (FCC)
is a must. FCC shall be suitably dimensioned to accommodate
the following :a
The wiring from RTCC shall be brought to marshalling box

and for terminating the same adequate numbers of
suitably rated terminal connectors shell be provided.
Necessary cable glands shall be included in the scope of

supply.
Arrangement for terminating the connecting leads of

OTI, WTI, buchholz, magnetic oil level gauge etc. shall be
made in the marshalling box. It should be possible to
read OTI and WTI readings without opening the box
through suitable glass window. All trip alarm and
repeater signals will be transferred to control room for
which arrangement will have to be made.
d Starters for cooling fans shall be housed in marshalling box

and necessary switches for local operation of fans shall be
provided.
e
Local remote control switch for OLTC shall be provided.
Space heater with switch, cubicle illumination lamp,

fuses, links overload protection arrangement for motors
and other accessories shall be included in the scope of
supply.
xxv
One set of indoor RTCC (Remote tap changer control) cubicle

complete with provision for remote operation of OLTC,
as
independent
or
master/follower
scheme, with
oil
and
winding temperature
repeater, tap position indicator
with
annunciation for
fan group ON/OFF and cooler supply fail
indication and Tap changer in progress including OTI repeater
& WTI remote indicator operated by remote sensors.
xxvi
One set of erection manual/relevant drawing/leaflets should be

secured permanently inside the RTCC cubicle as a guide line for
site erection and commissioning.
xxvii
Three separate connection i.e. connection from

core,
connection from end frame and connection from tank shall
be brought out on to a terminal box with cover. Arrangement
for inter connecting these terminals in the terminal box shall also
be provided. This arrangement shall facilitate verification of
core, end frame and tank insulation.
72 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
xxviii Mounting of radiators on the 33KV side of 72.5KV
bushing should be avoided. In no case, the radiators
should be projected above the main tank height.
xxix
All transformers shall be supplied with a full outfit of tools,

spanners,
jacks,
special tools as per Annexure IX
for
assembly and all spanners shall be double ended and of very
good quality of " Gedore " or "Taparia " or equivalent make.
2.
The equipments and accessories furnished with the transformer
shall be suitably mounted on the transformer for ease of operation, inspection
and maintenance and the mounting details shall be subject to the approval
of the purchaser. All valves shall be provided either with blind companion
flanges or with pipe plugs for protection.
3.
Indication, alarm and relay equipment shall have contacts suitable for
operation with 110V/220V DC supply. Any other accessories or appliances
recommended by the manufacturer for the satisfactory operation of the
transformer shall also have 110V/220V DC as input.
4.
a.
OLTC and its controls shall be as per clause 14 Section-I

of specification.
b.
All
cabinets
& panels shall
be
conforming
to
stipulations under Clause-16 of Section -I of specifications.
c.
All 132KV, 33KV and neutral bushings shall be

of OIP
condenser type and as per Clause 11.13 of Section I of
specification.
5.
Provision for Measurement of Degree of Polymerisation of
Insulation of Winding of Transformer :- To assess the life of paper
insulation of winding , a provision is to be made inside the transformer . For
this purpose, a container of insulating material of good electrical, mechanical
& chemical properties having free circulation of oil through it shall be provided
at suitable location where maximum oil temperature is expected. In the
container, atleast 10-12 spools of paper having size not more than one cm be
placed . The container shall be closed and there should not be any possibility
of spools coming out from the container due to natural circulation as well
turbulence of oil during fault etc.
Location of the container shall be selected such that spools may be
removed from the container as and when required by the purchaser during
service of transformer for the purpose of testing of insulating material for
Degree of Polymerisation (DP test).
6.
ACCESSORIES, WHICH ARE NOT INCLUDED IN THE ABOVE
SCHEDULE BUT DETAILS OF WHICH ARE GIVEN IN BID
SPECIFICATION AND WHICH ARE NECESSARY FOR SATISFACTORY
OPERATION OF TRANSFORMER SHALL BE DEEMED TO HAVE BEEN
INCLUDED IN THE ACCEPTED PRICE WITHOUT ANY EXTRA COST TO
THE PURCHASER.
73 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE -III
LIST OF TRANSFORMER ACCESSORIES AND THEIR TESTCERTIFICATES
TO BE SUBMITTED BY MANUFACTURERS/APPROVED VENDORS
S.
No.
Accessory
Condenser
Bushing
2.
Pronol france
Ref. Std.
Test-certificates required
IS2099,
IEC60137
1. Appearance, construction and dimensional

check
2. Test for leakage of internal filling at
a pressure of 1.0 kg/cm2 for 12hours.
3. Insulation
resistance
IS 2099
measurement with 2000V megger.
4. Dry/wet
power
frequency voltage
withstand test.
5. Dry/wet
power
frequency voltage
withstand test for test tap insulation
6. Partial discharge measurement up to 1.5
UN/_/3 KV.
7. Measurement
of
tangent delta and
capacitance.
IEC
1.
2.
3.
OLTC
4.
Winding
Temp
Indicator &
Dimensional check,
inflation/Deflation at 10
inflation/Deflation at 10 KPa
Pressure test at 10 KPa for 24 Hr.
IS 2026
part I,
IEC 60214
1. Oil tightness test for the 8468 diverter

switch oil chamber at an oil pressure of
0.5 kg/cm2 at 100 degree centigrade for 1
hour.
2. Mechanical operation test.
3. Operation sequence measurement
4. Insulation resistance measurement using
2000V megger
5. Power frequency voltage withstand test on
diverter switch to earth and between even
and odd contacts.
6. Power frequency voltage withstand
test
on
tap
selector-between
stationary
contacts, between max. and min. taps,
between phases and supporting frames,
between phases.
7. Operation test & dielectric test of complete
OLTC.
IS
1. Calibration test
2. Dielectric test at 2 kV for one minute.
3. Accuracy test for indication and switch
74 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
S.
No.
Accessory
Ref. Std.
Oil Temp
Indicator
setting scales.
4. Test for adjustability of switch setting
5. Test for switch rating
6. Measurement of temperature rise with
respect to the heater coil current.
5.
Pressure
Relief valve
IS13947
1. Functional test with Compressed air to

check bursting pressure, indicating flag
operation and switch operation.
2. Dielectric test at 2 KV for one minute.
3. Switch contact testing at 5A, 240 Volt AC.
4. Leakage test at 75% operating pressure
for 1Hr.
6.
Cooling Fan
and motor
assembly
IS 2312

check.
2. Insulation resistance measurement
3. Dielectric test at 2 KV between winding
and body for one minute
4. Operation check.
5. Power consumption, RPM, Current.
7.
Buchholz
Relay
IS:3407
1. Leak test with transformer oil

at
a
pressure of 3 kg/cm2 for 30 minutes at
ambient temperature for relay casing.
2. Insulation resistance measurement with
500V megger.
3. Dielectric test at 2 kV for 1 minute
4. Elements test at 1.75 kg/cm2 for 15
minutes using transformer oil at ambient
temperature.
5. Loss of oil and surge test.
6. Gas volume test
7. Mechanical strength test
8. Velocity calibration test
9. Appearance construction and dimensional
check.
8.
Oil Level
gauge
including
MOG
IS

check
2. Dielectric test at 2 KV for 1 minute
3. Switch contact test at 5A 240V AC
4. Switch operation for low level alarm
5. Test for oil levels
9.
Pressed Steel
Radiators
IS513
1. Appearance, construction &

dimensional
check.
2. Air pressure test at
2 kg/cm2 under
water for 15 minutes
75 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
S.
No.
Accessory
Ref. Std.
10.
OLTC Control
cubical/Cooler
Control
cubicle
IS
1. Appearance, construction & dimensional

check.
2. Electric operation
3. Insulation resistance measurement using
500 V meggar at ambient temperature
4. Dielectric test at 2kV for 1 minute
11.
Bushing
Current
Transformers
IS: 2705
1. Appearance, construction & dimensional

check. Polarity Check, Measurement of
insulation resistance.
2. H V power frequency test.
3. Determination of ratio error and phase
angle of measuring and protection BCTs
4. Interturn insulation test
5. Exciting
current characteristic test,
Secondary
winding
resistance
measurement
12.
Terminal
connector
IS5561
1. Dimensional check construction

2. Tensile test, resistance test
3. Galvanisation test as per IS 2633 on
galvanized parts .
13
Silica Gel
Breather
IS
1.Pressure tests
2. Visual & dimension tests
3. Operation test
4. silica gel test
5. Oil compatibility test
76 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE-IV
SCHEDULE OF INSPECTION COVER/ACCESS WINDOWS
No.
Particulars
Size
(Length x
Width)
(mm x mm)
Qty.
(Nos.)
Inspection cover (man hole)
450x900
Inspection cover/ Access Window

for OLTC
400x500

for HV Bushing
250x350

for LV Bushing
250x350

for Neutral Bushing .
250x350

for inspection of active parts /
connections
etc.
as
per
manufacturers design
for visual inspection internal
parts
77 of 99
As per design requirement
As per design requirement
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE-V
SCHEDULE OF VALVES
Item
Description of Valves
Size
Qty
Type
(Design)
Oil inlet valve for Radiator header
200NB
Gate valve
Oil outlet valve for Radiator header
200NB
Gate valve
Top Oil filter valve
50NB
Gate valve
Bottom Oil filter valve
50NB
Gate valve
Top oil sampling valve
15NB
Globe valve
Bottom oil sampling valve
15NB
Globe valve
Drain plug bottom tank
25NB
Drain valve (Tank)
100NB
Butterfly valve
Drain valve (Tank)
100NB
Gate valve
10
Radiator Isolating valve
100NB
11
Drain plug on radiators
Bsp
12
Air release plug on radiators
Bsp
13
Drain cum filter valve on header
14
As per Butterfly valve

design
50NB
Globe valve
Drain plug on header
Bsp
--
15
Air release plug on header
Bsp
16
Drain plug on inlet pipe
Bsp
17
Drain plug on outlet pipe
Bsp
18
Air release valve on tank cover
15NB
Gate valve
19
Pressure release valve (Main tank)
150NB
Gate valve
20
Valve for DGA
25NB
Gate valve
21
Thermosyphon drain valve
15NB
Globe valve
22
Thermosyphon filter valve
50NB
Gate valve
23
Drain plug on Thermosyphon filter
Bsp
24
Air release plug on Thermosyphon

filter
Bsp
25
Thermosyphon isolating valve
100NB
Butterfly valve
26
Oil surge relay isolating valve
25NB
Globe valve
27
OLTC equalizing valve
15NB
Gate valve
28
OLTC suction valve
25NB
Globe valve
29
OLTC Conservator drain valve
15NB
Globe valve
30
Buccholz relay isolating valve
80NB
Gate valve
31
Valve for Vacuum breaking during oil

filling
25NB
Gate valve
32
Gas Sampling valve
Bsp
Gate valve
78 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
Item
Description of Valves
Size
Qty
Type
(Design)
33
Main conservator Drain valve
50NB
Gate valve
34
Main conservator Air release valve
25NB
Gate valve
35
Main Breather isolating valve
25NB
Gate valve
* NOTE: 1. All valves shall have position indicators to indicate the status i.e.
valves are in
open or shut position.
2. All valves shall be made of gun metal (GM); cast iron valves are
not acceptable.
3. All plugs shall be made of cast iron (CI)/GM
NB- Normal Bore mm.
79 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE VI(A)
DRAWINGS AND DATA TO BE FURNISHED BY THE BIDDER.
The following drawings and data for each items are to be submitted
with the Bid
(a)
Outline dimensional drawings of transformer and its accessories

including conservator complete with Bill of material and details of
all parts, their
quantity, rating
& name of Vendors indicating
clearances of transformer body from live terminals i.e. HV,LV.
(b)
Drawing of
transformer tank with location of inspection windows,
thickness of side/bottom/top of tank, details of stiffener.
(c)
Drawing indicating limbed core construction with complete details of

no., width and wt. of core laminations with size of steps; thickness of
core laminations ; dimension of window; size of limbs; Gross and net
core ; wt. of complete core.
(d)
Drawing indicating core belting arrangement with details of belting,

belting material etc.
(e)
Large scale dimensioned drawings for HV &

transformer; size and no. of parallel of HV, LV
coil clamping arrangement, no./size & location
clamping
ring; top yoke arrangement etc.
commensurate with the short circuit calculations
each rating of transformer
(f)
Detailed drawing of transformer tank with complete core and winding

indicating clearances inside transformer tank as also passage and
space for free movement of at least two persons for inspection of
active parts etc .
(g)
Schematic diagram showing the flow of oil in the cooling system as

well as each limb and winding. Longitudinal and cross-sectional views
showing the duct sizes, cooling
pipes
etc. for the
transformers/radiators drawn to scale .
(h)
Drawings giving the weights for foundations.
(i)
Combined Rating and diagram plate including tap changing, which

should also include details of guaranteed and measured no load and
load losses as also winding resistances and percentage impedances at
all taps.
(j)
Schematic control and wiring diagram for all auxiliary equipment

and control cubicle.
(k)
Drawing showing constructional details,

dimensions, mechanical
& technical particulars of bushings. Arrangement of terminals and
80 of 99
LV windings of the
and of cooling ducts,
of pressure screws,
The details should
submitted by you for
40 MVA TRANSFORMER
Volume-II, Part-1
(l)
(m)
(n)
details of connection of bushing shall also be indicated in drawing with

their technical particulars.
Transportation drawing of transformer.
Details of fittings and cable box.
Drawing showing arrangement and details of tap changing gear
including selector switch, diverter switch and drive mechanism.
(o)
(p)
Valve Schedule plate.

Oil filling instruction plate for conservator fitted with Air cell breather
arrangement including equalizing arrangement if any required at
the time of taking full Vacuum at site.
(q)
(r)
Drawing and instruction for fitting of Air Cell.

Drawing of conservator indicating internal details of air cell MOG, oil
level gauge and silica gel breather pipe fitting arrangement.
(s)
Drawings of all HV & LV bushings with complete details meeting TS

requirement.
(t)
Drawings of HV,LV & neutral terminal connectors

thickness, no. of nut bolts with size and other details.
(u)
Drawing of foldable & detachable ladder with its complete details and
fitting arrangement on transformer/ conservator tank.
(v)
Drawing for HV/LV neutral earthing arrangement indicating voltage

rating of insulators and its fitting arrangements, size of copper strips,
terminal connectors etc.
(w)
Detailed drawing
transformer tank.
(x)
Drawing
of Thermosyphon filter with fixing arrangement
transformer tank.
(y)
Detailed internal drawing of transformer indicating transportation

locking arrangement provided to avoid shifting of core assembly.
(z)
Drawing showing weights of transformers, cooling fan structures, FCC

structures with distance from central line of transformer for casting of
civil foundation for transformer and associated equipments.
(aa)
Drawing of Earthing terminal box showing earthing arrangement for

core, end frame, tank giving details of voltage class and current rating
of terminal bushings.
(ab)
Drawing indicating insulation thickness details and other arrangement

provided between core assembly and bottom yoke and base of bottom
of tank.
(ac)
Drawing indicating details of O ring gasketting arrangement provided

in transformer tank covers.
indicating plate
indicating two views of all valves provided in the
81 of 99
with
40 MVA TRANSFORMER
Volume-II, Part-1
(ad)
(ae)
Detailed Drawing of jacks.

Drawing of stiffeners provided on top, each faces/sides of tank with
their number and size.
(af)
Drawing indicating number, location, size of shields/ magnetic shunts

and its material provided inside the tank as per clause 11.1 (g).
(ag)
Drawing indicating internal details of transformer giving complete

details of clearances from live parts.
(ah)
Drawing of internal LV winding termination arrangement indicating

minimum clearance between core and LV take off lead.
(ai)
Drawing of Neutral Current Transformer with details of its mounting

arrangement.
(aj)
Drawing for Lead termination to bottom of HV & LV bushings.
(ak)
Internal drawing & design of Core & Winding indicating all attachment
with identification numbers, description including take-off arrangement
of lead connection for Core & End frame and related Bill of Material
(al)
Locking arrangement drawing for tank top cover, core & winding with
complete dimension & details.
(am) Plan view of the bottom of Bell Tank for complete details of core coil
resting arrangement, indicating clearly dimensional details, material of
insulation, clamping arrangement with details of nuts/ bolts, clearance
from all sides provided at bottom.
(an)
Drawing indicating complete details, dimension & mounting

arrangement of OLTC inside the tank with respect to End frame.
(ao)
Drawing indicating complete details, dimensions & fixing arrangement

of static end rings if used.
(ap)
Other relevant drawings.
As soon as possible after the award of the contract the manufacturer shall
supply four (4) copies of the drawings as listed out above, which will
describe the equipment in details for approval and shall subsequently
provide ten complete sets of final drawings, one of which shall be autopositive suitable for taking blue prints. Ten sets of instruction books,
operation and maintenance manuals and spare part bulletin, shall be
supplied. In addition to above two sets of manuals and drawings with test
certificates for each unit to be despatched as per despatch instructions.
82 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE VI (B)
LIST OF DRAWINGS TO BE FURNISHED ALONGWITH BID AND
DETAILS TO BE SUBMITTED WITH THE BID
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Particulars
OGA drawing of transformer
List of fittings & accessories for OGA
Drawing for HV,LV , neutral OIP Condenser bushings
Makes of various accessories and source of raw material
Universal type bimetallic terminal connector for HV,LV, Neutral
Conservator with air cell breathing arrangement
Thermosyphon filter assembly with pump & without pump
Internal clearances detailed drawing
Dimensional details for transportation of transformer.
Radiator arrangement
Core earthing arrangement box
Yoke binding details
Neutral earthing arrangement
Foundation details
List of tools & tackles
Bottom locking & insulating arrangement
Core insulation details
MS Ladder
Sealing arrangement between top & bottom shell.
OLTC Conservator with breather arrangement
Drawings for various types of valves.
Core shunt fixing arrangement
Rating & diagram plate
Valve schedule plate
Oil filling instruction plate for conservator with air cell.
Roller assembly with anit-earthquake arrangement
Coil clamping arrangement
Oil flow diagram
Winding details arrangement with dimension
Core details with design data
Over fluxing curve
Drawing for tank stiffener & magnetic shunt inside transformer with
calculation.
Schematic drawings for OLTC, FCC & RTCC .
Cooler control cubicle cum marshalling box with schematic
RTCC panel drawing
Drawing for static end ring
Complete dimensioned details of bottom tank
83 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE VI
DESIGN CALCULATIONS & DESIGN DATA REQUIRED
TO BE ENCLOSED WITH THE BID FOR POWER TRANSFORMER
It should be specifically noted by the Bidders that submission of
following Design Calculations & Design Data with the offer is
necessary and bids wherein these calculations are not found enclosed
shall run risk of rejection.
(1) SHORT CIRCUIT WITHSTAND CAPABILITIES : The calculations to
prove dynamic and thermal short circuit withstand capability of transformer
as per clause 31.1.1 shall be submitted for the fault level indicated as
under:
132KV 33KV -
40 KA for 3 secs.
31.5KA for 3 secs.
Results of calculations shall be submitted with the bid. The design of winding
assembly, which is to be furnished in the drawing as per Sr. No. (e) of
Annexure VI(A) should be commensurating with these calculations. The
details of clamping ring shall be indicated in the drawing .
(2) DESIGN DATA OF CORE & WINDING : On the basis of offered flux
density and current density, the Bidders shall furnish furnish following
design calculations & data. Calculations regarding wt. of core & copper and
also calculations for losses will
be brought out to justify the offered
transformer losses. :
(A)
Core Data: Details of core material i.e Name of Manufacturer,

Manufacturers type designation for core , thickness of core, curve for
Loss Vs Flux density, No of steps of Core & No of limbs, gross core area
, stacking factor , Net core area ,height & width of core window, center
to center distance of limb, voltage per turn, wt. of core material,
working flux density , core loss in watts per kg marked on graph for
grade of core material & selected flux density, building factor
and
calculated no load loss in watts, guaranteed no load loss. Design data for
core as per clause 31.2.1 shall be submitted with the bid. A drawing
indicating details of core i.e. limbed construction, step width & thickness
, core belting, top & bottom yoke plate etc shall be submitted with the
Bid .
(B)
Winding Data: wt. of copper for HV,LV, tap , cross sectional area ,
current density, type of coil, ID/OD/mean dia of coils, size of winding
conductor including parallels, no. of turns per phase, no of spacers,
length of mean turn, weight of copper without paper covering, resistance
per phase of winding at 75 0C, I2R loss at 75 0C & normal tap, eddy
current & stray loss at 750C, total copper loss at 750C, guaranteed
transformer losses at 75 0C.
84 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
Complete details of Insulation components i.e. Top & Bottom clamping
rings, washers , Pressboard blocks & cylinders, Pressboard spacers &
Phase barriers, Pressboard segments etc shall be submitted indicating
qty , thickness in mm, width & height , wt. Design data for winding as
per clause 31.2.2 shall be submitted with the bid.
Dimensioned drawings indicating details of winding , ducts, insulation ,
take off arrangement, clamping ring , pressure points etc shall be
submitted with the Bid .
(3) DESIGN OF TANK : Complete mechanical design of transformer tank
including details of stiffeners as per clause 31.1.2 shall be submitted . The
tank shall be designed to withstand the following
without permanent
distortion.
(i)
(ii)
Vacuum filling of oil at 10 milli torr in
transformer with all fittings.
(iii) Continuous internal pressure of 35 kN/m2 over normal hydrostatic

pressure of oil.
(iv)
(v)
Short circuit forces &

Under seismic condition /events both horizontal/vertical .
The calculations for tank stiffeners shall be submitted with the bid to prove
no. & size of stiffeners are adequate to withstand full vacuum & pressure .
Drawing of tank shall be submitted indicating stiffners .
(4) DESIGN OF STATIC END RINGS (SER) AND MAGNETIC SHUNTS :
Details of Static End Rings (SER) and magnetic shunts , if provided , with
calculations as per clause 31.1.3 shall be submitted with the bid. A drawing
indicating locations, size, material of SER and magnetic shunts shall be
submitted with the Bid .
(5) QUANTITY OF OIL : Complete calculations of oil quantity to be utilized
in transformer for first filling shall be submitted with the bid. The calculations
shall indicate
(i) Volume of tank including turrets, conservator main & OLTC ,volume
of headers & Radiators, oil quantity in OLTC & thermosyphon filter.
(ii) Oil displacement by Active parts i.e. core - coil assembly,
(6) CAPACITY OF CONSERVATOR & SIZE OF AIR CELL : While furnishing
details of conservator & air cell type sealing arrangement, the Bidder shall
submit details & calculations for adequacy of size and capacity of Pronal
france make air cell for the rating of the power transformer and also for the
quantity of oil required with the bid. Catalogue of Pronal france should be
enclosed with the Bid clearly marking type designation of selected size of Air
cell. A drawing indicating complete details of conservator with Air cell shall be
submitted .
85 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(7) CAPACITY OF PRESSURE RELIEF DEVICE : Bidders must submit
calculation with the bid to prove that the capacity/rating of pressure relief
device and locations of the same for the transformer will adequately meet our
requirement. Constructional and design details of pressure relief device must
be furnished and it should be proved by calculation that the size
and
setting of pressure relief device is adequate considering the rating of the
transformer and quantity of oil in the transformer. A drawing indicating
complete details of PRDs & their locations on tank shall be submitted .
(8) CALCULATIONS FOR TEMPERATURE RISE & HOT SPOT WINDING
TEMPERATURE : The limits of temperature rise for windings, oil and hot spot
have been specified in Volume II . Temperature rise calculations at rated full
load, 110% load and 125% load considering 100% cooler banks, 50% cooler
banks and without coolers shall be furnished as indicated below :
(a)
(b)
(c)
- 100 % cooler bank

- 50 % cooler bank
- 100 % cooler bank
- 50 % cooler bank
- 100 % cooler bank
- 50 % cooler bank
- 100 % cooler bank
- 50 % cooler bank
- 100 % cooler bank
- 50 % cooler bank
- 100 % cooler bank
- 50 % cooler bank
The calculations shall indicate temperature gradient (for all windings i.e.
HV,LV,tap), load losses at lowest tap for all windings , Eddy current & stray
losses, thermal Constant Value & calculations with parameters affecting the
values for above conditions for top oil temperature & winding hot spot
temperature .The Calculations for Hot Spot winding Temperature and
Temperature Rise shall be submitted with the bid.
(9)
COOLING CALCULATIONS : Calculations of tank surface for heat
dissipation, details of radiators, fans for ONAN & ONAF cooling shall be
provided with the bid.
(10)
OVERFLUXING CAPABILITY: A curve to prove suitability of
transformer to withstand various Overfluxing conditions for the duration
indicated in clause 4.4.1 to 4.4.3 without core saturation shall be furnished
with the Bid.
86 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(11)
CAPACITY OF FILTER & BREATHER :
(A) Number and Capacity of each Thermosyphon Filter : The Bidder

shall submit details & calculations for adequacy of size and capacity of
thermosyphon filter for the oil quantity in the power transformer.
While furnishing details of thermosyphon filter arrangements, the
Bidder must confirm clearly the number of thermosyphon filter, its size
and capacity is adequate for the rating of power transformer. The
Bidder shall submit details & calculation to prove for adequacy of size
and capacity of thermosyphon filter with the bid.
(B)
Capacity of Silica Gel Breather : The Bidder shall submit details &
calculations for adequacy of size and capacity of silica gel breather
for the oil quantity in the power transformer with the bid.
(12)
RATING OF ON LOAD TAP CHANGER (OLTC) : To verify the

adequacy and suitability of the OLTC components, it is necessary to
furnish the calculations for selecting the proper rating of transition
resistance as well as the normal current rating of OLTC. The
calculations shall include the temperature rise of the OLTC diverter
switch and also the short circuit current considered for calculation of
temperature rise.
Calculations shall be submitted to prove that the current rating
of OLTC is adequate for the rating of the transformer winding taking in
to account the over loading capability as per IS 6600 . The basis for
selection of transition resistance and its current carrying capacity shall
also be submitted. In this regard the circulating current in tap winding
during tap change operation through transition resistance shall be
taken in to consideration. Adequacy of insulation provided in the OLTC
between various parts needs to be established with specific reference
to the voltage between two taps. Confirmation shall be given that the
OLTC is suitable for bidirectional flow of current. The through current
capacity shall be adequate to handle on continuous basis the winding
current including over loading as per IS 6600. The through current
rating and the rating of transition resistance shall take in to account the
short time current rating of the winding. Capability to handle short
circuit current to be established by calculations and also by test
reports. The above Calculations for OLTC shall be submitted with the
bid
(13)
Capacity of Nitrogen Cylinder, pressure in Nitrogen Cylinder to be used

during transportation shall be submitted with the bid.
Note : Bidders
may please
note
that submission of
above
calculations & design data as mentioned in clause 31 and in this
Annexure with technical bid is an essential requirement of
the Bid.
87 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE VIII
DETAILS OF INSPECTION PROGRAMME
1.
INSPECTION
PROGRAMME :
1.1 Manufacturer shall chalk out a detailed inspection and testing

programme
for
various
manufacturing activities
for the different
components, fittings & accessories. The MPPTCL also reserves the right to
carryout any tests by a third party at its sole discretion. All Costs of
inspection/ tests shall be borne by Manufacturer.
2.2
STAGE INSPECTIONS :
2.2.1 Manufacturer shall indicate the inspections and checks carried out at
various stages of the manufacture of the transformer. A complete record of
stage inspection shall be kept by Manufacturer and this record shall be made
available for inspection by the representative of the MPPTCL. Manufacturer
shall indicate the manufacturing programme and the MPPTCL will have a right
to depute its inspecting officers during the manufacture. The inspecting stages
shall be Fabrication of Tank & Conservator, core building, coil winding ,
assembly of coil on core, the condition of the coil and core after the
treatment in vacuum chamber, assembly within the transformer tank
together with application of tap changer etc .
2.2.2 It may be noted that stage inspections for all the units shall be done
by us at the following stages as per the different formats enclosed :
(i) STAGE I : Stage Inspection of Transformer Tank and Conservator
after fabrication. After fabrication, tank & conservator shall be inspected for
measurement of its dimensions, thickness of sheets used and leakage test by
applying requisite pressure.
In this stage following shall be measured ,recorded & checked in Format I
(A,B,C) .
(A) Format I (A) : Inspection of Tank & Conservator
a) Certification of chemical composition and mechanical properties
of plates.
b) Welder's and weld procedure qualification.
c) Testing of electrodes for quality of base materials as per ASME.
d) Dimensional check and visual Inspection of weld .
e) Crack detection, of
major strength weld seams by dye
penetration test.
f) Measurement of film thickness of inside and outside of X'mer tank
and conservator
i) Oil insoluble varnish
ii) Zinc chromate paint
iii) Light grey paint
g)
Check correct dimensions between wheels, rotation of wheels
through 90 deg.
88 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
h)
i)
j)
k)
l)
Check for physical properties of materials for lifting lugs, jacking

pads, etc.
All load bearing welds including lifting lug and jacking
parts shall be subjected to DP test.
Leakage test of conservator and tank.
Pressure and vacuum test of tank.
Surface cleaning by sand or shot blasting.
Certification of all test results.
(B)
Format I (B) : Inspection of Valves as per Schedule of Valves
(C)
Format I (C) : Inspection of Tank for Inspection Windows.
(ii) STAGE II : Stage Inspection of Transformer Core during Core

Building :
After the core is built but before its clamping,
MPPTCL representative shall inspect the core to take
complete
weight of the core and also to measure approximate core loss. If
necessary, a small strip of core shall also be taken for testing at CPRI,
Bangalore at our discretion or at any other testing lab. of repute for
measurement of specific loss .
During this stage, following documents shall be verified by our
inspector as a proof towards use of prime core material material for
manufacturer of transformer ordered by us .
i)
ii)
iii)
iv)
v)

Mills test certificate
Packing list
Bill of lading
Bill of entry certificate by custom's.
The core material shall be directly procured either from the

manufacturer
or through their accredited
reputed
marketing
organisation but
not through any agent. A copy of all above
documents shall be sent with joint inspection report for MPPTCL
records.
In this stage, following shall be measured, recorded & checked in
Format II (A,B,C)
(A) Format II (A) : Report in respect of Raw material viz core,
copper, insulating material ,tank steel etc.: Details of various raw
material shall be recorded viz. Name of Supplier/Sub supplier, Test
Certificate, QAP Report , Invoices, Bill of Lading ,bill of entry etc.
(B) Format II (B) : Report in respect of Accessories: Details of
accessories Viz Buchholz relay, Pressure Relief device, Axles and
wheels, Winding and oil temperature indicators , Cooling fan and
radiator, Condenser Bushing & Bushing Current Transformer, OLTC, Oil
level gauge ,OLTC Cubicle and fan control cubicle, RTCC , Valves,
Clamps, Air Cell Breather, Pronol Bag etc. shall be recorded i.e. Make,
Rating, Factory Test Certificate, QAP Report , Invoices etc.
89 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(C) Format II (C) : Inspection of Core .
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Checking of in house or vendor core cutting facilities. Sample

testing of core steel for checking specific total loss, ductility and
bend properties, resistivity, ageing , magnetisation characteristics
and thickness.
Check on the quality of surface insulation & surface finish;
Measurement of thickness and hardness of varnish on stampings;
Solvent resistance test to check that varnish does not react in hot
oil; Check over quality of varnish on stamping, to ensure uniform
shining colour, no hot spots, no over burnt varnish layer and no
bubbles on varnished surface.
Check on the amount of burrs i.e. cutting & edge; Bow Check on
stampings.
During core building dimension, leaning or waviness of core,
tightening torque, dia of resiglass tap to be checked.
Check for the over laping stampings. Corners of the sheets are to
be apart.
Visual and dimensional check during assembly stage.
Check for interlaminar insulation between core sections after
pressing.
Visual and dimensional check for straightness and roundness of
core.
High voltage test on fully built core 2 kV for one minute
between core & yoke bolts, core & core clamps, core clamps & yoke
bolts, core loss measurement, weighment of core.
Certification of all test results.
(iii)
STAGE III : Stage Inspection of Winding after their preparation
: Once the coils are prepared but before the same are
fitted on to
the core, stage inspection shall be done to take various measurements
and also for weighment of total weight of coil of each voltage class.
Measurement of winding resistance shall be also done. A small piece of
conductor for each type of winding shall be made available by the
manufacturer to our representative.
During this stage, following documents shall be verified by MPPTCL
inspector as a proof towards use of prime copper and insulating material
for manufacturer of transformer ordered by us :
i)
ii)
iii)
iv)
v)

Mills test certificate
Packing list
Bill of lading
Bill of entry certificate by custom's.
The winding and insulating material shall be directly procured either

from the manufacturer or through their
accredited
reputed marketing
organisation but not through any agent. A copy of all above documents
shall be sent with joint inspection report for our records.
90 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
In this stage, following shall be measured, recorded & checked in Format
III.
(A)
Winding:
a)
Sample check on winding conductor for mechanical

properties and electrical conductivity.
b)
Visual
dimensional
checks on conductor for
scratches,
dent marks etc.
c)
Sample check on insulating paper for PH value, electric
strength.
d) Check for the reaction of hot oil on insulating paper.
e) Check for the bonding of the insulating paper on conductor.
f)
Check and ensure that physical condition of all materials taken
for
winding is satisfactory and free of dust.
g) Check for absence of short circuit between parallel strands.
h) Check for brazed joints wherever applicable.
i)
Measurement of voltage to be carried out when core/yoke is
completely restacked and all connections ready.
j)
Conductor-enamel test for checking of cracks, leakage and pin
holes.
k) Conductor-flexibility test.
l)
Heat shrink test for enamelled wire.
m) Measurement of no. of turns, cross sectional area of each
winding , winding resistance and weighment of windings.
n) Certification of all test results.
(B)
Insulating Material:
a)
b)
c)
d)
e)
Sample check for physical & chemical properties of material.

Check for dielectric strength.
Visual and dimensional checks.
Check for the reaction of hot oil on insulating materials.
Dimensional stability test at high temperature for insulating
material.
f) Tracking resistance test on insulating material.
g) Certification of all test results.
(iv)
STAGE IV : Stage Inspection of Core Coil Assembly before

Vapour Phase Drying / Dryout : In this stage , following shall be
measured, recorded & checked in Format IV.
a) Check Clamping Ring with approved drawing. Check Core Belting,
Check condition of insulation on the conductor & between the
windings.
b) Check insulation distance between high voltage & low voltage
connections with respect to earth and other parts.
c) Insulation test of core earthing .
d) Check for proper cleanliness and absence of dust etc.
e) Certification of all test results.
91 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
(v)
STAGE V : Stage Inspection of Core Coil Assembly after Vapour

Phase Drying / Dryout : In this stage , following shall be measured,
recorded & checked in Format V.
a) Measurement and recording of temperature and drying time during
vacuum treatment.
b) Check for completeness of drying by measuring IR values & Tan
Delta.
c) Measure minimum clearance from all sides/bottom/top.
d) Certification of all test results.
(vi)
STAGE VI : Inspection of Final Assembly of Transformer after

boxing in of active material :
Complete details of all bought
accessories , their test certificates shall be appended. Minutes of
meeting shall record overall workmanship and other pertinent details.
a)
b)
Check
completed
transformer
against approved
drawing, provision for all fittings, finish level etc.
Jacking test on all the assembled Transformers.
out line
Pre-shipment Checks at Manufacturer's Works:

a)
b)
c)
d)
e)
Check
for
interchangeability
of
components
of
similar
Transformers for mounting dimensions.
Check for proper packing and preservation of accessories like
radiators, bushings, explosion vent, dehydrating breather, rollers,
buchholz relay, control cubicle, connecting pipes, conservator etc.
Check for proper provision of bracings to arrest the movement
of core and winding assembly inside the tank.
Gas tightness test to conform tightness.
Derivation of leakage rate and ensure adequate reserve gas
capacity.
2.2.3 Details of Procurement : Manufacturer shall provide us complete

details of procurement of raw materials i.e. core, insulation and copper .
Manufacturer shall also record a certificate .
2.2.4 The MPPTCL also reserves the right to carry out stage
inspections at other stages also, for which advance intimation shall
be given and all necessary cooperation shall be rendered by the
manufacturer.
92 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
ANNEXURE IX
LIST OF HAND TOOLS FOR SUPPLY
ALONG WITH EACH 132 KV, 40 MVA TRANSFORMER
A) One tool box consisting of the following Hand tools of GEDORE
or TAPARIA make shall be supplied with each transformer
1.
SPANNERS
a) Double Open Ended Spanner Set : 1 set of 10 nos spanners of size
6x7, 8x9, 10x11, 12x13, 14x15, 16x17,18x19, 20x22, 24x27 and
30x32.
b) Ring Spanner Set : 1 set of 12 nos spanners of size 6x7, 8x9,
10x11, 12x13, 14x15, 16x17, 18x19, 20x22, 21x23, 24x27, 25x28
and 30x32
c) Tubular Box Double Ended Spanners with 2 nos Tommy Bars
(100 & 150 mm long) : 1 set of 8 nos spanners of size 8x9, 10x11,
12x13, 14x15, 16x17, 18x19, 20x22 and 21x23.
d) Hexagon Bit socket set with suitable Tommy Bar : 1 set of 15
nos sockets of size 10, 11, 12, 13, 14, 15, 16, 17,18, 19, 20, 21, 22,
23, 24.
2.
ADJUSTABLE WRENCHES: 1No. wrench each of size 25mm & 35mm
3.
STANDARD TORQUE WRENCH : 1 No. each of following

Torque range
1-7 Kg mtr
7-35 Kg mtr
4.
Head width
30mm
32mm
Head
depth
45 mm
55mm
SCREW DRIVERS : 1 set comprising of 1 no of following sizes

Head of Bit
(mm)
3,0
4,0
5,5
8,0
8,0
10,0
5.
Square
drive
inch
inch
(mm)
3,0
4,0
5,5
6,0
8,0
9,0
Length of
steel (mm)
75
100
125
150
175
200
Total length of
Screw
Driver(mm)
155
190
225
250
285
310
PLIERS : 1 no each of Flat Nose, Round Nose, Side Cutting
6.
GASKET PUNCH : 1 set comprising of size 8, 10, 12, 14, 16, 18, 20,
22, 24, 25mm.
93 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
Annexure-X
DESCRIPTION OF EQUIPMENT FOR SCHEDULE OF RATES & PRICES
For this Bid which includes 132 KV 40 MVA transformers, description of main
equipments and other items should be brought out exactly as per details
furnished herein and accordingly schedule of price should be enclosed with
the Bid.
Item
Nos.
Description
Quantity
(Nos)
1.
As
Supply of 40 MVA 132/33KV, Three phase ONAN/ ONAF
cooled
transformer
fitted with Pronol air-cell, and all per price
accessories/ fittings as described under annexure II , duly Schedule
passed all routine additional routine and acceptance tests as
per IS-2026 with one set of tools & jacks as per annexure
IX complete with first filling of oil including wastage & 10%
extra of that quantity & meeting all technical requirement
as per Part-1 of Volume II & annexure I. The transformer
shall be supplied with essential spare bushings as described
in clause 37.1. The offered cost includes cost of all tests as
per clause 24.5 and conforming to all requirements as
described in bid document. The transformers shall be
supplied fitted with Impact Recorder (on returnable basis)
during transportation of Transformers and Vehicle tracking
system (GPRS/ GPS/ GSM based) to track the exact position
of the vehicle during transportation of Transformers as per
clause no. 37.0.
Against Item no.1 above, composite total cost of power

transformer alongwith various accessories , tools, testing
equipments & essential maintenance spares etc. as well as
cost of testing as described in details above, will be furnished
by the bidder. However, for the purpose of computation of
price variation as also in order to have separate price details
for OLTC which could be separately obtained in case of
emergency at a later date, the bidders are requested to
indicate the following break up of costs (which are already
included in composite cost mentioned under Item no. 1
above) for the purpose of computation price variation after
award of contact.
(a) Unit Ex-works cost of transformer with OLTC, all fittings
& accessories (excluding Impact Recorder and Vehicle
tracking system), transformer oil, included in cost offered at
Sr.No. 1 above
for the purpose of computation of price
variation.
(b) Cost of OLTC included in 2(a) above
SIGNATURE
WITH SEAL OF BIDDER
94 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
APPENDIX I
Calculation for Hot Spot winding temperature for EHV transformers
Overloading capability of the transformer and also the loading
capability of transformer with and without cooling fans (coolers) for a
short period of 10/20 minutes with out exceeding temperature rise of
winding beyond specified limits have been indicated in the technical
specification. In this regard following calculation based on maximum
ambient air temperature as 50 degree centigrade and maximum
yearly average weighted air temperature as 32 degree centigrade
using the under mentioned formulae or any other authentic formulae
shall be furnished.
c = a +
b0
+ ( b- bo) ( 1- e
2
b =
br
( 1+dk )
------------- ( 1+d) x
-t/
2y
) + ( c - b ) k
Where
a
Weighted ambient temperature (cooling medium)
Winding hot-spot temperature at K load = a + c
cr
Winding hot-spot temperature at rated load
Winding hot-spot temperature rise at K load
cr
Winding hot-spot temperature rise at rated load
bo
Original oil temperature
Top oil temperature at K load = a + b
br
Top oil temperature at rated load
Top oil temperature rise at load K
br
Top oil temperature rise at rated power
Time duration in hours of any load power
Oil air thermal time constant of transformer at rated

load, in hours
Ratio of any load/rated load
95 of 99
S /Sr
40 MVA TRANSFORMER
Volume-II, Part-1
K1
Ratio of initial load/rated load
= S1 /Sr
K1
Ratio of permissible load/rated load = S2 /Sr
K2
Ratio of permissible load/rated load
Exponent for oil rise
Exponent for winding rise
Ratio of load loss at rated load/no load loss.
Subscript representing ambient (cooling medium)
Subscript representing top oil
Subscript representing hot-spot of winding
Subscript representing rated value.
SIGNATURE
WITH SEAL OF
BIDDER
96 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
APPENDIX II
TECHNICAL PARTICULARS TO BE FILLED-IN BY BIDDER
S. No.
Particulars
Values
Maximum flux density (Tesla)
Maximum current density (Amp/sq.cm)
Magnetising current (mA)
Short time current rating (Amp.)
Losses
a. No load Losses (KW)
b. Load Losses including stray losses
(KW)
c. Auxiliary losses (KW)
Impedance voltage (Percentage)
Weight of copper (Kg)
Weight of core (Kg)
Weight of core + winding (Kg)
10
Quantity of oil
a. For first filling including
(KL/Kg)
b. 10% extra of a (KL/Kg)
11
Total weight of Transformer. (Kg)
12
Transport weight of main tank

a. with oil (Kg)
b. without oil (Kg)
wastage
SIGNATURE
WITH SEAL OF BIDDER
97 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
List of Abbreviation used in technical specification

1.
2.
3.
4.
5.
6.
7.
OLTC
OIP
DL type
COPS
RTCC
Cl
IEEMA
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
KV
KW
IV
LV
VPD
ONAN
ONAF
OFAF
CBIP
OTI
WTI
KA
TC
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
V
f
VN
FN
CT
PT
Xmer
PRD
PRV
MOLG
OSR
Isc
V
Zt
Zs
1
0
J
t
Iph
Zpu
Rdc
On load tap changer

Oil impregnated paper
Draw lead type
Conservator oil preservation system
Remote tap changer cubicle
Clause
Indian Electrical & Electronics Manufacturing
Association
Kilo voltage
Kilo Watt
Intermediate voltage
Low voltage
Vapour phase drying
Oil natural air natural
Oil natural air forced
Oil forced air forced
Central Board of Irrigation and Power
Oil temperature indicator
Winding temperature indicator
Kilo Ampere
Terminal connector or test certificates as
applicable
Voltage
Frequency
Normal voltage
Normal frequency
Current Transformer
Potential Transformer
Transformer.
Pressure Relief Device
Pressure Relief valve
Magnetic Oil Level Gauge
Oil Surge Relay
- RMS value of symmetrical short ckt current,KA
rated voltage of system ,KV
short ckt impedance of transformer ,Ohms
short ckt impedance of system ,Ohms
final temperature in degree centigrade
Initial temperature in degree centigrade
short ckt current density ,amp/mm sq.
duration of short ckt in secs
rated phase current in amps
per unit impedance
DC resistance of the per phase of winding at 75
degree centigrade
98 of 99
40 MVA TRANSFORMER
Volume-II, Part-1
48.
49.
50.
51.
52.
53.
54.
55.
56.
Hw
N
Dmi
Bi
E
Sn
Pu
Fa
Ai
57.
Ao
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
bo
Dmo
Ao
F
D
b
t
n
mA
kg
kl
temp.
max.
min.
vol.
height of winding in cm
no of turns per phase of winding
mean diameter of inside winding ,cm
thickness of inside winding conductor ,cm
modulus of elasticity of conductor, cm
rated KVA
per unit impedance
axial imbalance force, Kg
(no of spacers x length x width ) for inner
winding
(no of spacers x length x width ) for outer
winding
no of conductors in the radial direction= no of
turns x no of parallel conductor
thickness of outer winding conductor, cm
mean diameter of outer winding, cm
supported area of outer radial spacers
total axial force in MT
mean diameter of clamping ring ,cm
width of clamping ring ,cm
thickness of clamping ring ,cm
no of jacking or clamping points
milli ampere
kilogram
kilolitre
temperature
maximum
minimum
volume
99 of 99
40 MVA TRANSFORMER

VOLUME II
PART-2
BOOK I OF III


MPPTCL, JABALPUR
Description
Technical Book
Serial No.
Part-1

SUPPLY OF 220KV, 160MVA PROC/01/MAY13
POWER TRANSFORMERS
Part-2
Book I
of III

MATERIALS
Part-2
Book II
of III

MATERIALS
Part-2
of III
MATERIALS

PART-2(BOOK I OF III)
TECHNICAL SPECIFICATION FOR SUPPLY OF EHV
EQUIPMENTS/ MATERIALS
Tender document.
INDEX
VOLUME-II, PART-2
SUPPLY OF EHV EQUIPMENTS/ MATERIALS
Part 2 consist
of
BOOK-I of III
S. No.
Description of Items
1.0 Common Technical Requiarement

1.1
Scope of supply and other technical requiarements
1.2
Appendix-A - List of Standards
1.3
Appendix-B - List of Drawing
2.0 Technical Specificatin of equipments/material
Technical Specification for EHV Equipments
2.1
2.1.1
Circuit Breakers
BOOK-II of III
25
26
26
27
62
2.1.2
Control & Relay Panels and Syncronizing Trolley
63
199
2.1.3
Instrument Transformers (C.T & P.T )
200
241
2.1.4
Lightning Arresters
242
254
2.1.5
Isolators
255
276
2.1.6
Solid Core Insulators
277
282
2.1.7
Shunt Capacitor Banks
283
302
2.2
Technical Specification for PLCC Equipments

2.2.1
CVT & Coupling Capacitor
303
318
2.2.2
Wave Traps
319
332
2.2.3
Power Line Carrier Communication Equipments ( Carrier Cabinet &

Protection Coupler and Coupling Device)
333
351
2.2.4
EPAX & Telephone sets
352
361
2.2.5
Co-axial cable & Telephone cable
362
372
2.2.6
RTU
373
422
Technical Specification for Substation AC/DC Supply Arrangement

Equipments
2.3.1
Station Transformer, LT Distribution Box & D.O Set.
423
470
2.3.2
Battery & Battery Chargers
471
505
2.3.3
AC/DC Board & Junction Boxes.
506
529
2.3.4
Lighting Equipments.
530
538
2.3.5
Tubular poles, Lighting panels, Lighting Fixtures & G.I pipes.
539
539
540
555
Technical Specification for Bus Bar materials, Earthing materials,

Cables & Hardwares
2.5.1
ACSR Conductors, Screening conductor & Disc Insulators
556
580
2.5.2
M.S Flats & M.S Round
581
584
2.5.3
Copper Control & Aluminium Power Cable
585
592
2.5.4
Clamp & Connectors.
593
612
2.5.5
Substation Hardware
613
633
2.6
Oil Storage Tank 10 KL
634
644
2.7
Fire Fighting Equipment
645
667
2.3
2.4
Technical Specification for Substation Switchyard Structures

2.4.1
BOOK-III of III
Page No.
From To
2.5
Structures
Volume-II, Part-2, Book I of III
VOLUME-II
PART-2
1.1 SCOPE OF SUPPLY AND OTHER TECHNICAL REQUIREMENT
1.0
SCOPE:
The scope of this specification covers supply of EHV equipments for all the
works as brought out in Bill of quantity in Volume-VI of Bid specification. The scope
also covers Design, Engineering, Manufacture, Testing, supply on FOR destination site
basis including transportation, unloading storage, erection, testing and commissioning of
all the equipments / items, complete in all respect for each works covered in this
package are included in the scope of the Bid specification. The details of equipments /
items covered in the scope of bid documents are:i)
All EHV/HV switchgear, viz. Circuit Breakers, Isolators with & without Earth
Switch, Surge Arrester / Lightning Arresters & Capacitor Banks etc.
ii)
All EHV/HV Instrument Transformers, viz., Current Transformers, Potential

Transformers, Capacitive Voltage Transformers.
iii)
Control & Relay Panels with Protection System for feeders, transformers,
Bus Coupler, Bus tie, etc. complete in all respect.
iv)
200 KVA, 33/0.4 KV Station transformer alongwith all associated equipments

as per Bill of Quantity for LT supply.
v)
Complete PLCC system for speech and data transmission with wave trap for
all 220KV & 132KV lines emanating from EHV substations and specified in
the Bill of Quantity and technical specification.
vi)
LT switch gear (AC/DC Distribution Boards)
vii)
Battery & Battery Charger
viii)
Control Cable alongwith complete accessories for auxiliary supply and

control cable for control panels/ RTCC panels installed in Control Room, also
to marshalling box of transformers/ reactors etc.
ix)
Substation structures as per approved drawings of MPPTCL, except for

Circuit Breakers structures which will be as per manufacturers design.
x)
Bus post insulators (including requirements for wave trap) stringing

hardware, clamps & connectors. Equipment terminal connectors (excluding
transformers & reactors), Conductors, Aluminium Tubes, Bus Bar and
Earthing material. Bay marshalling box spacers cables supporting angle
etc., Channels, Cable Trays, covers junction boxes, cable trenches etc.
xi)
For complete lighting and illumination for the switchyard and peripheral
lighting, illumination system shall be designed and developed by the
contractor based on requirement given in the specification.
xii)
Complete main and auxiliary earth mat network including all associated
works.
xiii)
Any other equipment /material required to complete the specified scope.
Page 1 of 26

xiv)
The various equipments offered against this bid shall be designed,

manufactured as per standards mentioned in enclosed APPENDIX-A.
xv)
The technical specification of each equipment/material to be supplied by

bidder has been described in Part-1 & 2 of Volume-II. The bidders shall offer
all the equipments (covered under the package) of reputed make as per list
of preferred vendors enclosed with this section at Annexure-1(A) and 1(B),
Volume-VI of Bid specification.
The provisions under this section are to supplement common

requirements for material, equipments and servicers covered under various
sections of Bid document. The Part-1 & 2 of Volume-II contains technical
specification for all the equipments / materials covered under the scope of bid.
The bidders may, therefore, refer the relevant portion of the technical
specification applicable to this bid only for the items included in the Bill of
Quantity as per Annexure-2, Volume-VI of Bid specification. The bidders shall
furnish catalogues, engineering data/ technical information, design documents,
drawing etc. fully in conformity with the technical specification.
2.0
STANDARDS:
2.1
Bidders may please note that all offered EHV equipments and other items shall
be manufactured, tested and supplied with all guaranteed technical particulars generally
conforming to meet the requirement of technical specification as brought out in Part-1 &
2 of Volume-II and latest revisions of relevant standards of international electro technical
commission or equivalent national standards of India with latest amendments of relevant
standards rules and codes. The relevant standards are specified under Appendix-A of
this section.
2.2
If the equipment offered by Bidders conforms to any other standards, salient
points of comparison between the standards adopted and the specific standards shall
be clearly brought out in relevant schedule of technical deviation. It will be sole
responsibility of Bidders to prove that the salient features of offered equipment are
equivalent or better than IS.
2.3
The works covered by the specification shall be designed, engineered,
manufactured, built, tested and commissioned in accordance with the Acts, Rules Laws
and Regulations of India.
2.4
The bidder shall also note that list of standards presented in this specification is
not complete. Wherever necessary the list of standards shall be considered in
conjunction with specific IS/IEC.
2.5
When the specific requirements stipulated in the specifications exceed or differ
than those required by the applicable standards, the stipulation of the specification shall
take precedence.
2.6
The equipment conforming to standards other than specified under AppendixA individual sections for various equipments shall be subject to MPPTCLs approval.
3.0
TYPE TESTS:
3.1
The offered EHV equipments should be fully type tested as per the relevant
standards. In case the equipment of the type and design offered, has already been type
tested, Bidder shall invariably furnish type test reports from the reputed and approved
national/international laboratory/Government approved test houses to prove that
Page 2 of 26

specifications of EHV equipments offered conform to the relevant standard. Test
certificates shall clearly indicate the type and model number etc., so that relevant details
of offered EHV equipments could be verified. While submitting bids the model and type
etc., shall be clearly indicated. Type test reports so furnished should not pertain to the
period earlier than five years from the date of opening of Bid. In case the type tests
were carried out earlier than five years, the manufacturer will have to conduct these
tests before commencement of supply. In both the above cases type test certificate
must be submitted with the bid. The Bidders have to submit one complete set of Type
Test reports for the offered EHV equipments.
4.0
CLIMATIC CONDITIONS:
EHV equipments to be supplied against this specification shall be suitable for

satisfactory and continuous operation in the outside switchyard under the following
tropical conditions.
S. No.
i
ii
iii
iv
v
Conditions
Out door
50 Centigrade
1 Centigrade
35 Centigrade
95% (sometime
approaches saturation)
vi
Maximum altitude above mean sea level
1000 (Meters)
vii
Average Annual rainfall
1250 (mm)
viii
Maximum wind pressure
150 Kg/m
ix
Isoceraunic level
90 days per year
x
Seismic level (Horizontal acceleration )
0.3 g.
Moderately hot & humid tropical climate, conducive to rust & fungus growth.
6.0
Particulars
Location
Maximum ambient air temperature
Minimum ambient air temperature
Average daily ambient temperature
Maximum Relative humidity
AUXILIARY POWER SUPPLY:
6.1 The equipments offered under this specification shall be suitable for the following
auxiliary power supplies.
a.
Power Devices (like drive motors)
400 Volt, 3 phase, 4 wire, 50 Hz,

neutral grounded AC supply.
b.
AC control and protective devices,

lighting fixtures, spare heaters &
fractional horse power motors.
250 Volt, single phase, 2 wire, 50 Hz,

AC supply with neutral grounded.
c.
DC Alarm, Control and protective

devices
110 Volt DC, 2 Wire for 220 & 132KV

substation
The above supply voltages may vary as below and all devices shall be
suitable for continuous operation over entire range of voltages.
i.
AC supply
Voltage +10 to 25%; frequency 4%
ii.
DC supply
Voltage +10% to -20%
Page 3 of 26

7
MANUFACTURER'S AUTHORISATION:
The bidders shall have to submit the documentation from the manufacturer of
the goods that they are authorised to supply the goods, indicated in their bids.
8
SCHEDULE OF REQUIREMENT OF ACCESSORIES ETC.:
It is obligatory on the part of bidders to furnish details of accessories to be

provided with equipment in his offer.
9
GUARANTEE PERIOD:
9.1
All the EHV equipments & its accessories covered under the Bid shall be
guaranteed for performance and quality for a period of 24 months from the date of
commissioning of substations/ Feeder bays.
9.2
The following conditions shall also be applicable for the contract, to be placed
against this Bid:
(a)
In case any defect in the equipment/ material is found within guarantee period,
the same will be replaced/ repaired by the manufacturer on free of cost basis.
The replacement/ repairing will have to be organized by contractor expeditiously
and preferably within one month's time.
(b)
If for the purpose of replacement/ repairs, the equipment/ material is required to

be dispatched to manufacturers works, all charges towards transportation/
insurance/ packing and forwarding will have to be borne by the contractor for to
and fro dispatches.
(c)
If the equipment/ material develops defect within guarantee period after

installation at site, for the purpose of replacement/ repairs, the same will have to
be dismantled and taken out by MPPTCL. In such cases, actual cost of
dismantling, any other incidental cost and cost of re-erection/ re-assembly and
replacement of the equipment/ material will also be recoverable from the
contractor.
(d)
In case it is observed that replacement/repairs of equipment/ material is not

being provided to us within reasonable period and proper response is not
received from the supplier, then apart from operating Clause of Penalty (which
provides for imposition of liquidated damages, risk purchase at Contractors cost
and cancellation of contract) the MPPTCL may also take suitable penal action
against the contractor which may include debarring him from all future business
with the MPPTCL for a period which will be at the discretion of the MPPTCL.
10
SUBMISSION OF DRAWINGS AND INSTRUCTION MANUALS:
Within Two months after award of contract, Contractor shall submit the drawings
of all the equipments for approval. The number of drawings received for approval
and final drawings, operation and maintenance manual shall be submitted in
accordance with the schedule which will be indicated in the Contract. Comments/
approval on drawings shall be given by the MPPTCL within Two months of receipt of
drawings. Any fabrication work done prior to approval shall be at the contractors risk.
The contractor shall make all indicated changes in the design which are necessary to
make the equipment conforming to the provisions of specification without any
additional cost. Approval of the contractors drawings shall not relieve the contractor of
his obligation to meet the requirement of the specification or the responsibility for the
correctness of contractors drawings.
Page 4 of 26

11.0
INSPECTION AND TEST CERTIFICATES:
11.1 All machinery, apparatus or materials supplied will be subject to inspection and
approval by the MPPTCL's representative before despatch if possible otherwise on
arrival at the destination. Inspection before despatch will not however relieve the
contractor of his responsibility to supply strictly in accordance with the specifications.
11.2 All machinery, apparatus and materials shall conform to provisions of any
statutory acts such as the Indian Electricity Act, Indian Factory Act, the Indian Boiler
Act, etc. and corresponding rules and regulations as may be applicable.
11.3 The MPPTCL's representatives shall be entitled at all reasonable time during
manufacture to inspect, examine and test at the contractor's premises the material
and workmanship of the material to be supplied under this contract.
11.4 For Inspection / testing, the contractor shall intimate the MPPTCL 15 days in
advance about readiness of material as per the scheduled delivery so that action may
be taken for getting the material inspected. The material shall not be despatched
unless waiver of inspection is obtained or the material is inspected by the
MPPTCL's authorised representative. When the material has passed the specified
tests, the MPPTCL's representative shall furnish a certificate jointly signed by him and
contractors representative to this effect in writing to the contractor in any case. While
notifying the readiness of the equipment, the routine test certificates shall invariably be
sent. The material shall not be despatched unless the test certificates are approved
11.5 These test certificates should be in accordance with latest issue of the relevant
Indian Standards or as approved by the order placing authority.
12.0
COMPLETENESS OF EQUIPMENT:
12.1 All the equipments covered in the Bid shall be complete in every respect with all
minor fittings and accessories even though those may not be specifically mentioned in
the MPPTCL's specification or the Bidders offer. The contractor shall not be eligible for
any extra price in respect of such minor fitting and accessories which can be
considered as an mandatory part of the basic equipment even though not specifically
mentioned in the specification or the bid.
12.2 If any minor accessory has not been stipulated but is mandatoryly required for
satisfactory operation of the equipment, the same shall be deemed to have been
included in the prices and shall be supplied by the successful bidder without any extra
cost.
12.3 The bidder may please note that it shall be sole responsibility of them to ensure
that offered equipments/ materials of various manufacturers are complete with all fitting
& accessories as per technical specification of equipments. The offered equipments/
materials must comply to technical requirement as per stipulation in technical
specification of each equipments/ materials.
13.0
WORKMANSHIP:
All equipments /materials shall be of the best class and quality most suitable for
the conditions of operation under the climate conditions as per clause no. 5.0 above for
supply of equipments / materials. The workmanship shall be of the best grade and the
entire construction in accordance with the best modern practice.
Page 5 of 26

14.0
REPLACEMENT OF DEFECTIVE SUPPLIES:

Please note that the following conditions shall be applicable:-
(a)
In case any defect in the equipment material is found within guarantee period,
the same will be replaced / repaired on free of cost basis. The replacement /
repairing will have to be organized by contractor expeditiously and preferably
within one months time. It may please be noted that if repair/replacement of
equipment/material is not organized within 3 months of notice of defects/failure
being sent, MPPTCL shall recover the cost of such equipment from available
payments/S.D. as the case may be without further notice and with such penalty
as it may deem appropriate for non-compliance of contractual obligations.
(b)
All other conditions, as described under clause 9.0, Guarantee Period shall be
applicable for the purpose of replacement of defective supplies.
15.0
SCHEDULE OF QUANTITIES:
The works wise break-up of quantity of equipments/materials has been given in

Volume-VI of Bid specification. In this annexure short description of material has been
given. The details of all such description are given in Part-1 & 2 of Volume-II of
respective equipment. The bidder shall refer these detailed descriptions for clarity.
All equipment/items which have been indicated in bill of quantity in Volume-VI of
Bid specification shall be payable on unit rate basis. During actual execution, any
variation in such quantities shall be paid based on the unit rate under each item
incorporated in Letter of award.
Although all the quantity of equipments/materials have been included in the bid
as mentioned in Volume-VI of Bid specification. However there may be requirement of
some minor nature items required for successful erection / commissioning of bays and
substations work covered under this package. Bidder should include all such items in
the bid proposal sheets which are not specifically mentioned but are mandatory for the
execution of the contract. Item which explicitly may not appear in various schedules and
required for successful commissioning of substation shall be included in the bid price
and shall be provided at no extra cost to MPPTCL.
16.0
TECHNICAL DEVIATIONS:
In case of any deviation from the requirement indicated in our technical

specification then the deviation shall be mentioned explicitly and clearly for respective
equipment separately for equipment/material in Schedule-XI Volume-VI of Bid
specification. While MPPTCL may consider and accept such minor deviations which
may not affect overall performance of equipment/system; it may be noted that in case of
any major deviation, MPPTCL reserves the right to reject the bid without assigning any
reasons.
17.0
BASIC REFERENCE DRAWINGS:
17.1
Single line diagram and general arrangements, drawings are enclosed for
reference, which shall be further engineered by the bidder.
17.2 The bidder shall maintain the overall dimensions of the substation/ site, phase to
earth clearance, phase to phase clearance and sectional clearances as per enclosed
drawings / relevant applicable standards.
The enclosed drawings give the basic scheme, layout of substation, substation
buildings, associated services etc. In case of any discrepancy between the drawings
Page 6 of 26

and text of specification, the requirements of text shall prevail in general. However, the
Bidder is advised to get these clarified from MPPTCL.
17.3 The auxiliary transformers of rating 200 KVA shall be used for AC, 400 V supply
at sub-stations.
18.0
SPECIAL TOOLS AND TACKLE:
The bidder shall supply with the equipment one complete set of all special tools
and tackles for the erection, assembly, dis-assembly and maintenance of the
equipment. However, these tools and tackles shall be separately, packed and brought
on to Site.
19.0
QUALITY ASSURANCE PLAN & STAGE INSPECTION:
19.1 The successful bidder shall ensure that for the purpose of supply of equipments,
the manufacturer will have to follow strict quality assurance programme, which will
include thorough verification of samples of critical assemblies and accessories,
verification of sources of raw materials, detailed verification of drawing & design,
checking up of relevant calculations, stage inspections at various critical stages of
manufacture and minor modifications consequent to such stage inspections as per our
requirements and all other related requirements, which have generally been brought out
in bidding documents and the detailed contract. It is expected that bidder would be very
serious and prudent in meeting these requirements without any loss of time, so that
supply of equipments in line with quality assurance programme is ensured within
targeted schedule.
The MPPTCL reserves the right to specify various stages for stage inspections
and also for manufacture of a proto type unit for inspection & testing, before according
clearance for bulk manufacturing.
19.2 The bidder shall ensure that manufacturer must establish that they are following
a proper quality assurance programme for manufacture of offered equipments.
The bidder shall ensure that manufacturer invariably furnish following
information:i.
Statement giving list of important raw materials, names of sub supplier for
the raw material, list of standards according to which the raw material are
tested, list of tests normally carried out on raw material in presence of
manufacturers representative, copies of test certificates.
ii.
Information and copies of test certificates as in (i) above in respect of bought

out items.
iii.
List of manufacturing facilities available.
iv.
Levels of automation achieved and list of areas where manual processing

exists.
v.
List of areas in manufacturing process, where stage inspections are normally

carried out for quality control and details of such tests and inspection.
vi.
Special features provided in the equipment to make it maintenance free.
vii.
List of testing equipment available with the manufacturer for final testing of
equipment specified and test plant limitations, if any vis--vis type, special,
acceptance and routine tests specified in the relevant Indian Standards or
Page 7 of 26

equivalent international standard. These limitations shall be very clearly
brought out in schedule of deviations from specified test equipments.
19.3 The successful bidder shall within 30 days of award of Contract shall arrange
following information to the MPPTCL.
i.
Quality Assurance Plan (QAP) with hold points for MPPTCLs inspection.
The quality assurance plans and holds points shall be discussed between
the MPPTCL and Bidder before the QAP is finalized.
19.4 The successful Bidder shall also ensure that the manufacturer submits the
routine test certificates of bought out items and for raw material at the time of routine
testing of the fully assembled equipment.
20.0
S.
No.
SYSTEM PARAMETERS
Description of Parameters
220 KV
System
132 KV
System
33 KV
System
1.
System Operating Voltage
220 KV
132 KV
33 KV
2.
Maximum operating voltage of

the system (rms)
245 KV
145 KV
36 KV
3.
Rated Frequency
50 Hz
50 Hz
50 Hz
4.
No. of phase
5.
Rated Insulation levels
(i)
Full wave impulse withstand

voltage (1.2/50 microsecs.)
1050kVP
650 kVP
250 kVP /
170 kVP
(ii)
Switching impulse withstand

voltage (250/ 2500 micro sec.)
dry and wet
One minute power frequency

dry / wet withstand voltage
(rms)
460 KV
275 KV
95 KV/
70 KV
6.
Corona extinction voltage
156 KV
105 KV
7.
Max.
radio
interference
voltage for frequency between
0.5 MHz & 2 MHz at 508 kV
rms for 765 kV, 320 kV rms
for 400 KV system, 156 KV
rms for 220 KV system & 92
KV rms for 132 KV system
1000
microvolt
500
microvolt
6125 mm
3625 mm
900 mm
(iii)
8.
Minimum creepage distance

@ 25 mm/KV
9.
Min. Clearances
Page 8 of 26
S.
No.
Description of Parameters
132 KV
System
33 KV
System
i.
Phase
to
installation
for
4500 mm
2500 mm
1400 mm
ii.
Ground
clearances from
lowest
live
terminal
of
equipment from ground level
7000 mm
4600 mm
4000 mm
10.
Rated short circuit current /for

one sec. duration
40 KA for
three
seconds/
one second
as applicable
40 KA for
three
seconds/
one second
as applicable
25 KA for
three
seconds/
26.2 KA for
two seconds
11.
System Neutral earthing
Effectively
Earthed
Effectively
Earthed
Effectively
Earthed
spacing
220 KV
System
Page 9 of 26
APPENDIX-A
LIST OF STANDARDS
GENERAL
Indian Electricity Rules, Indian Electricity Act, Indian Electricity (Supply) Act, Indian
Factories Act
S.
No.
Indian Standard
Number
IS-5
IS-335
IS-617
(P1 to P145)
Title
Colours for Ready Mixed Paints &

Enamels
New Insulating Oils
Aluminium and Aluminium Alloy Ingots
and Castings for General Engineering
Purposes
IS-1448
(P1 to P145)
IS-2071 (P1 to P3)
IS-12063
IS-2165 1:1997
P2:1983
Insulation Coordination
IS:3043
Code of Practice for Earthing
IS-6103
10
IS-6104
11
IS-6262
12
IS-6792
Method for Determination of Electric

Strength of Insulating Liquids
13
IS-5578
Guide for Uniform System of Marking &

Identification of Conductors &
Apparatus Terminals
14
IS-11353
15
IS-8263
16
IS-9924
(Part 1,2 & 4)
17
Methods of Test for Petroleum and its

Products
Methods of High Voltage Testing
Classification of degrees of Protection
provided by enclosures of electrical
equipment
International &
Internationally
Recognised
Standards
-
Method of Test for Specific Resistance

(Resistivity) of Electrical Insulating
Liquids
Method of Test for Interfacial Tension
of Oil against Water by the Ring
Method
Method of Test for Power Factor &
Dielectric Constant of Electrical
Insulating Liquids
Methods for Radio Interference Test on

High Voltage
Methods of Radio Interference Test on
High Voltage Insulators
Low Voltage Fuses

High Voltage Test Techniques
IEC-60060
(Part 1 to P4)
Page 10 of 26

S.
No.
Indian Standard
Number
18
19
20
21
22
23
24
25
26
27
28
National Electrical Code
29
Guide for Surge Withstand Capability

(SWC) Tests
30
31
32
33
Specification for Sound Level Meters
34
Drawing Symbols
34
35
36
37
Title
Environmental Test
Graphical Symbols
Methods for the Determination of the
Electrical Strength of Insulation Oils
Partial Discharge Measurements
Specification and Acceptance of New
Sulphur Hexafluoride
Radio Interference Test on High
Voltage Insulators
Artificial Pollution Tests on High
Voltage Insulators to be used on AC
Systems
Common Sp4cification for High Voltage
Switchgear & Control gear Standards
Guide for the Selection of Insulators in
respect of Polluted Conditions
Short Circuit Current Calculation of
effects
Specification for Electromagnetic Noise

and Field Strength Instrumentation 10
KHz to 1 GHz
Techniques for Dielectric Tests
Standard General Requirements and
Test Procedure for Outdoor Apparatus
Bushings
11Gray Finishes for Industrial

Apparatus and Equipment No.61 Light
Gray
General Standards for Industrial
Control & Systems Part ICSI-109
Specification
for
CISPR
Radio
Interference Measuring Apparatus for
the frequency range 0.15 MHz to 30
MHz
Quality Assurance Program
Requirements
International &
Internationally
Recognised
Standards
IEC-60068
IEC-60117
IEC-60156
IEC-60270
IEC-60376
IEC-60437
IEC-60507
IEC-60694
IEC-60815
IEC-60865 (P1 &
P2)
ANSI-C.1/
NFPA.70
ANSI-C37.90A
ANSI-C.6321,
C63.3
C36.4 ANSI-C68.1
ANSI-C76.1/EEE21
ANSI-S14
ANSI-Y322/C337.2
ANSI-Z55.
NEMA-ICS-II
CISPR-1
CSA-Z299.1-1978h
Page 11 of 26

S.
No.
Indian Standard
Number
Title
International &
Internationally
Recognised
Standards
38
Quality Control Program Requirements
CSA-Z299.2-1979h
39
Quality Verification Program

Requirements
CSA-Z299.3-1979h
40
Inspection Program Requirements
CSA-Z299.4-1978h
EQUIPMENT-WISE SPECIFICATION
A) 220KV, 132KV & 33KV CIRCUIT BREAKERS:
Specification for alternating current
1
circuit breakers
Specification and acceptance of new
2
supply of SF6
3
IS-1885
Electro technical vocabulary
Marking
and
arrangement
for
4
IS-375
switchgear bus-bar, main connections
and auxiliary wirings.
5
IS-2147
IS-325
IS-13947
IS-2629
9
10
11
12
IS-5
IS-2099
IS-5561
IS-2516
Degree of protection provided for

enclosures for low voltage switchgear
and control gear.
13
14
15
IS-13118
Specification for three phase induction

motors.
LV Switchgears & control gear.
Recommended practice for hot dip
galvanizing of iron and steel.
Colour for ready mix paints.
High voltage porcelain bushings.
Electric Power connectors
Specification for circuit breaker
Synthetic Testing of High Voltage
alternating current circuit breakers
Pressurised hollow column insulators
Specification for
circuit breakers
alternating
current
B) 220 KV, 132 KV & 33KV C&R PANELS:

Application guide for electric relays for
1
IS-3842
AC system
IS-3231,
3231 Electric relays for power system
2
(P-3)
protection.
3
IS-1885
IS-1248/2419
Electric technical vocabulary electrical

relays and Electrical power system
protection
Indicating instruments
IEC-62271-1002001
IEC-376
IEC-50
-
IEC-947
IEC-137
IEC-6047
IEC-61264
IEC-62271-1002001 & IEC 60056
or latest
amendment thereof
IEC 50
-
Page 12 of 26

S.
No.
Indian Standard
Number
6
7
IS-722,
IS 1248
IS-2705
IS-3156
IS-4237
IS-375
10
IS-8686
11
IS-4483
12
13
14
IS-13947
IS-5
IS-2147
Title
Energy meters, control switches (LV

switching
Current transformers.
Voltage transformers.
General requirements for Switchgears
and control gear for voltage not
exceeding 1 kV.
Marking and arrangements for
Switchgears, busbars main connection
and auxiliary wiring,
15
16
17
18
19
20
21
22
23
24
25
26
27
Specification for static protective relays.

Preferred panels cut out dimensions for
relays
LV Switchgears & control gear.
Colour Shade.
Verification of degree of protection
Protocol
for
communication
for
numerical relays
Recommendations for direct acting
indicating
analogue
electrical
measuring instruments and their
accessories
Electrical relays
Dimensions of mechanical structures of
the 482.6 mm (19 inches) series
Expression of the performance of
electrical & electronics measuring
equipment
Symbols
for
alternating-current
electricity meters
Man machine interface (MMI) actuating
principles
Class 0.5, 1 and 2 alternating current
watt hour metes
Modular plug-in unit and standard 19
inch rack mounting unit based on NIM
standard
(for
electronic
nuclear
instruments)
Screw threads
Bolts and nuts
Relays, Station Controls etc.
Manual and automatic station control,
supervisory & associated telemetering
equipment
International &
Internationally
Recognised
Standards
IEC 186
IEC 185
-
IEC-947
IEC61850
IEC-60051
(P1 to P9)
IEC-60255:
(P1 to P23)
IEC-60297:
(P1 to P4)
IEC-60359
IEC-60387
IEC-60447
IEC-60521
IEC-60547
ANSI-81
ANSI-B18
ANSI-C37.1
ANSI-C37.2
Page 13 of 26

S.
No.
Indian Standard
Number
28
Relays and relay systems associated

with electric power apparatus
ANSI-C37.2
29
Requirements for electrical

indicating instruments
ANSI-C39.1
(C) BATTERY SETS

1
IS: 266-1977
Title
International &
Internationally
Recognised
Standards
analog
Specification for sulphuric acid
IS: 652-1960
Specification for wooden separators for

lead acid storage batteries
IS: 1069-1964
Specification for water for storage

batteries
IS: 1070-1960
Specification for water, distilled quality.
IS: 1146-1981
Specification for rubber and plastic

containers for lead acid storage
batteries.
IS: 1651-1979
Specification for stationary cells and

Batteries lead acid type (with tabular
positive plates).
IS: 3116-1965
Specification for scaling compound for

lead acid batteries.
IS: 6304-1980
Specification for stationary batteries

leads acid type with pasted positive
plates.
IS: 8320-1976
General requirement and methods of

tests for lead acid storage batteries.
10
IS:1652
11
IS:6071
12
IS:1248
Stationary cells and batteries, Leadacid type (with plates positive plates)
Synthetic separators for lead acid
batteries
Indicating instruments
13
IS:10918
Vented type nickel cadmium batteries
14
15
16
17
Vented type nickel cadmium batteries

Secondary cells & batteries-sealed NiCd rechargeable single cell
Secondary cells & batteries-sealed NiCd rechargeable single cell
Stationary lead acid batteries-vented
type general requirements & method of
tests
IEC:60623
IEC:60622
IEC:60623
IEC:60896-11
Page 14 of 26

S.
No.
Indian Standard
Number
Title
Recommended practices of sizing of

lead acid batteries
Sizing of Ni-Cd batteries
International &
Internationally
Recognised
Standards
18
19
20
Recommended practices for design &

installation of VRLA batteries
IEEE-1187
21
Recommended practices for design &

installation of VRLA batteries
IEEE-1188
22
23
24
25
Guide for selection of VRLA batteries

Recommended practice for design and
installation of storage batteries
batteries lead acid type with Plante
positive plates.
High Performance Plante Cells
IEEE-485
IEEE-1115
IEEE-1189
IEEE-484
IS:6071
BS:6290(Part 2)
D) BATTERY CHARGER:
1
IS: 1651
IS: 3895
3
4
5
6
IS: 9224
IS: 1248
IS: 2147
IS: 375
IS: 4540
IS: 6619
IS: 2026
10
IS: 2959
11
IS: 4237
12
IS: 4064
13
IS: 6005
14
15
16
IS: 5
IS: 5921
IS: 249
17
IS: 5578

batteries, lead-acid type (with tubular
positive plates)
Specification for Rectifier equipment in
general.
Specification for HRC fuses.
Indicating instruments.
Degree of protection for cubicles.
Specification for wiring.
Monocrystaline semiconductor rectifier
assemblies and equipment.
Safety code for semiconductor rectifier
equipment.
Transformers.
A.C. Contactors for voltage not
exceeding 1000V.
General requirement for switchgear and
control gear for voltage not exceeding
1000V.
Air breaks switches and fuse
combination units.
Code of practice for phosphating of Iron
and Steel.
Colour for ready mix paints.
Printed circuit Board.
Printed circuit Board.
Guide for making insulated conductor.
Page 15 of 26

S.
No.
Indian Standard
Number
Title
International &
Internationally
Recognised
Standards
E) AC/DC BOARDS:
1
IS-4237
General requirements for switchgear &

1000V.
IS-2147
Degrees of protection provided by

and control gear.
IS-375
4
5
6
7
8
9
IS-2208
IS-1248
IS-1554
IS-2516
IS-2705
IS-3156
10
IS-4047
11
IS-2208
Marking
and
arrangement
for
switchgear busbars main connection
HRC Cartridge fuse links upto 650V
Electrical Indicating Instruments.
PVC Insulated electrical cables.
AC Distribution Board breakers.
Current Transformers.
Voltage Transformers.
Heavy duty-Air break switches &
composite units & fuses for voltage
not exceeding 1000V.
HRC fuses
12
IS-13947 (Part-3)
Air break switches, air break

disconnectors & fuse combination units
for voltage not exceeding 1000V AC or
1200V DC
13
IS-3231
Electrical relays for power system

protection
14
15
Recommended design for installation

design and installation of large lead
storage batteries for generating stations
and substations
Sizing large lead storage batteries for
generating stations and substations
IEEE-484
IEEE-485
F) JUNCTION BOXES:
1
IS-4237
General requirements for switchgear &

1000V.
IS-2147
Degrees of protection provided by

and control gear.
IS-375
Marking
and
arrangement
for
switchgear busbars main connection
IS13947
Standard for manufacture of Junction

boxes
Page 16 of 26

S.
No.
Indian Standard
Number
IS:9537
IS:3480
IS:2667
IS:3837
9
IS:4649
10
IS:5133
11
IS:2629
G) LIGHTING FIXTURES:
1
IS:1913
IS:3287-1965
IS:1777-1978
IS:9974-1981
(Part-I & II)
IS:8019
6
7
Title
International &
Internationally
Recognised
Standards
Rigid steel conduits for electrical wiring
Flexible steel conduits for electrical

wiring
Fittings for rigid steel conduits for
electrical wiring
Accessories for rigid steel conduits for
electrical wiring
Adaptors for flexible steel conduits
Steel and cast iron boxes
Hot dip galvanizing of iron & steel
General and safety requirements for
electric lightning fittings
Industrial Lighting fitting with plastic
reflectors
Industrial Luminaries with metal
reflectors
High Vacuum Sodium Vapour Lamp
IS:3528
IS:4012
Vitreous enameled reflectors for use

with illuminating device.
Water proof electric lighting fittings
Dust proof electric lighting fittings
IS:4013
Dust tight proof electric lighting fittings
IS:10322
10
IS:10322
11
IS:2206
12
IS:10322
Industrial lighting fittings with metal

reflectors
Industrial lighting fittings with plastic
reflectors
Well glass lighting fittings for use under
ground in mines (non- flameproof type)
Specification for flood light

Specification for decorative lighting
13 IS:10322
outfits
14 IS:10322
Luminaries for street lighting
H) STATION TRANSFORMER 200 KVA, 33/0.4 KV
For Transformer manufacturing &
Testing
etc.
i) Latest revision of IS
2026 & IS 1180
1
For Transformer bushing
ii) IS 2099
For Oil
iii) IS 335
REC specification,
CBIP publication
no. 275
Page 17 of 26

S.
No.
Indian Standard
Number
International &
Internationally
Recognised
Standards
I) CURRENT TRANSFORMERS & POTENTIAL TRANSFORMERS FOR 220 KV, 132 KV &
33KV
1
IS:2165
2
3
IS:2705 (I to IV)
IS:2099
IS:3347
IS:2071
IS:335
IS:2147
10
11
12
13
14
IS:3156
15
16
17
IS:5561
IS:4800
18
IS:2629
19
Title
Insulation Co-ordination for equipment

of 100 KV and above.
Current Transformers
High voltage porcelain Bushings
Dimensions of porcelain transformer
bushings.
Method of High Voltage Testing
Insulating oil for transformers and
switchgears
IS: 4759
IS: 2633
IEC-60044-2
First supplement to IEC Publication 186
IEC:186A
Electrical Power Connector

Enamelled Round Winding Wires
galvanising of Iron & Steel
Fluids for electrotechnical applications Unused mineral insulating oils for

transformer & switchgear
IEC-60044-1
IEC-60137

enclosures for low voltage, switchgear
and control.
Partial Discharge Measurement
Instrument Transformer measurement
of PDs
Insulation co-ordination
High voltage testing techniques
Method for RIV test on high voltage
insulators
Indian Electricity Rules 1956.
Voltage Transformers
Guide for selection of Insulators in

polluted conditions
J) LIGHTNING ARRESTERS FOR 220 KV, 132 KV & 33KV
Metal Oxide Surge Arrestors without
1
gap for AC System
IS: 3070:
Specification for Lightning Arresters for
2
alternating current system
(Part-III) 1993
20
Hot dip zinc-coating on structural steel

and other allied products
Method for testing uniformity of coating
on zinc coated articles
IEC-270
IEC-60044-4
IEC-171
IEC-60
IEC-8263
IEC-296
IEC-815
IEC-60099-4
-
Page 18 of 26

S.
No.
Indian Standard
Number
Title
International &
Internationally
Recognised
Standards
IS: 5621
Specification for large hollow porcelain

for use in electrical installation
IS: 2147

and control
7
8
K)
1
2
3
4
5
6
7
8
Specification
for
Electric
Power
Connector
Indian Electricity Rules, 1956
ISOLATORS FOR 220 KV, 132 KV & 33KV VOLTAGE
Alternating
current
isolators
IS :9921
(disconnectors) & earthing switches
IS:2544
Insulators
IS:2147
enclosure
IS:4691
enclosure
IS:4722
Rotating electrical machines
IS:2629
galvanizing of iron and steel
Hot dip galvanization coating on
IS:4759
structural steel
IS: 5561
IS:2633
IEC-60129
-
Method of testing weight thickness and

uniformity of coating on fasteners.
Electroplated coating of zinc or iron and

Steel
10 IS:5561
Electric Power Connectors
11 IS:3033
Spring washers
12 IS:2016
Plain washers
13
-Indian Electricity Rules 1956.
L) SOLID CORE INSULATORS FOR 220 KV, 132 KV & 33KV VOLTAGE
Insulation Co-ordination for equipment
1
IS:2165
of 100 KV and above
2
IS:2544
Insulators
3
IS:5350
Post Insulators
Test on Post Insulators of nominal
4
voltage greater than 1000 Volt
5
Indian Electricity Rules 1956
M) 220 KV CAPACITIVE VOLTAGE TRANSFORMERS
1
IS- 3156
Voltage Transformers
2
IS- 9348
Coupling Capacitor
3
CVT/Coupling Capacitor
4
Voltage Transformer
9
IS:1573
IEC 168
IEC- 358
IEC- 186
Page 19 of 26

S.
No.
5
6
N)
1
2
3
Indian Standard
Number
Title
Instrument Transformer Measurement

of partial discharge
Coupling Capacitor and Capacitor
Dividers
220 KV & 132 KV WAVE TRAPS
IS- 8792
Line Trap For AC Power System
IS- 8793
Method For Test Line Trap
-
Line Traps for a. AC Power Systems
4
IS-3070
Lightning Arresters for AC system
O) POWER LINE CARRIER COMMUNICATION EQUIPMENTS
Single side band Power Line carrier
1
terminals
2
IS- 9482
Carrier Cabinet
3
Carrier Cabinet
4
Protection Coupler
5
Guide on power line carrier
6
IS- 8997
Coupling Device for PLC system
Methods of test for Coupling Device for
7
IS- 8998
PLCC System
Coupling Device for power line carrier
8
systems
8
Impulse Voltage withstand test
High Frequency disturbance
9
susceptibility test
Electrostatic discharge susceptibility
10
test
11
Radiated susceptibility
12
Fast Transient Susceptibility Test
Power
Line
Coupling
Voltage
13
Transformers
14
Planning of (Single side-band) power

line Power Line Carrier Systems
P) COAXIAL CABLE
1
IS-11967
Coaxial Cable
2
IS- 1554
Armoured Cable
3
Telephone Cable
Q) SUBSTATION SWITCHYARD STRUCTURES
1
IS:209-1992
Zinc ingot- Specification.
Code of practice for use of structural
steel in overhead transmission line
2
IS:802-Part-II-1978
towers Part II: Fabrication,
Galvanizing, Inspection & packing.
International &
Internationally
Recognised
Standards
IEC- 6044-4
IEC-60358
IEC-60353
IEC -60495
IEC-60495
IEC-834-1
CIGRE
IEC- 60481
IEC-255-4
IEC-255-22-1
IEC-801-2
IEC-801-3
IEC-801-4
ANSIC92.2
IEC 60683
GR/WIR-06/03
-
Page 20 of 26

S.
No.
Indian Standard
Number
Title
International &
Internationally
Recognised
Standards
IS:1363
(Part-III)-1992
Specification for Hexagon head bolts,

screws and nut for product grade C
Part-3 : Hexagon nuts (size range M5
to M64)
IS:1367-1979
Technical
supply
conditions
threaded fasteners (1st Revision).
IS:1367
(Part-III)-1991
Technical
supply
conditions
for
threaded steel fasteners Part-3:
Mechanical properties of fasteners
made of carbon steel and alloy steel
bolts, screws & studs.
IS:1367
(Part-VI)-1994
IS-1367
(Part-XIII)-1983
IS:1573-1991
IS:1586-1968
10
IS:1852-1991
11
IS:2016-1992
12
IS:2062-1992
13
IS:2614-1969
14
IS:2629-1990
15
IS:2633-1992
16
IS:3063-1994
Fasteners- Single Coil Rectangular

Section spring lock washers
Specification.
17
IS:3203-1972
Methods for testing local thickness of

electro plated coatings.
18
IS:3218(Part-V) -1979
Isometric screw threads Tolerance.
19
IS:3757-1992
20
IS:4072-1975
21
IS:4218 (Part-VI)-1978
for
Mechanical properties and test method

for nuts with specified proof loads.
Technical
supply
conditions
for
threaded steel fasteners Part-XIII: Hot
dip galvanized coating on threaded
fasteners.
Specification for electroplated coating
of zinc on Iron & steel.
Methods of Rock well hardness test (`B
& `C scales) for steel (first revision).
Rolling and Cutting Tolerances for Hot
Rolled Steel Products.
Specification for Plain Washers.
Hot Rolled low, medium and high
tensile structural steel.
Method for sampling of fasteners.
galvanizing of iron and steel.
Method of testing uniformity of coating
of zinc coated articles.
Specification for high Strength

Structural Bolts.
Specification for steel for spring
washers.
Isometric screw threads Part-VI: limits
of sizes for commercial bolts &
nuts(diameter range 1 to 52 mm).
Page 21 of 26

S.
No.
Indian Standard
Number
Title
Specification for Hot dip Zinc coatings

on Structural Steel and other Allied
products.
Hot dip galvanized coatings on
fasteners.
General Requirements for Plain
Washers.
Specification for Heavy Washers for
Steel Structures.
High Strength Structural Nuts Specification.
Methods for sampling of non threaded
fasteners.
International &
Internationally
Recognised
Standards
22
IS:4759-1990
23
IS:5358-1969
24
IS:5369-1991
25
IS:6610-1991
26
IS:6623-1992
27
IS:6821-1973
28
IS:10238-1989
Fasteners Threaded steel fasteners Step Bolts for Steel Structures.
29
IS:12427-1992
Fasteners Threaded steel fasteners

Hexagon Head Transmission Tower
Bolts Specification.
R) MS FLATS
1
IS:1852
IS:2062
IS:2830
Rolling and cutting tolerances for Hot

rolled steel products.
Hot Rolled Low, Medium and High
Tensile Structural Steel.
Carbon steel cast billet ingots, billets,
blooms and slabs for re-rolling into
steel for general structural purposes.
S) CLAMPS AND CONNECTORS

1
IS 2121
IS 5561
IS 2633
IS 2629
IS 5082
IS 617
IS 10162
Specification for conductors and earth

wire accessories for overhead power
lines.
Specification for Electrical power
connectors.
Method of testing uniformity of coating
of zinc coated articles.
galvanizing of iron & steel
Specification for wrought Aluminium
and Aluminium Alloy bars, Rods, Tubes
and sections for electrical purposes.
Specification for Aluminium and
Aluminium Alloy Ingots and Castings
for General Engineering Purposes.
Specification for Spacer and Spacer
dampers for Twin Horizontal bundle
conductors.
Page 22 of 26

S.
No.
Indian Standard
Number
Title
International &
Internationally
Recognised
Standards
T) COPPER CONTROL AND ALUMINIUM POWER CABLE

1
IS: 1554
Specification for PVC insulated (Heavy

Duty) Control cables for working
voltage up to & including 1100 Volts.
IS: 3961
Recommended current ratings for PVC

insulated and PVC sheathed heavy
duty cables.
Mild steel wires, strings and tapes for

armouring of cables.
4
IS: 4905
Methods of random sampling.
Specification for PVC insulation and
5
IS: 5831
sheath of electric cables.
Specification for Conductors for
6
IS: 8130
insulated electric cables and flexible
cords.
Specification for Drums for electric
7
IS: 10418
cables.
8
IS: 10810
Methods of test for cables.
U) TUBULAR BUS CONDUCTOR
3
IS: 3975
IS 5082
Specification for wrought Aluminium

and Aluminium Alloy bars, Rods, Tubes
and sections for electrical purposes.
Specification for Dimensions of steel

pipe for the petroleum industry.
B.S.1600
V)
ACSR CONDUCTOR
IS:209
2
3
IS:398 Part I to Part V Specification for Aluminium Conductors

for overhead Transmission purpose
(as relevant)
Reels and drums for Bare wires
IS:1778
IS:1521
Method of Tensile Testing of Steel wire
IS:2629
IS:2633
IS:4826
IS:6745
IS:8263
Recommended practice for Hot Dip

Galvanising Iron and Steel
Method of Testing Uniformity of Zinc
coating of Zinc coated Articles.
Galvanised coating on Round Steel
wire
Method of Determination of weight of
Zinc coating of zinc coated Iron and
Steel Articles
Method of Radio Interference Tests
10
IS:1841
Specification for Zinc
EC Grade Aluminium Rod produced by

rolling
Page 23 of 26

S.
No.
Indian Standard
Number
11
IS:5484
12
IS: 2141
W)
Title
International &
Internationally
Recognised
Standards
EC grade Aluminium Rod produced by

continuous casting and rolling
Method of Elongation test of steel wire
SCREENING CONDUCTOR (HIGH TENSILE GALVANISED STEEL EARTH WIRE)
IS:209
IS:2141
IS:1778
Specification for Earth wire

overhead Transmission purpose
Reels and drums for Bare wires
IS:1521
Method of Tensile Testing of Steel wire
IS:2629
IS:2633
IS:4826
IS:6745
IS: 12776

Galvanising Iron and Steel
Method of Testing Uniformity of Zinc
coating of Zinc coated Articles.
Galvanised coating on Round Steel
wire
Method of Determination of weight of
Zinc coating of zinc coated Iron and
Steel Articles
Method of Testing of Ground wire
for
70 KN, 90 KN, 120 KN & 160 KN ELECTROMECHANICAL STRENGTH PORCELAIN

DISC INSULATORS
IS:209-1992
IS:206-1991
IS:731-1991
IS:2071
Part(I)-1993
Part(II)-1991
Part(III)-1991
IS:2121
X)
Part(I)
Method for Chemical Analysis of Slab

Zinc
Porcelain insulators for overhead power
lines with a nominal voltage greater
than 1000V
Method of High Voltage Testing
Specification of Conductors and Earth

wire Accessories for Overhead Power
Lines.
Armour Rods, Binding Wires & Tapes
for Conductors
IS:2486
Specification for insulator fittings for

overhead power lines with a nominal
voltage greater than 1000V
Part I-1993
Part II-1989
Part III -1991
General Requirements & Tests

Dimensional Requirements
Locking Devices
Page 24 of 26

S.
No.
Indian Standard
Number
IS:2629-1990
IS:2633-1992
IS:3188-1988
10
IS:6745-1990
11
IS : 8263-1990
12
IS:8269-1990
Y)
Title

Galvanization for iron & steel
Testing for Uniformity of Coating of Zinc
coated articles
Dimensions for Disc Insulators
Determination of Weight of Zinc coating
on Zinc coated iron and steel articles
Methods of RIV Test of HV Insulators
Methods for Switching impulse test on

HV insulators
SUBSTATION HARDWARE
IS:209-1992
Specification for Zinc Ingot
IS:206-1992
Tee and Strap Hinges
IS:7814-1985
Phosphor Bronze Sheet and Strip
IS:2071
Method of high voltage testing
IS:731
IS:961
Porcelain Insulator for Overhead

Power Lines with a Nominal Voltage
Greater than 1000 V.
Structural Steel
IS:1385
IS:2004
IS:2107
Phosphor Bronze Rods & Bar Sheet

and Strips and Wire
Carbon Steel Forgings for General
Engineering Purpose
White Hearth Malleable Iron Castings
10
IS:2108
Black Hearth Malleable Iron Castings
11
IS:2121(Part-I & II)
12
IS:2486
13
IS:2629
14
IS:2633
15
IS:3138
Specification for Conductors and Ground

wire Accessories for Overhead Power
Line, Armour Rods Binding Wires and
Tapes for Conductor
Specification for Insulator Fittings for
Overhead Power Lines with a Nominal
Voltage Greater than 1000 V.
Recommended Practice for Hot Dip
Galvanization of Iron and Steel.
Testing of Uniformity of Coating of Zinc
coated Articles
Hexagon Bolts and Nuts
16
IS:6639
Hexagon Bolts for Steel Structures
17
IS:6745
18
IS:3188
Determination of Weight of Zinc

Coating on Zinc Coated Iron and Steel
Articles
Characteristic of String Insulators Units
19
IS:4218
ISO Metric screw Threads
International &
Internationally
Recognised
Standards
Page 25 of 26

S.
No.
Indian Standard
Number
Title
International &
Internationally
Recognised
Standards
20
IS:4172
Dimensions for Radii under the Heads

of Bolts & Screws
Dimensions for nominal lengths and
Thread length for Screws and Studs
(with amendment)
Hot Dip Zinc Coatings on Structural
Steel and other Allied Products
Electroplated Coatings of Zinc on Iron
and Steel
Specification for Aluminium Conductor
Steel Reinforced for overhead
transmission purpose.
Methods for determination of weight of
tin Coating on Tin Plates
Hot Dip Galvanised Coating on Round
Steel Wires
Hexagon Head Bolts, Screws & Nuts.
21
IS:4206
22
IS:4759
23
IS:1573
24
IS: 398
25
IS: 1327-1966
26
IS: 4826-1979
27
IS: 1363
28
IS: 1367
Technical
supply
conditions
threaded Steel Fasteners
29
IS: 9708
Stockbridge Vibration
Overhead Power lines.
30
IS: 8263
Method of Radio Interference Tests on

High Voltage Insulators.
31
IS:10162
Spacers and Spacer Dampers for twin

horizontal bundle Conductors.
32
IS: 2004
Carbon Steel Forgings for general

engineering purposes.
33
BS:970 (Part-I)
General Instructions and Testing

Procedures Specific Requirements for
Carbon and Carbon Manganese Alloy
and Stainless Steels.
OIL FILTER PLANTS
IS: 6034
for
Dampers for
Oil filter plants of all GPH
IS: 1866
For testing of oil filter plant
AA FRP OIL STORAGE TANK
1
IS: 10661
For oil storage tank
Page 26 of 26

VOLUME II
PART-2
BOOK II OF III


MPPTCL, JABALPUR
Description
Technical Book
Serial No.
Part-1

POWER TRANSFORMERS
Part-2
Book I
of III

MATERIALS
Part-2
Book II
of III

MATERIALS
Part-2
of III
MATERIALS

PART-2(BOOK II OF III)
Tender document.
INDEX
VOLUME-II, PART-2
Part 2
consist of
BOOK-I of III
S. No.

1.1
1.2
1.3
2.1
2.1.1
Circuit Breakers
BOOK-II of III
25
26
26
27
62
2.1.2
63
199
2.1.3
200
241
2.1.4
Lightning Arresters
242
254
2.1.5
Isolators
255
276
2.1.6
277
282
2.1.7
283
302
2.2

2.2.1
303
318
2.2.2
Wave Traps
319
332
2.2.3

333
351
2.2.4
352
361
2.2.5
362
372
2.2.6
RTU
373
422

Equipments
2.3.1
423
470
2.3.2
471
505
2.3.3
506
529
2.3.4
530
538
2.3.5
539
539
540
555

Cables & Hardwares
2.5.1
556
580
2.5.2
581
584
2.5.3
585
592
2.5.4
Clamp & Connectors.
593
612
2.5.5
Substation Hardware
613
633
2.6
634
644
2.7
645
667
2.3
2.4

2.4.1
BOOK-III of III
Page No.
From To
2.5
Structures
Volume-II, Part-2, Book-II of III
2.1 TECHNICAL SPECIFICATION FOR EHV EQUIPMENTS

2.1.1 TECHNICAL SPECIFICATION OF CIRCUIT BREAKERS
1.0
SCOPE:
The scope of this bid covers, design manufacturing and supply of equipment as per
Volume-II, Part-2, Book-I. The bidder mentioned in this Section of the Technical Bid means
Original Equipment Manufacturer (OEM). The purchaser means the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipments/material of
manufacturer as per this bid requirement shall rest on the bidder.
2.0
STANDARDS:
2.1
Applicable Standards for the offered equipments/items shall be as per Volume-II,
Part-2, Book-I.
2.2
If the equipment offered by Bidders conforms to any other standards, salient points of
comparison between the standards adopted and the specific standards shall be clearly
brought out in relevant schedule of technical deviation. It will be sole responsibility of Bidders
to prove that the salient features of offered equipment are equivalent or better than IS.
2.3
ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS:
In the preceding paragraph relevant Indian standard /IEC standard bid have been
shown. However, the equipment meeting any other authoritative international standard, which
ensures equal or better quality than the standards, mentioned shall also be acceptable.
Equipment for which Indian Standards are not available, the relevant British standards and
IEC recommendations will be applicable. Please attach photocopy of all such standards
according to which the equipment has been offered.
2.4
TYPE TESTS:
Circuit Breakers should be suitable to close and open successfully for specified idle
line charging current without developing dangerous over voltages. All offered circuit breakers
should be fully type tested as per the relevant standards. In case the equipment of the type
and design offered, has already been type tested, Bidders shall invariably furnish type test
reports from the reputed and approved national/international laboratory/Government
approved test houses to prove that bids of Circuit breakers offered conform to the relevant
standard. Test certificates shall clearly indicate the type and model number etc., so that
relevant details of offered circuit breakers could be verified. While submitting offers the model
and type etc., shall be clearly indicated. Type test reports so furnished should not pertain to
the period earlier than five years from the date of opening of Bid. Bidders have to submit one
complete set of Type Test reports for the offered circuit breakers for the following tests:
MPPTCL/ TECH/ PROC/ 05/ MAY13
27
Circuit Breakers
S.NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
TYPE TESTS REPORTS TO BE FURNISHED BY BIDDERS

Mechanical Operation Test (Mechanical endurance test)
Temperature rise test
Dielectric tests(Dielectric properties should be tested with the closing resistor)
a) Lighting impulse voltage withstand test
b) Power frequency voltage withstand test
c) Switching impulse voltage withstand test (wet)(for 400KV CB)
Power frequency voltage withstand test.
Making and breaking capacity test
Basic short circuit test (duties for terminal faults)
Critical Current Test
Short line fault test
Short time current test
Evolving Fault Test
Out of phase breaking test
Idle Line charging current breaking tests:
Seismic withstand test:
Corona inception and extinction voltage test (for 400 KV Breakers only)
Capacitor current switching test
Shunt reactor current-switching test
IP 55 test on marshalling box
Seismic withstand test on the complete equipment shall be carried out along with the
supporting structure etc. Seismic level specified shall be applied at the base of the structure.
The accelerometers shall be provided at the terminal pad of the equipment. Seismic test shall
be carried out in all possible combination of the equipments.
2.5
DISCREPANCY IN TECHNICAL PARTICULARS:
Regarding discrepancy in technical particulars stipulation under Volume-II shall be

applicable.
3.0
SYSTEM CONDITIONS:
3.1
Applicable climatic conditions shall be as per Volume-II.
3.2

Auxiliary Power Supply for offered EHV equipments shall be as per Volume-II.
4.0
DUTY REQUIREMENT
4.1
Circuit breakers shall be totally restrike free under all duty conditions and shall be
capable of performing specified duties.
4.2
Circuit breakers shall meet the duty requirements for all type of phase to phase and
ground fault, irrespective of fault location. Breakers shall also meet idle line charging and
28
Circuit Breakers

dropping when used on an effectively grounded system and perform make and break
operations as per stipulated duty cycles satisfactorily.
4.3
Circuit breakers shall be capable of following duty requirement as mentioned
in Appendix-A1 Principal Parameters:
i.
ii.
iii.
iv.
v.
vi.
Interrupting the steady and transient magnetizing inrush current of power

transformer.
Interrupting line charging current.
Clearing short line faults (kilometric faults) with source impedance behind the bus
equivalent to symmetrical fault current specified.
Breaking inductive currents of upto 10 Amp.
Out of phase breaking capacity.
Various voltage class circuit breakers should be capable for capacitor switching as
per IEC.
4.4
Breakers shall satisfactorily withstand high stresses imposed during fault clearing,
load rejection and re-energisation of lines with trapped charges. Breakers shall also
withstand the voltage specified in Appendix-A1 Principal Parameters:
5.0
GENERAL TECHNICAL REQUIREMENTS OF CIRCUIT BREAKERS:
5.1
Exposed live parts shall be placed high enough above ground to meet the
requirement of local safety codes.
5.2
Any part of the breaker, especially the removable ones, shall be freely
interchangeable without the necessity of any modification at site.
5.3
Complete circuit breaker with all the necessary items for successful operation shall
be supplied.
5.4
Circuit breakers shall be suitable for hot line washing.
5.5
All breakers shall be supplied with 1 set (6 nos.) terminal connectors. Details of
terminal connector required with each circuit breaker are given in clause 18.0 hereunder and
the Bidders are required to note that the terminal connectors shall form a part of scope of
supply.
5.6
Current density adopted for the design of the terminal pads shall in no case exceed
the following values:
i.
For copper pads - 1.6 Amp/sq.mm.
ii.
For others
- 1.0 Amp/sq.mm.
5.7
Provisions shall be made for attaching operation analyzer after installation at site to
record contact travel & speed and for making measurement of operation timings,
synchronization of contacts of all poles.
29
Circuit Breakers

6.0
CONTACTS:
6.1
Main contacts shall have ample area and contact pressure for carrying rated current
continuously and also the short time rated current of Breakers without excessive
temperature rise, which may cause their pitting or welding. Contacts shall be adjustable to
allow for wear, easily replaceable and shall have a minimum of moveable parts and
adjustments to accomplish desired results.
6.2
All external and internal make and break contacts shall be sealed and shall be free
from atmospheric effects. Contacts shall be designed to have adequate thermal and current
carrying capacity for the duty specified and to have long life expectancy so that frequent
replacement due to excessive burning is minimized. Provision shall be made for rapid
dissipation of heat generated by the arc on opening.
6.3
Main contacts shall be first to open and last to close to minimize contact burning and
wear.
6.4
Any device provided for voltage grading to damp oscillations or to prevent restrike
prior to the complete interruption of Circuit or to limit over voltages on closing shall have a
life expectancy compatible to that of Breakers as a whole.
6.5
Breakers shall be so designed that when operated within their specified rating,
temperature of each part will be limited to values consistent with a long life of the material
used. The temperature shall not exceed that indicated in IEC-56 under specified ambient
conditions.
7.0 PORCELAIN HOUSING:
7.1
Porcelain housing shall be of single piece construction without any joint or coupling.
It shall be homogeneous, free from lamination, cavities and other flaws or imperfections that
might affect high mechanical and dielectric strength and shall be thoroughly vitrified tough
and impervious to moisture.
7.2
Glazing of porcelain shall be uniform, brown or dark brown coloured, free from
blisters, burns and similar other defects with a smooth surface arranged to shed away
rainwater or condensed water particles (fog).
7.3
Housing shall be designed to have ample insulation, mechanical strength and rigidity
for satisfactory operation for the conditions under which they will be used. All housing of
identical ratings shall be interchangeable.
7.4
Puncture strength of housing shall be greater than the dry flashover value. When
operating at normal rated voltage there shall be no electric discharge between the
conductors and housing which would cause corrosion or injury to conductors, insulators or
supports by the formation of substance produced by electro-chemical action. These housing
when operating at the normal rated voltage shall cause no radio interference/disturbance.
30
Circuit Breakers

7.5
All iron parts shall be hot dip galvanised and all joints shall be airtight. Surfaces of
the joint shall be trued-up by grinding porcelain parts and by machining metal parts. Housing
design shall be such as to ensure a uniform compressive pressure on the joints.
7.6
Interrupter housing insulator and support insulator shall satisfactorily withstand
insulation level of circuit breaker specified in Appendix-A1 "Principal Parameters" and shall
also be suitable for contaminated and polluted atmosphere as per relevant standard.
8.0
AUXILIARY CONTACTS:
8.1
Auxiliary switches (contacts) required for satisfactory operation of Circuit breaker
including automatic reclosing (single shot, single and 3 phases), ON/OFF indicators both in
control room and cubical switchyard, semaphore indicators in the mimic diagram in the
control room and anti pumping feature shall be provided on each circuit breaker. All these
auxiliary switches and required relays with their scheme shall be included in the scope of
supply.
8.2 In addition to the auxiliary switches mentioned above, Bidders shall provide as spares
ten auxiliary contacts each of the "normally-open" and "normally-closed" types which shall
operate with the closing or opening of all the three poles of circuit breakers and further ten
auxiliary contacts each of "normally closed" and normally open" type which shall operate
with each of three individual poles of circuit breakers. These spare contacts shall be utilised
for additional safety inter-locking and other monitoring devices by the purchaser.
8.3 All auxiliary contacts shall be placed in a weatherproof casing and current rating of the
switches shall be mentioned in the Bid. Provision shall be available to convert these spare
"normally-open" contacts to "normally-closed" type and vice versa.
8.4
Auxiliary switch of Breakers shall be preferably driven by breaker operating rod.
However in case due to some constraint same is not possible then a plug-in device shall be
provided to simulate the opening and closing operations of circuit breaker for the purpose of
testing control circuits.
8.5
Arrangement proposed for connecting control cables to the auxiliary switches shall be
clearly stated. Provision shall be made for suitable cable glands fitted on gland plate for
receiving control cables required for inter connecting assemblies and the auxiliary switches
of the breaker. Additional Gland plates shall be supplied duly drilled and fitted with cable
glands. Gland plate and operating mechanism doors shall be provided with gasket properly.
These cable glands shall be suitable for armoured copper control cables. The cable glands
with suitable blanking arrangement shall be fitted on the gland plate that shall be fastened
suitably at the bottom of each control cabinet for connecting copper control cables provided
by the purchaser.
8.6.
Bidders may please note that 1.1 KV grade unarmoured copper control cables shall
be used by the purchaser and, therefore, the offered cable glands shall be suitable for the
sizes of these cables as specified under Appendix-A1 "Principal Parameters"
8.7.
The position of rotating Aux. switches in mechanism box should be such that
there should not be any difficulty in cable connection and tracing particular terminal.
All terminals marking should be clearly visible from front/outside the switch.
31
Circuit Breakers

9.0
TOTAL BREAK TIME:
9.1
"Total Break Time" as specified in Appendix-A1, "Principal Parameters" shall not
exceed under any circumstances for the following duties:
(i)
Test duties 1,2,3,4,5 (with TRV) as per IEC-62271-100 /IEC56
(ii)
Short line fault L90, L75 (with TRV) as per IEC-62271-100 /IEC56
9.2
Bidders may please note that specified break time of Breakers shall not exceed
under any duty conditions, variation of the trip coil voltage, pneumatic/ hydraulic pressure
and SF6 gas pressure etc.
10.0
OPERATING MECHANISM AND ASSOCIATED QUIPMENTS:
10.1
GENERAL REQUIREMENTS:
Bidders may please note that both closing and tripping mechanisms for all
rating of breakers need necessarily be of spring type. This is mandatory requirement.
10.1.1
Each circuit breaker shall be designed for remote control operations from the
control room. In addition, there shall be provision for local tripping & closing operations both
by electrical & mechanical control. Mechanical arrangement should be provided to facilitate
manual tripping of circuit breaker for emergency trip under emergent conditions e.g. failure
of DC supply, trip coil is burnt, trip coil mechanism is defective etc., while arc quenching
medium is healthy.
10.1.2
Operating mechanism shall be of spring type only, remotely operated by electrical
signal. Mechanism shall be adequately designed & capable of performing satisfactorily all
specified tripping and reclosing duty within the specified time. Entire operating mechanism
control circuitry including electrical controls & monitoring devices and all other accessories,
as required, shall be housed in an outdoor type, hot dip galvanised steel enclosure. This
enclosure shall conform to the degree of protection IP-55 of latest version of IS:2147. The
enclosure shall be invariably mounted on a separate concrete plinth of 300 mm height.
However, in case due to IP-55 protection limitations. If operating mechanism is mounted
below the pole housing. in that case it should be possible for the operating personnel
to manually charge closing spring / mechanism from ground level including ON/OFF
operation without using any stool or otherwise. However. due to any reason if
operating platform is absolutely necessary, the same shall be deemed to be included
in scope of supply.
10.1.3
All working parts in the mechanism shall be made of corrosion resistant material.
All bearings which require greasing shall be equipped with pressure grease fittings. Bearing
pins, bolts, nuts and other parts shall be adequately pinned or blocked to prevent loosening
or changing of adjustment with repeated operation of the breaker.
10.1.4
Design of the operating mechanism shall be such that it shall be practically
maintenance free. Guaranteed years of maintenance free operation, the number of full load
and full rated short circuit current breaking/operation without requiring any maintenance or
overhauling, shall be clearly stated in the Bid. As far as possible the need for lubricating the
operating mechanism shall be kept to the minimum and eliminated altogether, if possible.
32
Circuit Breakers

10.1.5
The operating mechanism shall be non-pumping and trip free electrically and
mechanically. A latch checking switch shall be provided on mechanically trip free
mechanism to prevent reclosing before Breakers latches have reset. There shall be no
objectionable rebounds in the mechanism and it shall not require any critical adjustments at
site. It shall be rigid, positive and fast in operation. Mechanism shall be such that the failure
of any auxiliary spring shall not cause false tripping or closing. Operation of the power
operated closing device, when Circuit breaker is already closed, shall not cause damage to
Circuit beaker or endanger the operator's life. Provision shall be made for attaching an
operation analyzer to facilitate speed test after installation of Breakers at site. ON-OFF
indicating lamps shall be provided on the mechanism box.
10.1.6
A mechanical indicator shall be provided to show "open" and "close" position of
Breakers in addition to facilitate for remote electrical indication. An operation counter shall
also be provided in the central control cabinet. Mechanical indicator and operation counter
shall be located in a position where it shall be visible to a man standing on the ground level
with the mechanism housing closed.
10.1.7
Circuit breaker operating mechanism shall incorporate an electrically achieved
positive acting anti-pumping feature to prevent Circuit breaker from reclosing after an
automatic opening when the initiating closing device is maintained in the position for closing.
Necessary anti-pumping relay shall be included in the scope of supply.
10.1.8
All material for making connection between Circuit breaker and its local control
cabinet shall be included in the scope of supply.
10.1.9
All the similar contacts of 3 pole circuit breaker shall be designed to touch or open
essentially simultaneously & in any case shall close or open within a period of half a cycle or
less. Auxiliary circuit through resistors shall be closed in sufficient time before the main
contacts closes to ensure that the over-voltage will be held to guarantee value under most
favorable sequence of contact closing.
10.1.10 Bidders shall furnish detailed operation and maintenance manual of the
mechanism along with the operation manual for Circuit beaker.
10.1.11 The mechanism shall be rated for minimum mechanical operations which is
covered under M2 class test with IEC 62271- 100.
10.1.12 The parts of the CBs like operating mechanism, links, operating arm etc.
should not be exposed to atmosphere. It means various parts of CBs should be
properly covered and should be tested for IP 55 are equivalent test.
10.2
MOTOR OPERATED SPRING CHARGING MECHANISM:
10.2.1. Spring operated mechanism shall be complete with motor, opening & closing spring
with visual indication for spring charged/ discharged condition and all necessary accessories
to make the mechanism a complete operating unit. Each mechanism shall be so designed
as to enable a continuous sequence of "opening" and "closing" operations to be obtained as
long as power is available to the motor and at least one "opening" and "closing" operation
33
Circuit Breakers

after failure of power supply to the motor. Breaker operation shall be independent of the
motor which shall be used solely for the purpose of compressing the closing spring. Motor
rating shall be such that it requires only about 30 seconds for charging the closing spring
fully. Closing action of Circuit breaker shall compress the opening spring ready for tripping.
Spring charging motor shall be AC motor (Single or 3 phase DC Motors are not acceptable.
Mechanism shall be capable of performing the rated operating duty cycle of 0-0.3 secondsCO-3 minutes-CO. In the event of failure of power supply to spring charging motor, the
mechanism shall be capable of performing one sequence of 0-0.3 seconds -CO duty. The
mechanism shall undergo olive green passivation.
10.2.2. For Manual spring charging operation through operating handle. it is
desired that mechanism box may be mounted at adequate height and gear ratio
shall be so chosen that one man standing at ground level is able to manually
charge the spring without much effort. The handle shall be either at normal
operable height or otherwise a suitable 3ft x 3ft platform nearly 4ft below the
manual operating handle with foldable ladder shall be provided to facilitate
manual charging of spring. The operating handle for charging the spring shall
be inserted from side of mechanism box and not from bottom. The spring
charging facility shall have ease of operation and the movement of handle shall
be in vertical plane only. The Bidder should enclose G.A. Drawings with their
offer.
10.2.3
The mechanism shall be strong, rigid positive and fast in operation. Provision
shall be made for local electrical control and local / remote selection with enough contacts in
the cubicle of the breaker. Manual emergency local tripping arrangement shall be provided
on the breaker for use in emergency during maintenance. This emergency trip is intended
for use, shall a failure of any part of DC control circuits including trip coil takes place
preventing remote electrical tripping.
10.3
MOTORS:
10.3.1 Motors shall be of self ventilated type having TEFC (totally enclosed fan cooled)
enclosure.
10.3.2 Depending upon the capacity and loading conditions supplier shall design suitable
grease lubricated or oil lubricated bearings for above motors. Bearing shall be so
constructed that the loss of grease and its creeping along with shaft into motor housing is
prevented. It shall also prevent dirt and water from getting into the motor.
10.3.3 Continuous motor rating (name plate rating) shall be at least ten (10) percent above
the maximum load demand of the driven equipment at design duty point & the motor shall
not be overloaded at any operating point of driven equipment that will arise in service.
10.3.4 Motors shall be capable of giving rated output without reduction in expected life span
when operated continuously in the system having the particulars as given in principle
parameters.
10.3.5 All induction motors shall be suitable for full voltage direct-on-line starting. These
shall be capable of starting and accelerating to the rated speed along with the driven
equipment without exceeding the acceptable winding temperature even when the supply
voltage drops down to 75% of the rated voltage.
34
Circuit Breakers
11.0 CONTROL:
11.1 Close and trip circuits shall be designed to permit use of momentary contact switches
and trip/neutral/close switch.
11.2 Each breaker pole shall be provided with two independent trip circuits, valves and coils
or two independent trip circuits with trip coils each connected to a different set of protective
relays using dedicated main and duplicate DC supplies. At no point mixing of two trip circuit
supplies shall be made. Trip coil circuits shall be suitable to trip circuit supervision in pre &
post closing conditions. Purchaser would provide the trip circuit supervision relays. Bidders
shall provide necessary terminals in the central control cabinet of Circuit breaker for pre &
post closing trip circuit supervision.
11.3 Each breaker pole shall be provided with closing circuit. Closing coil circuit shall be
suitable to closing coil supervision in pre and post closing conditions. In the Control & Relay
panel closing circuit supervision relays are provide. In the control cabinet of Circuit breaker
necessary terminals for pre and post closing close circuit supervision shall be provided.
11.4 Breakers shall normally be operated by remote electrical control. Electrical tripping
shall be performed by shunt trip coils. However, provisions shall also be made for local
electrical control. For this purpose, a local/remote selector switch and trip/neutral/close
switch shall be provided in Breakers central control cabinet. Remote located push buttons
and indicating lamps shall be provided by the Purchaser.
11.5 A conveniently located manual mechanical tripping lever or latch shall also be
provided for tripping Breakers and simultaneously opening the reclosing circuit.
11.6 Shunt trip coils shall operate correctly under all operating conditions of Circuit breaker
up to the rated breaking capacity of Circuit breaker and at all values of D.C. supply voltage
between 70% and 110% of rated voltage. However, at 50% of rated voltage, Breakers shall
be able to perform closing and opening operations. If additional elements are introduced in
the trip coil circuits, their successful operation and reliability for similar applications shall be
ensured.
11.7 For maintenance purposes, a local manual closing device along with a detachable
handle shall also be provided. Device should be easily operable by one man standing on the
ground. Direction of rotation of handle shall be clearly marked. Suitable arrangement for
safe storage of handle shall be provided.
11.8
Closing coil shall operate correctly at all values of voltage between 85% and 110%
of the rated voltage of closing coil.
12.0
SURFACE FINISH PAINTING & GALVANISING:
12.1
All interiors and exteriors of tanks, mechanism, enclosures, cabinets and other
metal parts shall be thoroughly cleaned to remove all rust, scales, corrosion, greases or
other adhering foreign matter. All steel surfaces in contact with insulating oil, as far as
35
Circuit Breakers

accessible shall be painted with not less than two coats of heat resistant, oil insoluble,
insulating paint.
12.2.
All ferrous metal surfaces exposed to atmosphere shall be given two primer coats
of zinc chromate and two coats of epoxy paint with epoxy base thinner or hot dip galvanized
or two packs of aliphatic polyurethane finished paint. All metal parts not accessible for
painting shall be made of corrosion resistant material. All machine finished or bright surfaces
shall be coated with a suitable preventive compound and suitably wrapped or otherwise
protected. All paints shall be carefully selected to withstand tropical heat and extremes of
weather within the limits specified. Paint shall not scale off or wrinkle or be removed by
abrasion due to normal handling. All external paintings shall be as per shade no. 697 of IS:5
or Polyurethane paint having shade Siemens grap RAL 7032. All ferrous parts & steel
structure including all sizes of nuts, bolts, plain and spring washers, support channels,
structures, etc. shall be hot dip galvanized or stainless steel or electro-galvanised.
13.0 EARTHING:
Operating mechanism housing, control cabinets, dead tanks, support structure etc.
shall be provided with two separate earthing terminals suitable for connection to earth mat of
substation switchyard.
14.0
NAME AND RATING PLATES:
Circuit breaker and its operating device shall be provided with a rating plate or plates
marked with but not limited to following details;
a)
Manufacturer's name & trade mark.
b)
Serial number or type designation making it possible to get all the relevant
Information from the manufacturer.
c)
Year of manufacture.
d)
Rated nominal/highest voltage.
e)
Rated insulation level.
f)
Rated frequency.
g)
Rated normal current.
h)
Rated capacitive/inductive breaking current
i)
Rated short circuit breaking current.
j)
First pole to clear factor.
k)
Rated duration of short circuit current.
I)
Rated out of phase breaking current.
m)
Rated auxiliary d.c supply voltage of closing and opening devices.
n)
Rated pressure of compressed air / gas for operation and interruption.
o)
Rated AC supply voltage of auxiliary circuits
p)
Mass of circuit breaker.
q)
Purchase's order no. & date
Rating plate shall be visible in position of normal service and installation. The rating
plate shall be engraved, weather proof and corrosion proof. Description on the rating plate
should be given in "legible English letters".
36
Circuit Breakers
15.0
TERMINAL CONNECTORS:
15.1.
Terminal connector shall conform to the latest version of IS:5561 or equivalent
International Standard. Standard drawing for terminal connectors is enclosed. Clamps shall
be designed adequately to take care of any bimetallic effect. Temperature at the clamp shall
not exceed 80 deg C. Corona rings shall be provided at the breaker terminals to control the
radio interference. Terminal connectors shall be tested for short circuit current capability,
temperature rise, Corona inception etc.
15.2.
The design of clamp shall be to our approval. The details of current take off as
required by us shall be detailed out in drawing and shall be submitted along with the bid. In
respect of the terminal connectors following should be ensured:(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(I)
The terminal connector should be made of A6 Aluminum Alloy and by pressure

/ gravity die cast only. Sand casted terminal connectors are not acceptable.
All castings shall be free from blow holes, surface blisters, cracks and
Cavities. All sharp edges should be rounded off.
No part of clamp shall be less than 12 mm thick.
The bimetallic strips / sleeve shall be 2 mm thick.
All nuts, bolts & washers shall be of Hot Dip Galvanised mild steel.
The conductor should be tightened by six bolts. Conductor hold length must not
be less than 100 mm.
The surface of clamps to be tightened by six bolts should be flat in shape so
that it may be possible to open the nuts and bolts by normal flat spanners.
Therefore, any type of groove in the clamp body for fixing of nuts should be
avoided.
The portion of clamp to hold the conductor should be flat and straight and not
zig-zag in construction, at both the sides, so that holding of clamp by throttling
action of current may be avoided.
Space of at least 50% of diameter of nuts should be available after the hole at
both the sides of conductor holding portion for better mechanical strength.
All current carrying parts shall be designed and manufactured to have minimum
contacts resistance.
The clamp for Twin Moose ACSR Conductor shall be in three pieces so that
each conductor may be tightened separately.
Size of terminal connector for which the clamp is designed and also rated
current under site conditions shall be embossed / punched on each part of
clamps except hardware.
15.3
400KV bus shall be of quadruple MOOSE conductor. All circuit breakers shall be
provided with flexible terminal connectors, which shall be of expansion type to receive 4 inch
IPS tube or Twin Moose ACSR conductor and suitable for horizontal take off.
16.0
FITTINGS AND ACCESSORIES:
16.1
Following is the list of the major fittings and accessories to be included by
manufacturers as an integral part of equipment. Number and exact location of these parts
shall be indicated in the Bid.
37
Circuit Breakers
S. No.
1
2
3
4
Particulars
Type of Circuit Breakers

SF6
Vacuum
Yes
Yes
Hollow insulator columns for poles of

Circuit Breaker
Operating mechanism housing in accordance with clause no.10.0 shall
complete with ;
Yes
Yes
a) Pistol grip circuit breaker control switch
having trip/ normal/close position.
Yes
Yes
b) Trip coils/ closing coil
Yes
Yes
c) Space heater equipped with industrial
grade switch
Yes
Yes
d) Cable glands
Yes
Yes
e) Industrial grade receiptable type 3 pin 15
Amps power plug & socket with switch.
Yes
Yes
f) Local/remote changeover switch.
Yes
Yes
g) Manually operated tripping push
button/lever (mechanical device convenient
located
to
trip
all
three
phases
simultaneously).
Yes
Yes
h) Padlocks and duplicating keys
Yes
Yes
i) Terminal Boards.
Yes
Yes
j) Spring charged discharged indicator.
Yes
Yes
k) Operation counter.
Yes
Yes
l) Facility for manual charging of spring.
Yes
Yes
m) Fuses/MCBs as required for AC & DC
supply.
n) The number of terminals provided shall
Yes
Yes
be adequate enough to wire out all contacts
and control circuits plus 20% spare
terminals for owner's use.
o) Manual charging spring operating handle
Yes
Yes
for maintenance.
Yes
Yes
p) Auxiliary switch
Yes
Yes
q) Mechanical ON & OFF Indicator.
Yes
Yes
r) Cubicle lamp with cage & switch.
Yes
Yes
s) Antipumping relay.
Yes
t) Out-of-Step relay.
Yes
Yes
u) Set of 6 nos. terminal connector clamps
v) Name & Rating plate in accordance with
Yes
Yes
IEC incorporating year of manufacture.
Yes
w) Damping resistors
Yes
x) Pressure Gauge for N2 Pressure
Portable/hand held SF6 gas leakage
Yes
detector.
SF6 Gas filling adapter
Yes
-
38
Circuit Breakers
17.0
FOUNDATION & SUPPORT STRUCTURES FOR BREAKER STRUCTURES:
17.1 Support Structure: Support structures along with the foundation bolts required for
mounting the breaker shall be within the scope of the bidder and prices for the same shall
be quoted inclusive of all the items of structures, hardware and accessories for mounting so
as to put circuit breaker in to service. The support structures for circuit breakers shall be
designed to maintained minimum ground clearance form the lowest live terminal to breaker
structure base plate (to be fix on concrete plinth ) as per Appendix-A1 principal parameter of
the bid.
17.2. Foundation:- Bidders shall furnish a drawing showing foundation plan for breakers
offered by them clearly indicating the i) Dynamic upward and downward loads for which it is
designed ii) static load iii) total weight of breaker considered for foundation design & iv) all
spacing and dimensional details alongwith details of foundation bolts. MPPTCL have
standardized foundation plan drawing for circuit breakers. The bidders shall have to match
their breaker structure dimensions strictly with this enclosed drawing for respective rating of
circuit breakers. The static and dynamic loading for foundation have been specified under
Appendix-A1 of this bid.
18.0
ESSENTIAL SPARE ITEMS:
The bidder may please note that the name of essential items required for
operation & maintenance of circuit breakers may please be included while offering
the prices for circuit breakers covered under the package.
19.0
TYPE TESTS & TEST REPORTS:
19.1. All the equipment offered, shall be fully type tested as per the relevant standards. In
case the equipment of the type and design, offered, has already been type tested, Bidders
shall furnish two sets of the type test reports along with the Bid. For any change in the
design/type already type tested and the design/type offered against this Bid the purchaser
reserves the right to demand repetition of tests without any extra cost on the first or any one
unit of any rating included in the Bid. In case the equipment has not been type tested earlier,
all the type tests as per relevant standards shall be carried out by the successful
Bidder/supplier in the presence of purchaser's representative without any extra cost. The
test reports submitted with the offer shall not be older than five years, prior to the date of
opening of Bid for various tests indicated in Clause 2.4 of this bid document.
19.2. Bidders shall indicate the manufacturer's standard routine tests. Bidders shall
completely assemble and test each breaker to ensure satisfactory working of all
components and also assembled breakers as a whole.
19.3.
All acceptance and routine tests as stipulated in the relevant standards shall be
carried out by the supplier in the presence of purchaser's representative.
19.4. Speed curves for each breaker shall be obtained with the help of a suitable operational
analyzer to determine Breaker contact movement during opening, closing, auto-reclosing
and trip free operation under normal as well as limiting operating conditions (control voltage,
39
Circuit Breakers

pneumatic pressure etc.). Tests shall show the speed of contacts directly at various stages
of operation, travel of contacts, opening time, closing time, shortest time between separation
and meeting of contacts at break/make operation etc. This test shall also be performed at
site for which the necessary operation analyzer along with necessary transducers, cables,
console, etc. shall be provided if required.
19.5. Preliminary copy of the test results shall be supplied for approval before
dispatch/shipment of Circuit breakers. 4 copies of complete test results shall be furnished
with Circuit breakers. These shall include complete reports and results of the routine test
and type tests carried out on circuit breakers of identical design.
19.6. ADDITIONAL TESTS:
Purchaser reserves the right for carrying out any other tests of a reasonable nature
at the works of the supplier / laboratory or at any other recognized laboratory/research
institute in addition to the above mentioned type, acceptance and routine tests at the cost of
the purchaser to satisfy that the material complies with the intent of this bid. Bidders may
please note that Insulation Resistance test by 5KV or 10KV megger at manufacturers works
shall be invariably carried out on each circuit breaker to record following IR values.
(a) Insulation resistance between top terminal to earth (for open and closed
condition of circuit breaker) in --- Mega Ohms.
(b) Insulation resistance between both top Terminals in open and close condition
of circuit breaker in --- Mega Ohms.
(c) Insulation resistance between both top Terminals to earth in open and close
Condition of circuit breaker --- Mega Ohms
20.0
INSPECTION:
20.1 Purchaser shall have access at all times to the works and all other places of
manufacture where Circuit Breaker are being manufactured and Bidders shall provide all
facilities for unrestricted inspection of the Bidder's works, raw materials, manufacture of all
the accessories and for conducting necessary tests as detailed herein. Purchaser reserves
the right to insist for witnessing the acceptance/routine testing of the bought out items.
Supplier shall submit the routine test certificates of bought out items and raw material, at the
time of routine testing of the fully assembled breaker
20.2 No material shall be dispatched from its point of manufacture unless the material has
been satisfactorily inspected and tested. Successful Bidder shall within 30 days of
placement of order, submit its of bought out accessories and the names of sub-suppliers.
20.3
Bidders shall indicate the inspections and checks carried out at various stages of the
manufacture of Circuit Breaker. Complete record of stage inspection would be kept by the
supplier and this record should be made available for inspection by the representative of the
Purchaser. The supplier should indicate the manufacturing programme and the Purchaser
will have a right to depute inspecting officers during the manufacture of the equipment.
Purchaser reserves the right to carry out stage inspections at all stages, for which advance
intimation shall be given and all necessary cooperation shall be rendered by the
manufacturer.
40
Circuit Breakers

20.4 At the time of inspection, the supplier shall identify each and every item/accessories
of the particular Circuit Breaker under testing. Unless all the items are identified, the
manufacture will not be treated as complete. Various tests stipulated in IS/IEC shall be
performed in the presence of purchaser's engineers or when the inspection waiver has been
given, in such a case, the testing shall be done at the manufacturer's works as per IS/IEC
stipulations and same should be confirmed by documentary evidence by way of Test
Certificate which shall be got approved by the purchaser.
20.5 It is expected that before a Circuit Breaker is finally offered for inspection, internal
testing of the same for various important parameters are already done. Routine test report
for such tests shall also accompany the letter of inspection call so that the Inspecting Officer
at the time of inspection may verify the parameters brought out in the preliminary report.
Details of all tests should be clearly brought out.
20.6
In case for any reasons inspection is not completed or equipment is not found to be
complete with all accessories as per confirmation given with the letter of inspection call,
purchaser will reserve the right to recover the complete cost of deputation of inspecting
team to the works of the manufacturer.
20.7 Acceptance of any quantity of circuit breaker & its accessories shall in no way relieve
the successful Bidder of his responsibility for meeting all the requirement of this bid and
shall not prevent subsequent rejection if such equipments are later found to be defective.
21.0
QUALITY ASSURANCE PROGRAMME:
21.1 Bidders must establish that a proper quality assurance program is being followed by
them for manufacture of circuit breakers. In order to ensure this, suitable QAP should form a
part of the technical Bid, which will be submitted against this Bid. Quality Assurance
Program must have a structure as detailed in the following paragraphs.
21.2 Quality assurance and failure prevention starts with careful study and scrutiny of our
technical bids and requirements. Supplier shall carefully study all the technical parameters
and other particulars & the supplier shall categorically give his confirmation that these
requirements shall be met in a satisfactory manner.
21.3 Supplier shall furnish the checks exercised in design calculations. The salient
features of design will have to be made available to the Purchaser.
21.4 Supplier shall indicate the various sources of the items being procured. The type of
checks, quantum of checks and acceptance norms shall be intimated and random test and
check results should be made available for inspection whenever so desired. Vendor list for
various bought out items shall be submitted with the Bid and the same shall be subject to
purchaser's approval. However, no change in vendor list shall be acceptable after placement
of order and list of vendors shall be freeze at the time of placement of order.
41
Circuit Breakers

22.0 DOCUMENTATION:
22.1 LIST OF DRAWINGS AND DOCUMENTS:
Bidders shall furnish four sets of relevant descriptive and illustrative published
literature pamphlets and the following drawings for preliminary study, along with the Bid.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
General outline drawings showing dimensions and shipping weights, quantity of

insulating media, air receiver capacity etc.
Sectional views showing the general constructional features of Circuit breaker
including operating mechanism, arcing chambers, contacts with lifting
dimensions for maintenance.
All drawings & data typical and recommended schematic diagram for control
Supervision & reclosing shall be annotated in English.
Schematic diagrams of breaker offered for control supervision and reclosing.
Structural drawing, design calculations and loading data for support structures.
Short circuit oscilleogram & certificates for similar type tested breakers.
General arrangement of foundation and structure mounting plan including
weights of varnish components and impact loading data for foundation design.
Type test reports.
22.2 Successful Bidder shall, within two weeks of placement of order, submit four sets of
final version of all the above drawings for purchaser's approval. Purchaser shall
communicate his comments/approval on the drawings to the supplier within two weeks.
Supplier shall, if necessary, modify the drawings and resubmit four copies of the modified
drawings for purchaser's approval within two weeks from the date of comments. After receipt
of purchaser's approval, the supplier shall, within three weeks, submit two prints of approved
drawings and two sets of good quality reproducible of the approved drawings for purchaser's
use.
22.3
Successful Bidder shall also furnish two sets each of bound manuals covering
erection, commissioning, operation and maintenance instructions and all relevant
information and drawings pertaining to the main equipment as well as auxiliary devices
alongwith each breaker. Marked erection drawings shall identify the component parts of the
equipment as shipped to enable erection by purchaser's own personnel. Each manual shall
also contain one set of all the approved drawings, type test reports as well as acceptance
reports of the corresponding consignment dispatched. Similar bound manuals for breakers
shall be made available to the purchaser on one per breaker basis.
Manufacturing of equipments shall be strictly in accordance with the approved drawings and
no deviation shall be permitted without the written approval of the purchaser.
22.4
Approval of drawings/work by the purchaser shall not relieve Bidders of any of his
responsibility and liability for ensuring correctness and correct interpretation of the drawings
for meeting the requirements of the latest revision of the applicable standards rules and
codes of practices. Equipment shall conform in all respects to high standards of engineering,
design, workmanship and latest revisions of relevant standards at the time of supply and
purchaser reserves the right to reject any work or materials which, in his judgment, is not in
42
Circuit Breakers

full accordance therewith.
22.5
Additional data to be furnished along with the Bid:

(a) Drawing, showing contacts in close, arc initiation, full arcing, arc extinction and
open position.
(b) Temperature v/s pressure curves for each setting of density monitor along with
details of density monitor.
(c) Method of checking the healthiness of voltage distribution devices (condensers)
provided across the breaks at site.
(d) Data on capabilities of circuit breakers in terms of time and number of
operations at duties ranging from 100% fault currents to load currents of the
lowest possible value without requiring any maintenance or checks.
(e) Effect of non-simultaneity between contacts within a pole or between poles and
also how it is covered in the guaranteed total break time.
(f) Sectional view of non return couplings if used for SF6 pipes.
(g)
Details and type of filters used in interrupter assembly and also operating
experience with such filters
(h) Details of SF6 gas:
i) Test methods used in controlling the quality of gas used in Circuit beakers
particularly purity and moisture content.
ii) Proposed tests to assess the conditions of SF6 within a circuit breaker after a
period of service particularly with regard to moisture contents in the gas.
iii) Precise procedure to be adopted by maintenance personnel for handling
equipment who are exposed to the products of arcing in SF6 gas so as to
ensure that they are not affected by possible irritants of the skin and
respiratory system.
23.0
PACKING AND FORWARDING:
Equipment shall be packed in suitable crates in such a manner to protect it from

damage and withstand handling during transit. Bidders shall be responsible for and make
good at his own expense, any or all damage to the equipment during transit. Fragile
materials shall be carefully packed and marked with the appropriate caution symbols.
Wherever necessary, proper arrangement for lifting such as lifting hooks etc. shall be
provided.
Each consignment shall be accompanied by a detailed packing list containing the
following information:
(a)
Name of the consignee.
(b)
Details of consignment.
(c)
Destination.
(d)
Total weight of consignment.
(e)
Sign showing upper/lower side of the crate.
(f)
Handling and unpacking instructions.
(g)
Bill of material indicating contents of each Lot
Supplier shall ensure that the packing list and bill of material are approved by the
purchaser before dispatch.
43
Circuit Breakers

24.0.
COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS:
Bidders must furnish the following information along with technical Bid:
24.1
Complete details of all the accessories which will be supplied with Circuit breaker
should be furnished. While furnishing these details, items which will be manufactured by
Bidders and balance items, which will be procured from sub-suppliers should be clearly
identified and indicated in the Bid.
24.2
It is obligatory on the part of Bidder to ensure that supply of all accessories along
with Main equipment are simultaneously delivered to avoid any holdup in erection and
commissioning. The responsibility for obtaining timely supplies of bought out items will rest
on Bidders and only on this basis, delivery period will be offered in the Bid.
24.3 It may be noted that in case of damages/shortages due to improper packing or any
other negligence, replenishment shall be arranged within one month time. For bought out
items, responsibility for guarantee and obtaining immediate replacement in case any defects
are noticed and also in case defective supply of any item is reported, will rest with the
Bidder. In case for attending to defects in any accessory or inspection/ replacement of the
accessory, which may be bought out item for the Bidder; if services of engineer of original
manufacturer is required, the same will be organized on immediate basis by Bidder at his
cost.
25.0
25.1
SPECIFIC TECHNICAL REQUIREMENTS OF SF6 CIRCUIT BREAKERS:

Offered circuit breakers shall be of sulphur hexafluoride (SF6) gas filled.
25.2 Circuit breakers shall comprise of three identical single pole units. The
duty of circuit breakers for various KV class has been indicated in the Principle
parameters and other requirement for circuit breakers Appendix-A1 of bid
document. Circuit Breakers shall be operated by spring charged mechanism
for both opening and closing. The mechanism shall be housed in a dust proof
and weather proof control cabinet.
25.3
Breaker assemblies with base, support structure for circuit breaker as well as for
control cabinet, central control cabinet and foundation bolts for main structure as well as
control cabinet and central control cabinet (except concrete foundations), Breaker terminals
and operating mechanisms. Support structures shall be hot dip galvanized.
25.4
Compressed SF6 gas, in each pole with provision of density monitor.
25.5
One central control cabinet and one control box for each pole with all the required
electrical devices mounted therein and the necessary terminal blocks for termination of inter
pole wiring. Necessary inter pole cables shall be in the scope of supply and the purchaser
based on the schematic, wiring diagram and termination schedule to be supplied by the
Bidder, shall do cabling at site.
25.6
Instruments, gauges for SF6 gas pressure with suitable number of NO/NC contacts
of required quantity for interlocking and other formalities as per schematics.
44
Circuit Breakers

25.7
All necessary parts to provide a complete and ready to use circuit breaker
installation such as main equipment, terminal connectors, control parts, cable connector,
pipe lines and other devices, whether specifically called for herein or not.
25.8
Circuit breakers shall be single pressure type, the design and construction of Circuit
beaker shall be such that there is minimum possibility of gas leakage and entry of moisture.
There should not be any condensation of SF6 gas on the internal insulating surface of circuit
breaker.
25.9
All gasketed surfaces shall be smooth, straight and reinforced to minimize distortion
and to make a tight seal. Operating rod connecting the operating mechanism to the arc
chamber (SF6 media) shall have adequate seals, single "0" ring seals without test holes
Double "0" ring seals or Double lip seals and test holes for leakage test of the internal seal
shall be provided on each static joint. A suitable pressure-monitoring device on each pole
may be provided to ensure pressure of insulating media for the entire assembly.
25.10
In the interrupter assembly there shall be an absorbing product box to eliminate
mixing of SF6 decomposition products and moisture. Material used in the construction of
Circuit breakers shall be fully compatible with SF6 gas.
25.11
Each pole shall form an enclosure filled with SF6 gas independent of two other
poles. The SF6 gas density of each pole shall be monitored and regulated by individual
density monitors.
25.12
SF6 gas density monitor shall be adequately temperature compensated. Density
monitor shall meet the following requirements:
i)
It shall be possible to dismantle the density monitor for checking/ replacement
without draining the SF6 gas by using suitable interlocked non-return
couplings.
ii)
It shall damp the pressure pulsation while filling the gas in service so that the
flickering of the pressure switch contacts does not take place.
iii)
Gas pressure indicators should be provided for each breaker pole. These
pressure indicators shall have uniform graduated dial.
25.13 Suitable arrangement for pressure relief shall be provided in the gas chamber of
circuit breaker to avoid the damages or distortion during occurrence of abnormal pressure
increase or shock waves generated by internal electric fault arcs. Position of pressure relief
devices (e.g. vents, diaphragms, etc.) shall be arranged to minimize danger to operating
personals in the event of gas or vapour escaping under pressure.
25.14
Facility shall also be provided to reduce the gas pressure within Breakers to a
value not exceeding 8 millibars within 4 hours or less. Each circuit breaker shall be capable
of withstanding this degree of vacuum without distortion or failure of any part.
25.15
Sufficient SF6 gas shall be provided to fill all circuit breaker poles after erection.
Additional 20% of the total SF6 gas requirement for each breaker shall be supplied in
separate cylinders.
45
Circuit Breakers

25.16 Portable/hand held SF6 gas leakage detector shall also be supplied along with each
SF6 breaker.
25.17 Contacts shall be kept permanently under pressure of SF6 gas. Gap between the
open contacts shall be such that it can withstand atleast the rated phase to ground voltage
continuously at zero gauge pressure of SF6 gas due to profuse and sudden leakage.
25.18 If multi break interrupters are used, these shall be so designed and augmented, that
uniform voltage distribution is developed across breaking contacts. Calculations/test reports
in support of this requirement shall be furnished along with the Bid. Thermal and voltage
withstand capability of the grading element shall be adequate for the specified duty and
service conditions.
25.19 Special contacts for use with the trip coils and single shot reclosing operation, which
permit the relative adjustment with respect to the travel of Circuit breaker, shall also be
provided.
25.20 Operating mechanism shall be suitable for high speed single/three phase tripping &
reclosing as per duty cycle indicated for various class of CBs in Principle parameters and
other requirement for circuit breakers Appendix-A1.
25.21 Should the settings of the three breaker poles not be the same (e.g. due to failure of
an operating or closing coil) all three poles shall trip simultaneously on appropriate electrical
command. An out of step relay shall be supplied with each breaker to give a remote trip
discrepancy alarm.
25.22 A non return valve should be provided so that in case of substantial pressure loss in
a pole the main interrupting chambers remain pressurised and can retain their full insulating
capacity for several more hours.
25.23 Motors shall be "squirrel cage" three phase induction motors of sufficient size capable
of satisfactory operation for the application and duty as required for driving equipment.
25.24 If arcing contacts are used they shall be first to close and the last to open. These
shall be easily accessible for inspection and replacement. If separate arcing contacts are not
mounted, in that case main contacts shall be easily accessible for inspection and
replacement. Tips of arcing contacts and main contacts shall either be made of graphite or
silver-plated or of tungsten alloy.
25.25 SULPHUR HEXAFLUORIDE GAS (SF6 GAS):
25.25.1
SF6 gas shall comply with latest version of IEC-376, 376A and 376B and shall be
suitable in all respects for use in the switchgear under the worst operating conditions.
25.25.2
High pressure cylinders in which the SF6 gas is shipped and stored at site shall
comply with latest version of IS:4379 (Identification of the contents of industrial gas
cylinders) and IS:7311 (Seamless high carbon steel cylinders for permanent and high
pressure liquefiable gases). These gas cylinders shall also meet Indian Boiler regulations.
25.25.3
SF6 gas shall be tested for purity, dew point, break down voltage, water contents
46
Circuit Breakers

as per latest version of IEC-376, 376A and 376B and test certificates shall be furnished for
each lot of SF6 gas.
25.26 CONTROL CABINETS:
a.
Control cabinets shall be of the free standing floor mounting type.
b.
Operating mechanism and all accessories shall be enclosed in weather & vermin
proof mechanism cabinet of hot dip galvanized sheet steel construction, the thickness of
which shall not be less than 3 mm intended for outdoor operation. Control cabinets shall be
provided with a hinged door. Door hinges shall be of union joint type for easy access to the
mechanism at the front. Sides shall be properly braced to prevent wobbling. Suitable gasket
shall be provided to make the mechanism housing waterproof and dust proof. Housing latch
shall accommodate padlock requiring a 12mm dia hole. Padlock and duplicate keys are also
included in the scope of supply.
c.
Bus bars shall be of tinned copper of adequate cross-section to carry the normal
current, without exceeding the permissible temperature rise over an ambient temperature of
50C outside the cubicle. Buses shall be braced to withstand forces corresponding to short
circuit current of 25 kA.
d.
Motors rated 1 kW and above being controlled from the control cabinet would be
suitable for operation on a 433 V, 3 phase 50 Hz system. Fractional kW motors would be
suitable for operation on a 230 V, 1-phase, 50 Hz supply system.
e.
Isolating switches shall be group operated units (3 pole for use on 3-phase supply
system and 2 pole for single phase supply systems) quick make quick break type, capable
of breaking safely and without deterioration, the rated current of the associated circuit.
Control cabinet door shall be interlocked with the operating handle of the switch so as to
prevent opening of the door when the switch is closed. A device for bypassing the door
interlock shall also be provided. Switch handle shall have provision for locking in both fully
open and fully closed positions.
f.
Fuses shall be HRC cartridge link type having prospective current rating of not less
than 4.6kA (rms). They shall be provided with visible operation indicators to show when they
have operated. One fuse pulling handle shall be supplied for every ten fuses or a part
thereof.
g.
Push button shall be rated for not less than 6 Amps, 433 V A.C. or 2 Amps, 220V DC
and shall be flush mounted on the cabinet door and provided with appropriate nameplates.
Red, Green and Amber indicating lamps shall be flush mounted and provided with series
resistors to eliminate the possibility of short circuiting of control supply in the event of fusing
of lamps.
h.
For motors upto 5 kW, contactors shall be direct-on-line, air break, single throw type
and shall be suitable for making and breaking the switching current of the associated motor
which shall be assumed equal to 6.5 times the full load current of the motor. For motors
above 5 kW, automatic star delta type starters shall be provided. 3 pole contactors shall be
47
Circuit Breakers

furnished for 3 phase motors and 2-pole contactors for single phase motors. Reversing
contactors shall be provided with electrical interlocks between forward and reverse
contactors. If possible, mechanical interlocks shall also be provided. Contactors shall be
suitable for uninterrupted duty and shall be of duty category class AC4 as defined in
IS:2959. The main contacts of the contactors shall be silver plated and the insulation class
for the coils shall be class E or better. Dropout voltage of the contactors shall not exceed
70% of the rated voltage.
i.
Contactors shall be provided with a three element, positive acting, ambient
temperature compensated, time lagged, hand reset type thermal overload relay with
adjustable setting alternatively MCB for motor protection. Hand reset button shall be flush
with the front door of the cabinet and suitable for resetting with starter compartment door
closed. Relays shall be either directly connected or CT operated depending on the rated
motor current.
j.
Single phasing prevention relay shall be provided for 3 phase motors to provide
protection against single phasing.
k.
Mini starters shall be provided with no volt coils whenever required.
l.
Purchaser's power cables will be of 1100/650 volts grade stranded aluminum
conductor. PVC insulated, PVC sheathed single steel wire armoured and PVC jacketed. All
necessary cable terminating accessories such as glands, crimp type tinned copper lugs etc.
for power as well as control cables shall be included in Bidder's scope of supply. Requisite
number of suitable brass cable glands shall be provided for cable entry at the bottom of the
operating cabinet to receive purchaser's control cables. These shall be mounted in
accessible position and floor level so that the cable joints can be made easily. Cable glands
shall be double compression type.
m.
Separate terminal blocks shall be provided in the mechanism housing for
terminating circuits of various voltage classes. Terminals for DC & AC shall be provided
separately and isolated from each other. CT loads shall be terminated on a separate block
and shall have provision for short circuiting the CT secondary terminals. Terminals for the
control & other circuits shall be suitable for accommodating 3mm stranded conductor cable
leads. A minimum of six spare terminals for control wiring shall be provided. Housing shall
be complete with all necessary wiring in the housing.
n.
Wiring for all control circuits shall be carried out with 1100/650 volts grade PVC
insulated tinned copper stranded conductors of sizes not smaller than 2.5 mm. Atleast 20%
spare terminal blocks for control wire terminations shall be provided on each panel. All
terminals shall be provided with ferrules indelibly marked or numbered and these
identifications shall correspond to the designations on the relevant wiring diagrams.
Terminals shall be rated for adequate capacity which shall not be less than 10 Amps.
o.
Control cabinet shall be provided with 230 V, 1-phase 50 Hz, 20 W fluorescent light
fixture and a suitably rated 230V, 1 phase, 5 amps, 3 pin socket for hand lamps. Suitably
rated power plug with switches shall be provided to enable the control supply to Breakers to
be cut off from the mechanism housing.
48
Circuit Breakers

p.
Suitable strip heaters shall be provided inside each cabinet complete with
thermostat to prevent moisture condensation. Heaters shall be controlled by suitably rated
double-pole miniature Circuit Breakers and by differential thermostat so that the cubicle
temperature is always maintained approximately 10 deg./ above the outside air temperature.
On-Off switch and fuse shall be provided. Heater shall be suitable for 230 volts AC supply
unless otherwise specified.
q.
Signal lamps provided shall be of neon screw type with series resistors, enclosed in
bakelite body. Each signal lamp shall be provided with a fuse integrally mounted in the lamp
body.
r.
Electric measuring instruments shall be of moving iron type Ammeters for measuring
current up to 30 Amps shall be directly connected while those for measuring above 30 Amps
shall be connected through suitable CTs Ammeters shall be provided with selector switches.
s.
Voltmeters shall be protected by HRC fuses and provided with selector switches.
t.
Items inside the cabinet made of organic material shall be coated with a fungus
resistant varnish.
u.
All doors, panels removable covers and breaker openings shall be gasketed all
around. All louvers shall have screen and filters. Cabinet shall be dust, moisture, and vermin
proof.
v.
All cabinets/boxes shall be designed for the entry of cables from bottom by means of
weatherproof and dust-proof connections. Suitable cable gland plate (at least 150 mm
above the base of cabinet/box) of HDG having minimum thickness of 3 mm, with necessary
cable glands shall be provided. The cable gland plate shall be re-movable type and shall
have provision for additional glands for future. The glands shall have provision for securing
armour of the cable separately and shall be provided with earthing tag. The glands shall be
cadmium plated. The cabinet/box shall be designed generously for clearance so as to avoid
interference between the wiring entering from below and any terminal block or accessories
mounted within the box or cabinet.
w.
Suitable relay for monitoring of DC supply voltage to the control cabinet shall be
provided. Pressure switches used for interlock purposes shall have adequate contact ratings
to be directly used in the closing and trip circuits. In case the contacts are not adequately
rated and multiplying relays are used then the interlock for closing/ opening operation shall
be independent of the relay logic i.e. if the DC supply to the interlock circuit fails then
operation lockout shall take place.
25.27 SERVICES FOR SUPERVISION OF ERECTION & COMMISSIONING OF
CIRCUIT BREAKERS:
25.27.1 SERVICES FOR SUPERVISION OF ERECTION & COMMISSIONING:
It is obligatory on the part of the Bidder to provide free services of their erection
& commissioning team to supervise erection & commissioning of each Circuit Breaker.
Although erection works shall be done by us, services of erection engineer will
have to be provided for supervision and guidance. It may be clarified that the breaker shall
be made ready for commissioning in all respect and services of your engineer will be
required for checking and final commissioning of the breaker. Normally MPPTCL has
49
Circuit Breakers

trained staff for erection of breaker based on guidelines, which are to be furnished by the
manufacturer. While undertaking erection work the purchaser will require services of
supervision engineer for suitable period depending upon design of equipment and these
services for required period will have to be made available on free of cost basis. In case any
manufacturer feels that their experienced engineer for final supervision of erection and
testing will need assistance of any junior grade supervisor also, services of the same should
also be provided on free of cost basis. In any case free services by way of deputation of
required number of personnel for sufficient period will have to be ensured by the bidder on
free of cost basis. The intention is that the services are made available until supervision of
erection & commissioning is completed. These services shall be provided for each unit. It
will be obligatory on the part of bidders to depute their erection supervisor and
commissioning engineer positively within one week of telephonic intimation from MPPTCL.
26.0
SPECIFIC TECHNICAL REQUIREMENTS OF VACUUM CIRCUIT BREAKERS:
26.1
Circuit breakers shall comprise of three identical pole units linked together
mechanically suitable for operation with a centrally located common operating mechanism
box i.e. Normal Duty type. Vacuum circuit breakers with all integral parts required for
satisfactory operation shall be supplied with all accessories in position and complete internal
wiring connected and terminated in the operating mechanism housing. Offered equipment
shall be complete in all respect.
26.2 For 33 KV circuit breaker, all contacts shall be of Butt type.
26.3
VACUUM INTERRUPTERS:
26.3.1 Design of vacuum interrupter shall be such that it gives trouble free operation under
normal load and fault condition throughout the life of the equipment. As the efficiency of
breaker depends on degree of vacuum inside the interrupter, manufacturer shall ensure that
the same is maintained consistently during service.
26.3.2 Insulating ceramic body of interrupter shall have high mechanical strength and it
shall be capable of withstanding high temperature without any significant deterioration in
mechanical and electrical properties.
26.3.3 Interrupter design shall ensure rapid deionization of the gap so that normal electrical
strength of the gap is restored instantaneously.
26.3.4 Vacuum interrupters which are used shall be so designed and augmented that an
uniform voltage distribution is developed across them. Calculation/ test reports in support of
the same shall be furnished along with the tender. Thermal and voltage withstand values of
the grading elements shall be adequate for the service conditions and duty specified.
26.3.5 Metallic bellow or the other sealing arrangement should be provided at the moving
contact and should have long fatigue free life. Manufacturers catalogue on vacuum bottle,
indicating all such details shall essentially be submitted with the tender.
50
Circuit Breakers
APPENDIX-A1
PRINCIPAL PARAMETERS AND OTHER REQUIREMENT FOR

CIRCUIT BREAKERS:
The 220kV, 132kV and 33kV Circuit Breakers shall conform to the specific technical
requirements mentioned hereunder:
S.
No.
1
2
3
4
5
6
6
7
8
9
Items
220KV
132KV
Nominal system voltage(KV rms )
220
132
Highest System voltage (KV rms)
245
145
36
Rated frequency (Hz.)

Rated normal current (Amperes
rms)at 50C ambient
temperature.
50
50
50
2000
2000
1250
Type
Duty Requirements
Mounting Structure Details
11
12
13
14
SPR duty
Rated operating sequence
33
Outdoor,
Vacuum
Normal Duty
Normal Duty
Hot dip galvanized lattice steel support structure.

3
Effectively earthed.
3
Suitable for single Suitable for three

pole tripping and pole tripping and
reclosing i.e. SPR
closing i.e.
duty
normal duty
Minimum clearances (mm)

a) Between phases
b) Between live parts and earth
c) Centre to Centre distance
between phases
Ground clearance from the
lowest live terminal to breaker
structure base plate (to be fixed
on concrete plinth)
Height of concrete plinth
provided by purchaser (mm)
Operating mechanisms
33KV
Outdoor SF6-Gas
System Neutral earthing.

Number of Poles
Type of Operation
10
Requirements
--4500
3
Suitable for
three pole
tripping and
closing i.e.
normal duty
---
---
1700
430
5500
4600
3700
300
300
300
Spring operating mechanism with electrical controls
0-0.3 sec-CO-3min-CO (0 stands for opening

and C stands for closing)
51
Circuit Breakers
S.
No.
15
16
17
18
19
20
21
22
23
24
25
Items
Requirements
220KV
132KV
First Pole to clear factor

Type of tripping
1.3
Trip free
1.3
Trip free
33KV
1.5
Trip free
Maximum closing time not

exceeding (milli-seconds)
150 ms
130 ms
80 ms
<60 ms
<60 ms
<60 ms
Maximum total break time (milli

seconds)
Circuit breaker opening time
Insulation level of breakera) 1.2 / 50 micro second lightning
impulse withstand voltage (kVP)
b) 250 / 2500 micro second
switching withstand voltage (kVP)
c) One minute power frequency
withstand voltage (kVrms)
i. Across earth
ii. Between terminals
Maximum radio interference
voltage at 266 kV rms line to
ground voltage (both in close
and open condition) (micro volt)
Rated breaking current capacity:
i.
Line charging at rated
voltage at 90 deg. Leading
power factor (This should be
possible with temporary over
voltage as high as 1.5 PU
without restrike) (Amp)
ii. Rated small inductive current
without switching o/v exceeding
2.3 p.u (Amp)
iii. Rated Short circuit breaking
current (AC component) Kilo Amp
iv. Out of phase breaking current
capacity Kilo Amp
Reactor loaded transformerinterrupting capacity.
Rated short circuit making
current capacity ) (Kilo Amp)
Power Xmer duty requirement
< 40 ms
< 40 ms
< 40 ms
1050
650
170
460
-
270
-
70
-
1000
1000
280
250
0-10
0-10
40
40
25
10
10
6.25
Bidder may state Limiting values, if applicable.

100
79
62.5
315 &
160MVA
160 &
63MVA
63MVA (Max.)
52
Circuit Breakers
S.
No.
Items
Requirements
220KV
132KV
33KV
26 Permissible limit of temperature

As per table given in APPENDIX-A2
rise
27 Maximum acceptable difference
in the instance of
5
5
5
closing/opening of contacts:
i. Within a pole (milli-second)
10
10
10
ii. Between poles (milli-second)
28 Total creepage distance of
3625
900
6125
support insulator (mm)
29 Short time current carrying
40 KA
25 KA
40 KA
capability for three seconds (Kilo
Amp)
10 Amp DC with
30 Breaking capacity of auxiliary
10 Amp (With
10 Amp DC
Circuit time
circuit time
with circuit time
contacts
constant less
constant less
constant less than
than
20
ms)
than 20 ms)
20 ms
31 Maximum Noise level at base
140
140
140
and upto 50 meters (dB)
32 Rated line charging current
breaking capacity (Amps)
33 Trip coil and closing coil voltage
34 No. of openings circuit breaker is
capable of performing without
inspection, replacement and
maintenance
i. at No load
ii. at 50% of rated current
iii. at 100% of rated current
iv. at 50% of breaking current
v. at 100% of breaking
capacity
35 Rated single shunt capacitor bank,
breaking current at 36KV Voltage
in line with IEC 62271-100. (1 x 24
MVAR Capacitor Bank)
36 Terminal Connector
a. Connection
b. Type
220/ 110VDC
110V DC
110V DC
--
10000
10000
10000
100
30
400 Amps (rms)
Twin Zebra
Twin Zebra
Twin Zebra
Suitable to receive
Twin Zebra ACSR
Suitable to
receive Twin
Zebra ACSR
Suitable to
receive Twin
Zebra ACSR
53
Circuit Breakers
S.
No.
Items
Quantity
d.
Arrangement
37
Control cable for CBs
Requirements
220KV
132KV
33KV
6 Nos.
6 Nos.
6 Nos.
both vertical as
well as horizontal
take off
both vertical as
both vertical as
well as
well as horizontal
horizontal take
take off
off
4 Core x 2.5sq.mm (15mm dia)
38 Auto reclosing
39
a.
b.
Static and dynamic load on

foundation
Static load (in Kg)
Dynamic load
(i) Upward (in Kg)
(ii) Down ward (in Kg)
40.
Drawing Reference
a.
For Foundation
b.
For Terminal Connector
Breaker shall be
suitable for
single phase
and 3 phase
high speed auto
reclosing
NA
NA
3000
1500
900
1500 2200
2000
2000
500
500
132KV CB
Foundation
Terminal Connector
33KV CB
Foundation
220KV CB
Foundation
54
Circuit Breakers
APPENDIX-A2
LIMITS OF TEMPERATURE RISE
Temperature rise and maximum temperature attained by on any part of equipment
when in service at site under continuous full load conditions and exposed continuously to
the direct rays of the sun shall not exceed the maximum temperature rise specified below
under conditions specified in test clauses. Permissible temperature rise indicated is for a
maximum ambient temperature of 50C. If maximum ambient temperature rises, permissible
values shall be reduced accordingly.
S.
No.
Nature of the Part or of the liquid
4
5
.
Contacts in air, silver-faced copper, copper alloy

105
or aluminum alloy (see notes (i) and(ii) )
Bare copper or tinned aluminum alloy
75
Contacts in oil:
Silver-faced copper, copper alloy or
90
aluminum alloy(see note ii)
Bare copper or tinned aluminum alloy
80
Terminals to be connected to external
conductors by screws or bolts silver faced (see
105
note iii)
Metal parts acting as springs
(See note iv)
Metal parts in contact with insulation of the following classes:
a) Class Y : (for non-impregnated materials)
b) Class A : (for materials immersed in oil or
impregnated)
c) Class E: in air
in oil
d) Class B: in air
in oil
e) Class F: in air
in oil
f) Oil base Enamel
Synthetic Enamel in air
Synthetic Enamel in oil
6
7
Maximum Value of
Rise in temp. at
Temp.
Max. ambient air temp.
not exceeding 50deg C
Any part of metal or of insulating material in

contact with oil, except contacts
Oil
55
25
40
30
55
90
40
100
50
120
100
130
100
155
100
100
120
100
70
50
80
50
105
50
50
70
50
100
50
90
40
Notes:
i) When applying temperature rise of 55C, care should be taken to ensure that no
damage is caused to the surrounding insulating materials.
55
Circuit Breakers

ii) Quality of the silver facing shall be such that a layer of silver remains at the points of
contact after the mechanical endurance test. Otherwise, contacts shall be regarded as
"bare".
iii) Values of temperature and temperature rise are valid whether or not conductor
connected to the terminals is silver-faced.
iv) Temperature shall not reach a value where the elasticity of the material is impaired. For
pure copper, this implies a temperature limit of 750C.
56
Circuit Breakers
APPENDIX-A3
DRAWINGS
S.
Description
No.
1 Foundation Drawing for 220KV SF6 Circuit Breaker
Foundation Drawing for 132KV SF6 Circuit Breaker
Foundation Drawing for 33KV VCB.
Drawing for Terminal connector for 220/132/33 KV CB
57
Circuit Breakers
150
1100
80
58
1400
650
1000
1400
YL
4500
FOR M.36 FOUNDATION BOLT
150X150X700 DEEP POCKET
10# @200 C/C BOTH WAYS
PCC 1:5:8
8# @200 C/C BOTH WAYS
WELL COMPACTED FILLING
8# 14 NOS.
50 MM THK. PCC 1:2:4
6 DIA. @190 C/C (2 TIES/SET)
C
L OF POLE OF C. B.
SEC. 2-2
SEC.1-1
8# 14 NOS.
1000
200
350
300
C
L
4500
C
L
FOR 220 KV SF6 CIRCUIT BREAKER (SPR) DUTY
STANDARD CIVIL FOUNDATION PLAN
325
325
1400
500
350
200
Circuit Breakers
DRAWING NUMBER :JICA/MPPTCL/TR-101 TO 107/220KV CB FOUNDATION
CL
YL
STP 6 DIA.@200 C/C
(2TIES/SET)
C
L OF FEEDER W AY
350
CL
OF POLE OF C. B.
STANDARD CIVIL FOUNDATION PLAN

FOR132 KV SF6 CIRCUIT BREAKER (NORMAL DUTY) TYPE
SECTION 2-2
ANCHOR BOLT M-24
RINGS 6 DIA
@ 200 C/C
(3 TIES / SET)
POCKET 250x80x400 DEEP
700
20 mm GROUT
12 NOS 12 #
YARD LEVEL
BUT NOT LESS THEN 1200
2
12 NOS 12 #
RINGS 6 DIA
@ 200 C/C
(3 TIES / SET)
80 200
UP TO FIRM SOIL
300
1000
YARD LEVEL
3400
SECTION 1-1
CL OF FEEDER WAY
P C C 1:5:8
1
150
250
200
250
150
POCKET 250X80X400 DEEP
8# @ 200 C/C BOTH WAYS

AT BOTH FACES.
280
1100
700
240
200 80 140 80
1000
200
1100
400
280
200
1000
1000
1000
200
1000
3400
FOUNDATION PLAN
D R A W IN G N U M B E R :JIC A /M P P T C L/T R -10 1 T O 107/132K V C B
F O U N D A T IO N
59
Circuit Breakers
350
S T A N D A R D F O U N D A T IO N P L A N F O R
3 3 K V V A C U U M C IR C U IT B R E A K E R
YL
YL
MINIMUM 1000
EARTH FILLING
4 NO S 8#
300
STP 8# @ 200 C/C

2 NO S 8#
C .C 1:5:8
80
UP TO THE FIRM SOIL
Y L
400
400
1880
SECTION 2-2
FOU ND ATIO N BOLT

M -20 (4 NOS )
YL
YL
MINIMUM 1000
EARTH FILLING
STP 6 DIA. @ 190 C/C
S TP .8# @
200 C/C
4 NO S 8#
4 N OS. 12 #
2 NO S 8#
C.C 1:5:8
80
UP TO THE FIRM SOIL
Y L
560
350
POCKET 200X200X300
600
600
1880
300
SECTION 1-1
1000
1400
300
300
300
400
4 NOS. 12 #
STP. 6 DIA. @ 190 C/C
400
400
1480
1880
FOU ND ATION PLAN

D R A W IN G N U M B E R :J IC A /M P P T C L /T R - 10 1 T O 10 7 /33 K V C B
F O U N D A T IO N
60
Circuit Breakers
61
Circuit Breakers
SCHEDULE-I (A)
DESCRIPTION OF EQUIPMENT FOR SCHEDULE FOR RATES & PRICES
TO BE FURNISHED IN VOLUME-VI
B
1
C
1
Particulars of equipment/ Item

220kV SF6 Circuit Breaker
Supply of 220KV SF6 Circuit breakers complete with all accessories
including mounting structures, terminal connectors, gas leak detector and
adapter for gas filling etc. conforming to all technical requirements as
described in the bid document including foundation bolt
132kV SF6 Circuit Breaker
Supply of 220KV SF6 Circuit breakers complete with all accessories
including mounting structures, terminal connectors, gas leak detector and
adapter for gas filling etc. conforming to all technical requirements as
described in the bid document including foundation bolt
33KV Vacuum Circuit Breaker
Supply of 33KV Vacuum Circuit Breaker complete with all accessories
including mounting structures, terminal connectors, etc. conforming to all
technical requirements as described in the bid document but including
foundation bolts
Qty.
As per Price Schedule
S.No.
A
NOTE:
1.
2.
The above description of the equipment is given for the purpose of offering the prices and to
mention description of equipment in invoice for claiming payment.
The quantity of above equipments has been mentioned in volume-VI.
62
Circuit Breakers
2.1.2 (A) TECHNICAL SPECIFICATION FOR

220KV INDOOR CONTROL AND RELAY PANELS
1.0
SCOPE:
The scope of this specification covers, design manufacturing and supply of

equipment as per Volume-II, Part-2, Book-I. The bidder mentioned in this Section of the
Technical Specification means Original Equipment Manufacturer (OEM). The purchaser
means the MPPTCL.
manufacturer as per this specification requirement shall rest on the bidder.
i.
220KV CONTROL & RELAY PANELS:
220 KV control, protection and relay Simplex design panels are also required for
220kV system. Offered protection and control schemes for 220 KV SIMPLEX panels shall
be suitable for TWO MAIN AND ONE TRANSFER BUS SWITCHING SCHEMES. Bidders
are required to offer following five categories of SIMPLEX type panels:
i.
SIMPLEX design Control & Relay panels for 220 KV transmission lines.
ii.
SIMPLEX design Control & Relay panels for 220KV Transfer Bus coupler application.
iii.
SIMPLEX design Control & Relay panels for 220 KV Bus tie application.
iv.
SIMPLEX design Control & Relay panels for 220/132/33KV, 160MVA transformer
2.0
LIMITS OF CONTRACT:
2.1
It is not the intent to specify completely here all the details of design and construction
of the control and relay panels. However, the C&R panels shall conform in all respects to the
high standard of engineering design and workmanship. Various control and relay panels and
other requirements specified under this section shall be complete in themselves in all
respect with all main and auxiliary relays, fuses, links & switches duly wired, labels terminal
panels, earthing terminals, indicating lamps, mimic diagram, annunciator, name plate,
foundation bolts, interior illumination, cable termination arrangement with cable glands fitted
on base mounting plate etc. including all other accessories which are essentially required for
satisfactory operation . Such components shall be deemed to be within the scope of supply
of the Bidder irrespective of whether these are specifically brought out in this specification or
not.
2.2
Supply and laying of control and power cables for interconnecting various
equipments is not covered under the specification. Cable terminating arrangements, viz. the
cable hold support boxes, multi-core cable glands, sealing ends for other types of cables
that may be specified, shall however be included in the offered price. These shall be subject
to approval of purchaser. It is the responsibility of Bidder to ensure that the equipment
specified and complimentary equipment required for completeness of the protection/control
scheme be properly accommodated in the panels without congestion and if necessary
Bidder may provide panels with larger dimensions in width only.
3.0
SYSTEM CONDITIONS:
63
C & R Panels

Applicable climatic conditions shall be as per Volume-II, Part-2, Book-I.
4.0
STANDARD SPECIFICATIONS:
220KV Simplex design C&R panels shall match with MPPTCL standard drawing
copies of which are enclosed.
4.1.1
PANEL FINISH AND COLOUR: 220KV SIMPLEX DESIGN PANELS:
220 KV C&R panels for all applications shall be of Simplex design and each panel
shall be constructed of stretched level selected sheet steel. Simplex type panels shall be
made in suitable sections so that while mounting the panels can be located side by side with
a view to form a compact unit. The 220KV Simplex design panels have swing type doors on
the front with rear blocked.
4.1.2 220 KV C&R panels shall be of SIMPLEX design having front swing door with relays
flush mounted and rear blocked. These panels will be of free standing unitized construction
with members folded and bolted.
Load bearing members (front panel, base frame, door frame) will be 3mm thick.
Non load bearing members (side panel, cubicle roof, door) will be 2mm thick.
Cubicle bottom will be closed and shall have slots for cable entry. These will be
covered by detachable plates.
Weight of one Control and Relay panel shall be 600 to 650 Kg approx.
Panels will comply with ingress protection degree IP54 as per IS2147.
All doors and metal joints will be provided with foam type gaskets as per IS 13847.
15mm thick anti vibration pad will be provided loose (to be fixed below the base
frame of the panel).
Width of the panel shall be strictly maintained as 1000mm.
Swin front panel shall be rigid with suitable guided bolt at bottom.
A drawing is appended herewith which shows the elevation, end view and 3D view of
Simplex design 220KV Control and Relay panels.
4.1.3
Common Features applicable for 220kV panels

220KV SIMPLEX panels shall be dust, moisture and vermin proof.
All unfinished surface of steel panels and frame work shall be thoroughly cleaned
by sand blasting, pickling and rinsing or by combination of processes or by other
latest and improved techniques to remove dust, scales, foreign adhering matter
and grease. Cleaning process shall be followed immediately by the application of
rust inhibiting wash process. All control panels surfaces shall then be given
suitable rust resisting primary coat and then one or more coats of opaline green
quick drying enamel to serve as a base and binder for finishing coat.
As mentioned earlier, purchaser has standardised colour schemes for
SIMPLEX design 220 KV C&R panels which shall be opaline green as per colour
shade No. 275 of IS : 5 for 220KV panels.
Purchaser will accept respective matching colour and shade equivalent to BS381 or any matching colour and shade of other authoritative equivalent standard.
Colour finish shall be applied as per above colour scheme on the exterior steel
works of the panels. Exterior painted surface shall not be fully glossy. Interior of
all panels shall be painted with Egg Shell White. Pretreatment & painting
process is described in Clause 14.0. All steel works shall be Phosphated in
accordance with IS-6005. Panels shall be provided a degree of protection not
less than IP-54 as per IS-2147.
64
C & R Panels

COMPLIANCE OF PANELS, RELAYS, INSTRUMENTS AND OTHER GADGETS
WITH STANDARD SPECIFICATIONS:
4.2.1
STANDARDS:
Applicable Standards for the offered equipments/items shall be as per

Appendix-A of Volume-II, Part-2, Book-I.
4.2.2
In Appendix-A of Volume-II, Part-2, Book-I relevant Indian standard

specification/IEC standards have been mentioned. Equipments meeting any other
authoritative standard, which ensures equal or better quality than the standards, mentioned
shall also be acceptable. Equipment for which Indian Standards are not available, the
relevant British standards and IEC recommendations will be applicable. Please attach
photocopy of all such standards according to which the equipment has been offered.
4.2.3 TYPE TESTS:
All offered numerical distance and differential protection relays as well as other
static/electromechanical relays and meters on C&R Panels offered by the Bidders and as
indicated below shall be fully type tested as per relevant standards. In case the equipment
of the type and design offered, has already been type tested, the Bidder shall invariably
furnish type test reports from the reputed and approved national/international
laboratory/Government approved test houses to prove that indicated accuracy and other
specifications of the relays offered conform to the relevant standards. Test certificates shall
clearly indicate the type and model number etc., so that relevant details of offered relays
could be verified. While submitting offers the model and type etc., shall be clearly indicated.
Type test reports so furnished should not pertain to the period earlier than five years from
the date of opening of Bid. It may be very specifically` noted by Bidders that non-submission
of type test reports about numerical and conventional relays and also about static meters
along with the Bid shall be treated as a disqualification.
4.2.4
i.
Numerical distance protection relays
ii.
Numerical differential protection relay for X-mer
iii.
iv.
Numerical, Non directional and non-communicable 3 O/C +

1 E/F Relays as backup protection on 220 KV panels
Static trivector energy meter of accuracy Class 0.2S
v.
Multifunction meter of accuracy Class 0.5
DISCREPANCIES IN TECHNICAL PARTICULARS:
Regarding discrepancy in technical particulars stipulation under Section-I VolumeII shall be applicable.
4.3.0
PANEL CUT OUT AND DIMENSIONS:
4.3.1
As mentioned earlier, the C&R panels for 220 KV shall be of Simplex design and
the Simplex design 220 KV panels shall have a swing type front door and rear blocked.
4.3.2. Bidders may please note that the scheme / arrangement of panels envisaged for
220KV systems is summarized below
65
C & R Panels
S.
No.
Description/ application
1.
Transmission line protection
01
2.
HV side of
transformer
01
3.
TBC application
01
4.
Bus-tie application
01
160
MVA
220KV system
Simplex design Control
& Relay panel
Bidders may please note that although GA drawings for individual applications
mentioned above are not being furnished with the Bid document, all the same, the
aforementioned table need be strictly followed in so far as number of panels for each
application is concerned.
4.3.3
Constructional details & dimensions for 220 KV SIMPLEX type panels shall be as
under:S. No.
Title
220 KV PANELS
Simplex design Control & Relay panel as shown in
MPPTCLs standard drawing.
Type
Height (mm)
2312 (Panel 2210 + Base frame 102)
Depth (mm)
750 mm
Width (mm)
1000 mm (Subject to variation as per scheme

requirement)
Base frame
Anticorrosive Black painted
Panel Exterior
Opaline Green
Panel Interior
Egg Shell white
Mimic strips over laid

type
Variation in dimension
of panels.
10
MPPTCLs Standard
Drawing
Dark Brown
Bidder may please note that the height and depth of
control panels will have to be maintained as mentioned
against Sl. No. 2&3 above. As far as width of the control
panels is concerned, this shall also be maintained as
1000 mm as per S.No.4 above.
Bidders shall ensure to match panels offered by them
with MPPTCLs standard drawing enclosed herewith.
4.3.4 The purchaser has standardized dimensions of panels for various applications and
therefore no deviation in height / depth of panels in particular shall be permitted. The width
of the panels is however subject to change. Bidders may please note that preferred cut out
66
C & R Panels

dimensions for mounting of control gadgets and relays shall be strictly inline with IS-4483
(Part I & II).
4.3.5
It is hereby clarified that standard drawing showing C&R panels 220KV
voltage classes have been developed considering that the Numerical Distance
Protection relays offered by the Bidders have the protection, recording and metering
functions listed elsewhere in the document, built in them. For example, relays type
LBB, trip circuit supervision and DC supply supervision, have been considered built
in the DPR and therefore has not been shown as discrete relays. Accordingly, Bidders
will have to offer discrete relays for those functions which are not built in. This has to
be noted specifically.
4.3.6
Control and Relay panels shall be floor mounting dead front sheet steel assemblies
of unitised design. Panels shall be made in suitable sections as described else where in the
specification so that while mounting, panels can be located side by side bolted together to
form a compact and composite unit. Design, material selection, workmanship, and width of
panels shall be such as to present a neat appearance, outside and inside with no works of
welds, rivets, screw or bolts head apparently visible from the exterior surface of the control
panels.
4.4.0
LIGHTING:
4.4.1
In each SIMPLEX panel, one 20 W, 230V AC tube light guarded with protected
cage shall be provided inside the central roofed access for adequate illumination & the same
shall be controlled by a door switch. Two incandescent 40 Watt (or15W CFL)230 Volt lamps
with switch housed in protective cage, one each on the front & rear side of the panels shall
be provided under the central roofed access.
One number 15A, 3 pin receiptable universal socket with switch shall be provided
in each simplex control panels. Third pin of the socket shall be effectively grounded through
the metallic structure. Socket shall be industrial grade control panels type complete with
protective metallic cover.
4.5.0.
4.5.1
AUXILIARY SUPPLY:
The auxiliary AC / DC supply shall be as per clause No. 6, Volume II Part-2, Book-I
of the specification
4.5.2
Isolating devices with H.R.C. fuses shall be provided in each panels for both A.C.
and D.C. power supplies. Distribution and wiring of the same shall be unitized through fuses
and links in such a way so that isolation of respective system unit is possible without
affecting the rest of the system or unit.
4.5.3
All H.R.C. fuses and links shall be with holder, and the same shall be mounted on
slant support with identification labels.
4.5.6
H.R.C. fuses shall be provided as per following details;

S. No.
Circuit
Fuse Rating
1.
Circuit breaker-closing circuit
16A
2.
Trip circuit I
16A
3.
Trip circuit II
16A
4.
Main Protection
10A
5.
Back up protection
10A
6.
Indication
6A
7.
Annunciation
6A
8.
P.T. Circuit main
6A
67
C & R Panels

9.
10.
P.T. supply for Metering circuit

A.C. supply
2A
10A
NOTE: Additional HRC fuses and links for individual circuit shall also be provided as per
the requirement for completing the offered protection scheme.
4.6.0
CONTROL WIRING:
4.6.1
Successful Bidders shall furnish and install complete wiring up to the terminal block
for the equipment, instrument devices mounted in the control panels strictly in accordance
with the approved wiring diagram prepared by the Bidder based on the purchaser's
information and schematic diagram.
4.6.2
Wiring shall be completed in all respects so as to ensure proper functioning of
control, protection and metering schemes.
4.6.3
All spare relay contacts and spare contacts of switches shall be wired up to the
terminal blocks.
4.6.4
Wiring shall be done with flexible heat resistant control panels wires, PVC insulated
with stranded copper conductor. Minimum number of strand in the wire shall be three. The
conductor size shall be equivalent to 2.5 mm square minimum for Current, potential & DC
Control circuit and 1.5mm sq minimum for other indications and annunciation circuits.
4.6.5
Coloured cores shall be used for wiring as per latest revision of IS-375 viz; red
yellow blue and black for R Y B phases and neutral respectively. Colour code for earthing
shall be Green, and for annunciation circuits gray colour code shall be used. For DC circuits
the colour code will be Red-positive & Black-negative.
4.6.6
Each wire shall be identified at its both ends with wire designation number by
plastic ferrule as per wiring diagram based on latest revision of IS-375 to denote the different
circuit functions. Bidders shall take approval for the system of wire numbering and colour
coding schemes.
4.6.7
All wire terminations shall be made with compression type connectors. Wires shall
not be tapped or spliced between terminal points. All wire shall have crimp type termination
and direct Tee connection at any place is not at all required.
4.6.8
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.
4.6.9
Fuses and links shall be provided for isolation of individual circuit from bus bars
without disturbing other circuits and equipment.
4.6.10 DC trip and DC voltage supplies and wiring to main protective gear shall be
segregated from those for special purposes. Each such group shall be fed through separate
fuses, either direct from main supply fuses or the bus bars.
4.6.11 Since a number of wires will run from one point to another, it is desired that the
support arrangement should be adequate and neat. Conventional method of bunching of
wires should not be adopted since the same creates problems in case any wire is to be
removed. Wires should be accommodated in suitable plastic channels with sliding plastic
cover, which may be suitably mounted inside the panels neatly. Inspection/ removal of wires
laid in the plastic channels should be possible by sliding the covers.
68
C & R Panels
4.6.12 Blank plastic channels should be provided by the sides of the panels to
accommodate incoming cables from switchyard through cable glands with suitable holding
arrangement rigidly fixed so that while handling other nearby cables no jerks are transferred
to the terminals inside the cubicle.
4.6.13 Wherever practicable wiring shall be accommodated in the sidewall of the cubicles.
Sharp bends shall be avoided.
4.7.0
TERMINAL BLOCKS:
4.7.1
Multi-way terminal blocks complete with necessary binding screws and washers for
wire connection and marking strip for circuit identification shall be furnished for terminating
the panel wiring and outgoing cables. Terminals shall be suitable for receiving atleast
2x7/0.737mm stranded copper conductor or equivalent aluminum conductor wires per
terminal. It may please be noted that the current rating shall be double the current rating
of 2x7/0.737 non stranded copper wire and terminal shall be suitable to receive 2x2.5sq
mm/or 2x4sq mm copper conductor of control cable.
4.7.2
Terminal blocks shall have shorting and disconnection facilities ,so that the Board
side and outgoing wires could be disconnected just by opening the disconnecting links
which slides up or down without dislodging the wires from their position. The
technical specification for these blocks shall conform to latest IEC 60947-7-1 as mentioned
hereunder The screw terminal block shall be manufactured as per IEC-60947-7-1. The insulating
material of Terminal Block shall be of polyamide 6.6 meeting VO / V2 inflammability class as
per UL 94. All metal parts including screws shall be copper alloy. The terminal shall be
suitable for mounting on both DIN as well as G type rail. All the metal parts shall be
captive and touch proof. The terminal block shall have screw locking design so that it can
be stand vibration level upto 5g and also prevent accidental loosening of conductors.
Non-disconnecting and disconnecting type terminal connectors shall be made of
polyamide and shall be preferably of ELMEX make having type designations KBTM4 and
KLTDM4 respectively.
4.7.3
Highly reliable Test terminal blocks with facilities of shorting and easy removal of
connection shall be provided for CT & PT circuits. Instrument transformer wires shall be
terminated through suitably mounted test terminal blocks to facilitate site testing of all main
and backup protection relays.
4.7.4
Test terminal blocks shall be grouped according to the circuit functions and each
terminal block group shall have at least 20% spare terminals for accommodating additional
input wires.
4.7.5
Not more than two wires shall be connected to any terminal or either side of the
terminal block. If necessary, a number of terminals shall be connected by jumpers to provide
additional wiring points.
4.7.6
Each terminal point shall be marked with designation obtained from the purchaser's
schematic drawings.
4.7.7
Adjacent rows of terminal blocks shall be spaced not less than 100mm apart.
These shall be mounted vertically at the sides of the cubicle and set obliquely towards the
69
C & R Panels

rear doors to give easy access to terminating end to enable ferrule number to be read
without difficulty.
4.7.8
Bottom of terminal blocks shall be spaced at least 200mm above the cable gland of
incoming multicore cables.
4.8
CABLE ENTRY:
4.8.1
All panels shall have provision of multiple cable entries from the bottom. Necessary
cable glands should also be provided in the rear & front side of panels on a 4 mm thick mild
steel gland plate to be bolted firmly with nut and bolts on base plate. Base plate shall be
bolted further on the base frame with adequate number of nuts & bolts as may be necessary
to allow free working space for cable connections and to facilitate its opening. Base plate
shall be in 3 pieces for Simplex panels and one piece for simplex panels with proper opening
for fixing gland plates. Thickness of these base plates shall not be less than 4 mm. Base
plate provided on the base frame is to facilitate free working space and also to serve as a
cover for control cables laid in the trenches from front to rear side of the Simplex panels.
Purchaser will arrange for necessary floor opening below the panels to suit the cable trench
design of purchaser's requirement.
4.8.2
Wiring through the terminal blocks shall be located in a manner that it becomes
convenient to provide termination of control cable for floor openings.
4.8.3
Gland plate shall be supplied duly drilled and fitted with cable glands. Gland plate
and doors shall be provided with gasket properly. Necessary glands as per clause- 4.8.5
below shall be fitted on the gland plate.
4.8.4
Rigid supports shall be provided along with terminal block for holding plastic
channel. Suitable clamps may also be provided in plastic channel for holding cables.
4.8.5
Following quantities of cable glands with suitable blanking arrangement shall be
fitted on the gland plate that shall be fastened suitably at the bottom of each of the 400 &
220 kV Simplex design panels quantities shown below shall be provided at the rear and
front both panels:i
ii
iii
iv
For 4 core x 2.5sq.mm 1.1KV Copper control cable

8 nos.
4 nos.
2 nos.
2 nos.
Bidders may please note that for control, protection and relay panels for use in 400
& 220KV substations, armoured / unarmoured copper control cables respectively shall be
used by the purchaser. Offered cable glands shall be suitable for armoured and unarmoured
copper control cables accordingly.
4.9.0
GROUNDING:
4.9.1
12.5mm x 6mm copper grounding bus shall be provided for each control panels
extending along with entire length of the panels for the purpose of effectively grounding all
metal structures.
4.9.2
Each continuous length of ground bus shall have provision of two terminals at two
extreme points for connection to main ground grid of the substation.
4.9.3
Common star /neutral point of Potential and current transformer shall be connected
with the grounding bus through a disconnecting type connector so as to adopt single point
70
C & R Panels

grounding of common star point either at the terminal block in the control panels or in the
marshalling box of the instrument transformer.
4.9.4
Whenever any circuit is shown grounded on the drawing a single wire for that
circuit shall be run independently up to the ground bus and connected to it.
5.0
CONTROL & RELAY PANELS:
As stated earlier, Control & Relay panels for 220KV voltage classes shall be of
Simplex design. Full constructional details in respect of these panels, their colour scheme,
details about the sheet steel utilized for construction and about other constructional aspects,
have been elaborated in para nos. 4.0 above..
6.0
CONTROL AND INDICATION CIRCUITS:
6.1
Control and Indication circuits for each circuit breaker
generally comprise of the following:
a.
b.
c.
d.
e.
f.
g.
h
i.
j.
k.
6.2
controlling feeder,
shall
Mimic diagram
A composite meter to indicate current, voltage, watts, VARS and Power factor.
Circuit Breaker Control switch.
"Trip coil / closing coil Healthy" lamps.
Alarm cancellation arrangement.
Breaker ON/OFF indication lamps.
Energy meter with display facility of various electrical quantities viz., MW, MVA,
MVAR, power factor etc.
Facia annunciating windows
Test terminal block and Relay Test Block on the front panels for testing of meters
and relays as per specified scheme in Simplex panels.
Relay Test Block on rear side of Simplex panels as per scheme.
Any other devices which may be necessary for completing scheme based on
improvement in design and adoption of new technology by the Bidder.
MIMIC DIAGRAM:
6.2.1
Mimic diagrams for 220KV Systems shall be made to represent TWO MAIN & ONE
TRANSFER BUS Scheme and shall be placed at the eye level to indicate position of each
breaker. Power transformer, voltage transformer shall be fixed on mimic by suitable symbols
having dark Black colour. Position indicator of isolating devices shall have matching colour
in accordance with the voltage class of the mimic. Arrangement shall be of overlaid design
using anodized aluminum section. Bidders may please note that Painted type mimic
diagrams are not acceptable.
6.2.3
Offered mimic diagram shall have colour scheme for representing 220KV the
colour scheme shall be dark brown / violet.
6.3
CIRCUIT BREAKER
(SEMAPHORES):
&
ISOLATING
DEVICE
POSITION
INDICATORS
6.3.1 Position indicators of `SEMAPHORE' TYPE shall be provided as part of the mimic
diagrams on panels for indicating the position of circuit breakers and isolating devices, as
mentioned earlier. Indicator shall be suitable for semi-flush mounting with only front disc
projecting out and with terminal connection from the rear. Colour of position indicator strips
shall be matching with the colour of associated mimic. Position indicators shall be suitable
for DC operation. When the supervised object is in the closed position, the pointer of the
indicator shall take up a position in line with the mimic bus bars, and at right angles to them,
when the object is in the open position. When supply failure to the indicator occurs, the
71
C & R Panels

pointer shall take up an intermediate position to indicate the supply failure. Position
indicators shall withstand 120% of rated voltage on continuous basis.
6.3.2 All 220 kV isolating devices and earth switches are required to be operated directly
from the control room. Isolator operation shall be interlocked with the breaker operation and
the earth switch operation shall be interlocked with the operation of both isolating device and
breaker. For above purpose 3- position (closeopen & return to neutral) pistol grip control
switch shall be provided near to the respective semaphore for closing and opening operation
of these devices by extending close and open command with desired interlocks specified
above.
7.0
ANNUNCIATION SYSTEM:
7.1
Alarm annunciation system shall be provided for each panels by means of visual
and audible alarm in order to draw the attention of the operating staff to the abnormal
operating conditions or the operation of some protective device. Annunciation equipment
shall be suitable for operation under the tolerance limit of voltages specified in this
specification.
7.2
Annunciation shall be of visual and audible type. Facia annunciator, flush mounted
on the front of the control panels, shall provide the visual annunciation. DC hooter or DC bell
shall provide the audible alarm. Apart from requirement of facia windows for annunciating
status of various relays, the Bidder shall also provide spare facia annunciator windows (two
nos. each) for trip and non-trip functions.
7.3
Each facia annunciator shall have a minimum size of 35 mm X 50 mm-translucent
plastic window for each Trip and alarm point. Translucent plastic plates of facia window shall
be engraved in black letters with respective inscriptions. All inscriptions shall be engraved on
each window in not more than three lines and size of letters shall not be less than 5 mm.
7.4
Each annunciation window shall be provided with two white lamps in parallel to
provide safety against lamp failure. Long life lamps shall be used. Lamp circuit shall include
series resistor of adequate rating. Cover plate of the facia windows shall be flush with the
panels and shall be capable of easy removal to facilitate replacement of lamps.
Transparency of cover plates and wattage of the lamps provided in the facia windows shall
be adequate to ensure clear visibility of the inscriptions in the control room having high
illumination intensity (500 Lux) from the location of the operating staff desk.
7.5
TRIP and NON TRIP facia shall be differentiated. All trip windows shall have red
colour translucent plastic window and all non-trip facia windows shall have white colour
translucent plastic window. Sequence of operation of the annunciator shall be as follows:
Alarm condition
Fault contact
Normal
Abnormal
Acknowledge push
button is pressed/
Reset push button is
pressed.
Lamp
test
push
button pressed.
Open
Close
a. Close
b. Open
a. Close
b. Open
Open
Visual
Annunciation
OFF
Flashing
Steady on
Steady on
ON
OFF
Steady on
72
Audible
Annunciation
OFF
ON
OFF
OFF
OFF
OFF
OFF
C & R Panels

7.6
Any new annunciation appearing after the operation of audible annunciation
cancel, shall provide a fresh additional annunciation accompanied with visual alarm even if
acknowledging or resetting of previous alarm is in process or yet to be carried out.
7.7
Annunciation system described above shall meet the following additional
requirements:
a.
b.
c.
d.
e.
f.
g.
h.
8.0
Annunciation system shall be capable of catering to at least 80% simultaneous

signals (of windows provided) at a time.
One self resetting push button shall be provided on each panels for testing the facia
window lamps. Push buttons for testing flasher and audible alarm circuit of
annunciation system and for testing the annunciation supply failure monitoring circuit
shall also be provided. These testing circuits shall also be so connected that while
test is being done it shall not prevent the registering of any new annunciation that
may land up during the test.
One set each of the following push buttons shall be provided on each panels as
shown in the front view drawing:
i
Reset push button for annunciation system.
ii
Accept push button for annunciation system.
iii
Test
push button for testing healthiness of annunciator.
The
operation of this button should not cause inadvertent operation of any
equipment.
Annunciation shall be repetitive type and shall be capable of registering the fleeting
signal. Minimum duration of fleeting signal registered by the system shall be 15milli
seconds.
Annunciation shall be suitable for operation with normally open potential free
contacts which close on a fault. It shall be possible at site to change operation of
annunciator from potential free contact from "close to fault" to "open to fault" and vice
versa.
In case of static annunciator scheme, special precaution shall be taken by
Bidder to ensure that spurious alarm condition does not appear due to influence
of external electromagnetic/electrostatic interference on the annunciator wiring
and switching disturbances from the neighboring circuits within the panels.
Offered annunciation scheme shall be complete in all respects including annunciator
relay, flasher relay, test, accept and reset push buttons.
Additional four spare windows two each for non trip and trip signals supported by trip
relay for future application by the purchaser shall be provided duly wired up and
terminated to the row of connectors.
PROTECTION SCHEMES:
8.1
Protection schemes for 220 kV systems included in this Bid are required for the
following applications:
220 KV SYSTEM
1
Control & Relay panels for 220 KV lines.
2
Control & Relay panels for Transfer Bus coupler bays.
3
Control & Relay panels for bus tie bays.
4
Control & Relay panel for 160MVA power transformer
8.2
PROTECTION SCHEMES FOR 220 kV LINES:
8.2.1 General philosophy for 220 KV lines the main protection shall also be in the form of
Numerical Distance protection scheme and besides the built in back up protection, there
73
C & R Panels

shall be one more discrete two O/C plus 1E/F relay which shall be a Numerical, directional
and non-communicable relay to function as backup protection. For the main Distance
protection for 220 KV lines, the voltage input shall be provided from Bus PTs. For 220 KV
lines the maximum fault current could be as high as 40 KA and the minimum fault current
could be 20% of rated CT secondary i.e. 1 A. As such, the starting and measuring units
should suit to these requirements. Finally, protection schemes for 220 KV lines shall be
Non-Switched Schemes having separate measurements for phase to phase to phase to
ground faults for each zone. Offered Numerical Distance relays shall be capable of
supporting IEC61850 Communication protocol.
8.2.2 SALIENT FEATURES OF 220kV LINE PROTECTION SCHEMES
i.
ii.
iii.
iv.
v.
vi.
Offered scheme shall have continuous self monitoring and diagnostic feature.
Offered scheme shall have stepped time-distance characteristics and three
independent zones ( zone 1, zone 2 and zone 3).
Offered scheme shall have mho or quadrilateral or other suitably shaped
characteristics for zone-1, zone-2 and zone-3.
Offered scheme shall have following maximum operating time (including trip
relay time, if any) of 30 milli seconds for all types of faults and source to line
impedance ratio of 4.0.
Offered relays shall have characteristics angle between 30 and 85 degrees.
Offered relays shall have resetting time of less than 50 milli seconds including
the resetting time of tripping relays.
Other important requirements about Numerical relays pertaining to their protection,

metering and recording functions have been elaborated in the subsequent clauses which
may be carefully noted.
8.2.3
For 220 KV lines, main protection shall be in the form of numerical distance relay
along with all standard supporting relays. It may be noted that, 400 as well as 220 KV circuit
breakers will have two trip coils which will receive simultaneous trip command. As such
schematic shall be made to select main DC supply or duplicate DC supply for each trip coil
as stated in the previous section. For this purpose, contact multiplication will not be
acceptable but the rating of the breaker control switch and each tripping relay contacts shall
be adequate to handle the burden of two trip coils. Pistol grip type breaker control switches
along with red and green indicating lamp for ON/OFF indication shall be provided.
Offered distance protection schemes for 220 KV lines shall be suitable for
single pole tripping and auto reclose duty and they shall have facility for check
synchronising.
Salient requirements about automatic reclosing scheme
Auto re-closing function shall be separate for 220kV line protection schemes and
shall have following features
i.
Single phase or / and three phase re-closing facilities
ii.
Have a continuously variable single phase dead time range of 0.1 to 2 secs.
iii.
Have a continuously variable three phase dead time range of 0.1 to 2 secs.
iv.
Shall have a continuously variable reclaim time range of 5 300 secs.
v.
Shall have a four position selector switch from which single phase / three
phase / single and three phase auto-reclose mode can be selected.
vi.
Shall have facilities for selecting check synchronizing or deadline charging
facilities.
vii.
Shall be of single shot type.
viii.
Shall include check synchronizing relay which will have following features
74
C & R Panels

a.
b.
c.
d.
e.
f.
A time setting range continuously variable between 0.5 and 5 secs. with
a facility of additional 10 secs.
Shall have a response time within 200 mili secs. with the timer
disconnected.
Shall have phase angle setting not exceeding 35 degrees.
Shall have voltage difference setting not exceeding 10%.
Shall include deadline charging relay which shall have 2 sets of relays
and each set shall be able to monitor the three phase voltage where 1
set shall be connected to the line CVT with a fixed setting of 20% of
rated voltage and the other set shall be connected to Bus PT with a fixed
setting of 80% of rated voltage.
Shall incorporate necessary auxiliary relays and timers to give a
comprehensive scheme.
8.2.4
All 220KV transmission lines are generally laid on double circuit transmission
towers and each circuit is protected against lightning by ground wire joined at each tower.
Maximum fault currents in both these voltage classes could be as high as 40KA for but the
minimum fault current could be as low as 20% of CT secondary rating (1A). Thus, starting
and measuring relay characteristics should satisfy both extreme conditions. Numerical
distance protection relay shall be suitable for use with CVTs also having non-electronic
damping and transient response as per IEC. It shall be ensured that no additional delay to
block tripping is involved in relay operating time created intentionally to have stable
operation. Power supply unit if provided as an integral part of relay scheme shall be fully
rated with liberal design in capacity. Insulation barriers shall be provided to ensure that
transient present in CT and VT signals due to extraneous sources do not cause damage to
static circuits. Circuits must comply with IEC recommendation for impulse withstands values.
Adequate measures shall be taken to ensure that equipment is protected against voltage
spikes occurring in auxiliary DC supply.
8.2.5
Numerical distance protection schemes offered by the Bidders for 220KV lines
shall have the following features -
Numerical distance protection relay shall be capable of providing flexible, reliable

integration of protection, control, and monitoring and measurement functions.
Offered relay shall have 6 nos. of impedance measuring loops.
Offered relay shall be suitable for protection of broken conductor following one out of
three phases getting open circuited without any line or ground fault. Protection shall
perform satisfactorily both for loaded and unloaded line condition.
Offered relay shall preferably have independent polygonal characteristics with
adjustable reactive and resistance reaches for maximum selectivity and maximum
fault resistance coverage due to arc resistance.
Offered relay shall provide selection and setting for mutual compensation of double
circuit lines.
Offered relay shall have minimum three directional zones and minimum one nondirectional zone. Zone setting ranges shall be sufficient to cover line lengths
appropriate to each zone. It shall be possible in future to add Carrier aided scheme
options of Zone-I extension, permissive under reach or over reach and blocking.
Offered relay shall have maximum operating time up to trip impulse generated from
relay (complete protection time including applicable carrier time and tripping time )for
the following source to line impedance ratios under all possible combination of
line fault with CVT being used on the line at 50% of Zone-I reach:-
for Source Impedance Ratio 0.01 4 : 30ms at nearest end and 50ms at other end
of line.
75
C & R Panels

for Source Impedance Ratio 4 -15
: 35ms at nearest end and 55ms at other

end of line.
Offered relay shall have a secured directional response under all conditions,
achieved by memory voltage polarizing or healthy phase voltage polarizing as may
be appropriate.
Offered relay shall have logic to detect VT fuse failure. Bidders shall clearly state if
VT fuse failure for all the three phases can be detected individually.
Offered relay shall have Trip Circuit supervision and DC supply supervision as built
in features. In case it is not so, then discrete relay shall be offered for Trip Circuit
supervision as well as DC supply supervision.
Offered relays shall be suitable to detect switch on to fault (SOTF) condition by
appropriate means. Bidders may elaborate the SWITCH ON TO FAULT logic.
Offered relay shall have LBB relay as a built in feature to take care of stuck breaker
condition. If it is not so, then the Bidders may have to offer discrete relay to take
care of stuck breaker condition.
Offered relay shall have power swing blocking feature with suitable coverage to
encircle distance relay characteristic with facilities for
(a) Fast detection of power swing
(b) Selective blocking of zones and
(c) Settable deblocking criteria for earth faults, phase faults and three phase faults.
Offered relay shall have minimum three directional and one non-directional step
time distance characteristics with independently variable time graded distance
protection zones to cover two adjacent line sections.
Offered scheme shall have minimum adjustable characteristics line angle setting
range of 30 -85 degrees.
Offered Distance schemes for 220KV lines shall be suitable for single pole
tripping and reclosing duty as stated in the previous para.
Offered relay shall be selective for internal and external faults.
Offered relay shall have minimum two independent continuous variable time setting
range of minimum 0-1 second for zone-2 and minimum 0-3 seconds for zoneVariable time settings for non-directional zone shall also be provided to set
minimum trip time of 0-5 seconds, over and above time settings for directional
zones.
It is desired that the total operating time of the offered relay need not exceed 30
ms.
Offered relay shall have maximum resetting time of less than 35ms.
Offered relay shall have built-in extensive self-supervision and diagnostic testing
facility.
Suitable number of potential free contacts if required (multiplied through reed
relays only) may be provided on each distance scheme for carrier aided selection
of permissive tripping and blocking and auto reclosing. Provision for event
sequence recorder, stuck breaker, disturbance recorder, fault locator etc. shall be
available.
Offered relay shall be capable of performing basic metering functions. Voltages,
Currents, Active and Reactive power registration shall be available on demand.
Offered Numerical Distance relays shall be suitable for use on series compensated
transmission lines. This is a desirable feature but it is not mandatory.
Offered relay shall be capable of supporting IEC 61850 communication standard.
Offered relay shall have two communication ports. Front port shall be for local
communication for relay settings, modifications, extraction / analysis of fault /
event / disturbance records from a lap top computer and there shall be rear port on
61850 standard for remote communication.
76
C & R Panels

Offered relay shall have following tools for fault diagnostics.
i.
FAULT RECORDS Relay shall have facility to store fault records with information on cause of
tripping, date, time and trip values of electric parameters. It shall be capable
of storing not less than 5 nos. of previous fault records.
ii.
EVENT RECORDS Relay shall have facility to store 200 nos. time stamped event records with 1
ms resolution.
iii.
DISTURBANCE RECORDS Number of available analogue channels and digital channels shall not be less
than 8 and 16 respectively. Triggering for capturing / recording of disturbance
should be possible from within the distance relay and / or from any other
disturbance within the EHV sub-station. Offered relay shall necessarily have
a storage capacity of atleast 8 disturbance records of 3 sec. duration each.
iv.
Disturbance recorder, fault recorder and distance to fault locator functions

shall be provided as integral part of the line protection relays.
Offered relay shall have front panels display with keys to enter scroll through the
settings and to view the measurements. It shall also be possible to take data from
a pre-stored file in the PC and download the settings to the relay through the front
port.
Offered relay shall have directional phase over current and earthfault protection.
Offered relay shall have non-directional phase over current and earthfault IDMT
protection with high set element for instantaneous tripping.
Offered relay shall have under / over voltage protection.
Offered relays shall conform to communication protocol no. IEC-61850 as stated
earlier.
Offered relay shall have self-monitoring and fault diagnostic feature with
appropriate annunciation. User definable LEDs shall be provided for visual
indication. Necessary serial ports and parallel ports with leads and termination
shall be provided.
Offered relay shall have facility for communication from remote sub-station (inline
with IEC 61850 standard) so that these relays can be used for sub-station
automation. Required hardware and software shall be included in the offered
relay.
Offered relays shall have port type IRIG for time synchronization.
Bidders shall elaborate following features of the numerical relays offered by them.
i. Various programmable features of the relay
ii. Application.
iii. Relay functions.
iv. Block diagram for hardware of the relay.
v. Metering and recording.
vi. Human machine interface.
vii. Suitability of the relay for IEC communication protocol no. IEC-61850.
77
C & R Panels

8.2.6
Besides the built in back-up protection in the Numerical Distance Relay, an

additional Numerical, Directional, Non Communicable, 3 O/C + 1 E/F Relay is
envisaged only on 220 KV feeder panels.
8.3. PROTECTION SCHEMES FOR 160MVA, 220/132/33KV POWER TRANSFORMERS

8.3.1. Transformer protections required for 160 MVA, 220/132/33 KV Power Transformers
shall be provided by fully numerical transformer differential protection relay. The offered
numerical differential relay shall be suitable for protection of 3 winding transformer without
external interposing CTs. In case protection requirement calls for providing interposing CTs,
same shall be provided by the bidder in the control panel without additional cost. It should be
ensured that differential Protection offered is stable under through fault condition, normal
and over fluxing conditions and shall not operate with magnetizing in rush current. Bidders
shall give all details of the protection offered. Differential relay shall have current rating of 1
Amp CT secondary and the total operating time shall not exceed 30 ms. from inception of
fault up to contact status changing of output relay. Relay should have Bias setting adjustable
from 15% to 50% with through fault current not less than 10 times the normal current.
Operating characteristics should have dual slope for enhanced sensitivity for internal faults
and better stability during through faults. Fifth harmonic by-pass filters shall be provided to
avoid possible mal-operation under over-fluxing conditions. Relay
shall
have three
instantaneous high set over current unit and shall have continuous self monitoring and self
diagnostic features. Visual indication and alarm shall be provided in this panel for over
fluxing relay, and for standard Transformer protections. Alarm indication for SF6 gas
pressure low, lockout, and air pressure low shall be provided along with, Inter trip and trip
transfer indication. The offered differential relays shall also be suitable for IEC
communication protocol 61850.
8.3.2 (A) Transformer differential protection relay shall have following built- in protections
i.
Thermal imaging.
ii.
Restricted earthfault
iii.
Local breaker back-up (LBB)
iv. Over excitation
v.
Back-up overcurrent and earthfault relay
vi. Overload protection
vii. Negative phase sequence imbalance detection
viii. Trip circuit supervision
ix. DC supply supervision
8.3.2(B) AUXILIARY RELAYS FOR ALARM AND TRIP FUNCTIONS:
We have envisaged hand reset type auxiliary relays for alarm and trip
functions as mentioned against Sl. No. 31 & 32 for 220kV C&R panels of the BOM in
clause no. 20. (A) & (B). Bidders may please note that these discrete relays are
essentially required even though they form integral part of the Numerical Differential
relay.
8.3.3
OVERFLUXING RELAY:
Power transformer should trip for over fluxing condition to isolate both from primary
and secondary sides. Accordingly over fluxing relay should be provided in the control panel
on the HV side for transformer protection, with provision of alarm and trip Contacts.
Transformer has following over fluxing capacity and the offered relay shall be suitable to
provide minimum settings as detailed hereunder:
Over fluxing factor
Duration.
78
C & R Panels

1.40
1.25
1.10
5 sec
60 sec.
continuous.
Relay shall have inverse characteristics and should be equipped with high set unit to
operate in less than 5 seconds whenever over fluxing exceed than the set value by 1.1
above 1.4 times. Over-fluxing relay shall have setting that may be continuously adjustable or
in steps, for over-fluxing ranging from 1.0 and upward. Resetting value shall not be less than
0.95 of the operating value. Settings shall be available in two stages. First stage auxiliary
element operation shall be around 1 sec. This stage shall be complete with auxiliary relay
so that alarm/facia etc. could be initiated. Thereafter in the second stage the auxiliary
element shall operate after a further adjustable time delay say 10 to 1000 sec. This stage
shall also be complete with auxiliary relay, which could be utilized for the tripping. Rating of
auxiliary relay shall be selected accordingly. Relay shall be complete with independent
operation indicator for the two stages. Bidders may please note that the basic setting on the
relay shall be with over fluxing factor with 1.1 and shall have continuous duration. However,
between the remaining two i.e. over fluxing factor of 1.25 or 1.40, any one can be utilized.
8.3.4
Numerical differential protection relays offered by the Bidders for 160MVA,
220/132/33KV Xmers shall have a definite time over current relay as a built-in feature with
variable setting range from 50 to 200 per cent of relay current alongwith a timer having a
setting range of 2.5 to 25.0 sec. This relay shall be utilized to function as overload
protection relay for 315 MVA and 160MVA Xmers.
8.3.5.
Other standard transformer protections such as gas operated Buchhloz relay,
winding temperature, oil temperature, low oil Level, Pressure release devices etc. will be
provided by the purchaser with the transformer. Bidders have to make provision for alarm
annunciation and tripping. These standard protections will be provided on the panels as
stated above.
8.3.6
Besides the built in back-up protection in the Numerical Differential Relay, an
additional Numerical, Non Directional, Non Communicable, 3 O/C + 1 E/F Relay is
envisaged on 315 MVA X-mer panels. Bidders may please note this very carefully.
8.4
PROTECTION SCHEMES FOR 220KV TRANSFER BUS COUPLER APPLICATION:
Protection scheme for 220kV TRANSFER BUS COUPLER shall be identical to the
LINE protection scheme specified above at 8.2.1 as such all standard features required for
the scheme shall be provided. The mimic shall represent scheme for transfer bus instead of
line.
8.5 (a) PROTECTION SCHEME FOR 220 kV BUS TIE APPLICATION:
220kV Bus Tie control and relay panel shall have two digital voltmeters with selector
switch to display voltage of BUS-I and BUS-II. Four-element auxiliary relay shall be provided
for monitoring circuit breaker parameters. The mimic shall be provided with semaphore for
automatic display of breaker and isolator status. A Numerical, Non directional, Non
communicable, 3O/C + 1E/F relay is envisaged on the 400 & 220kV Bus Tie Panels for
isolation of Buses (I) & (II).
9.0
OTHER IMPORTANT PROTECTIONS FOR FEEDER, TRANSFORMER, TBC, BUS

TIE PANELS AND REACTOR PANELS:
9.1
LOCAL BREAKER BACK UP:
79
C & R Panels

Local breaker back up relay shall be provided to take care of stuck breaker condition.
In case, it is a built-in feature of distance / differential protection relays, then no separate
LBB relay is required. This relay shall have following features
i.
ii.
iii.
iv.
v.
vi.
It will be a triple pole type relay

It shall have an operating time of less than 15 milli seconds
It shall have a resetting time of less than 15 milli seconds
It shall have three over current elements having setting range of 20 to 80% of
rated current
It shall have a continuous thermal withstand of 2 times the rated current
irrespective of setting
It shall have a timer with continuously adjustable setting range of 0.1 to 1.0
seconds.
In case of panels for bus tie applications however a separate LBB relay need be
provided. Necessary auxiliary relays for initiating tripping command to the 8 nos. circuit
breakers shall also be included as a part of the scheme. Tripping relays shall be capable of
handling burden of circuit breakers with two trip coils. Bidders shall provide a separate
panel to house two nos. tripping relays having 8 Nos. contacts per circuit for total 8
circuits in 220 kV systems where the switching arrangement is two main and one
transfer bus. This is further clarified in Clause no. 20 about the Schedule of
requirement also.
9.2
TRIP AND CLOSING CIRCUIT SUPERVISION:
9.2.1 Trip circuit supervision: Separate trip circuit supervision relay shall be provided for
each of the two trip coils in each panel, for continuous monitoring of trip circuit i.e. for both
pre and post close conditions in case trip circuit supervision does not form integral part of
the Numerical Distance/Differential Relays. These relays shall have following characteristics
i.
Relay shall be capable of monitoring the healthiness of each phase trip coil and
associated circuit of circuit breaker during ON and OFF conditions.
ii. Relay shall have adequate contacts for providing connection to alarm and event
loggers.
iii. Relay shall have time delay on drop-off of not less than 200 milli seconds and be
provided with operation indications for each phase.
Trip healthy lamp for each trip coil shall be provided separately for pre and post close
monitoring. During unhealthy condition of trip circuit the relay shall initiate an audible alarm
and visual indication on facia window. All 400 and 220 KV circuit breakers are provided with
two trip coils and hence separate trip circuit pre and post supervision for each trip coil is to
be provided by Tenderder. Each trip circuit supervision relay shall be provided with
operation indicator. Also for each trip coil circuit, separate DC circuit with fuses will be used.
9.2.2 Closing circuit supervision: As we have experienced certain problems in closing
circuit as well. As such we intend to supervise preclosing healthiness of closing coil of
Circuit Breaker also. May please note that we have been utilizing SPR type 220kV SF6
Circuit Breaker with one closing coil in each mechanism box separately in our system.
Accordingly Bidders may provide one suitable switch with indication lamp in 220kV C&R
panels to supervise the healthiness of closing coil of 220kV SF6 Circuit Breaker. Bidder may
also offer any other suitable scheme for this purpose. The detailed schematic drawing may
also be submitted alongwith offer.
9.2.3
DC SUPPLY SUPERVISION:
80
C & R Panels

Separate DC supply supervision relay for 220 KV panels in case this does not form
integral part of Numerical Distance/Differential Relay. Out of the two DC supply systems,
namely, protection and annunciation / indication, the offered relay shall be capable of
monitoring failure of DC supply of the protection circuits. It shall have adequate potential
free contacts to meet out the requirement of the scheme and also to meet the requirement
for providing alarm and facia indication. Relay shall have a time delay on drop off" of not
less than 100 milli second and be provided with operation indicator/flag. This relay shall
sound AC 230 V heavy-duty bell with provision for accept/reset and test facilities.
9.2.4
ALARM SCHEME:
Automatic tripping of the circuit breaker due to operation of protective relays shall
be indicated by a common audible alarm. Offered alarm scheme shall be complete in all
respects including one DC bell for non-trip alarm and one DC hooter for trip alarm with
relays and other accessories if any. With each panels one alarm scheme will be required.
10.0
a) MULTI-FUNCTION METER:
We envisage a Multi-function meter on the panel to provide digital display of

current, voltage, Watts, VARS and Power Factor. This meter shall have scrolling facility to
facilitate reading any of these parameters and it will have a size of 144 sq mm. Bidders may
please note that the meter shall be capable of reading voltages upto a maximum value of
250KV in case of 220 KV panels. This meter shall have an accuracy class of 0.5. The
multifunction meter shall have four and a half digit display, for example 210.8KV, with
minimum display height of 25mm. This meter shall conform to IS 722 and shall be provided
with non-reflecting glass fronts. Bidders may please note that the Multi function meter shall
be suitable for DC Supply voltage of 110Volts. AC Supply operated meters are not
acceptable to us. The offered Multi function meter shall be of reputed make. Bidders may
please note very carefully that multifunction meter shall have communication facility
through serial port RS-485 with Mod bus protocol complete with down loading
software.
b)
Bidder may please note that in addition to multifunction meter, 1 No.
analogue type center zero MVAR meter is also required to be provided in each
category of C&R panel covered under the bid.
11.0
ACCESSORIES:
11.1
Four Element Hand Reset Auxiliary Relay For Monitoring Circuit Breaker
Parameters:
Four-element hand reset auxiliary Relay for each 220,132 and 33 kV breakers is
required to provide flag indication and display shall be provided in facia window annunciator
for monitoring circuit breaker parameters of each breaker control provided in the panels as
under ;
SF6 gas pressure low alarm
Air pressure low alarm
Spring discharge alarm
Spare
11.2.0
ENERGY METERS:
The energy meter for each circuit shall be 3 phase 4 wire, 0.2S accuracy class with
availability based tariff. One meter shall be provided for each circuit, as a self-contained
device for measurement of power transmittals, in each successive 15 minute block, and
certain other functions. The meters provided in C&R panels shall be utilized for
81
C & R Panels

measurement of active energy and average frequency in a programmable time clock initially
set at 15 minute blocks. Meters shall measure and display reactive energy under voltage low
(97%) and voltage high (103%) condition as per tariff requirement. Meters shall measure
cumulative active energy import and export on daily basis and monthly basis. The Base
Computer software (BCS) shall be configurable to cater to tariff applications like Time of Day
(TOD) metering. In case of change of threshold values of voltages, the supplier shall
undertake to set new threshold values of voltage. It shall be possible to select parameters of
Meters as per requirement of Purchaser. Meter shall be fully static having non volatile
memory and fully programmable. Meter shall have four quadrant registering facility with
provision for recording/display various parameters like KWh, KVAh, KVARh, Line current
and voltages including power factor. Load survey capability for 35 days shall be available to
forecast load growth. Meter shall have 0.2S accuracy class.
11.2.1 MEASUREMENT ACCURACY: Measurement accuracy of meters shall be as per
IEC 62052-11-2003, IEC 62053-22-2003 as under:
0.2s for Active Energy
0.5s for Reactive Energy or better
11.2.2 APPLICABLE STANDARDS FOR METERS: The meters shall fully comply with all
stipulations in IEC standards 62052-11:2003 and 62053-22:2003. The reference ambient
temperature shall be 23oC as per IEC. Errors shall be reasonable for all power factor angles
from 0o to 360o. For reactive power (VAR) and reactive energy (VArh) measurement, IEC
62053-23:2003 shall be complied with. The meters shall conform to following Indian
standards with latest amendments.
i)
ii)
iii)
iv)
CBIP Technical Report No.88 (with latest amendments issued June 2000)
specifications for AC Static Electricity Energy Meters.
IS 14697(1999) AC static transformer operated Watt-hour and VAR-hour
meters for class 0.2s and 0.5s.
IS 12063 Degree for Protection.
IS 3202 Climatic Proofing of Electrical Equipment.
The meter shall also comply with specifications & requirement as stipulated in Part
V: Transmission Metering Code as published in Gazette of Madhya Pradesh dated 20-0804 by Madhya Pradesh Electricity Regulatory Commission (MPERC) as Grid Code.
11.2.3 PRINCIPAL PARAMETERS: The energy meters shall indoor type connected with
the secondary side of out door current and voltage transformers.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Item
Type of installation
CT secondary
VT secondary
System frequency
Earthing System
Auxiliary DC supply if required
Details
Indoor Flush/ Rack/ Cubicle mounted
1A
110 V/ 3 Volts
50 HZ + 5%
Solidly Grounded
110V+ 20%
Multiplying factor to arrive at actual primary values wherever applicable shall be calculated
from the CT and PT ratio of the installed CT and PT using the base computer software
(BCS).
11.3.0
SWITCHES:
82
C & R Panels

11.3.1 Control and instrument switches shall be rotary operated with escutcheon plates
clearly marked to show operating position and circuit designation plates and suitable for
flush mounting with only switch front plate and operating handle projecting out. Handles of
different shapes and suitable inscriptions on switches shall be provided as an aid to switch
identification.
11.3.2
Selection of operating handles for different type of switches shall be as follows:

a.
Breaker control switches
: Pistol grip, black
b.
Selector switches
: Oval or knob black.
c.
Instrument switches
: Round, Knurled, black
d.
Protection transfer switch
: Pistol grip lockable and black.
11.3.3 Breaker control switch shall be of spring return to neutral 3-position type. Control
springs shall be strong and robust enough to prevent inadvertent operation due to light
touch. The spring return type switch shall have spring return from close and trip positions to
'after close' and after trip position respectively.
11.3.4 Lockable switches which can be locked in selected position shall be provided for
trip transfer scheme. Key locks shall be fitted on the operation handle. The trip transfer
switch will have three position Normal / Intermediate /Transfer.
11.3.5 In 220 KV SIMPLEX type panels, selector switch for manual selection of
semaphore position indicator strip position shall be provided for displaying matching position
of isolating devices in the switchyard. These selection switches shall have two way
selections and shall be mounted near to respective semaphore device.
11.4
INDICATING LAMPS:
11.4.1 All indicating lamps on the 220 kV C&R panels shall be LED Display type. This is a
mandatory requirement.
11.4.2 Indicating lamps shall be panels mounting type with rear terminal connections.
Lamps shall be provided with series connected resistors preferably built in the lamp
assembly. Lamps shall have translucent lamp covers to diffuse different colours e.g. red,
green, amber, clear white or blue to differentiate system function. Lamp cover shall be
preferably of screwed type, unbreakable and moulded from heat resistant material.
11.4.3 Wattage of the neon lamp shall be 0.25 to 0.5W if provided. Bulbs and lenses shall
be interchangeable and easily replaceable from the front of the panels. Indicating lamp with
resistor shall withstand 120% of rated voltage on continuous basis.
11.5
PUSH BUTTONS:
Push buttons shall be momentary contact type with rear terminal connections.
Where ever required the push buttons shall be suitably surrounded to prevent inadvertent
operation. These shall be provided with integral inscription plates engraved with their
functions. All push buttons shall have minimum two normally open and two normally closed
contacts. Contact faces shall be silver plated. Contacts shall be suitable to make/break and
carry appropriate currents for the functions desired.
12.0
RELAYS:
All electromechanical relays shall have compliance to the following requirements.
83
C & R Panels

12.1
All relays shall be contained in dust proof cases. All cases shall be mounted on the
control and relay panels and the details of mounting shall be to purchaser's approval.
Relays shall be of the projecting pattern or flush pattern as specified.
12.2
Indicators shall also be provided on such additional equipment to identify faulty
phase and type of fault. Each indicator whether electrically or mechanically operated shall
be reset by hand without opening the relay case. Each indicator shall be so designed that it
should not be moved before the relay has completed its operation. It shall not be possible
to test and operate any relay by hand without opening case.
12.3
All elements of relays shall be arranged such that on opening the case dust
particles collected in or upon the case should not fall on the relay mechanism.
12.4
All relays shall conform to the requirement of IS-3231 or other applicable approved
standards. Relays shall be suitable for flush or semi flush mounting on the front with
connections from the rear. Relays shall be rectangular in shape and shall have dust proof,
dull black or egg shell black enamel painted cases with transparent cover removable from
the front.
12.5
All relays shall be draw out pattern or plug in type/modular construction with proper
testing facilities. Testing facilities provided on the relays shall be specifically stated in the
Tender. Necessary test plugs shall be supplied loose and shall be included in scope of
supply. Test block and switches shall be located immediately below each relay for testing.
As an alternative to "test block" and "test plug arrangements" the Bidder may supply
alternative testing facility for protective relays.
12.6
All induction relays shall be designed to operate at system frequency of 50 Hz.
Voltage operated relays shall be designed for star connected 110 Volt VT secondary supply
and current operated relays of 1 amp CT secondary as specified in the specification.
DC auxiliary relays and timers shall be designed for specified DC voltage and shall operate
satisfactorily at 70% to 110% rated voltage. Voltage operated relays shall have adequate
thermal capacity for continuous operation.
12.7
Relays shall be suitable for efficient and reliable operation of the protection scheme
described in the specification. Necessary auxiliary relays and timers should be provided for
interlocking scheme, multiplying main contacts, switching contact of protective relays and
monitoring of control supplies and circuits, lockout relay monitoring circuits etc. and
also as may be required for complete Protection schemes described in specification. All
protective relays shall be provided with minimum two pair of potential free contacts.
Auxiliary relays and timers shall have pairs of contacts as may be required to complete the
scheme. All contacts shall be silver faced with spring action. Relay case sizes should not
pose limitations in using available contacts on the relay due to inadequacy of terminals.
Paralleling of contacts, shall be done at the external terminals of relay if required.
12.8
All auxiliary relays except the lock out relays and interlocking relays shall be
provided with self reset type contacts. All protective relays shall be provided with externally
hand reset positive action operation indicators with proper inscription. All protective relays
which do not have built-in-hand reset operation indicators shall be provided with additional
auxiliary relay having operating indicators (Flag relays) for this purpose. Similar separate
operating indicator (auxiliary relays) shall be provided in all relays associated with protection
tripping such as Buchholz relays, oil and winding temperature protection, pressure relief
devices, fire protection etc.
12.9
Provision shall be made for easy isolation of trip circuits of each relay for the
purpose of testing and maintenance
84
C & R Panels
12.10
Auxiliary seal-in-units provided on the protective relays shall preferably be of shunt
reinforcement type. If series relays are used the following shall be strictly ensured:
a.
b.
c.
Operating time of the series seal-in-unit shall be sufficiently shorter than that of
the trip coil or trip relay in series with which it operates to ensure definite
operation of the flag indicator of the relay.
Seal-in-unit shall obtain adequate current for operation when one or more
relays operate simultaneously.
Impedance of the seal-in-unit shall be small enough to permit satisfactory
operation of the trip coil on trip relays when the DC supply voltage is minimum.
12.11
All numerical, solid state and electronic relays shall have compliance to the
following requirements:
a.
b.
c.
d.
e.
f.
g.
h.
Printed circuit panels/cards shall be fin type and its contact shall be gold
plated. All connections with the connector pegs shall be through wire
wrapping. All solder joints on the printed circuit panels shall be encapsulated
or covered with varnish.
Components used in these relays shall be loaded under normal condition by
less than half of their rated values. Resistors shall be of carbon composition
or metal oxide type and the capacitors shall be plastic film or tantalum type.
Stringent measures including shielding of long internal wiring should be taken
to make relays immune to voltage spikes as per IEC. Relays must meet the
requirements of IEC-255-4 appendix È' class III regarding BF, disturbance
tests IEC-255-4 regarding impulse test at 5KV and transients present in CT
& VT connections due to extraneous sources, do not cause damage to any
of associated static circuits.
All relays shall be designed for satisfactory performance under tropical and
humid conditions. Special mention shall be made in the technical deviations
schedule of the Bid for those relays, if any that Bidder proposes to use which
differ from specified requirements.
All devices required for correct operation of each relay shall be provided by
contractor without any extra cost.
It will be ensured that the terminals of the contacts of the relays are readily
brought out for connections as required in the final approved scheme. Type of
relay case size offered shall not create any restriction on availability of the
contact terminals for wiring connections.
DC/DC converter or power supply unit shall be provided for the solid state
protective relay wherever necessary in order to provide a stable auxiliary
supply for relay operation.
Solid state relays shall be stable and suitably protected against
transient/induced over voltages and noise signals. Bidders shall state
clearly in their Tenders, special requirements if any for DC input
arrangement or cabling considered necessary for satisfactory operation of
solid state relays quoted by him.
Timers shall be of the solid state type. Short time delay in term of
milliseconds may be obtained by using copper lugs on auxiliary relays. In
such case it shall be ensured that the continuous rating of the relay is not
affected. Time delay in terms of milliseconds obtained using external
capacitor resistor combination is not preferred and shall be avoided to the
extent possible.
85
C & R Panels

12.12
In order to minimize effect of galvanic actions associated with electro chemical
effect, flag coils and DC relay operating coils shall be so placed in the circuit that these are
not connected to the positive pole of the battery except through contacts which are normally
open.
13.0
TESTS:
Manufacturer shall carry out type and routine tests on the relays and complete
panels as per relevant Indian Standards or any equivalent International Standards and as
specified hereunder.
13.1
ROUTINE AND ACCEPTANCE TESTS:
All modules and sub-assemblies shall be energized and tested for routine and
acceptance tests jointly carried out in presence of purchasers representative as per relevant
IEC Specifications or any other international standards individually as well as in assembled
form at the factory.
Relay and control panels shall be subjected to the following tests:
o Mechanical operation test.
o Verification of Degree of protection as per IS:2147
o High voltage test as per IS or IEC as may be applicable.
o Electrical control, Interlock and sequential operation tests.
o Verification of wiring as per approved schematic.
o Other routine tests on all associated equipment and relays as per relevant
Indian Standards or IEC.
13.2
13.3
After all tests have been carried out, 4 (four) copies of each test report/inspection
report shall be furnished. Each report shall supply the following information
i.
ii.
Complete identification data including serial number of all relays and their
routine test reports.
Routine test reports for all the panels.
13.4 Supply of equipment shall be subject to the approval of Test Certificates by

purchaser.
14.0
CONTROL CONNECTIONS AND INSTRUMENT WIRING:
14.1
Connections for switchgear operation and indications between the control and
relay panels where ever separate termination for instrument and relay wiring on these
control & relay panels and multicore cable terminal boxes are involved, these shall form
a portion of the scheme for panels and the cost shall be included in the price of the control
panels as stated by the Bidder.
14.2
Panels connection shall be insulated and securely fixed neatly to the back of the
panels. All instrument and panels wiring shall be fire retardant. All panels wiring shall be
taken to terminal panels which shall comply with requirements of multicore cable boxes
where applicable. Control panels wiring shall be PVC impregnated with flame proof
compound. Rubber insulation is not acceptable.
14.3
All wiring diagrams shall be clearly marked with the numbers which are shown on
the ferrules of the individual cores. 20% spare and blank ferrule shall be supplied with each
panel.
86
C & R Panels

14.4
Flat washers shall not be used but both end of each instrument or control wire shall
be properly crimped and terminated with a Rose Courtney or other sophisticated washer.
14.5
Each set of current & voltage transformer secondary connections shall be complete
in all respect and shall be connected to form common star point. Star point shall be earthed
at one point only. Each such earthing connection to the earth bar shall be made in
accordance with the requirement of the earthing system and shall be made through a
disconnecting link of approved design which can be removed when insulation tests are
required without breaking any circuit normally carrying current.
14.6
For each circuit on the panels, the control indication and trip wiring shall be suitably
segregated so that these could be isolated to permit testing or other work. Semaphore and
other indication circuits shall be connected to the DC bus by a set of fuses. Similarly, the
trip and close circuits shall also be connected by a separate set of fuses. Fuses shall be
labeled clearly showing the circuits connected.
All secondary fuses shall be of an approved type. HRC fuses of standard make shall only be
used. Where ever specified test blocks shall be provided for testing of meters and relays.
These shall be of the switchboard type with connection at the back, mounted on front of
panels. Test blocks shall provide complete isolation of meters, instruments and relays and
the arrangements shall be such that power supply for testing could be connected at the test
block from the external source or may be taken from the instrument transformer. Provision
shall be made for short circuiting current transformer secondary and disconnection of
potential transformer, by sliding and disconnecting type connectors.
15.0
PRETREATMENT AND PAINTING PROCESS:
Sheet steel fabricated members shall be subjected to pretreatment process before

painting and process can be broadly divided as `Metal treatment and painting.
15.1
METAL TREATMENT:
Degreasing: This can be achieved either immersing in hot alkaline degreasing bath or in hot
di-chloroethelene solution. After degreasing operation the surface shall be cleaned
thoroughly with cold water.
Pickling : This is to remove rust and metal scales by immersing metal sheets in dilute
sulphuric acid (approximately 20%) at nearly 60 deg. centigrade so as to totally remove
scale and rust.
o
o
o
o
o
o
o
15.2
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.
Phosphating Immerse in grenadine zinc phosphate solution for about 20 minutes at
80 to 90 degree centigrade . Uniform phosphate coating of 4 to 5 gm per sq. meter
shall be achieved.
Swill in cold water.
Rinse in Deorylyte bath at 70 to 80 degree centigrade to neutralize any traces of
salts.
Seal the above phosphate coating with hot/dilute chromate solution.
Dry with compressed air
PAINTING:
87
C & R Panels

Primer spray: One coat on wet surface by specially developed `High luster' zinc
chromate primer and to stove at 150-160 deg. Centigrade for 25 to 30 minutes.
Alternatively red-oxide primer with zinc chromate contents may be used. However former
process shall be preferred.
Rubbing and putting : Apply putty to fill up the scars if any to present smooth surface and
stove 15 to 20 minutes. Apply putty several times to get the perfect smooth finish.
Surfacing:
Primer:
Finish paint:
Surfacing:
NOTE : i
ii
iii
Sand down with mechanical abrasive and stove for 20 minutes.

Spray second coat of primer as per (i) above or grey primer surface on
wet and stove for 20 to 40 minutes at 150 deg. centigrade.
Rubbing down dry and spray first coat of synthetic enamel finish paint
on wet and stove for 30 minutes.
Sand down or rub dry to prepare for final finish spray. Coats of
synthetic enamel finish paint on wet and stove it at 150 deg. centigrade
for 30 minutes.
Necessary stiffeners may be welded between large cut ducts to provide
rigidity before painting process.
Painting process shall be done within 24 hrs. of completion of treatment.
Small coating paint shall be supplied along with equipment for touching up
at site.
16.0
DRAWING AND LITERATURE:
16.1
G.A. drawings for each type of panels shall be submitted with the Bid.
16.2
As soon as possible after the award of contract the manufacture shall submit GA
and Schematic drawings of each panel for the approval of purchaser.
16.3
Successful Bidders shall have to supply four sets each containing of approved GA,
Schematic and wiring drawings illustrative pamphlets, literature, operation and maintenance
instructions of the relay/panels under his scope of supply.
17.0 GUARANTEED TECHNICAL PARTICULARS :
Guaranteed technical particulars for all relays, instruments, meters and all other
accessories shall be furnished along with the Bid. While submitting technical particulars,
please ensure to stipulate very clearly the class of accuracy, (wherever necessary), current
and voltage rating, physical dimensions, weight, make, model No., type etc. in order to give
a clear picture of device offered, along with literature/write-up. All 220KV C&R panels
shall be suitable for 110 V DC as per our requirement.
18.0
OTHER IMPORTANT REQUIREMENT:
18.1
The Quality Assurance Programme of this specification shall be as per

Volume-II, Part-2, Book-I.
18.2.0
INSPECTION:
18.2.1 Bidders shall chalk out a detailed inspection and testing program for manufacturing
activities for the various components. Purchaser reserves the right to get carried out any
tests by a third party. All Cost of inspection/tests shall be borne by the Bidder. No material
88
C & R Panels

shall be despatched from its point of manufacture unless the material has been satisfactorily
inspected and tested.
18.2.2 Acceptance of any quantity of panels/material shall in no way relieve the successful
Bidder of his responsibility for meeting all the requirement of this specification and shall not
prevent subsequent rejection if such equipments are later found to be defective.
18.2.3 At the time of inspection, Bidders shall identify each and every item/accessories.
Unless all the items are identified, manufacture will not be treated as complete. Serial
number of Relays & other accessories shall be entered into the test report. Various tests
stipulated in IS shall be performed in the presence of purchasers engineers or when the
inspection waiver has been given, in such a case, the testing shall be done at the
manufacturer's works as per IS stipulations and same should be confirmed by
documentary evidence by way of Test Certificate which shall be got approved by the
purchaser.
18.2.4 Whenever inspection call is given, the letter of inspection call will accompany the
following:
a.
List of various panels and loose relays which are ready at the works and will be
offered for inspection. Inspecting Officer will carry the list and check the items
declared to have been offered for inspection.
b.
It is expected that before any equipment is offered for inspection, internal testing of
the same for various important parameters are already done. Routine test report
for such tests shall also accompany with the letter of inspection call.
c.
In case for any reasons inspection is not completed or equipment is not found
complete with all accessories, the Purchaser will reserve the right to recover the
complete cost of deputation of inspecting team to the works of the manufacturer.
19.0
Responsibility for obtaining timely supplies of bought out items will rest on the
Bidder and only on this basis, delivery period will be offered in the Bid. For bought out items,
responsibility for guarantee and obtaining immediate replacement in case any defects are
noticed and in case defective supply of any item is reported will rest on the Bidder. In case
for attending to defect in any accessory or inspection/ replacement of the accessory, which
may be bought out item for the Bidder; services of engineer of original manufacturer is
required, the same will be organized on immediate basis by the Bidder at his cost.
Bidders may ensure that Bid document containing number of pages have been properly
page numbered and signed by the Bidder. All Bid documents including schedules should be
indexed properly and Index of the document should be enclosed/placed at the beginning of
the Bid document.
20.0
A.
SCHEDULE OF REQUIREMENT:
220 KV CONTROL & RELAY PANELS:
220KV Simplex type Control and relay panels shall have following instruments,
relays and accessories to be provided per circuit on each feeder, transformer, TBC and Bustie panels as per the type of protection indicated above under clause-8.1 by the purchaser:
S.
No.
PARTICULARS
TYPE-A
220KV
Line
89
TYPE-D
TYPE-C
TYPE-B
160MVA Xmer 220KV TBC 220KV Bus
Tie
Panel
(220KV Side)
C & R Panels

S.
No.
PARTICULARS
I
1
2
CONTROL PANEL
Type of panels
Box type circuit label inscription
(50x100mm) indicating Name of
feeder/Transformer in side & out
side of panels
Purchasers order no.,
Serial
no.& Tenderers label
Over laid Mimic diagram with
uniform 3mm thickness &10mm
width for horizontal strip & 6mm
strip for droppers.
Red and Green lamps(LED type)
with holder for circuit breaker
ON/OFF position indication for
each Transformer/feeder circuit.
Pistol grip Circuit breaker control
switch with three positions; ON,
OFF & return to neutral.
Semaphore to indicate circuit
breaker position automatically
Semaphore to indicate isolator
position automatically.
Multifunction meter to indicate
phase and line currents, phase &
line voltages, active power (MW),
reactive power (MVAR) & Power
factor. This meter shall have
scrolling facility to facilitate reading
any of these parameters. This
meter shall be of size 144 sq. mm
and it shall have a scale of 0 to
250KV
for
voltage
reading
(secondary rating 110V Phase to
phase and 1 Amp). The meter
shall have an accuracy of 0.5, the
digit size shall be 25 mm and it will
have LED display for the letters
Analog type center zero MVAR
meter
Facia
window
annunciator
complete with flasher and function
relays
Test plug/port for testing of Main
protection Relay complete with
connecting leads
Test terminal block for static
trivector meter
Static trivector Energy meter 3
phase 4 wire, having accuracy
class as 0.2s.
Push button for facia annunciator
testing of all lamps/accept/ reset
arrangement.
3
4
6
7
8
9(a)
9(b)
10
11
12
13
14
TYPE-A
220KV
Line
TYPE-B
TYPE-C
TYPE-D
(220KV Side)
Panel
Tie
Simplex
Two
Simplex
Two
Simplex
Two
Simplex
Two
One
One
One
One
Two Main And One Transfer Bus
One
Set
One
Set
One
Set
One
Set
One
One
One
One
One
One
One
One
Three
Three
Three
Two
One
One
One
One
One
One
One
One
18
WAYS
36 WAYS
18WAYS
12
WAYS
One
One
One
One
One
One
One
One
One
One
Three
Three
Three
Three
90
C & R Panels

S.
No.
PARTICULARS
15
Four-element hand reset auxiliary

relay to monitor circuit breaker
Parameters to display in facia
annunciator.
TYPE-A
220KV
Line
One
Two
Push button for main and
duplicate
DC
Supply
fail
test/accept/reset
Six
17
a) Trip circuit supervision healthy
indication lamp with push button
to select pre & post close
supervision
Three
b) Push button and indicating
lamp for pre closing supervision
of closing coil of CBs
One
18
Protection transfer switch with lock
as per clause
no. 11.3.4 for continuous display in
Facia annunciator
19
DC supply fail indication AC
Two
lamp.
One
20
Additional accessories such as
Set
pistol grip for carrier IN/OUT &
other
devices
required
for
completing the offered schemes.
II
RELAY PANEL
Two
21
Box type circuit label inscription
(50x100mm) indicating Name of
feeder/ transformer in side & out
side of panels
One
22
Numerical Distance protection
scheme
complete
with
all
modules & auxiliary relays etc. as
per clause 8.2.
23(a) Numerical transformer / reactor
differential
protection
relay
complete with all modules &
auxiliary relays as per clause 8.3
23(b) Numerical backup impedance
protection scheme complete with
all modules and auxiliary relays
as per cl.no.8.7.2
24
Pre & post close Trip circuit
Six
supervision relay *
25
DC supply healthy monitoring
Two
relay *
26
PT supply selection switch with
One
aux. relay
27
Numerical, Non directional, Non
One
Communicable 3 O/C + 1 E/F (Directional)
Relay. For feeders relay shall be
directional.
28 LBB relay (Tenderers may clarify if
One
(a) this is a built-in feature of
numerical distance/ differential
relay). **
(b)
Restricted earth fault relay
16
91
TYPE-B
TYPE-C
TYPE-D
(220KV Side)
Panel
Tie
One
One
One
Two
Two
Two
Six
Six
Six
Three
Three
Three
One
One
Two
Two
Two
One
Set
One
Set
One
Set
Two
Two
Two
One
ONE
Six
Six
Six
Two
Two
Two
One
One
One
One
One
One
One
One
C & R Panels

S.
No.
PARTICULARS
29
Separate LBB relay for bus tie

panel as per Cl.No. 9.3.1
30
Over fluxing relay complete with

timer etc.***
Hand reset auxiliary trip relay
with flag indication for :
i. Oil temp high trip
ii. Winding temp high trip
iii. Main buchholz trip
iv. OLTC oil surge relay trip
v. Pressure relief device trip
vi. Spare
Hand reset alarm relay with flag
indication for :
i. Oil temp high alarm
ii. Winding temp high alarm
iii. Main buchholz alarm
iv. OLTC oil surge
relay alarm
v. Pressure relief device alarm
vi. Spare
Overload relay, inform of a
definite time over current relay
with variable setting range from
50 to 200 % of relay current &
with a timer having setting range
of 2.5 to 25.0 sec. ****
High speed tripping relay for
master trip/inter-trip duty.
Non-directional three element
overcurrent relay for 33 KV
tertiary winding
Single element overcurrent relay
for circulating current protection
of tertiary winding
Differential protection for 25
MVAR reactor to be provided on
tertiary winding
Non-directional
two
element
overcurrent & one element
earthfault relay for 33KV reactor
31
32.
33.
34.
35.
36.
37.
38.
TYPE-A
220KV
Line
-
One
One
One
One
One
One
One
Additional
auxiliary
relays As Required
required for completing offered
protection schemes
III EQUIPMENT MOUNTED INSIDE
40
Space heaters with switch in
One
each panel.
One
41.
15/5A, 250Volts power socket
with protective metallic cover &
switch.
42.
20Watt Tube light with door
One
switch.
43.
40Watt incandescent or 15Watt
Two
39.
TYPE-B
TYPE-C
TYPE-D
(220KV Side)
Panel
Tie
One LBB
With 2 Nos.
Tripping
Relays
One
-
92
As Required
As Required As Required
One
One
One
One
One
One
One
One
One
Two
Two
Two
C & R Panels

S.
No.
44.
45.
46.
47.
48.
49
PARTICULARS
CFL lamp with switch.
DC bell for NON TRIP alarm
complete with accept, reset and
test facilities.
DC hooter for trip alarm complete
with accept, reset and test facility
AC
Bell
for
DC
supply
supervision.
Gland plate fitted with Cable
glands at the front & rear panel
Foundation bolts
Additional relays or accessories
offered by Tenderer, which are
essentially
required
for
completing protection scheme.
TYPE-A
220KV
Line
TYPE-B
TYPE-C
TYPE-D
(220KV Side)
Panel
Tie
One
One
One
One
One
One
One
One
One
One
One
One
One Set
One Set
One Set
One Set
One Set
One Set
One Set
One Set
One Set
One Set
One Set
One Set
For the purpose of confirmation to supply all items mentioned above, the Bidders shall
furnish an undertaking as per schedule XIII of volume-VI .
IMPORTANT NOTE:
i.
Bidders shall indicate Unit prices for all the gadgets and relays offered by them for
the 220 KV C&R panels. This has to be strictly complied. A Schedule for this purpose
is enclosed and this shall form a part of Schedule-I about details of equipment and
quantity for 220 KV C&R Panels.
ii.
Bidders may please refer Clause no. 9.1 and arrange to provide a separate two nos.
tripping relays having 8 NO contacts per circuit with bus tie panel. They shall keep a
provision for 8 such circuits to start with.
REMARKS: (i) Number of trip circuit supervision relays are based on two trip coils per pole
of the breaker i.e. six numbers for one breaker. Discrete relays shall be
offered in case of bus-tie panels. In case of feeder, transformer and TBC
panels, these relays shall be offered only if they do not form integral part of
the numerical distance or differential relays. Same analogy applies for DC
supply supervision relays also.
(ii) In case the LBB relay forms an integral part of the numerical distance as
well as differential relay then Bidders need not offer separate relays.
Bidders may clarify accordingly.
(iii) In case over fluxing relay forms an integral part of the numerical
differential relay, then Bidders need not offer a separate relay. This may
be clarified.
(iv) In case Òverload relay forms integral part of Xmer diff. relay,
separate (discrete) relay need not be offered.
then
(v) In case the restricted earth fault relay forms an integral part of the
numerical differential relay for 160 Xmer then Bidders need not offer
separate relays. Bidders may clarify accordingly.
93
C & R Panels
2.1.2 (B) TECHNICAL SPECIFICATION FOR 220KV BUS BAR PROTECTION

SCHEME
1.0
SCOPE:

means the MPPTCL.
2.0
FEATURES OF BUS BAR DIFFERENTIAL SCHEME
2.1
The offered Numerical, LOW IMPEDENCE, Centralized configurations bus bar
protection scheme shall be suitable for 1A secondary current, 110V secondary PT voltage,
50 Hz. Double bus bar with transfer bus and/or single bus bar with transfer bus arrangement
of the proposed EHV substations. The bus bar protection scheme shall be suitable for
following requirement:
1.
2.
3.
4.
5.
6.
7.
8.
9.
The Numerical, Low Impedance, Centralized configuration type with biased

differential characteristics, should have operative and restraint characteristics
suitable for 110V DC Aux. Supply with variation of minus 20% and plus 10%. The
automatic selection facility for DC voltage shall be provided in the scheme to make it
suitable for selection of 110V DC voltage as per our requirement. Therefore provision
of autoselection of DC auxiliary supply voltage need be made in C&R panels for
Busbar protection.
The offered scheme shall be suitable to ensure the isolation of the faulty zone, stable
during through fault and shall be backed up by check zone and end zone protection.
The scheme shall have maximum operating time up to trip impulse to trip relay for all
types of faults not more than 20 milli seconds.
The scheme shall have operating selectivity for each bus bar, and shall also have
dynamic zone selection through isolator replica without the use of external CT
switching relays. It shall be possible to isolate any particular bay or zone of the
busbar protection scheme during the maintenance activity without affecting the
protection of the complete scheme. The scheme shall be highly stable for external
fault.
It shall give hundred percent security up to 40KA fault level.
The scheme shall have continuous supervision for CT secondary against any
possible open circuit and CT saturation and if it occurs, shall render the relevant zone
of protection inoperative and initiate an alarm.
The scheme shall be of phase segregated and triple pole, not give false operation
during normal load flow in bus bars and incorporate clear zone indication.
The scheme shall have independent zones of protection. The scheme shall
annunciate all faults events and monitoring status on the 24 window annunciator.
However, adequate number of windows shall be provided to fulfill scheme
requirement.
The scheme shall include necessary CT switching through relay software or through
isolator contact/replica directly without using external CT switching relays.
94
C & R Panels

10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
The scheme shall include individual high speed hand reset tripping relay for each
feeder.
The scheme shall ensure that all configuration and logic are realized in the relay
software. The dynamic replicas shall be provided to show bus bar linking as desired
by the system.
The scheme shall include logic to monitor open/close operations of all the isolators of
the substation. For bus bar protection scheme status of isolators through auxiliary
contacts from yard upto C&R panels may not be available at no. of substations
because of old installation. Hence to sort out this problem, replica of isolators of
switchyard for each bay and for all zone of protection shall be required with offered
scheme. Therefore, adequate no. of switches for isolators position may be provided
in Bus bar protection panel itself.
The scheme shall have adequate number of independent settings groups
The scheme should be transient free in operation.
The scheme should include continuous DC supplies supervision for alarm and trip
circuits.
The scheme shall include protection IN/OUT switch for each zone with alarm and
window on annunciation indication.
The scheme shall have disturbance recorder, event logger etc. i.e complete in all
respect
The busbar protection scheme shall have atleast two communication port. It shall
have one no. independent front Ethernet port RJ45/ RS-232/LAN port for local
communication for relay setting, modifications,
extraction and analysis of
fault/event/disturbance records from laptop and a rear fiber optic port on IEC-61850
standard for remote communication to SCADA system. In addition the scheme shall
have capability for accurate time synchronization with GPS clock through (IRIG-B
port/PPM/SNTP). The scheme should confirm to atleast following requirements of
IEC-61850 and necessary certificates shall be furnished for the compliance.
a) Basic Data Exchange
b) Data Sets
c) Un buffered reporting
d) Generic Object Oriented substation events
e) Time synchronization
f) File transfer.
The scheme shall have continuous comprehensive self diagnostic feature to monitor
the healthiness of the all hardware and software elements of the relay. Any failure
detected shall be annunciated.
The scheme shall be a complete package in all respects including all softwares,
hardwares etc. all auxiliary relays, individual high speed hand reset tripping relays
for each feeder, indication lamps, etc. if required.
The scheme shall ensure that No region within the bus bar zone should be left
unprotected by the offered bus bar scheme. Fault between isolator and CT in bus
coupler section should be detected by the bus bar scheme.
The scheme shall include necessary software for CT ratio correction No ICT etc.
shall be allowed to be used.
There shall be provision of one No.24 point Annunciations to accommodate all
annunciations related to the scheme. The scheme should have at least 8 nos.
LEDs for fault indication.
Bidders may incorporate additional check zone with a view to obtain greater degree
of stability.
It shall include continuous supervision of each DC supply separately.
Test Terminal Block shall be fully enclosed with removable covers and shall be made
of moulded, non-inflammable good quality material with boxes barriers moulded
integrally.
95
C & R Panels

27. The offered control panel and protective scheme shall be expandable beyond the
present scope of existing feeders, transformers and buses as per single line diagram
enclosed with the Bid documents. Over and above this, provision of expanding
minimum 6 nos. bays in future shall be available. This requirement is very specific
and shall be noted carefully.
28. The existing CTs shall be 5 core. These CTs shall be used bus differential protection
scheme. At some places independent core for bus differential protection scheme
may not be available because existing core may be in use with other protection. For
such cases, CT in and out connections for 3 phases and one neutral shall be
required. Hence, the scheme should be suitable to receive three phase and neutral
of CT for in & out connection for each CT. It means internal neutral formation shall
not be acceptable. May please note that disconnecting type connector for CTs
connections shall only be acceptable.
29. The scheme should not trip for the differential current below the load current of
heaviest loaded feeder. This feature should be provided with enable/disable option.
30. The scheme shall provide on the unit and should be accessible for checking of the
menu, setting and DR etc. at least in the following ways.
a) HMI on the front of the relay. The busbar protection scheme shall have a
large HMI in the front capable of displaying bay currents and all calculated
differential currents etc.
b) The relay should display the menu, setting, DR & ER etc. through
the
keyboard provided on the front of the relay.
c) The scheme should have RS 232/LAN port on the front of the panel for
accessing by using personal computer to go through the Menu. Setting
measurements and Disturbance records and dynamic busbar replica etc.
This may be on the propriety Protocol. The associated softwares shall be
supplied alongwith the relay.
d) It should be provided with suitable port so that all the relays in the system
could be brought on the common bus and connected to a common computer
available in the substation for communication for accessibility of menu,
Disturbance records, event record and busbar replica etc.
31. The offered numerical relay should have in-built breaker failure for each CT input with
the operating and resetting time not more than 20 m.secs. The relay shall have
adjustable time delay of 100 to 500 ms with tripping time delay of relay not more than
20 milli secs.
In existing substations, all necessary co-ordination /inter-connections between
existing schemes/feeder panels shall be fully covered in the scope of the Bidder. Auxiliary
relays, trip relays, flag relays, switches etc. if required to facilitate the operation of the
scheme detailed in this Bid shall be fully covered in the scope of the Bidder/offer.
The cables required for the scheme shall be supplied/ laid by MPPTCL and
commissioning of panels shall be done under the supervision of the service engineer of
the supplier.
2.2
WEATHER PROOF RELAY PANELS:

a) This panel shall include necessary number of electrically reset relays each with at
least eight contacts for isolator auxiliary contracts multiplication and for changing the
CT and DC circuits to relevant zones of bus bar protection.
b) The panel shall be sheet steel enclosed and shall be dust, weather and vermin proof.
Sheet steel used shall be at least 2.0 mm thick and properly braced to prevent
wobbling
96
C & R Panels

c) The enclosures of the panel shall provide a degree of protection of not less than IP55 (as per IS: 2147).
d) The panel shall be free standing floor mounting type or pedestal mounting type as
per requirement.
e) The panel shall be provided with double hinged doors with padlocking arrangement.
f) All doors, removable covers and panels shall be gasketed all around with synthetic
rubber gaskets Neoprene/EPDM generally conforming with provision of IS 11149.
However, XLPE gaskets can also be used for fixing protective glass doors.
Ventilating louvers, if provided shall have screens and filters. The screens shall be
made of either brass or GI wire mesh.
g) Cable entries shall be from bottom. Suitable removable cable gland plate shall be
provided on the cabinet for this purpose.
h) All sheet steel work shall be digressed, picked, phosphated and then applied with two
coats of zinc chromates primer and two coats of finishing systematic enamel paint,
both inside and outside. The colour of the finishing paint shall be light grey in
accordance with shade no. 697 of IS.5.
i)
j)
Suitable heaters shall be mounted in the panel to prevent condensation. Heaters

shall be controlled by thermostats so that the cubicle temperature does not exceed
30oC. On-off switch and fuse shall be provided. Heater shall be suitable for 240V
AC supply voltage.
The test terminal blocks (TTB) to be provided shall be fully enclosed with removable
covers and made of moulded, non-inflammable plastic material with boxes and
barriers moulded integrally. All terminals shall be clearly marked with identification
numbers or letters to facilitate connection to external wiring. Terminal block shall
have shorting.
3.0. REQUIREMENT: The requirement of 220kV panel for bus bar protection scheme shall
be strictly as per price schedule enclosed with the bid document. Bidders may please note
that 220kV simplex design with front door opening and rear blocked panels shall be
preferred. May please also note that although in some of the 220KV Substations at present
there is provision of main -I and transfer bus. However all these substations will be
augmented having provision of main bus - II also in near future. As such, Bidders are
requested to offer the bus differential scheme suitable for main-I + main-II and transfer bus
arrangement with in-dependent zone of protection.
4.0
LIMITS OF CONTRACT:
4.1
It is not the intent to specify completely here all the details of design and construction
of the control and relay panels. However, the C&R panels shall conform in all respects to the
high standard of engineering design and workmanship. Various control and relay panels and
panels, earthing terminals, indicating lamps, mimic diagram, annunciator, name plate,
satisfactory operation . Such components shall be deemed to be within the scope of supply
of the Bidder irrespective of whether these are specifically brought out in this specification or
not.
4.2
that may be specified, shall however be included in the offered price. These shall be subject
to approval of purchaser. It is the responsibility of Bidder to ensure that the equipment
97
C & R Panels

Bidder may provide panels with larger dimensions in width only.
5.0
6.0
7.0
PANEL FINISH AND COLOUR:
SIMPLEX panels shall be dust, moisture and vermin proof.
All unfinished surface of steel panels and frame work shall be thoroughly cleaned
by sand blasting, pickling and rinsing or by combination of processes or by other
latest and improved techniques to remove dust, scales, foreign adhering matter
and grease. Cleaning process shall be followed immediately by the application of
rust inhibiting wash process. All control panels surfaces shall then be given
suitable rust resisting primary coat and then one or more coats of opaline green
quick drying enamel to serve as a base and binder for finishing coat.
As mentioned earlier, purchaser has standardised colour schemes for SIMPLEX

design 220 KV C&R panels which shall be opaline green as per colour shade
No. 275 of IS : 5 for 220 KV panels.
Purchaser will accept respective matching colour and shade equivalent to BS381 or any matching colour and shade of other authoritative equivalent standard.
Colour finish shall be applied as per above colour scheme on the exterior steel
works of the panels. Exterior painted surface shall not be fully glossy. Interior of
all panels shall be painted with Egg Shell White. Pretreatment & painting
process is described in Clause 14.0. All steel works shall be phosphated in
accordance with IS-6005. Panels shall be provided a degree of protection not
less than IP-54 as per IS-2147.

7.1
Applicable Standards for the offered equipments/items shall be as per Volume-II,
Part-2, Book-I.
7.2
In above table relevant Indian standard specification/IEC standards have been

mentioned. Equipments meeting any other authoritative standard, which ensures equal or
better quality than the standards, mentioned shall also be acceptable. Equipment for which
Indian Standards are not available, the relevant British standards and IEC recommendations
will be applicable. Please attach photocopy of all such standards according to which the
equipment has been offered.
7.3
TYPE TESTS:
The offered numerical bus-bar protection scheme as well as other

static/electromechanical relays and meters on C&R Panels offered by the Bidders shall be
fully type tested as per relevant standards. In case the equipment of the type and design
offered, has already been type tested, the Bidder shall invariably furnish type test reports
from the reputed and approved national/international laboratory/Government approved test
houses to prove that indicated accuracy and other specifications of the relays offered
conform to the relevant standards. Test certificates shall clearly indicate the type and model
number etc., so that relevant details of offered relays could be verified. While submitting
98
C & R Panels

offers the model and type etc., shall be clearly indicated. Type test reports so furnished
should not pertain to the period earlier than five years from the date of opening of Bid.
It may be very specifically` noted by Bidders that non-submission of type test reports about
numerical and conventional relays and also about static meters along with the Bid shall be
treated as a disqualification.
7.4.
DEVIATION FROM TECHNICAL PARTICULARS:
No deviation from technical particulars of equipments and material will be allowed,

which may please be noted.
7.5.

Constructional details & dimensions for 220 KV SIMPLEX type panels shall be as
under:S. No.
Title
220 kV PANELS
Type
Simplex design Control & Relay panel
Height (mm)
2312 (Panel 2210 + Base frame 102)
Depth (mm)
750 mm
Width (mm)
1000 mm
Base frame
Anticorrosive Black painted
Panel Exterior
7
8
9
Panel Interior
Mimic strips over laid type
Variation in dimension of
panels.
8.0
Opaline Green
Egg Shell white
Dark Brown
Bidder may note that the height and depth of control
panels will have to be maintained as mentioned against Sl.
No. 2&3 above. As far as width of the control panels is
concerned, this shall also be maintained as 1000 mm.
LIGHTING:
In each SIMPLEX panel, one 20 W, 230V AC tube light guarded with protected
cage shall be provided inside the central roofed access for adequate illumination & the same
shall be controlled by a door switch. Two incandescent 40 Watt (or15W CFL) 230 Volt lamps
with switch housed in protective cage, one each on the front & rear side of the panels shall
be provided under the central roofed access.
One number 15A, 3 pin receiptable universal socket with switch shall be provided
in each simplex control panels. Third pin of the socket shall be effectively grounded through
the metallic structure. Socket shall be industrial grade control panels type complete with
9.0.
AUXILIARY SUPPLY:
The auxiliary AC and DC supply shall be as per clause No. 6 Volume-II, Part-2,
Book-I.
10.0
CONTROL WIRING:
10.1
Successful Bidders shall furnish and install complete wiring up to the terminal block
for the equipment, instrument
devices mounted
in
the control panels strictly in
99
C & R Panels

accordance with the approved wiring diagram prepared by the Bidder based on the
purchaser's information and schematic diagram.
10.2
Wiring shall be completed in all respects so as to ensure proper functioning of
10.3
terminal blocks.
10.4
Wiring shall be done with flexible heat resistant control panels wires, PVC insulated
with stranded copper conductor. Minimum number of strand in the wire shall be three. The
conductor size shall be equivalent to 2.5 mm square minimum for Current, potential & DC
Control circuit and 1.5mm sq minimum for other indications and annunciation circuits.
10.5
Coloured cores shall be used for wiring as per latest revision of IS-375 viz; red
yellow blue and black for R Y B phases and neutral respectively. Colour code for earthing
shall be Green, and for annunciation circuits gray colour code shall be used. For DC circuits
10.6
coding schemes.
10.7
10.8
10.9
10.10
DC trip and DC voltage supplies and wiring to main protective gear shall be
10.11
Since a number of wires will run from one point to another, it is desired that the
10.12
Blank plastic channels should be provided by the sides of the panels to
10.13
Wherever practicable wiring shall be accommodated in the sidewall of the cubicles.
11.0
TERMINAL BLOCKS:
11.1
Multi-way terminal blocks complete with necessary binding screws and washers for
100
C & R Panels

2x7/0.737mm stranded copper conductor or equivalent aluminum conductor wires per
11.2
Terminal blocks shall have shorting and disconnection facilities ,so that the Board
side and outgoing wires could be disconnected just by opening the disconnecting links
which slides up or down without dislodging the wires from their position. The
technical specification for these blocks shall conform to latest IEC 60947-7-1 as mentioned
hereunder The screw terminal block shall be manufactured as per IEC-60947-7-1. The
insulating material of Terminal Block shall be of polyamide 6.6 meeting VO / V2
inflammability class as per UL 94. All metal parts including screws shall be copper alloy.
The terminal shall be suitable for mounting on both DIN as well as G type rail. All the
metal parts shall be captive and touch proof. The terminal block shall have screw locking
design so that it can be stand vibration level upto 5g and also prevent accidental loosening
of conductors.
Non-disconnecting and disconnecting type terminal connectors shall be made of
polyamide and shall be preferably of ELMEX make having type designations KBTM4 and
KLTDM4 respectively.
11.3
11.4
input wires.
11.5
11.6
Each terminal point shall be marked with designation obtained from the purchaser's
schematic drawings.
11.7
without difficulty.
11.8
12.0
CABLE ENTRY:
12.1
All panels shall have provision of multiple cable entries from the bottom. Necessary
cable glands should also be provided in the rear & front side of panels on a 4 mm thick mild
steel gland plate to be bolted firmly with nut and bolts on base plate. Base plate shall be
bolted further on the base frame with adequate number of nuts & bolts as may be necessary
to allow free working space for cable connections and to facilitate its opening. Base plate
shall be in 3 pieces for Simplex panels and one piece for simplex panels with proper opening
for fixing gland plates. Thickness of these base plates shall not be less than 4 mm. Base
101
C & R Panels

plate provided on the base frame is to facilitate free working space and also to serve as a
cover for control cables laid in the trenches from front to rear side of the Simplex panels.
Purchaser will arrange for necessary floor opening below the panels to suit the cable trench
design of purchaser's requirement.
12.2
12.3
and doors shall be provided with gasket properly. Necessary glands as per clause- 4.8.5
12.4
12.5
Following quantities of cable glands with suitable blanking arrangement shall be
fitted on the gland plate that shall be fastened suitably at the bottom of each of the 400 &
220 kV Simplex panels respectively. Quantities of cable glands shall be provided at the
bottom of each panel as per breakup given below:
S.
No.
1.
2.
3.
4.
Cable gland suitable for

2 core 2.5 sq.mm
4 core 2.5 sq. mm
4 core 4 sq.mm (armoured cable)
12 core 2.5 sq.mm
Qty. of glands
for 220 KV S/s
8 nos.
8 nos.
-8 nos.
Bidders may please note that for control cables for 220 KV C&R shall be Unarmoured type.
Offered cable glands shall be suitable for unarmoured copper control cables accordingly.
Please note that above quantity of cable glands are tentative and if required same will be
revised as per scheme requirement.
13.0
GROUNDING:
Bidders may please note that all existing panels at our 220 KV substations have
been provided with 12.5 x 6mm copper grounding bus extending along the entire length of
the panels for the purpose of effective grounding of all metal parts. Simplex design panel for
bus bar scheme shall also be provided with a copper strip of size 12.5 x 6mm for the
purpose of grounding for all the proposed 220 KV substations also, the copper grounding
bus shall have a dimension of 12.5 x 6 mm.
14.0
ALARM SCHEME:
14.1 Automatic tripping of the circuit breaker due to operation of protective relays shall be
indicated by a common audible alarm. Offered alarm scheme shall be complete in all
relays and other accessories if any. With each panels one alarm scheme will be required.
14.2 DC SUPPLY SUPERVISION RELAY: Separate DC supply supervision relay, one
each for the main and duplicate 220/110 V DC supply system shall be provided for 220 KV
panels. Scheme shall be capable of monitoring failure of DC supply of the circuit to which it
is connected. It shall have adequate potential free contacts to meet out the requirement of
the scheme and also to meet the requirement for providing alarm and facia indication. The
scheme shall have a time delay on drop off of not less than 100 m.secs and be provided
102
C & R Panels

with operation indicator/flag. This relay shall sound AC 230 V heavy-duty bell with provision
for accept/reset and test facilities.
14.3
HIGH SPEED TRIPPING RELAYS:
Adequate number of High Speed Tripping Relays will be provided for extension of
tripping command from busbar protection scheme to the circuit breakers in each circuit. This
relay will have adequate no. of NO & NC contacts suitable for 110/220V DC voltage as per
offered scheme requirement. If needed no. of NO & NC contact may be increased based on
actual requirement as per scheme. This relay shall have following features:
a)
High speed operation
b)
High degree of mechanical stability
c)
Compact
15.0
15.1

o
o
o
o
o
o
Mechanical operation test.

Verification of Degree of protection as per IS:2147
High voltage test as per IS or IEC as may be applicable.
Electrical control, Interlock and sequential operation tests.
Verification of wiring as per approved schematic.
Other routine tests on all associated equipment and relays as per relevant
15.2
After all tests have been carried out, 4 (four) copies of each test report/inspection
report shall be furnished. Each report shall supply the following information
i.
ii.
purchaser.
16.0

painting and process can be broadly divided as `Metal treatment and painting.
16.1
METAL TREATMENT:
Degreasing: This can be achieved either immersing in hot alkaline degreasing bath or in hot
di-chloroethelene solution. After degreasing operation the surface shall be cleaned
thoroughly with cold water.
Pickling: This is to remove rust and metal scales by immersing metal sheets in dilute
sulphuric acid (approximately 20%) at nearly 60 deg. centigrade so as to totally remove
scale and rust. 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
103
C & R Panels

again wash with running water. Phosphating Immerse in grenadine zinc phosphate solution
for about 20 minutes at 80 to 90 degree centigrade. Uniform phosphate coating of 4 to 5 gm
per sq. meter shall be achieved. Swill in cold water. Rinse in Deorylyte bath at 70 to 80
degree centigrade to neutralize any traces of salts. Seal the above phosphate coating with
hot/dilute chromate solution. Dry with compressed air
16.2
PAINTING:
Primer spray: One coat on wet surface by specially developed `High luster' zinc
chromate primer and to stove at 150-160 deg. Centigrade for 25 to 30 minutes.
Alternatively red-oxide primer with zinc chromate contents may be used. However former
process shall be preferred.
Rubbing and putting : Apply putty to fill up the scars if any to present smooth surface and
stove 15 to 20 minutes. Apply putty several times to get the perfect
smooth finish.
Surfacing:
Sand down with mechanical abrasive and stove for 20 minutes.
Primer:
Spray second coat of primer as per (i) above or grey primer surface
on wet and stove for 20 to 40 minutes at 150 deg. centigrade.
Finish paint:
Rubbing down dry and spray first coat of synthetic enamel finish paint
Surfacing:
Sand down or rub dry to prepare for final finish spray. Coats of
synthetic enamel finish paint on wet and stove it at 150 deg.
centigrade for 30 minutes.
NOTE : i

Small coating paint shall be supplied along with equipment for touching up
at site.
ii
iii
17.0
17.1
G.A. drawings for each type of panels shall be submitted with the Bid.
17.2
As soon as possible after the award of contract the manufacture shall submit GA
and Schematic drawings of each panel for the approval of purchaser.
17.3
Successful Bidders shall have to supply four sets each containing of approved GA,
Schematic and wiring drawings illustrative pamphlets, literature, operation and maintenance
instructions of the relay/panels under his scope of supply.
18.0
GUARANTEED TECHNICAL PARTICULARS :
accessories shall be furnished along with the Bid. While submitting technical particulars,
and voltage rating, physical dimensions, weight, make, model No., type etc. in order to give
a clear picture of device offered, along with literature/write-up. All 220KV C&R panels
shall be suitable for 110 V DC or 220V DC as per our requirement.
104
C & R Panels
19.0
19.1
The Quality Assurance Programme of this specification shall be as per

19.2
INSPECTION:
19.2.2 Acceptance of any quantity of panels/material shall in no way relieve the successful
19.2.3 At the time of inspection, Bidders shall identify each and every item/accessories.
Unless all the items are identified, manufacture will not be treated as complete. Serial
purchaser.
following:
a.
List of various panels and loose relays which are ready at the works and will be
declared to have been offered for inspection.
b.
It is expected that before any equipment is offered for inspection, internal testing of
the same for various important parameters are already done. Routine test report for
such tests shall also accompany with the letter of inspection call.
c.
20.0
Responsibility for obtaining timely supplies of bought out items will rest on the
Bidder and only on this basis, delivery period will be offered in the Bid. For bought out items,
Bidders may ensure that Bid document containing number of pages have been properly
page numbered and signed by the Bidder. All Bid documents including schedules should be
105
C & R Panels

indexed properly and Index of the document should be enclosed/placed at the beginning of
the Bid document.
MISCELLANEOUS ACCESSORIES :
21.0
i.
Plug point
240V, single phase, 50 Hz AC socket with switch cubicle to accept 5 Amps
and 15 Amps pin round standard Indian plug shall be provided in the interior
of the panel.
ii.
Interior lighting Panel shall be provided with a fluorescent lighting fixture suitable for 240V,
single phase, 50 Hz AC supply.
iii.
Switches and fuses

Busbar protection panel shall be provided with necessary arrangements for
receiving, distributing and isolating DC and AC supplies.
iv.
Space heater
Panel shall be provided with a space heater rated for 240V, single phase, 50
Hz supply for internal heating of the panel to prevent condensation of
moisture.
106
C & R Panels
APPENDIX-B1
DRAWINGS
S.No.
Description
Elevation Drawing for 220KV Control & Relay Panel
General Arrangement Drawing for 220KV Control & Relay

Panel
107
C & R Panels
2210
CL
ANN.
IL 3
PB 1
MFM
2
2
220KV MAIN BUS -1
1105
1055
1005
220KV MAIN BUS -2

220KV TRANSFER BUS
29 S2
29 S3
29 S4
52 S1
52CS
TTS
29 S5
21
86
300
30
ABCD
86 LBB
TTB
50/51 N
RTB
0
102
100
850
100
1000
ELEVATION
DRAWING NUMBERJICA/MPPTCL/TR-101 TO 107/ EL 220KV CRP
108
C & R Panels
102
HINGES
CL
2
3
4
4
FRONT DOOR
PROVIDED WITH
GLASS COVER
2210
102
750
END VIEW
MPPTCL'S STANDARD DESIGN
MFM
MVAR
220KV MAIN BUS -1

220KV MAIN BUS -2
50/51 N
TTS
29 S4
220KV TRANSFER BUS
220KV SIMPLEX TYPE CONTROL & RELAY PANEL AS PER
52 S1
29 S3
29 S5
30
ABCD
RTB
FRONT SWING DOOR WITH RELAYS FLUSH

MOUNTED. REAR BLOCKED.
29 S2
PB 1
IL 3
ANN.
86 LBB
52CS
21
86
TTB
3D VIEW
Multi Function Meter of

accuracy class 0.5
MVAr Meter
Trivector Meter of
accuracy class 0.2S
Breaker Control Switch
Trip Transfer Switch
Semaphores
Indicating lamps
Push buttons
PT Selection switch
Distance Protection Relay
Back-up Relay
Tripping Relay
Tripping Relay for LBB
TCS & DC Supervision
Relays Considered
Built-in DPR (21).
Aux. Relay for Breaker
3.0/ 2.5mm.
Eggshell White
Opaline Green
Subject to approval
Overlaid Type
12.5x6mm. Copper Based
Double Compression
220KV PANEL DETAILS
Sheet Metal Thickness

Colour Inside
Colour Outside
Colour of Mimic
Mimic Strip
Earth Bus Size
Brass Cable Glands
Type
MFM
MVAR
TVM
52CS
TTS
29 S1 TO S5
IL
PB
VTS
21
50/51N
86
86 LBB
195, 295, 80 ABC
30 ABCD
CONSTRUCTION :
PANELS WILL BE OF FREE STANDING UNITISED CONSTRUCTION WITH
MEMBERS FOLDED & BOLTED
LOAD BEARING MEMBERS (FRONT PANEL, BASE FRAME, DOOR
FRAME) WILL BE 3 MM THICK
NON-LOAD BEARING MEMEBERS (SIDE PANEL, CUBICLE ROOF, DOOR)
WILL BE 2MM THICK
CUBICLE BOTTOM WILL BE CLOSED AND HAVE CABLE SLOTS
COVERED BY DETACHABLE PLATES
DOOR WILL BE PROVIDED AT THE BACK WITH FLUSH TYPE LOCK
ARRANGEMENT
WEIGHT OF 1 CONTROL & RELAY PANEL WILL BE 600 KGS(APPROX.)
PANELS WILL COMPLY WITH INGRESS PROTECTION DEGREE IP54 AS
PER IS 2147
ALL DOORS AND METAL JOINTS WILL BE PROVIDED WITH FOAM TYPE
GASKETS AS PER IS 13847
15mm THICK ANTI-VIBRATION PAD WILL BE PROVIDED AS LOOSE (TO
BE FIXED BELOW PANEL BASE FRAME)
RELAY PANELS WILL BE RACK MOUNTING (FRAME) TYPE WITH
PERSPEX DOOR IN THE FRONT
WIDTH OF THE PANEL SHALL BE RETAINED AS 1000MM (can be adjusted
as per requirement of layout of Relays)
ALL DIMENSIONS ARE IN MM.

NOT TO SCALE.
DRG. No:- JICA/MPPTCL/TR-101- 107/ GA 220KV CRP
C & R Panels
109
2210
M. P. POWER TRANSMISSION Co. LTD. JABALPUR
2312
SCHEDULE-I(A)
DESCRIPTION OF EQUIPMENT INCLUDED IN THE PRICE SCHEDULE
FOR RATES AND PRICES TO BE FURNISHED IN VOLUME-VI
S.No.
A
1
3
4
5
Prices for 220KV C&R Panels

220 KV Simplex type C&R Panels for protection of 220KV feeder circuit complete with all relays
& accessories as described in the specification
220 KV Simplex type C&R Panels for 220KV Transfer bus coupler applications complete with
all relays & accessories as described in the specification
220 KV Simplex type C&R Panels for bus tie application complete with all relays & accessories
as described in the specification
220 KV Simplex type C&R Panels for 220/132/33 KV 160 MVA transformer with all relays &
accessories as described in the specification
220 KV Simplex type C&R Panels for busbar protection of 220 KV switchyards complete with
all relays & accessories as described under clause 2.0 of 2.1.2 (B). The number bays for
220KV substations shall be (14+6 addl.) i.e total 20 nos. bays
NOTE:
1.
The above description of the equipment is given for the purpose of offering the prices and to
2.
The quantity of above equipments has been mentioned in Volume-VI.
3.
May please note that 220KV C&R panels for busbar protection scheme shall be suitable for
total 20 nos. bays irrespective of the Single Line Diagram for 220kV substations enclosed
with the bid document.
As per Price
Schedule
Qty.
Particulars of Item
110
C & R Panels
2.1.2 (C)TECHNICAL SPECIFICATION FOR 132KV CONTROL AND RELAY

PANELS
1.0
SCOPE:
The scope of this specification covers, design manufacturing and supply of equipment as per
Volume-II, Part-2, Book-I. The bidder mentioned in this Section of the Technical
Specification means Original Equipment Manufacturer (OEM). The purchaser means the
MPPTCL.
1.1
Protection schemes to be supplied under this Bid are required for following
applications:
TYPE - A
SIMPLEX TYPE Control & Relay Panels for 132 KV transmission lines.
TYPE - B
SIMPLEX TYPE Control & & Relay Panels for 132KV side of 63 & 40
MVA 132/33KV Power Transformers
TYPE C
SIMPLEX TYPE Control & Relay Panels for LV side 160MVA X-mer
TYPE - D
SIMPLEX TYPE Control & Relay Panels for 132 kV transfer bus
coupler bays.
2.0
LIMITS OF CONTRACT:
2.1 It is not the intent to specify completely here all the details of design and construction
of the control and relay panels. However, the equipment shall conform in all respects to the
high standard of engineering design and workmanship. Various control and relay panels
and other requirements specified under this section shall be complete in themselves in all
respect with all main and auxiliary relays, fuses, links & switches duly wired, labels
terminal boards, earthing terminals, indicating lamps, mimic diagram, annunciator, name
plate, foundation bolts, interior illumination, cable termination arrangement with cable
glands fitted on base mounting plate etc. including all other accessories which are
essentially required for satisfactory operation. Such components shall be deemed to be
within the scope of supply of the Bidders irrespective of whether these are specifically
brought out in this specification or not.
2.2
equipment is not covered under the specification. Cable terminating arrangements, viz. the
that may be specified, shall however be included in the offered price. These shall be
subject to approval of purchaser. It is the responsibility of Bidders to ensure that the
equipment specified and complimentary equipment required for completeness of the
protection/control scheme be properly accommodated in the panel without congestion and
if necessary provide panels with larger dimensions in width only.
3.0
The climatic condition shall be as per Volume-II, Part-2, Book-I of this bid.
111
C & R Panels

4.0
STANDARD SPECIFICATIONS:
4.1
132KV C&R panels shall match with MPPTCLs standard drawing, a copy of
which is enclosed.
4.2
PANEL FINISH AND COLOUR: 132KV SIMPLEX DESIGN PANELS:
132 KV C&R panels for all applications shall be of Simplex design and each panel
shall be constructed of stretched level selected sheet steel. Simplex type panels shall be
made in suitable sections so that while mounting the panels can be located side by side with
a view to form a compact unit. The 132 KV Simplex design panels shall have front door of
swing type and rear blocked with control gadgets and relays flush mounted.
4.2.1 132KV C&R panels of SIMPLEX design shall consist of a vertical front panel with all
equipment mounted thereon including the control gadgets and relays as shown in
MPPTCLs standard drawing. These panels shall have a front door of swing type as shown
in the drawing with rear portion blocked. The front swing type door shall have a
Transparent Protective unbreakable front Door cover to prevent deposition of dust on
the control gadgets and relays.
4.2.2 132KV C&R panels having swing type of front door shall be free standing unitized
construction with members folded and bolted. Other salient features shall be as follows
All doors and metal joints will be provided with foam type gaskets as per IS13847.
Dimensions of 132kV (C&R) panels shall be as stipulated in clause 4.4.2.

the Simplex design 132KV Control and Relay panels.
4.2.3
Other salient features applicable for 132 KV Simplex design panels -
132 KV SIMPLEX panels shall be dust, moisture and vermin proof.

All unfinished surfaces of steel panels and frame work shall be thoroughly cleaned by
sand blasting, pickling and rinsing or by combination of processes or by other latest and
improved techniques to remove dust, scales, foreign adhering matter and grease.
Cleaning process shall be followed immediately by the application of rust inhibiting wash
process. All control panels surfaces shall then be given suitable rust resisting primary
coat and then one or more coats of opaline green quick drying enamel to serve as a
base and binder for finishing coat.
As mentioned earlier, purchaser has standardised colour schemes for SIMPLEX design
132 KV C&R panels and these shall have opaline green colour as per shade No.275 of
IS: 5.
Exterior painted surface shall not be fully glossy. Interior of all panels shall be painted
with "Egg Shell White". Pretreatment & painting process is described in Clause 14.0. All
steel works shall be phosphated in accordance with IS-6005. Panels shall be provided a
degree of protection not less than IP- 54 as per IS-2147.
112
C & R Panels
4.3

WITH STANDARD SPECIFICATION:
Applicable standards for the offered equipment/items shall be as per Volume-II,

Part-2, Book-I.
4.3.1
In the paragraph 4.3 above relevant Indian standard /British standard / IEC standard
specification have been mentioned. However, the equipment meeting any other authoritative
international standard, which ensures equal or better quality than the standards, mentioned
shall also be acceptable. Equipment for which Indian Standards are not available, the
4.3.2
TYPE TEST:
All offered numerical distance and differential protection relays as well as other
static/electromechanical relays and meters on C&R Panels offered by the bidders and as
of the type and design offered, has already been type tested, the bidder shall invariably
furnish type test reports from the reputed and approved national/international
could be verified while submitting offers the model and type etc., shall be clearly indicated.
the date of opening of bid.
It may be very specifically noted by Bidders that non-submission of type test
reports about numerical and conventional relays and also about static meters along
with the bid shall be treated as a disqualification.
i.
ii.
iii.
iv
v.
4.3.4
Numerical distance protection relays

Numerical differential protection relay
Numerical, Non-directional / directional 3 O/C + 1 E/F Relay
Static trivector energy meter of accuracy Class 0.2S.
Multi function meter of accuracy Class 0.5.

4.4
4.4.1
As mentioned earlier, control and relay panels for 132 KV voltage class shall be of
Simplex design and shall strictly conform to MPPTCLs standard drawing. Further, as
clarified earlier, the 132KV C&R panel of Simplex design shall have a swing type front door
with a transparent unbreakable cover and rear portion blocked.
4.4.2 The constructional details and size of panels for 132KV voltage class shall strictly
comply to MPPTCLs standard drawing and as mentioned belowMPPTCL/ TECH/ PROC/ 05/ MAY13
113
C & R Panels
S.No.
1.
2.
3.
4.
5.
6.
7.
8.
Description
Type
Height
Depth
Width
Base frame
Panel exterior
Panel interior
MIMIC strips (Over laid
type)
132KV C&R panel

Simplex
2300 mm (panel height 2240 mm with base
frame as 60 mm)
750 mm
850 mm
Anti corrosive, black painted
Opaline green shade
Egg shell white shade
Blue grey shade
4.4.3 The purchaser has standardized dimensions of panels for various applications and
therefore no deviation in height / depth of panels in particular shall be permitted. The width
of the panels is however subject to change. Bidders may please note that preferred cut out
dimensions for mounting of control gadgets and relays shall be strictly inline with IS4483
(Part I & II).
4.4.4.
It is hereby clarified that standard drawings showing C&R panels for 132 KV
voltage class have been developed considering that the Numerical Distance / Differential
Protection relays offered by the bidders shall have the protection, recording and metering
functions listed elsewhere in the document, built in them. For example, relays type LBB, trip
circuit supervision and DC supply supervision, have been considered built in the DPR and
therefore has not been shown as discrete relays. Accordingly, bidders will have to offer
discrete relays for those functions which are not built in. This has to be noted specifically.
4.4.5. Simplex control and Relay panels shall be floor mounting front swing type door with
sheet steel assemblies of unitised design. Panels shall be made in suitable sections as
described else where in the specification so that while mounting, panels can be located side
by side bolted together to form a compact and composite unit. Design, material selection,
workmanship, and width of panels shall be such as to present a neat appearance, outside
and inside with no works of welds, rivets, screw or bolts head apparently visible from the
exterior surface of the control panels.
4.5.0
PANEL LIGHTING:
4.5.1 In each SIMPLEX control panel one 20W, 230V AC tube light guarded with protected
cage or alternatively CFL shall be provided inside the central roofed access for adequate
illumination & the same shall be controlled by a door switch. Two incandescent 40 Watt 230
Volt lamps with protective cage with switch one each on the front & rear side of the panel
shall be provided under the central roofed access.
4.5.2 One number Universal 15A/5A, 3 pin receiptable socket with plug and switch shall be
provided in each control panel. The third pin of the socket shall be effectively grounded
through the metallic structure. Socket shall be industrial grade control panel type complete
with protective metallic cover.
4.6.0 AUXILIARY SUPPLY
4.6.1
The auxiliary AC / DC supply shall be as per clause No. 6 of Volume II, Part-2,
Book-I of the specification.
114
C & R Panels

4.6.2 Bidders shall arrange to provide extension of these power supplies to different panels
of the control board group.
4.6.3
Isolating devices with H.R.C. fuses shall be provided in each panel for both A.C. and
D.C. power supplies. Distribution and wiring of the same shall be unitized through
fuses and links in such a way so that isolation of respective system unit is possible
without affecting the rest of the system or unit.
4.6.4
All H.R.C. fuses and links shall be with holder, and the same shall be mounted on
4.6.5
H.R.C. fuses shall be provided as per following details;

S. NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
CIRCUIT
Circuit breaker-closing circuit
Trip circuit -I
Trip circuit -II
Main Protection
Back up protection
Indication
Annunciation
P.T. Circuit main
A.C. Supply fuses and links
FUSE RATING
16A
16A
16A
10A
10A
6A
6A
6A
2A
10A
NOTE: Additional HRC fuses for individual circuit shall also be provided as per the
requirement for completing the offered protection scheme.
4.7.0 CONTROL WIRING 4.7.1 Successful Bidders shall furnish and install complete wiring up to the terminal block
for the equipment, instrument devices mounted in the control panel strictly in
accordance with the approved wiring diagram prepared by the Bidder based on the
purchaser's information and schematic diagram.
4.7.2 Wiring shall be complete in all respects so as to ensure proper functioning of control,
protection and metering schemes.
4.7.3 All spare relay contacts and spare contacts of switches shall be wired up to the
terminal blocks.
4.7.4 Wiring shall be done with flexible heat resistant switch board wires, PVC insulated
with stranded copper conductor. Conductor size shall be equivalent to 2.5 mm square
minimum for Current, potential & DC Control circuit and 1.5mm sq minimum for other
indications and annunciation circuits.
4.7.5 Coloured cores shall be used for wiring as per latest revision of IS-375 viz; red yellow
blue and black for R Y B phases and neutral respectively. Colour code for earthing shall be
Green, and for annunciation circuits gray colour code shall be used. For DC circuits the
colour code will be Red-positive & Black-negative.
4.7.6 Each wire shall be identified at its both ends with wire designation number by plastic
ferrule as per wiring diagram based on latest revision of IS-375 to denote the different circuit
functions. Bidders shall take approval for the system of wire numbering and colour coding
schemes.
4.7.7 All wire terminations shall be made with compression type connectors. Wires shall
115
C & R Panels

4.7.8 All series connected devices and equipment shall be wired up in sequence. Loop-in
4.7.9 Fuses and links shall be provided for isolation of individual circuit from bus bars
4.7.10 The DC trip and DC voltage supplies and wiring to main protective gear shall be
4.7.13 Wherever practicable wiring shall be accommodated in the side wall of the cubicles.
4.8.0
TERMINAL BLOCKS:
4.8.1 Multi-way terminal blocks complete with necessary binding screws and washers for
2x7/0.737mm stranded copper conductor or equivalent aluminium conductor wires per
4.8.2 Terminal blocks shall have shorting and disconnection facilities ,so that the Board
side and outgoing wires could be disconnected just by opening the disconnecting links which
slides up or down without dislodging the wires from their position.
4.8.3 Highly reliable Test terminal blocks with facilities of shorting and easy removal of
4.8.4 Test terminal blocks shall be grouped according to the circuit functions and each
input wires.
4.8.5 Not more than two wires shall be connected to any terminal or either side of the
terminal block If necessary, a number of terminals shall be connected by jumpers to provide
4.8.6 Each terminal point shall be marked with designation obtained from the purchaser's
schematic drawings.
4.8.7 Adjacent rows of terminal blocks shall be spaced not less than 100 mm apart. These
shall be mounted vertically at the sides of the cubicle and set obliquely towards the rear
116
C & R Panels

doors to give easy access to terminating end to enable ferrule number to be read without
difficulty.
4.8.8 Bottom of terminal blocks shall be spaced at least 200mm above the cable gland of
4.9.0
CABLE ENTRY:
4.9.1 Control Panel shall have provision of multiple cable entries from the bottom.
Necessary cable glands should also be provided on a 4 mm thick mild steel gland plate to be
bolted firmly with nut and bolts on base plate. Base plate shall be bolted further on the base
frame with adequate number of nuts & bolts. Purchaser will arrange for necessary floor
opening below the panels to suit the cable trench design of purchaser's requirement.
4.9.2 Wiring through the terminal blocks shall be located in a manner that it becomes
4.9.3 Gland plate shall be supplied duly drilled and fitted with cable glands. The gland plate
and doors shall be provided with gasket properly. Necessary glands as per clause 4.9.5
4.9.4 Rigid supports shall be provided along with terminal block for holding plastic channel.
Suitable clamps may also be provided in plastic channel for holding cables.
4.9.5
Following quantities of cable glands with suitable blanking arrangement shall be fitted
on the gland plate that shall be fastened suitably at the bottom of each panel :
S.
Particulars
Core
No
size
1 132kV feeder
2 132kV transformer panel for 2.5
sq.
63/40 MVA
mm
3 132KV C&R panels for
160MVA Xmer
4 132kV bus coupler
Cable glands for cable

19 core 12 core 8 core 4 core 2 core
2
2
4
8
5
3
3
4
8
6
2
4.10.0 GROUNDING:
4.10.1 12.5mm x 6mm copper strip grounding bus shall be provided for each control board
extending along with entire length of the board for the purpose of effectively grounding all
metal structures.
4.10.2 Each continuous length of ground bus shall have provision of two terminals at two
4.10.3 Common star /neutral point of Potential and current transformer shall be connected
with the grounding bus through a disconnecting type connector so as to adopt single point
grounding of common star point either at the terminal block in the control panel or in the
marshalling box of the instrument transformer.
4.10.4 Whenever any circuit is shown grounded on the drawing a single wire for that circuit
shall be run independently up to the ground bus and connected to it.
117
C & R Panels

5.0
CONTROL & RELAY PANELS:
As stated earlier, 132 KV Control & Relay panels shall be of Simplex design. Full
constructional details in respect of these panels, their colour scheme, details about the sheet
steel utilized for construction and about other constructional aspects, have been elaborated
in para no. 4.4. Bidders may please note that the 132KV C&R panels shall be utilized at
new as well as existing sub-stations, and in view of this, bidders will have to match these
panels with those already existing. The successful bidders shall be furnished details in this
regard.
5.1
Labelling for each circuit shall be provided on each control and relay panel.
5.2
Panels shall be of uniform thickness (minimum 2.5mm) and made of level sheet
steel. Bottom of the cubicle shall be made in a manner to open it for the purpose of wiring
and cable entry. Panels shall be designed to be of self-supporting type and wherever
additional structural strength is required, inconspicuous bracing, gusset, welding etc., shall
be used. All control panels and switchgear cubicles shall be made absolutely vermin proof
design of the approval of the purchaser.
5.3
Panels shall be made in suitable sections to facilitate easy transport and handling
and shall be later assembled at site. It may please be noted carefully that a single
continuous sheet steel should not be used for a substation to make a single board for all the
panels required. Panels should have unitised construction with facility to bolt together the
panels where more than one panel is involved.
5.4
Some of the Simplex control panel required for existing installation will have to be
matched with the existing panels in respect of colour shade, height, depth and width of
corridor. Details in this regard shall be furnished to successful Bidders.
6.0
CONTROL & INDICATION CIRCUITS:
6.1
Control and indication circuits for each circuit breaker controlling feeder, bus coupler
or transformer shall generally comprise of the following:
a.
b
c.
d.
e.
f.
g.
Mimic diagram
A composite meter to indicate current, voltage, Watts ,VARs and power factor.
"Trip Healthy" lamps.
Energy meter with display facility of various electrical quantities viz. voltages, MW,
MVA, MVAR, Line current, power factor etc.
h . Facia annunciating windows Semaphore indicators for CB & Isolators.
i.
Semaphore indicators for circuit breakers and isolators.
j. Selector Switch for isolator Semaphores
k. Test terminal block and Relay Test Block on the front panel for testing of meter and
relays as per specified scheme
l. Relay Test Block on rear side of Simplex panel as per scheme.
m. Any other devices which may be necessary for completing scheme based on
improvement in design and adoption of new technology by the Bidder.
118
C & R Panels

6.2
MIMIC DIAGRAM -
6.2.1 Coloured mimic diagram and symbols shall represent the exact representation of
system. Mimic diagram for 132KV and 33 KV systems shall be made to represent ONE
MAIN & TRANSFER BUS Scheme. Mimic diagram shall be placed at the eye level to
indicate the position of each breaker. Power transformer, voltage transformer shall be fixed
on mimic by suitable symbols having dark Black colour. Position indicator of isolating
devices shall have matching colour in accordance with the voltage class of the mimic.
Arrangement shall be of over laid design using anodized aluminum section. Painted type
mimic diagram is not acceptable.
6.2.2
6.3.
Offered mimic diagram shall have colour scheme for representing various voltage
levels as per the details indicated under:i
132KV Blue gray shade 695 of IS 5
ii
33 KV Azure blue shade 104 of IS 5
CIRCUIT BREAKER & ISOLATOR POSITION INDICATORS (EMAPHORES)
6.3.1. Position indicators of `SEMAPHORE' TYPE shall be provided as part of the mimic
diagrams on panels for indicating the position of circuit breakers. Indicator shall be suitable
for semi-flush mounting with only front disc projecting out and with terminal connection from
the rear. Colour of position indicator strips shall be matching with the colour of associated
mimic. Position indicators shall be suitable for DC operation. When the supervised object is
in the closed position, the pointer of the indicator shall take up a position in line with the
mimic busbars, and at right angles to them, when the object is in the open position. When
the supply failure to the indicator occurs, the pointer shall take up an intermediate position to
indicate the supply failure. Position indicators shall withstand 120% of rated voltage on
continuous basis.
6.3.2.
For 132 kV isolators, selector switch for manual selection of semaphore
position indicators shall be provided for displaying matching position of isolators in
the switchyard. These selection switches shall have two way selections and shall be
mounted near to respective semaphore for isolators.
7.0
ANNUNCIATION SYSTEM:
7.1
Alarm annunciation system shall be provided for each panel by means of visual and
audible alarm in order to draw the attention of the operating staff to the abnormal operating
conditions or the operation of some protective device. Annunciation equipment shall be
suitable for operation under the tolerance limit of voltages specified in this specification.
7.2 Annunciation shall be of visual and audible type. Facia annunciator, flush mounted on
the front of the control panel, shall provide the visual annunciation.
DC hooter or DC bell shall provide the audible alarm. Apart from requirement of facia
windows for annunciating status of various relays, Bidders shall also provide spare facia
annunciator window two nos. each for trip and non-trip function.
7.3
Each facia annunciator shall have a minimum size of 35 mm X 50 mm-translucent
plastic window for each Trip and alarm point. Translucent plastic plates of facia window shall
be engraved in black letters with respective inscriptions. All inscriptions shall be engraved on
each window in not more than three lines and size of letters shall not be less than 5 mm.
7.4 Each annunciation window shall be provided with two white lamps in parallel to provide
safety against lamp failure. Long life lamps shall be used. Lamp circuit shall include series
119
C & R Panels

resistor of adequate rating. Cover plate of the facia windows shall flush with the panel and
shall be capable of easy removal to facilitate replacement of lamps. Transparency of cover
plates and wattage of the lamps provided in the facia windows shall be adequate to ensure
clear visibility of the inscriptions in the control room having high illumination intensity (500
Lux) from the location of the operating staff desk.
7.5 TRIP and NON TRIP facia shall be differentiated. All trip windows shall have red
colour translucent plastic window and all non-trip facia windows shall have white colour
translucent plastic window.
Sequence of operation of the annunciator shall be as follows:
Alarm condition
Normal
Abnormal
Acknowledge push button is
pressed/
Reset push button is pressed.
Lamp test push button pressed.
Fault contact
a
b
a
b
Open
Close
Close
Open
Close
Open
Open
Visual
Annunciation
OFF
Flashing
Steady on
Steady on
ON
OFF
Steady on
Audible
Annunciation
OFF
ON
OFF
OFF
OFF
OFF
OFF
7.6
Any new annunciation appearing after the operation of audible annunciation cancel
shall provide a fresh additional annunciation with accompanied visual alarm even if
acknowledging or resetting of previous alarm is in process or yet to be carried out.
7.7 Annunciation system described above shall meet the following additional requirements:
a)
Annunciation system shall be capable of catering to at least 80%

simultaneous signals(of windows provided) at a time.
b)
One self resetting push button shall be provided on each panel for testing the
facia window lamps. Push buttons for testing flasher and audible alarm circuit
of annunciation system and for testing the annunciation supply failure
monitoring circuit shall also be provided. These testing circuits shall also be
so connected that while test is being done it shall not prevent the registering
of any new annunciation that may land up during the test.
c)
One set each of the following push buttons shall be provided on each panel as
shown in the front view drawing:
i.
ii.
Reset push button for annunciation system.

Accept push button for annunciation system.
iii.
Test push button for testing healthiness of annunciator. Operation of

this button should not cause inadvertent operation of any equipment.
d)
Annunciation shall be repetitive type and shall be capable of registering the

fleeting signal. Minimum duration of fleeting signal registered by the system
shall be 15milli seconds.
e)
Annunciation shall be suitable for operation with normally open potential free
contacts which close on a fault. It shall be possible at site to change operation
of annunciator from potential free contact from "close to fault" to "open to
fault" and vice versa.
120
C & R Panels
f)
In case of static annunciator scheme, special precaution shall be taken by

Bidder to ensure that spurious alarm condition does not appear due to
influence of external electromagnetic/ electrostatic interference on the
annunciator wiring and switching disturbances from the neighboring circuits
within the panels.
g)
Offered annunciation scheme shall be complete in all respects including

annunciator relay, flasher relay, test, accept and reset push buttons.
h)
Additional four spare windows two each for non trip and trip signals supported
by trip relay for future application by the purchaser shall be provided duly
wired up and terminated to the row of connectors.
8.0
PROTECTION SCHEMES :
8.1.
Protection schemes are required for following applications:

TYPE A
TYPE B
TYPE C
TYPE D
For 132 KV Feeder protection

For 132 KV side of 63 or 40 MVA , 132/33KV Transformers
For 132KV Side of 160MVA,220/132/33kv Xmer
For 132 kV Transfer bus coupler bays.
Protection schemes meant for above applications are described hereunder: 8.2
Protection Scheme For 132KV Transmission Lines (TYPE-A) :
8.2.1 General concept for protection of 132 KV transmission lines is to have one main and
one discrete back up relay (3O/C + 1 E/F, IDMT relay having directional feature). Main
protection for the lines shall be a three zone, three step distance scheme having MHO or
quadrilateral characteristics. Maximum fault current could be as high as 40KA for 132KV
System but minimum fault current could be as low as 20% of rated current. Thus, the starting
and measuring relay characteristic should satisfy both extreme conditions.
Numerical
distance relays for 132 KV lines shall be suitable for use with Bus PTs.
8.2.2 BIDDERS MAY PLEASE NOTE THAT THE NUMERICAL DISTANCE RELAYS
FOR 132 KV LINES SHALL BE SUITABLE FOR 110V DC SUPPLY UNLESS
OTHERWISE SPECIFIED AND THAT AUTO-RECLOSE FEATURE IS NOT REQUIRED
FOR THESE DISTANCE RELAYS.
8.2.3. All 132 kV transmission lines are generally laid on double circuit transmission towers.
DC supply for numerical relay shall be from DC/DC converter and these shall be liberally
designed and adequately rated for operation under extremely adverse operating conditions
during service. Insulation barriers shall be provided to ensure that transient present in CT
and VT signals due to extraneous sources do not cause damage to static circuits. Circuits
must comply with IEC recommendation for impulse withstands values. Adequate measures
shall be taken to ensure that equipment is protected against voltage spikes occurring in
auxiliary DC supply.
8.2.4 Numerical distance protection relays shall have the following functions/features:
Numerical distance protection relay shall be capable of providing flexible, reliable
integration of protection, control, and monitoring and measurement functions.
Offered relay for 132KV lines shall have 6 nos. of impedance measuring loops.
121
C & R Panels
Offered relay shall be suitable for protection of broken conductor following one out of
three phases getting open circuited without any line or ground fault. Protection shall
perform satisfactorily both for loaded and unloaded line condition.
Offered relay shall preferably have independent polygonal characteristics with
adjustable reactive and resistance reaches for maximum selectivity and maximum
fault resistance coverage due to arc resistance.
Offered relay shall provide selection and setting for mutual compensation of double
circuit lines.
Offered relay shall have minimum three directional zones and minimum one nondirectional zone. Zone setting ranges shall be sufficient to cover line lengths
appropriate to each zone. It shall be possible in future to add Carrier aided scheme
options of Zone-I extension, permissive under reach or over reach and blocking.
Offered relay shall have maximum operating time up to trip impulse generated from
relay (complete protection time including applicable carrier time and tripping time )for
the following source to line impedance ratios under all possible combination of
line fault with CVT being used on the line at 50% of Zone-I reach :for Source Impedance Ratio 0.01 - 4 :
30ms at nearest end and 50ms at

other end of line.
for Source Impedance Ratio 4 -15 : 35ms at nearest end and 55ms
at other end of line.
Offered relay shall have a secured directional response under all conditions,
achieved by memory voltage polarizing or healthy phase voltage polarizing as may
be appropriate.
Offered relay shall have logic to detect VT fuse failure. Bidders shall clearly state if
VT fuse failure for all the three phases can be detected individually.
Offered relay shall have Trip Circuit supervision and DC supply supervision as built
in features. In case it is not so, then discrete relay shall be offered for Trip Circuit
supervision as well as DC supply supervision.
Offered relays shall be suitable to detect switch on to fault (SOTF) condition by
appropriate means. Bidders may elaborate the SWITCH ON TO FAULT logic.
Offered relay shall have LBB relay as a built in feature to take care of stuck breaker
condition. If it is not so, then the bidders may have to offer discrete relay to take care
of stuck breaker condition.
Offered relay shall have power swing blocking feature with suitable coverage to
encircle distance relay characteristic with facilities for
(a)
(b)
Fast detection of power swing

Selective blocking of zones and
(c) Settable deblocking criteria for earth faults, phase faults and three phase faults.
Offered relay shall have minimum three directional and one non-directional step time
distance characteristics with independently variable time graded distance protection
zones to cover two adjacent line sections.
Offered relay shall have minimum adjustable characteristics line angle setting range
of 30 -85 degrees.
Offered distance relay need not be suitable for auto reclosing of 132KV lines
Offered relay shall be selective for internal and external faults.
Offered relay shall have minimum two independent continuous variable time setting
range of minimum 0-1 second for zone-2 and minimum 0-3 seconds for zoneVariable time settings for non-directional zone shall also be provided to set minimum
trip time of 0-5 seconds, over and above time settings for directional zones.
It is desired that total operating time of the offered relay need not exceed 30 ms.
Offered relay shall have maximum resetting time of less than 35ms.
122
C & R Panels
Offered relay shall have built-in extensive self-supervision and diagnostic testing
facility.
Suitable number of potential free contacts if required (multiplied through reed relays
only) may be provided on each distance scheme for carrier aided selection of
permissive tripping and blocking and auto reclosing. Provision for event sequence
recorder, stuck breaker, disturbance recorder, fault locator etc. shall be available.
Offered relay shall be capable of performing basic metering functions. Voltages,
Currents, Active and Reactive power registration shall be available on demand.
Offered relay shall have protection against broken line conductor. (Snapping of
conductor or jumper of one of the phases of the line but not involving earth).
Offered Numerical Distance relays shall be suitable for use on series compensated
transmission lines. This is a desirable feature although not mandatory.
Offered relay shall be capable of supporting IEC 61850 communication standard.
Relay shall have two communication ports.
Front port shall be for local
communication for relay settings, modifications, extraction / analysis of fault / event /
disturbance records from a lap top computer and there shall be rear port on 61850
standard for remote communication.
Offered relays shall have following fault diagnostic features :
i.
FAULT RECORDS:
Relay shall have facility to store fault records with information on cause of
tripping, date, time and trip values of electric parameters. It shall be capable
of storing not less than 5 nos. of previous faults records.
ii.
EVENT RECORDS:
Relay shall have facility to store 200 nos. time stamped event records with 1
ms resolution.
iii.
DISTURBANCE RECORDS:
Number of available analogue channels and digital channels shall not be less
than 8 and 16 respectively. Triggering for capturing / recording of disturbance
should be possible from within the distance relay and / or from any other
disturbance within the EHV sub-station. Offered relay shall necessarily have a
storage capacity of atleast 8 disturbance records of 3 sec. duration each.
iv.
Disturbance recorder, fault recorder and distance to fault locator functions

shall be provided as integral part of the line protection relays.
Offered relay shall have front panels display with keys to enter scroll through the
settings and to view the measurements. It shall also be possible to take data from a
pre-stored file in the PC and download the settings to the relay through the front port.
Offered relay shall have directional phase over current and earthfault protection.
Offered relay shall have non-directional phase over current and earthfault IDMT
protection with high set element for instantaneous tripping.
Offered relay shall conform to communication protocol no. IEC-61850 as stated
earlier.
Offered relay shall have self-monitoring and fault diagnostic feature with appropriate
annunciation. User definable LEDs shall be provided for
visual indication.
Necessary serial ports and parallel ports with leads and termination shall be
provided.
123
C & R Panels
Offered relay shall have facility for communication from remote sub-station (inline
with IEC 61850 standard) so that these relays can be used for sub-station
automation. Required hardware and software shall be included in the offered relay.
Offered relay shall have port type IRIG B for time synchronisation.
Bidders shall elaborate following features of the numerical relays offered by them.
i.
ii.
iii.
iv.
v.
vi.
vii.
Various programmable features of the relay

Application of the relays
Relay functions
Block diagram for hardware of the relay.
Metering and recording.
Human machine interface.
Suitability of the relay for IEC communication protocol no. IEC-61850.
8.2.5 Besides the built in back-up protection in the Numerical Distance Relay, an
additional Numerical, Directional, Non Communicable, 3 O/C + 1 E/F Relay is
envisaged on 132 kV feeder panels as backup protection.
8.3. PROTECTION SCHEME FOR 132/33 kV TWO WINDING POWER TRANSFORMERS
OF RATING 63 / 40 MVA (Type- B) :
8.3.1. Transformer protection is required for 63/40 MVA, three phase, 132/33KV
transformers shall be provided by fully numerical transformer differential protection relay.
Offered numerical differential relay shall be suitable for protection of two winding transformer
without external interposing CTs. In case protection requirement calls for providing
interposing CTs, same shall be provided by the Bidders in the control panel without
additional cost. It should be ensured that differential Protection offered is stable under
through fault condition, normal and over fluxing conditions and shall not operate with
magnetizing in rush current. Bidders shall give all details of the protection offered.
Differential relay shall have current rating of 1 Amp CT secondary and the total operating
time shall not exceed 30 ms. from inception of fault up to contact status changing of output
relay. Relay should have Bias setting adjustable from 15% to 50% with through fault current
not less than 10 times the normal current. Operating characteristics should have dual slope
for enhanced sensitivity for internal faults and better stability during through faults. Fifth
harmonic by-pass filters shall be provided to avoid possible mal-operation under over-fluxing
conditions. Relay shall have three instantaneous high set over current unit and shall have
continuous self monitoring and self diagnostic features. Visual indication and alarm shall be
provided in this panel for over fluxing relay, and for standard Transformer protections. Alarm
indication for SF6 gas pressure low, lockout, and air pressure low shall be provided along
with, Inter trip and trip transfer indication.
8.3.2
Differential protection relay shall have following built-in protections

i.
Thermal overload
ii.
Restricted earthfault
iii.
Local breaker back-up (LBB)
iv. Over excitation
v.
Back-up overcurrent and earthfault relay
vi. Overload protection
vii. Negative phase sequence imbalance detection
viii. Trip circuit supervision
ix. DC supply supervision
124
C & R Panels

8.3.3
AUXILIARY RELAYS FOR ALARM AND TRIP FUNCTIONS :
We have envisaged hand reset type auxiliary relay for alarm and trip
functions as mentioned against Sl. No. 29 and 30 of the BOM in clause no. 19.
Bidders may please note that these discrete relays are essentially required even
though these may form integral part of the Numerical Differential relay.
8.3.4
OVERFLUXING PROTECTION Power transformer should trip for over fluxing
condition to isolate both from primary and secondary sides. Accordingly over fluxing relay
should be provided in the control panel for HV side. Offered relay shall be suitable to provide
minimum settings as detailed hereunder:
Over fluxing factor
1.40
1.25
1.10
Duration.
5 sec
60 sec.
continuous.
Relay should have inverse characteristics and should be equipped with high set unit to
operate in less than 5 seconds whenever over fluxing exceed than the set value by 1.1
above 1.4 times. Over-fluxing relay should have setting that may be continuously adjustable
or in steps, for over-fluxing ranging from 1.0 and upward. Resetting value shall not be less
than 0.95 of the operating value. Settings shall be available in two stages. First stage
auxiliary element operation shall be around 1 sec. This stage shall be complete with
auxiliary relay so that alarm/facia etc. could be initiated. Thereafter in the second stage the
auxiliary element shall operate after a further adjustable time delay say 10 to 100 sec. This
stage shall also be complete with auxiliary relay, which could be utilized for the tripping.
Rating of auxiliary relay shall be selected accordingly. Relay shall be complete with
independent operation indicator for the two stages. Bidders may please note that the basic
setting on the relay shall be with over fluxing factor with 1.1 and shall have continuous
duration. However, between the remaining two i.e. over fluxing factor of 1.25 or 1.40, any
one can be utilized.
8.3.5
Numerical differential protection relay offered by the Bidders for 63 / 40 MVA,
132/33KV Xmers shall have a definite time over current relay as a built-in feature with
variable setting range from 50 to 200 per cent of relay current alongwith a timer having a
setting range of 2.5 to 25.0 sec. This relay shall be utilized to function as overload
protection relay for 63 / 40 MVA Xmers.
8.3.6 Other standard transformer protections such as gas operated Buchhloz relay, oil
surge relay, winding temperature, oil temperature, low oil Level, Pressure release devices
etc. will be provided by the purchaser with the transformer. Bidders have to make provision
for alarm annunciation and tripping. These standard protections will be provided on the
control panels as stated above.
8.3.7 Besides the built in back-up protection in the Numerical Differential Relay, an
additional Numerical, Non Directional, Non Communicable, 3 O/C + 1 E/F Relay is
envisaged on 132 kV X-mer panels.
8. 4 PROTECTION SCHEME FOR 132 KV AND 33 KV SIDES OF 160 MVA, 220/132/33
KV POWER TRANSFORMER (TYPE-C) :
Transformer protection for 132KV side of 160 MVA, 220/132/33KV transformer shall
have back up protection comprising of a Numerical, Non directional three over current plus
one Earth fault relay. The relay shall have IDMT characteristics. The purchaser has provided
one CT in one phase of 33 KV winding before delta formation, thus a single element
125
C & R Panels

induction over current relay shall be provided to safe guard against excessive flow of
circulating current in the tertiary winding. One digital Ampere meter for monitoring circulating
current shall be provided. It may be noted that the 132 kV as well as 33 kV circuit breakers
will have two trip coils which will receive simultaneous trip command as such offered
schematic shall be suitable to select main DC supply or duplicate DC supply for each trip
coil. For this purpose, contact multiplication will not be acceptable but the rating of the
breaker control switch and each tripping relay contacts shall be adequate to handle the
burden of two trip coils. Pistol grip type breaker control switches along with red and green
indicating lamp for ON/OFF indication shall be provided.
8.5
PROTECTION SCHEME FOR 132 KV TRANSFER BUS COUPLER (TYPE-D)
Protection scheme for 132 KV TRANSFER BUS shall be identical to the LINE
protection scheme specified above at 8.2.1 as such all standard features required for the
scheme shall be provided. Mimic shall however represent scheme for transfer bus instead of
line which may please be noted.
8.6
OTHER IMPORTANT PROTECTIONS FOR FEEDER, TRANSFORMER AND TBC

PANELS:
8.6.1. LOCAL BREAKER BACK UP:

Local breaker back up relay shall be provided to take care of stuck breaker condition.
This relay shall have three current operated elements with a time delay unit (delay of 0.1 to 2
sec) to ensure that the scheme operates only under the condition when there is a persisting
fault and the breaker has failed to trip. Setting range of over current element shall be 50% to
200% and for earth fault element 20% to 80%. Necessary auxiliary relay for initiating tripping
command to a total of eight number circuit breakers shall also be included as a part of the
scheme. Tripping relay included shall be capable of handling burden of circuit breaker with
two trip coils. Please note that all breakers shall be normal duty type having two trip coils
receiving trip command in parallel.
8.6.2 TRIP CIRCUIT SUPERVISION:
Separate trip circuit supervision relay shall be provided for each of the two trip coils
for each feeder/transformer circuit of 132 kV in all panels, for continuous monitoring of trip
circuit i.e. for both pre and post close conditions in case trip circuit supervision does not form
integral part of the Numerical Distance/ Differential Relays. Trip healthy lamp for each trip
coil shall be provided separately for pre and post close monitoring. During unhealthy
condition of trip circuit the relay shall initiate an audible alarm and visual indication on facia
window. All circuit breakers are provided with two trip coils and hence separate trip circuit
pre and post supervision for each trip coil is to be provided by Bidders. Each trip circuit
supervision relay shall be provided with operation indicator. Also for each trip coil circuit,
separate DC circuit with fuses will be used.
8.6.3
DC SUPPLY SUPERVISION:
Separate DC supply supervision relay shall be provided for 132 KV class Simplex
type C&R panels in case this does not form integral part of Numerical Distance/Differential
Relays. Bidders may please note that the DC supply source shall be one only and out of the
two DC supply systems, namely, protection and annunciation / indication, the offered relay
shall be capable of monitoring failure of DC supply of the protection circuits effectively. It
shall have adequate potential free contacts to meet out the requirement of the scheme and
also to meet the requirement for providing alarm and facia indication. Relay shall have a
time delay on drop off" of not less than 100 milli second and be provided with operation
126
C & R Panels

indicator/flag. This relay shall sound AC 230 V heavy-duty bell with provision for accept/reset
and test facilities.
8.6.4. ALARM SCHEME:
Automatic tripping of the circuit breaker due to operation of protective relays shall be
indicated by a common audible alarm. Offered alarm scheme shall be complete in all
respects including one DC bell for non-trip alarm and one DC hooter for trip alarm with relays
and other accessories if any. With each panel one alarm scheme will be required.
9.0
a) MULTI-FUNCTION METER:
We envisage a Multi-function meter on the panel to provide digital display of current,

voltage, Watts, VARS and Power Factor. This meter shall have scrolling facility to facilitate
reading any of these parameters and it will have a size of 144 sq mm. Bidders may please
note that the meter shall be capable of reading voltages upto a maximum value of 150KV.
This meter shall have an accuracy class of 0.5. The Multi function meter shall have four and
a half digit display, say for example 110.8KV, with minimum display height of 25mm. This
meter shall conform to IS 722 and shall be provided with non-reflecting glass fronts. Bidders
may please note that the meter shall be suitable for DC Supply voltage of 110Volts or
220Volts as the case may be. AC Supply operated meters are not acceptable to us. Offered
meter shall be of reputed make. Bidders may please note very carefully that
multifunction meter shall have communication facility through serial port RS-485 with
mod bus protocol complete with down loading software.
b)
10.0
ACCESSORIES & ENERGY METER:
10.1
ENERGY METERS: (TRIVECTOR METERS):
In each circuit for feeder, bus coupler, and transformer panel 3 phase 4 wire ABT
feature energy meter shall be provided. Bidder may please note that technical specification
of energy meter to be provided with each category of 132KV C&R panels covered by this
specification shall be in line with meter specification under section II(B) clause No.9.0.
Meter shall be fully static having non volatile memory and fully programmable. Meter shall
have four quadrant registering facility with provision for recording/display various parameters
like KWh, KVAh, KVARh, Line current and voltages including power factor. Load survey
capability for 35 days shall be available to forecast load growth. Meters shall be of 0.2S
accuracy class.
IEC 62052-11-2003, IEC 62053-22-2003 as under:
127
C & R Panels
v)
vi)
vii)
viii)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Item
CT secondary
VT secondary
System frequency
Earthing System
Details
1A
110 V/ 3 Volts
50 HZ + 5%
Solidly Grounded
110V/220V+ 20%
(BCS).
10.2
Four Element Hand Reset Auxiliary Relay For Monitoring Circuit Breaker
Parameters:
Four-element hand reset aux. Relay shall be provided for monitoring circuit breaker
parameters. It shall provide flag indication and display in the panel for following parameters;
1.
2.
3.
4.
10.3
SF6 gas pressure low alarm

Air pressure low alarm
Spring discharge alarm
Spare
AUXILIARY RELAYS
TRANSFORMER:
FOR
ALARM
&
TRIP
FUNCTIONS
OF
As stated earlier, we have envisaged hand reset type auxiliary relays for Alarm and
trip functions of the power transformer. This has been detailed in Sl. Nos. 29 and 30 of the
Bill of Material. Bidders may please note that the auxiliary relay for trip functions shall
cover oil temp. high, winding temp. high, main Buchholz, oil surge relay and PRV. Auxiliary
relay for alarm functions shall cover oil temp. high, wind temp. high main Buchholz oil surge
relay and the PRV. Bidders may keep provision of atleast two spare contacts in these
relays. Bidders may please note that provision of these relays is mandatory.
10.4
SWITCHES:
128
C & R Panels

identification.
10.4.2 Selection of operating handles for the different type of switches
shall be
as follows:
a)
b)
Selector switches
c)
Instrument switches
d)
: Pistol grip lockable and black
10.4.3 Breaker control switch shall be of spring return to neutral 3 position type. Control
touch. Spring return type switch shall have spring return from close and trip positions to
10.4.4 Instrument selection switches shall be of maintained contact(stay put) type.
Ammeter selection switches shall have make-before-break type contacts so as to prevent
open circuiting of CT secondary when changing the position of the switch. Voltmeter
switches shall be suitable for reading all line to line voltages for effectively earthed and
unearthed system.
trip transfer scheme. Key locks shall be fitted on the operation handle.
10.4.6 In 132kV C&R Simplex type panel, selector switches for manual selection of
Semaphore position indicator shall be provided for displaying matching position of isolators
devices in the switchyard. These selection switches shall have two way selection and shall
be mounted near to respective semaphore indicators for isolators.
10.5
INDICATING LAMPS:
10.5.0 All indicating lamps shall be LED Type.

10.5.1. Indicating lamps shall be panel mounting type with rear terminal connections. Lamps
shall be provided with series connected resistors preferably built in the lamp assembly.
Lamps shall have translucent lamp covers to diffuse various colours e.g. lights coloured red,
green, amber, clear white or blue to differentiate system function. Lamp cover shall be
preferably of screwed type, unbreakable and moulded from heat resistance material.
Wattage of the indicating lamps shall be as follows:
a) 220V
b) 110V
- 5 to 10W
- 5 to 10W
10.5.2 Wattage of the neon lamp shall be 0.25 to 0.5W if provided. Bulbs and lenses shall
be interchangeable and easily replaceable from the front of the panel. Indicating lamp with
resistor shall withstand 120% of rated voltage on continuous basis.
10.6
PUSH BUTTONS:
Push buttons shall be momentary contact type with rear terminal connections. Where
ever required the push buttons shall be suitably surrounded to prevent inadvertent operation.
These shall be provided with integral inscription plates engraved with their functions. All
push buttons shall have minimum two normally open and two normally closed contacts.
Contact faces shall be silver plated. Contacts shall be suitable to make/break and carry
appropriate currents for the functions desired.
129
C & R Panels
11.0
RELAYS:
All electromechanical relays shall have compliance to the following requirements.

11.1 All relays shall be contained in dust proof cases. All cases shall be mounted on the
11.2 Indicators shall also be provided on such additional equipment to identify faulty phase
and type of fault. Each indicator whether electrically or mechanically operated shall be reset
by hand without opening the relay case. Each indicator shall be so designed that it should
not be moved before the relay has completed its operation. It shall not be possible to test
and operate any relay by hand without opening case.
11.3 All elements of relays shall be arranged such that on opening the case dust particles
collected in or upon the case should not fall on the relay mechanism.
11.4 All relays shall conform to the requirement of IS-3231 or other applicable approved
the front.
11.5 All relays shall be draw out pattern or plug in type/modular construction with proper
testing facilities. The testing facilities provided on the relays shall be specifically stated in the
Bid. Necessary test plugs shall be supplied loose and shall be included in scope of supply.
Test block and switches shall be located immediately below each relay for testing. As an
alternative to "test block" and "test plug arrangements" the Bidder may supply alternative
testing facility for protective relays.
11.6 All induction relays shall be designed to operate at system frequency of 50 Hz.
Voltage operated relays shall be designed for star connected 110Volt VT secondary supply
and current operated relays of 1 amp CT secondary as specified in the specification. DC
auxiliary relays and timers shall be designed for specified DC voltage and shall operate
11.7 Relays shall be suitable for efficient and reliable operation of the protection scheme
monitoring of control supplies and circuits, lockout relay monitoring circuits etc. and also as
may be required for complete Protection schemes described in specification. All protective
relays shall be provided with minimum two pair of potential free contacts. Auxiliary relays
and timers shall have pairs of contacts as may be required to complete the scheme. All
contacts shall be silver faced with spring action. Relay case sizes should not pose limitations
in using available contacts on the relay due to inadequacy of terminals. Paralleling of
contacts, shall be done at the external terminals of relay if required.
11.8 All auxiliary relays except the lock out relays and interlocking relays shall be provided
with self reset type contacts. All protective relays shall be provided with externally hand reset
positive action operation indicators with proper inscription. All protective relays which do not
have built-in-hand reset operation indicators shall be provided with additional auxiliary relay
having operating indicators (Flag relays) for this purpose. Similar separate operating
indicator (auxiliary relays) shall be provided in all relays associated with protection tripping
130
C & R Panels

such as Buchholz relays, oil and winding temperature protection, pressure relief devices, fire
protection etc.
11.9 Provision shall be made for easy isolation of trip circuits of each relay for the purpose
of testing and maintenance.
11.10 Auxiliary seal-in-units provided on the protective relays shall preferably be of shunt
reinforcement type. If series relays are used the following shall be strictly ensured:
a)
Operating time of the series seal-in-unit shall be sufficiently shorter than that
of the trip coil or trip relay in series with which it operates to ensure definite
operation of the flag indicator of the relay.
b)
Seal-in-unit shall obtain adequate current for operation when one or more
relays operate simultaneously.
c)
Impedance of the seal-in-unit shall be small enough to permit satisfactory

operation of the trip coil on trip relays when the DC supply voltage is
minimum.
11.11 In order to minimize effect of galvanic actions associated with electro chemical effect,
flag coils and DC relay operating coils shall be so placed in the circuit that these are not
connected to the positive pole of the battery except through contacts which are normally
open.
11.12 Numerical distance relays shall be suitable for IEC communication protocol 61850.
Relays shall comply following requirements also:
a)
Printed circuit boards/cards shall be fin type and its contact shall be gold
plated. All connections with the connector pegs shall be through wire
wrapping. All solder joints on the printed circuit boards shall be encapsulated
or covered with varnish.
b)
Components used in these relays shall be loaded under normal condition by

less than half of their rated values. Resistors shall be of carbon composition
or metal oxide type and the capacitors shall be plastic film or tantalum type.
Stringent measures including shielding of long internal wiring should be taken
to make relays immune to voltage spikes as per IEC. Relays must meet the
requirements of IEC-255-4 appendix È' class III regarding BF, disturbance
tests IEC-255-4 regarding impulse test at 5KV and transients present in CT
& VT connections due to extraneous sources, do not cause damage to any
of associated static circuits.
c)
All relays shall be designed for satisfactory performance under tropical and
humid conditions. Special mention shall be made in the technical deviations
schedule of the Bid for those relays, if any that Bidder proposes to use which
differ from specified requirements.
d)
All devices required for correct operation of each relay shall be provided
without any extra cost.
e)
It will be ensured that the terminals of the contacts of the relays are readily
brought out for connections as required in the final approved scheme. The
type of relay case size offered shall not create any restriction on availability
of the contact terminals for wiring connections.
131
C & R Panels
12.0
f)
DC/DC converters or power supply modules shall be provided for solid state
protective relay wherever necessary in order to provide a stable auxiliary
supply for relay operation.
g)
Solid state relays shall be stable and suitably protected against

transient/induced over voltages and noise signals. Bidders shall state clearly
in their Bids, special requirements if any for DC input arrangement or cabling
considered necessary for satisfactory operation of solid state relays quoted by
him.
h)
Timers shall be of the solid state type. Short time delay in term of
milliseconds may be obtained by using copper lugs on auxiliary relays. In
such case it shall be ensured that the continuous rating of the relay is not
affected. Time delay in terms of milliseconds obtained using external
capacitor resistor combination is not preferred and shall be avoided to the
extent possible.
TESTS :
Manufacturers shall carry out the type tests and routine tests on the relays and
complete panels as per relevant Indian Standard or any equivalent International Standards
and as specified hereunder.
12.1
ROUTINE AND ACCEPTANCE TESTS :
12.2

a)
b)
c)
d)
e)
f)
Other routine tests on all associated equipment and relays as per
relevant Indian Standards or IEC.
12.3 After all tests have been carried out, 4 (four) copies of each test report/inspection
report shall be furnished. Each report shall supply the following information a)
b)
Complete identification data including serial number of all the relays

and their routine test reports.

purchaser.
13.0
CONTROL CONNECTIONS AND INSTRUMENT WIRING:
13.1 Connections for switchgear operation and indications between the control and
relay panels where ever separate termination for instrument and relay wiring on these
132
C & R Panels

control & relay panels and multicore cable terminal boxes are involved, these shall form a
portion of the scheme for panel and the cost shall be included in the price of the control
panel as stated by the Bidder.
13.2 Panel connection shall be insulated and securely fixed neatly to the back of the
panel. All instrument and panel wiring shall be fire retardant. All panel wiring shall be taken
to terminal boards which shall comply with requirements of multicore cable boxes where
applicable. Switch board wiring shall be PVC or VC braid impregnated with flame proof
13.3 All wiring diagrams shall be clearly marked with the numbers which are shown on the
ferrules of the individual cores. 20% spare and blank ferrule shall be supplied with each
panel.
13.4 Flat washers shall not be used but both end of each instrument or control wire shall
be properly crimped and terminated with a Rose Courtney or other approved type of washer.
13.5 Each set of current & voltage transformer secondary connections shall be complete
in all respect and shall be connected to form common star point. Star point shall be earthed
at one point only. Each such earthing connection to the earth bar shall be made in
accordance with the requirement of the earthing system and shall be made through a
disconnecting link of approved design which can be removed when insulation tests are
required without breaking any circuit normally carrying current.
13.6 For each circuit on the panel, the control indication and trip wiring shall be suitably
other indication circuits shall be connected to the DC bus by a set of fuses. Similarly, the trip
and close circuits shall also be connected by a separate set of fuses. Fuses shall be labeled
clearly showing the circuits connected.
13.7 All secondary fuses shall be of an approved type. HRC fuses of standard make shall
only be used. Where ever specified test blocks shall be provided for testing of meters and
relays. These shall be of the switchboard type with connection at the back, mounted on front
of panel. Test blocks shall provide complete isolation of meters, instruments and relays and
14.0

painting. Process shall be carried out as under. Process can broadly be divided as `Metal
treatment and painting'.
14.1
i.
ii.
iii.
METAL TREATMENT:
Degreasing: This can be achieved either immersing in hot alkaline degreasing
bath or in hot di-chloroethelene solution. After degreasing operation the
surface shall be cleaned thoroughly with cold water.
Pickling: This is to remove rust and metal scales by immersing metal sheets
in dilute sulphuric acid (approximately 20%) at nearly 60 deg. centigrade so as
to totally remove scale and rust.
133
C & R Panels

iv.
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 90 degree centigrade . The uniform phosphate coating of 4 to
5 gm per sq. meter shall be achieved.
vi. Swill in cold water.
vii. Rinse in Deorylyte bath at 70 to 80 degree centigrade to neutralize any traces of
salts.
viii. Seal the above phosphate coating with hot/dilute chromate solution.
ix. Dry with compressed air
14.2
PAINTING :
i.
Primer spray: One coat on wet surface by specially developed `High luster'
zinc chromate primer and to stove at 150-160 deg. Centigrade for 25 to 30
minutes. Alternatively red-oxide primer with zinc chromate contents may be
used. However former process shall be preferred.
ii.
Rubbing and putting: Apply putty to fill up the scars if any to present
smooth surface and stove 15 to 20 minutes. Apply putty several times to get
the perfect 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
v. Finish paint : Rubbing down dry and spray first coat of synthetic enamel
finish paint on wet and stove for 30 minutes.
vi. Surfacing : Sand down or rub dry to prepare for final finish spray. Coats of
synthetic enamel finish paint on wet and stove it at 150 deg. centigrade for 30
minutes.
NOTE: i.
ii.
iii.
Necessary stiffeners may be welded between large cut ducts to

provide rigidity before painting process.
Painting process shall be done within 24 hrs. of completion of
treatment.
Small coating paint shall be supplied along with equipment for
touching up at site.
15.0
15.1
G.A. drawings for each type of panel shall be submitted with the Bid.
15.2 As soon as possible after award of the contract the successful Bidder shall submit
GA and Schematic drawings of each panel for the approval of purchaser.
15.3 Successful Bidder shall have to furnish four sets of manuals per panel each
containing of approved GA, Schematic and wiring drawings illustrative pamphlets, literature,
operation and maintenance instructions of the relay/panels under his scope of supply.
16.0
GUARANTEED TECHNICAL PARTICULARS:
accessories shall be furnished along with the bid. While submitting technical particulars,
134
C & R Panels

and voltage rating physical dimensions, weight, make, model No. type etc. in order to give a
clear picture of device offered, along with literature/write-up. Unless otherwise specified,
the panels shall be suitable for the auxiliary DC voltage of 110 V DC or 220V DC as per our
requirement.
17.0
17.1
QUALITY ASSURANCE PROGRAMME :
17.1.1 Bidders must establish that a proper quality assurance program is being followed by
them for manufacture of control and relay boards. In order to ensure this, suitable QAP
should form a part of the technical Bid, which will be submitted against this Bid specification.
Quality Assurance Program must have a structure as detailed in the following paragraphs.
17.1.2 Quality assurance and failure prevention starts with careful study and scrutiny of our
technical specifications and requirements. Bidders shall carefully study all the technical
parameters and other particulars & the Bidders shall categorically give their confirmation that
these requirements shall be met in a satisfactory manner.
17.1.3 Bidders shall furnish the checks exercised in design calculations particularly in
selection of main protection scheme. Salient features of design & selection criteria of
protection scheme will have to be made available to the Purchaser.
17.1.4 Bidders shall indicate the various sources of the bought out items. Type of checks,
quantum of checks and acceptance norms shall be intimated and random test and check
results should be made available for inspection whenever so desired. Vendor list for various
bought out items shall be submitted with the Bid and the same shall be subject to
purchasers approval. However, no change in vendor list shall be acceptable after placement
of order and list of vendors shall be freezed at the time of placement of order It will however
be obligatory on the part of Bidder to allow third party inspection of all important material and
in case during independent third party inspection any of the above material is found different
than from approved list of vendors, Purchaser reserves the right to summarily reject
complete lot and the manufacturer has to replace the entire material from the vendors
approved by the Purchaser.
17.1.5 Based on above QAP and offered delivery schedule a tentative program chart
indicating period for various manufacturing/ testing activities shall be submitted alongwith
QAP Program chart should specify periods for various activities i.e. design, ordering of new
materials, assembly, testing etc.
17.2
INSPECTION:
17.2.2 Acceptance of any quantity of panel/material shall in no way relieve the successful
135
C & R Panels

17.2.3 At the time of inspection, Bidder shall identify each and every item/accessories.
Unless all the items are identified, the manufacture will not be treated as complete. Serial
purchaser.
following:
a. List of various panels and loose relays, which are ready at the works and will be
declared to have been offered for inspection
b. It is expected that before any equipment is offered for inspection, internal testing
of the same for various important parameters are already done. Routine test
report for such tests shall also accompany with the letter of inspection call.
c. In case for any reasons inspection is not completed or equipment is not found
18.
Responsibility for obtaining timely supplies of bought out items will rest on the Bidder
and only on this basis, delivery period will be offered in the Bid. For bought out items,
18.1. Please ensure that pages have been properly numbered and signed by the Bidder.
All Bid documents including schedules should be indexed properly and index of the
document should be enclosed/placed at the beginning of the Bid document.
19. 0
SCHEDULE OF REQUIREMENTS:
Simplex type control and relay panels for 132KV system shall have following
instruments, relays and accessories to be provided per panel as per the type of protection
indicated above under clause-8 by the purchaser:
S
No
PARTICULARS
(I) CONTROL PANEL

1
Type of panel
2
Box type circuit label
inscription (50x100mm)
indicating
Name
of
TYPE-A
For
132KV
Feeder
TYPE-B
For 132KV
side
of 132/33KV
Transformer
(63/40 MVA
Capacities)
Simplex
Simplex
Simplex
Simplex
TWO
TWO
TWO
TWO
136
TYPE-D
TYPE-C
For
For 132KV
Side of 220/ 132KV
132/33KV Transfer
Bus
Transformer
Coupler
bay
C & R Panels

S
No
3
4
PARTICULARS
feeder/ transformer in
side & out side of panel
Purchasers order no.
Serial no.& Bidders label
Over laid Mimic diagram
with
uniform
3mm
thickness, 10mm width
for horizontal strip and
6mm width for droppers.
Red and Green lamps
(LED type) with holder
for
circuit
breaker
ON/OFF
position
indication
for
each
Xmer/feeder circuit.
Pistol grip Circuit breaker
control switch with three
positions; ON, OFF &
return to neutral.
Semaphore to indicate
circuit breaker position
automatically
TYPE-A
For
132KV
Feeder
TYPE-B
For 132KV
side
of 132/33KV
Transformer
(63/40 MVA
Capacities)
TWO
TWO
TYPE-D
TYPE-C
For
For 132KV
Side of 220/ 132KV
132/33KV Transfer
Bus
Transformer
Coupler
bay
TWO
ONE MAIN AND TRANSFER BUS
ONE
SET
ONE
SET
TWO SETS
ONE
SET
ONE
ONE
TWO
ONE
ONE
ONE
ONE
ONE
8.
Digital Ampere meter

with selector switch for
monitoring
circulating
current in tertiary winding
(Size 144 sq mm).
TWO; ONE
FOR 132KV &
OTHER FOR
33KV BREAKER
ONE
9a
One multifunction meter

to indicate phase and
line currents, phase and
line
voltages,
active
power (MW), reactive
power (MVAR) & Power
factor. This meter shall
have scrolling facility to
facilitate reading any of
these parameters. This
meter shall be of size
144 sq. mm and it shall
have a scale of 0 to
150KV
for
voltage
reading
(secondary
rating 110V Phase to
phase and 1 Amp). The
ONE
ONE
ONE
TWO
137
C & R Panels

S
No
PARTICULARS
TYPE-B
For 132KV
side
of 132/33KV
Transformer
(63/40 MVA
Capacities)
TYPE-A
For
132KV
Feeder
TYPE-D
TYPE-C
For
For 132KV
Side of 220/ 132KV
132/33KV Transfer
Bus
Transformer
Coupler
bay
meter shall have an

accuracy class of 0.5,
shall have LED display
for letters and the size of
digit shall be 25 mm.
One
One
One
9b
Analogue of type center

zero MVAR meter
One
10
Facia
window
annunciator
complete
with flasher and function
relays
18
WAYS
24
WAYS
12
WAYS
18
WAYS
11
Test plug/port for testing

of Main protection Relay
complete with connecting
leads
Test terminal block for
static trivector meter
ABT
feature
static
trivector energy meter - 3
phase 4 wire - type of
accuracy class 0.2s
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
Push button for facia

annunciator testing of all
lamps/accept/
reset
arrangement.
Four element hand reset
auxiliary relay to monitor
circuit
breaker
Parameters to display in
facia annunciator.
Trip circuit supervision
healthy indication lamp
with push button to select
pre & post close
supervision
with lock for continuous
display
on
Facia
annunciator
AC
panel
indication
lamps with holder for DC
supply supervision.
THREE
THREE
TWO ONE
FOR MV
WIND-ING
AND THE
OTHER FOR
TERTIARY
WIND-ING
THREE
THREE
ONE
ONE
ONE
ONE
TWO
TWO
FOUR
TWO
ONE
ONE
ONE
ONE
TWO
TWO
TWO
TWO
12
13
14
15
16
17
18
138
C & R Panels

TYPE-D
TYPE-C
For
For 132KV
Side of 220/ 132KV
132/33KV Transfer
Bus
Transformer
Coupler
bay
ONE
ONE
SET
SET
S
No
PARTICULARS
TYPE-A
For
132KV
Feeder
19
Additional accessories &

other devices required to
complete the offered
schemes
RELAY PANEL
Box type circuit label
inscription (50x100mm)
indicating
Name
of
feeder/ transformer in
side & out side of panel
Numerical
Distance
protection
scheme
complete
with
all
modules and auxiliary
relays etc. as per clause
8.2.of
technical
specification.
Numerical Differential
protection relay for power
transformers complete
with inter posing CTs
etc; in line with clause
no. 8.3. of technical
specification.
Pre & post close Trip
circuit supervision relay .
(*)
ONE
SET
TYPE-B
For 132KV
side
of 132/33KV
Transformer
(63/40 MVA
Capacities)
ONE
SET
TWO
TWO
TWO
TWO
ONE
--
--
ONE
--
ONE
--
--
*TWO
* TWO
*TWO
TWO
TWO
FOUR
FOR
132&33KV
BREAKERS
TWO
--
ONE
--
--
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
(II)
20
21
22
23
24
25
26
27
DC
supply
healthy
monitoring relay. (*)
Over
fluxing
relay
complete with timer etc.
**
LBB relay ** alongwith
auxiliary relay having
minimum 8 NO contacts
as described in Clause
no.8.6.1
Fast acting high speed/
master trip relay with
contacts suitable
for
handling burden of 2 nos.
circuit breaker trip coils in
parallel.
139
TWO
C & R Panels

S
No
PARTICULARS
TYPE-A
For
132KV
Feeder
TYPE-B
For 132KV
side
of 132/33KV
Transformer
(63/40 MVA
Capacities)
ONE
-28 Hand reset auxiliary trip

relay with flag indication for
:
i. Oil temp high trip
ii. Winding temp high trip
iii. Main buchholz trip
iv. OLTC oil surge relay trip
v. Pressure relief device
trip
-ONE
29 Hand reset alarm relay with
flag indication for :
i. Oil temp high alarm
ii. Winding temp high alarm
iii. Main buchholz alarm
iv.OLTC oil surge relay
alarm
v. Pressure relief device
alarm
vi. Spare
ONE
ONE.
30. Numerical,
Non
directional,
Non (DIRECTI
ONAL)
Communicable 3 O/C + 1
E/F Relay. (Directional
relay for feeder and TBC
panels only).
--31. Single
element
over
current
relay
for
circulating
current
protection for tertiary
winding
-ONE (Over
32. Definite time over current
load protection
relay with continuously
for Xmer)
variable current setting
range from 50% to 200%
of relay current with timer
having setting range of
2.5 sec to 25 sec.(* * *)
33
Additional aux. relays

required to complete
offered
protection
schemes with details.
As
Required
As
Required
TYPE-D
TYPE-C
For
For 132KV
Side of 220/ 132KV
132/33KV Transfer
Bus
Transformer
Coupler
bay
---
--
--
ONE.
ONE
(DIRECTIONAL)
ONE
--
--
--
As Required
As
Required
34
(III) EQUIPMENT MOUNTED INSIDE
35
Space
heaters
with
switch in each panel.
ONE
ONE
ONE
15/5A, 250Volts power
ONE
ONE
ONE
140
C & R Panels

S
No
PARTICULARS
TYPE-A
For
132KV
Feeder
TYPE-B
For 132KV
side
of 132/33KV
Transformer
(63/40 MVA
Capacities)
TYPE-D
TYPE-C
For
For 132KV
Side of 220/ 132KV
132/33KV Transfer
Bus
Transformer
Coupler
bay
socket with protective

metallic cover & Switch.
35
20Watt Tube light with

door switch.
ONE
ONE
ONE
36
40Watt incandescent or
15Watt CFL lamp with
switch.
TWO
TWO
TWO
37
DC bell for NON TRIP

alarm
complete with
accept, reset and test
facilities.
ONE
ONE
ONE
38
DC hooter for trip alarm

complete with accepting,
reset and test facility
ONE
ONE
ONE
39
AC Bell for DC supply

supervision.
TWO
TWO
TWO
40
Gland plate fitted with

Cable glands.
ONE
SET
ONE SET
ONE
SET
41
Foundation bolt
ONE
SET
ONE SET
ONE
SET
42
Additional
relays
or
accessories offered by
Bidder,
which
are
essentially required for
completing
protection
scheme.
As per
As per
As per
Requirem Requirement
ent
Requirem
ent
For the purpose of confirmation to supply all items mentioned above, Bidders
shall furnish an undertaking as per schedule XIII of volume-VI.
IMPORTANT NOTE:
i)
ii) (*)
Bidders shall indicate Unit prices for all the gadgets and relays
offered by them for the 132KV Class type A,B,C&D panels. This has
to be strictly complied. Prices of the gadgets and relays shall form a
part of the Schedule-I about details of equipment and quantity for
132KV C&R panels.
As mentioned elsewhere in the bid specification, trip circuit
supervision and DC supply supervision shall form integral part of
the numerical distance as well as differential relays and discrete
relays shall be offered by the bidders only if these two functions do
not form the integral part of the offered numerical relays.
141
C & R Panels
ii)(**)
In case, LBB and over-fluxing relays are built-in features of line

distance protection relay and transformer differential relay, then
Bidders may confirm accordingly and need not provide these relays
separately.
iii)(***)
In case, definite time over current relay forms an integral part of

numerical differential relay then a separate relay as envisaged need
not be provided. Bidders need to clarify this point.
iv)
Bidders may please refer Clause no. 8.6.1 about the LBB relay and
Sl. No. 29 of the B.O.M. and shall provide an auxiliary relay having
minimum 8 NO contacts per circuit.
142
C & R Panels
APPENDIX-B2
DRAWINGS
S.No.
Description
Elevation Drawing for 132KV Control & Relay Panel
General Arrangement Drawing for 132KV Control & Relay

Panel
143
C & R Panels
2300
CL
ANN.
MFM
IL 3 1
PB 1
4
3
6
5
132KV MAIN BUS
132KV TRANSFER BUS
52CS
1650
TTS
21
1370
1305
86
300
30
ABCD
86 LBB
TTB
50/51 N
RTB
60
850
ELEVATION
DRAWING NUMBERJICA/MPPTCL/TR-101 TO 107/ EL 132KV CRP
144
C & R Panels
145
CO
VE
(B
L
C & R Panels
CK
)
50/51 N
TTS
RTB
30
ABCD
132KV TRANSFER BUS
132KV MAIN BUS
MFM
CUBICLE COVER
CL
PB 1
1 IL 3
DRAWING NUMBERJICA/MPPTCL/TR-101 TO 107/ GA 132KV CRP
TTB
86 LBB
52CS
ANN.
FRONT SWING DOOR WITH RELAYS FLUSH

MOUNTED. REAR BLOCKED.
60mm BASE FRAME
60
SIDE COVER
2300
EA
2240
86
21
3D VIEW
EQUIPMENT FRAME
SWINGING TYPE
FRONT DOOR
PROVIDED WITH
GLASS COVER
60
2240
END VIEW
750

NOT TO SCALE.
WIDTH OF THE PANEL SHALL BE RETAINED AS 850MM
RELAY PANELS WILL BE RACK MOUNTING (FRAME) TYPE WITH

PERSPEX DOOR IN THE FRONT
(TO BE FIXED BELOW PANEL BASE FRAME)
TYPE GASKETS AS PER IS 13847

15mm THICK ANTI-VIBRATION PAD WILL BE PROVIDED AS LOOSE
AS PER IS 2147
ALL DOORS AND METAL JOINTS WILL BE PROVIDED WITH FOAM
PANELS WILL COMPLY WITH INGRESS PROTECTION DEGREE IP54
ARRANGEMENT
WEIGHT OF 1 CONTROL & RELAY PANEL WILL BE 600 KGS(APPROX.)
DOOR WILL BE PROVIDED AT THE BACK WITH FLUSH TYPE LOCK
COVERED BY DETACHABLE PLATES
CUBICLE BOTTOM WILL BE CLOSED AND HAVE CABLE SLOTS
DOOR) WILL BE 2MM THICK
NON-LOAD BEARING MEMEBERS (SIDE PANEL, CUBICLE ROOF,
FRAME) WILL BE 3 MM THICK
LOAD BEARING MEMBERS (FRONT PANEL, BASE FRAME, DOOR
WITH MEMBERS FOLDED & BOLTED
PANELS WILL BE OF FREE STANDING UNITISED CONSTRUCTION
CONSTRUCTION :
52CS
TTS
29 S1 TO S5
IL
PB
21
50/51N
86
86 LBB
30 ABCD
195, 295, 80 ABC
TVM
3.0/ 2.0mm.
Eggshell White
Opaline Green
Blue Gray
Overlaid Type
12.5x6mm. Copper Based
Double Compression Type
Multi Function Meter of
accuracy class 0.5
Trivector Meter of
accuracy class 0.2S
Breaker Control Switch
Trip Transfer Switch
Semaphores
Indicating lamps
Push buttons
Distance Protection Relay
Back-up Relay
Trip Relay
Trip Relay (LBB)
Aux. Relay for Breaker
TCS & DC Supervision
Relays Considered
Built-in DPR (21).
132KV PANEL DETAILS

Colour Inside
Colour Outside
Colour of Mimic
Mimic Strip
Earth Bus Size
Brass Cable Glands
MFM
SCHEDULE-I (A)
DESCRIPTION OF EQUIPMENT FOR
SCHEDULE FOR RATES AND PRICES TO BE FURNISHED
IN VOLUME-VI
Particulars of Item
1(a)
132 KV Simplex design C & R panels (type A) for protection of

132KV feeder circuits complete with all relays & accessories as
described in the specification
132KV simplex design C & R panels (type B) for 63/40 MVA, 132
/ 33KV Xmer complete with all relays & accessories as
described in the specification
132KV simplex type C & R panels (type C) for 132KV side of 160
MVA, 220/132 KV transformers complete with all relays &
accessories as described in the specification
132 KV Simplex design C & R panels (type D) for protection of

132KV Bus coupler bay complete with all relays & accessories
as described in the specification
Qty.
S.
No.
NOTE:
1.
The above description of the equipment is given for the purpose of offering the
prices and to mention description of equipment in invoice for claiming
payment.
2.
The quantity of above equipments has been mentioned in volume-VI.
146
C & R Panels
2.1.2 (D)TECHNICAL SPECIFICATION FOR INDOOR 33KV CONTROL AND

RELAY PANELS
1.0
SCOPE:
1.1
This section contains technical specification for design, manufacture, testing at
manufacturers works packing & supply of 33KV C&R Panels type (1T+1F), 3F and 1F
complete with all fittings & accessories, specified herein for connecting outdoor
Switchgears and other electrical equipment in EHV Sub-stations of Madhya Pradesh
Power Transmission Co. Ltd. Panels shall be floor mounting free standing type, meant for
indoor installation in various 220 kV and 132 kV EHV substations located within the state
of Madhya Pradesh.
1.2
The simplex design 33 kV control and relay panels included in this bid document
are required for following applications.
TYPE A
TYPE B
TYPE C
2.0
Control & Relay panels for one Transformer plus one

Feeder circuit.
Control & Relay panels for Three-Feeder circuits
Control & Relay panels for one-Feeder circuit
LIMITS OF CONTRACT:
2.1
It is not the intent to specify completely all the details of design and construction of
the control and relay panels. However, the panels shall conform in all respects to the high
standard of engineering design and workmanship. Various control and relay panels and
panels, earthing terminals, indicating lamps, mimic diagram, alarm scheme, name plate,
satisfactory operation . Such components shall be deemed to be included in the scope of
supply of the Bidders irrespective of whether these are specifically brought out in this
specification or not.
2.2
Supply and laying of control and power cables for interconnecting various equipment
is not covered under the specification. Cable terminating arrangements, viz. the cable hold
support boxes, multicore cable glands, sealing ends for other types of cables that may be
specified, shall however be included in the offered price. These shall be subject to approval
of purchaser. It is the responsibility of Bidders to ensure that the equipment specified and
complimentary equipment required for completeness of the protection/control scheme be
properly accommodated in the panels without congestion and if necessary provide panels
with larger dimensions in width only.
3.0
Climatic condition shall be applicable as per Volume-II, Part-2, Book-I of the bid.
4.0
PANEL FINISH AND COLOUR 33KV SIMPLEX DESIGN PANEL:
33KV C&R panels shall be of Simplex design and each panel shall be constructed of
stretched level selected sheet steel. Simplex type panels shall be made in suitable
sections so that while mounting the panels can be located side by side with a view to form a
147
C & R Panels

compact unit. The 33KV Simplex design panels shall have front door of swing type and rear
blocked with control gadgets and relays flush mounted.
4.1
33KV C&R panels of SIMPLEX design shall consist of a vertical front panel with all

4.1.2 Other salient features applicable for 33 KV Simplex design panels
4.2

IS: 5.
4.2.1 Applicable standards for the offered equipment/item shall be as per Volume-II, Part-2,
Book-I.
4.2.2 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS:
In the paragraph 4.2.1 above, relevant Indian /British /IEC standard specifications
have been mentioned. However, the equipment meeting any other authoritative international
148
C & R Panels

standard, which ensures equal or better quality than the standards, mentioned shall also be
acceptable. Equipment for which Indian Standards are not available, the relevant British
standards and IEC recommendations will be applicable. Please attach photocopy of all such
standards according to which the equipment has been offered.
4.2.3 TYPE TESTS:
All offered Numerical/ static/electromechanical relays and meters on C&R Panels
of the type and design offered, has already been type tested, the shall invariably furnish
type
test
reports
from
the
reputed
and
approved
national/international
the date of opening of tender.
It may be very specifically` noted that non-submission of type test reports about
numerical relays and also about static meters along with the bid shall be treated as a
disqualification.
i.
ii.
iii.
iv.
4.2.4
Numerical IDMT relay having two over current and one earth fault element (Non
directional). Time of operation 1.3. Seconds at 10 times current setting
Numerical IDMT Non-directional relay having three over current and one earth
fault elements having time of operation as 3.0 Seconds at 10 times current setting
Static tri-vector meter of accuracy Class 0.2S.
Multifunction meter of accuracy Class 0.5.
DEVIATION FROM TECHNICAL PARTICULARS :

4.3.0
4.3.1
33kV Control & relay panels shall be of SIMPLEX design. Each panel shall be
constructed of stretch-level selected steel sheets. Panels shall be made in suitable sections
so that while mounting, panels can be located side by side, bolted together to form a
compact unit.
4.3.2
33 kV SIMPLEX type panels shall consist of a vertical front panel with all
equipment mounted thereon including protective relay, indicating/recording instruments and
energy meters etc. and having wiring access from the rear. Double leaf door with lift off
hinges shall be provided at the back. Doors shall have handles with built in locking facility.
4.3.3
Control panels shall be sheet steel enclosed and shall be dust, moisture and vermin
proof. Panels shall be fabricated of 2.5 mm thick steel sheet on all sides free from all surface
defects. Panels shall have sufficient structural reinforcement to ensure a plain surface and
rigidity to limit vibration during dispatch, installation and service.
4.3.4
Constructional details and sizes for 33 kV C&R panels shall be as under:(MPPTCLs standard drawing may please be referred)
149
C & R Panels

S.No.
1
2
3
4
5
6
7
8
9
10
PARTICULARS
Type
Height(mm)
Depth(mm)
Width (mm) (Subject to
variation as per scheme
requirement)
Base frame
Panel exterior
Panel Interior
Number of feeder(F)OR
Transformer(T)
circuits per panel
Variation in dimension of
panels.
33KV PANELS
Simplex
2250(Panel Height 2190mm + Base frame of
60mm)
560 (without corridor)
660 for 1F
1000 for 3 F
660 for 1T+1F
Anti-corrosive Black painted
Opaline Green
Egg Shell white
Azure blue
Control panels are required in the following three
formations:
i. One transformer plus one feeder circuit.
ii. Three feeder circuits.
iii. One feeder circuit.
Bidders may note that the height and depth of
control panels will have to be maintained as
mentioned against Sl. No. 2 & 3 above. As far as
width of the control panels is concerned the
same may be offered based on optimum design
to accommodate specified number of circuits as
also the various relays and accessories, which
are to be mounted on the panels.
DIMENSIONAL DETAILS FOR 33 KV C&R PANELS

S
No.
Category of panels
Height (mm)
Width
(mm)
Depth
(mm)
1.
1T + 1F category panels having

vertical versions of over current and
earth fault relays
2250 (2190mm + 60
mm base pad)
660
560
2.
3F category
2250 (2190mm + 60
mm base pad)
1000
560
3.
1F category
2250 (2190mm + 60
mm base pad)
660
560
4.3.5
Preferred panel cut out dimensions for mounting of the relays shall be as per Indian
Standard Specification IS-4483 (PART I & II) and MPPTCLs standard shown in drawing.
Please note that since purchaser has standardised dimensions of the panels for their
system, therefore no deviation in height/depth will be permitted. Bidders must submit general
arrangement drawing for each type of panel offered by them.
4.3.6
Control & Relay panels shall be floor mounting dead front sheet steel assemblies of
unitised design. Panels shall be made in suitable sections as described else where in the
form a compact and composite unit. Design, material selection, workmanship and width of
panels.
150
C & R Panels

4.4.0
PANEL LIGHTING:
4.4.1
In each SIMPLEX panel, one 20W, 230 Volt tube light guarded with protected cage
or CFL shall be provided below the central roof for adequate illumination & the same shall be
controlled by door switch.
4.4.2
One number universal 15A/5A pin receiptable socket with cover and switch shall be
provided in each control panels. Third pin of the socket shall be effectively grounded through
the metallic structure. Socket shall be of industrial grade control panels type complete with
4.5.0
AUXILIARY SUPPLY:
4.5.1 The auxiliary AC / DC supply shall be as per clause No. 6 Volume-II, Part-2, Book-I of
the specification.
4.5.2
Bidders may please note that there shall be only one source of DC supply (110 or
220 Volts) and this DC supply shall be common for protection, and indications on each of the
33KV C&R panels
4.5.3
Bidders shall arrange for providing extension of these power supplies to different
circuit of the control panels group.
4.5.4
Isolating devices with H.R.C. fuses shall be provided in each panel for both A.C.
and D.C. power supplies. Distribution and wiring of the same shall be unitised through fuses
4.5.5
All H.R.C. fuses and links shall be with holder and the same shall be mounted on
4.5.6
H.R.C. fuses shall be provided as per following details:

S.NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
CIRCUIT
Circuit breaker-closing circuit.
Trip circuit -I
Trip circuit II
Main Protection
Indication
Annunciation
P.T. Circuit main
AC supply fuses and links
FUSE RATING.
16A
16A
16A
10A
6A
6A
6A
2A
10A
NOTE: Additional HRC fuses for individual circuits shall also be provided as per the
4.6.0
CONTROL WIRING:
4.6.1 Successful Bidders shall furnish and install complete wiring up to the terminal block
for the equipment, instrument devices mounted in the control panels strictly in accordance
151
C & R Panels

with the approved wiring diagram prepared by the Bidders based on the purchaser's
information and schematic diagram.
4.6.2
Wiring shall be complete in all respects so as to ensure proper functioning of
4.6.3
terminal blocks.
4.6.4
Wiring shall be done with flexible heat resistant wires, PVC insulated with stranded
copper conductor. Minimum number of strand in the wire shall be three. Conductor size
shall be equivalent to 2.5 sq mm for Current, potential & DC Control circuit and 1.5 sq mm
for other indications and annunciation circuits.
4.6.5
Coloured cores shall be used for wiring as per latest revision of IS-375 viz; red,
yellow, blue and black for R Y B phases and neutral respectively. Colour code for earthing
shall be Green and for annunciation circuits gray colour code shall be used. For DC circuits
4.6.6
coding schemes.
4.6.7
4.6.8
4.6.9
4.6.10
4.6.11
Since a number of wires will run from one point to another, it is desired that the
4.6.12
Blank plastic channels should be provided by the sides of the panels to
4.6.13
Wherever practicable wiring shall be accommodated in the sidewall of the
cubicles. Sharp bends shall be avoided.
152
C & R Panels

4.7.0
TERMINAL BLOCKS:
the panels wiring and outgoing cables. Terminals shall be suitable for receiving at least
2x7/0.737mm stranded copper conductor or equivalent Aluminium conductor wires per
terminal. It may please be noted that the current rating shall be double the current rating of
2x7/0.737 non stranded copper wire and terminal shall be suitable to receive 2x2.5sq. mm or
2x4sq. mm copper conductor of control cable.
4.7.2
Terminal blocks shall have shorting and disconnection facilities, so that the panels
4.7.3
4.7.4
input wires.
4.7.5
4.7.6
Each terminal point shall be marked with designation obtained from the
purchaser's schematic drawings.
4.7.7
without difficulty.
4.7.8
4.8.0
CABLE ENTRY:
4.8.1
Control panels shall have provision of multiple cable entries from the bottom.
Necessary cable glands should also be provided in the panels on a 4 mm thick mild steel
gland plate to be bolted firmly with nut and bolts on base plate. Base plate shall be bolted
further on the base frame with adequate number of nuts & bolts. Purchaser will arrange for
necessary floor opening below the panels to suit the cable trench design of purchaser's
requirement.
4.8.2
Adequate support for cables entering the panels is an utmost necessity. Cable
entry and subsequent distribution of individual cables should present a tidy look and for
achieving this, bunching shall be avoided. Plastic channels need necessarily be used.
4.8.3.
153
C & R Panels

4.8.4
Control panels shall have provisions for fixing the multicore cable glands, which
shall be included by the BIDDER in scope of supply. For fixing these cable glands,
detachable gland plates of 4mm thickness shall be mounted on the base frame by nuts and
bolts.
4.8.5
and doors shall be provided with gasket properly. Necessary glands as per clause-4.8.6
4.8.6
4.8.7 Following quantities of cable glands per circuit with suitable blanking arrangement
shall be fitted on the gland plate that shall be fastened suitably at the bottom of the control
panels in each simplex panel as per the following details:
i.
ii.
iii.
iv.
v.
For 2 core x 2.5sqmm 1.1KV grade control cable

For 19 core x 2.5sqmm 1.1KV grade Control cable
: 3 nos.
: 2 nos.
: 4 nos.
: 1 no.
: 1 no.
4.9.0 GROUNDING:
4.9.1
Copper strip having size not less than 12.5mm x 6mm grounding bus shall be
provided for each control panel extending along entire length of the panel for the purpose of
effectively grounding all metal structures.
4.9.2
4.9.3
Common star /neutral points of Potential and current transformers shall be
connected with the grounding bus through a disconnecting type connector so that purchaser
may adopt single point grounding of common star point either at the terminal block in the
control panels or in the marshalling box of the instrument transformer.
4.9.4
5.0
CONTROL AND RELAY PANELS:
5.1
Simplex panels shall be provided with lockable doors on rear side. All indicating
instruments, controls, protective relays & mimic diagram etc. for multi feeders shall be
provided on the front side of the control panels.
5.2
Labeling for each circuit shall be provided at each of the front control panels, as
well as inside of the SIMPLEX panels.
5.3
Panels shall be of uniform thickness (minimum 2.5mm) and made of level sheet
steel. Bottom of the cubicle shall be made in a manner to open it for the purpose of wiring
and cable entry. Panels shall be designed to be of self-supporting type and wherever
additional structural strength is required, inconspicuous bracing, gusset-welding etc., shall
be used. All control panels and switchgear cubicles shall be made absolutely vermin proof
design of the approval of the purchaser.
154
C & R Panels
5.4
Panels shall be made in suitable sections to facilitate easy transport and handling
and shall be later assembled at site. It may please be noted carefully that single continuous
sheet steel should not be used for a substation to make a single composite panels for all the
panels where more than one panels is involved.
5.5
Purchaser may ask for accommodation and wiring to be provided on Panels for
additional apparatus supplied under different contracts. Bidders shall agree to make such
provision in accordance with the instructions of the purchaser.
6.0
6.1
Control and indication circuit for each circuit breaker controlling feeder or
transformer shall generally comprise of the following:
6.2
a.
Mimic diagram
b.
A composite meter of size 144 sq mm to indicate current, voltage, Watts

VARs and power factor.
c.
d.
"Trip Healthy" lamps.
e.
f.
g.
3 phase, 4 wire static trivector meter of accuracy class 0.2
MIMIC DIAGRAM:
6.2.1
Coloured mimic diagram and symbols shall represent the exact representation of
system. The mimic diagram for 33 kV shall be made to represent ONE MAIN & TRANSFER
BUS Scheme. Mimic diagram shall be placed at the eye level to indicate the position of
each breaker. Horizontal strip and the droppers shall have width of 10mm and 6 mm
respectively and the strip shall be 3mm thick. Power transformer, voltage transformer shall
be fixed on mimic by suitable symbols having dark Black colour. Position indicator of
isolating devices shall have matching colour in accordance with the voltage class of the
mimic. Arrangement shall be of over laid design using anodized aluminum section. Painted
mimic diagram shall not be acceptable.
6.2.2
Offered mimic diagram shall have colour scheme for representing 33 kV voltage
level as per the details indicated below: Azure blue shade 104 of IS 5
6.3
SEMAPHORE INDICATOR FOR BREAKERS:
6.3.1
Rotating disc semaphore indicator to be provided for this purpose on mimic
diagram shall indicate the position of 33 kV circuit breaker whether closed or open. Position
indicator strip of all semaphore indicators for breaker shall have the colour scheme matching
with specified colour scheme of mimic for various voltage levels.
6.3.2
ON and OFF display position of circuit breakers shall be automatically indicated by
semaphore operation indicator strip on mimic of 33 kV panels using auxiliary switching
contacts of outdoor equipments.
155
C & R Panels

6.3.3
For 33 kV isolators, semaphore indicators need not be provided. Instead of
this, a circle indicating a 45 degree position may be indicated for the isolators.
7.0
ALARM SCHEME:
7.1 Facia annunciators are not envisaged in the scope of supply of equipment to be
provided on the 33KV C&R panels covered by this tender. Instead, an alarm scheme
to provide visual indication and audible alarm during tripping of a feeder or
transformer breaker as envisaged is detailed below:i.
Each category of 33KV C&R Panels covered in this bid shall be supplied with
following items;
a. One No. flasher relay with indicating lamp.
a.
Push buttons for alarm accept and reset.
Relay contacts shall break immediately after the alarm is accepted and reset but not
before the flag of feeder O/C + E/F relay is reset manually. Bidders shall develop the
schematic for alarm scheme accordingly.
iii.
Any other improved version for alarm scheme shall also be acceptable.
8.0
PROTECTION SCHEME:
8.1
Protection scheme to be supplied for this package shall be required for the following
applications:
TYPE-A : Control & Relay Panel for one Transformer plus one Feeder circuit.
TYPE-B : Control & Relay Panel for three-Feeder circuits.
TYPE-C : Control & Relay Panel for one Feeder circuit
Protection schemes meant for above applications are described hereunder:
8.2
PROTECTION SCHEME FOR 33KV ONE TRANSFORMER PLUS ONE FEEDER

CIRCUITS (TYPE-A):
8.2.1 33KV two-circuit panels Type-A, shall have independent control and protection for
one transformer circuit and one feeder circuit. All controls, relays, instruments and other
devices shall be mounted on the front vertical panels. Mimic diagram shall show one main
and transfer bus arrangement for feeder as well as for transformer circuit.
8.2.2
PROTECTION SCHEME FOR FEEDER CIRCUITS :
Out of the two circuits, one circuit on this panel shall have feeder protection required
for 33KV Sub transmission lines. This will be in the form of a Numerical, non-directional and
non-communicable relay having (2O/C + 1E/F elements) an operating time of 1.3 secs at 10
times current setting. Definite time for the over current element shall be continuously
variable and the earth fault element shall have IDMT characteristics as well as high set
feature to take care of currents of smaller as well as larger magnitudes. Bidders shall
elaborate the IDMT characteristics as well as the setting ranges available for high set feature
in the earthfault element.
It may be noted that although the DC supply source is one, 33 kV circuit breakers will
have two trip coils which will receive simultaneous trip command. For this purpose, contact
multiplication will not be acceptable but the rating of the breaker control switch and each
tripping relay contacts shall be adequate to handle the burden of two trip coils. Pistol grip
156
C & R Panels

type breaker control switches along with red and green indicating lamp for ON/OFF
indication shall be provided.
8.2.3 PROTECTION SCHEME FOR TRANSFORMER CIRCUIT:
8.2.3.1
Out of the two, the other circuit on this panel shall have protection for for 33KV
incomer of 132/33KV transformers of capacities of 63, 40 or 20MVA. This protection shall
also be in the form of a Numerical, Non-directional and Non-communicable relays but having
(3O/C + the relay 1E/F) overcurrent and earthfault elements having operating time of 3
seconds at 10 times the current setting. Bidders shall elaborate the IDMT characteristics
available in the relay and different setting possibilities and may please note that high set
feature is not required for the earthfault element of this relay.
8.2.3.2 Bidders may please note that we have envisaged under frequency relay with
tripping relay in 33kV (1T + 1F) category panels. Technical details for these relays
have been given under clause No. 22.0 of this section. Bidders are requested to go
through technical details of these relays while submitting offer for 33 kV (1T+1F)
category panels.
Bidders may quote rates for 33kV (1T+1F) with/without under
frequency relays and tripping relays in the Schedule-I Price Schedule. This is
mandatory requirement.
8.2.4 PROTECTION SCHEME FOR 33KV THREE FEEDER CIRCUITS (TYPE-B):
8.2.4.1
33KV three-feeder circuit panels Type-B, shall have independent control and
protection for each of the three Feeder Circuits. All controls, relays, instruments and other
devices shall be mounted on the front vertical panels. Mimic diagram shall show one main
and transfer bus arrangement for each feeder circuit as stated earlier.
8.2.4.2 33 kV three-feeder circuit panels shall have dedicated protection and control
scheme described above under clause 8.2.2 for feeder protection and mimic diagram shall
have symbol for each feeder circuit.
8.2.5: PROTECTION SCHEME FOR 33KV ONE FEEDER CIRCUIT (TYPE C).
8.2.5.1 33KV Control and relay panel for one Feeder circuit shall have control and
protection for one 33KV feeder. All controls, relays, instruments and other gadgets shall be
mounted on front of the panel and mimic diagram shall show one main and a transfer bus
arrangement for feeder circuit.
8.2.5.2
33KV one feeder circuit shall have dedicated protection and control scheme
required for 33KV Sub transmission lines. This will be in the form of a Numerical, nondirectional and non-communicable relay having (2O/C + 1E/F elements) an operating time
of 1.3 secs at 10 times current setting. Definite time for the over current element shall be
continuously variable and the earth fault element shall have IDMT characteristics as well as
high set feature to take care of currents of smaller as well as larger magnitudes. Bidders
shall elaborate the IDMT characteristics as well as the setting ranges available for high set
feature in the earthfault element.
8.2.5.3 It may be noted that although the DC supply source is one, 33 kV circuit breakers
will have two trip coils which will receive simultaneous trip command. For this purpose,
contact multiplication will not be acceptable but the rating of the breaker control switch and
each tripping relay contacts shall be adequate to handle the burden of two trip coils. Pistol
grip type breaker control switches along with red and green indicating lamp for ON/OFF
indication shall be provided.
157
C & R Panels

8.3
OTHER IMPORTANT PROTECTIONS:
8.3.1
TRIP CIRCUIT SUPERVISION :
Trip circuit supervision relays are envisaged only on transformer circuits. It is hereby
clarified that 33KV Vacuum circuit breakers shall be provided with two trip coils although
source of DC 110V Supply is only one. As such we envisage one Trip circuit supervision
relay for each coil of the breaker to monitor protection DC exclusively. These relays shall
continuously monitor trip circuit for both pre and post close conditions. Trip healthy lamps
shall be provided for pre and post close monitoring and while pre close lamp shall be on
demand type, the post close lamp shall be of continuous display type. During failure of trip
circuit, the trip circuit supervision relay shall initiate an audible alarm.
9.0
DC SUPPLY SUPERISION:
Bidders may clarify if DC supply supervision is a built in feature of the Numerical

relays offered by them. If not, then they may offer discrete relay for both the transformer
and feeder protection scheme.
10.
ACCESSORIES:
10.1
ENERGY METERS:
The energy meter for each circuit shall be 3 phase 4 wire, 0.2S accuracy class with
availability based tariff. One meter shall be provided for each circuit, as a self-contained
device for measurement of power transmittals, in each successive 15 minute block, and
certain other functions. The meters provided in C&R panels shall be utilized for
measurement of active energy and average frequency in a programmable time clock initially
set at 15 minute blocks. Meters shall measure and display reactive energy under voltage low
(97%) and voltage high (103%) condition as per tariff requirement. Meters shall measure
cumulative active energy import and export on daily basis and monthly basis. The Base
Computer software (BCS) shall be configurable to cater to tariff applications like Time of Day
(TOD) metering. In case of change of threshold values of voltages, the supplier shall
undertake to set new threshold values of voltage. It shall be possible to select parameters of
Meters as per requirement of Purchaser. Meter shall be fully static having non volatile
memory and fully programmable. Meter shall have four quadrant registering facility with
provision for recording/display various parameters like KWh, KVAh, KVARh, Line current
and voltages including power factor. Load survey capability for 35 days shall be available to
forecast load growth. Meter shall have 0.2S accuracy class.
IEC 62052-11-2003, IEC 62053-22-2003 as under:
ix)
158
C & R Panels

x)
xi)
xii)

(vii)
(viii)
(ix)
(x)
(xi)
(xii)
Item
CT secondary
VT secondary
System frequency
Earthing System
Details
1A
110 V/ 3 Volts
50 HZ + 5%
Solidly Grounded
110V/220V+ 20%
(BCS).
10.2 a) MULTIFUNCTION METER:
10.2.1
We envisage a multifunction meter on the panel to provide digital display of
current, voltage, Watts, VARS and Power Factor. This meter shall have scrolling facility to
facilitate reading any of these parameters and it will have a size of 144 sq mm. Bidders may
please note that the meter shall be capable of reading voltages upto a maximum value of
50KV. This meter shall have an accuracy class of 0.5.
10.2.2 The multifunction meter shall have four and a half digit display, for example,
132.8KV, with a height of each digit as 25.0mm. This meter shall conform to IS 722 and
shall be provided with non-reflecting glass fronts. Bidders may please note that the meter
shall be suitable for DC Supply voltage of 110Volts or 220Volts as the case may be.
AC Supply operated meters are not acceptable. Offered meter shall be of reputed make
subject to our approval.
Bidders may please note very carefully that the Multi function meter shall have
communication facility through serial port type RS485 with Modbus protocol complete with
downloading software.
b)
10.3
SWITCHES:
identification.
159
C & R Panels
Selection of operating handles for
10.3.2
follows:
a.
b.
c.

Selector switches
Instrument switches
the different type of switches shall be as

10.3.3 Breaker control switch shall be of spring return to neutral 3 position type. Control
10.4
INDICATING LAMPS:
10.4.1 All indicating lamps shall be LED type.

10.4.2 Indicating lamps shall be panels-mounting type with rear terminal connections. Lamps
Lamps shall have translucent lamp covers to diffuse different colours e.g. red, green, amber,
clear white or blue to differentiate system function. Lamp cover shall be preferably of
screwed type, unbreakable and moulded from heat resistance material. Wattage of
indicating lamps shall be as follows:
a.
b.
10.4.3
220V - 5 to 10W
110V - 5 to 10W
Wattage of the neon lamp shall be 0.25 to 0.5W if provided.
10.4.4 Bulbs and lenses shall be interchangeable and easily replaceable from the front of
the panels. Indicating lamp with resistor shall withstand 120% of rated voltage on continuous
basis.
10.5 CIRCUIT BREAKER POSITION INDICATORS:
Position indicators of `SEMAPHORE' TYPE shall be provided as part of the mimic
mimic busbars and at right angles to them, when the object is in the open position. When
supply failure to the indicator occurs, pointer shall take up an intermediate position to
continuous basis. No semaphores shall be provided for isolator position . Instead, a
circle showing isolator position at 45 degrees shall be made as mentioned earlier.
10.6 PUSH BUTTONS: Push buttons shall be momentary contact type with rear terminal
connections. Where ever required the push buttons shall be suitably surrounded to prevent
inadvertent operation. These shall be provided with integral inscription plates engraved with
their functions. All push buttons shall have minimum two normally open and two normally
closed contacts. Contacts faces shall be silver plated. and shall be suitable for make/break
and carry appropriate currents for the functions desired.
160
C & R Panels

11.0
RELAYS:
11.1. All relays to be supplied with 33KV C&R panels covered by this bid shall be hand reset type.
11.3 Indicators shall also be provided on such additional equipment to identify faulty
phase and type of fault. Each indicator whether electrically or mechanically operated shall be
resetted by hand without opening the relay case. Each indicator shall be so designed that it
should not be moved before the relay has completed its operation. It shall not be possible to
test and operate any relay by hand without opening case.
the front.
11.6 All relays shall be designed to operate at system frequency of 50 Hz. Voltage
operated relays shall be designed for star connected 110 Volt VT secondary supply and
current operated relays of 1 amp CT secondary as specified in the specification. DC
auxiliary relays and timers shall be designed for specified DC voltage and shall operate
contacts shall be done at the external terminals of relay if required.
11.8 Timers shall be of the solid-state type. Short time delay in term of milliseconds may
be obtained by using copper lugs on auxiliary relays. In such case it shall be ensured that
the continuous rating of the relay is not affected. Time delay in terms of milliseconds
obtained using external capacitor resistor combination is not preferred and shall be avoided
to the extent possible.
12.0 Numerical relays shall have compliance to following requirements All numerical, solid state and electronic relays shall have compliance to the following
requirements:
161
C & R Panels
a. Printed circuit panels/cards shall be fin type and its contact shall be gold plated. All
connections with the connector pegs shall be through wire wrapping. All solder joints
on the printed circuit panels shall be encapsulated or covered with varnish.
b. Components used in these relays shall be loaded under normal condition by less
than half of their rated values. Resistors shall be of carbon composition or metal
oxide type and the capacitors shall be plastic film or tantalum type. Stringent
measures including shielding of long internal wiring should be taken to make relays
immune to voltage spikes as per IEC. Relays must meet the requirements of IEC255-4 appendix È' class III regarding BF, disturbance tests IEC-255-4 regarding
impulse test at 5KV and transients present in CT & VT connections due to
extraneous sources, do not cause damage to any of associated static circuits.
c. All relays shall be designed for satisfactory performance under tropical and humid
conditions. Special mention shall be made in the technical deviations schedule of the
Bid for those relays, if any that Bidder proposes to use which differ from specified
requirements.
d. All devices required for correct operation of each relay shall be provided by
contractor without any extra cost.
e. It will be ensured that the terminals of the contacts of the relays are readily brought
out for connections as required in the final approved scheme. Type of relay case size
offered shall not create any restriction on availability of the contact terminals for
wiring connections.
f.
DC/DC converter or power supply unit shall be provided for the solid state protective
relay wherever necessary in order to provide a stable auxiliary supply for relay
operation.
g. Solid state relays shall be stable and suitably protected against transient/induced
over voltages and noise signals. Bidders shall state clearly in their Tenders,
special requirements if any for DC input arrangement or cabling considered
necessary for satisfactory operation of solid state relays quoted by him.
h. Timers shall be of the solid state type. Short time delay in term of milliseconds may
be obtained by using copper lugs on auxiliary relays. In such case it shall be
ensured that the continuous rating of the relay is not affected. Time delay in terms of
milliseconds obtained using external capacitor resistor combination is not preferred
and shall be avoided to the extent possible.
13.0 TESTS:
Manufacturers shall carry out type and routine tests on the relays and complete
panels as per relevant Indian Standard or any equivalent International Standards and as
13.1
162
C & R Panels

13.2
i.
ii.
iii.
iv.
v.
vi.

Other routine tests on all associated equipment and relays as per relevant
Verification of indication and alarm operation.
vii.
13.3 After all tests have been carried out, four copies of each test report/inspection report
shall be furnished. Each report shall supply the following information
i.
ii.
The routine test reports for all the panels.
13.4
Supply of equipment shall be subject to the approval of Test Certificates by
purchaser.
14.0 CONTROL CONNECTIONS AND INSTRUMENT WIRING:
14.1 Connections for switchgear operation and indications between the control and relay
panels where ever separate termination for instrument and relay wiring on these control &
relay panels and multicore cable terminal boxes are involved, these shall form a portion of
the scheme for panels and under scope of supply of the control panels gear as stated by the
Bidder.
14.2
Panels connection shall be insulated and shall be neatly and securely fixed to the
back of the panels. All instrument and panels wiring shall be of approved type, which shall
be fire retardant and shall be run in porcelain or non-rustable metal cleats or in non-rustable
tubes or galvanized steel tubes as may be approved. All panel wiring shall be taken to
terminal panels, which shall comply with requirements of multicore cable boxes where
applicable. Panel wiring shall be PVC or VC braided impregnated with flameproof
14.3 All wiring diagrams shall be clearly marked with the numbers, which are shown on
panel.
14.5 Each set of current & voltage transformer secondary connections shall be complete in
all respect and shall be connected to form common star point. Star point shall be earthed at
one point only. Each such earth connection to the earth bar shall be made in accordance
with the requirement of the earth system and shall be made through a disconnecting link
which can be removed when insulation tests are required without breaking any circuit
normally carrying current.
14.6 For each circuit on the panels, the control indication and trip wiring shall be suitably
163
C & R Panels

relays. These shall be of the switch board type with connection at the back, mounted on front
of panels. Test blocks shall provide complete isolation of meters, instruments and relays and
15.0

painting. Process can be broadly divided as `Metal treatment and painting'.
15.1
METAL TREATMENT:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
15.2
Degreasing: This can be achieved either by immersing in hot alkaline

degreasing bath or in hot di-chloroethelene solution. After degreasing
operation the surface shall be cleaned thoroughly with cold water.
in dilute sulphuric acid (approximately 20%) at nearly 60 deg. centigrade so
as to totally remove scale and rust.
Phosphating : Immerse in grenadine zinc phosphate solution for about 20
minutes at 80 to 90 degree centigrade . Uniform phosphate coating of 4 to 5
gm per sq. meter shall be achieved.
Rinse in Deorylyte bath at 70 to 80 degree centigrade to neutralize any traces
of salts.
PAINTING:
Sequence of Processes shall be as follows:i.
ii.
iii.
iv.
Primer spray: Apply one coat of primer spray on wet surface by specially
developed `High luster' zinc chromate primer and to stove at 150-160 deg.
Centigrade for 25 to 30 minutes. Alternatively red-oxide primer with zinc
chromate contents may be used. However former process shall be preferred.
Rubbing and putting : Apply putty to fill up the scars if any to present
smooth surface and stove 15 to 20 minutes. Apply putty several times to
get the perfect smooth finish.
Surfacing: Sand down with mechanical abrasive and stove for 20 minutes.
Primer: Spray second coat of primer as per (i) above or grey primer surface
164
C & R Panels

v.
vi.
Finish: Rubbing down dry and spray first coat of synthetic enamel finish paint
Surfacing: Sand down or rub dry to prepare for final finish spray. Coats of
minutes.
NOTE:
i
ii
iii
16.0

Small coating paint shall be supplied along with equipment for touching up at
site.
DRAWINGS & LITERATURE (PANEL METERS & RELAYS):
16.1.1
General arrangement and schematics showings with all major details shall be
submitted with the tender.
16.1.2
Immediately after award of the contract, manufacturer shall submit GA and
schematics drawing of each panel for the approval of the purchaser.
16.1.3
Successful Bidders shall have to supply one set of drawings and a set of
manuals per panels properly packed in plastic jacket; each containing approved GA,
Schematic and wiring drawings illustrative pamphlets of meters, literature and
commissioning instructions for all relays under his scope of supply. Besides this, one
set of drawings (GA+Schematic) and a set of manual per panels shall be forwarded to
the O/o CE(PLG).THIS IS MANDATORY.
17.0
accessories shall be furnished along with the tender. While submitting technical particulars,
clear picture of device offered, along with literature/write-up. Unless otherwise specified, all
the 33KV panels shall be suitable for the auxiliary DC voltage of 110 V.
18.0
18.1
18.1.1
Bidders must establish that they are following a proper quality assurance program
for manufacture of control and relay panels. In order to ensure this, suitable QAP should
form a part of the technical tender, which will be submitted against this Bid document.
Quality Assurance Program must have a structure as detailed in the following paragraphs.
18.1.2 Quality assurance and failure prevention starts with careful study and scrutiny of
our technical specifications and requirements. Suppliers shall carefully study all the technical
parameters and other particulars & the supplier shall categorically give his confirmation that
18.1.3
Supplier shall furnish the checks exercised in design calculations particularly in
165
C & R Panels

18.1.4
Supplier shall indicate the various sources of the bought out items. Type of
checks, quantum of checks and acceptance norms shall be intimated and random test and
check results should be made available for inspection whenever so desired. Vendor list for
various bought out items shall be submitted with the Bid and the same shall be subject to
be obligatory on the part of Bidders to allow third party inspection of all important material
and in case during independent third party inspection any of the above material is found
different than from approved list of vendors, Purchaser reserves the right to summarily reject
18.1.5
Based on above QAP and offered delivery schedule a tentative program chart
QAP. Program chart should specify periods for various activities i.e. design, ordering of new
18.2
INSPECTION:
18.2.1 Acceptance of any quantity of panels shall in no way relieve the successful Bidders
of his responsibility for meeting all the requirement of this specification and shall not prevent
18.2.2 No material shall be dispatched from its point of manufacture unless the material has
been satisfactorily inspected and tested.
18.2.3 At the time of inspection, the Bidders shall identify each and every gadget and
relays on the ordered panels. Unless all the items are identified, the manufacture will not be
treated as complete. Serial number of Relays & other gadgets shall be entered into the test
report. Various tests stipulated in IS shall be performed in the presence of purchasers
engineers or when the inspection waiver has been given, in such a case, the testing
shall be done at the manufacturer's works as per IS stipulations and same should be
confirmed by documentary evidence by way of Test Certificate which shall be got
approved by the purchaser.
18.2.4 Whenever inspection call is given, letter of inspection call will accompany the
following:
a.
Number of panels type 1T + 1F, 1F and 3F which are ready at the works and
shall be offered for inspection. The Inspecting Officer shall get the number of
panels checked before commencing the inspection.
b.
The Inspecting Officer shall randomly select panels type 1T + 1F, 1F and 3F
(approx. 10% quantity of the offered panels) for conducing the routine tests
after all the gadgets and relays provided on the panel have been verified.
c.
complete with all accessories, the Purchaser will reserve the right to recover
the complete cost of deputation of inspecting team to the works of the
manufacturer.
18.3
Responsibility for obtaining timely supplies of bought out items will rest on the and
only on this basis, delivery period will be offered in the Tender. For bought out items,
166
C & R Panels

may be bought out item for the Bidders; services of engineer of original manufacturer is
required, the same will be organized on immediate basis by the Bidders at their cost.
18.4 Bidders may ensure that pages have been properly numbered and signed. All bid
documents including schedules should be indexed properly and Index of the documents
should be enclosed/placed at the beginning of the Bid document.
19.0
33KV Control and relay panels shall have following instruments, relays and
accessories to be provided per circuit on each feeder and transformer panels as per the type
of protection indicated above under clause-8.1 by the purchaser:
(Quantity and Number Shown Below Are Required For Each Transformer Circuit &
Feeder Circuit in Single and Multi Circuit Control Panels)
S.
No.
1
2
3
4
5
6
7
8a
8b
9
10
Particulars
Type of panel
Box type circuit label inscription (50x100mm)
indicating Name of feeder/Xmer in side & out side of
panel
Purchasers order no. Serial no.& Bidders label to
be placed inside of panel.
Over laid Mimic diagram with uniform 3mm
thickness 10mm width for horizontal strip and 6mm
width for the droppers.
Red and Green lamps (LED Type) with holder for
circuit breaker ON/OFF position indication for each
transformer/feeder circuits.
Pistol grip Circuit breaker control switch with three
positions; ON, OFF & return to neutral.
Semaphore to indicate circuit breaker position
automatically
One multifunction meter to indicate line and phase
currents, line and phase voltages, active power
(MW), reactive power (MVAR) & Power factor. This
meter shall have scrolling facility to facilitate reading
any of these parameters. This meter shall have four
and a half digit display and shall be of size 144 sq.
mm and it shall have a scale of 0 to 50KV for
voltage reading (secondary rating 110V Phase to
phase and 1 Amp). The meter shall have an
accuracy class of 0.5, shall be suitable for LED
display of letters and the size of digit shall be 25
mm.
Analogue of type center zero MVAR meter
Test terminal block for 3phase 4wire static energy
meter. (Make of the TTB shall be to purchasers
approval).
Static trivector Energy meter - 3 phase 4 wire type
having an accuracy class of 0.2S
167
Feeder
Circuit
Simplex
Two
Transformer
Circuit
Simplex
Two
One
One
One Main One Main and

Transfer Bus
and
Transfer
Bus
One
One
Set
Set
One
One
One
One
One
One
One
One
One
One
One
One
C & R Panels

S.
No.
11
12 (A)
12 (B)
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Particulars
Push buttons for DC supply fail test/accept/reset
facilities.
Trip circuit supervision relays for pre and post close
supervision (**)
DC supply supervision relay
Trip circuit supervision healthy indication lamp with
push button to select pre & post close supervision.
The pre close supervision shall be on demand and
post close supervision shall be continuous.
Numerical, non-directional and non-communicable
IDMT relay having two overcurrent and one
earthfault elements having time of operation at 1.3
Sec. at 10 times current settings for protection of 33
kV feeder circuits. The earthfault element shall have
IDMT characteristics as well as high set feature (as
described in Clause no. 8.2.2 of the specification.
Numerical, non-directional and non-communicable
IDMT relay having three overcurrent and one
earthfault elements and also having time of
operation at 3.0 Sec. at 10 times current settings
(as described in Clause no. 8.2.3 of the
specification).
Fast acting master trip/high speed trip relay with
contacts suitable for handling burden of 2 nos.
circuit breaker trip coils in parallel.
Under Frequency Relay
Tripping relays for u/f relay with 10 Nos NO contacts
Space heaters with switch in each panel.
15/5A, 250Volts universal power socket with plug
with protective metallic cover & switch.
20Watt Tube light or CFL with door switch.
DC hooter for trip signals
AC Bell for DC supply supervision
Gland plate fitted with Cable glands.
Fixing bolts
Any other accessories/gadget/relay needed for
correct and successful operation/protection for the
control and relay panel offered by the Bidders.
Feeder
Circuit
Three
Transformer
Circuit
Three
-One
Two
Two(One For
Each Trip Coil)
One
Two
One
--
--
One
One
One
--One
One
One
One
One
One
One
One
One
One Set
One Set
One Set
One
One
One
One Set
One Set
One Set
(**)Bidders may please note that although the breaker shall have two trip coils,
the source of DC supply shall be only one. Accordingly, two trip circuit supervision
relays are envisaged for the transformer circuits only.
IMPORTANT NOTE:
1.
Bidders shall indicate Unit prices for all the gadgets and relays for the 33KV
Class panels for feeder and transformer circuits offered by them. This has to be
strictly complied. Prices of the gadgets and relays shall form a part of the Schedule-I
about details of equipment and quantity for 33KV C&R panels.
168
C & R Panels
2.
Bidders may elaborate the setting possibilities available in the over current as
well as earthfault elements of IDMT numerical relays offered by them.
20.0 DOUBLE STAGE UNDER FREQUENCY RELAY WITH CONTACT MULTIPLIERS
TRIPPING RELAY:
20.1 These relays are required to monitor the System frequency on continuous basis.
Sudden tripping / outage of generator sets or sudden increase in load in integrated grid
system operation, always results in lowering down of system frequency, which may lead to
emergency conditions. Under such system distress conditions it becomes necessary to
resort to immediate load relief to control system frequency for maintaining load and
generation balance. Under frequency relays should be able to sense lowering of system
frequency and shall have provision to initiate trip command to trip circuit breakers of
identified feeders for load shedding. Our requirement in this regard is described below:20.2 It is desired that the load shedding is to be resorted to, in two stages through under
frequency relays. i.e. on a particular set frequency the circuit breakers of one group of
feeders may be tripped, and in addition at another frequency setting, the circuit breakers
of another group of feeders are made to trip. Initiation of tripping commands for both groups
will be based on operation of under frequency relays on account of decrease in system
frequency. Feeder trippings sometimes are also required to be delayed and therefore in
each stage of under frequency relay separate timer is required for our load shedding
scheme. Since in every EHV substation there may be more than one feeder which is to be
tripped simultaneously, thus the offered under frequency relays shall have independent
tripping relays having minimum 10 pairs of normally open contacts in addition to a timer. The
N/O contacts of trip relay shall be hand reset type.
20.3 Both the stages of
under frequency relay shall have provision for independent
frequency setting, independent timers for time delay settings and independent tripping relays
for tripping of minimum eight breakers of group of feeders. The contact rating of tripping
relays shall be such that these are capable of handling normal wattage of 200 Watts of the
trip coils.
20.4.
We have to ensure to provide specified load relief to the system under varying
under frequency conditions. This calls for a relay of high accuracy and also calls for sure
setting arrangement to detect lowering of frequency. In case of relays having potentiometer
setting arrangement, accurate setting of the order 0.05Hz is not possible and may lead to
doubtful performance. Therefore preference will be given for under frequency relays with
digital matrix setting. Please specify the method adopted in the offered relays. As stated
earlier, bidders may please note that the under frequency relays covered by this bid shall be
hand reset type.
20.5.
Each timer of the double stage under frequency relay should have a provision for
minimum setting of time delay continuously varying from 0.05 to 5 seconds in step of 0.05
seconds. Each independent tripping relay should have minimum 10 pairs of normally open
hand reset type contacts with flag indicating arrangement. Each pair of contact of a tripping
relay shall be adequately rated to break inductive DC current of trip coils having approximate
200 Watt burden as stated earlier.
20.6
In addition to the requirements indicated above the under frequency relay should
meet following specifications :
i.
ii.
Input to the relay

Auxiliary DC voltage
110V AC ph to ph from Bus PT.

110V OR 220 V.
169
C & R Panels

iii.
iv.
v.
vi.
vii
viii.
Range of setting of each stage 47 to 53Hz in steps of not more than 0.05Hz.
of
double
stage
Under
frequency relay
Accuracy
Within (+)/(-) 5% of setting
AC burden
Should be low so that existing PTs are not
overloaded. In any case combined burden
should be less than 10VA for double stage.
No. of Contacts for tripping 10 pairs of N/O contacts are required. These
relays
contacts should be liberally rated to handle trip
coil DC inductive burden of approx. 200 Watt.
Contacts shall preferably be H/R type.
No. of Contacts for under 2 pairs of NO contact for each stage
frequency relay
Indicator
Operation indicator is required for each stage of
U/F relay.
ix
Range of Timer
Case
Continuously varying from 0.05 to 5 secs. in

steps of 0.05 sec for both the states separately.
The relays shall be panel mounting type of flush
pattern.
170
C & R Panels
2.1.2 (E)TECHNICAL SPECIFICATION FOR INDOOR 33KV CONTROL AND

RELAY PANELS FOR CAPACITOR BANK
1.0
SCOPE:

means the MPPTCL.
1.1
The Simplex design 33 kV control and relay panels included in the instant bid are
required for the Protection of Shunt Capacitor Bank.
2.0
LIMITS OF CONTRACT:
2.1
It is not the intent to specify completely all the details of design and construction of
the control and relay panels. However, the panels shall conform in all respects to the high
standard of engineering design and workmanship. Various control and relay panels and
panels, earthing terminals, indicating lamps, mimic diagram, alarm scheme, name plate,
satisfactory operation . Such components shall be deemed to be included in the scope of
supply of the Bidders irrespective of whether these are specifically brought out in this
specification or not.
2.2
cable hold support boxes, multicore cable glands, sealing ends for other types of cables that
may be specified, shall however be included in the offered price. These shall be subject to
approval of purchaser. It is the responsibility of Bidders to ensure that the equipment
provide panels with larger dimensions in width only.
3.0
3.1
4.0
PANEL FINISH AND COLOUR 33KV SIMPLEX DESIGN PANEL :
33KV C&R panels shall be of Simplex design and each panel shall be constructed of
stretched level selected sheet steel. Simplex type panels shall be made in suitable
sections so that while mounting the panels can be located side by side with a view to form a
compact unit. The 33KV Simplex design panels shall have front door of swing type and rear
blocked with control gadgets and relays flush mounted.
4.1
33KV C&R panels of SIMPLEX design shall consist of a vertical front panel with all
171
C & R Panels

Door will be provided at the back with flush type lock arrangement.

4.1.2 Other salient features applicable for 33 KV Simplex design panels
IS: 5.
4.2 COMPLIANCE OF PANELS, RELAYS, INSTRUMENTS AND OTHER GADGETS

4.2.1 Applicable Standards for the offered equipments/items shall be as per Volume-II,
Part-2, Book-I.
4.2.2 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS:
In the paragraph 4.2.1 above, relevant Indian /British /IEC standard specifications
have been mentioned. However, the equipment meeting any other authoritative international
standard, which ensures equal or better quality than the standards, mentioned shall also be
172
C & R Panels

acceptable. Equipment for which Indian Standards are not available, the relevant British
standards and IEC recommendations will be applicable. Please attach photocopy of all such
standards according to which the equipment has been offered.
4.2.3 TYPE TESTS:
All offered Numerical/Static/Electromechanical relays and meters on C&R Panels
of the type and design offered, has already been type tested, the shall invariably furnish
type
test
reports
from
the
reputed
and
approved
national/international
the date of opening of Tender.
It may be very specifically` noted that non-submission of type test reports about
conventional relays and also about static meters along with the Bid shall be treated as a
disqualification.
(A) Details of Relays & Meters to be used with C&R Panels for Capacitor Bank:i.
ii.
iii.
iv
v
4.2.4
Numerical IDMT relay having two over current and one earth fault element (Non
directional). Time of operation 1.3. Seconds at 10 times current setting
Over Voltage & Under Voltage Protection Relays
Unbalance Protection relay
Ammeter and Voltmeter having accuracy class 0.5
MVAR meter having accuracy class 0.5

4.3.0
4.3.1
33kV Control & relay panels shall be of SIMPLEX design. Each panel shall be
constructed of stretch-level selected steel sheets. Panels shall be made in suitable sections
so that while mounting, panels can be located side by side, bolted together to form a
compact unit.
4.3.2
33 kV SIMPLEX type panels shall consist of a vertical front panel with all
equipment mounted thereon including protective relay, indicating/recording instruments and
energy meters etc. and having wiring access from the rear. Double leaf door with lift off
hinges shall be provided at the back. Doors shall have handles with built in locking facility.
4.3.3 Control panels shall be sheet steel enclosed and shall be dust, moisture and vermin
proof. Panels shall be fabricated of 2.5 mm thick steel sheet on all sides free from all surface
defects. Panels shall have sufficient structural reinforcement to ensure a plain surface and
rigidity to limit vibration during dispatch, installation and service.
4.3.4
Constructional details and sizes for both type 33 kV C&R panels shall be as under:(MPPTCLs standard drawing may please be referred)
173
C & R Panels

S.No.
1
2
Particulars
33KV Panels
Simplex
2250(Panel Height 2190mm + Base frame of
60mm)
560 (without corridor)
660
Type
Height(mm)
3
4
Depth(mm)
Width (mm) (Subject to variation as
per scheme requirement)
5
6
7
8
9
Base frame
Panel exterior
Panel Interior
Number of feeder(F)OR
Transformer(T)
circuits per panel
Anti-corrosive Black painted

Opaline Green
Egg Shell white
Azure blue
Control panels are required in the followting
three formations:
i. One transformer plus one feeder
circuit.
ii. Three feeder circuits.
iii. One feeder circuit.
10
Variation in dimension of panels.
Bidders may note that the height and depth

of control panels will have to be maintained
as mentioned against Sl. No. 2 & 3 above. As
far as width of the control panels is
concerned the same may be offered based
on optimum design to accommodate
specified number of circuits as also the
various relays and accessories, which are to
be mounted on the panels.
DIMENSIONAL DETAILS FOR 33 KV C&R PANELS

S
No.
1.
Category of panels
Height (mm)
Capacitor Bank Panel
2250 (2190mm + 60 mm base pad)
Width
(mm)
660
Depth
(mm)
560
4.3.5
Preferred panel cut out dimensions for mounting of the relays shall be as per
Indian Standard Specification IS-4483 (PART I & II) and MPPTCLs standard shown in
drawing. Please note that since purchaser has standardised dimensions of the panels for
their system, therefore no deviation in height/depth will be permitted. Bidders must submit
general arrangement drawing for each type of panel offered by them.
4.3.6
Control & Relay panels shall be floor mounting dead front sheet steel assemblies of
unitised design. Panels shall be made in suitable sections as described else where in the
form a compact and composite unit. Design, material selection, workmanship and width of
panels.
4.4.0
PANEL LIGHTING:
4.4.1
In each SIMPLEX panel, one 20W, 230 Volt tube light guarded with protected cage
shall be provided below the central roof for adequate illumination & the same shall be
controlled by door switch.
174
C & R Panels

4.4.2 One number universal 15A/5A pin receiptable socket with cover and switch shall be
provided in each control panels. Third pin of the socket shall be effectively grounded through
the metallic structure. Socket shall be of industrial grade control panels type complete with
4.5.0
AUXILIARY SUPPLY:
4.5.1 The auxiliary AC / DC supply shall be as per clause No. 6 Volume-II, Part-2, Book-I
of the specification
4.5.2 Bidders may please note that there shall be only one source of DC supply (110 or 220
Volts) and this DC supply shall be common for protection, and indications on each of the
33KV C&R panels
4.5.3
Bidders shall arrange for providing extension of these power supplies to different
circuit of the control panels group.
4.5.5
Isolating devices with H.R.C. fuses shall be provided in each panel for both A.C.
and D.C. power supplies. Distribution and wiring of the same shall be unitised through fuses
4.5.5
All H.R.C. fuses and links shall be with holder and the same shall be mounted on
4.5.6
H.R.C. fuses shall be provided as per following details:

S.NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
CIRCUIT
Circuit breaker-closing circuit.
Trip circuit -I
Trip circuit II
Main Protection
Indication
Annunciation
P.T. Circuit main
AC supply fuses and links
FUSE RATING.
16A
16A
16A
10A
6A
6A
6A
2A
10A
NOTE: Additional HRC fuses for individual circuits shall also be provided as per the
4.6.0 CONTROL WIRING:
4.6.1 Successful Bidders shall furnish and install complete wiring up to the terminal block for
the equipment, instrument devices mounted in the control panels strictly in accordance with
the approved wiring diagram prepared by the Bidders based on the purchaser's information
and schematic diagram.
4.6.2
Wiring shall be complete in all respects so as to ensure proper functioning of
175
C & R Panels

4.6.3
terminal blocks.
4.6.4
Wiring shall be done with flexible heat resistant wires, PVC insulated with stranded
copper conductor. Minimum number of strand in the wire shall be three. Conductor size
shall be equivalent to 2.5 sq mm for Current, potential & DC Control circuit and 1.5 sq mm
for other indications and annunciation circuits.
4.6.5
Coloured cores shall be used for wiring as per latest revision of IS-375 viz; red,
yellow, blue and black for R Y B phases and neutral respectively. Colour code for earthing
shall be Green and for annunciation circuits gray colour code shall be used. For DC circuits
4.6.6 Each wire shall be identified at its both ends with wire designation number by plastic
ferrule as per wiring diagram based on latest revision of IS-375 to denote the different circuit
functions. Bidders shall take approval for the system of wire numbering and colour coding
schemes.
4.6.7
4.6.8
4.6.9
4.6.10
4.6.13 Wherever practicable wiring shall be accommodated in the sidewall of the cubicles.
4.7.0
TERMINAL BLOCKS:
the panels wiring and outgoing cables. Terminals shall be suitable for receiving at least
2x7/0.737mm stranded copper conductor or equivalent Aluminium conductor wires per
terminal. It may please be noted that the current rating shall be double the current rating of
176
C & R Panels

2x7/0.737 non stranded copper wire and terminal shall be suitable to receive 2x2.5sq. mm or
2x4sq. mm copper conductor of control cable.
4.7.2 Terminal blocks shall have shorting and disconnection facilities, so that the panels
4.7.3
4.7.4
input wires.
4.7.5
4.7.6 Each terminal point shall be marked with designation obtained from the purchaser's
schematic drawings.
4.7.7
without difficulty.
4.7.8
4.8.0
CABLE ENTRY:
4.8.1
Control panels shall have provision of multiple cable entries from the bottom.
Necessary cable glands should also be provided in the panels on a 4 mm thick mild steel
gland plate to be bolted firmly with nut and bolts on base plate. Base plate shall be bolted
further on the base frame with adequate number of nuts & bolts. Purchaser will arrange for
necessary floor opening below the panels to suit the cable trench design of purchaser's
requirement.
4.8.2
Adequate support for cables entering the panels is an utmost necessity. Cable
entry and subsequent distribution of individual cables should present a tidy look and for
achieving this, bunching shall be avoided. Plastic channels need necessarily be used.
4.8.3.
4.8.4
Control panels shall have provisions for fixing the multicore cable glands, which
shall be included by the BIDDER in scope of supply. For fixing these cable glands,
detachable gland plates of 4mm thickness shall be mounted on the base frame by nuts and
bolts.
4.8.5
and doors shall be provided with gasket properly. Necessary glands as per clause-4.8.6
177
C & R Panels
4.8.6 Rigid supports shall be provided along with terminal block for holding plastic channel.
Suitable clamps may also be provided in plastic channel for holding cables.
4.8.7 Following quantities of cable glands per circuit with suitable blanking arrangement
shall be fitted on the gland plate that shall be fastened suitably at the bottom of the control
panels in each simplex panel as per the following details:
i.
ii.
iii.
iv.

For 19 core x 2.5sqmm 1.1KV grade Control cable
:
:
:
:
2 nos.
4 nos.
1 no.
1 no.
4.9.0 GROUNDING:
4.9.1
Copper strip having size not less than 12.5mm x 6mm or alternatively 25 mm x 3
mm grounding bus shall be provided for each control panel extending along entire length of
the panel for the purpose of effectively grounding all metal structures.
4.9.2
4.9.3
Common star /neutral points of Potential and current transformers shall be
connected with the grounding bus through a disconnecting type connector so that purchaser
may adopt single point grounding of common star point either at the terminal block in the
control panels or in the marshalling box of the instrument transformer.
4.9.4
5.0
CONTROL AND RELAY PANELS:
5.1
Simplex panels shall be provided with lockable doors on rear side. All indicating
instruments, controls, protective relays & mimic diagram etc. for feeder & Capacitor bank
shall be provided on the front side of the control panels.
5.2 Labeling for each circuit shall be provided at each of the front control panels, as well as
inside of the SIMPLEX panels.
5.3 Panels shall be of uniform thickness (minimum 2.5mm) and made of level sheet steel.
Bottom of the cubicle shall be made in a manner to open it for the purpose of wiring and
cable entry. Panels shall be designed to be of self-supporting type and wherever additional
structural strength is required, inconspicuous bracing, gusset-welding etc., shall be used. All
control panels and switchgear cubicles shall be made absolutely vermin proof design of the
approval of the purchaser.
5.4 Panels shall be made in suitable sections to facilitate easy transport and handling and
shall be later assembled at site. It may please be noted carefully that single continuous
sheet steel should not be used for a substation to make a single composite panels for all the
panels where more than one panels is involved.
5.5
Purchaser may ask for accommodation and wiring to be provided on Panels for
additional apparatus supplied under different contracts. Bidders shall agree to make such
provision in accordance with the instructions of the purchaser.
178
C & R Panels

6.0
6.1
Control and indication circuit for Capacitor Bank shall generally comprise of the
following:
a.
b.
c.
d.
e.
f.
g.
j.
6.2
Mimic diagram
Ammeter & Voltmeter (144 Sq.mm size)
MVAR meter (144 Sq.mm size)
Trip Healthy lamps.
Facia annunciating windows Breaker ON/OFF indication lamps. Test terminal
block and Relay Test Block.
Any other devices which may be necessary for completing scheme based on
improvement in design and adoption of new technology by the Bidder
MIMIC DIAGRAM:
6.2.1
Coloured mimic diagram and symbols shall represent the exact representation of
system. The mimic diagram for 33 kV shall be made to represent ONE MAIN & TRANSFER
BUS Scheme. Mimic diagram shall be placed at the eye level to indicate the position of
each breaker. Horizontal strip and the droppers shall have width of 10mm and 6 mm
respectively and the strip shall be 3mm thick. Power transformer, voltage transformer shall
be fixed on mimic by suitable symbols having dark Black colour. Position indicator of
isolating devices shall have matching colour in accordance with the voltage class of the
mimic. Arrangement shall be of over laid design using anodized aluminum section. Painted
mimic diagram shall not be acceptable.
6.2.2
Offered mimic diagram shall have colour scheme for representing 33 kV voltage
level as Azure blue shade 104 of IS 5
6.3
SEMAPHORE INDICATOR FOR BREAKERS:
6.3.1
Rotating disc semaphore indicator to be provided for this purpose on mimic
diagram shall indicate the position of 33 kV circuit breaker whether closed or open. Position
indicator strip of all semaphore indicators for breaker shall have the colour scheme matching
with specified colour scheme of mimic for various voltage levels.
6.3.2
ON and OFF display position of circuit breakers shall be automatically indicated by
semaphore operation indicator strip on mimic of 33 kV panels using auxiliary switching
contacts of outdoor equipments.
6.3.3
For 33 kV isolators, semaphore indicators need not be provided. Instead of
this, a circle indicating a 45 degree position may be indicated for the isolators.
7.0
ALARM AND ANNUNCIATION SCHEMES:
7.1
(A) ANNUNCIATION SCHEME FOR CAPACITOR BANK

(i)
Alarm annunciation system shall be provided for each panel by means of

visual and audible alarm in order to draw the attention of the operating staff to
the abnormal operating conditions or the operation of some protective device.
The annunciation equipment shall be suitable for operation under the
tolerance limit of voltages specified in this specification.
179
C & R Panels

(ii)
The annunciation shall be of visual and audible type. Facia annunciator, flush
mounted on the front of the control panel, shall provide the visual
annunciation. The DC hooter or DC bell shall provide the audible alarm.
(iii)
Each facia annunciator shall have a minimum size of 35 mm x 50 mm

translucent plastic window for each Trip and alarm point. The translucent
plastic plates of facia window shall be engraved in black letters with
respective inscriptions. All inscriptions shall be engraved on each window in
not more than three lines and size of letters shall not be less than 5 mm.
(iv)
Each annunciation window shall be provided with two white lamps in parallel
to provide safety against lamp failure. Long life lamps shall be used. The
lamp circuit shall include series resistor of adequate rating. The cover plate of
the facia windows shall flush with the panel and shall be capable of easy
removal to facilitate replacement of lamps. The transparency of cover plates
and wattage of the lamps provided in the facia windows shall be adequate to
ensure clear visibility of the inscriptions in the control room having high
illumination intensity (500 Lux) from the location of the operating staff desk.
(v)
TRIP and NON TRIP facia shall be differentiated. All trip windows shall have
red colour translucent plastic window and all non-trip facia windows shall
have white colour translucent plastic window.
(vi)
The annunciation system described above shall meet the following additional
requirements:
a)
Annunciation system shall be capable of catering to atleast 80%

simultaneous signals (of windows provided) at a time.
b)
One self-resetting push button shall be provided on each panel for

testing the facia window lamps. Push buttons for testing flasher and
audible alarm circuit of annunciation system and for testing the
annunciation supply failure monitoring circuit shall also be provided.
These testing circuits shall also be so connected that while test is
being done it shall not prevent the registering of any new annunciation
that may land up during the test.
c)
One set each of the following push buttons shall be provided on each
panel as shown in the front view drawing:
i Reset push button for annunciation system.
ii Accept push button for annunciation system.
iii Test push button for testing healthiness of annunciator. The
operation of this button should not cause inadvertent operation of
any equipment.
d)
Annunciation shall be repetitive type and shall be capable of

registering the fleeting signal. Minimum duration of fleeting signal
registered by the system shall be 15 milli-seconds.
e)
Annunciation shall be suitable for operation with normally open

potential free contacts, which close on a fault. It shall be possible at
site to change operation of annunciator from potential free contact
from close to fault to open to fault and vice versa.
180
C & R Panels

f)
In case of static annunciator scheme, special precaution shall be

taken by Bidder to ensure that spurious alarm condition does not
appear due to influence of external electromagnetic/ electrostatic
interference on the annunciator wiring and switching disturbances
from the neighboring circuits within the panels.
g)
Offered annunciation scheme shall be complete in all respects

including annunciator relay, flasher relay, test, accept and reset push
buttons.
7.1 (B) ALARM SCHEME FOR CAPACITOR BANK:

Automatic tripping of the circuit breaker due to operation of protective relays shall be
indicated by a common audible alarm. The offered alarm scheme shall be complete in all
relays and other accessories if any. With each panel one alarm scheme will be required.
8.0
PROTECTION SCHEME:
8.1
Protection scheme to be supplied for Capacitor Bank Control & Relay Panel against
this bid are described hereunder: 8.2
PROTECTION SCHEME FOR SHUNT CAPACITOR BANKS:
8.2.1
Two Nos. 36 KV, 12 MVAR capacitor bank will be installed at 33KV bus of EHV
substations. Capacitor banks in double star formation will be controlled by a connection of
One No. 33KV Vacuum Circuit Breaker. For protection of capacitor bank following will be
applicable;
8.2.2
Over Current & Earth Fault Protection:
The capacitor bank shall be protected by over current relay and protection of triple
pole IDMT relay with two poles for over current protection and one pole for earth fault
protection. This will be in the form of a Numerical, non-directional and non-communicable
relay having (2O/C + 1E/F elements) an operating time of 1.3 secs at 10 times current
setting. Definite time for the over current element shall be continuously variable and the
earth fault element shall have IDMT characteristics as well as high set feature to take care of
currents of smaller as well as larger magnitudes. Bidders shall elaborate the IDMT
characteristics as well as the setting ranges available for high set feature in the earthfault
element.
It may be noted that although the DC supply source is one, 33 kV circuit breakers will
have two trip coils which will receive simultaneous trip command. For this purpose, contact
multiplication will not be acceptable but the rating of the breaker control switch and each
tripping relay contacts shall be adequate to handle the burden of two trip coils. Pistol grip
type breaker control switches along with red and green indicating lamp for ON/OFF
indication shall be provided. All controls, relays, instruments and other gadgets shall be
mounted on front of the panel and mimic diagram shall show one main and a transfer bus
arrangement for feeder circuit. The range of over current relay shall be 50 to 200% in steps
of 25%. In case of earth fault relay the range shall be 10 to 40% or 20 to 80% in steps of 5%.
8.2.3
Over Voltage & Under Voltage Protection:
The over voltage relay shall be provided with adjustable voltage setting in steps of
5% in the range of 110 to 140%. The relays shall be provided with suitable timer to give fixed
time delay to avoid tripping of capacitor bank due to inrush during switching or in transit. The
181
C & R Panels

under voltage relay shall be provided with adjustable voltage setting in steps of 10% in the
range of 30 to 60%. The over voltage and under voltage protection shall include time delay
relay and auxiliary relay. The over voltage relay shall be energized from 33 KV PT
connected to main bus bars on the source side of circuit breaker controlling the capacitor
banks.
8.2.4
Unbalance Protection (NDR):
The unbalance protection relays shall be current operated. In this scheme capacitor
bank is connected in double star formation with neutral interconnection through Neutral
Current Transformer (NCT) for each bank. The unbalance protection relay shall be of
instantaneous type having range of 20 to 80% in steps of 10%. The relays used shall detect
two current levels one for alarm and one for trip and be able to provide an alarm in the event
of failure of one or two units, before tripping. Number of capacitor units on failure of which
alarm shall sound and tripping is initiated shall be clearly mentioned in the Tender. Bidder
may please note that each panel shall be supplied with two nos. unbalance protection relay
(NDR) so that the same panel could be utilized for two set of 12 MVAR capacitor bank as and
when required.
8.3 OTHER IMPORTANT PROTECTION:

8.3.1
Trip circuit supervision: (on panels for Capacitor Bank only)
Separate trip circuit supervision relay shall be provided for each of the two trip coils in
all panels, for continuous monitoring of trip circuit i.e. for both pre and post close conditions.
The trip healthy lamp for each trip coil shall be provided separately for pre and post close
monitoring. During unhealthy condition of trip circuit the relay shall initiate an audible alarm
and visual indication on facia window. All circuit breakers are provided with two trip coils and
hence separate trip circuit pre and post supervision for each trip coil is to be provided by
Bidder. Each trip circuit supervision relay shall be provided with operation indicator. Also for
each trip coil circuit, separate DC circuit with fuses will be used.
9.0
ACCESSORIES FOR CAPACITOR BANK PANELS:
9.1 All indicating instruments shall conform to IS-722 and shall have a size of 144 sq.mm.
These shall be suitable for semi flush mounting with only flanges projecting on vertical
panels. These shall be capable of carrying 150% rated full load current continuously without
undue heating. All indicating instruments shall be provided with non-reflecting glass fronts.
Selection shall be available to display dual ratio by toggle switch based on dual ratio current
transformer. In case of digital type instrument, the display shall have 8 digits with minimum
25 mm display height. In case of analog meter they shall have long, clearly divided indelibly
marked scales of engraved or enameled metal and the pointers shall be of clean outline. The
pointers and scales shall be of purchasers approval.
9.2
The instruments shall not be damaged by the passage of fault current through the
primary of corresponding instrument transformer and approved means shall be provided for
zero adjustment without dismantling the instrument. Voltmeters shall be calibrated while hot.
All potential circuits to instruments shall be protected by a fuse on each pole of the circuit
placed as close as possible to the instruments transformer terminals or where instruments
are directly connected as close as possible to the main connection. All instruments and
apparatus shall be back connected and all instrument cases shall be earthed. Where
specified, selection switch shall be provided to connect the main ammeter to measure the
current flowing in each of the three phases. All indicating instruments shall be of accuracy
class 0.5.
9.3
Ammeters and current coils of watt meters and VAR meters shall continuously
withstand 150% of rated current. Potential coils of wattmeters VAR meters and Voltmeters
182
C & R Panels

shall withstand 110% of rated voltage continuously and twice the rated voltage for 0.5
Second without loss of accuracy.
9.4
ENERGY METERS:
Bidder may please note that all the C&R panels for capacitor banks shall be
supplied with 3 phase 4 wire, 0.2S accuracy class energy meter with availability based tariff.
Meters shall measure and display active & reactive energy under voltage low (97%) and
voltage high (103%) condition as per tariff requirement. Meter shall be fully static having
non volatile memory and fully programmable. Meter shall have four quadrant registering
facility with provision for recording/display various parameters like KWh, KVAh, KVARh, Line
current and voltages including power factor. Load survey capability for 35 days shall be
available to forecast load growth. Meter shall have 0.2S accuracy class. The measurement
accuracy of the meter for active power shall be 0.2 s whereas for reactive energy 0.5s as
per IEC 62052-11-2003, IEC 62053-22-2003 as under:
10. 0
SWITCHES:
10.1
Control and instrument switches shall be rotary operated
with escutcheon plates
identification.
10.2
Selection of operating handles for the different type of switches shall be as follows:
a.
b.
c.
d.

Selector switches
Instrument switches
:
:
:
:
Pistol grip, black

Oval or knob black.
Round, Knurled, black
Pistol grip lockable and black.
10.3
Breaker control switch shall be of spring return to neutral 3 position type. Control
10.4
Lockable switches which can be locked in selected position shall be provided for
10.5
In 33 KV panels, knob switch for manual selection of semaphore position indicator
strip position shall be provided for displaying matching position of isolating devices in the
switchyard. These selection switches shall have three way selections and shall be mounted
near to respective semaphore device.
11.0
INDICATING LAMPS:
11.1
All indicating lamps shall be LED type.
11.2 Indicating lamps shall be panels-mounting type with rear terminal connections. Lamps
Lamps shall have translucent lamp covers to diffuse different colours e.g. red, green, amber,
clear white or blue to differentiate system function. Lamp cover shall be preferably of
screwed type, unbreakable and moulded from heat resistance material. Wattage of
indicating lamps shall be as follows:
a.
220V - 5 to 10W
b.
110V - 5 to 10W
183
C & R Panels
11.3
Wattage of the neon lamp shall be 0.25 to 0.5W if provided.
11.4
Bulbs and lenses shall be interchangeable and easily replaceable from the front of
the panels. Indicating lamp with resistor shall withstand 120% of rated voltage on continuous
basis.
12.0 CIRCUIT BREAKER POSITION INDICATORS:
Position indicators of `SEMAPHORE' TYPE shall be provided as part of the mimic
mimic busbars and at right angles to them, when the object is in the open position. When
supply failure to the indicator occurs, pointer shall take up an intermediate position to
continuous basis. No semaphores shall be provided for isolator position . Instead, a
circle showing isolator position at 45 degrees shall be made as mentioned earlier.
13.0
PUSH BUTTONS:
Push buttons shall be momentary contact type with rear terminal connections. Where
ever required the push buttons shall be suitably surrounded to prevent inadvertent operation.
These shall be provided with integral inscription plates engraved with their functions. All
push buttons shall have minimum two normally open and two normally closed contacts.
Contacts faces shall be silver plated. and shall be suitable for make/break and carry
appropriate currents for the functions desired.
14.0
RELAYS:
14.1. All relays to be supplied with 33KV C&R panels covered by this Bid shall be hand reset type.
14.3 Indicators shall also be provided on such additional equipment to identify faulty
phase and type of fault. Each indicator whether electrically or mechanically operated shall be
resetted by hand without opening the relay case. Each indicator shall be so designed that it
should not be moved before the relay has completed its operation. It shall not be possible to
test and operate any relay by hand without opening case.
the front.
184
C & R Panels

14.6 All induction relays shall be designed to operate at system frequency of 50 Hz.
Voltage operated relays shall be designed for star connected 110/220 Volt VT secondary
supply and current operated relays of 1 amp CT secondary as specified in the
specification. DC auxiliary relays and timers shall be designed for specified DC voltage and
shall operate satisfactorily at 70% to 110% rated voltage. Voltage operated relays shall
have adequate thermal capacity for continuous operation.
contacts shall be done at the external terminals of relay if required.
14.8 Timers shall be of the solid-state type. Short time delay in term of milliseconds may
be obtained by using copper lugs on auxiliary relays. In such case it shall be ensured that
obtained using external capacitor resistor combination is not preferred and shall be avoided
to the extent possible.
15.0 Numerical relays shall have compliance to following requirements:
All numerical, solid state and electronic relays shall have compliance to the following
requirements:
a. Printed circuit panels/cards shall be fin type and its contact shall be gold plated. All
connections with the connector pegs shall be through wire wrapping. All solder joints on
the printed circuit panels shall be encapsulated or covered with varnish.
b. Components used in these relays shall be loaded under normal condition by less than
half of their rated values. Resistors shall be of carbon composition or metal oxide type
and the capacitors shall be plastic film or tantalum type. Stringent measures including
shielding of long internal wiring should be taken to make relays immune to voltage
spikes as per IEC. Relays must meet the requirements of IEC-255-4 appendix È' class
III regarding BF, disturbance tests IEC-255-4 regarding impulse test at 5KV and
transients present in CT & VT connections due to extraneous sources, do not cause
damage to any of associated static circuits.
c. All relays shall be designed for satisfactory performance under tropical and humid
conditions. Special mention shall be made in the technical deviations schedule of the
Bid for those relays, if any that Bidder proposes to use which differ from specified
requirements.
d. All devices required for correct operation of each relay shall be provided by contractor
e. It will be ensured that the terminals of the contacts of the relays are readily brought out
for connections as required in the final approved scheme. Type of relay case size
185
C & R Panels

offered shall not create any restriction on availability of the contact terminals for wiring
connections.
f.
DC/DC converter or power supply unit shall be provided for the solid state protective
relay wherever necessary in order to provide a stable auxiliary supply for relay
operation.
g. Solid state relays shall be stable and suitably protected against transient/induced over
voltages and noise signals. Bidders shall state clearly in their Tenders, special
requirements if any for DC input arrangement or cabling considered necessary for
satisfactory operation of solid state relays quoted by him.
h. Timers shall be of the solid state type. Short time delay in term of milliseconds may be
obtained by using copper lugs on auxiliary relays. In such case it shall be ensured that
obtained using external capacitor resistor combination is not preferred and shall be
avoided to the extent possible.
16.0 TESTS:
Manufacturers shall carry out type and routine tests on the relays and complete
panels as per relevant Indian Standard or any equivalent International Standards and as
16.1
16.2
I.
II.
III.
IV.
V.
VI.

Other routine tests on all associated equipment and relays as per relevant Indian
Standards or IEC.
16.3 After all tests have been carried out, four copies of each test report/inspection report
shall be furnished. Each report shall supply the following information
i.
ii.
The routine test reports for all the panels.
16.4
Supply of equipment shall be subject to the approval of Test Certificates by
purchaser.
17.0 CONTROL CONNECTIONS AND INSTRUMENT WIRING:
17.1 Connections for switchgear operation and indications between the control and relay
panels where ever separate termination for instrument and relay wiring on these control &
186
C & R Panels

relay panels and multicore cable terminal boxes are involved, these shall form a portion of
the scheme for panels and under scope of supply of the control panels gear as stated by the
BIDDER.
17.2
Panels connection shall be insulated and shall be neatly and securely fixed to the
back of the panels. All instrument and panels wiring shall be of approved type, which shall
be fire retardant and shall be run in porcelain or non-rustable metal cleats or in non-rustable
tubes or galvanized steel tubes as may be approved. All panel wiring shall be taken to
terminal panels, which shall comply with requirements of multicore cable boxes where
applicable. Panel wiring shall be PVC or VC braided impregnated with flameproof
17.3 All wiring diagrams shall be clearly marked with the numbers, which are shown on
panel.
17.5 Each set of current & voltage transformer secondary connections shall be complete in
all respect and shall be connected to form common star point. Star point shall be earthed at
one point only. Each such earth connection to the earth bar shall be made in accordance
with the requirement of the earth system and shall be made through a disconnecting link
which can be removed when insulation tests are required without breaking any circuit
normally carrying current.
17.6 For each circuit on the panels, the control indication and trip wiring shall be suitably
relays. These shall be of the switch board type with connection at the back, mounted on front
of panels. Test blocks shall provide complete isolation of meters, instruments and relays and
18.0

painting. Process can be broadly divided as `Metal treatment and painting'.
18.1
METAL TREATMENT:
i.

degreasing bath or in hot di-chloroethelene solution. After degreasing
operation the surface shall be cleaned thoroughly with cold water.
187
C & R Panels

ii.
in dilute sulphuric acid (approximately 20%) at nearly 60 deg. centigrade so
as to totally remove scale and rust.
iii.
iv.
v.
Phosphating: Immerse in grenadine zinc phosphate solution for about 20

minutes at 80 to 90 degree centigrade. Uniform phosphate coating of 4 to 5
gm per sq. meter shall be achieved.
vi.
vii.
Rinse in Deorylyte bath at 70 to 80 degree centigrade to neutralize any traces

of salts.
viii.
ix.
18.2
PAINTING:
Sequence of Processes shall be as follows :i.
Primer spray: Apply one coat of primer spray on wet surface by specially
developed `High luster' zinc chromate primer and to stove at 150-160 deg.
Centigrade for 25 to 30 minutes. Alternatively red-oxide primer with zinc
chromate contents may be used. However former process shall be preferred.
ii.
Rubbing and putting : Apply putty to fill up the scars if any to present
get the perfect 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
v.
Finish: Rubbing down dry and spray first coat of synthetic enamel finish paint
vi.
Surfacing: Sand down or rub dry to prepare for final finish spray. Coats of
minutes.

NOTE:
188
C & R Panels
19.0
ii
iii
Small coating paint shall be supplied along with equipment for touching up at
site.
DRAWINGS & LITERATURE (PANEL METERS & RELAYS):
19.1
General arrangement and schematics showings with all major details shall be
submitted with the Tender.
19.2
Immediately after award of the contract, manufacturer shall submit GA and
schematics drawing of each panel for the approval of the purchaser.
19.3
Successful BIDDER shall have to supply one set of drawings and a set of
manuals per panels properly packed in plastic jacket; each containing approved GA,
Schematic and wiring drawings illustrative pamphlets of meters, literature and
commissioning instructions for all relays under his scope of supply. Besides this, one
set of drawings (GA+Schematic) and a set of manual per panels shall be forwarded to
the O/o CE(PLG).THIS IS MANDATORY.
20.0
accessories shall be furnished along with the Tender. While submitting technical particulars,
clear picture of device offered, along with literature/write-up. Unless otherwise specified, all
the 33KV panels shall be suitable for the auxiliary DC voltage of 110 V.
21.0 OTHER IMPORTANT REQUIREMENT:
21.1 QUALITY ASSURANCE PROGRAMME:
21.1.1 Bidders must establish that they are following a proper quality assurance program for
manufacture of control and relay panels. In order to ensure this, suitable QAP should form a
part of the technical Tender, which will be submitted against this Bid document. Quality
Assurance Program must have a structure as detailed in the following paragraphs.
21.1.2 Quality assurance and failure prevention starts with careful study and scrutiny of
our technical specifications and requirements. Suppliers shall carefully study all the technical
parameters and other particulars & the supplier shall categorically give his confirmation that
21.1.3 Supplier shall furnish the checks exercised in design calculations particularly in
21.1.4 Supplier shall indicate the various sources of the bought out items. Type of checks,
quantum of checks and acceptance norms shall be intimated and random test and check
results should be made available for inspection whenever so desired. Vendor list for various
bought out items shall be submitted with the Bid and the same shall be subject to
be obligatory on the part of Bidders to allow third party inspection of all important material
189
C & R Panels

and in case during independent third party inspection any of the above material is found
different than from approved list of vendors, Purchaser reserves the right to summarily reject
21.1.5 Based on above QAP and offered delivery schedule a tentative program chart
QAP. Program chart should specify periods for various activities i.e. design, ordering of new
21.2
INSPECTION:
21.2.1 Acceptance of any quantity of panels shall in no way relieve the successful Bidders
of his responsibility for meeting all the requirement of this specification and shall not prevent
21.2.2 No material shall be dispatched from its point of manufacture unless the material has
been satisfactorily inspected and tested.
21.2.3 At the time of inspection, the Bidders shall identify each and every gadget and
relays on the ordered panels. Unless all the items are identified, the manufacture will not be
treated as complete. Serial number of Relays & other gadgets shall be entered into the test
report. Various tests stipulated in IS shall be performed in the presence of purchasers
engineers or when the inspection waiver has been given, in such a case, the testing
shall be done at the manufacturer's works as per IS stipulations and same should be
confirmed by documentary evidence by way of Test Certificate which shall be got
approved by the purchaser.
21.2.4 Whenever inspection call is given, letter of inspection call will accompany the
following:
21.3
a.
Number of panels i.e. one feeder or capacitor bank panel which are ready at
the works and shall be offered for inspection. The Inspecting Officer shall get
the number of panels checked before commencing the inspection.
b.
The Inspecting Officer shall randomly select panels of one feeder & capacitor
bank (approx. 10% quantity of the offered panels) for conducing the routine
tests after all the gadgets and relays provided on the panel have been
verified.
c.
complete with all accessories, the Purchaser will reserve the right to recover
the complete cost of deputation of inspecting team to the works of the
manufacturer.
Responsibility for obtaining timely supplies of bought out items will rest on the and
only on this basis, delivery period will be offered in the Tender. For bought out items,
noticed and in case defective supply of any item is reported will rest on the BIDDER. In
case for attending to defect in any accessory or inspection/ replacement of the accessory,
which may be bought out item for the Bidders; services of engineer of original manufacturer
is required, the same will be organized on immediate basis by the Bidders at their cost.
190
C & R Panels

21.4 Bidders may ensure that pages have been properly numbered and signed. All Bid
documents including schedules should be indexed properly and Index of the documents
should be enclosed/placed at the beginning of the Bid document.
22.0
33KV Control and relay panels shall have following instruments, relays and
accessories to be provided per circuit on each feeder and transformer panels as per the type
of protection indicated above under clause-8.1 by the purchaser:
A - Quantity and Number Shown Below are Required For Capacitor Bank Control &
Relay Panels :S.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
PARTICULARS
I CONTROL & RELAY PANEL
Type of panel
Box type circuit label inscription (50x100mm) indicating Name
of CIRCUIT
Purchasers order no. Serial no.& Bidders label
Over laid Mimic diagram with uniform 3mm thickness and
10mm width.
Red and Green lamps with holder for circuit breaker ON/OFF
position indication.
Pistol grip Circuit breaker control switch three position ON, Off
& return to neutral.
Semaphore to indicate circuit breaker position automatically
QUANTITY
Simplex
One
One
One
One
Set
One
One
One
10.a
Ampere meter with selector switch for reading individual phase

current (144 sq.mm size)
Voltmeter (0-40KV) with selector switch for reading individual
line voltage (144 sq.mm size)
3 phase 3 wire MVAR meter (0-50 MVAR) (144 sq.mm size)
10.b
3 phase 4 wire ABT Energy meter o.2s accuracy class
One
11.
Facia window annunciator complete with flasher and function

relays
Test plug/port for testing of Main protection Relay complete with
connecting leads
Test terminal block for MVAR meter
Push button for facia annunciator testing of all lamps /accept/
reset arrangement.
Push button for main DC supply fail test/accept
Indicating lamp for DC fail.
Trip circuit supervision healthy indication lamp with push button
to select pre-close & post-close supervision.
Additional accessories & other devices required completing the
offered schemes.
Neutral current unbalance relay (NDR) alongwith timer and
auxiliary relay for Alarm & Trip
Pre & post close Trip circuit supervision relay.
Numerical, non-directional and non-communicable IDMT relay
having two overcurrent and one earthfault elements having time
of operation at 1.3 Sec. at 10 times current settings for
protection of 33 kV feeder circuits. The earthfault element shall
9.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
191
One
One
6
Ways
One
One
Three
Two
One
Two
One
Set
Two
Two
One
C & R Panels

S.
NO.
22.
23.
PARTICULARS
have IDMT characteristics as well as high set feature (as
described in Clause no. 8.2.2 of the specification.
High speed tripping relay
QUANTITY
One
Under voltage protection scheme including time delay relay and

auxiliary relay
Over voltage protection scheme including time delay relay and
auxiliary relay
Additional aux. relays required to complete offered protection
schemes with details.
II EQUIPMENT MOUNTED INSIDE
Space heaters with switch in each panel.
One
Set
One
Set
As Required
15/5A, 230Volts power socket with protective metallic cover &

Switch.
20Watt Tube light with door switch.
One
One
6.
DC bell for NON TRIP alarm complete with accept, reset and
test facilities
DC hooter for trip alarm complete with accept reset and test
facility
Glands plate fitted with Cable glands.
One Set
7.
Foundation bolts
One Set
8.
Additional relays or accessories offered by Bidder, which are

essentially required for completing protection scheme.
24.
25.
1.
2.
3.
4.
5.
One
One
One
As per
Requirement
(**) Bidders may please note that although the breaker shall have two trip coils, the
source of DC supply shall be only one. Accordingly, two trip circuit supervision
relays are envisaged for the transformer circuits only.
IMPORTANT NOTE:
1.
Bidders shall indicate Unit prices for all the gadgets and relays for the 33KV
Class panels for feeder capacitor banks offered by them. This has to be strictly
complied. Prices of the gadgets and relays shall form a part of the Schedule-I about
details of equipment and quantity for 33KV C&R panels.
2.
Bidders may elaborate the setting possibilities available in the overcurrent as
well as earthfault elements of IDMT numerical relays offered by them.
192
C & R Panels
APPENDIX-B3
DRAWINGS
S.No.
Description
General Arrangement Drawing for 33KV 1T+1F Control &

Relay Panel
General Arrangement Drawing for 33KV 3F Control & Relay

Panel
General Arrangement Drawing for 33KV 1F Control & Relay

Panel
General Arrangement Drawing for 33KV Capacitor Bank

Control & Relay Panel
193
C & R Panels
GENERAL ARRANGEM ENT OF 33 KV TW O CIRCUIT (ONE X-M ER & ONE FEEDER)

CONTROL AND RELAY PANEL AS PER MPPTCL'S STANDARD DESIGN
LIFTING HOOKS
CIRCUIT LABELS
F RONT DOOR
PROVIDED WITH
L1 L2 L3 L4 L5
L1 L2 L3 L4 L5
GLAS S COVER
M FM -2
M VAR
M VAR
144
144
M FM -1
HINGES
T CH
AA
T DC
T CH
AR
86t
T DC
86f
2250
10
29B
29A
29A
52f1
29C
1650
195A
T C-1
1295
52 CS 2
2250
52 CS 1
1360
29B
52t
29C
E QUIP MENT
F RAME
S WINGING TY PE
195B
T C-1
51A
51B
51C
195C
T C-2
X -M ER
30/C
RELAY
DMT3
SECS
195D
T C-2
144
TVM
51A
50
51C
F EEDER
20/C
+IE/F
RELAY.
DMT -1.3
S ECS.
TVM
E /F 64
X -MER
TTB 2
60
300
TTB 1
660
560
3D VIEW
REAR BLOCKED
SIDE VIEW
CATEGORY
1 T/1F
1T+1F
3F
150
360 mm
30
STANDARD DIM ENSIONAL DETAILS

75
BOTTOM VIEW
ALL D IM ENSION S ARE IN MM.
N OT TO SCALE
W IDTH
660
660
1000

Colour Inside
Colour Outside
Colour of Mimic
Mimic Strip
Earth Bus Size
Brass Cable Glands
Multifunction Meters
Trivector Meters
DEPTH
560
560
560
HEIGHT
2250
2250
2250
2.5mm.
Eggshell White
Opaline Green
Azure Blue
Overlaid Type
12.5x6mm. Copper Strip
Accuracy Class 0.5
Accuracy Class 0.2S
M. P. POW ER TRANSMISSION Co. LTD. JABALPUR

DRAWING NO:- JICA/MPPTCL/TR-101 TO 107/GA 33KV 1T+1F CRP
194
C & R Panels
65
300
60
1295
29B
L1 L2 L3 L4 L5
L1 L2 L3 L4 L5
29C
52F2
29B
TDC
MFM
TCH
29A
TTB 3
86F3
TVM
3
TVM
2
TVM
1
52 CS 2
AR
MFM
52F2
29B
AA
MVAR
29A
29C
TTB 2
86F2
TCH TDC
MVAR
CIRCUIT LABELS
L1 L2 L3 L4 L5
144
MFM
TDC
MVAR
TCH
29A
MAIN BUS
52F1
29C
105
86F1
264
TTB 1
FRONT VIEW
1000
20/C+1E/F Highset RELAY

DMT 1.3 SECS.
FEEDER
O/C 51A&51C&E/F64/50
FDR III

DMT 1.3 SECS.
FEEDER
O/C 51A&51C&E/F64/50
FDR II

DMT 1.3 SECS.
FEEDER
O/C 51A&51C&E/F64/50
FDR I
52 CS 1
TRANSFER BUS
144
10
52 CS 3
FRONT DOOR
GLASS COVER
PROVIDED WITH
EQUIPMENT
FRAME
SWINGING
TYPE
REAR BLOCKED
75
150
1.
THE SPACE AVAILABLE BETWEEN THE METERS

WILL BE AROUND 20mm THEREFORE PROPER
REINFORCMENT SHOULD BE PROVIDED IN THE
SHEET FROM INSIDE.SHOULD BE AROUND 1000mm.
IN CASE OF PANELS COMPRISING THREE CIRCUITS

THE DOORS SHOULD BE OF CENTRE OPENING TYPE
HAVING HINGES ON BOTH OUTER SIDES.
BOTTOM VIEW
THE DRAWING IS ONLY TO INDICATE REFERENCE

HEIGHTS OF INSTRUMENTS CONTROL SWITCH
MIMIC ETC.
2250
HEIGHT
2250
2250
560
560
DEPTH
560
660
WIDTH
660
2.5mm.
Eggshell White
Opaline Green
Azure Blue
Overlaid Type
Accuracy Class 0.5
Accuracy Class 0.2S
1000

Colour Inside
Colour Outside
Colour of Mimic
Mimic Strip
Earth Bus Size
Brass Cable Glands
Trivector Meters
3F
1T+1F
1 T/1F
CATEGORY
STANDARD DIMENSIONAL DETAILS

NOT TO SCALE
3.
NOTE:-
360 mm
33 KV THREE FEEDER CONTROL & REALY PANEL

AS PER MPPTCL's STANDARD DESIGN.
LIFTING FOUR No.LUGS
560
SIDE VIEW
30
DRAWING No:- JICA/MPPTCL/TR-101-107/GA 33KV 3Feeder CRP
C & R Panels
195
118
76
HINGES
1360
1650
2250
2250
2190
MFM
29B
AA
MVAR
TCH TDC
29A
29C
52
AR
L1 L2 L3 L4 L5
CIRCUIT LABEL
TRANSFER BUS
MAIN BUS
86

DMT 1.3 SECS.
FEEDER
O/C 51A&51C&E/F64/50
TTB
TVM
660
52 CS 2
FRONT VIEW
10
FRONT DOOR
GLASS COVER
PROVIDED WITH
EQUIPMENT
FRAME
SWINGING TYPE
75
150
THE SPACE AVAILABLE BETWEEN THE METERS

WILL BE AROUND 20mm THEREFORE PROPER
REINFORCMENT SHOULD BE PROVIDED IN THE
SHEET FROM INSIDE.SHOULD BE AROUND 1000mm.
BOTTOM VIEW
1.
THE DRAWING IS ONLY TO INDICATE REFERENCE

HEIGHTS OF INSTRUMENTS CONTROL SWITCH
MIMIC ETC.
WIDTH
660
Colour Inside
Colour Outside
Colour of Mimic
Mimic Strip
Earth Bus Size
Brass Cable Glands
Trivector Meters
CATEGORY
1F
HEIGHT
2250
2.5mm.
Eggshell White
Opaline Green
Azure Blue
Overlaid Type
Accuracy Class 0.5
Accuracy Class 0.2S
DEPTH
560
ALL DIMENSIONS ARE IN MM. NOT TO SCALE
TCH = Trip Circuit Healthly Check

TDC = DC Fail Test
AA = Alarm Accept
AR = Alarm Reset
86 = Trip Relay
MFM = Multi Function Meter
2.
NOTE:-
360 mm
DRAWING No:- JICA/MPPTCL/TR-101-107/GA 33KV 1F CRP
REAR VIEW
30
33 KV ONE FEEDER CONTROL & REALY PANEL

AS PER M.P.P.T.C.L's. STANDARD DESIGN.
560
SIDE VIEW
1295
C & R Panels
196
HINGES
65
300
60
1650
1360
2250
197
65
300
29A
660
29C
52
29B
86
52 CS 2
AA
144
TTB
NDR NDR
UVR
OVR
SS
MVAR METER
144
L1 L2 L3 L4 L5
FRONT VIEW
RTB
264
TCS
RELAY

DMT 1.3 SECS.
FEEDER
O/C 51A&51C&E/F64/50
TRANSFER BUS
MAIN BUS
TCH TDC
AR
SS
SS
ANN
VOLT METER
144
L1 L2 L3 L4 L5
AMETER
144
L1 L2 L3 L4 L5
144
CIRCUIT LABELS
144
1295
1360
DRAWING NOJICA/MPPTCL/TR-101 TO 107/GA 33KV CAP. BANK CRP
60

76
10
2190
SIDE VIEW
560
EARTH BUS 12.5x6mm
DOOR HANDLE
HA
30
BOTTOM VIEW
150

Colour Inside
Colour Outside
Colour of Mimic
Mimic Strip
Earth Bus Size
Brass Cable Glands
Ammeter, Volt Meter,
MVAR Meter
CATEGORY WIDTH
CAPS. BANK 660
HEIGHT
2250
Accuracy Class 0.5

10.09.2007
2.5mm.
Eggshell White
Opaline Green
Azure Blue
Overlaid Type
DEPTH
560
REAR VIEW
ALL DIMENSIONS ARE IN MM. NOT TO SCALE
SS = Selector Switch
UVR = Under Voltage Relay
OVR = Over Voltage Relay
NDR = Un Balance Relay
TCS = Trip Circuit Supervision Relay
ANN = Annunciator
TCH = Trip Circuit Healthly Check
TDC = DC Fail Test
AA = Alarm Accept
AR = Alarm Reset
86 = Trip Relay
NOTE:-
SK / 117
HINGES
TURN TWIST LOCKS
TERMINAL
BLOCK
REAR VIEW
TURN TWIST LOCKS
75
360 mm
33 KV CAPACITOR BANK CONTROL & REALY PANEL AS PER M.P.P.T.C.L's. STANDARD DESIGN.
2250
C & R Panels
SCHEDULE-I(A)
IN VOLUME-VI
2
3
4
Particulars Of Item
33KV C & R panels for protection of one transformer and
one feeder circuit complete with all relays & accessories
as described in the tech. specification with u/f and
tripping relays
33KV C & R panels for protection of three feeder circuits
complete with all relays & accessories as described in the
tech. specification.
33KV C & R panels for protection of one feeder circuit
complete with all relays & accessories as described in the
tech. specification.
C & R panels for protection of 2 Nos. 36KV, 12 MVAR
Shunt Capacitor Bank complete with all relays &
accessories as described in the tech. specification.
Qty.
S.
No.
1(a)
NOTE:
1.
The above description of the equipment is given for the purpose of offering the
prices and to mention description of equipment in invoice for claiming
payment.
2.
The quantity of above equipments has been mentioned in Volume-VI.
198
C & R Panels
2.1.2
(F) TECHNICAL SPECIFICATION OF SYNCHRONIZING

EQUIPMENT/TROLLY :
For the purpose of synchronization at 220 KV Substation at Sirmour

synchronizing equipment will also be required by us. The details of this
equipment shall be as under;
(vi) The synchronizing instruments shall be mounted on a synchronizing
trolley. The trolley shall be equipped with double analog voltmeters and
double analog frequency meters, synchroscope and lamps fully wired.
The size of voltmeters and frequency meters provided in the synchronizing
trolley shall not be less than 144 x 144 sq.mm. Suitable auxiliary voltage
transformers wherever necessary shall also be provided for synchronizing
condition.
In case the synchroscope is not continuously rated, a
synchroscope cutoff switch shall be provided and an indicating lamp to
indicate that the synchroscope is energized shall also be provided.
(vii) Synchronizing check relay with necessary auxiliary equipments shall be
provided which shall permit breakers to close after checking the
requirements of synchronizing of incoming and running supply. The
phase angle setting shall not exceed 35 degree and have voltage
difference setting not exceeding 10%. This relay shall have a response
time of less than 200 milliseconds when the two system conditions are
met within present limits and with the timer disconnected. The relay
shall have a frequency different setting not exceeding 0.45% at rated
value and at the minimum time setting.
The relay shall have a
continuously adjustable time setting range of 0.5 -20 seconds. A guard
relay shall be provided to prevent the closing attempt by means of
synchronizing check relay when control switch is kept in closed position
long before the two systems are in synchronism.
(viii)
The trolley shall be of mobile type with four rubber-padding wheels
capable of rotating in 360 degree around the vertical axis. Suitable
bumpers with rubber padding shall be provided all round the trolley to
prevent any accidental damage to any panel in the control room while
the trolley is in movement. The trolley shall have two meter long flexible
cord fully wired to the instruments and terminated in a plug in order to
facilitate connecting the trolley to any of the panels. The receptacle to
accept the plug shall be provided on the panel.
199
C & R Panels
2.1.3 (A)TECHNICAL SPECIFICATION FOR

CURRENT TRANSFORMERS
1.0
SCOPE :
The scope of this specification covers design, manufacturing and supply of
equipment as per Volume-II, Part-2, Book-I. The bidder mentioned in the Section of
the Technical Specification means Original Equipment Manufacturer (OEM). The
Purchaser means the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipment/material of
2.0
STANDARDS :
Applicable Standards for the offered equipments / items shall be as per Volume-II,
Part-2, Book-I.
3.0
CLIMATIC CONDITIONS :
.
4.0
SYSTEM PARTICULARS :
Applicable System Particulars shall be as per Volume-II, Part-2, Book-I.
5.0
BASIC DESIGN
TRANSFORMER :
AND
TECHNICAL
REQUIREMENT
FOR
CURRENT
5.1
BASIC DESIGN :
5.1.1
The 220 KV and 132 KV Current transformer will be dead tank or live tank design. In
case of dead tank design, only hair pin design shall be accepted. The 33 KV Current
transformer will be of dead tank design with a top dome/ tank to accommodate
primary terminal assembly, oil level gauge/ pressure relief device etc. and a bottom
tank to accommodate secondary core, terminal box etc. The equipment shall be
outdoor, single phase oil immersed and self cooled type suitable for services
indicated as above complete in all respect, conforming to modern practices of design
and manufacture.
Current Transformer with cascade design / interposing CTs / auxiliary CTs are not
acceptable
As stated, all Current transformers shall be paper insulated oil filled and dead tank
type. The Current transformer after providing paper insulation shall be housed in the
tank containing oil. Please note epoxy casting in primary & secondary cores is not
acceptable. The compound filled CTs are also not acceptable. Manufacturers should
briefly describe complete process of manufacturing.
5.1.2
The insulation as per latest version of IS:4800 or equivalent International Standard of

the current transformers shall be so designed that the internal insulation shall have
higher electrical withstand capability than the external insulation. The designed
dielectric withstand values of external and internal insulations shall be clearly brought
out in the guaranteed technical particulars. The dielectric withstand values specified
in this specification are meant for fully assembled current transformers.
200
5.1.3
The Current transformers covered under this specification shall meet the technical
requirements indicated in Appendix-C1 enclosed with the specification.
5.2
PORCELAIN HOUSING:
5.2.1
The Current transformer should be designed using single porcelain housing. No

joints shall be provided in the porcelain. The housing shall be made of
homogeneous, vitreous porcelain of high mechanical and electrical strength. Glazing
of porcelain shall be of uniform brown or dark brown colour with a smooth surface
arranged to shed away rain water or condensed water particles (fog). The profile of
porcelain shall be aerodynamic type as per latest version of IEC-815.
5.2.2
Details of attachment of metallic flanges to the porcelain shall be brought out in the
Bid.
5.3
METAL TANK :
Special precaution will have to be taken towards selection of material for the metal
tank and the following will have to be ensured.
i.
Material for metal tank which should be minimum 3 mm thick (i.e. mild steel/
stainless steel/ aluminium alloy) shall be carefully selected depending upon
the primary current and the material should be clearly mentioned against
technical questionnaire.
ii.
The practice of providing inserts of non-magnetic material in the body of the

tank with suitable welding to reduce eddy current shall not be acceptable.
This problem should be avoided by selection of tank of suitable material.
iii.
Welded joints have to be minimized to avoid possibility of oil leakage. In any

case welding in horizontal plane shall be avoided.
iv.
The slot/ hole cutting in the bottom tank should be done smoothly to avoid
any sharp edges within the tank. All welded surfaces need to be
smoothened and shall be covered with pressboard or other insulating
material of good mechanical properties.
v.
The bottom tank should not have any dents and pitting to ensure proper
tightening of gasket and to avoid any oil leakage. Fabrication of bottom tank
shall be done by utilizing fresh sheet steel only.
The material selected for the tank shall be justified with suitable explanation.
5.4
PREVENTION OF OIL LEAKAGES AND ENTRY OF MOISTURE :
5.4.1
The sealing of Current transformer shall be properly achieved. The following should
be properly taken care of & arrangement provided by the Bidder shall be described.
i.
Locations of emergence of primary and secondary terminals.
ii.
Interface between porcelain housing and metal tank.
iii.
Cover of the secondary terminal box.
5.4.2
For gasketed joints, wherever used, nitrile butyl rubber gaskets, neoprene or any
other improved material shall be used. The gasket shall be fitted in properly
machined groove with adequate space for accommodating the gasket under
compression. You have to submit complete details and justify that the quality of
201

gaskets which will be used between the joints and also for mounting of oil level
indicator will be of best quality to avoid leakage of oil. The quality of gasket should
be selected keeping in mind that the ambient temperature in MP now touches 50
deg centigrade.
5.4.3
The CT shall be of dead tank/live tank design and shall be so constructed that it can
be easily transported to site within the allowable transport limitation and in horizontal
position if the transport limitations so demand. The CTs shall be hermetically sealed
and method of such sealing shall be detailed out in the bid.
5.5
TERMINAL CONNECTORS :
The terminal connectors required for connection of the current transformer to
Owner's bus bar, shall be in Bidder's scope. Rigid type terminal connector for Twin
Zebra ACSR should be suitable for horizontal and vertical takeoff.
The terminal connector shall conform to the latest version of IS:5561 or equivalent
International Standard. The drawings for terminal connectors are enclosed with Bid
document for guidance.
The design of clamp shall be to our approval. The details of current take off as
required by us shall be detailed out in drawing and shall be submitted along with the
bid. In respect of the terminal connectors following should be ensured:a.
The terminal connector should be made of A6 Aluminium Alloy and by
gravity/pressure die cast only. Sand casted terminal connectors are not
acceptable. The current rating of terminal connector will be 1.5 times the
rated current. The current density shall not exceed 1 Amp/sq.mm. in any part.
b.
cavities. All sharp edges should be rounded off.
c.
No part of clamp shall be less than 12mm thick.
d.
All current carrying parts shall be designed and manufactured to have
minimum contact resistance. The bimetallic strips/sleeve shall be 2 mm thick.
e.
All nuts/bolts/washers shall be made of HDG Mild steel with minimum
diameter of 12 mm.
f.
The conductor should be tightened by six bolts. Conductor hold length must
not be less than 100mm.
g.
The clamp for Twin Moose ACSR conductor shall be made of three pieces so
that each conductor may be tightened separately.
h.
clamp except hardware.
i.
that it may be possible to open the nuts and bolts by normal spanners.
avoided.
j.
zig-zag in construction, at both the sides, so that holding of clamp by throttling
k.
5.6
MOUNTING :
The Current transformer shall be suitable for mounting on our steel structure, which
shall be arranged by the purchaser. The mounting dimensions of equipment shall
match with the mounting dimensions of structure indicated in enclosed Appendix-C2.
202
5.7
INSULATING OIL :
The insulating oil for first filling of oil in each transformer shall be in the scope of
bidder. Only best quality new EHV Grade transformer oil should be used with the
equipments with minimum BDV of 70 kV. The BDV of oil will have to be recorded in
the test certificate. The oil shall comply in all respect with the provisions of the latest
version of IS: 335 or IEC publication no. 296 (as amended up to date). The oil
parameters viz., Tan Delta value, resistivity, PPM and BDV filled in the CTs shall be
recorded in the test certificates of respective CT.
5.8
SURFACE FINISH :
The metal tanks shall be coated with atleast two coats of zinc rich epoxy painting or
hot dip galvanised. All the ferrous hardware, exposed to atmosphere, shall be hot dip
galvanised conforming to the latest version of IS: 2629 or equivalent International
Standard. All other fixing nuts, bolts, washers shall be made out of HDG Mild steel.
5.9
TEMPERATURE RISE :
The temperature rise of current transformer when carrying a primary current equal to
125% of rated current at a rated frequency and with a unity power factor burden
corresponding to rated output connected at the secondary winding shall be 5 (five
degree) less than the permissible values given in the latest version of IS:2705 or
equivalent international standard.
5.10
ARRANGEMENT FOR COMPENSATION OF OIL VOLUME :
5.10.01 For 220kV and 132kV current Transformer, compensation of variation in the oil
volume due to variation in ambient temperature, stainless steel bellows shall be
used. No other arrangement for this purpose shall be accepted. For indication of oil
level, a ground glass window shall be provided to monitor the position of metal
bellow.
5.10.02 For 33kV current Transformer, compensation of variation in the oil volume due to
variation in ambient temperature, stainless steel bellows or any other proven
suitable arrangement which may be equal or superior shall be used. Rubber
diaphragms shall not be permitted for this purpose. For indication of oil level, a
ground glass window shall be provided to monitor the position of metal bellow.
5.11
SECONDARY TERMINALS TERMINATION :

The following may please be noted for strict compliance: (a)
The C.T. secondary terminals shall be brought out in a weather proof terminal
box. Firstly the connections will be terminated on a internal board and then
the same shall be brought out in the outer Secondary terminal box. The
secondary terminals termination should be bolted type with wire size 4
sq.mm. copper for connections.
(b)
The outer Secondary terminal box should have two separate compartments
with separate covers for the purpose of sealing. Each compartment will have
the terminals of each metering core. Suitable gland plates for both the
compartments will have to be provided. This is required because covers of
metering cores compartment will be provided with suitable seals to be
operated by separate agencies who will verify the cover periodically for
metering purpose.
203
5.12
(c)
The terminal box shall be provided with removable gland plate and gland/s
suitable for 1100 volts grade, PVC insulated, PVC sheathed multicore 2.5
sq.mm. stranded copper cable.
(d)
The terminal box shall be dust and vermin proof. Suitable arrangement shall
be made for drying of air inside the secondary terminal box.
(e)
The dimensions of the terminal box and its openings shall be adequate to
enable easy access and working space with use of normal tools.
(f)
The outer cover of secondary terminal box shall have provision for sealing by
way of insertion of wire in the bolt hole. A drawing indicating above
arrangement may please be furnished alongwith the bid.
(g)
For measuring tan delta values, separate tan delta test terminal shall be
provided on the opposite side of secondary terminal box.
POLARITY :
Polarity shall be invariably marked on each primary and secondary terminal. Facility
shall be provided for short circuiting & grounding of the CT secondary terminals
inside the terminal box. All marking shall be engraved or through anodized plate
which should be firmly fixed.
5.13
RATING PLATE :
The C.T. shall be provided with a rating plate with dimensions and markings as per
latest version of IS: 2705 / IEC-185. The markings shall be punched/ engraved and
not painted. This rating plate shall also contain our purchase order no. and date.
5.14
OIL FILLING AND SEALING :

The current transformer shall be vacuum filled with oil after processing and thereafter
hermetically sealed to eliminate breathing and to prevent air and moisture from
entering the tanks. Oil sampling valve provided at the bottom of CT should be
protected by providing metallic cover or blanking plug/plate. Valve should be welded
to avoid any leakage. Nitrogen filling valve should be fitted with an indicator or cap to
prevent leakage of nitrogen. The method adopted for hermetic sealing shall be
described in the bid.
5.15
CASTING :
The castings of base, collar etc. shall be die cast and tested before assembly to
detect cracks and voids if any.
5.16
INSTRUMENT SECURITY FACTOR :

The instrument security factor of metering core shall be low enough and not greater
than 5. This shall be demonstrated on all the ratios of the metering core, in
accordance with procedure specified in latest version of IS:2705 or IEC-185.
5.17
EARTHING :
Current transformer shall be provided with two separate earthing terminals for bolted
connection to 75 x 10 mm / 50 x 8 mm MS flat to be provided by the Purchaser for
connection to station earth-mat.
5.18
LIFTING ARRANGEMENT :
Current transformer shall be provided with suitable lifting arrangement, to lift the
entire unit. The lifting arrangement shall be clearly shown in the general arrangement
204

drawing. Lifting arrangement (lifting eye) shall be positioned in such a way as to
avoid any damage to the porcelain housing or the tanks during lifting for installation/
transport. Necessary sling guides shall be offered which shall be of removable type.
5.19
PRIMARY WINDING :
(a)
For 220kV and 132kV Current Transformer, Primary winding shall be made
out of electrolytic grade 99.9% conductivity copper/Aluminium conductor.
Conductors used for the primary winding shall be rigid and housed in rigid
metallic shell. Joints in the primary winding shall not be provided. For primary
winding current density shall not exceed 1.50 Amp / sq.mm in case of copper
and 1.00 Amp/ sq.mm in case of Aluminium at continuous overloading of 25%
above rated current.
(b)
For 33kV Current Transformers, Primary winding shall be made out of

electrolytic grade 99.9% conductivity copper. Conductors used for the primary
winding shall be rigid and housed in rigid metallic shell. Joints in the primary
winding shall not be provided. For primary winding current density shall not
exceed 1.50 Amp / sq.mm in case of copper at continuous overloading of
25% above rated current.
(c)
The design density for short circuit current as well as conductivity of the
metal used for primary winding shall meet the requirement of latest version
of IS:2705 or IEC-185. The Bidder shall in his bid furnish detailed calculations
for selection of winding cross-sections. The selected amp-turns for CTs
shall be justified on the basis of type test reports.
(d)
It is desired that from the point of view of adequate mechanical strength in the
normal course and also during short circuit, proper precaution should be
taken. The following arrangement or any equivalent suitable arrangement,
which should be described in the bid, shall be provided for this purpose:
i.
The primary conductor should be housed in suitable tube of adequate

mechanical strength. The arrangement shall be explained through
suitable drawing and material of tube should be indicated.
ii.
The primary conductor should be held firmly and for this purpose
suitable clamping arrangement at the bottom shall be provided and
explained through suitable sketch. Firm clamping arrangement is a must
and holding of winding using nylon rope etc. shall not be acceptable.
iii.
The neck of brass tube should be properly fixed to support the primary
windings of CT. It is suggested that piece of strong material of length
around 8 inches on both the sides of brass tube should be fixed to
properly hold the primary windings so that dislocation of primary
windings during transport is avoided.
iv.
The edges of the brass pipe should be smoothened to avoid any

damage to insulation.
v.
A sturdy arrangement should be provided to secure the bottom of

primary winding in place. Also separate arrangement will be necessary
to hold the secondary windings in place. The arrangements for primary
winding and for secondary cores shall be independent of each other.
Any common arrangement is not acceptable.
vi.
At least two clamping should be done on each sides of the primary

winding and a minimum number of 4 Nos. nuts and bolts should be
provided on each side. The nuts and bolts arrangement used for holding
205

active parts should be suitably dimensioned. The bolts should be
tightened with the nuts and also a check nut for proper locking.
5.20
vii.
The arrangement for bringing out connection from outer shielding for
grounding purpose should be made properly. For this purpose the full
length copper strip of width around 2 cm. may be used on the outer dia.
of bottom portion to ensure proper shielding / earthing of outer
condenser. For shielding preferably aluminium foil should be used.
viii.
Minimum 10 mm space should be available between neck of eye bolt

and porcelain for adequate passage of oil.
SECONDARY WINDINGS :
Suitably insulated copper wire of 99.9% conductivity electrolytic grade shall be used
for secondary windings. The exciting current of the CT shall be as low as possible.
The Bidder shall furnish along with his bid the magnetization curve/s for all the
core/s.
Enamel, if used for conductor insulation, shall be either polyvinyl acetate type or
amide emide type and shall meet the requirements of latest version of IS: 4800 or
equivalent International Standard.
5.21
PRIMARY TERMINALS :
For various ratings of CTs selection of primary terminal only of copper material shall
be made carefully. The primary terminal on either side of the tank shall be of proper
length preferably not less than 100 mm to accommodate terminal connector and ratio
changing strip. The dia/ size of the primary terminal shall be such that the current
rating available is at least 1.5 times the rated current of the CT. It would be
obligatory on the part of the bidder to specify material, diameter, length and current
rating of primary terminal which shall be used for CTs of different ratio. The primary
terminal studs to accommodate terminal connector for take off shall be plain and not
threaded. The details may be explained through suitable sketch.
The primary terminals shall be of heavily tinned electrolytic copper. The minimum
thickness of tinning shall be 15 microns.
5.22
SECONDARY TERMINALS :
Secondary terminal studs shall be provided with at least three nuts and adequate
plain and spring washers for fixing the leads. The studs, nuts and washers shall be of
brass, duly nickel-plated. The minimum out side diameter of the studs shall be of
proper size preferably not less than 8 mm. The length of at least 15 mm shall be
available on the studs for inserting the leads. The horizontal spacing between centres
of the adjacent studs shall be at least 1.5 times the outside circumdia of the nuts. The
arrangement should be shown through suitable sketch.
5.23
CORE:
The grade M4 toroidal core or any equivalent/superior grade core material 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. The
current transformer core to be used for metering shall be made of mumetal and shall
be of accuracy class specified. The current transformer core to be used for metering
shall be of accuracy class specified. 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. The 5P10 core shall be designed for a minimum saturation factor
of 10 for the highest setting. The magnetization curves for this core shall be furnished
206

with the bid. As far as PS class core is concerned all precautions shall be taken in
design to achieve the knee point voltage without exceeding requirement of excitation
current as specified in Appendix-C1. Magnetization curve for the same shall be
furnished.
5.24
RATIO CHANGING ARRANGEMENT :

Primary current ratio changing arrangement is not required.
5.25
SPECIAL REQUIREMENT FOR CURRENT TRANSFORMERS :
5.25.1 OVERLOADING:
The CTs shall be suitable for continuous overloading upto 125% maximum rated
primary current. The following requirements therefore should be noted:a)
It should be specifically confirmed that the CTs offered against the
specification are suitable for continuous overloading of 25% above rated
current. For this purpose, precaution taken in design of equipment may be
suitably explained.
b)
For all the CTs which are to be designed for 25% overloading, the
permissible temperature rise of CT winding over the reference ambient
temperature of 50 C at 125% rated current, rated frequency and with a
unity power factor burden corresponding to the rated output connected to
the secondary windings shall not exceed 45, i.e. 5 less than the
permissible value as specified in IS.
5.25.2 CONSISTENCY OF ACCURACY :
It should be specifically confirmed that with 25% continuous overloading, the ratio/
phase angle errors of the CTs shall be maintained strictly within specified limits
without any drift and no variation shall take place due to overloading of Current
Transformers.
6.0
TESTS :
6.1
TYPE TEST :
All the equipments offered, shall be fully type tested as per relevant Indian Standards
or any equivalent International Standard during the last five years from the date of
bid opening. Copy of type test reports shall be enclosed with the bid. For any change
in the design/ type already type tested and the design/ type offered against this bid,
the Purchaser reserves the right to demand repetition of same or all type tests
In the event of order for supply of 220 KV & 132 KV CTs, the supplier has to furnish
type test report for the following tests :i.
Chopped Impulse Test
ii.
Multiple Chopped Impulse Test
iii.
RIV Test
iv.
Mechanical Test on Terminals
v.
Seismic Test
vi.
Tan Delta Test at full Voltage
vii.
Thermal Stability Test
viii.
Temperature Coefficient Test
6.2
ACCEPTANCE AND ROUTINE TESTS :
6.2.1
The manufacturer shall carry out all acceptance and routine tests as stipulated in the
relevant Indian Standards or equivalent International Standards in presence of
Purchasers representative.
207
6.2.2
In addition to other acceptance tests for 220kV and 132kV CTs, the following tests
shall also be carried out :a/
Sealing test :
The sealing test shall be carried out on minimum one randomly selected CT of each
ratio out of each offered lot of CTs. The procedure for sealing test is as under :i.
ii.
iii.
iv.
v.
vi.
b/
Test shall be performed on completely assembled unit.

Test shall be performed on proto-type as well as during acceptance test on
minimum one randomly selected unit.
Temperature of CT under test will be elevated and maintained at 500C and
simultaneously it shall be subjected to internal pressure of 103 kPa (@1.1 kg /
sq.cm) for 12 hours.
Arrangement shall be made by manufacturer to maintain required pressure
and temperature for 12 hours.
During and after the test, there shall not be any oil leakage from any part or
joint of CT.
Readings of temperature, internal pressure applied and duration of test along
with observation of leakage, if any, shall be noted in inspection report.
Temperature Coefficient Test:
This test will be carried out on minimum one randomly selected 220kV and 132kV CT
of each ratio out of each offered lot of CTs.
6.2.3
Immediately after finalization of the programme of type/ acceptance/ routine testing,

the manufacturer shall give sufficient advance intimation to the Purchaser, to enable
him to depute his representative for witnessing the tests.
6.2.4
During measurement of errors, the resistance of leads connecting the CT under test,
the burden box and the standard CT to the measuring bridge should be kept
minimum so that accuracy of measurement of CT errors is negligible
7.0
INSPECTION :
i.
The Purchaser shall have access at all times to the works and all other
places of manufacture, where the current transformers are being
manufactured and the Bidder shall provide all facilities for unrestricted
inspection of the Bidders works, raw materials, manufacture of all the
accessories and for conducting necessary tests as detailed herein.
ii.
The successful Bidder shall keep the Purchaser informed in advance of the
time of starting and of the progress of manufacture of equipment in its
various stages, so that arrangements could be made for inspection.
iii.
During final inspection of CTs & PTs, the purchaser reserves the right to
carry out thorough internal inspection of two or three CTs & PTs randomly
selected out of offered lot, during which the CTs & PTs will be completely
opened to verify the dimensional and other details.
iv
Besides above purchaser reserves the right to carry out type test at NABL
accredited laboratory on one of the randomly selected CT & PT out of the
supplied / offered CTs & PTs.
v.
No material shall be dispatched from the point of manufacture unless the
material has been satisfactorily inspected and tested.
vi. The acceptance of any quantity of the equipment shall in no way relieve the
successful bidder of his responsibility for meeting all the requirement of this
208

specification and shall not prevent subsequent rejection if such equipment
are later found to be defective.
8.0
QUALITY ASSURANCE PLAN & STAGE INSPECTION :

QAP & stage inspection shall be as per Volume-II, Part-2, Book-I.
9.0
DOCUMENTATION :
9.1
All drawings shall conform to latest version of international standards organization

(ISO) A series of drawing sheet/ Indian Standards Specification IS-11065. All
drawings shall be in ink and suitable for micro filming. All dimensions and data shall
be in S.I.Units.
9.2
LIST OF DRAWINGS AND DOCUMENTS :

The Bidder shall furnish four sets of following details and drawings along with his bid.
a.
General outline and assembly drawings of the equipment.
b.
Graphs showing the performance of equipments in regard to magnetization
characteristics.
c.
Sectional views showing:
i.
General Constructional Features.
ii.
Materials/ Gaskets/ Sealings used.
iii.
The insulation of the winding arrangements, method of connection of
the primary/ secondary winding to the primary/ secondary terminals
etc.
iv. Porcelain used and its dimensions alongwith the mechanical and
electrical characteristics
9.3
d.
Complete primary terminal assembly which should include the following :i.
Complete primary terminal.
ii.
All sub-assemblies with the help of which the primary terminal shall
be brought out from the top tank including washers/ locking
arrangements, check nut, main nut etc.
iii.
Sub-assembly to demonstrate the arrangement of connection of
primary winding to primary terminal inside the tank.
iv. Terminal connector
e.
Details of rupture type pressure relief device

specifying size of diaphragm and its thickness etc.
f.
Name plate.
g.
Schematic drawing.
h.
Type Test reports in case the equipment has already been type
tested.
i.
Test reports, literature, pamphlets of the bought out items and raw material.
with
diaphragm,
The successful Bidder shall within two weeks of placement of order, submit four sets
of final versions of all the above drawings for Purchasers approval. The Purchaser
shall communicate his comments/approval on the drawings to the Bidder within
reasonable time. The Bidder shall, if necessary, modify the drawings and resubmit
four copies of the modified drawings for Purchasers approval within two weeks from
the date of Purchasers comments. After receipt of Purchasers approval, the Bidder
209

shall within three weeks submit 20 prints and two good quality reproducible of the
approved drawings for Purchasers use.
9.4
The Bidder for distribution, before commencement of supply, shall submit six sets of
the type test reports, duly approved by the Purchaser. Adequate copies of
acceptance and routine tests certificates, duly approved by the Purchaser shall
accompany the dispatched consignment.
9.5
The manufacturing of the equipment shall be strictly in accordance with the approved
drawings and no deviation shall be permitted without the written approval of the
Purchaser. All manufacturing and fabrication work in connection with the equipment
prior to the approval of the drawing shall be at the Bidders risk.
9.6
Twenty (20) copies of nicely printed and bound volumes of operation, maintenance
and erection manuals in English Language, for each type and rating of equipment
supplied shall be submitted by the Bidder for distribution, prior to the dispatch of the
equipment. The manual shall contain all the drawings and information required for
erection, operation and maintenance of the equipments. The manual shall also
contain a set of all the approved drawings, type test reports etc.
9.7
Approval of drawings/ work by Purchaser shall not relieve the Bidder of his
responsibility and liability for ensuring correctness and correct interpretation of the
latest revision of applicable standards, rules and codes of practices. The equipment
shall conform in all respects to high standards of engineering, design, workmanship
and latest revisions of relevant standards at the time of ordering and Purchaser shall
have the power to reject any work or material, which in his judgment is not in full
accordance therewith.
10. 0
Important Requirements for ensuring quality of manufacture and processing of

equipments.
10.1
For processing and vacuum treatment of core / coil assembly, it is desired that a
separate heating chamber and a separate vacuum chamber should have been
installed for vacuum treatment of core / coil assembly. Facility should be available to
measure quantum of water released during vacuum treatment of core/coil assembly.
Make, quality and capacity of vacuum chamber alongwith vacuum level may be
brought out.
10.2
Completely dust free shop should be available for preparation of winding. This should
be confirmed.
10.3
What is the process employed for wrapping of insulation on primary winding. Is it

being done manually or through suitable wrapping machine.
10.4
Various stages of quality checks during manufacture should be highlighted.
11.0
PACKING AND FORWARDING :

Bidder shall ensure that the equipment shall be packed in crates suitable for
vertical/horizontal transport, as the case may be and suitable to withstand handling
during transport and outdoor storage during transit.
12.0

No deviation from technical particulars of equipment and materials will be allowed,
210
APPENDIX C1
PRINCIPAL TECHNICAL PARAMETERS OF
CURRENT TRANSFORMERS
I)
S.No.
Item
220 KV
132 KV
33 KV
Single phase,
dead tank or
Live Tank, oil
filled,
hermetically
sealed,
outdoor type
Single phase,
dead tank, oil
filled,
hermetically
sealed,
outdoor type
Single phase,
dead tank, oil
filled,
hermetically
sealed,
outdoor type
Type of CT/ Installation
2
3
a.
b.
4
Type of mounting
Pedestal Type
Suitable for :System Frequency
50 Hz
Rated Voltage (KV rms)
245
145
Nominal System Voltage (KV
220
132
rms)
Highest System Voltage (KV
245
145
rms)
i)1200/1-1-1i) 800/1-1-1 A
Current Ratio
1-1 A
ii) 400/1-1-1 A
ii) 800/1-1-1-1- iii) 200/11A
1-1 A
5
6
Single ratio
CT
Single ratio
CT
Effectively earthed
36
33
36
i) 1200/1-1-1-1
A
ii) 800/1-1-1-1
A
iii) 400/1-1 A
iv) 5/1 A (for
NCT)
4 (for 1200 A
& 800 A CT), 2
(for 400 A CT)
&
1 (for
NCT)
Single ratio
CT
No. of Secondary Cores
Ratio taps
Method of earthing of the

system to be connected to
Rated continuous thermal
125% of rated current.
current
5 Degree Centigrade less than the limit
Acceptable
limit
of
specified in latest version of IS 2705 or
temperature rise above the
equivalent international standard taking
specified
ambient
temperature for continuous ambient temperature as 50 Degree Centigrade
operation at rated current
Acceptable partial discharge
Less than 10 pico coulombs
level at 1.1 times the rated
voltage
Radio interference voltage at
Less than 500 micro volts
1.1 times the rated voltage
250 / 2500 micro second
switching impulse withstand
voltage (KVp) (dry & wet)
1.2/50 microsecond lightning
1050
650
170
impulse withstand voltage
10
11
12
13
14
15
211

S.No.
Item
(KVp)
16 1 minute dry/wet power
frequency withstand voltage
primary winding (KV rms)
17 Power frequency overvoltage
withstand requirements for
secondary winding (KV rms)
18 Min. creepage distance of
porcelain housing (mm)
19 Rated short time withstand
current with duration (KA rms
for seconds)
20 Rated dynamic withstand
current (KAp)
21 Visual corona extinction
voltage (KV rms)
22 Seismic
acceleration
(horizontal)
23 Tan Delta at 900 C (max)
24 Material for Primary Winding
25 Terminal Connector
a. Type
b. Quantity
c. Conductor
d. Arrangement for current
take off
26 Mounting details (mm)
220 KV
132 KV
33 KV
460
275
70
6125
3625
900
40 KA for 1
sec.
40 KA for 1
sec.
26.2 KA for 2
sec.
100
100
65.5
176
106
0.3g
0.3g
0.3g
0.005
Copper
0.005
Copper
Copper
Rigid Type
Rigid Type
Rigid Type
(One clamp
(One clamp
shall be
shall be
through clamp
through clamp
type)
type)
2 Nos
2 Nos
2 Nos
Twin
/Single
Twin
/Single
Twin Moose /
Zebra ACSR
Zebra ACSR
Twin Zebra
ACSR
Horizontal & Vertical Take off
400x750
450x450
(As per drg.

220 KV CT&PT
Base Plate)
(As per drg. 132

KV CT Base
Plate)
212
200x350
(As per drg.
33 KV
CT,PT,LA,PI
Base plate)
II) DETAILS OF CT RATIO AND CORE PARTICULARS

i.
220 KV CT
No. of Core
cores no.
Current
ratio
10
Main
Protection
1200/
1-1-1-1-1A
800/
1-1-1-1-1A
N.A.
PS
1100.
50
N.A.
PS
1100.
50
N.A.
PS
1100.
50
15
0.2S
N.A.
N.A
N.A.
5 or
less
30
5P10
300
50
2
1
Main
Protection
Main
Protection
Metering
Back up
ii
InstruMax.
Max.
Output Accuracy Min. knee
ment
Exciting
point
CT Sec.
burden
Winding current at Security
(VA)
Class as voltage
(Volts) resistance knee point factor
voltage
(Ohms)
per IEC
(mA)
185
Application
1200/
1-1-1-1-1A
800/
1-1-1-1-1A
1200/
1-1-1-1-1A
800/
1-1-1-1-1A
1200/ 1-1-11-1A
800/
1-1-1-1-1A
1200/
1-1-1-1-1A
800/
1-1-1-1-1A
132 KV CT
No. of
cores
Core
no.
Application
Current
ratio
2
1
4
800/1-1-1A
400/1-1-1A
200/1-1-1A
Main
Protection
Back up
Metering
Min.
Out-put Accuknee
burden
racy
point
(VA) Class as
per IEC volt-age
(Volts)
185
Max.
CT Sec.
Winding
resistance
(Ohms)
Max.
Exciting
current at
knee point
voltage
(mA)
Instrument
Security
factor
10
N.A.
PS
1100
800/1-1-1A
400/1-1-1A
200/1-1-1A
30
5P10
300
50
800/1-1-1A
400/1-1-1A
200/1-1-1A
15
0.2S
N.A.
N.A
50
5 or
less
213
50

iii) 33 KV CT
(a) CT ratio 1200/1-1-1-1 Amp & 800/1-1-1-1 Amp.
No.
Of
cores
Application
Current
ratio
(Amp)
Output
burden
(VA)
Accuracy
Class
s per
IEC
185
Min.
knee
point
voltag
e
(Volts)
Max. CT
Sec.
Winding
resistance
(Ohms)
Max.
Exciting
current at
knee
point
voltage
(mA)
Instrument
Security
factor
3
Main
Protection
4
a)1200/1
b) 800/1
10
N.A.
PS
1100
50
Back-up
Protection
a)1200/1
b) 800/1
30
5P10
100
Metering
15
0.2S
N.A.
N.A.
N.A.
Metering
15
0.2S
N.A.
N.A.
N.A.
Min.
knee
point
voltag
e
(Volts)
Max. CT
Sec.
Winding
resistance
(Ohms)
Max.
Exciting
current
at knee
point
voltage
(mA)
9
100 on
all taps
Core
no.
2
1
a)1200/1
b) 800/1
a)1200/1
b) 800/1
5 or
Less
5 or
Less
(b) CT ratio 400/1-1 Amp.

No. Core
of
no.
cores
1
2
Instrument
Security
factor
Application
Current
ratio (Amp)
Output
burden
(VA)
Accuracy
Class
as
per
IEC
185
6
Protection
30
5P10
N.A.
Metering
15
0.2S
N.A.
N.A
N.A
Min.
knee
point
voltag
e
(Volts)
Max. CT
Sec.
Winding
resistance
(Ohms)
Instrument
Security
factor
Max.
Exciting
current
at knee
point
voltage
(mA)
9
400/ 1
400/ 1
10
5 or
Less
(c) NCT ratio 5/1 Amp.

No.
of
cores
Core
no.
Application
Current
ratio (Amp)
Output
burden
(VA)
Accuracy
Class
as
per
IEC
185
6
Protection
5/1
15
5P10
214
10
APPENDIX- C2
DRAWING OF TERMINAL CONNECTOR & BASE PLATE DETAILS
The following drawings showing mounting dimensions of structures and general
requirement of terminal connectors are enclosed here with for general guidance:
Description
SNo.
1
Vertical / Horizontal take off Arrangement of Terminal

Connector
Terminal connector suitable for single zebra conductor
Terminal connector suitable for twin zebra ACSR conductor
Base Plate details for mounting of 220 KV CT
Base Plate details for mounting of 132 KV CT Structure
Base Plate details for mounting of 33 KV CT Structure
215
216
217
218
219
220
221
SCHEDULE I(A)
DESCRIPTION OF EQUIPMENT FOR SCHEDULE FOR RATES AND PRICES TO BE
FURNISHED IN VOLUME-VI
Particulars of Equipment / Item
A
1
220 KV Current Transformer

220 KV Current Transformer ratio 1200/1-1-1-1-1 Amp complete with two
Nos terminal connectors, meeting all the technical requirements of tender
specification
220 KV Current Transformer ratio 800/1-1-1-1-1 Amp. complete with two
specification
132 KV Current Transformer ratio 800/1-1-1 Amp. complete with two Nos.
terminal connectors, meeting all the technical requirements of tender
specification
specification.
specification.
33 KV Current Transformer ratio 1200/1-1-1-1 Amp. complete with two
specification
33 KV Current Transformer ratio 800/1-1-1-1 Amp. complete with two Nos.
specification.
33 KV Current Transformer ratio 400/1-1 Amp. complete with two Nos.
specification.
33KV Neutral Current Transformer ratio 5/1 Amp complete with two Nos.
specification.
B
3
C
6
10
Qty.
SNo.
NOTE :
1. The above description of the equipment is given for the purpose of offering the prices
and to mention description of equipment in invoice for claiming payment.
2. The quantity of above equipments has been mentioned in Volume-VI.
222
2.1.3 (B) TECHNICAL SPECIFICATION FOR

POTENTIAL TRANSFORMERS
1.0
SCOPE :
The scope of this specification covers design, manufacturing and supply of equipment as
per Volume-II, Part-2, Book-I. The bidder mentioned in the Section of the Technical
Specification means Original Equipment Manufacturer (OEM). The Purchaser means
the MPPTCL.
2.0
STANDARDS :
Applicable Standards for the offered equipments / items shall be as per Volume-II, Part2, Book-I.
3.0
4.0
5.0
BASIC DESIGN AND TECHNICAL REQUIREMENT FOR POTENTIAL

TRANSFORMERS:
5.1
BASIC DESIGN :
5.1.1 The potential transformers will consist of a top dome /tank to accommodate primary
terminal assembly, oil level gauge, pressure relief device (rupture type) etc. and a
bottom tank to accommodate secondary core, terminal box etc. The equipment shall be
outdoor, single phase oil immersed and self cooled type suitable for services indicated
as above complete in all respect, conforming to modern practices of design and
manufacture.
As stated, all potential transformers shall be paper insulated oil filled type. The potential
transformers units after providing paper insulation shall be housed in the tank containing
oil. Please note epoxy casting in primary & secondary cores is not acceptable.
Manufacturers should briefly describe complete process of manufacturing
5.1.2 The insulation as per the latest version of IS: 4800 or equivalent International Standard of
the potential transformers shall be so designed that the internal insulation shall have
higher electrical withstand capability than the external insulation. The designed dielectric
withstands values of external and internal insulations shall be clearly brought out in the
guaranteed technical particulars. The dielectric withstand values specified in this
specification are meant for fully assembled potential transformers.
5.1.3
The Potential Transformers covered under this specification shall meet the technical
requirement indicated in Appendix-C3 enclosed with the specification.
223
Potential Transformers

5.2
PORCELAIN HOUSING:
5.2.1
The equipments should be designed using single porcelain housing. No joints shal be
provided in the porcelain. The housing shall be made of homogeneous, vitreous
porcelain of high mechanical and electric strength. Glazing of porcelain shall be of
uniform brown or dark brown colour with a smooth surface arranged to shed away rain
water or condensed water particles (fog.). The profile of porcelain shall be aerodynamic
type as per the latest version of IEC-815.
5.2.2 Details of attachment of metallic flanges to the porcelain shall be brought out in the bid.
5.3
METAL TANK:
Special precaution will have to be taken towards selection of material for the metal tank
and the following will have to be ensured.
i.
ii.
iii.
iv.
v.
5.4
5.4.1
Material for metal tank which should be minimum 3 mm. thick. ( i. e. Mild steel /
stainless steel / aluminium alloy) shall be carefully selected depending upon the
primary current and the material should be clearly mentioned against technical
questionnaire.
The practice of providing inserts of non-magnetic material in the body of the tank with
suitable welding to reduce eddy current shall not be acceptable. This problem should
be avoided by selection of tank of suitable material.
Welded joints have to be minimised to avoid possibility of oil leakage. In any case
welding in horizontal plane shall be avoided. The material selected for the tank shall be
justified with suitable explanation.
The slot / hole cutting in the bottom tank should be done smoothly to avoid any sharp
edges within the tank. All welded surfaces need to be smoothen and shall be
covered with pressboard or other insulating material of good mechanical properties.
The bottom tank should not have any dents and pittings to ensure proper tightening
of gasket and to avoid any oil leakage. Fabrication of bottom tank shall be done by
utilizing fresh sheet steel only.
PREVENTION OF OIL LEAKAGES AND ENTRY OF MOISTURE:
The sealing of potential transformers units shall be properly achieved. The following
should be properly taken care of & arrangement provided by the Bidder shall be
described.
a)
b)
c)
5.4.2
Locations of emergence of primary and secondary terminals.

Interface between porcelain housing and metal tank.
Cover of the secondary terminal box.
For gasketed joints, wherever used, nitrile butyl rubber gaskets, neoprene or any
other improved material shall be used. The nitrile butyl rubber O Ring should be
fitted in properly machined groove with adequate space for accommodating the
gasket under compression at interface between main porcelain bottom flange and
metal tank. You have to submit complete details and justify that the quality of
gaskets which will be used between the joints and also for mounting of oil level
indicator will be of best quality to avoid leakage of oil. The quality of gasket should
be selected keeping in mind that the ambient temperature in MP now touches 50
deg. centigrade
224

5.4.3
5.5
The potential transformers shall be so constructed that it can be easily transported to

site within the allowable transport limitation and in horizontal position if the transport
limitations so demand. The equipment shall be hermetically sealed and method of
such sealing shall be detailed out in the bid.
TERMINAL CONNECTORS:
The terminal connectors required for connection of the potential transformers to Owner's
bus bar, shall be in bidders scope. The terminal connectors shall be suitable for Zebra
ACSR Conductor with arrangement for both vertical and horizontal take off. The terminal
connector shall conform to the latest version of IS: 5561 or equivalent International
Standard. The drawing for terminal connector is enclosed with the specification for
guidance.
The design of clamp shall be to our approval. The details of current take off as required
by us should be detailed out in drawing and should be submitted along with the bid. In
respect of the terminal connectors following should be ensured:a)
The terminal connector should be made of A6 Aluminium Alloy and by gravity

diecast only. Sand casted terminal connectors are not acceptable.
b)
All castings shall be free from blow holes, surface blisters, cracks and cavities.
All sharp edges should be rounded off.
c)
No part of clamp shall be less than 12 mm thick.
d)
The bimetallic strips/sleeve shall be 2 mm thick.
e)
All nuts/bolts/washers shall be made of HDG Mild Steel with minimum diameter of
12 mm.
e)
contact resistance. The bimetallic strips/sleeve shall be 2 mm thick.
f)
Size of terminal connector for which the clamp is designed and also rated current
under site conditions shall be embossed / punched on each part of clamp except
hardware.
g)
The conductor should be tightened by six bolts. Conductor hold length must not be
less than 100 mm.
h)
The surface of clamps to be tightened by six bolts should be flat in shape so that it
may be possible to open the nuts and bolts by normal spanners. Therefore, any
type of groove in the clamp body for fixing of nuts should be avoided.
i)
The portion of clamp to hold the conductor should be flat and straight and not zigzag in construction, at both the sides, so that holding of clamp by throttling action
of current may be avoided.
225

j)
5.6
Space of at least 50% of diameter of nuts should be available after the hole at both
the sides of conductor holding portion for better mechanical strength.
MOUNTING :
The potential transformers shall be suitable for mounting on our steel structure, which shall
be arranged by the purchaser. The mounting dimensions of equipment shall match with the
mounting dimensions of structure indicated in enclosed Appendix-C4.
5.7
INSULATING OIL :
The insulating oil for first filling of oil in each transformer shall be in the scope of bidder.
Only best quality new EHV Grade transformer oil should be used with the equipments with
minimum BDV of 70KV. The BDV of oil will have to be recorded in the test certificate. The oil
shall comply in all respect with the provisions of the latest version of IS: 335 or IEC publication
no. 296 (as amended up to date)
5.8
SURFACE FINISH :
The metal tanks shall be coated with at least two coats of zinc rich epoxy painting or hot
dip galvanised. All the ferrous hardware, exposed to atmosphere, shall be hot dip galvanised
conforming to the latest version of IS: 2629 or equivalent International Standard. All other fixing
nuts, bolts, washers shall be made of HDG Mild steel.
5.9
ARRANGEMENT FOR COMPENSATION OF OIL VOLUME :
For compensation of variation in the oil volume due to variation in ambient temperature,
stainless steel bellows or any other suitable arrangement which may be equal or superior shall
be used. Rubber diaphragms shall not be permitted for this purpose. For indication of oil level,
a ground glass window shall be provided to monitor the position of metal bellow.
5.10
SECONDARY TERMINALS TERMINATION :
The P.T. secondary terminals shall be brought out in a weather proof terminal box.
Firstly the connections will be terminated on a internal board and then the same shall be
brought out in the Secondary terminal box. The secondary terminals termination should be
bolted type with wire size 4 sq.mm copper for connections. The terminal box shall be provided
with removable gland plate and gland/s suitable for 1100 volts grade, PVC insulated, PVC
sheathed multicore 2.5 sq.mm stranded copper cable.
The terminal box shall be dust and vermin proof. Suitable arrangement shall be made for
drying of air inside the secondary terminal box. The dimensions of the terminal box and its
openings shall be adequate to enable easy access and working space with use of normal tools.
The outer cover of secondary terminal box shall have provision for sealing by way of insertion
of wire in the bolt hole. A drawing indicating above arrangement may please be furnished
along with the bid.
5.11
RATING PLATE :
The P.T. shall be provided with a rating plate with dimensions and markings as per the
latest version of IS:3156 or equivalent international standard. The markings shall be punched /
engraved and not painted. This rating plate shall also contains our purchase order no. and date.
226

5.12
OIL FILLING AND SEALING :
The potential transformer shall be vacuum filled with oil after processing and thereafter
hermetically sealed to eliminate breathing and to prevent air and moisture from entering the
tanks. Oil sampling valve provided at the bottom of CT should be protected by providing metallic
cover or blanking plug/plate. Valve should be welded to avoid any leakage. Nitrogen filling valve
should be fitted with an indicator or cap to prevent leakage of nitrogen. The method adopted for
hermetic sealing shall be described in the bid.
5.13
CASTING :
The castings of base, collar etc. shall be die cast and tested before assembly to
detect cracks and voids if any.
5.14
EARTHING :
Potential transformer shall be provided with two separate earthing terminals for bolted
connection to 50 x 8 mm MS flat to be provided by the Purchaser for connection to station
earth-mat.
5.15
LIFTING ARRANGEMENT :
Potential transformer shall be provided with suitable lifting arrangement, to lift the entire
unit. The lifting arrangement shall be clearly shown in the general arrangement drawing. Lifting
arrangement (lifting eye) shall be positioned in such a way as to avoid any damage to the
porcelain housing or the tanks during lifting for installation/transport. Necessary sling guides
shall be offered which shall be of removable type.
5.16
5.17
PRIMARY WINDING :
a.
Primary winding shall be made out of electrolytic grade 99.9% conductivity

copper. Joints in the primary winding shall not be provided.
b.
It is desired that from the point of view of adequate mechanical strength in the
normal course and also during short circuit, proper precaution should be taken.
The primary conductor should be held firmly and for this purpose suitable
clamping arrangement at the bottom shall be provided and explained through
suitable sketch.
Firm
clamping arrangement is a must and holding of
winding using nylon rope etc. shall not be acceptable.
c.
All primaries of PTs will be connected in phase to neutral with neutral point
solidly earthed. The neutral of the system is also solidly earthed.
SECONDARY WINDINGS :
All PTs for phase to ground connection shall be provided, with separate windings. The
star winding to be used for metering & relaying shall be of accuracy class as specified for
appropriate class. The rated burden of the winding shall not be less than specified value.
Suitably insulated copper wire of 99.9% conductivity electrolytic grade shall be used for
secondary windings.
227

Enamel, if used for conductor insulation, shall be either polyvinyl acetate type or amide
emide type and shall meet the requirements of the latest version of IS:4800 or equivalent
international standard.
5.18
PRIMARY TERMINALS :
Selection of primary terminal only of copper material shall be made carefully. Primary
terminal on either side of tank should be of minimum 100 mm long and 30 mm dia. to
accommodate terminal connector. The primary terminals shall be of heavily tinned electrolytic
copper. The minimum thickness of tinning shall be 15 microns.
5.19
SECONDARY TERMINALS :
Secondary terminal studs shall be provided with at least three nuts and adequate plain
and spring washers for fixing the leads. The studs, nuts and washers shall be of brass, duly
nickel plated. The minimum out side diameter of the studs shall be of proper size preferably not
less than 8 mm. The length of at least 15 mm shall be available on the studs for inserting the
leads. The horizontal spacing between centres of the adjacent studs shall be at least 1.5 times
the outside circum dia of the nuts. The arrangement should be shown through suitable sketch.
5.20
CORE :
The grade M4 toroidal core shall be of high grade non- ageing electrical silicon
laminated steel of low hysterisis loss and high permeability to ensure high accuracy. The
potential transformer core to be used for metering shall be of accuracy class specified.
5.21
SPECIAL REQUIREMENT FOR POTENTIAL TRANSFORMERS :
a)
MAXIMUM CONTINUOUS OPERATING VOLTAGE :
The PTs shall be suitable for continuous over voltage up to 125% of rated voltage. The
following requirement therefore should be noted:
b)
i)
It should be specifically confirmed that all potential transformers offered against

the tender specification are suitable for continuous over voltage of 25% above
rated voltage. For this purpose, precaution taken in design of equipment may be
suitably explained.
ii)
For all the potential transformers which are to be designed for 25% overvoltage,
the permissible temperature rise of Potential Transformer windings over the
reference ambient temperature of 50 C at 125% rated voltage rated frequency
and at rated burden at any power factor between 0.8 lagging and unity shall not
exceed 45 C, i.e. 5 deg. less than the permissible value as specified in IS/IEC.
CONSISTENCY OF ACCURACY :
It should be specifically confirmed that with 25% continuous overvoltage above rated
voltage, the ratio/phase angle errors of the potential transformer shall be maintained strictly
within specified limits without any drift and no variation shall take place due to over voltage of
Potential Transformers.
228

6.0
TESTS :
6.1
TYPE TEST :
All the equipments offered, shall be fully type tested as per relevant Indian Standards
or any equivalent International Standard during the last five years from the date of bid opening.
Copy of type test reports shall be enclosed with the bid. For any change in the design/ type
already type tested and the design/ type offered against this bid, the Purchaser reserves the
right to demand repetition of same or all type tests without any extra cost.
6.2
6.2.1
relevant Indian Standards or equivalent International Standards in presence of purchasers
representative.
6.2.2
Immediately after finalization of the programme of type/ acceptance/ routine testing, the
manufacturer shall give sufficient advance intimation to the Purchaser, to enable him to depute
his representative for witnessing the tests.
7.0
8.0
INSPECTION :
i.
The Purchaser shall have access at all times to the works and all other places
of manufacture, where the potential transformers are being manufactured and
the bidder shall provide all facilities for unrestricted inspection of the Bidders
works, raw materials, manufacture of all the accessories and for conducting
necessary tests as detailed herein.
ii.
The successful bidder shall keep the purchaser informed in advance of the time
of starting and of the progress of manufacture of equipment in its various
stages, so that arrangements could be made for inspection.
iii.

iv.
The acceptance of any quantity of the equipment shall in no way relieve the
specification and shall not prevent subsequent rejection if such equipment are
later found to be defective.

9.0
DOCUMENTATION :
9.1
All drawings shall conform to the latest version of international standards
organization (ISO) A series of drawing sheet/ Indian Standards Specification IS-11065. All
drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in S.I.
Units.
229
9.2

The Bidder shall furnish four sets of following details and drawings along with his bid
:a.
General outline and assembly drawings of the equipments.
b.
Graphs showing the performance of equipments in regard to magnetization

characteristics.
c.

i)
ii)
iii)
iv)

The insulation of the winding arrangements, method of connection of the
primary/ secondary winding to the primary/ secondary terminals etc.
Porcelain used and its dimensions alongwith the mechanical and electrical
characteristics.
d.
Complete primary terminal assembly which should include the following:i.

Complete primary terminal.
ii.
All sub-assemblies with the help of which the primary terminal shall be
brought out from the top tank including washers/ locking arrangements,
check nut, main nut etc.
iii.
Sub-assembly to demonstrate the arrangement of connection of primary
winding to primary terminal inside the tank.
e.
Details of rupture type pressure relief device with diaphragm, specifying size of
diaphragm and it's thickness.
f.
Name plate.
g.
Schematic drawing.
h.
Type Test reports in case the equipment has already been type tested.
i.
9.3
of final versions of all the above drawings for Purchasers approval. The Purchaser shall
communicate his comments/approval on the drawings to the Bidder within reasonable time.
The Bidder shall, if necessary, modify the drawings and resubmit four copies of the modified
drawings for Purchasers approval within two weeks from the date of Purchasers comments.
After receipt of Purchasers approval, the Bidder shall within three weeks submit 20 prints and
two good qualities reproducible of the approved drawings for Purchasers use.
9.4
The Bidder for distribution, before commencement of supply, shall submit six sets of
the type test reports, duly approved by the Purchaser. Adequate copies of acceptance and
routine tests certificates, duly approved by the Purchaser shall accompany the dispatched
consignment.
9.5
drawings and no deviation shall be permitted without the written approval of the Purchaser. All
230

manufacturing and fabrication work in connection with the equipment prior to the approval of the
drawing shall be at the Bidders risk.
9.6
and erection manuals in English Language, for each type and rating of equipment supplied shall
be submitted by the Bidder for distribution, prior to the dispatch of the equipments. The manual
shall contain all the drawings and information required for erection, operation and maintenance
of the equipments. The manual shall also contain a set of all the approved drawings, type test
reports etc.
9.7
Approval of drawings/ work by Purchaser shall not relieve the Bidder of his
responsibility and liability for ensuring correctness and correct interpretation of the latest
revision of applicable standards, rules and codes of practices. The equipment shall conform in
all respects to high standards of engineering, design, workmanship and latest revisions of
relevant standards at the time of ordering and Purchaser shall have the power to reject any
work or material, which in his judgment is not in full accordance therewith.
10. 0
Important Requirements for ensuring quality of manufacture and processing of

equipments.
10.1
For processing and vacuum treatment of core / coil assembly, it is desired that a
separate heating chamber and a separate vacuum chamber should have been installed for
vacuum treatment of core / coil assembly. Facility should be available to measure quantum of
water released during vacuum treatment of core/coil assembly. Make, quality and capacity of
vacuum chamber alongwith vacuum level may be brought out.
10.2
Completely dust free shop should be available for preparation of winding. This
should be confirmed.
10.3
What is the process employed for wrapping of insulation on primary winding. Is it
being done manually or through suitable wrapping machine.
10.4
Various stages of quality checks during manufacture should be highlighted.
11.0
Bidder shall ensure that the equipment shall be packed in crates suitable for vertical/
horizontal transport, as the case may be and suitable to withstand handling during transport and
outdoor storage during transit.
12. 0
No deviation from technical particulars of equipment and materials will be allowed,

231
APPENDIX C3
I)
PRINCIPAL TECHNICAL PARAMETERS OF

POTENTIAL TRANSFORMERS
SNo.
Item
1.
Type/ Installation
2.
3.
Type of mounting
Suitable for : -
a.
System Frequency
b.
Rated Voltage (KV

rms)
Nominal
System
Voltage (KV rms)
Highest System
voltage (KV rms)
Number of secondary
cores
Voltage Ratio
i) Rated primary
voltage (KV rms)
ii) Secondary voltage
(volts)
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
220 KV
33 KV
Single phase, oil filled, hermetically sealed,

outdoor type
Pedestal Type
50 Hz
245
145
36
220
132
33
245
145
36
Three
Two
Two
220/3
132/ 3
33/ 3
110/ 3 V
Method of earthing of
the system to be
connected to
Lightning
impulse
withstand
voltage
(KVp)
1 minute dry power
frequency
withstand
voltage
primary winding (KV
rms)
1
minute
power
frequency withstand
voltage for secondary
winding (KV rms)
Min.
creepage
distance of porcelain
housing (mm)
Rated voltage factor
Effectively earthed
1050
650
170
460
275
70
3
6125
3625
900
1.25 continuous
1.5 for 30 seconds
Visual
corona
extinction voltage (KV
rms)
132 KV
176
232
106
SNo.
Item
15.
220 KV
132 KV
33 KV
Partial discharge level

at rated voltage (pico
Less than 10
coloumbs)
Max. temperature rise 5 Deg. Cent. less than the limit specified in IS
over ambient of 50 3156 / IEC 185 taking ambient temp. as 50
deg.C
Deg. C.
Seismic acceleration
0.3 g
(horizontal)
200 x 350
Mounting Details (mm)
450 x 735
660 x 910
16.
17.
18.
(As per drawing No.

JICA/MPPTCL/TR
101-107/220 KV
CT& PT Base plate)
II)
(As per drawing

No.
JICA/MPPTCL/TR
101-107/132 KV
PT Base plate)
(As per drawing

No.
JICA/MPPTCL/TR
101-107/33 KV
CT,PT,LA,PI Base
plate)
DETAILS OF RATIO AND CORE PARTICULARS

(i)
220 KV PT
S.No.
1
2
3
4
5
6
7
8
(ii)
Particulars
Rated primary voltage
Type
No. of cores
Rated secondary voltage (Volts)
Application
Accuracy
Output Burden (VA)
Requirements
220/ 3 KV
Single phase PT
Three
1.25 continuous
1.5 for 30 seconds
Core I
Core II
Core III
110/3
110/ 3
110/ 3
Protection Metering Metering
3P
0.2
0.2
200
100
100
132 KV PT
S.No.
1
2
3
4
5
6
7
8
Particulars
Type
No. of cores
Application
Accuracy
Output Burden (VA)
233
Requirements
132/ 3 kV
Single phase PT
Two
1.25 continuous
1.5 for 30 seconds
Core I
Core II
110/3
110/ 3
Protection
Metering
3P
0.2
200
100

(iii)
33 KV PT
S.No.
1
2
3
4
5
6
7
8
Particulars
Type
No. of cores
Application
Accuracy
Output Burden (VA)
234
Requirements
33/ 3 kV
Single phase PT
Two
1.25 continuous
1.5 for 30 seconds
Core I
Core II
110/ 3
110/ 3
Protection
Metering
3P
0.2
100
100
APPENDIX C4
The following drawings showing mounting dimensions of structure for Potential
Transformer and general requirement of terminal connector are enclosed herewith for general
guidance:
SNo
1.
Description
Base Plate details for mounting of 220 KV PT
2.
3.
4.
5.
Vertical/ Horizontal take off arrangement of terminal

connector
Terminal connector suitable for single zebra conductor
235
236
237
238
239
240
SCHEDULE I(A)
Qty.
220 KV Potential Transformer
220 KV Potential Transformer complete with one No. terminal

connector, meeting all the technical requirements of tender
specification
B
2

connectors, meeting all the technical requirements of tender
specification
C
3
connector, meeting all the technical requirements of tender
specification
SNo.
NOTE :
1. The above description of the equipment is given for the purpose of offering the prices and to
241
2.1.4 - TECHNICAL SPECIFICATION FOR

LIGHTNING ARRESTERS
1.0
SCOPE :
the MPPTCL.
2.0
STANDARDS :
3.0
4.0
5.0
GENERAL TECHNICAL REQUIREMENT :
5.1
The 220 KV, 132 KV, 36 KV and 33 KV Lightning Arresters covered under this
specification shall meet the technical requirement indicated in Annexure-I enclosed with
the specification.
5.2
The materials and components not specifically stated in this specification but which are
necessary for satisfactory operation of the equipment are deemed to be included in the
scope of supply unless specifically excluded.
5.3
The supplier should offer nearest rating of surge arresters & maximum residual voltage
shall comply with the requirement indicated in Appendix-D1.
5.4
The transformer, which is to be protected, has BIL 900 KVp, 550 KVp & 170 KVp for 220
KV, 132 KV & 33 KV system respectively. Considering 20% safe margin as per IEC the
impulse voltage of more than 720 KVp, 440 KVp & 136 KVp respectively for 220 KV,
132 KV & 33 KV systems, should not appear across the transformer. The Lightning
Arresters will be installed at a distance of 5/10 metres from transformer (another 5
metres be added towards height of Lightning Arresters lead length and bushing of
transformers). It should be explained with suitable graphs and calculations that the
voltage more that specified above will not appear on transformer.
5.5
The graph for Temporary Over Voltage (TOV) capability should be submitted along with
the bid.
242
Lightning Arresters

5.6
ENERGY HANDLING CAPABILITY :

Calculation for energy handling capability should essentially be submitted along with the
bid. The calculations should be as per latest version of IEC-99-4. The energy handling
capability for single shot of wave and multiple shots of wave as per IEC should be
submitted alongwith the bid.
5.7
SEPARATING DISTANCE :
The minimum permissible separation between the surge arresters and any earthed
object shall be indicated in the bid.
5.8
SEALING :
Each and every individual unit of surge arrester shall be hermetically sealed and fully
protected against ingress of moisture. The hermetic seal shall be effective for entire
lifetime of arresters and under the service conditions specified. The bidder shall furnish
sectional view showing details of sealing employed. Complete details of sealing
arrangement may please be furnished.
5.9
GRADING RING :
The grading ring on each complete arrester may be provided for proper stress
distribution for attaining relevant technical particulars in case of 400 KV, 220 KV & 132
KV Lightning Arresters.
5.10
PRESSURE RELIEF DEVICE :

The surge arresters shall be fitted with pressure relief devices and arc diverting ports
and shall be tested as per the requirements of IEC specification for minimum
prospective symmetrical fault current as specified in clause 4(e) above.
5.11
INTERCHANGEABILITY :
All the units of arresters of same rating shall be interchangeable without adversely
affecting the performance.
5.12
MOUNTING :
a)
The lightning (surge) arresters shall be suitable for pedestal type mounting which will be
arranged by the purchaser. The drawing of mounting structure for Lightning Arresters is
enclosed in Appendix-D2.
b)
All necessary bolts, nuts, clamps etc., required for mounting of LAs on support structure
to be supplied by the purchaser shall be included in the scope of supply.
5.13
TERMINAL CONNECTORS :
The terminal connectors required for connection of lightning arresters to the bus bar,
shall be in the bidders scope. The design of Terminal connectors shall be to
Purchasers approval. Terminal connectors shall be manufactured and tested as per
latest version of IS: 5561 or equivalent International Standard and should be type
tested. In respect of terminal connectors following should be ensured:-
243
Lightning Arresters

a)
All casting shall be free from blowholes, surface blisters, crakes and cavities. All
sharp edges and corners shall be blurred and rounded off.
b/
contact resistance.
c/
The contact surface must be machined smooth to obviate excessive current

density.
d/
The terminal connectors for connection of conductor should be suitable for Moose /
Zebra ACSR conductor with vertical as well as horizontal take off arrangement and
should have adequate current carrying capacity.
e/
The terminal connectors shall be manufactured out of aluminum alloy grade A6 as

per latest version of IS 5561 or equivalent grade specified in relevant International
Standard and by gravity die casting process only.
f/
Terminal connector should have six bolts to hold the conductors. The conductor hold
length shall not be less than 100 mm. All nuts, bolts, washers etc. shall be made of
HDG mild steel.
g/
The minimum thickness of any part of clamps body should not be less than 12 mm.
h/
The surface of clamps to be tightened by six bolts should be flat in shape so that it may
be possible to open the nuts and bolts by normal spanners. Therefore, any type of
groove in the clamp body for fixing of nuts should be avoided.
i/
The portion of clamp to hold the conductor should be flat and straight and not zig-zag
in construction, at both the sides, so that holding of clamp by throttling action of
current may be avoided.
j/
Spacer of at least 50% of diameter of nuts should be available after the hole at both
5.14
PORCELAIN BUSHING :
a/
All porcelain housing shall be free from lamination cavities and other flaws affecting
the maximum level of mechanical and electrical strength.
b/
The porcelain shall be well vitrified and non -porous.
c/
The creepage distance of the arrester housing shall comply with the requirement
indicated in Annexure-I.
d/
The porcelain petticoats shall be preferably of self-cleaning type (Aerofoil design). The
details of the porcelain housing such as height, angle of inclination, shape of
petticoats, gap between the petticoats, diameter (ID and OD) etc., shall be indicated by
the bidder in the form of a detailed drawing.
e/
The arrester housing shall conform to the requirements of IEC specification.
5.15
i/
ii/
GALVANISATION, NICKEL PLATING ETC :

All ferrous parts exposed to atmosphere shall be hot dip galvanised as per latest
version of IS:2629 or equivalent International Standard. Tinned copper/brass lugs shall
be used for internal wiring of discharge counter. Screws used for electrical connections
shall be either made of brass or nickel-plated.
Ground terminal pads and name plate brackets shall be hot dip galvanised.
244
Lightning Arresters

iii/
5.16
The material shall be galvanised only after completing all shop operations.
MANUFACTURE OF ZINC OXIDE (ZnO) ELEMENTS :
a) It is desired that the bidder should have all modern facilities to manufacture zinc oxide
discs, with special emphasis on automation of each element of processing of raw
materials, mixing of ingredients employed for manufacture of discs, verification of
homogeneity of powder mixture, preparation and compression of disc element and stage
verification/ testing of disc elements. The bidder must confirm that the process employed
for the purpose is fully automatic and should describe all critical stages of manufacture,
including the following:
i.
Batch Mixing
ii.
Batch Grinding
iii.
Batch Homogenising
iv.
Spray Drying
v.
Sieving or Sizing
vi.
Sintering
b) The bidder should also briefly describe the methods adopted and instruments used for
measurements to check the quality in following areas as also other important areas
during manufacturing process:
5.17
i.
The fineness of material having sub micron size of particles.
ii.
To measure the particle sizes of input and process materials.
iii.
Determination of trace impurities in all the metallic oxides.
iv.
The determination of viscosities of the metal oxide slips during powder preparation.
v.
To determine the impurity levels of Chlorides, Nitrates and Sulphates as a spot

check.
vi.
To check the porosity and the grain sizes of pressed metal oxide elements.
vii.
Process of testing of each disc after final finishing.
EARTHING :
The Lightning Arrester shall be provided with two separate earthing terminals for bolted
connection to 65 x 10 and 50 x 8 mm MS flat to be provided by the Purchaser for
connection to station earth-mat.
5.18
NAME PLATE :
The arresters shall be provided with non-corrosive legible nameplate indelibly marked
with the following information:
i. Madhya Pradesh Power Transmission Co. Ltd.
ii. Order No. & Date
245
Lightning Arresters

iii. Manufacturer's name or trademark, type and identification no. of the arresters being
supplied.
iv. Rated voltage
v. Maximum continuous operating voltage
vi. Type
vii. Rated frequency
viii. Nominal discharge current
ix. Long duration discharge class
x. Pressure relief rated current in kA rms.
xi. B.I.L. of the equipment to be protected.
xii. Year of manufacture
xiii. Identification of the assembly positions of the unit (for multi unit arresters only).
5.19
MOUNTING STRUCTURE:
The drawing of standard mounting structure of Lightning Arresters is enclosed. The
suppliers should confirm specifically the Lightning Arresters shall be suitable for
mounting on our structures.
6.0
TESTS :
6.1
TYPE TEST
All the equipment offered, shall be fully type tested as per relevant Indian Standards or
any equivalent International Standard (as specified in clause-2) during the last five
years from the date of BID opening. Copy of test reports shall be enclosed with the bid.
For any change in the design / type already type tested and the design/type offered
against this bid, the Purchaser reserves the right to demand repetition of same or all
type tests without any extra cost.
6.2.
ACCEPTANCE AND ROUTINE TESTS:
6.2.1
6.2.2
Immediately after finalisation of the programme of type/ acceptance/ routine testing, the
manufacturer shall give sufficient advance intimation to the Purchaser, to enable him to
depute his representative for witnessing the tests.
6.2.3
Acceptance tests, whenever possible shall be conducted on the complete arrester unit.
The number of samples to be subjected to acceptance tests shall be decided by the
purchaser at the time of actual testing.
6.2.4
The special thermal stability test shall be carried out as acceptance test. The
acceptance tests shall include the galvanisation test on metal parts.
246
Lightning Arresters

6.2.5
The functional (operational) acceptance tests shall be carried out on the surge counter
by way of checking its operation at following nominal discharge currents ;
a)
100 Amps with 8/20 microsecond wave shape
b)
10 kA with 8/20 microsecond wave shape.
7.0
INSPECTION :
8.0
i.
The Purchaser shall have access at all times to the works and all other places
of manufacture, where the isolators are being manufactured and the Bidder
shall provide all facilities for unrestricted inspection of the Bidders works, raw
materials, manufacture of all the accessories and for conducting necessary
tests as detailed herein.
ii.
time of starting and of the progress of manufacture of equipment in its various
iii.

iv.

QAP & stage inspection shall be as per Volume II, Part-2, Book-I.
9.0
DOCUMENTATION :-
9.1
All drawings shall conform to latest version of international standards organization (ISO)
A series of drawing sheet/ Indian Standards Specification IS-11065. All drawings shall
be in ink and suitable for microfilming. All dimensions and data shall be in S.I. Units.
9.2
LIST OF DRAWINGS AND DOCUMENTS:

The Bidder shall furnish four sets of following details and drawings along with the bid:i. General outline drawings of complete Lightning Arrester with technical parameters.
ii. Drawings showing clearance from grounded and other live objects and between
adjacent poles of Lightning Arresters required at various heights of Lightning
Arresters.
iii. Drawing showing details of pressure relief device.
iv. Sectional view to explain pressure relief arrangement.
v. Detailed drawing of discharge counters along with the wiring and schematic
drawing of discharge counters & meters.
vi. Details of grading rings if used.
vii. Outline drawing of insulating base.
viii. Mounting details of Lightning Arresters.
ix. Details of the line terminal connector and ground terminals.
247
Lightning Arresters

x. Volt time characteristics of Lightning Arresters.
xi. Details of galvanising being provided on different ferrous parts.
xii. The detailed dimensional drawing of porcelain housing such as ID, OD, thickness
and insulator details such as height, profile of petticoats, angle of inclination & gap
between successive petticoats, total creepage distance etc.
xiii. Name plate drawing.
xiv. Sectional view of sealing arrangement and pressure relief device.
xv. Type test reports in case the equipment has already been type tested.
xvi. Test reports, literature, pamphlets of the bought out item and raw material.
9.3
The successful Bidder shall within two weeks of placement of order, submit four sets of
final version of all the above drawings for Purchasers approval. The Purchaser shall
communicate his comments/approval on the drawings to the Bidder within reasonable
time. The Bidder shall, if necessary, modify the drawings and resubmit four copies of the
modified drawings for Purchasers approval within two weeks from the date of
Purchasers comments. After receipt of Purchasers approval, the Bidder shall within
three weeks submit 20 prints and two good quality reproducible of the approved
drawings for Purchasers use.
9.4
The Bidder before commencement of supply shall submit six sets of the type test
reports, duly approved by the Purchaser. Two copies of acceptance and routine tests
certificates, duly approved by the Purchaser shall accompany each dispatched
consignment.
9.5
Purchaser. All manufacturing and fabrication work in connection with the equipment
prior to the approval of the drawing shall be at the Bidders risk.
9.6
Twenty (20) copies of nicely printed and bound volumes of operation, maintenance and
erection manuals in English Language, for each type and rating of equipment supplied
shall be submitted by the Bidder for distribution to field officers, prior to the dispatch of
the equipment. The manual shall contain all the drawings and information required for
erection, operation and maintenance of the equipments. The manual shall also contain
a set of all the approved drawings, type test reports etc.
9.7
Approval of drawings/work by Purchaser shall not relieve the Bidder of his responsibility
and liability for ensuring correctness and correct interpretation of the latest revision of
applicable standards, rules and codes of practices. The equipment shall conform in all
respects to high standards of engineering, design, workmanship and latest revisions of
relevant standards at the time of ordering and Purchaser shall have the power to reject
any work or material, which in his judgment is not in full accordance therewith.
10.

horizontal transport, as the case may be and suitable to withstand handling during
transport and outdoor storage during transit..
248
Lightning Arresters
11.

No deviation from technical particulars of equipment and materials will be allowed, which
may please be noted.
249
Lightning Arresters
APPENDIX D1
PRINCIPAL TECHNICAL PARAMETERS OF LIGHTNING ARRESTERS
S.
No.
1
2
3
4
5
8
9
10
11
12
13
14
15
16
a.
b.
c.
Particulars
Nominal system voltage
Rated arrester voltage
Highest system voltage
Maximum continuous operating
voltage(KV rms)
Temporary over voltage
capability (KV Rms)
a/ 0.1 sec.
b/ 1.0 sec.
c/ 10 sec.
220 KV
132 KV
220 KV
198 KV
245 KV
168
132 KV
120 KV
145 KV
96
237
218
198
139
132
120
36 KV
33 KV
33 KV
36 KV
30 KV
36 KV
30
24
44
42
39
36
34
32
Nominal discharge current

10
10
10
10
corresponding to 8/20 micro
second wave shape (KA)
4.7
4.7
4.7
2.83
Minimum energy discharge
capability (as per long duration
discharge class of IEC- 99-4) in
KJ/KV
Long duration discharge class.
3
3
3
2
Maximum residual voltage at
480
300
110
90
nominal discharge current of
8/20 micro sec. wave for 10 KA
(KV peak)
Minimum prospective
40 KA for one sec.
26.2 KA for two sec
symmetrical fault current for
pressure relief test
High current Impulse withstand
100
100
100
100
(KA)
Creepage distance of porcelain
6125
3625
950
900
housing (mm)
Pressure relief device.
-- Class A--Insulation level of housing
(Lightning Impulse withstand
1050
650
250
170
voltage) (KVp)
Cantilever strength (Kgm)
1000
300
Terminal connector
Quantity
1 No.
1 No.
1 No.
1 No.
Conductor
Zebra
Arrangement of current take off
Horizontal & Vertical
250
Lightning Arresters
APPENDIX D2
The following drawings showing mounting dimensions of structure & general
requirement of surge counter are enclosed here with for guidance:
SNo.
Description
1.
Base plate details for mounting of 220 KV, 132 KV & 33

KV Lightning Arresters
2.
Pad Clamp for Zebra ACSR Conductor
251
Lightning Arresters
252
Lightning Arresters
253
Lightning Arresters
SCHEDULE I(A)
SNo.
Qty.
A
1
220 KV Lightning Arresters

a. 220 KV metal oxide gapless type Lightning Arresters complete
with terminal connector & grading ring etc. meeting all the
technical requirements of tender specification
B
2

a. 132 KV metal oxide gapless type Lightning Arresters complete
with terminal connector & grading ring etc. meeting all the
technical requirements of tender specification
b. Porcelain insulating base for above
C
3
D
4
36 KV metal oxide gapless type Lightning Arresters complete with
terminal connector etc. meeting all the technical requirements of
tender specification
33 KV metal oxide gapless type Lightning Arresters complete with
terminal connector etc. meeting all the technical requirements of
tender specification
b. Porcelain insulating base for above.
NOTE :
254
Lightning Arresters
2.1.5 TECHNICAL SPECIFICATION FOR

220 KV, 132 KV & 33 KV ISOLATORS
1.0
SCOPE :
the MPPTCL.
2.0
STANDARDS :
3.0
4.0
5.0
GENERAL TECHNICAL REQUIREMENT FOR 220 KV, 132 KV & 33 KV

ISOLATOR WITH / WITHOUT EARTH SWITCH :
5.1
TYPE & RATING :
5.1.1
Three phase / Single phase double break Isolators shall have three posts per phase
triple pole /single pole single throw, gang operated outdoor type, silver plated contacts with
horizontally operating blade and isolators posts arranged vertically. Single phase horizontal
centre break Isolators without earth switch, shall have two posts per phase, double pole gang
operated outdoor type silver plated contacts with horizontally operating blade and isolators
posts arranged vertically. Rotating blade feature with pressure relieving contacts is necessary,
i.e. the isolators shall have turn and twist arrangement. This arrangement shall be described in
details alongwith the bid. However, the design of turn & twist arrangement shall be to our
approval. Banging type feature is not acceptable.
All isolators with/ without earth switch shall operate through 90 degree from their
fully closed position to fully open position, so that the break is distinct and clearly visible from
the ground level. All 220 KV & 132 KV isolators will have manual operating mechanism with
worm and reduction gear, whereas 33 KV Isolators will have manual operating mechanism
without worm and reduction gear. The earth switch shall have separate operating mechanism
but without worm and reduction gear.
5.1.2
The equipment offered by the bidders shall be designed for a normal current rating of
1250 Amp for 220 KV Isolators & 1200 Amp / 800 Amp for 132 KV & 33 KV Isolators suitable
for continuous service at the system voltages specified herein. The isolators are not required to
operate under load but they must be called upon to handle magnetisation currents of the power
transformers and capacitive currents of bushings, busbars connections, very short lengths of
cables & current of voltage transformers and dividers.
255
Isolators
The bidders shall ensure that the isolators to be supplied shall be suitable for
mounting on our standard structures details of which are indicated in Appendix-E2 of the
specification.
5.1.3
It may please be noted that the all types of Isolators are to be supplied with matching
structure and Solid core Insulator. Structure to be supplied shall be as per our specification for
which drawing is available in the Tender document. As Civil foundation for structure will be as
per our civil drawing, structure base should be suitable for civil foundation. The prices of
isolators are to be quoted accordingly including the cost of structure and Solid core Insulator.
Further one prototype Isolator assembly complete with structure and solid core insulator duly
assembled as per MPPTCL drawings at the premises of Isolator manufacturer shall be offered
for inspection of MPPTCL before taking up mass supply. The proto assembly shall be checked
for proper operation and fitting to avoid any mismatch during actual erection in the field.
5.1.4
The rated insulation strength of the equipment shall not be lower than the levels
specified in IS-9921/IEC Publication No. 129.
5.2
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 45 degree centigrade above ambient. The limit of temperature rise shall not be
exceeded when corrected for the difference between ambient temperature at site and the
ambient temperature specified in the approved specifications. The corrections proposed shall
be stated in the bid and shall be subject to approval of the purchaser.
5.3
ISOLATOR INSULATION :
5.3.1
Insulation to ground, insulation between open contacts and the insulation between
phases of the completely assembled isolating switch shall be capable of withstanding the
dielectric test voltage specified in IS-9921 / IEC Publication No. 129. Insulation between open
contacts of a pole shall be atleast 15% more than the insulation between the live parts of pole
to ground.
5.3.2
The insulator for the isolators shall be arranged separately by the purchaser. The
scope of the present specification is for the supply of the isolator and base channel but without
insulator for the mounting of the isolator. The mounting structure for the isolator shall be
arranged by the purchaser separately. However, the following is binding on the bidder :a. The isolators offered shall be suitable for solid core insulator. Solid core
insulators shall be arranged by the purchaser separately.
b. The bidder shall have to specifically given an assurance in the bid that the
isolator of his supply shall be manufactured to make it suitable for us with
insulators with following fixing details :Sl.
No.
Voltage
rating
Details of
flange
220 KV
Top
127 mm
M16
Bottom
254 mm
18
Top
127 mm
M16
132 KV
PCD of which these

holes are provided
256
No. of
holes
Size of
holes
Isolators
33 KV
Bottom
225 mm
18
Top
76 mm
M12
Bottom
76 mm
M12
c. The isolators are to be supplied with mounting base channel and fixing nuts
and bolts. The structure would be arranged separately by the purchaser. The
drawings of our standard structures for 220 KV, 132 KV & 33 KV Isolators are
enclosed herewith in Appendix-E2.
The bidder will have to give a specific assurance that the isolators of his supply
shall be suitable for mounting on the structure as per drawing enclosed with specification.
5.4
MAIN CONTACTS :
All isolators shall have heavy duty self aligning and high pressure line type fixed
contact of modern design and made of hard drawn electrolytic copper. The fixed female contact
should be of reverse loop type. The various parts shall be accordingly finished to ensure interchangeability of similar components. The fingers of fixed contacts shall be preferably in three
pieces and each shall form the reverse loops to hold moving contacts. Stopper provided in the
fixed contact will over lap inside reverse loop assembly strips to stop over travel of moving
contact pipe. It should be made of material having high melting point eg Teflon to withstand rise
in temperature. The screw to secure the stopper in fixed contact for moving pipe should be
flushed properly to avoid damage to moving contact surface. The fixed contacts would be
placed in 'C' clamp. The thickness of Jaw holding bracket ('C' clamp) to hold fixed contact jaws
should not be less than 6 mm made of HDG Mild steel. This 'C' clamp shall be placed on a
channel of adequate thickness. This channel shall be welded on a insulator mounting plate of 8
mm thickness. The spring of fixed contact shall have housing to hold in place. This spring shall
be made of stainless steel minimum thickness of 14 SWG. The cap on spring should be made
of Teflon to withstand rise in temperature. The pad for connection of terminal connector shall be
of Aluminium Alloy. The minimum size of isolator pad available for fixing of terminal connector
shall be 100 mm x 100 mm with thickness not less than 12 mm, to suit terminal connector
included in scope of supply.
Suitable rain hood shall be provided overlapping the bushes on turn twist
arrangement to prevent accumulation of dust and other foreign particles so as to avoid jamming
of rotation of moving contact pipe. Center post top pin for holding the turn & twist assembly
should be adequate in size to avoid any bending of turn twist mechanism. Nut & bolt
arrangement is preferable to hold the pin in place of lock pin. The turn & twist assembly of
moving centre post top contact should be provided with sealed ball bearing at centre of
mechanism. Flat washers 2 Nos. on each side of turn and twist spring may be provided (4
Nos.). In turn and twist mechanism size of hook lever should not be less than 20 mm.
The switch blades forming the moving contacts shall be made from tubular section
of hard drawn electrolytic copper having outer diameter not less than 38 mm and suitable
thickness. These contacts shall be liberally dimensioned so as to withstand safely the highest
short-circuit and over voltages that may be encountered during service. The surfaces of
contacts shall be rendered smooth and silver plated. The thickness of silver plating shall not be
less than 25 microns. In nut shell, the male and female contacts assemblies shall be robust
construction and design of these assemblies shall ensure.
257
Isolators

a.
b.
c.
d.
e.
f.
Electro-dynamic withstand ability during short circuit without any risk of

repulsion of contacts.
The current density in the Copper parts & Aluminium parts shall be less than
2.0 Amp/sqmm & 1 Amp/sq.mm respectively.
Thermal withstand ability during short circuit
Constant contact pressure even when the live parts of the insulator stacks
are subjected to tensile stresses due to linear expansion of connected
busbar of flexible conductors either because of temperature variations or
strong winds.
No wiping action during closing and opening.
Self alignment assuring closing of the switch without minute adjustment. The
details/drawings of contacts, springs, fixing arrangement, contact pressure,
current transfer assembly, limit of temperature rise etc., shall be furnished
alongwith the bid.
The thickness of moving contact pipe should be uniform on the periphery at all
points. Due care should be taken to ensure that the copper pipe of good quality from reputed
source and of electrolytic grade only is utilized in manufacture of moving contacts. The moving
contact pipe should be supported with 2 mm thickness brass bushes at rotating points with
lubricating facility for smooth operation. The bushes should be machined having one side
proper collar and other side to be press fitted. The earthing switches shall each be provided
with three sets of suitable type of fixed contacts below the fixed contacts assemblies of the
main switch on the incoming supply side and three sets of moving contacts having ganged
operation. These contacts too shall be fabricated out of electrolytic copper for isolators with
earth switch and dimensioned to withstand the current on the line. Nut & Bolts of minimum 12
mm size shall be used, except in case of current carrying parts.
5.5
ARCING CONTACTS/HORN :
Arcing contacts of first to make and last to break type shall be provided for main
contacts.
5.6
AUXILIARY SWITCHES :
5.6.1
All 220 KV isolators and earthing switches shall be provided with 220Volt / 110 Volt
DC auxiliary switches for their remote position indication on the control board and for electrical
interlocking. The auxiliary switch shall have the following number of contacts :
a. For all earthing switches
b. For all main isolators
3 normally open and

3 normally closed.
6 normally open and
6 normally closed set of
contacts.
All contacts should be brought out on terminals. Provision shall be kept for adding
more auxiliary switch contacts at a later date. Auxiliary switches shall be of robust construction
of some reputed make and housed in weather proof, vermin proof, dust free covers mounted on
the respective operating mechanism. Schematic diagram for set of contacts shall be furnished.
The auxiliary switches should be positive type. They are spring loaded so that contacts are
258
Isolators

either NO or NC. The wire connection to the auxiliary switches shall be through suitable lug
screwed to the switch. The connection to the auxiliary switch should be screw on type.
The auxiliary switches shall be capable of carrying the current of atleast 10 Amps
continuously and shall be capable of breaking atleast 2A in 220V/ 110V DC circuit, with time
constant of not less than 20 milliseconds. The auxiliary switches shall be actuated by a cam or
similar arrangement directly mounted on the isolator and shall be without any intermediate
levels/ linkages to ensure fool proof operation.
It shall be possible to change normally closed contact into normally open contacts
and vice versa at site.Auxiliary switches are not required
5.6.2
For 132 KV & 33 KV Isolators, auxiliary switches are not required.
5.7
CLAMPS/CONNECTORS :
i)
The clamps/connectors shall be made of Aluminium alloy Grade A6 as per

IS:5561(1970) and shall be suitable for twin moose / twin zebra ACSR for
isolators without earth switch and single Zebra ACSR conductor for isolator
with earth switch with universal take off arrangement. The details in regard to
dimension, the number of bolts to be provided, material and manufacture shall
be furnished in the bid.
ii)
The design of clamp shall be to our approval. The clamps to be offered should
be manufactured by gravity die-casting method only and not by sand casting
process.
iii)
It is necessary that suitable clamps are offered alongwith the isolator and
also it is obligatory to give complete technical particulars of clamps alongwith
the drawing, as per details given above and as per following details.
iv)
a.
The terminal connector shall be manufactured and tested as per IS5561 or equivalent International standard.
b.
cavities. All the sharp edges shall be blurred and rounded off.
c.
No part of the clamp shall be less than 12 mm thick. The minimum size
of terminal connector pad for fixing on isolator pad shall be 100 mm x
100 mm.
d.
All current carrying parts shall be designed and manufactured to have

minimum contact resistance.
e.
Connectors shall be designed to be corona free as per relevant

standard.
f.
All nuts and bolts shall be made of HDG mild steel.
g.
Bimetallic sleeve/liner shall be 2 mm
h.
The conductor should be tightened by six bolts. Conductor hold length

must not be less than 100mm.
Wherever necessary bi-metallic strip of standard quality shall be used.
259
Isolators

v)

that it may be possible to open the nuts and bolts by normal spanners.
avoided.
vi)
zig-zag in construction, at both the sides, so that heating of clamp by throttling
vii)
viii) The clamp for twin moose/ twin zebra ACSR Conductor shall be in three
pieces so that each conductor may be tightened separately.
ix)
5.8
clamps except hardware.
ISOLATOR AND EARTH SWITCH OPERATION :
5.8.1
Each 220 KV & 132 KV isolator switch shall be equipped with local manual operating
device with worm & reduction gear. It shall be possible to pad lock the manual operating handle
both in the open and close positions of the switches. Additional castle type outer lock shall be
provided on the manual operating handle and control cubicle as to prevent the operation of
isolator manually & locally when the corresponding circuit breaker is ON. The earth switch may
be local manual operated by separate mechanism without worm & reduction gear.
5.8.2
All 33 KV Isolators and earthing switches shall have manual operating mechanism
without worm and reduction gear.
5.8.3
OPERATING MECHANISM FOR 220 KV, 132 KV & 33 KV ISOLATOR :
All Isolators and earthing switches shall have separate dependent manual
operation. The main isolator operation for 220 KV & 132 KV Isolator shall be through worm and
reduction gear and without worm and reduction gear for 33 KV. The operating mechanism shall
provide quick, simple and effective operation. The design of manual operation shall be such
that one man shall be able to operate the isolator without undue effort and isolator should
open/close with about 20 revolutions of crank. In case of any operational problem in worm and
reduction gear assembly, suitable arrangement should be incorporated for manual operation of
main switch, after by passing worm/reduction gear assembly. To hold operating pipe of main
switch in position, suitable guide should be provided to arrest movement in case of by passing
of worm & reduction gear assembly. The earth switch shall have simple manual operating
mechanism. In the earth switch only banging type feature is required, therefore the operating
mechanism should be such that the blade goes very smoothly in the fixed contact. There
should not be any jerk during operation. The earth switch plate should not move due to gravity.
In the rotating insulator, the design should be such that the shaft length is enough to
accommodate the locknut in a proper manner. Flexible copper strips should be provided for
main and earth handle.
5.8.4
The isolators may be required to operate occasionally with considerable long idle
intervals. Special care shall be taken for selection of material of gear to meet this requirement.
The gear shall made of alluminium bronze or any better quality material and lubricated for life
260
Isolators

with suitable lubricant. Gear operating box should be properly sealed to prevent any leakage of
grease / lubricating material. Provision for future lubrication should also be made. The gear
box enclosure should be made by casting process and not of sheet steel to provide proper
gear alignment. It should be filled with graphite grease or non hardening grease. Complete
details of component, material and grade, lubricant material and grade shall be furnished in the
bid.
5.8.5
The gear operating mechanism shall be housed in cabinet made out of 12 SWG
sheet steel with adequate channel support to withstand weight of gear. The operating handle
shall also be placed in the cabinet. The cabinet shall be liberally designed to have sufficient
working space. 2 Nos. rectangular frames made of 50x50x6 mm angle shall be provided to fix
gear operating box on structure angles (for 220 KV & 132 KV Isolator). 20 x 14 mm slots both
in horizontal and vertical direction will be provided on gear operating box support to facilitate
adjustment for fixing.
5.8.6
The isolators and isolator with earth switches inclusive of their operating
mechanism, should be such that they cannot come out of their open or closed positions by
gravity, wind pressure, vibrations reasonable shocks, or accidental touching of connecting rods
of the operating mechanism. Isolators and earth switches should be capable of resisting in
closed position, the dynamic and thermal effects of maximum possible, short circuit current at
the installation point. They shall be so constructed that they do not open under the influence of
the short circuit current. The operating mechanism should be robust constructions, easy to
operate by a single person and conveniently located for local operation in the switchyard.
Operating mechanisms for main switch & earth switch should be provided with flexible copper
strips for earthing of handle.
5.8.7
ON/OFF marking will be given on operating mechanism of main switch and earth
switch. Direction will also be indicated. Proper locking arrangement with lock & key of
operating handle in ON & OFF position should be provided.
5.9
PIPES :
Tandem pipes and operating handle shall be class B pipe having atleast 32 mm, 30
mm & 24 mm internal diameter for 220 KV, 132 KV & 33 KV Isolators respectively. The
operating pipe shall also be class B with internal diameter of atleast 50mm for 220 KV & 132
KV Isolator and 38 mm for 33 KV Isolator. The pipe shall be terminated into suitable universal
type joints between the insulator bottom bearing and operating mechanism.
Bushes may be provided on coupling of tandem pipe with insulator rotating base
(3 Nos.). Bushes may also be provided on both sides of operating down pipe (2 Nos.) at
support clamps. Bushes shall be made by machining process for smooth movement and
should have minimum thickness of 2 mm. Bushes should be machined having one side proper
collar and other side to be press fitted. Flange type joint should be provided at the bottom and
universal coupling at top of down operating pipe to avoid any play during operation.
The 33 KV Isolator with earth switch shall be mounted on gantry structure at height
of 4240 mm from ground level. The operating mechanism for earth switch and main switch are
to be fixed on the gantry columns which are at a distance of 1600 mm on either side from the
isolator pole. Therefore the phase coupling pipe for earth switch and main switch should have
length of 4500 mm each for proper operation. The length of operating pipes for main switch
and earth switch should also be about 3700 mm.
5.10
BASE CHANNELS :
261
Isolators

The isolator shall be mounted on a base fabricated from steel channel section of
adequate size not less than 125x65 mm for 220 KV & 132 KV Isolators and 100x50 mm for 33
KV Isolators respectively to withstand total weight of Isolator and insulators and also all the
forces that may encountered by the isolator during service. The strengthening /jointing of base
channels should be made by same size channels, to eliminate any vibrations during
operations. Mounting plates for insulators shall be big enough to properly accommodate
insulator metal parts (Base flanges). For fixing of bearing housing one M.S. plate of 8 mm
thickness should be welded on mounting channels, covering entire width of mounting channel
base. The M.S. Plate will have slotted round hole in the middle for accommodating bearing
assembly. Suitable holes shall be provided on the base channel to facilitate its mounting on our
standard structures as detailed in enclosed drawing. The steel channel in each phase shall be
mounted in vertical position and over it two mounting plates atleast 8 mm thick with suitable
nuts and bolts shall be provided for minor adjustment at site. Suitable marking on various parts
including mounting channel should be provided for proper identification.
5.11
CLEARANCES :
We have adopted the following minimum clearances for isolators in our system.
The bidders should therefore keep the same in view while submitting their bids.
Sl.
No.
Description
Centre distance
Distance between
between poles (centre
centre lines of
to centre) i.e ph. to ph.
outer posts on
clearance
same pole.
a. 220 KV 3 Phase
Double Break Isolator
4.0 metres
3.2 metres
b. 220 KV Single Phase

HCB Isolator
4.0 metres
2.6 metres
132 KV Isolator
2.5 metres
2.1 metres
33 KV Isolator
1.4 metres
0.96 metre
The plate provided for fixing insulator shall be of hot dip galvanized steel with
thickness not less than 8 mm. " size bolt should be used on insulator mounting plate for
adjustment of height of insulators.
5.12
INTERLOCKS AND EARTH SWITCHES :

i)
Line earth switches shall consist of three earthing links per isolator which will
normally rest against the frame when the connected isolator is in closed
position. The earthing links for the three phase shall be mechanically linked to
a coupling shaft which shall be capable of being fitted on either side of the
isolator. Earth switch shall be mechanically interlocked with the main switch so
that is possible to close or open the earth switch only when the main switch is
in the open position & its closing operation shall not be possible. In the earth
switch only banging type feature is required. Therefore, the earthing switches
should be provided with counter balance weight so that the earth switches do
not fall due to gravity and it moves very smoothly in upward direction i.e.
against gravity. The length of lever and counter weight should be selected
carefully so that earth switch is in horizontal position in fully opened condition.
Each earthing switch shall be designed to withstand electrodynamics stress
262
Isolators

due to currents upto 50 KA (peak) as per IEC recommendations. The contacts
shall be of silver plated copper only.
ii)
5.13
All shafts, couplings etc shall be galvanised. Flexible copper connectors of

atleast 50sq.mm cross-section shall be provided between the rotating shafts
and the frame work.
BEARINGS :
The design and construction of the various bearings shall embody all the features
required to withstand climatic conditions specified, so as to ensure dependable and effective
operation even after long periods of in-action of these isolators and switches. Bearing
housings should be weather proof. Facilities should be provided for lubrication of bearings.
The location and number of bearings provided for reducing friction shall be clearly intimated
alongwith suitable drawings.
The bearing housing shall be made of gravity die-cast alluminium with smooth
surface suitably machined for sealing the bearings. Each bearing assembly shall have two
nos. (taper roller thrust and ball) bearing with adequate shaft diameter. A minimum distance
of 150 mm,100 mm & 70 mm between thrust and ball bearings shall be provided for 220
KV,132 KV & 33 KV isolators respectively, to avoid wobbling during operation. The bearings
shall be of reputed make e.g. SKF, HMT,NBC,TATA & lubricated for life. All other friction
locations shall be provided with suitable bearings/ stainless steel or brass bushes. Complete
details of arrangement offered shall be furnished.
5.14
DESIGN, MATERIAL AND WORKMANSHIP :
The successful bidder shall assume full responsibility for co-ordination and
adequate design. All materials used in the construction of the equipment shall be of the
appropriate class, well finished and of approved design and name. All similar parts should be
accurately finished and inter-changeable.
5.15
PAINTING, GALVANISING AND CLIMATE PROOFING :
All interiors and exteriors of control cabinets shall be thoroughly cleaned to remove
all rust, scales, corrosion, grease and other adhering foreign matter and the surfaces treated
by recognized phosphating (e.g seven tank phosphating sequence). After such preparation of
surfaces, two coats of zinc oxide primer shall be given by suitable staving and air drying before
final painting. Colour of the final paints shall be of shade No. 697 of ISI i.e. epoxy light gray.
The finally painted cubicle shall present aesthetically pleasing appearance free from any dent
or un-even surface. Paint inside the metallic housing shall be of anti-condensation type and
the paint on outside surfaces shall be suitable for outdoor installation. All components shall be
given adequate treatment of climate proofing as per IS-3202 or equivalent international
standard so as to withstand corrosive and severe service condition.
5.16
All ferrous parts shall be heavily hot dip galvanised. Bolts, nuts, pins and washers,
etc. used on the isolators shall also be galvanised. All the nuts, bolts and washers in current
carrying parts shall also be of hot dip galvanised. Special attention shall be paid to give
tropical treatment to 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.
263
Isolators
5.17
GENERAL:
As described in the above paragraphs, the bidder shall quote the prices of isolators
inclusive of set of terminal connectors. Mounting structure and post insulators will be arranged
by the purchaser separately. The bidder should not include post insulators and mounting
structures in this bid. The base channel alongwith nuts, bolts and washers for the mounting of
isolator on our structure and operating down pipe shall however be included. The operating
mechanism together with down take pipe operating handle etc., will be included in the scope of
supply by the bidder. Bill of material will be provided with details of all minor /major items. The
counter balance spring cushions etc. shall be provided to prevent impact at the end of travel in
both on opening and closing. The name plate engraved and riveted on the channel and
operating mechanism shall be provided. The name plate shall contain all details e.g.
customers name, order No. and date, type serial no. rated voltage, rated current, rated short
time current etc.
6.0
TESTS :
6.1
TYPE TEST :
All the equipment offered, shall be fully type tested as per relevant Indian Standards
or any equivalent International Standard (as specified in clause-2) during the last five years
from the date of bid opening. Copy of test reports shall be enclosed with the bid. For any
change in the design/type already type tested and the design/type offered against this bid, the
MPPTCL reserves the right to demand repetition of same or all type tests without any extra
cost. Non compliance of this requirement will make the bid non-responsive.
6.2
7.0
a)
The manufacturer shall carry out all acceptance and routine tests as stipulated
in the relevant Indian Standards or equivalent International Standards in
presence of Purchasers representative.
b)
Immediately after finalisation of the programme of type/acceptance/ routine

testing, the manufacturer shall give sufficient advance intimation to MPPTCL,
to enable him to depute his representative for witnessing the tests.
INSPECTION :
i.
MPPTCL shall have access at all times to the works and all other places of
manufacture, where the isolators are being manufactured and the Bidder shall
provide all facilities for unrestricted inspection, raw materials, manufacture of
all the accessories and for conducting necessary tests as detailed herein.
ii.
iii.

iv.
264
Isolators

8.0

9.0
DOCUMENTATION :
9.1
(ISO) A series of drawing sheet/Indian Standards Specification IS-11065. All drawings shall be
in ink and suitable for micro filming. All dimensions and data shall be in S.I. Units.
9.2

The Bidder shall furnish four sets of following details and drawings along with his bid
:i.
ii.
Complete assembly drawing showing plan and elevation views of the isolator,
complete with details of operating mechanism, mounting dimensions etc.
Sketches and descriptive details of :
a.
The outline dimensions of the isolating and earth switches.
b.
Details of main contacts.
c.
The mechanical interlock between earth and isolating switches.
d.
The details of fixed and moving contacts and the arrangement of pressure
relief.
e.
Turn and Twist mechanism.
f.
Bearing assembly.
g.
Terminal connectors.
h.
Name plates to be provided.
i.
Operating mechanism, type of gear, size and thickness of box, gland

plate, gland etc.
iii.
Drawings with details to substantiate the suitability of the jaw design.
iv.
9.3
of final versions of all the above drawings for Purchasers approval. The Purchaser shall
communicate his comments/approval on the drawings to the Bidder within reasonable time. The
Bidder shall, if necessary, modify the drawings and resubmit four copies of the modified
drawings for Purchasers approval within two weeks from the date of Purchasers comments.
After receipt of Purchasers approval, the Bidder shall within three weeks submit 20 prints and
two good quality reproducible of the approved drawings for Purchasers use.
9.4
The Bidder before commencement of supply, shall submit six sets of the type test
certificates, duly approved by the Purchaser shall accompany the dispatched consignment.
265
Isolators
9.5
drawings and no deviation shall be permitted without the written approval of the Purchaser. All
manufacturing and fabrication work in connection with the equipment prior to the approval of the
drawing shall be at the Bidders risk.
9.6
and erection manuals in English Language, for each type and rating of equipment supplied shall
be submitted by the Bidder for distribution to field officers prior to the dispatch of the equipment.
The manual shall contain all the drawings and information required for erection, operation and
maintenance of the equipments. The manual shall also contain a set of all the approved
drawings, type test reports etc.
9.7
Approval of drawings/work by MPPTCL shall not relieve the Bidder of his
revision of applicable standards, rules and codes of practices. The equipment shall conform in
all respects to high standards of engineering, design, workmanship and latest revisions of
work or material, which in his judgment is not in full accordance there with.
10.
10.1
Bidder shall ensure that the equipment shall be packed in crates suitable for
vertical/horizontal transport, as the case may be and suitable to withstand handling during
transport and outdoor storage during transit.
11.
No deviation from technical particulars of equipments and materials will be allowed,

266
Isolators
APPENDIX- E1
PRINCIPAL TECHNICAL PARAMETERS
OF ISOLATORS
SNo.
1
2
3
4
5
7
8
9
10
11
11.1
11.2
12
Item
Rated Frequency (Hz)
System Neutral Earthing
No. of Phases (Poles)
Temperature Rise
Suitable for:Rated Voltage (kV rms)
Frequency (Hz)
Type of disconnect (AB)
Rated
normal
current
(Amp.rms)
Rated short time with stand
current of disconnects and
earthing switches Duration
(KA rms)
Rated peak withstand current
(kA)
Rated short circuit current of
Earth Break (kA peak).
Rated insulation level:
1.2/50 micro second lightning
impulse withstand voltage
(+ve or ve polarity)
a) To earth (kVp)
b) Across insulating distance:
One terminal subjected to
lightning impulse (kVp) and
opposite terminal subjected
to power frequency (kV rms)
Voltage
Rated 1 minute power
frequency with stand voltage
(kV rms)
Minimum creepage distance of
support and rotating insulator
(mm)
267
220 KV
132 KV
33 KV
50
Effectively Earthed
3
As per relevant IS/IEC Publication
245
50
Double Break
(DB) /
Horizontal
Centre Break
(HCB)
1250
145
50
Double
Break (DB)
36
50
Double
Break
(DB)
800/1200
800/1200
40 KA for 1
sec.
40 KA for 1
sec
26.2 KA
for 2 sec
100
100
65.5
100
100
65.5
1050
1200
650
750
170
195
460
275
70
6125
3500
900
Isolators

13
14
15
16
17
18
19
20
21
Rated Mechanical Terminal

Load for two column horizontal
break disconnect
a) Straight load (N)
b) Across load (N)
Rated magnetizing/ capacitive
current make and break
capacity (Amp.rms)
Phase to Phase spacing for
installation (mm)
Minimum clearance (mm):
a) Phase to earth
b) Phase to Phase
Height of center line of
terminal pad above ground
level (mm)
Maximum radio interference
voltage at 1 MHz and 1.1 x
rated phase to earth voltage
(micro Volts)
Minimum corona extinction
voltage (kV RMS)
Rating of auxiliary contacts.
Approximate Height of
insulator (not included in
scope of supply) (mm)
268
800
270
0.7
0.5
0.5
4000
2500
1400
2150
3500
7000
1075
2500
4600
480
1400
3900
500
176
10A at 220V
DC & 110V
DC with
breaking
capacity of 2 A
DC with time
constant not
less than 20
millisecond.
2500
1500
508
Isolators
APPENDIX E2
DRAWING OF SUPPORT STRUCTURES & GENERAL ARRANGEMENT
The drawings showing general arrangement and support structure for 220 KV, 132 KV & 33
KV Isolator is enclosed herewith for general guidance:
S.No.
Description
Drawing of support structure for 220 KV Isolator
GA Drawing for 132 KV Isolator with earth switch
Pad Clamp suitable for Twin Zebra ACSR Conductor
269
Isolators
270
Isolators
271
Isolators
272
Isolators
273
Isolators
274
Isolators
SCHEDULE I (A)
SCHEDULE FOR RATES AND PRICES
275
Qty.
As per Price sCHEDULE
SNo.
A 220 KV Isolators(with structure and Solid core Insulator)
1. 220 KV 1250 A Double Break 3 Phase Isolator with earth switch
complete with the following:a. Manual operating mechanism for main switch with worm & reduction
gear.
b. Manual operating mechanism for earth switch
c. Pad locks with three keys for main switch and earth switch and castle
interlock.
d. 6 Nos Terminal connectors.
e. 3 Nos. Base channels
f. 6NO + 6NC contacts for main switch.
g. 3NO +3NC Contacts for earth switch.
h. All other accessories as per technical specification
2. Same as 1 above but without earth switch (i.e. except item (b) & (g)
above)
3. 220 KV 1250 A Single Phase Horizontal Centre Break Isolator without
earth switch complete with the following:a. Manual operating mechanism for main switch with worm & reduction
gear.
b. Pad locks with three keys.
c. 2 Nos Terminal connectors.
d. 1 No. Base channel
e. 3NO + 3NC contacts for main switch.
f. All other accessories as per technical specification
B 132 KV Isolators(with structure and Solid core Insulator)
4. 132 kV 800A double break three phase isolator with earth complete with
the following :a. Manual operating mechanism for main switch with worm & reduction
gear.
b. Manual operating mechanism for earth switch.
c. Pad locks with three keys for main switch and earth switch and
castle interlock.
d. 6 Nos. Terminal connectors.
f. All other accessories as per technical specification.
5. Same as 4 above but without earth switch (i.e. except item ( b) above).
Isolators
C
7.
8
9
33 KV Isolators(with structure and Solid core Insulator)

33 kV 800A double break three phase isolator with earth switch complete
with the following :a. Manual operating mechanism for main switch.
b. Manual operating mechanism for earth switch.
c. Pad locks with three keys for main switch and earth switch and
castle interlock.
d. 6 Nos. Terminal connectors.
f. All other accessories as per technical specification.
Same as 7 above but without earth switch (i.e. except item (b) above).
Qty.
SNo.
6. 132 KV 800 A Single Phase Double Break Isolator without earth switch
and complete with the following:a. Manual operating mechanism for main switch with worm & reduction
gear.
b. Pad locks with three keys.
c. 2 Nos. Terminal connectors.
d. 1 No. Base channel
e. All other accessories as per technical specification
Same as 7 above but 33 KV, 1200 Amp without earth switch (i.e. except
item (b) above).
NOTE:
276
Isolators
2.1.6
1.0
TECHNICAL SPECIFICATION FOR

SOLID CORE INSULATORS
SCOPE :
the MPPTCL.
2.0
STANDARDS :
3.0
4.0
5.0
GENERAL TECHNICAL REQUIREMENT :
5.1
The insulators shall conform to the latest applicable Indian or IEC Standard and in
particular to IS-2544.
5.2
Porcelain used for the manufacture of insulators shall be homogenous, free from flaws
or imperfections that might affect the mechanical or di-electric quality. They shall be
thoroughly vitrified, tough & impervious to moisture. The glazing of the porcelain shall be
of uniform brown colour, free from blisters, burnsters and other similar defects. Insulators
of the same rating and type shall be interchangeable.
5.3
The porcelain and metal parts shall be assembled in such a manner that any thermal
differential expansion between the metal and porcelain parts throughout the range of
temperature variation shall not loosen parts or create undue internal stresses, which
may affect the electrical or mechanical strength and rigidity. Each cap and base shall be
machine faced and smoothly hot dip galvanized. The cap and base of the insulators
shall be interchangeable with each other.
5.4
Special care shall be taken for cementing the hardware into the porcelain insulators and
also for using proper cementing for forming solid core insulators assembly. The bidder
must specify the type of cementing used and should give proper explanation duly
supported with necessary test certificates to justify that the cementing used is of the
highest quality to ensure trouble free performance of solid core insulators.
5.5
The metallic flanges, nuts, bolts & washers shall be hot dip galvanized. The nuts, bolts &
washers for making one complete insulator stack and also for fixing the isolators shall be
included alongwith insulators.
277

5.6
The tapped holes shall be of standard size except that the diameter may be oversize by
not more than 0.25 mm. They shall be suitable for steel bolts having standard
dimensions after galvanizing. The length of full thread shall not be less than the nominal
bolt diameter. The threads of tapped holes in galvanized fittings shall be cut after
galvanizing.
6.0
TESTS :
6.1
Type Test :
All the insulators offered, shall be fully type tested as per relevant Indian Standards or
any equivalent International Standard (as specified in clause-2) during the last five years
from the date of bid opening. Copy of test reports shall be enclosed with the bid. For any
change in the design / type already type tested and the design / type offered against this
bid, the Purchaser reserves the right to demand repetition of same or all type tests
6.2
Acceptance And Routine Tests :
6.2.1
Immediately after finalisation of the program of type/ acceptance/ routine testing, the
6.2.2
7.0
INSPECTION :
i.
ii.
iii.
iv.
8.0
The Purchaser shall have access at all times to the works and all other places of
manufacture, where the solid core insulators are being manufactured and the Bidder
shall provide all facilities for unrestricted inspection of the Bidders works, raw
materials, manufacture of all the accessories and for conducting necessary tests as
detailed herein.
The successful Bidder shall keep the Purchaser informed in advance of the time of
starting and of the progress of manufacture of insulator in its various stages, so that
arrangements could be made for inspection.
No material shall be dispatched from the point of manufacture unless the material
has been satisfactorily inspected and tested.
The acceptance of any quantity of the insulator shall in no way relieve the successful
bidder of his responsibility for meeting all the requirement of this specification and
shall not prevent subsequent rejection if such insulator are later found to be
defective.

9.0
DOCUMENTATION :
9.1
All drawings shall conform to latest version of International Standards Organizations

(ISOs) A series of drawing sheet / Indian Standards Specification IS-11065. All
278

drawings shall be in ink and suitable for microfilming. All dimensions and data shall be in
S.I. Units.
9.2
List of Drawings And Documents :

The Bidder shall furnish two sets of following details and drawings along with his bid.
a.
General outline and assembly drawings of the insulators together with technical
particulars.
b.
Sectional views showing top and bottom portion of insulator alongwith depth of
threaded portion on metal cap, details of bottom flange etc.
c.
Shed profile with complete details of various parameters.
d.
Details of flanges joining upper and lower stack of insulator.
e.
Details of nuts and bolts to be provided on top and bottom portion of

insulator included in the scope of supply.
f.
Mounting details of top and bottom portion.
g.
Type Test reports in case the insulator has already been type tested.
h.
Test reports, literature, pamphlets of the bought out items and raw
material.
9.3
The successful Bidder shall within two weeks of placement of order, submit four sets of
final versions of all the above drawings for Purchasers approval. The Purchaser shall
communicate his comments / approval on the drawings to the Bidder within reasonable
three weeks submit 20 prints and two good qualities reproducible of the approved
9.4
The Bidder before commencement of supply shall submit six sets of the type test
certificates, duly approved by the Purchaser shall accompany the dispatched
consignment.
9.5
The manufacturing of the insulator shall be strictly in accordance with the approved
Purchaser. All manufacturing and fabrication work in connection with the insulator prior
to the approval of the drawing shall be at the Bidders risk.
9.6
Ten (10) copies of nicely printed and bound volumes of operation, maintenance and
erection manuals in English Language, for each type and rating of insulator supplied
shall be submitted by the Bidder for distribution to field officers, prior to the dispatch of
the insulator. The manual shall contain all the drawings and information required for
erection, operation and maintenance of the insulators. The manual shall also contain a
set of all the approved drawings, type test reports etc.
9.7
Approval of drawings / work by Purchaser shall not relieve the Bidder of his responsibility
applicable standards, rules and codes of practices. The insulator shall conform in all
279

10.0

Bidder shall ensure that the equipment shall be packed in crates suitable for vertical /
horizontal transport, as the case may be and suitable to withstand handling during
transport and outdoor storage during transit.
11.0

280
APPENDIX - F
PRINCIPAL PARAMETERS OF
SOLID CORE INSULATORS
S
No.
1
Type
PARTICULARS
220 KV
System Neutral Earthing.
Suitable for:Rated Voltage (KV)

One minute power frequency with
stand voltage(Wet) (KV)
Lightning Impulse withstand test
voltage (KV)
Switching Impulse withstand
Voltage (KV)
Minimum creepage distance Total
(mm).
Visible discharge voltage (KV)
6
7
8
9
10
--Effectively Earthed--
Mechanical strength.
Ultimate Bending Strength (Nm)
Torsional Strength (Nm)
Compression Strength (N)
11
Height of Insulator (mm).
12
Top metal fitting pitch circle dia

(mm).
Bottom metal fitting pitch circle dia
(mm).
No. of holes & diameter.
i)
Top flange
13
14
ii)
15
Bottom flange
No. of units per stack
33 KV
Outdoor Cylindrical Porcelain

Solid Core Post Insulator
---50---
132 KV
281
245
50
460
145
50
275
36
50
70
1050
650
170
6125
3500
900
154
105
27
8000
6000
6000
4000
260000
2500
3000
140000
1500
1500
60000
508
127
127
76
254
225
76
4 holes
of M16
8 holes
of 18
2
4 holes
of M16
8 holes
of 18
1
4 holes of
M12
4 holes of
M12
1
SCHEDULE I (A)
B
2
C
3

220 KV Solid Core Insulators
Qty.
Supply of 220 KV outdoor cylindrical porcelain solid core

insulator complete with top and bottom fixing nuts, bolts and
washers meeting all technical requirements of tender
specification.
specification.
specification.
SNo.
A
1
NOTE :
282
2.1.7 TECHNICAL SPECIFICATION FOR 36 KV, 1x12 MVAR

SHUNT CAPACITOR BANKS
1.0
SCOPE :
the MPPTCL.
2.0
STANDARDS :
3.0
4.0
5.0
DESIGN CRITERIA REQUIREMENTS AND CONSTRUCTIONAL DETAILS OF

CAPACITOR BANK :
5.1
The Capacitor Bank shall be suitable for being installed outdoors.
5.2
The Shunt Capacitor Bank should be designed for satisfactory operation even with
presence of harmonics in the system. For the purpose of shunt capacitor design, values
of 6%, 3%, 8% and 2% of the second, third, fifth and seventh harmonic level should be
assumed. However, the correctness of design of the capacitors and the entire scheme
will be the responsibility of the successful bidder.
5.3
At each location 36 KV, 1x12 MVAR Shunt Capacitor Bank shall be connected in double
star formation and each star connected bank shall be unearthed with a floating neutral,
but interconnected by a neutral protective Current Transformer (NCT) of suitable ratio to
operate protective relay at its 20% current setting whenever one capacitor unit fails. The
NCT shall be arranged separately by the purchaser. The capacitor banks should be
offered in three tier arrangement so that limitation of space may not create problem for
the purchaser.
5.4
Capacitor unit should be made up of 100% polypropylene dielectric with NON PCB
impregnant liquid and provided with internal fuse. Units should be painted and arranged
in open galvanised steel rack with copper tinned bus bars for their interconnections.
5.5
If the failure of one or more elements causes an over voltage of less than 10% tolerable
on the other remaining healthy units, then the unbalance current shall cause in the first
step to sound an alarm. But if more than the above number of elements fails causing a
283

voltage rise of more than 10% on the other healthy units then the unbalance current
shall cause to trip and isolate the capacitor bank instantaneously in the second step.
5.6
The per phase and individual star group rating shall be built up by series parallel
combination of individual units as per details indicated in Appendix-G1 enclosed, so as
to achieve the desired bank rating.
5.7
The insulation level and creepage distance of bushing used for capacitor units shall be
suitable for number of series groups in each rack. The mounting racks shall be
completely galvanized. The racks shall be suitably insulated by adequate post insulators
duly considering the number of series groups in each rack. The complete assembly shall
also be duly insulated from earth potential by solid core insulators. The mounting racks
shall be complete with rack insulators, hardware etc. for assembly into complete bank.
The design of mounting rack for capacitor bank assembly shall conform to enclosed
sample drawings in Appendix-G2.
5.8
Although the tolerances in the output rating of each individual unit shall be as per IS13925 (Part I) 1998 or any equivalent International Standard, yet it shall be ensured that
in a completely assembled bank, the departures from the nominal rating and within the
specified tolerance values shall not cause nuisance alarm or tripping since such alarm or
tripping shall be to meet only with the protective requirements specified above,
5.9
Individual units shall be designed to meet with the requirements of the permissible
overloads as specified in IS 13925 (Part-I) 1998, or any equivalent International
Standard. Each unit shall also be provided with internal discharge devices complying
with the requirements of IS 13925 (Part-I) 1998, or any equivalent International
Standard.
5.10
Internal fuses for individual elements within unit shall be as per the manufacturer's
design and shall be ensured for adequacy such as to withstand normal switching inrush
transient currents, discharge current when the bank is switched off. Fuses shall be
capable of disconnecting a faulty unit or element over a wide range of unit terminal
voltages from 70% to 150%. In case all the elements in the same row are fused out in
cascade in an internal fuse unit then the fuse element blown out shall be capable of
successful disconnection, with a voltage of not less than 100% rated voltage appearing
across its terminals. The unit shall also withstand this voltage successfully and
continuously. An internal element/ elements fuse blowing out shall not cause case
rupture of the container of the unit.
5.11
The individual capacitor units shall be of ungrounded case type with two bushings and
fully insulated for the unit rated voltage. The capacitance shall be built up with high
grade, all polypropylene dielectric film and aluminium foil. The polypropylene film shall
cover the aluminium foil smoothly, evenly and without any locked air pockets or voids.
The containers shall be of mild steel duly welded and hermetically sealed. All welded
joints shall be finished smoothly. All welding shall be done using modern welding
technique and bushings of each unit shall be preferred to be of welded type. The
intention is that the capacitor units shall be totally leak proof so that even if the units are
mounted horizontally on the racks problem of oil leakage is not involved during the entire
life of capacitor units. The interior of the capacitor shall be degreased and de-rusted and
shall not be painted. The exterior of the containers shall be sand blasted, phosphated
and painted on the exterior with anticorrosive base primers and finished with two coats
284

of admiralty gray paint conforming to IS 117 shade No. 632 and Phosphate treatment
shall conform to IS 6005, or any equivalent International Standard. The insulating liquid
shall be such that it shall remain chemically inert to the dielectric film and aluminium foil
and shall not degrade chemically itself while in service. The capacitance value in
microfarad and rating in KVAR shall be engraved on each capacitor unit.
5.12
The rated voltage and BIL of each capacitor unit bushings shall be carefully selected in
line with the provisions and duty as indicated under IS:13925 (Part-I), or any equivalent
International Standard.
5.13
Guaranteed failure rate i.e. number of units failed per year should be less than 0.5% per
annum during the period of guarantee. In case of failure of any unit within guarantee
period the supplier will have to give free replacement of capacitor units for each failed
unit. This may be noted carefully.
5.14
The complete assembly of the capacitor bank shall be on a galvanized mild steel bolted
type structure. The support structure for capacitor bank shall provide minimum phase to
ground clearance of 3.7 metres. The details of mounting structure connections with
relevant drawings shall be furnished. The mounting structure details for mounting the
capacitor banks has to be furnished by the Bidder. The capacitor banks shall be
mounted suitably ensuring sufficient clearances. The design of mounting structure for
capacitor bank shall conform to enclosed sample in Appendix-G2.
5.15
It may be noted by the bidders that only 166.67 KVAR, 6.93 KV rating internal fuse
capacitor units are acceptable to the purchaser. Lower or higher rating units are not
acceptable.
5.16
Each unit shall be of self contained outdoor type with two bushings. The container of
each capacitor unit shall have outer dimension and mounting dimensions as per
enclosed sample drawings in Appendix-G2. The container shall be made out of minimum
1.6 mm CRCA sheet duly painted with epoxy based paint to resist severe atmospheric
condition, making the unit suitable for outdoor installation. The bushing shall be of
porcelain and shall be joined to the case by solder sealing method. The welding of
container and sealing of bushing has to be done properly to avoid leakage of oil during
service period.
5.17
Each capacitor unit shall contain an internal discharge resistor designed to drain out the
residual voltage to 50 volts or less within 10 minutes after disconnection from supply.
6.0
COMPLETENESS OF EQUIPMENT :
6.0
For each installation, 1 No. 36 KV, 12 MVAR, 3 phase 50 Hz double star connected
capacitor bank is required complete with the following accessories.
6.0.1 Each 12 MVAR bank will comprise of 72 capacitor units of 166.67 KVAR, 6.93
KV rating.
6.0.2 Each 12 MVAR capacitor bank will be organized in double star formation i.e. with
36 units in each star and the two stars of 12 MVAR capacitor bank will be
protected through neutral current transformer. The NCT shall be arranged
separately by the purchaser.
285

6.0.3
6.0.4
6.1
7.0
36 units in each star of the bank will be mounted in 3 series groups such that
each series group will have four units of 166.67 KVAR, 6.93 KV rating in parallel.
It shall be ensured that the bottom most stack of insulators under the main
capacitor bank structure shall be suitably rated to provide the BIL of 170 KV as
per our specification.
For each substation, 1x12 MVAR bank as per above description shall be required
complete with the following :
a.
72 Nos. 166.67 KVAR, 6.93 KV Capacitor Units for each 12 MVAR capacitor
bank. On the body of each Capacitor Unit rated voltage, rated KVAR rating, rated
capacitance, S.No. (in the manner MPPTCL / SNo.), make and year of
manufacture shall be engraved / inscribed.
b.
One No. galvanized mounting structure, of required height and approved sturdy
design, for each 12 MVAR bank, as per approved drawing.
c.
All interconnections, mounting arrangement, terminations, earthing arrangement,
mounting racks, base insulator, terminal connector, nuts/ bolts, required quantity
of conductor/ strip for formation of neutral point and making connections to NCT
and all other required accessories for completing the bank in a neat manner. The
terminal connector shall be suitable for Zebra ACSR.
d.
Foundation bolts of 20 mm dia for bolted type hot dip galvanized steel support
structure.
e.
One complete set of 2 mm thick MS sheet foundation templates for structure of

each 12 MVAR capacitor bank, to be delivered in advance alongwith foundation
bolts.
f.
1 No. Digital Capacitance Meter to measure capacitance for each substation.
g.
2 Nos. caution boards, of size 915 mm x 610 mm with inscription as per

approved drawings, for each capacitor bank painted with anti corrosive base
primers and finished with two coats of white paint.
h.
A minimum of 5% additional nuts and bolts required for mounting individual

capacitor units of each capacitor bank.
i.
6 Nos. spare capacitor units of rating 166.67 KVAR, 6.93 KV as per description
furnished above for each substation where 1 No. 12 MVAR capacitor bank will be
installed.
TESTS ON CAPACITORS:
The capacitor units will be tested at the manufacturers work for all tests as per IS:
13925 (1998), or any equivalent International Standard including the following tests.
a.
Type Tests
As per clause 10.1 and sub clauses thereof as per IS 13925 (1998).
The endurance test reports for power capacitor as per IS-13925 / IEC 871
2 (latest) shall be submitted alongwith the tender.
b.
Routine Tests
As per IS 13925 (1998), or any equivalent International Standard.
c.
Acceptance Tests
As per IS 13925 (1998), or any equivalent International Standard.
286

8.0
TECHNICAL SPECIFICATION FOR STEEL STRUCTURES
8.1
SCOPE :
8.1.1 The scope of supply of structural work includes the following items:
i.
Support structure for 36 KV, 1x12 MVAR Capacitor Bank. The design of support
structures for capacitor bank shall conform to enclosed sample drawings in
Appendix-G2. The description of support structures are indicated in Appendix
G2.
ii.
33 KV Post Insulator structure complete with post insulators for connection of

Capacitor Bank (in three tier formation) with adjacent equipment shall conform to
enclosed drawings of Structure Assembly in Appendix-G2.
iii.
The bidder will have to submit his design for support structure required for
capacitor bank only. It may be noted that the structure for 33 KV Post Insulator
shall be as per standard design of purchaser. It is in this context that
design/drawing for 33 KV Post Insulator structure as per the purchasers
standard specification specified in Clause 8.3 may be adopted by the bidder.
8.1.2 It is not the intent to specify completely herein all the details and construction of
fabricated structures. However the material shall conform, in all respect, to high
standards of workmanship and shall be capable of performing duties specified herein.
The material offered shall be complete in all respect.
8.2
STANDARDS :
8.3
TYPE OF STRUCTURES:
The bidder shall submit his design for the support structure for capacitor bank. For 33
KV Post Insulator structure, standard design/ drawing as specified by the purchaser may
be adopted by the bidder. The specification of structures which are to be supplied as per
the standard design of purchaser are indicated as under:
S.No.
Particulars
1.
33 KV Post Insulator
(for Capacitor Bank)
Structure
Unit Weight (MT)

0.376
8.3.1 WEIGHT OF STRUCTURE:

i.
The supply of fabricated switchyard structures includes its accessories e.g. bolts,
nuts, spring & plain/pack washers etc. Scope of supply shall also include
foundation bolts and nuts required for foundation.
ii.
The Bidders may please note that weight of Structure mentioned above is the
weight of steel sections (excluding the weight of nuts, bolts and washers; required
alongwith the structures).
8.3.2 QUANTITY OF NUTS & BOLTS ETC. :
287

The details of nuts, bolts and washers and quantity required alongwith each 33 KV post
insulator structure for capacitor banks are as under:-
SNo
Type of Structure
Plain Washers
Size of Foundation
Sizes / Unit Weight
for 16 mm dia
Bolts (dia x length) in
of Nuts and Bolts
bolt ( Qty in
mm and quantity (Nos)
(Qty in Nos)
Nos)
33 KV Post Insulator
16 mm dia x 55 mm
Structure (for
- 15 Nos.
Capacitor Banks)
15
30 mm dia x 1320 mm
- 4 Nos.
NOTE:
i.
ii.
iii.
8.3.4
A set of one bolt and one nut required for assembly of structure shall have one
number spring washer and one number plain washer.
Each foundation bolt shall have three numbers nuts, one number Anchor plate and
one number plain washer. The anchor plate shall have a hole at the centre suitable
for diameter of foundation bolt.
Accessories which are not indicated in above tables but details of which are given
in our technical specification or which are necessary for completeness and
satisfactory operation of structures shall be deemed to be included in Bidders
scope of supply.
BASIS OF PRICE:
The bidders are requested to offer their rates ON PER STRUCTURE BASIS. The prices
on per structure basis should include cost of fabricated steel sections, cost of galvanized
nuts, bolts, foundation bolts, washers etc. and other specified accessories.
8.3.5
DRAWING AND DESIGN:

The successful bidder will be required to supply structures as per the details furnished
by the purchaser. By and large, steel sections like Channels, Angles, Flats and Plates
would be required for fabrication of structures covered in this specification. Tubular type
structures will not be required.
8.3.6
SHOP DRAWINGS:
The successful bidder shall prepare shop drawings for fabrication of structures and 2
sets of shop drawings of each type of structure shall be made available to the purchaser
for his record.
8.4
MATERIAL, FABRICATION AND WORKMANSHIP

The structures shall be of structural steel quality conforming to latest version of IS:2062.
Structural steel sections manufactured according to latest IS: 808, or any equivalent
International Standard shall be taken into consideration for fabrication of structures.
Tested steel sections having yield strength not less than 2550 kg/sq cm shall be used.
8.4.1
PROCUREMENT OF STEEL BY THE BIDDER:
288

The following provisions shall apply in connection with the procurement of steel by the
bidder:
8.4.2
8.4.3
i.
The steel used for the fabrication of structures, etc., shall be mild-steel of tested
quality as per latest version of IS:2062, or any equivalent International Standard.
ii.
The steel shall generally be procured from the Main Steel Producers. However, in
case of sections not rolled/ available from the main producers, the same could be
procured from re-rollers as per quality conforming to relevant IS provided:
a.
Re-rolling of structural steel sections is done from billets/ingots of tested

quality only.
b.
Re-rolled sections are duly tested as per relevant IS, or any equivalent
International Standard. It may, however, be noted that additional cost, if any,
on account of procurement of steel sections from re-rollers shall not be
payable.
iii.
The bidders should take into account the fabrication wastage while offering the
prices. The purchaser shall not accept any liability in connection with the actual
wastage of steel during fabrication or otherwise and no additional cost will be
allowed on this account.
iv.
Substitutions, if any, of steel sections of the structure parts by higher size, due to
their non-availability or otherwise shall be to the bidders account. The purchaser
shall not accept any liability on this account.
FABRICATION WORKMANSHIP:
i.
Except where hereinafter modified, details of fabrication shall conform to latest

version of IS: 802, or any equivalent International Standard. The fabrication shall
be done strictly in accordance with the drawing made available by the purchaser.
ii.
The structures shall be accurately fabricated to bolt together easily at site without
any undue strain on the bolts.
iii.
The diameter of the hole shall be equal to the diameter of the bolt plus 1.5mm.
iv.
Necessary drain holes shall be provided at all points of the structures where
pockets of depressions are likely to hold water.
v.
All similar parts shall be made strictly interchangeable. All steel sections before
any work is done on them, shall be carefully leveled, straightened and made true
to detailed drawings by methods which should ensure that granular configuration
of steel is not distorted. Further, while assembly the adjacent matching surfaces
should be in close contact throughout. No rough edges shall be permitted in the
entire structures. Hammering is not permitted for straightening.
vi.
Cutting may be done by shearing, cropping, flame cutting or sawing. The surface
so cut shall be cleaned smooth, reasonably square and free from deformation
and distortion.
DRILLING AND PUNCHING:

i.
The holes in the member shall either be drilled or punched with a jig, the former
process will be preferred.
289

ii.
Punching may be adopted for providing holes in steel sections up to 12 mm

thickness. For thicker sections, drilling shall be done.
iii.
The holes shall be punched/ drilled after bending and relative position of these
holes shall be maintained with the use of proper templates/ jigs and fixtures.
iv.
The holes shall be perfectly circular and no tolerance in this respect is

permissible. The holes shall be perpendicular to the Steel sections.
v.
All burrs left by drills or punch shall be removed completely. When the structure
members are in position, the holes shall be truly opposite to each other. Drilling
or ramming to enlarge defective holes shall not be permitted.
vi.
The minimum spacing of bolt and edge distance shall be as under:
vii.
8.4.4
8.4.5
a.
For 16 mm diameter bolt, edge distance of 20 mm from hole centre to rolled

or swaned edge and 23 mm from hole centre to sheared or flame cut edge.
b.
The gap between the edges of the connected members in butt joint shall
not be more than 6 mm and less than 4 mm.
The bolt gauge distance in flanges of angle sections shall generally be in

accordance with "Hand Book for structural Engineers-Structural Steel Sections
Revised)."
GALVANISING:
i.
Structural steel wherever applicable as per clause 8.1.1 above shall be

galvanised after fabrication. Galvanising of Steel section shall conform to latest
version of IS:2629 & IS:4759 and shall withstand tests as per IS:2633, or any
ii.
The galvanising shall be done after all fabrication work is completed, except that
the nuts may be tapped or re-run after galvanising. Threads of bolts and nuts
shall have a net fit and shall be such that they can be turned with finger
throughout the length of the threads of bolt and they shall be capable of
developing full strength of the bolts. Spring washers shall be electro-galvanised
as per latest version of IS: 1573, or any equivalent International Standard.
GALVANISED BOLTS, NUTS AND WASHERS:

i.
The bolts (5.6 quality) and nuts (5.0 quality) shall be of HRH mild steel and hot
dip galvanized. Spring washers shall be supplied for insertion under all nuts.
These washers shall be of steel, electro galvanized, and positive lock type and of
3.5 mm thickness. Bolt heads and nuts shall be of hexagonal shape.
ii.
The nuts shall be forged and tapped after galvanizing and then lubricated. The
nuts shall be chamfered on one face only; the other face shall be machined.
iii.
The bolts shall be manufactured by cold/ hot forging process and the threads
shall be rolled.
iv.
The bolts and nuts shall be free from forging and threading defects such as cuts,
splits, burrs, bulging, taper, centricity, loose fit etc. The bolts shall be threaded
upto standard length only as per relevant Indian Standard and not to full length.
v.
The bolts and nuts shall conform to IS:1967, IS:12427, IS:1363, IS:1367, or any
290
8.5
8.6
vi.
The spring washers suitable for diameter of the bolts shall be manufactured out
of rectangular section with tolerances as per IS:3063, or any equivalent
International Standard. The spring washer steel shall conform to IS:4072, or any
equivalent International Standard. The spring washers after coiling shall be
suitably heat treated so as to result in the finished washer having hardness 43
to 50 HRC when tested in accordance with latest version of IS:1586, or any
equivalent International Standard. Surface of the washers shall be free of scales
and burrs. The washers shall be coiled without any kinks (except for the shape
with turned-up ends). The ends of the washer shall not abut when the washers
are compressed. The ends shall be so served as to prevent tangling.
vii.
The spring washer shall be electro galvanized with chromate passivation. The
electro galvanizing of washers should conform to 'severe' grading service
conditions incorporated in IS:1573, or any equivalent International Standard. The
local thickness of zinc coating should be minimum 25 microns and average
thickness 38 microns. It should be further suitably heat treated to avoid any
danger of hydrogen embrittlement.
viii.
Plain/ pack washers shall be 4 mm thick and shall be suitable for diameter of
respective bolts.
ix.
A set of one bolt and one nut required for assembly of structure shall have one
number spring washer.
x.
Every foundation bolt shall have two numbers nuts.
TOLERANCES:
i.
The maximum allowable difference in the diameter of the hole on the two sides of
the plate or angle shall not exceed 0.8 mm.
ii.
The tolerance cumulative or between consecutive holes shall be within +0.5 mm.
iii.
The tolerance on the overall length of member shall be within + 1.6 mm.
iv.
The tolerance on gauge distance shall be within + 0.5 mm.
v.
Rolling and weight tolerance of steel sections shall be as per latest version of
IS:1852 and IS:808, or any equivalent International Standard.
MARKING:
Every member of the structure shall be distinctly given punch mark as per structural
drawings. Bidders identification mark shall also be punched. The marking shall be done
with marking dies of minimum 18 mm size and this mark shall be in "legible English
letters".
8.7
PACKING AND MARKING ON PACKING:
8.7.1
The material shall be boxed or bundled for transport preferably in the following
manner:
i.
Large members like angles, channels etc., shall be packed in bundles securely
wrapped four times around each end and over 900 mm with steel wire of 3.55
mm diameter with ends twisted tightly. As far as practicable, a bundle shall
consist of all the large members of one structure only.
291
8.7.2
ii.
Small loose pieces shall be nested and bolted together holes wrapped round at
least four times with steel wire of 3.55 mm diameter and its ends twisted tightly or
packed in wooden crates. Gross weight of each bundle shall not exceed 200
Kgs.
iii.
Bolts, nuts and washers required for structures shall be packed in heavy gunny
bags accurately tagged in accordance with the contents and a number of bags
packed in a solid box of 22 mm thick lumber with paneled ends to be accurately
nailed and further reinforced with 22 mm x 75 mm Buttons round the sides at the
ends with 25 mm x 1.26 mm iron band stretched entirely around the buttons with
ends overlapping atleast 150 mm. Gross weight of each box shall not exceed
approximately 200 Kgs.
iv.
Packing list incorporating all relevant details e.g., quantity of structures, number
and size of steel sections, quantity of nuts, bolts, washers etc., shall be
forwarded alongwith each consignment.
v.
In the nut shell, the packing arrangement should be such that all packages of one
particular type of structure are identifiable at site for the purpose of allocation for
a particular work. In case more than one structure of a particular type is delivered
in Transmission Stores/ Work Site, combined packing arrangement by way of
clubbing members of similar type (for more than one structure) in a combined
package should not be done. Unified packing procedure for each structure
should be adopted.
Each bundle or packing shall be marked in "legible English letters" in the following
manner :i.
Reference of purchase order.
ii.
The name of the consignee (as per dispatch instructions given by the purchaser).
iii.
Ultimate destination (if any) as required by the purchaser.
iv.
The relevant marks and number of structure members or reference or bolts, nuts
and small components for easy identification.
v.
Bidders identification:
The marking shall be stenciled and indelibly inked on the top members in the bundles,
on wooden boxes and also on gunny bags containing smaller components.
8.8
GENERAL GUIDE-LINE FOR INSPECTION:
8.8.1
For Fabricated Structure Members:

i.
ii.
iii.
iv.
v.
vi.
vii.
Visual examination and quantity verification of offered lot.

Sample selection from the offered lot.
Dimension, fabrication and trueness verification of structure members from shop
drawing.
Galvanising test of each sample i.e., dip test, hammer test and mass of Zinc test.
Random verification Zinc coating over Galvanized surface by Alko meter.
Tensile test and bend test of each sample.
Chemical composition test of at least two samples per offered lot.
292

viii.
8.8.2
Verification of manufacturers test certificate for mild steel used in structure

members.
For Bolts, nuts and washers:
i.
ii.
Sample selection from the offered lot as per relevant IS for each items.
iii.
Dimension, fabrication and trueness verification.
iv.
Galvanizing test of each sample.
Other acceptance tests for respective items as per relevant IS

9.0
TESTS :
9.1
TYPE TEST :
any equivalent International Standard (as specified in clause 2.1) during the last five
years from the date of bid opening. Copy of test reports shall be enclosed with the bid.
For any change in the design/ type already type tested and the design/ type offered
against this bid, the Purchaser reserves the right to demand repetition of same or all
type tests without any extra cost.
9.2

Immediately after finalization of the programme of type/ acceptance/ routine testing, the
10.
11.0
INSPECTION :
i.
MPPTCL shall have access at all times to the works and all other places of
manufacture, where the isolators are being manufactured and the Bidder shall
provide all facilities for unrestricted inspection, raw materials, manufacture of
all the accessories and for conducting necessary tests as detailed herein.
ii.
iii.

iv.

293
12.0
DOCUMENTATION :
12.1
(ISO) A series of drawing sheet/Indian Standards Specification IS-11065. All drawings shall be
in ink and suitable for micro filming. All dimensions and data shall be in S.I. Units.
12.2
12.2.1 The Bidder shall furnish four sets of following details and drawings along with his bid.
i.
Complete assembly drawing showing plan and elevation views of the capacitor
banks, complete with details of various accessories viz. support insulators,
connecting strip, racks etc.
ii.
Sketches and descriptive details of :

a.
Rack assembly drawing
b.
Capacitor unit.
c.
Terminal connector, Insulators etc.
d.
Rating plate and caution board.
iii.
Structural drawing, design calculations and loading data for the support structure
for capacitor bank.
iv.
v.
Calculations towards unbalance current.
vi.
12.2.2 The successful Bidder shall within two weeks of placement of order, submit four sets of
three weeks submit 20 prints and two good quality reproducibles of the approved
12.2.3 The Bidder for distribution, before commencement of supply, shall submit six sets of the
type test reports, duly approved by the Purchaser. Adequate copies of acceptance and
routine tests certificates, duly approved by the Purchaser shall accompany the
dispatched consignment.
12.2.4 The manufacturing of the equipment shall be strictly in accordance with the approved
Purchaser. All manufacturing and fabrication work in connection with the equipment prior
to the approval of the drawing shall be at the Bidders risk.
294

12.2.5 Twenty (20) copies of nicely printed and bound volumes of operation, maintenance and
erection manuals in English Language, for each type and rating of equipment supplied
shall be submitted by the Bidder for distribution, prior to the dispatch of the equipment.
The manual shall contain all the drawings and information required for erection,
operation and maintenance of the equipments. The manual shall also contain a set of all
the approved drawings, type test reports etc.
12.2.6 Approval of drawings/ work by Purchaser shall not relieve the Bidder of his responsibility
applicable standards, rules and codes of practices. The equipment shall conform in all
13.0
13.1
horizontal transport, as the case may be and suitable to withstand handling during transport and
14.

295
APPENDIX G1
PRINCIPAL PARAMETERS OF
36 KV, 12 MVAR CAPACITOR BANKS
S.No.
Particulars
Parameters
1.
33 KV
2.
36 KV
3.
Rated capacitor bank voltage
36 KV
4.
Basic insulation level
170 KVp
5.
P.F. withstand voltage
70 KV
6.
Type of connection
7.
Rating of Shunt Capacitor at highest voltage
8.
Number of phases
9.
KVAR and voltage rating of each unit
10.
Total Nos. of units in each bank of 1x12

MVAR
11.
Total Nos. of Series Groups per phase per

Star group
12.
Number of units in parallel per series group

per phase
13.
Type of fuse
Double Star
12 MVAR
3
166.67 KVAR /
6.93 KV
72 Nos.
Internal fuse
design
296
APPENDIX- G2
DRAWINGS OF CAPACITOR UNITS, RACK ASSEMBLY AND STRUCTURES
The following sample drawings showing dimensions of capacitor unit, rack assembly and
mounting structure for 36 KV, 1x12 MVAR Capacitor Bank and 33 KV special PI Structure (for
capacitor Bank) are enclosed here with for general guidance :SNo.
Description
1.
Dimensions for capacitor unit
2.
Rack Assembly suitable for 24 units
3.
Pedestal Assembly for 12 MVAR Capacitor Bank
4.
33 KV Special Bolted Type Post Insulator Structure
297
298
299
300
301
SCHEDULE I (A)
SNo.
Qty.
a.
2.
36 KV, 1x12 MVAR Capacitor Bank with 72

Nos. Internal Fuse Capacitor Units of 166.67
KVAR, 6.93 KV rating in double star formation
complete with all interconnections, mounting
arrangement, base insulators, foundation
templates, caution boards (2 Nos.), nuts and
bolts for mounting individual units
b.
Bolted type hot dip galvanized steel support
structure with foundation bolts for item 1a
above.
c.
Digital capacitance meter
d.
Internal Fuse Capacitor Units of 166.67 KVAR,
6.93 KV rating (6 Nos. as spare with each
Bank)
33 KV Post Insulator Structure (for Capacitor
Bank) complete with Post Insulators.
NOTE:
302
2.2 TECHNICAL SPECIFICATION FOR PLCC EQUIPMENTS

2.2.1
1.0
TECHNICAL SPECIFICATION FOR 220 KV CAPACITIVE VOLTAGE

TRANSFORMER (CVT) AND 132 KV COUPLING CAPACITOR
SCOPE :
Volume-II, Part-2, Book-I. The bidder mentioned in this Section of the Technical Specification
means Original Equipment Manufacturer (OEM). The purchaser means the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipments/materials of
2.0
STANDARDS:
2.1
Applicable Standards for the offered equipments /items shall be as per Volume-II, Part-2,
Book-I.
2.2
If the equipment offered by the Bidders conforms to any other standards, salient points
of comparison between the standards adopted and the specific standards shall be clearly
brought out in relevant schedule of technical deviation. It will be sole responsibility of Bidders to
prove that the salient features of offered equipment are equivalent or better than IS.
2.3
ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS :
In the preceding paragraph relevant Indian standard / IEC standard bid have been
Equipment for which Indian Standards are not available, the relevant British standards and IEC
recommendations will be applicable. Please attach photocopy of all such standards according
to which the equipment has been offered.
3.0
3.1
3.2

Auxiliary Power Supply for offered EHV equipments shall be as per Volume-II, Part-2,
Book-I.
4.

303
CVT & CC

5.0
TECHNICAL
REQUIREMENTS
FOR
220
KV
TRANSFORMERS & 132 KV COUPLING CAPACITOR
CAPACITIVE
5.1
220 KV CAPACITOR VOLTAGE TRANSFORMERS(CVT) :
VOLTAGE
The 220KV capacitor voltage transformers shall be of outdoor type, oil immersed,
self cooled suitable for operation in 3phase 220KV solidly grounded system under the climatic
conditions specified. These CVTs should be mechanically strong to withstand the stresses due
to wind pressure of 150kg/Sq. meter. The outer shell be wet processed porcelain with liberal
creepage distance to prevent flashover under the most adverse tropical conditions.
The capacitor voltage transformers shall have three secondary windings. Two
windings are meant for metering purpose and other secondary winding is for protection. All the
three secondary shall be rated for 63.5V. The 220KV capacitor voltage transformers shall have
the following ratings.
Rated frequency
Earthing
No.of secondary windings
Application
Voltage ratio for all the three
secondary windings
Class of accuracy
Rated out put burden VA
Rated simultaneous burden
Resultant high frequency
Capacitance(pf)
Creepage distance
Frequency pass band
5.1.1
220KV
245KV
50 c/s
Effective
Three
Secondary-I
Secondary-II
Protection
Metering
220 KV / 110 V
3
3
3P
0.2
100
50
75VA
1050KVp
4400 + 10% -5 %
Secondary-III
Metering
0.2
50
25mm/KV
50-500KHz
Technical Requirement:
(i)
The CVT shall incorporate potential devices, suitable for

connection to
synchronising equipment comprising of
synchronoscope, voltmeter,
synchronising lamps and the automatic synchroniser.
(ii)
Each CVT shall be suitable for connection directly to the line without the
use of auxiliaries such as isolating switches or fuses. The capacitors
of the unit shall be so designed that the application of impulse voltage
shall not damage the internal working elements or cause a change in
their electrostatic capacitance.
(iii)
The primary and secondary capacitors shall preferably be housed in

entirely sealed and oil filled porcelain insulator to eliminate breathing and
prevent ingressing air and moisture in to the assembly. Provision shall
304
CVT & CC

however be made to accommodate the expansion and contraction of
oil.
(iv)
5.1.2
The magnetic type intermediate transformer for CVT shall be of oil

immersed and self cooled design and shall be suitable for metering,
relaying and synchronizing services. The core of this transformer shall be
of high grade, non-ageing, cold rolled, laminated, electrical silicon steel of
low hysterisis loss and of high permeability so as to ensure high accuracy
at normal and high over voltages. The primary windings shall be
connected through a compensating reactor between phase and neutral with
the neutral point solidly grounded. An oil level gauge should be provided
on the EMU.
Damping Device :
Each capacitor voltage transformer shall be provided with suitable damping device
so that Ferro resonance oscillations due to saturation of iron core of transformer or of any
inductance connected in parallel with it or initiated by any other condition shall disappear
immediately and shall not affect the proper working of protective relays. The design of the
compensating reactor and the intermediate transformer as well as of the additional
damping devices inserted in the secondary of intermediate transformer shall be such that
the phenomenon of Ferro resonance cannot occur.
5.1.3
5.1.4
The design of capacitors shall generally be based on the following requirements:

i.
Comparatively low specific voltage between capacitor coils.
ii.
iii.
iv.
v.
vi.
Low dielectric loss over a wide frequency band.

Low variation of capacitance due to changes of temperature.
Very high natural frequency.
Corona free design to keep the noise level of carrier frequency link low.
Low stray capacity to ground to reduce the carrier frequency energy losses
in the neighborhood of carrier connection.
vii.
High mechanical strength of porcelain and its fastenings to ensure that it is

resistant against bending stresses which might occur due to a wind pressure
of 150kg/sq. meter.
The design of the potential unit of the CVTs shall be based on the
requirements in connection with protective relaying.
following
i.
They must transmit accurately sudden drops of primary voltage.
ii.
The measuring errors on the three phases of a set of CVTs should be

matched in accuracy.
iii.
The CVTs must not enter into sub harmonic resonance and transient
oscillations during energisation must be damaped out sufficiently/ rapidly.
iv.
They must have sufficiently low short circuit impedance as seen from
secondary.
305
CVT & CC
5.1.5
v.
The transient response should be such that the value of the secondary
voltage of CVT after 20 milliseconds from the instant of short circuit should be
less than 10 % of the peak voltage before test.
vi.
A suitable device should be provided to limit the over voltage impressed on

the transformer
Base Housing :
The measuring or the secondary unit comprising of compensating reactor,

intermediate transformer along with its accessories, damping impedances etc, shall be
contained in a heavily hot dip galvanized steel enclosure which will also serve as a mounting
base for the capacitor stack and a housing for carrier accessories.
5.1.6
Terminal Connector :
1. Terminal connectors suitable for single Zebra ACSR conductor shall be offered
along with the equipment. The drawings of clamps and connectors shall be got
finalized and approved by us before supplying the equipment. The clamps shall be
made of LM9 or LM25 aluminum alloy by gravity die casting process or pressure
die casting process only and sand die casting process in not acceptable. Any other
process followed or material used for manufacturing the clamps shall also be
indicated in the offer.
a.
5.1.7
The secondary terminals of the potential device and the terminal for high
frequency coupling as well as the earthing terminal shall be placed inside a
water proof terminal cabinet outside the steel enclosure. This cabinet shall also
be hot dip galvanised and shall have hinged door provided with locking
arrangements. Cable boxes to receive high frequency cable and control
equipments shall be mounted on the bottom of this cabinet and shall be included
in the scope of supply.
Mounting :
Each 220KV CVT shall be of self supporting type and shall be supplied without
mounting pedestal (structure). The CVT shall be suitable for mounting on our steel structure,
which shall be arranged by the purchaser. The mounting dimensions of the offered CVT shall
match with the mounting dimensions of structures indicated in enclosed Appendix-H3. However
before manufacturing CVT the drawing of the CVT including the details of base mounting
arrangement of the unit shall be got approved by us so as to fabricate a matching mounting
structure at our end. Data regarding minimum recommended phase to phase spacing between
the 220KV CVTs and the clearance from grounded objects required at various heights of
CVTs shall be mentioned in the offer.
5.1.8
Insulation Oil :
The insulating oil for first filling of oil in each CVT shall be in the scope of bidder.
Only best quality new EHV Grade transformer oil should be used with the equipments with
minimum BDV of 70KV. The BDV of oil will have to be recorded in the test certificate. The oil
shall comply in all respect with the provisions of the latest version of IS: 335 or IEC publication
no. 296 (as amended up to date). The potential transformer shall be vacuum filled with oil after
processing and thereafter hermetically sealed to eliminate breathing and to prevent air and
moisture from entering the tanks. Oil sampling valve provided at the bottom of CT should be
306
CVT & CC

protected by providing metallic cover or blanking plug/plate. Valve should be welded to avoid
any leakage. Nitrogen filling valve should be fitted with an indicator or cap to prevent leakage of
nitrogen. The method adopted for hermetic sealing shall be described in the bid.
5.1.9
PAINTING & FINISH
All interiors and exteriors of tanks, and other metal parts shall be thoroughly cleaned to
remove all rust, scales, erosion, grease or other adhering foreign matter. All steel surfaces in
contact with insulating oil as far as accessible shall be painted with not less than two coats of
heat resistant, oil insoluble, insulating varnish. Steel surfaces exposed to the weather shall be
given a priming coat of zinc chromate and two coats of final paint. All metal parts not accessible
for painting shall be made of corrosion resisting material. All machine finished or bright surfaces
shall be coated with a suitable preventive compound and suitably wrapped, or otherwise
protected. All paints shall be carefully selected to withstand tropical heat and extremes of
weather. The paint shall not scale off or crinkle or be removed by abrasion due to normal
handling. Bolts and nuts exposed to the atmosphere shall be of galvanized steel. In view of
severe climatic conditions, hot dip galvanized steel parts shall be required to prevent corrosion.
5.1.10 No separate over voltage protection device e.g. spark gap, voltage arrester, voltage
dependent resistor etc. shall be used in the CVT.
5.2
TECHNICAL REQUIREMENTS FOR 132KV COUPLING CAPACITOR
5.2.1 The 132KV coupling capacitors shall be of outdoor type, oil filled, pedestal mounted
and mechanically
strong
to withstand
the stresses due to wind pressure of
150KG/sq.meter.The outer shell will be one piece wet processed porcelain with liberal
creepage distance to prevent flashover under the most adverse tropical condition.
The 132KV coupling capacitor shall have the following electromechanical characteristics:
132KV
145KV
Installation
Outdoor
One minute power frequency withstand test voltage (dry)
275KV
One minute power frequency withstand test voltage(wet)
275KV
Impulse withstand votlage

Rated capacitance
Rated frequency
5.2.2
650 KV
4400pf + 10% -5%
50 Hz
Technical Requirements :
(i)
(ii)
Please note that we are standardizing value of capacitors in our

system and
intending to use capacitor value as 4400pf. It is therefore requested that capacitor
for 132KV system should be offered with a rated capacitance value of 4400pf.
The 132KV coupling capacitors must conform to the basic impulse level, dry and
wet withstand voltage and the creepage distances.
307
CVT & CC

(iii)
(iv)
6.0
The clamps shall be made of LM9 or LM25 aluminum alloy by gravity die casting
process or pressure die casting process only and sand die casting process in not
acceptable. Any other process followed or material used for manufacturing the
clamps shall also be indicated in the offer. The successful bidders will arrange to
supply sufficient number of clamps and connectors along with the main equipment.
The drawings of clamps and connectors shall be got finalized and approved by us.
The 132kV coupling capacitor shall be supplied without mounting pedestal
(structure). The Coupling Capacitor shall be suitable for mounting on our steel
structure, which shall be arranged by the purchaser. The mounting dimensions of
the equipments shall match with the mounting dimensions of structures indicated in
enclosed Appendix H3. However before manufacturing coupling capacitor the
drawing of the coupling
capacitor including the details of base mounting
arrangement of the unit shall be got approved by us so as to fabricate a matching
mounting structure at our end.
GUARANTEED TECHNICAL PARTICULARS FOR 220 KV CVT & 132 KV COUPLING

CAPACITOR :
Guaranteed technical particulars for 220 KV CVT & 132KV Coupling Capacitor
called for shall be furnished along with the bid. Particulars which are subject to guarantee
shall be marked clearly. Any other particulars considered essential may please also be
furnished.
7.0
TESTS :
7.1
Type Test :
All the equipment offered, shall be fully type tested as per relevant Indian Standards or any
Equivalent International Standard during the last five years from the date of bid opening. In
case the equipment of the type and design offered has already been type tested, the Bidder
shall furnish two sets of the type test reports along with the bid. The Purchaser reserves the
right to demand repetition of some or all the type tests in the presence of Purchasers
representatives. For this purpose, the Bidder may quote unit rates for carrying out each type
test. This will not be considered for price evaluations. For any change in the design/type
already type tested and the design/type offered against this bid, the Purchaser reserves the
right to demand repetition of same or all type tests without any extra cost. Non compliance of
this requirement will make the bid non responsive.
7.2
7.2.1
relevant Indian Standards or equivalent International Standards in presence of Purchasers
representative.
7.2.2
Immediately after finalization of the programme of type/ acceptance/ routine testing,
the manufacturer shall give advance intimation to the Purchaser, to enable him to depute his
representative for witnessing the tests.
7.2.3
The CVTs shall be subject to the following routine / site tests in addition to routine
tests as per IEC/IS.
308
CVT & CC

(i)
(ii)
(iii)
(iv)
8.0
Capacitance and loss angle measurement before and after voltage test ( as
per IEC:358)
Partial discharge test on capacitor dividers ( as per IEC- 358)
Sealing test (as per IEC-358)
Natural frequency of capacitor unit determination (Resonant frequency of
capacitor units).
INSPECTION:
i.
manufacture, where the 400KV & 220KV Capacitor Voltage Transformer & 132 KV
Coupling Capacitors are being manufactured and the Bidder shall provide all
facilities for unrestricted inspection of the Bidders works, raw materials, manufacture
of all the accessories and for conducting necessary tests as detailed herein.
Purchaser reserves the right to insist for witnessing the acceptance/routine testing of
the bought out items. Supplier shall submit the routine test certificates of bought out
items and raw material, at the time of routine testing of the fully assembled cvt/cc.
ii.
staring and of the progress of manufacture of equipment of the various stages, so
that arrangements could be made for inspection.
iii.
No material shall be dispatched from its point of manufacture unless the material has
placement of order, submit list of bought out accessories and the names of subsuppliers.
iv.
successful bidder of his responsibility for meeting all the requirements of this
specification and shall not prevent subsequent rejection if such equipment are later
found to be defective.
v.
complete with all accessories as per confirmation given with the letter of inspection
call, purchaser will reserve the right to recover the complete cost of deputation of
inspecting team to the works of the manufacturer.
9.0
QUALITY ASSURANCE PLAN:
9.1
The Bidder must establish that they are following a proper quality assurance
programme for manufacture of 220 KV CVT & 132 KV Coupling Capacitor. The Bidder shall
invariably furnish following information along with his offer. Information shall be separately given
for individual type of equipment offered.
i)
ii)
Statement giving list of important raw materials, names of sub supplier for the
raw material, list of standards according to which the raw material are tested, list
of tests normally carried out on raw material in presence of Bidders
representative and copies of test certificates.
Information and copies of test certificates as mentioned in (i) above in respect of
bought out items.
309
CVT & CC

iii)
iv)
v)
vi)
vii)

Levels of automation achieved and list of areas where manual processing exists.
carried out for quality control and details of such tests and inspection.
List of testing equipment available with the Bidder for final testing of equipment
specified and test plant limitations, if any, vis--vis type test, acceptance and
routine tests specified in the relevant Indian Standards or equivalent international
standard. These limitations shall be very clearly brought out in schedule of
deviations from specified test equipments.
The successful Bidder shall submit following information to the Purchaser.
9.2
i)
ii)
iii)
List of raw materials as well as bought out accessories and the names of sub
supplier selected from the lists furnished along with offer.
Type test certificate of the raw material and bought out accessories.
Quality Assurance Plan (QAP) with hold points by Purchasers inspection. The
quality assurance plans and hold points shall be discussed between the
Purchaser and Bidder before the QAP is finalized.
9.3
The successful Bidder shall submit the routine test certificates of bought out items and
for raw material at the time of routine testing of the fully assembled equipment.
10.0
DOCUMENTATION:
10.1
All drawings shall conform to the latest version of International Standards
Organization (ISO)À series of drawing sheet/Indian Standards Specification IS-11065. All
drawings shall be in ink and suitable for micro testing. All dimensions and data shall be in SI
Units.
11.0
11.1
The Bidder shall furnish four sets of following drawings along with his offer.
a) General outline and assembly drawings of the equipment showing front & side
elevation and plan views and all accessories, external features with detailed
dimensions, net & shipping weights, size of lifting lugs, quantity of insulating oil .
b) Sectional views showing General Constructional Features, lifting lugs, etc.
c) Name plate drawing with terminal markings & connection diagram.
d) Schematic drawing.
e) Dimensional drawing of terminal clamps and connectors showing material
composition, permissible temperature rise, current carrying capability etc.
f) Type Test reports
g) Test reports, literature, pamphlets of the bought out items.
11.2
The successful Bidder shall within two weeks from signing of contract, submit four
sets of all the above drawings for Purchasers approval. The Purchaser shall communicate his
comments/approval on the drawings to the Bidder within reasonable time. The Bidder shall, if
310
CVT & CC

necessary, modify the drawings and resubmit four copies of the modified drawings for
Purchasers approval within two weeks from the date of Purchasers comments. After receipt of
Purchasers approval, the Bidder shall within three weeks submit 20 prints and two good quality
reproducible (Soft copy) of the approved drawings for Purchasers use.
11.3
The manufacturing of the equipment shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written approval of the
Purchaser. All manufacturing and fabrication work in connection with the equipment prior to the
approval of the drawing shall be at the Bidders risk.
11.4
The bidder shall submit nicely printed and bound volumes of operation,
maintenance and erection manuals in English Language, for each type and rating of equipment
supplied for distribution, along with the equipments. The manual shall contain all the drawings
and information required for erection, operation and maintenance of the equipments. The
manual shall also contain a set of all the approved drawings and type test reports etc.
11.5
Approval of drawings by Purchaser shall not relieve the Bidder of his responsibility
and liability for ensuring correctness and correct interpretation of the latest revision of applicable
standards, rules and codes of practices. The equipment shall conform in all respects to high
standards of engineering, design, workmanship and latest revisions of relevant standards at the
time of ordering and Purchaser shall have the power to reject any work or material, which in his
judgment is not in full accordance therewith.
12.0
ENGRAVING, PACKING AND FORWARDING:
12.1
The details such as order no. and date, year of manufacture and MPPTCL should
be engraved on each and every equipment. The equipment shall be packed in crates suitable
for vertical/horizontal transport, as the case may be and suitable to withstand handling during
transport and outdoor storage during transit. The Bidder shall be responsible for any damage
during transit, due to improper and inadequate packing and handling. The easily damageable
material shall be carefully packed and marked with the appropriate caution symbols. Wherever
necessary, proper arrangement for lifting, such as lifting hooks etc. shall be provided. Bidder
shall supply, any material, found short inside the packing cases without any extra cost.
12.2
a)
b)
c)
d)
e)
f)
12.3
13.0

Destination
Bill of material indicating contents of each package.
The Bidder shall ensure that the packing list and bill of material is approved by the
Purchaser before despatch.
SCHEDULE
Schedules and annexure attached with this specification are the integral part of the
specification and shall be submitted duly filled in by the Bidders alongwith the offer. Bill of
311
CVT & CC

material for each equipment shall be submitted by the bidder separately. Makes of the
equipment shall be clearly indicated. Bidders may please note that a general mention that the
components shall be of reputed make will not be acceptable.
14.0
14.1 Bid shall be complete in all respects and shall include all minor component, accessories,
small wiring
etc., not specifically mentioned in the Schedule, specifications etc; but
essential for the completeness of the system. Bidders shall not be eligible for extra charges in
respect of such minor components, accessories, small wiring etc., though not included
specifically in this specification but requires for satisfactory operation of equipment offered.
14.2
Bidders must furnish following information along with technical Bid.
14.2.1 Complete details of all the accessories which will be supplied

14.2.2 It is obligatory on the part of bidders to ensure that supply of all accessories along with
Main equipment are simultaneously delivered to avoid any holdups. Responsibility for obtaining
timely supplies of bought out items will rest on the bidders and only on this basis, delivery period
will be offered in the Bid.
14.2.3 It may be noted that in case of damages/shortages due to improper packing or any other
negligence ,replenishment shall be arranged within one months time. For bought out items,
noticed and also in case defective supply of any item is reported, will rest on the bidders.
15.0
GUARANTEE FOR SUPPLY OF SPARES FOR 10 YEARS OPERATION:
As specified in the bid document, the bidder has to furnish an undertaking that the
spares required for satisfactory operation of offered goods shall be made available at
reasonable cost over a minimum period of 10 years from the date of commissioning of goods in
purchaser's system. In the absence of such an undertaking, the offer will be treated as nonresponsive.
16.0
Please ensure the Bid document containing number of pages has been properly
page numbered and signed by the bidder. All Bid documents including Schedules and
Annexure should be indexed properly and index of the document should be enclosed/placed at
the beginning of the document.
312
CVT & CC

APPENDIX-H1
PRINCIPAL PARAMETERS FOR 220 KV CVT
Rated frequency
Earthing
No.of secondary windings
Application
Voltage ratio for all the three
secondary windings
Class of accuracy
Rated out put burden VA
Rated simultaneous burden
Resultant high frequency
capacitance(pf)
Creepage distance
Frequency pass band
220KV
245KV
50 c/s
Effective
Three
Secondary-I
Secondary-II
Protection
Metering
220 KV / 110 V
3
3
3P
0.2
100
50
75VA
1050KVp
4400 + 10% -5 %
Secondary-III
Metering
0.2
50
25mm/KV
50-500KHz
313
CVT & CC

APPENDIX-H2
PRINCIPAL PARAMETERS FOR 132 KV COUPLING CAPACITOR
132KV
145KV
Installation
Outdoor
One minute power frequency withstand test voltage (dry)
275KV
One minute power frequency withstand test voltage(wet)
275KV
Impulse withstand votlage

Rated capacitance
Rated frequency
650 KV
4400pf + 10% -5%
50 Hz
314
CVT & CC

APPENDIX-H3
S.No
Description
Base Plate Drawing for 132KV CC
Base Plate Drawing for 220 KV CVT
315
CVT & CC
BASE PLATE MOUNTING DETAILS

132KV COUPLING CAPACITOR (3KO2)
800
340
340
TOP PLAN
316
CVT & CC
BASE PLATE DETAILS FOR 220KV CVTs
850
735
450
650
10MM THICK PLATE

FIXED WITH
5
8" CSK BOLTS
TOP PLAN
317
CVT & CC
SCHEDULE-I (A)
Particular of equipment/item
220 KV CVT
Supply of 220 KV CVT complete with all accessories including

mounting structure, terminal connectors etc confirming to all
technical requirements as described in the bid document
132 KV Coupling Capacitor
132 KV Coupling Capacitor With Capacitance of 4400 pF along with
Clamps and Connectors but without Pedestal meeting all technical
requirements of the specification etc.
Qty.
SNo
Note : 1. The above description of the equipment is given for the purpose of offering
the prices and to mention description of equipment in invoice for claiming
payment.
318
CVT & CC
2.2.2 TECHNICAL SPECIFICATION FOR 220 kV & 132 kV WAVE TRAP

1.0
SCOPE :
2.0
STANDARDS :
2.1
Book-I
2.2
2.3
3.0
3.1
3.2
AUXILIARY POWER SUPPLY :

Book-I.
4.
No deviation from technical particulars of equipment/materials will be allowed, which

may please be noted.
5.0
5.1
TECHNICAL SPECIFICATION FOR 220 KV & 132 KV WAVE TRAP

BASIC DESIGNS OF 220KV WAVE TRAPS:
5.1.1 The 220 KV out door type, wave traps shall be offered with suspension type mounting,
complete main coil with tuning pot, lightning arrestor, protective device, bird barriers, set of
319
Wave Trap

clamps and connectors and associated hardwares and accessories.The wave traps shall be of
0.5mH ,1250A rating for 220KV system . However, it should be made explicitly clear that the
wave traps are to be suitably designed to block any desired frequency in the range of 40
kHz to 500kHz by providing suitable tuning pot in such a manner that a minimum
resistive component of 570 ohms is available. The tuning pot should be such that with the
rating of wave trap i.e. 0.5mH, 250A for 220 KV, any frequency between 40 kHz to 500kHz may
be blocked. The various blocking bands which could be offered with 0.5mH 220kv wave traps
may please be stated in your offer. However, it may please be clearly confirmed that suitable
strapping are provided for different blocking bands with each rating of wave traps offered.
5.1.2 The wave traps shall be suitable for out door suspension mounting and shall be
mechanically strong to withstand the stresses due to maximum wind pressure of 260 kg per sq.
meter.
For suspension mounting the bidder shall be required to coordinate the mounting
arrangement with the existing arrangement. Non-magnetic suspension hook/link of adequate
length and tensile strength to provide necessary magnetic clearance between the wave trap
and the suspension hardware shall be supplied. The standard arrangement for suspension
mounting of 220 KV wave traps shall be adopted. A drawing showing the standard suspension
arrangement should be furnished for approval and the mounting arrangement should be
provided as per the design approved by us.
5.1.3
The wave traps shall have the following specifications:
SNo
Particulars
For 220KV
1.
220 KV
2.
Maximum voltage of the line on which the traps are to be used.
3.
System frequency
245 KV
50Hz
4.
Design ambient temperature
500C
5.
Nominal discharge current of the station class protective device
10KA
6.
Type of tuning
Broad band
7
8
Minimum resistive component of impedance within the blocking band 450 Ohms
570 Ohms
Resistive component of impedance within its carrier frequency the
blocking range shall not be less than
Continuous current rating
1250Amps
10
Instantaneous symmetrical short circuit current capacity.
40KA(1Sec)
11
Tuning range
90-150 Hz &
150500
KHz
12
Change in resonant frequency due to ambient temperature

variation not to exceed.
0.01%
Per0C
13
Change in impedance due to ambient temperature variation not to

exceed.
0.3% Per0C
320
Wave Trap

5.1.4
TERMINAL CONNECTORS FOR 220 KV WAVE TRAP :
5.1.4.1 220KV Wave Traps shall be provided with terminal connectors suitable to receive
Single Zebra ACSR conductor shall be provided with terminal connectors suitable to receive
Single Zebra ACSR conductor on one side and single Panther conductor on other side with
arrangement for both vertical as well as horizontal takeoff. The prices offered for each
equipments should take into account the cost of set of clamps & connectors. Clamps shall be
designed adequately to take care of any bimetallic effect. Temperature at the clamp shall not
exceed 800C. Terminal connectors shall be tested for short circuit current capability, temperature
rise etc.
5.1.4.2
Terminal connectors shall also meet the following requirements:
Terminal connectors shall be manufactured & tested as per IS:5561.
Terminal connector should be made of Aluminium alloy Grade LM9 or LM 25 as per

IS 5561 and shall be manufactured by by gravity die casting or by pressure die
casting process. Sand casted terminal connectors are not acceptable.
All castings shall be free from blow holes, surface blisters, cracks and cavities. All
Terminal connector shall be designed to corona free as per relevant standard.
No part shall be less than 12 mm thick.
The nuts, bolts & washers used in the current path shall be of good quality HDG mild
steel material only.
Wherever necessary by bimetallic strips, copper aluminium liner /by metallic sleeve of
minimum thickness of 2 mm shall be provided.
contact resistance.
The terminal connectors should be tightened by six bolts. Conductor hold length
must not be less than 100mm.
The surface of clamp to be tightened by six bolts should be flat in shape so that it
may be possible to open the nut bolts by normal spanners. Therefore any type of
groove in the clamp body for fixing of nuts should be avoided.
The portion of clamp to hold the conductor should be flat and straight and not zig-zag
in construction at both the sides so that heating of clamp by throttling action of
current may be avoided.
Space of atleast 50% of diameter of nuts should be available after the hole at both
321
Wave Trap
Size of terminal connector for which the clamp is designed and also rated current
under site conditions shall be embossed / punched on each part of clamps, except
hardware.
5.1.4.3
It is essential that design of clamps i.e. details in this regard to dimensions, the
number of bolts to be provided, material and manufacturing process should be submitted for our
approval. Any modification in the design shall have to be carried out without any extra cost.
Thus the clamps shall be manufactured finally as per design and drawing duly approved by us.
5.2
5.2.1
TECHNICAL SPECIFICATION FOR 132 KV WAVE TRAP

BASIC DESIGNS 132 KV WAVE TRAPS:
5.2.1.1 The Wave Traps shall be generally in accordance with the latest IEC 353 for Wave
Traps and shall comprise of main coil, protective device and a tuning device, bird barrier,
associated clamps, connectors, hardware and other accessories. The Wave Traps shall be
epoxy impregnated type to ensure reliability in adverse field conditions. Each Wave Traps shall
be supplied duly equipped with the following accessories;
(i)
One set of copper connectors, with fixing nuts and bolts for connection between main
coil, tuning device and protective device.
(ii)
One set of hardware for suspension of the wave trap from the Substation gantry or the
line conductor.
15
One set of connecting clamps for connecting the line trap to EHT Line and substation
side equipment.
The above items shall not be supplied in loose but shall be duly fitted with the main coil of
the Wave Trap.
5.2.1.2 Wave Trap shall be provided with a protective device in the form of surge arrester
which shall be designed and arranged such that neither significant alteration in the protective
function nor physical damage shall result from either temperature rise or magnetic field of the
main coil at continuous rated current or rated short time current.
The lightning arrester shall be of standard design and of latest technology. Its rated
discharge current shall be 10KA. The Lightning arrester provided with the wave trap shall fully
comply with the requirements of IS : 3070 Part-I / IEC 99 I Part I . It shall conform to
type tests as applicable and type test certificates for the same shall be submitted by the bidder.
5.2.1.3 Out door type of wave traps shall be of 0.5mH, 630A rating for 132KV system.
However, it should be made explicitly clear that the wave traps are to be suitably designed
to block any desired frequency in the range of 40 kHz to 500kHz by providing suitable
tuning pot in such a manner that a minimum resistive component of 570 ohms is
available. The tuning pot should be such that with the rating of wave trap i.e. 0.5mH, 630A for
132 KV, any frequency between 40 kHz to 500kHz may be blocked. The various blocking
bands which could be offered with 0.5mH 132 wave traps may please be stated in your offer.
However, it may please be clearly confirmed that suitable strapping are provided for
different blocking bands with each rating of wave traps offered.
322
Wave Trap
5.2.1.4
The wave traps shall have the following specifications:
Sl.
No
Particulars
For 132 KV
1.
132 KV
2.
145 KV
3.
System frequency
50Hz
4.
500C
5.
10KA
6.
Type of tuning
Broad band
Minimum resistive component of impedance within the blocking

band
450 Ohms

570 Ohms
630 Amps
10
20 KA (1Sec)
11
Tuning range
90-150 Hz &
150- 500 KHz
12

0.01% Per 0C
13

exceed.
0.3% Per0C
5.2.1.5 The wave trap shall be suitable for out-door suspension mounting and shall be
mechanically strong enough to withstand the stresses due to maximum wind pressure of 260
Kg per sq. meter.
5.2.1.6 For suspension mounting, the bidder shall be required to co-ordinate the mounting
arrangement with the existing arrangement. Non-magnetic suspension hook / link of adequate
length and tensile strength to provide necessary magnetic clearance between the Wave Trap
and suspension hardware shall be supplied. The standard arrangement of suspension
mounting of 132 KV Wave Trap shall be adopted. A drawing showing the standard suspension
arrangement should be furnished for our approval and the mounting arrangement should be
provided as per the design approved by us.
5.2.2
TERMINAL CONNECTORS FOR 132 KV WAVE TRAP :
5.2.2.1
Wave Traps shall be provided with terminal connectors suitable to receive Single
Zebra ACSR conductor on one side and single Panther conductor on other side with
arrangement for both vertical as well as horizontal takeoff. The prices offered for each
equipments should take into account the cost of set of clamps & connectors. Clamps shall be
designed adequately to take care of any bimetallic effect. Temperature at the clamp shall not
323
Wave Trap

exceed 800C. Terminal connectors shall be tested for short circuit current capability,
temperature rise etc.
5.2.2.2
Terminal connectors shall also meet the following requirements:

Terminal connectors shall be manufactured & tested as per IS:5561.
No part of clamp or connector (including hardware) shall be of magnetic material.
Terminal connector should be made of Aluminium alloy Grade LM9 or LM 25 as per
IS 5561 and shall be manufactured by by gravity die casting or by pressure die
casting process. Sand casted terminal connectors are not acceptable.
All castings shall be free from blow holes, surface blisters, cracks and cavities. All
Terminal connector shall be designed to corona free as per relevant standard.
No part shall be less than 12 mm thick.
The nuts, bolts & washers used in the current path shall be of good quality HDG mild steel
material only.
Wherever necessary by bimetallic strips, copper aluminium liner /by metallic sleeve of
minimum thickness of 2 mm shall be provided.
All current carrying parts shall be designed and manufactured to have minimum contact
resistance.
The terminal connectors should be tightened by six bolts. Conductor hold length must
not be less than 100mm.
The surface of clamp to be tightened by six bolts should be flat in shape so that it may be
possible to open the nut bolts by normal spanners. Therefore any type of groove in the
clamp body for fixing of nuts should be avoided.
The portion of clamp to hold the conductor should be flat and straight and not zig-zag in
construction at both the sides so that heating of clamp by throttling action of current may
be avoided.
Space of atleast 50% of diameter of nuts should be available after the hole at both the
sides of conductor holding portion for better mechanical strength.
Size of terminal connector for which the clamp is designed and also rated current under
site conditions shall be embossed / punched on each part of clamps, except hardware.
5.2.2.3
It is essential that design of clamps i.e. details in this regard to dimensions, the
number of bolts to be provided, material and manufacturing process should be submitted for our
approval. Any modification in the design shall have to be carried out without any extra cost.
Thus the clamps shall be manufactured finally as per design and drawing duly approved by us.
6.0
TECHNICAL REQUIREMENTS for 220 KV & 132 KV WAVE TRAPS:
6.1
The wave traps shall effectively block the high frequency currents but allow the 50
cycles current to pass without losses.
6.2
Wave trap shall be robust in construction with the metal parts made of non-magnetic
materials to reduce heating due to induced heavy load and short circuit conditions. Sharp
corners shall be avoided on the outer surface of the wave traps to minimise corona losses.
324
Wave Trap

Insulating material used shall be un-affected by the moisture. Suitable barrier shall be provided
to prevent the entry of birds into the device. Suitable surge arrestor shall be provided in the
wave traps for protection. A set of clamps for wave trap of each rating shall be supplied along
with the wave trap and prices offered for wave trap should take into account the cost of set of
clamps. The clamps should be suitable for horizontal as well as vertical take off. It is essential
that the design of clamps should be submitted for our approval. Any modification in the design
shall have to be carried out without any extra cost. Thus the clamps shall be manufactured
finally as per design and drawing duly approved by us.
6.3
The design of wave traps should be robust and maintenance- free without any
need to tighten the coils to maintain inter- form spacing. The design should ensure very high
short circuit strength and mechanical strength. The performance of wave traps shall not get
affected in the long run even if the same are utilised in polluted atmosphere. All terminal bolts
and fasteners used shall be of HDG mild steel to avoid any risk of corrosion. The installation
should not be very heavy in weight. The mounting arrangement i.e. suspension eye bolt shall
be provided centrally at the top as well as at the bottom of the wave trap.
6.4
The bidders are requested to mention blocking bands of wave traps at suitable
place on the outside of the wave traps in bold letters by paint, so that after its installation on
gantry, the frequency band can be read out from ground. The paint should be such that it
should not fade at a later stage. In order to avoid the risk to affect the performance in polluted
atmosphere and also to ensure high electrical and mechanical strength, it may be noted that we
will prefer wave traps of completely encapsulated design, where the equipment is fully
encapsulated in epoxy impregnated fiber glass material. Any other design, which may offer
equal or better performance, would also be acceptable.
7.0
GUARANTEED TECHNICAL PARTICULARS FOR 220 KV & 132 KV WAVE TRAPS :
Guaranteed technical particulars for 220 KV & 132KV Wave Traps called for shall be
furnished along with the bid. Particulars which are subject to guarantee shall be marked
clearly. Any other particulars considered essential may please also be furnished.
8.0
TESTS :
8.1
Type Test :
any Equivalent International Standard during the last five years from the date of bid opening. In
case the equipment of the type and design offered has already been type tested, the Bidder
shall furnish two sets of the type test reports along with the bid. The Purchaser reserves the
right to demand repetition of some or all the type tests in the presence of Purchasers
representatives. For this purpose, the Bidder may quote unit rates for carrying out each type
test. This will not be considered for price evaluations. For any change in the design/type
already type tested and the design/type offered against this bid, the Purchaser reserves the
right to demand repetition of same or all type tests without any extra cost. Non compliance of
this requirement will make the bid non responsive.
8.2
8.2.1 The manufacturer shall carry out all acceptance and routine tests as stipulated in the
relevant Indian Standards or equivalent International Standards in presence of Purchasers
representative.
325
Wave Trap
8.2.2 Immediately after finalization of the programme of type/ acceptance/ routine testing, the
manufacturer shall give advance intimation to the Purchaser, to enable him to depute his
9.0
INSPECTION :
i.
manufacture, where the 220KV & 132 KV Wave Traps Voltage are being
manufactured and the Bidder shall provide all facilities for unrestricted inspection of
the Bidders works, raw materials, manufacture of all the accessories and for
conducting necessary tests as detailed herein. Purchaser reserves the right to insist
for witnessing the acceptance/routine testing of the bought out items. Supplier shall
submit the routine test certificates of bought out items and raw material, at the time
of routine testing of the fully assembled Wave Traps.
ii.
iii.
iv.
v.
10.0
QUALITY ASSURANCE PLAN :
10.1
programme for manufacture of 220 KV & 132 KV Wave Traps. The Bidder shall invariably
furnish following information along with his offer. Information shall be separately given for
individual type of equipment offered.
ii)
iii)
iv)
v)
Bidders representative and copies of test certificates.
Information and copies of test certificates as mentioned in (i) above in
respect of bought out items.
exists.
326
Wave Trap

vi)
vii)
viii)
10.2
List of areas in manufacturing process, where stage inspections are

normally carried out for quality control and details of such tests and
inspection.
List of testing equipment available with the Bidder for final testing of
equipment specified and test plant limitations, if any, vis--vis type test,

i)
ii)
iii)
Quality Assurance Plan (QAP) with hold points by Purchasers inspection.
The quality assurance plans and hold points shall be discussed between the
10.3
11.0
DOCUMENTATION :
11.1
Units.
12.0
12.1
b) Sectional views showing General Constructional Features, lifting lugs,
connectors etc.
12.2
327
Wave Trap

12.3
12.4
12.5
13.0
ENGRAVING, PACKING AND FORWARDING :
13.1
13.2
a)
b)
c)
d)
e)
f)

Destination
13.3
14.0
SCHEDULE
328
Wave Trap

15.0
15.1
Bid shall be complete in all respects and shall include all minor component,
accessories, small wiring etc., not specifically mentioned in the Schedule, specifications etc;
but essential for the completeness of the system. Bidders shall not be eligible for extra charges
in respect of such minor components, accessories, small wiring etc., though not included
15.2
15.2.1
Complete details of all the accessories which will be supplied
15.2.2
It is obligatory on the part of bidders to ensure that supply of all accessories along
with Main equipment are simultaneously delivered to avoid any holdups. Responsibility for
obtaining timely supplies of bought out items will rest on the bidders and only on this basis,
delivery period will be offered in the Bid.
15.2.3
It may be noted that in case of damages/shortages due to improper packing or any
other negligence ,replenishment shall be arranged within one months time. For bought out
items, responsibility for guarantee and obtaining immediate replacement in case any defects are
16.0
17.0
Please ensure the Bid document containing number of pages has been properly page
numbered and signed by the bidder. All Bid documents including Schedules and Annexure
should be indexed properly and index of the document should be enclosed/placed at the
beginning of the document.
329
Wave Trap
APPENDIX- I1
PRINCIPAL PARAMETERS FOR 220 KV WAVE TRAP
Sl.
No
Particulars
For 220KV
1.
220 KV
2.
3.
System frequency
245 KV
50Hz
4.
500C
5.
10KA
6.
Type of tuning
Broad band

band
450 Ohms

570 Ohms
1250Amps
10
40KA(1Sec)
11
Tuning range
90-150 Hz & 150500 KHz
12

0.01%
Per0C
13

exceed.
0.3% Per0C
330
Wave Trap
APPENDIX- I2
PRINCIPAL PARAMETERS FOR 132 KV WAVE TRAP
Sl.
No
Particulars
For 132 KV
1.
132 KV
2.
145 KV
3.
System frequency
50Hz
4.
500C
5.
10KA
6.
Type of tuning
Broad band

band
450 Ohms

570 Ohms
630 Amps
10
20 KA (1Sec)
11
Tuning range
90-150 Hz &
150- 500 KHz
12

0.01% Per 0C
13

exceed.
0.3% Per0C
331
Wave Trap
SCHEDULE-I(A)
Particulars of equipment/item
220KV WAVE TRAP
Qty.
220 KV, 1250 Ampere, 0.5 mH Wave Trap with suspension type
of mounting accessories, main coil with Suitable Tuning Pot
along with Strapping for Different Blocking Bands, Protective
Device, Bird Barrier and Set of Clamps and Connecters etc.
meeting all technical requirement of the specification
C
132 KV WAVE TRAP

132KV, 630 Ampere, 0.5 Millihenery Wave Trap with suspension type
of mounting accessories, main coil with Suitable Tuning Pot along
with Strapping for Different Blocking Bands, Protective Device, Bird
Barrier and Set of Clamps and Connecters etc. meeting all technical
requirements of the specification
SNo
B
payment.
332
Wave Trap
2.2.3
1.0
TECHNICAL SPECIFICATION FOR POWER LINE CARRIER

COMMUNICATION EQUIPMENTS i.e CARRIER CABINET,
PROTECTION COUPLER & COUPLING DEVICE
SCOPE :
2.0
STANDARDS :
2.1
Book-I.
2.2
2.3
3.0
3.1
3.2

Book-I.
4.

5.0
5.1
TECHNICAL SPECIFICATION FOR CARRIER CABINETS:

BASIC DESIGN :
Carrier cabinets shall be multipurpose PLCC terminals suitable for transmission of

speech & Superimposed VFT channels for teleindication, telecontrol, teleprinting, tele-metering
333
PLCC Equipments

purposes etc. and for teleprotection purpose over power transmission lines. The PLCC offered
shall be IC version, fixed frequency, single channel and twin channel PLCC terminals working
on SSB modulation principle.
rposes etc., and for tele-protection purpose over power transmission lines. The PLCC offered
shall be IC version, fixed frequency, Single channel PLCC terminals working on SSB modulation
principle.
Carrier cabinets shall be of latest technology, highly reliable and must have been type
tested. Carrier cabinets shall render following services i
ii
iii
iv
Telephone communication between the stations.

Carrier links protective relaying.
VFT facilities such as telemetering services, Telecontrol, telex/fax.
Express channel.
While at present it is proposed to provide the carrier link with protection on some links,
the equipments to be supplied and installed shall be such that the same can be inserted in the
cabinet afterwards if required, without carrying out any modifications in the equipments. The
supplier should provide in PLCC cabinet, sharp cut off filter for limiting the speech frequencies
transmitted. Hence the Bidders shall clearly mention in his proposal for future development
and the extent to which such additional facilities can be added at a later date. This is essential
and the Bidder must clearly explain the same.
5.1.1
COMMUNICATION SYSTEM :
Bidders may offer power line carrier equipment according to their standard practice to
fulfill the requirement of the specification. The equipment shall be manufactured according to
frequency to be indicated by us. Each of the station of the carrier telephony system must be
able to transmit and receive simultaneously during conversation, to enable calls in duplex
principle.
5.1.2 Bidders may please note that it is mandatory requirement that carrier cabinet of both
ends of transmission line shall be identical. In case of Line in Line out (LILO) lines, for matching
of carrier cabinet at both ends of transmission lines bidder may offer same type of carrier
cabinet as already provided at other end of lines. If in any case bidder offers different type of
carrier cabinet than matching of carrier cabinet can be arranged by interchanging of carrier of
other end and in this case the commissioning of carrier cabinet (both ends) shall be arranged by
bidder without ant extra cost to MPPTCL.
5.1.2
FREQUENCIES TO BE ADOPTED :
Frequencies to be employed may be confined to the band 40-500 KHz.
5.2
CARRIER FREQUENCY TRANSMITTER RECEIVER CABINET :
5.2.1 Carrier cabinets shall be made from 14/16 SWG sheet steel. It will be designed for
efficient cooling with a cooling fan at the top inside the cabinet. The cabinet shall be suitable for
floor mounting type with adequate arrangement for ventilation and provision to avoid dust
getting in and to avoid any adverse effects from
moisture during rainy season. The cabinet
shall be finished with paints coated inside and outside according to standard painting procedure.
334
PLCC Equipments

It shall be Aircraft Grey as per colour shade No. 693 of IS:5 or equivalent BS-381 or matching
colour and shade of other authoritative equivalent standard is also acceptable. Colour finish
shall be applied as per above colour scheme on the exterior steel works of the cabinet. Exterior
shall not be fully glossy. Interior of the cabinet shall be painted with Egg Shell White.
The height of the cabinet shall not be more than 2 meter. Bidder shall match the colour
and height of the cabinet as specified. Normally the cable entry shall be from bottom. However,
suitable provision shall be made for cable entry from top, which shall be covered by blanking
plate at the time of supply.
5.2.2 All individual parts of the equipment shall be accessible from the front to permit testing
and repair. The front shall have hinged doors equipped with handles and locks. Necessary
testing and indicating devices shall be provided on the front panel to enable checking of
important functions and circuits. The whole circuit shall be mounted on one panel, which is
hinged at top and bottom of cabinet. This will facilitate approach to back side of the circuit. The
cubicle shall be provided with foundation rail and holes for fixing the same on foundation.
5.2.3 10 mm Red LED & Green LED shall be provided on the top of the panel for visual and
alarm indications to announce failure of power supply, absence of carrier signal for both receiver
and transmitter etc. The audio alarm would be provided for this purpose, which should be
audible from 8 meters distance. Three way HF co-axial clamp with terminal shall be provided
inside the cubicle at rear side. A suitable Lightning Arrestor should be provided between HF
main & earth terminals. One 8 way electrical connector, a three-pin plug with fuse shall be
provided for 230V AC , 50 Hz. supply. 24 Nos disconnectable type terminals should be fitted in
cabinet for inter connection with Distance Protection Relay. The cubicle shall be fully wired.
5.2.4 Equipment shall operate through 48 V DC supply with voltage variation from + 20% to
10% and maximum ripple of 2%. The carrier power supply module shall be provided with a
circuit breaker, which shall automatically trip due to over voltage to carrier equipment and / or
over modulation. The miniature circuit breaker shall be provided in front of power supply
module so that it is easily accessible. This miniature circuit breaker shall be provided with a
facility to switch on and to switch off the same mechanically by hand, by pressing and releasing
a push button switch. A fuse shall also be provided in series of this miniature circuit breaker,
which shall operate in case of failure of the miniature circuit breaker.
5.2.5 Carrier cabinets shall be suitable for operation with private automatic exchange. In
addition, two telephone sets shall be provided with each carrier set (one Jack telephone and
one four wire telephone), for testing purposes and for carrying out emergency conversion
without the help of the associated automatic exchange. It should have also facility to
connect 2 wire telephone. Built in indicating meter and oscillator shall be provided on the
panel with a selector switch to indicate voltage & current value and all-important signal levels
(DC, VF, IF & HF). A built in "PLC EQUALIZER shall be provided to overcome effect of
amplitude distortion due to mismatch etc. A supervision module with necessary circuitry shall
be provided to monitor Transmitter, Receiver and Power Supply. The carrier set shall be
provided with relay for blocking all other signals when the tripping signal is being transmitted to
give more power for the transmission of the tripping signal.
5.2.6 Interfacing data modules should be supplied along with each Carrier Cabinet. The
Bidders shall clearly confirm that prices for these interfacing modules are included in the offered
price of Carrier Cabinet. It shall be possible to test the equipment locally by a dummy load. It is
preferable that equipment is provided with facility to test transmitter and receiver locally by
335
PLCC Equipments

connecting them back-to-back. Built-in AGC Test for HF level variation of +14 dB/- 45 dB may
be necessary. The local testing facility provided shall be described in detail by all the Bidders.
5.2.7 All the test points with standard values, indications etc. shall be provided in front of the
cabinet and shall be easily accessible. The equipment shall be suitable for co-axial impedance
of 75/125 ohm unbalanced or 150 ohm balanced. This should be
programmable. Carrier
Terminal shall be provided with 4 wire and jack telephone and 125-ohm load in loose. The
equipment shall be provided with a nameplate indicating make, serial no., order no. with date,
Transmit & Receive frequency and Station Direction.
5.2.8 Carrier cabinets offered shall have compandors as a built-in feature. If required the
purchaser shall have the facility of disabling the same. The offered PLCC terminals shall be
provided with the following built in features:
1.
HF hybrid so that adjacent channel working is possible.
2.
Necessary transit band pass filter for transit interconnection of teleoperation
channels.
3.
It should have remote subscriber facility to extend the subscriber of an EPAX to a
remote end through PLCC.
5.2.9 PLC terminals shall be fully coordinated to match the existing equipment. Because of
strict requirements of high speed of operation, security, reliability and efficient operation of
protection channel along with the carrier terminal, Bidders shall ensure complete coordination
between the PLC and protection equipment as specified in Clause 6. It shall therefore be
necessary to have a provision of mounting the protection coupler in the same rack of PLC
terminal without any mismatch or necessity of any wiring or any intermediate coordination unit.
The PLC terminal shall use amplitude modulation with suppressed carrier, single side band,
multipurpose, 4KHz and shall be site programmable for Audio frequency, Carrier Frequency,
Pilot Frequency and the transit band pass filters. Please furnish ranges. The equipment shall be
suitable for duplex working and shall use the latest technology using Digital Signal Processor.
Further, the PLCC equipments shall employ the latest SMT technology.
5.2.10 Protection coupler to be supplied can be mounted in the same PLCC cabinet and
necessary wiring should of standard type. In future, if any VFT is to be procured by the
purchaser, the same could be mounted in the same carrier cabinet with standard wiring. PLCC
terminal shall conform to the latest IEC 495. Carrier cabinets shall conform to the voltage
withstand and electromagnetic compatibility test as per the latest IEC standards.
Each PLCC channel shall be suitable for the following:
a.
Nominal bandwidth shall be 300 - 3600 Hz and shall be suitable

transmission of facsimile messages at 2400 baud.
b.
One speech channel 300 - 2000 Hz plus a band of 2160 -3600 Hz for the
transmission of data. Data signaling rates of 50, 200,300,600,1200 baud
shall be possible. The speech band and data band should be
programmable either for speech or data over entire 4KHz bandwidth.
c.
Three 600-baud channels or one 2400-baud channel for full band of 3003600 Hz.
336
PLCC Equipments
for

d.
Protection couplers shall be based on frequency shift or coded signal

principle for transmission / reception of protection signals. This has been
described in detail in subsequent clauses.
5.2.11 PLC equipment may be required to be expanded by addition of channels to a link ( i.e.
upgrade to 2 or 4 channels as appropriate). The PLC equipment shall be modular in
construction and shall permit such upgrading to be carried out even at a later date. The Bidder
shall describe how the single channel equipment will be upgraded to more channels. The PLC
terminal shall use multiple modulation/demodulation techniques (preferably 3 stage modulation)
so as to have better selectivity and overall frequency response. The equipment shall be suitable
for use with E&M signaling between telephone exchanges at both the ends of the line. Signaling
shall be done by shifting the pilot frequency so that a separate band for signaling is not required.
The output power of PLC equipment at coaxial terminal shall be 40 watts which can be adjusted
if required at site to 20 watts. PLC equipment shall be designed to operate over a frequency
band of 40 to 500 KHz. The spacing between transmitter and receiver shall be as follows for
single channel as well as twin channel operation:
i. Transmitter to adjacent transmitter
ii. Transmitter to its own receiver
8KHz
4KHz
5.2.12 The return loss within the nominal carrier frequency band in the transmit direction shall
not be less than 2dB.The maximum permissible level of spurious emission shall meet the
requirements of IEC- 495.The generation of carrier frequencies shall be fully synthesized. It
shall be possible to select any carrier frequency at site within the whole carrier frequency range
in discrete steps of 4KHz.Carrier frequency stability shall be 10 x 10-6 (5Hz).Further, there
should be a synchronization between transmitter and receiver. Bidder shall describe how the
synchronization is achieved between the PLC terminals.
5.2.13 Preferably the Krone type terminal strip in addition to conventional terminal strips
should be provided for inter connection along with krone tool so as to have firm / tight
connection.
5.3
Transmitter:
5.3.1 The transmitter shall have 2 wire/4wire interface. The nominal level of 2 wires shall be
0 dBr across 600 Ohms balanced impedance. The input level range shall be adjustable from 16dBr to -6dBr.Nominal input level for 4wire should be -3.5dBr across 600 Ohms balanced
impedance. The input level range shall be adjustable from -20dBr to 10dBr. The AF band shall
have the programming facility so that it can be programmed at site for any of the following
bands:
300-2000 Hz
300-2200 Hz
300-2400 Hz
300-3400 Hz
The data band shall be adjusted accordingly for the following bands:
2160-3600 Hz
2400-3600 Hz
337
PLCC Equipments

2640-3600 Hz
5.3.2
Care should be taken to use components used in the power amplifiers of adequate
capacity.
5.4
RECEIVER:
5.4.1 The receiver shall have 2-wire/ 4-wire interfaces. The nominal output level for 2 wires
should be -7dBr across 600 Ohms balanced. It shall be possible to adjust this level from -16dBr
to +6dBr. The nominal output level for 4 wire shall be -3.5dBr across 600 Ohms balanced and
shall be adjustable from -20dBr to + 10dBr.
5.4.2 The near and far end cross talk should be -50 dBm Op. The group delay distortion
shall conform to IEC- 495. The compander shall be a built in function and shall have the
characteristics as per ITU-T. Automatic gain control shall be provided so that AF output should
remain constant within + 0.5 dB for a +14/-45dB variation in the RF input level. The local loop
test facility shall be provided so that the equipment can be tested locally. The remote loop test
facility shall be provided so that equalization can be done at site from one end by looping
back the signal at the other end without the need of an engineer at the other end.
5.5
SUPERVISION AND ALARM:
5.5.1 The supervision facility shall be provided for supervising the PLC terminal so that it
can automatically check the functioning of the PLC terminal and incase of any failure of
module or any other condition affecting the correct operation of individual components shall be
displayed on the front panel with suitable error code. Alarm shall be given under following
conditions:
-
loss of transmitter signal

loss of receiver signal
high SNR in speech and telecontrol channels
loss of auxiliary supply
excessive impulse interference
A green LED to show healthy ness of 48V DC supply should be provided next to Alarm LED.
5.6
GENRAL REQUIRMENTS:
5.6.1 All cabinets having PLC terminal shall be provided with lamps of sufficient wattage for
interior illumination with switch. The PLC terminal shall be suitable for remote subscriber
application. The PLC terminal should have in built test meter for carrying out tests at site. It
should have a facility to generate at least two tones of different frequency apart from 1 KHz
tone.
5.6.2 The power supply of the offered PLCC carrier set shall be based on SMPS technique
which ensures that in the event of a short circuit the power supply is switched off and hence
there will be no damage to power supply circuit. It should also have over voltage protection.
338
PLCC Equipments

5.6.3 For ease of maintenance, power amplifier unit should be supplied in one card. This unit
should not be combined with filter & RF hybrid. In case of failure of power amplifier the same
could be replaced by new one without disturbing filter and RF hybrid.
5.6.4 Specific confirmation regarding supply of following accessories with each Carrier
Cabinet may please be positively indicated.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
Compander & expander print.

Test Meter Print.
Jack telephone hand set.
Transit band pass filter.
4 wire & 2 wire table telephone set with push button.
Dummy load with switch, so that, we can connect coaxial cable to carrier
cabinet, or a dummy load representing the line to the cabinet. The switch
provided for switching Dummy load / line should be of very good quality
as it is being facility very frequency.
Print puller
Suitable lock with key for carrier cabinet
Exhaust fan
A frequency tone generator of 1KHz and two tone generator of different
frequency for measurement of various level of voice and data signal and
also for sending the calling signal at the other end. Therefore, above
arrangement or any other equivalent arrangement for this facility during
testing will be accepted.
5.6.5 Under clause 5.6.4, the essential accessories for carrier cabinet has been listed.
However, it is desired and it would be obligatory on the part of the Bidder to include any such
accessory also (i.e. over & above listed under clause 5.6.4) which may be necessary for proper
and trouble free functioning of the carrier cabinet. Details of such additional accessory, if any,
may be furnished. It may be noted that no additional cost shall be permitted for such additional
accessory required for proper functioning of equipment. In nut shell cost of all such accessories
described above should be included in the price of main equipment and this price only shall be
mentioned in formats of price Schedule available at Section-II
6.0
TECHNICAL SPECIFICATION FOR PROTECTION COUPLERS:
6.1
BASIC DESIGN:
6.1.1 Bidders shall offer voice frequency transmission equipment which shall work on
frequency shift or coded signal principle for transmission /reception of protection signals.
6.1.2
Bidders shall take cognizance of our following requirement;

(i)
The equipment shall be immune to a field strength of 10V/m expected to be caused

by portable radio transmitters in the range of 20-1000 MHz.
(ii)
The voice frequency transmission equipment shall not only be insensitive to

corona noise but shall also remain
unaffected by impulse type of noise
generated
by electrical discharge and by opening and closing of circuit
breakers, isolators & earth switches etc. In their offers,, bidders shall clearly
explain as to what measures have been taken to make the equipment insensitive
339
PLCC Equipments
(iii)
(iv)
(v)
to corona noise, white noise and to impulse noise of an amplitude larger than the
wanted signal and submit full field test and laboratory test reports. The guarantee
on design data shall not be acceptable.
Equipment shall be unaffected by spurious tripping signals. Bidders shall
substantiate their claim.
Offered Protection Couplers shall be suitable for transmission / reception of
minimum four protection signals.
Overall PLC, VFT and transmission path for permissible trip / block shall be one
cycle or 20 ms or less and for direct tripping, it shall be 30ms or less.
6.1.3 Protection couplers are to be used together with the PLC equipment, as such it shall
comprise of modules which are directly plugged into reserved slots of PLC terminal so as to
avoid any wiring / mismatch between PLC terminal and protection coupler. In a nutshell, the
Protection Coupler shall be housed in PLC Cabinet and will not be acceptable in a separate
cabinet. Protection couplers shall be suitable for at least one command for each of permissive
tripping, blocking as well as direct trip signals.
6.1.4 Protection couplers shall be designed in accordance with IEC 834-1 and shall be
complete with test and inter connection unit and counters. The offered couplers shall be suitable
for transmission of four commands to take care of protection of double circuit lines and shall
also be suitable for transmission/reception of four commands. The offered couplers may ensure
very high reliability during fault conditions and shall not tend to operate due to spurious signals
which may generate in electrical system. Loop testing facility shall be provided in each AF
coupler. Bidders must explain the design with complete details and should justify reliability of
their equipments.
6.1.5 The trip signal frequency should fall within the teleprotection band
without any
necessity of separate band for protection commands. Whenever the protection coupler receives
the command, it shall disconnect the speech. This interruption will continue for a short period
of the teleprotection command after which the normal operation of the carrier equipment
will be restored. During transmission of teleprotection signals or when a fault has been
detected by the protective relays the entire output power of the carrier set will be made
available for transmission of teleprotection signals.
6.1.6 Protection couplers designed using logic circuitry to provide total transmission time for
teleprotection signals shall not exceed 20 ms for permissive trip and 30 ms for direct trip.
Protection coupler designed using logic circuitry to provide Transmission time of less than 20
ms for both direct and permissive trips is also acceptable. The protection coupler shall use
microprocessor techniques with digital signal processing to meet the stringent requirements
for command transmission over PLC links even under adverse channel conditions. Digital
counters shall be provided for counting of transmitted and received commands. For each
code, 6 No disconnectable type terminals may be fitted in cabinet for inter connection with
Distance Protection Relay.
6.2
TEST FACILITIES:
Protection couplers shall be constructed such that operational reliability of protection
channels may be checked over the carrier link by means of local and remote loop test. It shall
be possible to carry out the above test from either end of the carrier link. During healthy
condition of the transmission line the loop test shall not initiate a tripping command. In the
event of a system fault, while loop test is in progress, protection signal shall over ride the test
signal. While the loop test is in progress no false tripping command shall be generated. The
340
PLCC Equipments

remote loop test shall be initiated either automatically
manually by means of test buttons.
7.0
7.1
after a particular time interval or
TECHNICAL SPECIFICATION FOR COUPLING DEVICES :

BASIC DESIGN:
7.1.1 Coupling devices shall be housed in a weather proof non corrosive box and should be
suitable for outdoor mounting on the pedestal support of coupling capacitor / CVT. Offered
coupling devices should be suitable for phase to phase coupling arrangements. Coupling
devices shall be interposed between the coupling capacitor/CVT and coaxial line to the PLC
terminal. Coupling devices in conjunction with the coupling capacitor/CVT shall ensure efficient
transmission of carrier frequency signals between the carrier frequency connection and power
line. In addition safety of personnel and protection of low voltage parts and installation, against
the effects of power frequency voltage and transient over voltage shall be ensured. The
complete coupling devices suitable for phase to phase coupling should be housed in two
weather proof boxes. One box should contain high pass filter module, a drain coil, a surge
arrestor and an external earth switch. The other box should contain high pass filter module with
balancing / hybrid transformer, a drain coil, surge arrestor and a external earth switch. Apart
from above an additional separate earth switch suitable for mounting on pedestal shall be
supplied with each box of coupling device.
7.1.2 Coupling device shall be compact and modular in nature. In our system we have
coupling capacitor/CVT of different capacitance value. Coupling devices offered should be site
programmable type so that it is suitable for operation with coupling capacitor / CVT of different
capacitance value without carrying out any modification at site and without any cost
implications. This may please be confirmed.
7.1.3 Coupling devices shall comply with the latest issue of IS & IEC. Coupling device
including the drainage coil, surge arrestor and earthing switch shall conform to type tests and
shall be subjected to routine tests as per latest IS & IEC. Bidders shall furnish along with his
offer copies of all type and routine tests conducted earlier on similar coupling device in
accordance with relevant standards.
7.1.4 Coupling devices in conjunction with coupling capacitor / CVT shall form an electronic
filter of high pass type and shall have following features:a.
It shall match characteristic impedance of 132/220/400KV HT line to impedance

of the carrier frequency connection (i.e. coaxial cable).
b.
It shall be possible to change coaxial cable side impedance simply by changing

the straps at site. It should be suitable for 125ohm unbalanced, 75ohms
unbalanced or 150ohm balanced as per site requirement.
c.
It shall be possible to tune coupling device by changing strapings at site to use

with any coupling capacitor having different values.
d.
It shall be possible to use it as phase to ground device and phase to phase

device with balancing /hybrid transformers.
e.
Power frequency currents derived by the CVT may be drained to the earth by
drain coil of suitable rating.
341
PLCC Equipments
f.
Voltage surges coming from the power line at the terminals of the coupling
device shall be limited by a non-linear surge arrester of suitable rating in the
primary side. The surge arrester of very good quality should be used and offer
with good quality surge arrester shall be preferred. The details of surge arrester
giving constructional features, design etc. shall be furnished.
g.
For direct and efficient earthing of its primary terminals, the coupling device shall
be equipped with an earthing switch. The coupling device shall be designed such
that it shall not be possible to remove the cover before the earthing switch is
operated to the earthed position. Further, an additional earth switch shall be
available for earthing of CVT-HT terminals, when the coupling filter units are
removed from circuit for maintenance / replacement. The design shall take due
regard of requirements for safety in accordance with the Indian Electricity Rules.
7.1.5 Two numbers phase to earth type coupling filters shall be used to achieve in, secure
phase to phase coupling. Connection between secondary of the two phase to earth type
coupling device shall be through a balancing/hybrid transformer such that reliable
communication shall be ensured even when one of the coupled phase is earthed or open
circuited on the line side.
7.1.6 Coupling device shall conform to latest IS/IEC-481 and shall have the following carrier
frequency characteristics.
a.
b.
c.
d.
e.
f.
Nominal line side

Impedance
Nominal equipment side
Impedance
Composite loss
Return Loss
Bandwidth
Nominal peak envelope power
(For inter- modulation product
80 dB down)
Characteristic impedance of
400/220/132KV line.
125/75 Ohms (unbalanced) or
150 Ohm balanced
Not more than 2 dB
Not less than 12 dB
Shall suit the frequency plan
Not less than 650Watt
7.1.7 Coupling devices shall withstand an insulation voltage of 10KV RMS 50Hz for one
minute and impulse withstand voltage (1.2/50 micro secs) of 10KV Peak.
7.1.8 All the elements of coupling devices shall be housed in a weather proof non corrosive
box. The general arrangement, weight and dimensional details of box shall be furnished.
Bidders shall submit detailed drawing indicating general arrangement, interconnection and all
other details for approval.
7.1.9 Coupling device shall have at least two terminals for carrier equipment connection.
Bidder shall confirm that such a parallel connection to coupling device directly will not result in
any additional attenuation.
8.0
TESTS:
8.1
TYPE TEST:
342
PLCC Equipments
All the equipments offered, shall be fully type tested as per relevant Indian Standards or
any Equivalent International Standard during the last five years from the date of bid opening. In
case the equipment of the type and design offered has already been type tested, the Bidders
shall furnish sets of the type test reports along with the offer. The Purchaser reserves the right
to demand repetition of some or all the type tests in the presence of Purchasers
representatives. For this purpose, the Bidders may quote unit rates for carrying out each type
test. This will not be considered for price evaluations. For any change in the design/type already
type tested and the design/type offered against this bid, the Purchaser reserves the right to
demand repetition of same or all type tests without any extra cost. Non compliance of this
requirement will make the bid non responsive.
8.2
8.2.1 The manufacturer shall carry out all acceptance and routine tests as stipulated in the
relevant Indian Standards or Equivalent International Standards in presence of Purchasers
representative.
8.2.2 Immediately after finalization of the program of type/ acceptance/routine testing, the
manufacturer shall give advance intimation to the Purchaser, to enable him to depute his
9.0
INSPECTION :
i.
manufacture, where the Carrier Cabinet with Protection Coupler are being
manufactured and the Bidder shall provide all facilities for unrestricted inspection of
the Bidders works, raw materials, manufacture of all the accessories and for
conducting necessary tests as detailed herein. Purchaser reserves the right to insist
for witnessing the acceptance/routine testing of the bought out items. Supplier shall
submit the routine test certificates of bought out items and raw material, at the time
of routine testing of the fully assembled Wave Traps.
ii.
iii.
iv.
v.
343
PLCC Equipments

10.0
QUALITY ASSURANCE PLAN :
10.1
programme for manufacture of Carrier Cabinet, Protection Coupler & LMU. The Bidder shall
invariably furnish following information along with his offer. Information shall be separately given
for individual type of equipment offered.
i)
Bidders representative and copies of test certificates.
ii)
iii)
iv)
exists.
v)
inspection.
vi)
vii)
equipment specified and test plant limitations, if any, vis--vis type test,
10.2

i)
ii)
iii)
Quality Assurance Plan (QAP) with hold points by Purchasers inspection.
The quality assurance plans and hold points shall be discussed between the
10.3
11.0
DOCUMENTATION :
11.1
Units.
12.0
344
PLCC Equipments
12.1
b) Sectional views showing General Constructional Features, lifting lugs, etc.
12.2
12.3
12.4
12.5
13.0
13.1
345
PLCC Equipments

13.2
a)
b)
c)
d)
e)
f)

Destination
13.3
14.0
SCHEDULE
15.0
15.1
Bid shall be complete in all respects and shall include all minor component,
accessories, small wiring etc., not specifically mentioned in the Schedule, specifications etc;
but essential for the completeness of the system. Bidders shall not be eligible for extra charges
in respect of such minor components, accessories, small wiring etc., though not included
15.2
15.2.1
Complete details of all the accessories which will be supplied
15.2.2
It is obligatory on the part of bidders to ensure that supply of all accessories along
with Main equipment are simultaneously delivered to avoid any holdups. Responsibility for
obtaining timely supplies of bought out items will rest on the bidders and only on this basis,
delivery period will be offered in the Bid.
15.2.3
other negligence ,replenishment shall be arranged within one months time. For bought out
items, responsibility for guarantee and obtaining immediate replacement in case any defects are
16.0
GUARANTEED TECHNICAL PARTICULARS
346
PLCC Equipments

Bidders shall furnish Guaranteed Technical Particulars for offered equipments.
17.0
GUARANTEE FOR SUPPLY OF SPARES FOR 10 YEARS OPERATION :
18.0
Please ensure the Bid document containing number of pages has been properly page
numbered and signed by the bidder. All Bid documents including Schedules and Annexure
should be indexed properly and index of the document should be enclosed/placed at the
beginning of the document.
347
PLCC Equipments

APPENDIX-J1
PRINCIPAL PARAMETERS FOR CARRIER CABINETS (SINGLE CHANNEL/ TWIN
CHANNEL)
1
Mode of transmission
Amplitude Modulation single side band

with suppressed carrier
2
3
Carrier frequency range

Nominal carrier frequency bandwidth
40 to 500KHz
Oscillator for generating carriers
5
6
7
Frequency stability
Effectively transmitted speech frequency
band
Available band for super imposed signals
Signaling frequency
3780 30Hz(options available)
HF Power Output
20/40 Watt PEP for single channel

Adjustable at site.
10
i.
Nominal impedance
Carrier frequency side
ii.
11
I
I
ii
iii
Iv
13
14
15
16
V.F. side
Return loss
Within the nominal Carrier frequency band at
the line output.
Within the effectively transmitted frequency
band at AF input/output points
Relative VF levels across 600 Ohms
(Balanced)
4 Wire transmit
4 Wire receive
2 Wire transmit
2 Wire receive
Details of power supply required.
Power Consumption
Spurious emissions
Receiver Sensitivity
17
Automatic volume control
18
Signal to Noise ratio over carrier channel
<40dB
19
Permissible limit for variation of overall loss of

speech channel relative to 800Hz for back to
back operation of one pair of terminals
As per IEC 495
20
Frequency difference between voice

frequency transmitted and received in a pair
of PLCC terminal
0Hz
ii
12
4kHz for Single Channel terminal

8kHz for Twin Channel terminal
Crystal controlled oscillator with
frequency divider
Less than 5Hz
300-2000Hz or 300-2400Hz
Depends on the speech cut off frequency
75/125 Ohms unbalanced
348
600 Ohms
20dB
20dB
-3.5dBr
-3.5dBr
0dBr
-7dBr
48V DC + 20% -15%
100Watts approx. for single channel
As per IEC 495
-24dBm referred to the Test Tone level at
the RF I/P
AF O/P level remains within0.5dB for a
+14/-26dB variation of RF I/P level
PLCC Equipments
APPENDIX-J2
PRINCIPAL PARAMETERS FOR PROTECTION COUPLER
1)
The equipment shall be immune to a field strength of 10V/m expected to be caused by

portable radio transmitters in the range of 20-1000 MHz.
2)
The voice frequency transmission equipment shall not only be insensitive to corona
noise but shall also remain
unaffected by impulse type of noise generated by
electrical discharge and by opening and closing of circuit breakers, isolators & earth
switches etc. In their offers,, bidders shall clearly explain as to what measures have
been taken to make the equipment insensitive to corona noise, white noise and to
impulse noise of an amplitude larger than the wanted signal and submit full field test and
laboratory test reports. The guarantee on design data shall not be acceptable.
3)
Equipment shall be unaffected by spurious tripping signals. Bidders shall substantiate

their claim.
4)
Offered Protection Couplers shall be suitable for transmission / reception of minimum

four protection signals.
5)
Overall PLC, VFT and transmission path for permissible trip / block shall be one cycle or
20 ms or less and for direct tripping, it shall be 30ms or less.
349
PLCC Equipments

APPENDIX-J3
PRINCIPAL PARAMETERS FOR COUPLING DEVICE
1
Maximum temperature limit for satisfactory

operation of coupling device mounted outdoor
2
3
Nominal primary side Impedance

Nominal secondary side impedance
4
5
6
Composite loss within passband.

Return loss within passband
Available bandwidth
7
i
Nominal peak envelope power

At 50KHz
ii.
8
At 100KHz
Power frequency impedance between primary
terminal and earth terminals of coupling
device
One minute power frequency insulation level
between primary and secondary terminals of
coupling device
Impulse(1.2/50 micro sec) withstand Level
between primary and secondary terminals of
coupling device
DRAIN COIL:
Continuous current
Short time current for 0.2sec
Inductance of drain coil with tolerance(at
50Hz)
Impedance at mains freq.
SURGE ARRESTOR :
Power frequency spark over voltage
Type of construction
Maximum permissible short time current (2.2
micro sec)
Impulse spark over voltage 1.2/50 sec
e
f
16
a.
b.
c.
Rated voltage
Power frequency discharge current for 0.2 sec
EARTHING SWITCH :
Rated voltage
Rated current
Short time current
10
11
A
B
c
d
15
a
b
c
50C (satisfactory operation up to 65

Deg.C)
240/320 Ohms (Phase to Ground)
75/125 Ohms Unbalanced, 150 ohms
balanced
Not more than 2dB
Not less than 12dB
4400 pF:78-500KHz
6600 pF:70-500KHz
8800 pF:52-500KHz
400Watts
350
1000Watts
Less than 20 Ohms
10KV rms
10KV peak
1.5 A (rms)
50A
Primary of Matching transformer acts
as a Drainage Coil, 0.2 to 0.7m H.
1.5
Min 1300 volts rms
Non linear resistor type
As per IS:3070 (Part-I)
50A
Withstand voltage is 10KV
200A rms continuous
16kA, 1 sec.
PLCC Equipments
SCHEDULE-I (A)
Carrier Cabinet with Protection Coupler (Single Channel/Twin
Channel
Carrier Cabinet with Protection Coupler meeting all technical
requirements as described in the specification
Carrier Cabinet without Protection Coupler (Single Channel/Twin

Channel
Carrier Cabinet without Protection Coupler meeting all technical
requirements as described in the specification
Coupling Device (LMU)

Coupling Device (LMU) for phase to phase coupling meeting all
technical requirements of the specification
Qty.
SNo
A
payment.
351
PLCC Equipments
2.2.4 TECHNICAL SPECIFICATION FOR EXCHANGES, TELEPHONE

SETS
1.0
SCOPE :
The scope of this bid covers, design manufacturing and supply of equipment as
per Volume-II, Part-2, Book-I. The bidder mentioned in this Section of the Technical
Specification means Original Equipment Manufacturer (OEM). The purchaser means
the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipments/materials
of manufacturer as per this specification requirement shall rest on the bidder.
2.0
STANDARDS:
2.1
The specifications of above equipments / Materials shall conform to the
requirement of the latest issue of relevant Indian Standards/ International
Electromechanical Commission (IS/ IEC) except as detailed out for each equipment in
subsequent paras.
The EPAX / Telephone sets shall have approval of Telecom Engineering
Center or Department of Telecom of India. The equipments / materials having
equivalent International standards are also acceptable. Equipment meeting any other
authoritative standard which ensures an equal or better quality than the
standard mentioned above, is also acceptable. The photocopy of such standards
duly signed by the bidder will have to be furnished.
2.2
When the equipment/materials offered by the Bidder conforms to other
standards, salient points of difference between standards adopted and the
standards specified in this specification shall be clearly brought out in the relevant
schedule. Four copies of such standards with authentic translation in English shall be
furnished along with the offer.
2.3
In this bid, the Bidders will have to furnish an undertaking as per schedule XIII
of volume-VI.
3.0
3.1
3.2
Auxiliary Power Supply for offered EHV equipments shall be as per Volume-II,
Part-2, Book-I.
4.
No deviation from technical particulars of equipments and materials will be

allowed, which may please be noted.
352
Exchanges, Telephone sets
5.0
TECHNICAL SPECIFICATION FOR ELECTRONIC PRIVATE AUTOMATIC

EXCHANGE (EPAX) :
5.1
Basic Design:
5.1.1 The Bidder shall offer the latest digital based Microprocessor EPAX suitable for
direct connection to the Power Line Carrier Communication ( PLCC ) terminals without
the need of any four wire interconnecting device. The EPAX shall employ stored
programmed technique and utilize Time Division Multiplexing. The EPAX shall be
suitable for internal communication between the local subscribers as well as for
selective communication over tie lines.
5.1.2
The special features of the EPAX shall be as follows :

a.
EPAX shall be of latest microprocessor based design which employs

Pulse Code Modulation/Time Division Multiplexing principle and
shall have high traffic handling capacity (fully non blocking type).
b.
Self checking diagnostics facility as a built in feature of the EPAX

shall be preferred.
c.
The design of the software structure should be very flexible. Using

any standard telephone instrument, the following programming shall
be done at site without requirement of any additional testing
equipments:
- Modification of local subscriber number
- Modification of subscriber priority
- Modification of subscriber facilities i.e. Access to Tie lines and
Follow Me
- Modification of Tie line number
- Modification of Tie line groups
- Modification of Exchange number
- Allocation of Alternate route
- Transit call barring
d.
Built-in main distribution frame with Protective devices such as surge

arresters and fuses for all limbs of subscriber lines and tie lines to
protect the sophisticated electronic circuitry of the exchange from
damage due to external surges/spikes may be provided.
e.
The EPAX may be suitable for easy expansion if required at a later

date.
5.1.3 EPAXs should be equipped with 16 subscriber lines and 8 trunk lines (PLCC
directions E&M trunks) for 16/8 line exchange and EPAX should be wired for 48
subscriber lines & 24 trunk lines (E&M trunks).
353

5.1.4 The EPAX shall have facility to expand either the number of subscriber lines or
tie lines if required, at a later date. The EPAX should be microprocessor based and be
programmable at site. The software shall support E & M signaling.
5.1.5 The EPAX shall be fully automatic and should function without the help of an
operator. The site programming facility with telephone or operator console shall be
provided.
5.1.6 The exchange shall be self protecting against transients in the input DC supply
and against failure of any component or cable in the entire communication system.
The additional central processing unit (CPU) and Power Supply Unit (PSU) of
exchange should also be supplied extra with each exchange for more reliability. In the
event of one of main CPU or PSU card failure, the additional CPU / PSU card can be
used to minimize any break down time. The EPAX shall be supplied with Krone type
MDF with protection for both the subscriber and tie (PLCC) lines. All the lines shall be
provided with surge arrestors and fuses for protection from transients. The krone type
protective units shall be housed in a suitable wall mounted junction box & krone
insertion tool shall be supplied for erection / maintenance of EPAX without any extra
cost.
5.1.7
The EPAX shall have the following facilities:

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Follow me / call forward

Call transfer & Conference
Automatic alternate route selection (hunting)
Ring when free
Line Lock out
Either party release
Real time clock
Call pickup facility
Audible and visual alarm on all fault conditions & with auto restart
facility.
The priority facility should be such that it should work in trunk busy
condition as well as subscriber (local) busy condition i.e. by
applying the priority button / priority code the subscriber will come
in conversation with the called party (subscriber / Trunk).
Reset button (to reset the EPAX in case of hang condition)
5.1.8 The EPAX shall be self-contained and provide its own ringing current and
tones. Visual display with LED's shall be available on each line and trunk card to
display call status. Visual and audible alarms shall be provided on all fault conditions
based on the self diagnostic routines will be preferred. The exchange shall be housed
in a sheet steel cabinet and shall be sturdy, impact resistant, dust, and damp
proof. The EPAX shall operate on 48V DC +15% -10% supply. The loop resistance for
subscriber lines is 1200 ohms maximum and for tie lines 1500 ohms maximum. The
exchange should be housed in with cooling fan.
354

5.1.9 The system software shall be posted on flash memory as per the latest
International standards for fast and reliable operations. The EPAX shall also support a
minimum dialing of .16 digits at a time and a maximum of 20 digits.
5.1.10 The EPAX should be provided with universal ports/slots for peripheral cards so
that any combination of subscribers and trunks can be selected by the user by inserting
suitable interface cards. It may please be noted that subscriber & trunk cards are
equipped for maximum of 8 subscribers & 8 trunk per card.
5.1.11 The EPAX shall support the system software to work as an exclusive PLCC
exchange. The EPAX shall work in conjunction with the existing EPAXs of other makes
in the grid.
5.1.12 The exchange should have facility to adjust the transmitter and receiver voice
and data level on
trunks
so that
proper audible communication could be
established with out-stationed subscriber.
5.1.13 The offer EPAX should support Telephone billing software. EPAX should be
equipped with Operator Console so that programming done at site may be viewed on
the screen of the Operator Console.
5.1.14 The EPAX must have been EMI/ EMC tested as per IEC-495. The exchange
should be approved by TEC. A copy of certificate of TEC approval for the type of
exchange offered must be enclosed.
6.0
TECHNICAL SPECIFICATION FOR TELEPHONE SET :
6.1
Basic Design :
The specification covers supply of ordinary push button telephone set. The
Technical requirement of telephones are as follows:
6.1.1 The ordinary electronic push button telephone should be of desk top type and
shall have approval of Telecom Engineering Center or Department of Telecom of
India. In this connection, a photo copy of documentary evidence must be submitted
along with the bid. In absence of documentary evidence the offer shall be nonresponsive. The telephone shall support dialing on 2 wire loop mode and should be
compatible for operation with all type of electronic exchanges being used by DOT
of all technologies (indigenous & foreign). The telephone instrument must be suitable
for climatic conditions stated in Clause no.3 of Section-II mentioned above. The
instrument should be sturdy and should have good appearance. The instruments
should be supplied in different pleasant colours based on our approval. The telephone
shall be provided with following features:
i.
ii.
iii.
iv.
v.
Tone / pulse switchable

User selectable dialing mode operation like Tone/DTMF.
Automatic last number redial facility up to maximum of 32
digits
Ringer indication with ringer volume control.
Electronic speech circuitry with regulated speech levels.
355

vi.
vii.
viii.
ix.
Pause insertion for intermediate tones.

Automatic gain control for long line attenuation.
Good quality of transmitter transducers.
Extreme temperature resistant components for operation
reliability.
Digit pulses during dialing are muted.
x.
6.1.2
Apart from above, telephones offered should meet following specifications

i
System voltage
48V DC 10%
ii
Pulse rate
iii
Break-make ratio
iv
Inter-digit pause 800 m sec(minimum)
10 PPS
66:33/60:40
6.1.3 The push button telephone, should be supplied complete in all respect. Any
accessory/ feature which is not specifically mentioned but is considered necessary
for satisfactory operation of the equipment have to be included and the instrument
incorporating such facility shall be supplied without any extra cost. The telephone sets
shall be procured preferably from reputed and experienced manufacturer of
telephones.
7.0
Acceptance And Routine Tests:
7.1
The manufacturer shall carry out all acceptance and routine tests as stipulated
in the relevant Indian Standards or Equivalent International Standards in presence of
7.2
Immediately after finalisation of the programme of type/ acceptance/routine
testing, the manufacturer shall give advance intimation to the Purchaser, to enable him
to depute his representative for witnessing the tests.
8.0
INSPECTION:
(i)
other places of manufacture, where the equipments are being
(ii)

of the time of starting and of the progress of manufacture of
equipment in its various stages, so that arrangements could be made
for inspection.
(iii)
No material shall be despatched from the works of manufacturer

(iv)
The acceptance of any quantity of the equipment shall in no way

relieve the successful bidder of his responsibility for meeting all the
356

requirements of this specification and shall not prevent subsequent
rejection if such equipments are later found to be defective.
9.0
9.1
programme for manufacture of equipments. The Bidder shall invariably furnish
following information along with his offer. Information shall be separately given for
individual type of equipment offered.
i)
ii)
iii)
iv)
v)
vi)
vii)
Statement giving list of important raw materials, names of sub supplier

for the raw material, list of standards according to which the raw
material are tested, list of tests normally carried out on raw material in
presence of Bidders representative and copies of test certificates.
Levels of automation achieved and list of areas where manual
processing exists.
inspection.
Special features provided in the equipment to make it maintenance
free.
equipment specified and test plant limitations, if any, vis--vis type
test, acceptance and routine tests specified in the relevant Indian
Standards or equivalent international standard. These limitations
shall be very clearly brought out in schedule of deviations from
specified test equipments.
9.2
The successful Bidder shall within 30 days of placement of order, submit
following information to the Purchaser.
i)
ii)
iii)
List of raw materials as well as bought out accessories and the

names of sub supplier selected from the lists furnished along with
offer.
Quality Assurance Plan (QAP) with hold points by Purchasers
inspection. The quality assurance plans and hold points shall be
discussed between the Purchaser and Bidder before the QAP is
finalised.
9.3
The successful Bidder shall submit the routine test certificates of bought out
items
and for raw material at the time of routine testing of the fully assembled
equipment.
10.0
DOCUMENTATION :
10.1 All drawings shall conform to latest version of International Standards

Organization (ISO)À series of drawing sheet/Indian Standards Specification IS-
357

11065. All drawings shall be in ink and suitable for micro testing. All dimensions and
data shall be in S.I. Units.
11.0
11.1
a)
b)
Sectional views showing General Constructional Features.
c)
Name plate.
d)
Schematic drawing.
e)
Type Test reports
g)
Test reports, literature, pamphlets of the bought out items.
11.2
The successful Bidder shall within two weeks from signing of contract,
submit four sets of all the above drawings for Purchasers approval. The Purchaser
shall communicate his comments/approval on the drawings to the Bidder within
reasonable time. The Bidder shall, if necessary, modify the drawings and resubmit
four copies of the modified drawings for Purchasers approval within two weeks from
the date of Purchasers comments. After receipt of Purchasers approval, the Bidder
shall within three weeks submit 4 prints and two good quality reproducible (Soft Copy
in CD) of the approved drawings for Purchasers use.
11.3
approved drawings and no deviation shall be permitted without the written approval of
the Purchaser. All manufacturing and fabrication work in connection with the
equipment prior to the approval of the drawing shall be at the Bidders risk.
11.4
The successful Bidder shall furnish nicely printed and bound volumes of
operation, maintenance and erection manuals in English Language, for each type and
rating of equipment alongwith the equipments. The manual shall contain all the
drawings and information required for erection, operation and maintenance of the
equipments. The manual shall also contain a set of all the approved drawings and
type test reports etc.
11.5
Approval of drawings by Purchaser shall not relieve the Bidder of his
12.0
12.1
The details such as order no. and date, year of manufacture and MPPTCL
should be engraved on each and every equipment. The equipment shall be packed in
crates suitable for vertical/horizontal transport, as the case may be and suitable to
withstand handling during transport and outdoor storage during transit. The Bidder
shall be responsible for any damage during transit, due to improper and inadequate
358

packing and handling. The easily damageable material shall be carefully packed and
marked with the appropriate caution symbols.
Wherever necessary, proper
arrangement for lifting, such as lifting hooks etc. shall be provided. Bidder shall
supply, any material, found short inside the packing cases without any extra cost.
12.2
Each consignment shall be accompanied by a detailed packing list
containing the following information:
a)
b)
c)
Destination
d)
e)
f)
12.3
The Bidder shall ensure that the packing list and bill of material is approved
by the Purchaser before despatch
13.0
SCHEDULE
Schedules and annexure attached with this specification are the integral part of
the specification and shall be submitted duly filled in by the Bidders alongwith the offer.
Bill of material for each equipment shall be submitted by the bidder separately. Makes
of the equipment shall be clearly indicated. Bidders may please note that a general
mention that the components shall be of reputed make will not be acceptable.
14.0
COMPLETENESS OF EQUIPMENT/MATERIAL AND BOUGHT OUT ITEMS
14.1 Bid shall be complete in all respects and shall include all minor component,
accessories, small wiring
etc., not specifically mentioned in the Schedule,
specifications etc; but essential for the completeness of the system. Bidders shall not
be eligible for extra charges in respect of such minor components, accessories, small
wiring etc., though not included specifically in this specification but requires for
satisfactory operation of equipment offered.
14.2

14.2.2 It is obligatory on the part of bidders to ensure that supply of all accessories
along with Main equipment are simultaneously delivered to avoid any holdups.
Responsibility for obtaining timely supplies of bought out items will rest on the bidders
and only on this basis, delivery period will be offered in the Bid.
14.2.3 It may be noted that in case of damages/shortages due to improper packing or
any other negligence ,replenishment shall be arranged within one months time. For
bought out items, responsibility for guarantee and obtaining immediate replacement in
359

case any defects are noticed and also in case defective supply of any item is reported,
will rest on the bidders.
15.0 GUARANTEED TECHNICAL PARTICULARS:
It is obligatory on the part of bidders to furnish Guaranteed Technical
Particulars for offered equipments.
16.0
As specified in the bid document, the bidder has to furnish an undertaking that
the spares required for satisfactory operation of offered goods shall be made available
at reasonable cost over a minimum period of 10 years from the date of commissioning
of goods in purchaser's system. In the absence of such an undertaking, the offer will be
treated as non-responsive.
17.0
Please ensure the Bid document containing number of pages has been
properly page numbered and signed by the bidder. All Bid documents including
Schedules and Annexure should be indexed properly and index of the document
should be enclosed/placed at the beginning of the document.
360
SCHEDULE-I(A)
DESCRIPTION OF EQUIPMENT FOR SCHEDULE FOR RATES AND PRICES
Epax & Telephone sets
16/8 LINES ELECTRONIC PRIVATE AUTOMATIC
EXCHANGE (EPAX) meeting all technical requirements of
the specification.
Telephone sets meeting all technical requirement of the
specification
Qty.
As per Price
Schedule
SNo
A
1
Note : 1.
The above description of the equipment is given for the purpose

of offering the prices and to mention description of equipment in
invoice for claiming payment.
361
2.2.5
1.0
TECHNICAL SPECIFICATION FOR HF COAXIAL CABLE &

TELEPHONE CABLES
SCOPE :
The scope of this bid covers, design manufacturing and supply of equipment as
per Volume-II, Part-2, Book-I. The bidder mentioned in this Section of the Technical
the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipments/materials
2.0
STANDARDS :
2.1
Applicable Standards for the offered equipments /items shall be as per VolumeII, Part-2, Book-I.
2.2
If the equipment offered by the Bidders conforms to any other standards, salient
points of comparison between the standards adopted and the specific standards shall
be clearly brought out in relevant schedule of technical deviation. It will be sole
responsibility of Bidders to prove that the salient features of offered equipment are
equivalent or better than IS.
2.3
In the preceding paragraph relevant Indian standard / IEC standard bid have
been shown. However, the equipment meeting any other authoritative international
standard, which ensures equal or better quality than the standards, mentioned shall
also be acceptable. Equipment for which Indian Standards are not available, the
3.0
3.1
3.2
Auxiliary Power Supply for offered EHV equipments shall be as per Volume-II,
Part-2, Book-I.
4.

5.0
TECHNICAL SPECIFICATION OF HF COAXIAL CABLE
5.1
Basic Design :
5.1.1 The Coaxial cable or HF cable shall be used for connections between the line
matching unit and the transmitter receiver set. The insulation of the cable shall be of
362
Coaxial Cable & Telephone Cable

very high quality to minimise leakage at the carrier frequencies. The cable shall be
screened by means of tinned braided copper and armoured with G.I. wire & finally
overall PVC sheathed. The capacitance of the cable shall be low so as to minimize
the attenuation in the carrier frequency range. The size, details of insulation
etc. shall be furnished in the bid. The cable length may be laid in ducts or directly
imbedded in ground. Thus the cable offered should be suitable to be laid in duct
or imbedded in ground. The characteristic impedance of the cable should be 125
ohm unbalanced.
The impedance of the cable shall match with the output
impedance of the PLC terminals and the impedance of the coupling unit over the
entire frequency range of 40- 500 KHz. The attenuation per kilometer for high
frequency range of 40-500 KHz should be furnished. The dimensions and materials
used for conductors, insulation, copper braiding, inner PV sheath(Jacket), PVC
tape, G.I. wire & final PVC sheath shall be as indicated below. The conductor material
should use highly annealed electrolytic tinned copper. The insulation material should
be of high quality and should not deteriorate even if imbedded in ground for 10
years or more. There should be no action of chemical and moisture on it. The outer
covering of the cable should be free from attack by termites.
5.1.2 The cable shall be designed to withstand a test voltage of 4 KV between the
conductor and outer sheath for one minute. The voltage withstand test and the test
to ascertain the attenuation figures offered shall be carried out at the manufacturers
work.
5.1.3 The HF cable shall be supplied in non-returnable wooden drums having
lengths between 500 Meters and 525 meters. Please note that, non standard
length are not acceptable & same should not be supplied. A quantity variation
of 2% on total ordered quantity will only be acceptable.
5.1.4 A drawing showing constructional details indicating dimension and other
details of each component used for manufacturing the cable is enclosed along
with this specification. In order to clarify the Bidders regarding our exact
requirement and also for the purpose of submitting various technical details of
the cables, the following additional information is furnished.
i.
ii.
iii.
iv.
v.
vi.
vii.
As for as possible characteristic impedance of the cable should be 125 ohm.

However, a variation of 5% on 125 ohm shall be permitted.
Minimum diameter of the bare copper conductor should be 0.8mm.
The bare copper conductor should be wrapped with PE thread of 1.6mm
diameter.
Over the bare copper conductor wrapped with PE thread, extruded tube of PE
with minimum wall thickness of 1.75mm should be provided, diameter of
extruded tube should be approximately 7.6mm.
Over PE tube single braid of tinned copper wire(diameter 0.2mm)of size
24x8x0.2(i.e 24 spindle with 8 wire per spindle and diameter of each wire
should be 0.2mm) with 50mm lay shall be applied. Diameter over braiding
should be approximately 8.5mm.
Over the copper braiding a PVC/Melinex tape of thickness o.15/0.025mm shall
be applied.
A PVC inner jacket with nominal wall thickness of 1.2mm shall be applied over
PVC/Melinex tape.
363

viii.
ix.
x.
xi.
After PVC inner jacket tape, lap armouring of GI wire of diameter 0.5mm of size
48x1x0.5 with 100mm lay approximately shall be provided.
A PVC/Melinex tape of thickness 0.15/0.025mm shall be applied over
armouring.
Finally outer jacket of PVC with wall thickness of 1.4mm shall be provided. Over
all diameter of cable shall be about 16mm ( 17mm max).
On
the above basis, please
furnish
drawing,
showing complete
constructional details of the cable and also thickness of various sheath/tape
used for the cable shall be specified keeping in view of our minimum
requirements as furnished above.
6.0
TECHNICAL SPECIFICATION OF TELEPHONE CABLE:
6.1
Basic Design 10 Pair PVC Armoured Telephone Cable.
The multicore telephone cables suitable for overhead and underground system
are required for Purchasers departmental telephone system. The telephone cable shall
generally conform to specification No.G/WIR-06/02 with latest amendment. The cable
shall be manufactured as per following specifications.
6.1.1
Requirement and Size of Cables:
10 pair PVC armoured telephone cable suitable for under ground system. In
case of armoured cable armouring and outer sheath should be provided as per IS1554.
6.1.2
(a)
(b)
(c)
(d)
(e)
6.1.3
(a)
Type of Conductor, Insulation of Conductor and Twinning:

The conductor must consists of bright clean and scale free solid wire
(round) of annealed high conductivity tinned copper. The surface of the
conductor shall be smooth and untarnished.
The diameter of conductor should be 0.60mm.
Maximum average resistance of conductor at 20 degree centigrade should
be 64 ohm /km.
The conductor must be insulated with PVC. The minimum thickness of
insulation should be 0.2+0.05 mm-0.02mm. The cable insulation must be
flame retardant and shall not support own combustion and must be self
extinguishing. PVC used must be high resistant to ageing and fading of
colours. The insulation shall be applied by extrusion process and shall form
a compact homogenous body uniformly enclosing the copper conductor. It
shall be possible to strip the insulation readily from the copper conductor
without damaging them.
Two insulated conductors must be uniformly twisted together to form a pair.
The lays of the twists of the pairs must be different for all pairs so that cross
talk is kept to a minimum.
Identifications, Sheathing & other requirements:
The conductors should be laid such that each pair can be identified easily.
The colour should be readily identifiable under the normal lightning
conditions. The range of pigment used for colouring PVC shall be such that
the colour should not fade out. The colour code must be clearly mentioned
in offer and lapping of PVC tape should be applied.
364
7.0
(b)
All insulated cores are first twisted in to pairs. All the 10 pair / 6 pair / 2 pair
should be bunched to form a unit. The cable thus formed shall be tightly
lapped with a PVC tape of 0.13 mm thickness with a 30% overlap.
Alternatively, the cable shall be lapped with polythene teraphthalate tape of
0.013 mm thickness, having an overlap of not less than 30% or two such
tapes may be applied over breaking joint. Finally an outer sheathing of PVC
of thickness of 0.65mm for 6 pair and 2 pair and 0.75 mm for 10 pair
unarmoured PVC cable shall be provided. For 10 pair armoured PVC cable,
minimum thickness of outer sheath should be 1.4mm. The armouring should
be done with wire / strip as per IS 1554.
(c)
The telephone cable shall be supplied in non returnable wooden drums

having lengths between 500 meters and 525 meters or 1000 meters and
1050 meters. Please note that non standard length should not be supplied.
A quantity variation of 2% on total ordered quantity will only be
acceptable.
GUARANTEED TECHNICAL PARTICULARS :-
It is obligatory on the part of bidders to furnish guaranteed technical

particulars offered cables in their bid.
8.0
TESTS :
8.1
Type Test :
All the cables offered, shall be fully type tested as per relevant Indian
Standards or any Equivalent International Standard during the last five years from the
date of bid opening. In case the equipment of the type and design offered has already
been type tested, the Bidder shall furnish four sets of the type test reports along with
the offer. The Purchaser reserves the right to demand repetition of some or all the
type tests in the presence of Purchasers representatives. For this purpose, the Bidder
may quote unit rates for carrying out each type test. This will not be considered for
price evaluations. For any change in the design/type already type tested and the
design/type offered against this bid, the Purchaser reserves the right to demand
repetition of same or all type tests without any extra cost. Non compliance of this
requirement will make the bid non responsive.
8.2
Acceptance And Routine Tests:
8.2.1 The manufacturer shall carry out all acceptance and routine tests as stipulated
in the relevant Indian Standards or Equivalent International Standards in presence of
8.2.2 Immediately after finalisation of the programme of type/ acceptance/routine
testing, the manufacturer shall give advance intimation to the Purchaser, to enable him
to depute his representative for witnessing the tests.
9.0
INSPECTION:
(i)
other places of manufacture, where the cables are being
365

10.0
(ii)

of the time of starting and of the progress of manufacture of cables in
its various stages, so that arrangements could be made for inspection.
(iii)
No material shall be despatched from the works of manufacturer

(iv)
The acceptance of any quantity of the cables shall in no way relieve

the successful bidder of his responsibility for meeting all the
requirements of this specification and shall not prevent subsequent
rejection if such cables are later found to be defective.
10.1
The Bidder must establish that they are following a proper quality
assurance programme for manufacture of cables. The Bidder shall invariably furnish
following information along with his offer. Information shall be separately given for
individual type of cable offered.
i)

presence of Bidders representative and copies of test certificates.
ii)

iii)
iv)

processing exists.
v)

inspection.
vi)
Special features provided to make it maintenance free.
vii)
cable specified and test plant limitations, if any, vis--vis type test,
acceptance and routine tests specified in the relevant Indian
Standards or equivalent international standard. These limitations
shall be very clearly brought out in schedule of deviations from
10.2 The successful Bidder shall within 30 days of placement of order, submit
i)

offer.
366

ii)
iii)
finalised.
10.3 The successful Bidder shall submit the routine test certificates of bought out
items and for raw material at the time of routine testing of the fully assembled
equipment.
11.0
DOCUMENTATION :
11.1
All drawings shall conform to latest version of International Standards
Organization (ISO)À series of drawing sheet/Indian Standards Specification IS11065. All drawings shall be in ink and suitable for micro testing. All dimensions and
data shall be in S.I.Units.
12.0
12.1
a)
General outline drawings.
b)
Sectional views showing General Constructional Features.
c)
Marking on the cables
d)
Type Test reports
e)
Test reports, literature, pamphlets of the bought out items.
12.2 The successful Bidder shall within two weeks from signing of contract, submit
four sets of all the above drawings for Purchasers approval. The Purchaser shall
time. The Bidder shall, if necessary, modify the drawings and resubmit four copies of
the modified drawings for Purchasers approval within two weeks from the date of
three weeks submit 4 prints and two good quality reproducible (Soft Copy in CD) of the
approved drawings for Purchasers use.
12.3
The manufacturing of the cables shall be strictly in accordance with the
the Purchaser. All manufacturing work in connection with the cable prior to the
12.4 The successful Bidder shall furnish nicely printed and bound volumes of
manuals in English Language, for each type and rating of equipment/materials
alongwith the equipments.
12.5 Approval of drawings by Purchaser shall not relieve the Bidder of his
367
13.0
13.1 The details such as order no. and date, year of manufacture and MPPTCL
should be engraved on each and every cable. The cable shall be packed in crates
suitable for vertical/horizontal transport, as the case may be and suitable to withstand
handling during transport and outdoor storage during transit. The Bidder shall be
responsible for any damage during transit, due to improper and inadequate packing
and handling. The easily damageable material shall be carefully packed and marked
with the appropriate caution symbols. Wherever necessary, proper arrangement for
lifting, such as lifting hooks etc. shall be provided. Bidder shall supply, any material,
found short inside the packing cases without any extra cost.
13.2
Each consignment shall be accompanied by a detailed packing list containing
the following information:
a)
b)
c)
d)
e)
f)

Destination
13.3
The Bidder shall ensure that the packing list and bill of material is approved by
the Purchaser before despatch.
14.0
SCHEDULE
Schedules and annexures attached with this specification are the integral part
of the specification and shall be submitted duly filled in by the Bidders alongwith the
offer. Bill of material for each equipments shall be submitted by the bidder separately.
Makes of the equipment shall be clearly indicated. Bidders may please note that a
general mention that the components shall be of reputed make, will not be
acceptable.
15.0
15.1 Bid shall be complete in all respects and shall include all minor component,
specifications etc; but essential for the completeness of the system. Bidders shall not
be eligible for extra charges in respect of such minor components, accessories, small
15.2

15.2.2 It is obligatory on the part of bidders to ensure that supply of all accessories
along with Main equipment are simultaneously delivered to avoid any holdups.
368

Responsibility for obtaining timely supplies of bought out items will rest on the bidders
and only on this basis, delivery period will be offered in the Bid.
15.2.3 It may be noted that in case of damages/shortages due to improper packing or
any other negligence ,replenishment shall be arranged within one months time. For
will rest on the bidders.
16.0
As specified in the bid document, the bidder has to furnish an undertaking that
the spares required for satisfactory operation of offered goods shall be made available
at reasonable cost over a minimum period of 10 years from the date of commissioning
of goods in purchaser's system. In the absence of such an undertaking, the offer will be
treated as non-responsive.
17.0
Please ensure the Bid document containing number of pages has been
properly page numbered and signed by the bidder. All Bid documents including
Schedules and Annexure should be indexed properly and index of the document
should be enclosed/placed at the beginning of the document.
369
APPENDIX-K
S.No
Description
Constructional details of HF Coaxial Cable
370
CONSTRUCTIONAL DETAILS OF
HF COAXIAL CABLE
INNER CONDUCTOR WITH DIA 0.8mm

CONDUCTOR WRAPPED WITH PE THREAD
OF DIA 1.6mm
EXTRUDED TUBE OF PE WALL THICKNESS
1.75mm
OUTER CONDUCTOR TINNED COPPER
WIRE,SINGLE BRAID
PVC INNER JACKET OF DIA 1.2mm
PVC TAPE
ARMOUR GI WIRE 48x1x0.5mm
PVC TAPE
PVC OUTER JACKET OF DIA 1.4mm
371
SCHEDULE-I(A)
Qty.
HF COAXIAL CABLES & TELEPHONE CABLES
1.
HF Coaxial Cable conforming to technical specifications and

meeting all design, constructional features and technical
particulars as described in bid document.
Telephone Cables of following sizes, conforming to technical
specification of the bid document and meeting all design,
constructional features and technical particulars as described
in bid document.
10 Pair PVC Aarmopured
a)
S.No.
Note : 1.
The above description of the equipment is given for the purpose

of offering the prices and to mention description of equipment in
2. The quantity of above equipments has been mentioned in volume-VI.
372
2.2.6
TECHNICAL SPECIFICATION FOR REMOTE

TERMINAL UNIT
Scope :
This document contains the specifications, cover design, engineering,
manufacturing & testing before supply, packing & dealing of Remote Terminal Units
(RTUs) and associated equipment to be supplied to the employer along with the
installation work. Information concerning employers objectives is presented in the
form of acceptable design approaches.
1.1
Scope of Supply:
The contractor shall provide the complete RTUs, interface cabinets, transducers,
multi Function meters, cabling, installation and implementation and associated support
requirements defined in this Specification.
Employer may not initially procure all capabilities specified with this document,
Regardless of the RTU configuration purchased; the RTUs shall be capable of all functions
specified herein with the addition of the necessary hardware and software modules in the
field when required by employer.
Should the contractor elect to subcontract manufacturing, installation or any other
work defined herein, it shall remain the contractors responsibility to manage the complete
procurement.
The contractor shall be responsible for supplying all hardware, software,
installation, and field implementation as defined in this Specification. The contractor shall
also provide complete documentation, training and testing to fully support the hardware
and software provided.
The RTUs, interface cabinets, transducers, cables and all associated hardware and
software procured with this Specification will be installed at substations which will be
supervised by employers representative.
It is employers intent that the contractors use as much standard hardware and
software as possible, however, all of the functional requirements of this Specification must
be satisfied. The use of the contractors standard hardware and software may cause the
contractor to conclude that there is need for additional items not specifically mentioned in
this Specification. The contractor shall supply all such items and provide a complete RTU
design that meets all of employers functional requirements defined in this Specification.
The RTUs are used for real-time monitoring and control of the MP power
system and will be located in transmission substations. The control systems will include
the capability for control of substation, although it may not be implemented initially.
The Remote Terminal Units and Associated Hardware & Accessories offered shall
be complete with all component necessarily for their effective and trouble free operation.
Such component deemed to be within the scope of supply of tenderer irrespective of
whether these are specifically brought out in this specification and / or in the commercial
order or not.
373
RTU
2.0
2.1
The equipments / materials shall be suitable for continuous satisfactory
operation under climatic conditions listed below:
1
2
3
4
5
6
7
8
9
10
11
12
Location
Maximum Ambient Air Temperature
Minimum Ambient Air Temperature
Average daily Ambient Air Temp.
Maximum relative humidity
In the state of Madhya Pradesh

50O C
1O C
30O C
95%(sometime approaches
to saturation)
Average no. of thunderstorm days per annum
50
Average no. of rainy days per annum
90
Average annual rainfall
125 cm.
Months of tropical monsoon condition in the June to October
year.
Maximum wind pressure.
150 Kg/sq.m.
Altitude not exceeding
1000 meters
Seismic level (horizontal acceleration)
0.3 g
Note: Moderately hot and humid tropical climate is conducive to rust and fungus
growth. The climatic conditions are also prone to wide variations in ambient conditions.
Smoke is also present in the atmosphere. Heavy lightning also occurs during June to
October.
3.0
SYSTEM PARTICULARS:
3.1
The equipments/materials offered under this specification shall be used in the
substations having following system parameters:
S.No
1
2
3
4
5
6
PARTICULARS
Frequency
Number of phases
Earthing
Basic insulation level (kV peak)
SYSTEM PARAMETERS
400KV 220KV 132KV 33KV
420KV 245KV 145KV 36KV
---------------- 50 Hz ---------------------------------- Three --------------------Effectively earthed---1425
1050
630
170
4.0 TECHNICAL SPECIFICATION FOR REMOTE TERMINAL UNIT REQUIREMENTS

This section describes the overall functions to be performed by the RTUs. Each
function is presented in sufficient detail to provide the contractor with as much insight as
possible into both the initial and future requirements of the RTUs. All functional capability
374
RTU

described herein shall be provided by the contractor even if a function is not initially
implemented.
As a minimum, the RTUs shall be capable of performing the following function :

(a)
(b)
(c)
(d)
(e)
4.1
Collecting, processing and transmitting status changes, accumulated values

and analog values.
Receiving and processing digital and analog commands from the master
station(s)
Accepting polling messages from the master station(s)
Supporting data transmission rates from 50 to 9600 bits per second.
Supporting upto six communication ports and multiple concurrent protocols,
including the IEC 60870-5-101protocol.
Communication Interface :
The RTUs shall have minimum capability to support simultaneous communications

with multiple independent masters stations and a local user maintenance inter-phase.
The RTU shall have minimum communication ports as follows:
(a)
Two ports for multiple master stations connectivity in case of non-critical

RTUs or four ports for multiple master stations connectivity in case of
critical RTUs.
(b)
One port for RTU maintenance and configuration terminal.
Critical RTUs (see Appendix A) shall have redundant communication ports and
non-critical shall have a non-redundant communication port, for master station
connectivity. Therefore, each critical RTU shall have minimum six communication ports
and each non-critical RTU shall have minimum four communication ports. It should be
possible to add communication port in future to interface with a local SCADA/Human
Machine Interface(HMI), without any change in RTU software/firmware.
The communication interface to the master stations shall allow scanning and control
of defined points within the RTU independently for each master station. The RTU shall
simultaneously respond to independent scans and commands from employers master
stations. The RTU shall support the use of a different communication data exchange rate
(bits per second), scanning cycle and / or communication protocol to each master station.
Also each master stations data scan and control commands may be different for different
data points within the RTUs database.
All communication ports shall use CCITT V.24 and V.28 signal specifications to
interface to the modems. All ports shall be accessible to employer to attach the interface
equipment and to provide access for the maintenance, test and monitoring equipment.
375
RTU

4.1.1
Master station communication Interface :
The RTU shall provide multiple communication ports for possible concurrent
communication to SCADA system master stations. Two of the ports shall provide
redundant communication to a single master station (Critical RTUs), while additional ports
may serve other master station(s). Data sent to each master station shall be independent,
with different scan groups and different data points as definable from the RTU database.
Employer will supply communication channels between the RTUs and the SCADA
system master stations. Use of dedicated or party-lined communication channels shall be
supported. The RTU data transfer rate for each RTU is specified in Appendix-A. The
communication channels provided by employer will consist of power line carrier, optical
fiber and cable communication channels during the modems specified below.
4.1.2
Modems :
The contractor shall supply two (2) number modems alongwith each critical RTU
(at RTU end) and one number modem alongwith each non-critical RTU (at RTU end) for
communicating with the master station identified in Appendix-A. The identical counterpart
of respective two nos. Modem for each critical RTU and respective one no. Modem for
each non critical RTU at the control center end/ Wide band node also shall be supplied for
each RTU data channel. These modems can be located either at the FEP or at wideband
node. In case the modem is located at wideband node, then it shall be stand-alone type.. A
single modem combining all of the characteristics defined below is preferred such that
changing the communication data rate shall only require reconfiguration of the RTU
modem.
The modems shall not require manual equalization and shall include self-test
features such as manual mark / space keying analog loop-back and digital loop back. The
modems shall provide for convenient adjustment of output level and receive sensitivity.
The configuration of tones and speed shall be programmable and maintained in nonvolatile memory in the modem.
The Modems at wideband nodes shall be housed in 19'inches rack with suitable
capacity power supply module .The connections from PLCC/Wideband communication
equipment shall be terminated at the rear side of the Modem.
The modems shall meet the following requirements :a) Use CCITT Standards including V.24, V.28, V.52 and V.54
b) Communicate data rates of 200, 300, 600 and 1200 bits per second.
c) Use CCITT V.21, V.23, R35, R37, R38 and R.38b and standard tones for
the selected RTU data rate.
d) Use frequency shift keying (FSK) modulation
e) Use both 2-wire and 4-wire communication lines
f) Receive level adjustable from 0 to -40 dBm@600 ohms
g) Transmit level adjustable from 0 to -24 dBm@600 ohms
h) Have a minimum sensitivity of -48 dBm
376
RTU

i)
PLCC modem shall use bandwidth upto 4khz and shall accommodate
multiple data channels over and above voice channels. It shall conform to
CCITT-38 standards.
4.1.3 Local user Maintenance Interface :

The RTUs shall include the interface to support the portable configuration and
maintenance terminal defined in Section 4.8.3. The interface shall provide easy access to
allow employer to use the maintenance terminal at the RTUs installed in the field.
4.2
Master Station Communication Protocol :
The Contractor shall provide a communication protocol for communicating with

employers master stations using the IEC 60870-5-101 communication standard. The
communication protocol shall support all the requirements of this standard. The
communication protocol shall be non-proprietary and the contractor shall provide complete
description and documentation of the protocol to employer for future implementation on
additional RTUs form any supplier and in the master stations. The configuration of the
protocol shall be as per the interoperability Matrix which shall be provided by the
employer.
The RTU shall also be capable of supporting other communication protocols that
may be required to communicate with additional master stations in the future. The offered
RTU will not require any software/firmware change to support additional master stations.
The only change could be addition of communication ports and re-configuration of RTU.
4.2.1 Communication Channel Control :
The RTU shall perform as a slave on the communication channel to employers
SCADA systems. All communication shall be initiated by the SCADA system master
stations. Where the RTU must notify the master stations of an unusual condition at the
RTU (such as a power fail/restoration or RTU malfunction) or must initiate the transfer of
changed data, the notification shall be accomplished with the framework of the periodic
data acquisition exchanges.
4.2.2 Scan Groups :
Analog and digital input points (including points reported by exception) shall be
assignable to scan groups. A scan group shall be a specified set of data points within the
RTUs central database which will be communicated to a master station when requested by
a specific (addressed) scan request. A scan group size shall only be limited by the
communication protocol message length. Any RTU input point shall be assignable to any
scan group. The RTUs shall support at least sixteen scan groups and all scan groups per
communication port (i.e. master station / maintenance terminal interface).
377
RTU

The contractor shall provide a convenient and flexible scheme for assigning points
in the RTU to scan groups. The contractor shall provide all special equipment necessary to
configure the RTU and assign points to scan groups.
4.2.3 Exception Reporting :

The RTU communication protocol shall report status changes by exception. The
communication protocol shall also support an update demand scan of all status data by
master stations regardless of the lack of any change data. The update scan will report the
status of all RTU data assigned to the scan group.
The reply to an exception scan request for status points shall consist of an indication
of the presence or absence of a change of the status indication points in the RTU. A master
station will then request the input of the changed points. The RTU shall continue to
indicate exception changes until the master station acknowledges successful receipt of the
changed data. The RTU shall report the current state of all status indication points to the
master station in response to an update scan even if data has not changed.
Analog points shall only reply to a scan request for the analog points whose scan
group contains the assigned points. No exception scanning of analog point shall be
allowed.
4.2.4 Message Security :
Each RTU communication message shall include an error code, the use of which
shall result in a very low probability of an erroneous message being accepted as valid. The
error code shall be determined and appended to the message for all messages transmitted
by the RTU and verified by the RTU for all messages addressed and received by the RTU.
Cyclic error detection codes such as CRC are required.
High data integrity and consistency is required of the RTU protocols. The protocols
used shall provide an adequately low Residual Error Rate (RER) depending on the Bit
Error Rate (BER) of the line in use. The minimum required RER is as specified for the
IEC 60870-5-101 protocol with the T-101 profile. This requires the following integrity:
BER
RER
105
10-14
10-4
10-10
-3
10
10-6
The implemented protocol shall ensure satisfactory performance at Bit Error Rate of
4
1 x 10 .
4.2.5 Control Security :
Operation of control outputs shall use a true select-check-before-execute command
sequence between the RTU and the SCADA system master station. The sequence shall
include as a minimum, the following functional capabilities :
378
RTU
a)
b)
c)
d)
4.3
The master station shall transmit a control selection message addressing the
proper RTU and control point within the RTU and indicate the control
action desired (such as Close).
The RTU shall initialize its control logic, reassemble the control selection
message received in (a) above, and transmit the reassembled message to the
master station. The information in the message sent to the master station
shall be generated by the RTUs point-selection logic indicating the point and
control function selected. It shall not be a simple repeat of the master
stations message transmission.
The master station will verify the returned message with the message sent in
(a) above and, if valid, shall issue an execute control message to the RTU.
The RTU shall only operate the control point selected after the checkbefore-execute sequence above has been performed without error or
interruption by any other messages. The RTU shall reset its control logic
upon any error in the sequence or if the execute message is not received
within a set time (user adjustable 2 20 seconds) after the command
message is received at the RTU.
Analog Inputs :
The RTU shall accommodate analog current inputs which are isolated, unipolar or
bipolar, 2-wire ungrounded differential signals with full resolution as follows :
(a)
(b)
(c)
+4 to + 20 mA
0 to + 10 mA
10 to +10 mA
The analog input accuracy shall be 99.8% or better at 25C ambient temperature.
Mean accuracy shall drift no more than 0.002% perC with the temperature range of 5 to
55C. Determination of accuracy shall be made while the analog multiplexer is operating
at rated speed. The analog-to-digital converter shall have a minimum resolution of 2048
counts (sign plus 11 data bits).
Each input shall have surge protection and filtering to provide protection against
voltage spikes and residual current: at 50 Hz, 0.1 ma (peak-to-peak). Overload of upto
50% of the input shall not sustain any failures to the input.
The RTU shall make all appropriate signal level conversion and conditioning to
allow full utilization of analog inputs and meaningful reasonability checking. Including
signal conditioning components, the input impedance shall not be greater than 250. Input
scaling shall allow for 20% over range.
RTU shall also accommodate the analog points MW, MVAR, Voltage&
Frequency.The OLTC transducers shall be of 4-20 mA output type and Active Power,
Reactive Power, Bus Voltage & Bus Frequency output shall be obtained from Multi
Function Meter/transducers.
379
RTU
4.4
Digital Status inputs :
The digital inputs interface shall be capable of accepting isolated wet or dry contact
status inputs. The contractor shall supply necessary sensing voltage, current limiting,
optical isolation galvanic protection, surge protection and debounce filtering independently
for each digital status input. The contractor supplied sensing voltage shall not exceed 48 V
DC. The sensing voltage source shall be isolated from that of the RTUs logic power such
that any noise or a short circuit across the sensing supplys output terminals would not
dispute the RTU operation other than the shorted digital status input.
The RTU shall store all status changes detected for retrieval by the master stations.
For communication delays or short-term failure of communications with a master station,
the RTU shall store a minimum of 300 status change events. The RTU shall report any
overflow of this status change buffer to the master stations.
4.4.1
Two-State Devices :
All switching devices (breakers) shall be supported by a dual-contact status

indication. Breakers with reclosing capability shall also be supported with momentary
change detection (MCD). All other status indications shall be two-state single-contact
status points without MCD.
Single contact two-state status point inputs will be from a single normally-open
(NO) or normally closed (NC) contact. Dual-contact two-state status point inputs will be
from two complementary contacts (one NO and one NC). A switching device status is
valid only when one contact is closed and the other contact is open. Invalid states shall be
reported when both contacts are open or both contacts are closed. The state definition shall
be set by employer for each contact position.
The RTU shall be set to capture contact operations of 20 ms or more duration.
Operations of less than 20 ms duration shall be considered no change (contact bounce).
The duration used to determine change versus bounce shall be adjustable from 4 to 25 ms
in increments of 1 ms.
4.4.2
Momentary Change Detection :
Two-state status input points with momentary change detection shall be used by
employer for points where multiple operations (changes of state) can occur between RTU
scans (e.g. breakers with reclosing devices that operate faster than the scan rate). The RTU
shall capture and maintain all of the momentary changes, upto 4 per MCD digital status
point. The MCD status input points shall be set to capture operations of greater than 20 ms
duration. Operation of less than 20 ms shall be considered no change (contact bounce).
The capture duration shall be adjustable between 4 and 25 ms in increments of 1 ms.
4.4.3 Pulse Accumulators :
The RTUs shall be capable of counting and storing the number of contact closures
generated by a kWh metering device external to the RTU. The device will supply either an
isolated Form. A normally open or Form C contact. The accumulator shall be incremented
380
RTU

one count for each cycle of the input (operation of the normally open and normally closed
contact of the Form C contact). Each accumulator shall have a 24-bit counter for counting
input operations before rolling over. The accumulator shall be capable of accepting counts
at a rate of ten counts per second. The count shall be frozen (transferred to a buffer
register) when commanded by the master station or when commanded by locally generated
contact inputs.
4.4.4
Digital Telemetry :
Digital telemetry input points shall be provided for sixteen-bit inputs from employer
telemetry contacts. The digital telemetry may use BCD (4-bit decimal characters without
sign) and / or binary (16 bit) codes
4.4.5
RTU Sequence of Events (SOE) Collection :
The RTU shall collect digital status input data and time-of-operation from fastacting power system devices. The RTU shall maintain a clock and shall time-stamp the
data with a time resolution of one millisecond. The time resolution will enable employers
operating and engineering personnel to determine the sequential operation device state
changes throughout the power system.
All dual contact two-state status input points (Appendix-A) in addition to being
scanned as digital status points, shall be assigned as SOE points. Any digital status input
data point in the RTU shall be assignable by Employer as an SOE point.
Each time a SOE status indication point changes state, the RTU shall time-tag the
change and store the change (open, close) and the time tag of the event in SOE buffers
within the RTU. Separate and independent SOE data storage buffers shall be provided in
the RTU for each master station. Each SOE buffer shall be sized to store, as a minimum, a
number of events equal to three times the number of SOE points in the RTU (Appendix
A).
The time-tag recorded with each event shall be generated from a clock internal to
the RTU. The time tagging of events within RTU shall have an accuracy of one millisecond
(1 ms). The accuracy of the internal clock for SOE time-tagging shall maintained by
messages from the master station.
When requested from a SCADA system master station, the RTU shall transmit the
SOE data stored in its buffer corresponding to that master station. An acknowledgement of
receipt by the master station shall be made prior to the loss of any data in the RTU SOE
buffer. Data not received at the master station shall be retransmitted. An indication that
SOE storage at an RTU is approaching capacity (at 80%) shall be transmitted to the master
station in the normal periodic scan so that a priority scan can be sent by the master station
to retrieve the SOE data. An additional indication shall provide the status of RTU SOE data
buffer overflow.
The RTU shall be capable to monitor Status of all circuit breakers, all isolators and
Sequence of events.
381
RTU

4.5
Digital Control Outputs :
The RTU shall provide the capability for a master station to select and change the
state of digital output points. Device control will be used by employer to control power
system devices including :
Two-state Devices :
Circuit breakers, motor-operated switches, auto/manual switches, relay
disable/enable and other two-state devices.
Variable Output Devices :
Transformer load-tap-changers (LTC) and other variable output devices.
The RTUs shall have the capability for control outputs as described in the following
sections.
4.5.1
Two-state Momentary Control :
A pair of outputs shall be supplied for each two-state (open/close) control output
point that drive control relays. One output shall be supplied for open, the other for close.
Upon command from a master station using the check-before-execute sequence, the
appropriate control output shall be operated for a preset (momentary) time period. The
operation period shall be adjustable for each point from 0.1 to 2 seconds.
4.5.2
Raise/Lower Pulse Outputs :
The raise / lower output controls will also be used for transformer tap position
settings.
A pair of outputs shall be supplied for each (raise/lower) control output point that
drive control relays. One output shall be supplied for raise, the other for lower. When
commanded from the master station, the appropriate raise or lower output shall be operated
for the selected time interval. The closure time interval for raise/lower pulse output points
shall be specified in the operate command from the master station. The raise/lower output
for each point shall operate over a range of 0.1 to 4 seconds in a minimum of eight equal
increments.
4.5.3 Control Outputs Relays (Double Contact Digital Output) :
Control output interposing relays shall be supplied by the Contractor for each
control output described above. Each control relay shall consist of two isolated single-pole
double throw contacts. The output contacts shall be rated 10 Amps at 110V / 220 V DC
and shall provide arc suppression to permit interruptions of an inductive load. Relay coils
shall be shunted with diodes to suppress inductive transients associated with energizing and
de-energizing of the relay coils. The relays shall conform to the IEC 255-1-00 and IEC
255-5 requirements.
382
RTU
4.5.4
RTU Control Security and Safety Requirements :

The RTU shall include the following security and safety features as minimum:
(a)
Select-check-operate sequence for control output. The verification message for

check-before-operate control sequences shall be obtained by re-encoding the
verification message directly from the control point selection lines. Thus, a simple
reflection of the received message is not acceptable.
(b)
No more that one control point shall be selected at any given time. A detection and
lockout method shall be provided that prevents a control operation if more than one
control point has been selected.
(c)
The control selection shall be automatically canceled if after receiving the control
selection message, the operate command is not the next received message and is
not received within the set time period.
If between the time of a select and execute command, a status related to any point
monitored by the RTU, changes state, the received execute command shall not be
completed by the RTU. No false output shall result from a single point of failure in
the RTU.
(d)
(e)
No false output shall result during power up or power down. No false output shall
result form inadvertent connections to a circuit card.
(f)
All connections with a voltage of fifty (50) volts or more shall have a protective
cover.
(g)
All control output connections shall have protective covers.
4.5.5 Control Disable :

A manual Local / Remote switch shall be provided for each RTU to disable all
control output interposing relays by breaking the power supply connection to the control
output interposing relays. When in the Local position, the Local / Remote switch shall
allow testing of the control outputs without activating the interposing control relays.
A status input indication shall be provided for the Local / Remote switch to allow
the SCADA system to monitor the position of the switch. This point is in addition to the
point count defined in Appendix A.
4.6
Time Facility :
The Internal RTU time base shall have a stability of 1 ppm that is 3.6 milli seconds
per hour or better. The RTU will be set from time synchronization messages received from
master station.
383
RTU

However, the RTU shall also be capable of receiving synchronization signals from
local GPS terminal. The RTU shall synchronize its internal clock with the master station
system clock when time synchronization messages are available.
4.7 Analog Data Update with Master Station:
The RTUs Analog data update with the Master Station shall be 10-15 seconds .It is
estimated that 40 analog points shall be updated in 15 seconds at 300 bps.
4.8 Support facilities :
The RTUs shall provide all support hardware and software to allow maintenance
access to the RTU database, configuration and functional operation. The maintenance
access shall be used by employer to define the structure of the RTU configuration and to
maintain the operation of the RTU.
Employer intends to be self-reliant for both RTU hardware and software
maintenance. To this end, the Contractor shall provide the support hardware, software and
documentation necessary to maintain repair, configure and document the configuration of
the RTU. The support facilities shall include but not be limited to spare parts, portable
RTU configuration and maintenance terminals, maintenance manuals, and any other
support facilities as they are applicable to the Contractors RTU design.
4.8.1 Spare parts :
The contractor shall provide spare parts for the RTUs purchased.
following essential mandatory spare parts is to be provided by the bidder.
S.
No.
1.
2.
3.
4.
5.
6
7
8
9.
10
Item
Power supply unit for the RTU
CPU for the RTUs
Analog input card
Digital Input card
Modem set (including power supply unit)
separate quantity for RTU & master end
Signal conditioning module if required
Communication interface module for RTU
(if required)
Communication interface module for
communication with Multi Function Meter
(MFM)
Multi Function Meter (MFM)
OLTC ( on line tap changer ) transducer
Qty. for each

location
2
2
2
2
1
1 sets of
Total
Qty.
2
2
2
2
1
2
2
2
2
4
1
4
1
The bidder shall submit in the technical bid a list of recommended spare parts
along with the quantities that the bidder deems necessary to achieve the specified system
384
RTU

availability for a period of 5 years. A list of recommended spare parts shall be submitted to
the Employer.
On review of the submitted list, employers will categorize the items on the list as
either mandatory spare parts or optional spare parts. The mandatory spare parts will be
included where as the optional spare parts will not be included, as part of proposal
evaluation. The Employer shall have the option of placing an order for any of the optional
parts for the respective system at the price quoted in the price bid up to six months after the
system is taken over by the employer.
The contractor shall hand over all the required spare parts after completion of the
system availability tests. Any other spare parts needed to support availability testing shall
be arranged by the contractor to be on hand in advance. If necessary, the required spare
parts may be used to maintain the system during its availability tests. Such parts, however,
shall be replenished within a month.
Prior to handling over, all spare parts shall be installed and tested at the employer
sites, wherever possible.
4.8.2 Maintenance Support hardware :
The contractor shall provide one set of maintenance support hardware to repair and
maintain the RTUs. The minimum support hardware to be provided shall include at least
one of each of the following for each master station card extenders with test points for each
connector pin, Field simulator device, test cables to connect any test equipment, and any
other RTU test equipment as applicable to the Contractors RTU design.
4.8.3
Portable RTU Configuration & Maintenance Terminals :
Portable configuration and maintenance terminals shall be provided by the

Contractor along with all software and hardware needed to interface to the RTU and
provide the configuration capabilities. The Contractor shall also provide all database and
software interfaces (RTU diagnostics, database compiler, PROM programmer, software
listings, RTU configuration listings, etc.) required for employer to maintain and configure
the RTUs. The local RTU interface defined in Section 4.1.3 shall be used for the
configuration and maintenance terminal.
One portable RTU configuration and
maintenance terminal with protective covering case and suitable sets of chargeable batteries
together with battery charger per set shall be provided .
The RTU configuration and maintenance terminal shall have diagnostics for the
RTUs processor(s), memory, I/O ports and any other functional areas of the RTU. The
configuration and maintenance terminal shall also provide display and setting of memory
table contents and provide debugging tools for the RTU software.
The portable RTU configuration and maintenance terminals shall also be used to
monitor and test RTUs operation and communication interfaces. The configuration and
maintenance terminals shall be capable of emulating both the master station and the RTU.
The configuration and maintenance terminals shall have the capability of interfacing to
either the analog or digital side of the modem.
385
RTU
The configuration and maintenance terminal shall be capable of receiving single

and repeated messages using the supplied RTU communication protocol. Each received
message shall be checked for validity, including the check code. The configuration and
maintenance terminals shall maintain and display error counters so that the number of
errors during a period of unattended testing can be accurately determined. The
configuration and maintenance terminals shall be capable of formatting and transmitting,
both as one-time and periodic transmissions, any master station-to-RTU command. It shall
also be possible to operate illegal messages, such as messages having invalid check codes,
for transmission. After the configuration and maintenance terminal has received for
transmitted a message, it shall be possible to immediately turn around and transmit or
receive a response message.
The configuration and maintenance terminals shall also be capable of passively
monitoring all communication traffic on a channel without interfering with channel
operation. Channel traffic captured in the active or passive modes of configuration and
maintenance terminals operation shall be displayed. All fields of a message shall be
displayed. A pass / fail indication for the security check code shall be included with each
code displayed.
The supplier shall provide a service over the lifetime of this contract, follow-oncontracts, and the life of the RTU that enables the Purchaser to upgrade the firmware in the
RTUs and test set.
If and when an RTU firmware change is required, as a result of correcting
problems, the Supplier shall provide at no charge, a master PROM IC and a working
PROM IC of the new firmware revision or alternately the supplier may also provide the
configuration file loadable into the RTU firmware, configuration & maintenance terminal.
The Supplier shall also provide a written description of the change(s) and shall recommend
if the change must be implemented immediately or can be scheduled during routine
maintenance.
4.9 Consumables:
The contractor shall supply, at its own expense, all consumables required for use
during all phases of the project through completion of the system availability tests. A
complete itemized list of proposed consumables, including quantities shall be submitted
with the technical proposals.
All consumable shall be readily available off the shelf with a storage life i.e.
virtually unlimited.
4.10
Power Supply :
The RTU will be powered from the employer station battery power system; either
by battery, battery charger or a battery / battery charger in parallel. The RTU shall accept
power from the DC system with the following characteristics:
386
RTU

a)
Nominal voltage of 48 V DC with operation between 38 and 58 V DC. The

voltage may vary during normal operation between these limits with
duration not less than 1 ms.
b)
Maximum AC component of frequency equal to or greater than 100 Hz and

0.012 times the rated voltage peak-to peak.
c)
Reversed polarity protection.
The contractor shall supply any hardware required to convert RTU input voltage to
the required internal voltages for the RTU hardware. The RTUs shall operate with
grounded input power from employer. The RTU shall not place a ground on the input
power.
Each RTU shall have the capability of automatic startup and initialization following
restoration of power after an outage without need of master station intervention. All
restarts shall be reported to the connected master stations.
Secondary power shall be provided to the RTU at 230V AC, 50 Hz, single-phase
for non-critical auxiliary equipment including heaters, internal lighting and internal
maintenance outlets.
4.10.1
Power Supply Protection :
Over voltage and under voltage protection shall be provided within the power
supply to prevent the RTU internal logic from being damaged as a result of a component
failure in the power supply and to prevent the RTU internal logic from becoming unstable
and causing misoperations as a result of voltage fluctuations.
4.10.2 Power Supply Failure Indicators :
The RTU shall have a status point which shall be set if the power to the RTUs has
been cycled (off-on) for any reason (including maintenance). The master station shall reset
the power fail status point. This point is not included in the RTU point count in Appendix
A.
4.11
Interface Cabinets :
4.11.1 The contractor shall provide interface cabinets between the RTU and the employer
field equipment. The interface cabinet shall house all Multi Function Meters, transducers,
interposing control relays and interface terminal blocks. Generally the interface cabinet
shall be mounted adjacent to the RTU cabinet. However, in a few cases, the interface
cabinet may be mounted separately at different places. All RTU signals shall be connected
to the transducers, Multi Function Meter, interposing relays and field signals in the
interface cabinet.
The interface cabinet shall house various pieces of equipment that are needed to
interface to the RTU. It shall be of modular type. The equipment shall be rail/wall
mounted or plug in type. The connections shall be on the front end for incoming or
outgoing circuits and on the rear end for internal connections between different
subassemblies of the interface cabinet.
387
RTU

Prewired and standardized solutions for cabling shall be used. This shall enable a
few standardized designs for the interface cabinet to be developed all of which shall have
identical provision for various types of plug-in boards / modules (e.g. position indication;
MW and MVAR measuring signals).
The interfacing components for each typical bay shall comprise typical modules and
subassemblies logically sorted by type of interface. For example, interface components
associated to a double bus bar type feeder shall consist of a module for the circuit breaker
position indication, a module for the associated bus bar isolators position indication, a
module associated to power measurements and a module associated to position control.
Each module or subassembly shall be provided with all testing (switching, disconnecting
and inserting) facilities allowing easy maintenance.
Wireways not more than 50% full for the maximum RTU configuration shall be
provided to route the necessary conductors from the Purchasers choice of top or bottom
access to the I/O terminations. For wireway sizing purposes, the RTU Supplier shall
assume that each point uses an independent cable. Analog and digital inputs shall be
shielded.
RTU hardware may be mounted in the interface cabinet, provided that all future
expansion needs as per specifications are being met.
4.12
Enclosures :
The Contractor shall provide enclosures for the RTU and interface cabinets meeting
the following requirements:
(a)
The enclosures shall be finished inside and out. All cabinet metal shall be
thoroughly cleaned and sanded and welds chipped to obtain a clean, smooth finish.
All surfaces shall be treated to resist rust and to form a bond between the metal and
the paint. RTU enclosures shall be finished a semi-gloss smoke gray color.
(b)
The enclosures shall be free standing, floor mounted and shall not exceed 220 cm in
height.
(c)
The enclosure shall be built up as a 48.26 cm (19-inch) rack-mounted system with

hinged units provided as necessary.
(d)
Maintenance access to the hardware and wiring shall be through lockable, full
height, frond doors.
(e)
Provisions for top and bottom cable entry shall be provided with wiring gaskets and
stuffing glands on cabinet mounting plates.
(f)
Signal and safety ground networks within the enclosure shall be provided. The
safety ground shall be insolated from the signal ground and shall be connected by
the Contractor to the ground network and to the ground wire of the ac power input.
388
RTU

The signal ground shall terminate at a separate stud connection sized for a lugged
16 mm2 ground wire. Each ground network shall be a copper bus bar, braid or cable.
Use of the enclosure frame, skins or chassis mounting hardware for the ground
network is not acceptable.
(g)
All enclosures shall be supplied with 230 V AC, 50 Hz, single-phase convenience
out-lets compliant with local Indian standards.
(h)
All enclosures shall be provided with an internal maintenance lamp, gaskets and
eyelets for bundling and routing internal wearing.
(i)
All enclosures shall be indoor, dust-proof with rodent protection, and meet ISOIP41 class specifications.
(j)
Wherever operating voltages within the enclosures exceed 50 Volts the equipment
shall be covered or shielded from accidental contact and shall be labeled
accordingly.
(k)
There shall be no sharp corners or edges. All edges shall be rounded to prevent
injury.
(l)
Material specified in the design of the enclosures shall be fire resistant and
approved by the Purchaser as consistent with safety codes.
(m)
Document Holder shall be provided inside the cabinet so as to keep test report,
drawing, maintenance register etc.
4.13
Equipment Packaging :
All materials shall be new and of the best commercial grade used in the
manufacture of all RTU equipment. All electronic components shall be solid-state. All
wire and cable connection and terminators shall be permanently labeled for identification.
All connection points for external cables and wires shall be easily accessible for connection
/ disconnection and shall be permanently labeled. All components and equipment shall be
of current production from component manufacturers. To facilitate expansion and
maintenance, modularity shall be employed through out the hardware equipment. All
wiring shall be neatly laced or clamped. Materials that are susceptible to corrosion shall not
be used.
Each RTU chassis backplane shall be prewired to accept the ultimate capacity of
plug in I/O modules (180% as per Clause 4.21). The hardware shall be sufficiently sturdy
to withstand placement and start-up without damage.
4.14
Interconnections :
All cabling between component units of the RTU, RTU to interface cabinet, and to
the employer control and relay panels (located in the sub-station control house) shall be
supplied and installed by the Contractor and shall be shown on Contractor supplied
389
RTU

drawings. Plug-type connectors with captive fasteners or compression type connectors
shall be used for all internal interconnections. The connectors shall be polarized to prevent
improper assembly. Each end of interconnection cables shall be identified by a marker
which includes the cable number and the identifying number and location of each of the
cables terminations; this information shall match with the Contractors drawings.
Contractor wiring within enclosures shall be neatly arranged and shall not be
directly fastened to the enclosures frame. All internal interconnection wiring and cables
shall be routed separately from field wiring to the RTU terminals. All wiring shall use
copper conductors and shave flame retardant insulation. Conductors in multi-conductor
cables shall be individually color coded.
The use of nonflammable, self-extinguishing, plastic wire troughs is permissible.
Metal clamps must have insulating inserts between the clamps and the wiring. Wiring
between stationary and movable components such as wiring across door hinges or to
components mounted on extension slides, shall allow for full movement of the component
without binding or chafing of the wiring.
The Contractor shall supply all signal / control wiring between the interface cabinet
and Employers control and relay panels. Adequate space and hardware shall be provided
for routing of the field wiring within the enclosures. The Contractor shall describe the
recommended shielding for such cable connections to provide satisfactory protection of the
I/O points from noise and electromagnetic interface.
4.15 WIRING TECHNICS:The following techniques, materials and practices shall be used in the internal wiring of the
RTUs.
(a)
Terminations :
All connections for interconnecting wiring integral to the Suppliers equipment
shall be of a durable and reliable type.
(b)
Signal Separation :
All wires that carry low-level signals shall be adequately protected and separated as
far as possible from power wiring.
(c)
Pin and Socket Identification :

Each pin and its associated socket connection shall be clearly identified by a coding
scheme that is uniform within each system.
(d)
Connector Alignment Features :

Plugs and receptacles shall have keys, aligning pins, or other devices to indicate and
ensure proper insertion of connectors.
(e)
Mating to Adjacent Connectors :

Plugs and matching receptacles shall be physically positioned or constructed to
preclude improper mating with adjacent plugs or connectors.
390
RTU

(f)
Plug and Receptacle Accessibility :

All plugs and receptacle shall be mounted and positioned for ease of replacement or
repair.
(g)
Cable Harnesses :
Wherever possible, wires shall be bundled into harnesses formed by plastic or nylon
cable ties.
(h)
Cable Routing :
Cables shall be routed so that wires or insulation can not be over-flexed, pinched or
damaged by doors, drawers, disassembly, or by other operations required for
installation, testing and maintenance.
(i)
Cable Accessibility :
Cables and wiring shall be easily accessible by maintenance personnel and shall be
installed in conspicuous location.
(j)
Cable Bending :
Cables shall connect or disconnect easily without bending or crimping.
(k)
Cable Mounting :
Cables or wiring shall be mounted on stationary panels where practical, stress
points shall not occur on connectors. Cable glands shall be provided wherever
required.
(l)
Cable Protection :
Grommets or other protective devices shall be used to protect cables or wires that
are routed through panel holes or over sharp-edged surfaces.
(m)
Card Edge Connectors :

All printed circuit card edge connectors shall have gold plated contact surfaces and
shall have positive contact wiping action.
4.16
Terminal Blocks :
Terminal Blocks shall be screw-type/ stud type/ cage clamp type/ self stripping
type/ spring type with full depth insulating barriers made from molded self-extinguishing
material. Rust proofing of metallic components shall be provided by means of the metal
used or a suitable coating. Terminal blocks shall be appropriately sized and rated for the
electrical capacity of the circuit and wire used.
The surface for the wires shall be flat with only slight ridges for maintaining the
integrity of the connection. The mechanical design shall be such that the wires maintain a
tight connection to the terminals. All terminals and blocks shall be clearly labeled.
No more than two wires shall be connected to any terminal. The Contractor shall
provide two input terminals and a shield termination for each analog input signal. Contact
391
RTU

input and output signals shall require two terminals per point plus a shied termination for
each group of signals.
Test Terminal block shall be grouped according to the circuit functions & each
terminal block group shall have atleast 20 % spare terminal for accommodating additional
wires if requires.
4.17
Assembly and Components Identification :
Each assembly (to the level of printed circuit cards) shall be clearly marked with the
manufacturers part number, serial number and the revision level of the component.
Changes to assemblies shall be indicated by an unambiguous change to the marked revision
level.
All electronic parts (such as capacitors, resistors and integrated circuits) shall be
marked either with the characteristics of the part or with an industry standard part number.
Where custom parts are provided (such as read-only memories), the part shall be marked
such as to specifically identify the part when similar parts may exist.
All printed circuit card cages and all slots within the cages shall be clearly labeled.
Printed-circuit cards shall be keyed for proper insertion. It is desirable that printed cards be
keyed to prevent insertion into incorrect locations.
4.17.1 Assembly of Equipment :
The following requirements shall be met :
(a)
Component Mounting :
Mounting of components shall be on plug-in printed circuit cards of epoxy
glass or equivalent quality. Cards and their associated slots shall be plainly
identified so that they can be readily associated with information on
drawings and in Supplier furnished manuals.
(b)
Plug-In Assemblies :
Plug-in assemblies and subassemblies shall be employed wherever possible,
using as few mounting screws as possible consistent with stress and
vibration requirements.
(c)
Guide Pins :
Guide pins or other devices shall be provided for alignment of subunits
during connecting and disconnecting so that pin and socket connectors are
protected.
(d)
Sub-unit Replacement :
Replacement of one modular sub-unit shall not require removal of other
modular sub-units.
392
RTU

(e)
Mounting Hardware :
Fasteners for modular sub-units shall require no specialized tools, mounting
Hardware shall be interchangeable, suing as few sizes as practical.
(f)
Limit Stops :
Positive limit stops with manual unlatching shall be used on all swing-out
and roll out racks and drawers.
(g)
Grounding :
Each cabinet provided under these Specifications shall be grounded.
(h)
Equipment Assembly :
Equipment shall be assembled to allow for easy access without disassembly
of components contained within enclosures; slide-out or hinged mountings
shall be employed where enclosures would otherwise prevent access to
equipment. Equipment shall be mounted so as to provide easy access to test
points, fuses, switches, and all items requiring replacement, adjacent or
calibrations.
(i)
Wireways :
Wireways and I/O cabling shall not interface with removal, repair or
adjacent or RTU power supplies, circuit cards and terminations.
4.17.2
Equipment Components:
Components shall be selected which have quality levels that conform to standard
engineering and industry requirements for comparable equipment. Solid state and other
electronic components shall be applied within their specified operating ranges. No
components which have been selected for special characteristics from a group of the
Suppliers standard product shall be used unless specifically authorized by the Purchaser. If
such components are authorized, detailed selection procedures, along with a list of specific
test equipment which is needed for the selection, shall be provided in the equipment
manual.
No single source components shall be supplied unless specific written permission is
given by the Purchaser.
4.17.2.1
Integrated Circuits :
Integrated circuits shall operate within normal temperature range characteristics.

4.17.2.2 Discrete Components :
All discrete components, including semiconductors, resistors, capacitors, fuses and
lamps, shall be selected in accordance with standard commercial and industrial quality
assurance methods.
393
RTU
4.17.2.3 Circuit Breakers :

All circuit protection breakers shall be of the manually operated, moulded-case type
and shall provide thermal over-current and instantaneous short-circuit protection in each
pole. All circuit breakers for 48V DC circuits or less shall be rated at not less than 125 V
DC. 240-V AC circuit breakers shall be rated at not less than 480-VAC.
4.18 Noise Level :
The audible noise generated by the RTU equipment shall not exceed 50 dbA one
meter from the enclosure.
4.19
Environment Requirements :
The RTUs will be installed in control buildings without temperature of humidity

control. The RTUs shall be capable of operating in ambient temperature from 5 to + 55 C
and relative humidity from 5 to 95%, non-condensing with rate of temperature change of
20 C/hour.
4.20
Availability :
The RTUs will perform data acquisition and control of important equipment
necessary for the operation of Employers power system. Any failure of RTU to perform
its functions will adversely affect power system operations. An availability of 99.9% is
required exclusive of communication channel availability. The RTU shall be considered
unavailable when:
(a)
(b)
(c)
(d)
(e)
4.21
Any function is lost for all points of a single type.

One entire data scan group fails
More than one input card or output card of the same type fails
One input card or output card of each type fails
Failure of any modem
RTU Size and Expandability :
RTUs associated transducers, Multi Function Meters and support equipment will be
procured with this Specification as defined and equipped as provided in Appendix A, .
Twenty percent (20%) of each RTU point type shall be provided in the RTU as wired
available reserve capacity which can be used with no further hardware additions including
circuit board terminals and terminal blocks.
The RTU delivered shall have the capability to add additional point modules to
expand the overall point count of the RTU by a minimum of fifty percent (50%) i.e. 180%
of the actual RTU count. Expansion shall be accomplished in the field by employer by
only adding additional distributed input / output modules within the main unit.
394
RTU

4.22
Maintainability :
The RTU design shall facilitate isolation and correction of all failures. The
following features which promote rapid problem isolation and replacement of failed
components shall be provided:
(a)
(b)
(c)
4.23
Self-diagnostic capabilities within each RTU which can be initiated at the

RTU site.
On-line error detection capabilities within the RTU and detailed reporting to
the connected stations of detected errors.
Local indication of major RTU failures.
Life Span :
Each RTU shall have a design life of 15 years from the date of final acceptance.
The Contractor shall make available at no cost to employer the manufacturing drawings
and rights to manufacture those subassemblies which the manufacturer will not support or
discontinues support for during this life span including subassemblies not included in the
original RTU procurement. For each subassembly, the specific parts supplied shall be
identified and referenced in supplied documentation.
5.0
TRANSDUCER/
The contractor shall provide the Multi Function Meters, transducers and cabling as
specified in the following section.
5.1
Transducers
5.1.1 Transducers :
The Contractor shall supply transducer for the analog points to monitor MW
,MVAR of all feeders ,Transformers ,transfer buscoupler, bus tie and All Bus Voltages,
Frequencies of respective substion. The Transducer shall include Transformer Tap Position
indicator. The transducers procured with this Specification will be installed in the RTU
for each sub-station by the Contractor.
The transducers shall use state-of-the art solid-state technology. The transducers
shall comply with the latest standards including the IEC 688.
5.1.1.1 Sockets :
The transducers shall be either modular surface mounted or plug-in printed circuit
board type. Plug in transducer units shall include a safety socket keyed to prevent plugging
in the wrong transducers and shall be easily removable and replaceable. The transducers
using current sources shall be shorted, not allowing an open circuit, when removed.
All transducers shall be mounted on 48.26 cm (19-inch) panels or the walls of the
interface cabinet. Plug-in transducers shall be in their own rack.
395
RTU

5.1.1.2 Socket Terminal Blocks :
Electrical socket connections shall be screw-type/stud type/ cage clamp type/ self
stripping type/ spring type terminals with indirect wire pressure. The terminals shall accept
upto 2.5 mm2 or one 4 mm2 wires.
(a)
Top Row :
Measured voltage (or other non-current quantity) inputs, auxiliary supply
voltage, and output current loop.
(b)
Bottom Row :
Measured current inputs and neutral.
5.1.1.3 Transducer Identification :

Each transducer shall have an externally visible label that complies with the IEC
688 standards.
5.1.1.4 Transducers Auxiliary Power Supply :
Transducers shall use a 48 V DC auxiliary power supply as specific in Section 4.10.
The transducers shall have a maximum power consumption of three watts.
5.1.1.5
Transducer Protection:
All input, output and auxiliary circuits shall be isolated from each other and earth
ground. The transducer output shall be ungrounded with short circuit and open circuit
protection. The transducers shall be tested with the following requirements without damage
to the transducer.
(a)
Voltage :
Voltage test and other safety requirement compliance as specified in IEC 688 and
IEC 414.
(b)
Impulse Withstand :
IEC 688 compliance is required.
(c)
Electromagnetic Compatibility :
IEC 688 and IEC 801-3, level 1 compliance is required.
(d)
Permanent Overload Protection:

396
RTU

(e)
Temporary Overload Protection :

(f)
High Frequency Disturbance :

5.1.1.6 Other Characteristics:

The transducers shall comply with the following general characteristics:
(a)
Shock Resistance:
Minimum severity 50 A, IEC 68-2-27 requirements
(b)
Vibration Strength:
Minimum severity 55/05, IEC 68-2-6 requirements.
(d)
Reference Conditions For accuracy Class :

(e)
Temperature Rise :
5.1.1.7 Transformer Tap Position Transducer:

The existing transformer tap position indications shall be normally of Variable resistance
type.
The conductor shall provide suitable resistance tap position transducers which shall
have the following characteristics:
(a)
(b)
5.2
The input measuring ranges shall be from 0 to 1000 ohms per step, which is tunable
at site with at least 16 steps.
Dual output signal of 4 to 20 mA DC, 0.5% accuracy class as per IEC 688 shall be
provided. One output will be used for driving a local digital indicator (to be
provided by the contractor) and the other will be used for interfacing with the RTU.
These Transducers shall be mounted on OLTC panel with local digital indicator.
Contact Multiplying Relays (CMRS)
The description of Contact Multiplying Relays as under is substituted in place of

hardware requirement at SLDC & Sub LDC:
397
RTU
(i) Contact Multiplying Relays (CMRs) are required to multiply the contacts of breaker and
isolators etc. The contacts of these relays shall be used to provide status inputs to the
RTUs.
(ii) The relays shall be DC operated, self reset type. The rated voltage for relay operation
shall be 220V DC / 110V DC depending on the station DC supply.
(iii)The relay shall operate for a voltage range of 80% to 120% for 220V/110V DC rated
voltage.
(iv)The relay shall have a minimum of two change over contacts, out of which one shall be
used for telemetry purposes.
(v) The relay shall conform to following requirement.
Power Frequency withstand voltage of 2kV for 1 minute as per IEC 255-5.
Insulation Resistance of 100M ohms for a voltage equal to 500V DC.
(vi) The relays must be protected against the effects of humidity, corrosion & provide with
a dust tight cover. The connecting terminals shall be screw type & legibly marked. The
relays shall have a visual operation indicator. The relays are to be mounted in existing
Control & Relay (C&R) panels and therefore shall be equipped with suitable mounting
arrangements.
6.0
Software requirement :
The software provided to support the functions of the RTUs shall meet the
characteristics described in this section. The term software is used throughout this
Specification to mean either software or software implemented in firmware.
6.1
Design Characteristics :
All software shall be implemented according to the Contractors established design

and coding standards. Employer reserves the right to reject any software that does not
conform to these standards. Complete and comprehensive documentation shall be provided
for all software.
At the time the RTU is accepted, all software delivered must be up to date and in
final form, including all standard software changes and field changes initiated by the
Contractor or the Contractors suppliers prior to acceptance. The software documentation
must reflect these changes.
6.2
Operating System :
The Contractor shall use a non-proprietary operating system capable of managing

the distributed applications of the RTU. If a proprietary system is offered then contractor
shall provide the corresponding source code. The operating system shall support multiMPPTCL/ TECH/ PROC/ 05/ MAY13
398
RTU

tasking and multi programming. The minimum real-time facilities to be provided shall
include process, job database and memory management, process, synchronizing, message
services for communication between jobs and device and interrupt handling.
6.3
Initialization / Restart Program
Software shall provide automatic restart of the RTU upon power restoration,
memory parity errors, hardware failures and upon manual request. The software shall
initialize the RTU and begin execution of the RTU functions without intervention by
master station. All restarts shall be reported to the connected master stations.
6.4
RTU Operations Monitoring:
Software shall be provided to continuously monitor operation of the RTU and

report RTU hardware errors to the connected master stations. The software shall check for
memory, processor and input / output errors and failures.
6.5
RTU Configuration Support :
The Contractor shall supply a database compiler which will enable to configure and
document each RTUs database.
A compiler shall be provided to completely generate or modify the database of the
RTUs. The database compiler shall provide error detection services and shall produce a
printed listing of the input data and the resulting RTU configuration. It shall be possible to
maintain the RTU database locally and from a master station.
6.6
Diagnostic Software :
The Contractor shall supply diagnostic software which monitors and individually
tests each of the components of the distributed RTU. The diagnostics shall provide
comprehensive user interaction and printout capabilities.
7.0
INSTALLATION REQUIREMENTS :
The contractor shall be responsible for the complete adaptation and installation of
the RTUs, interface cabinets, Multi Function Meters, transducers & relays in the employer
substations. This includes the following requirements:
a)
Preparation of all input and output signals to interface with the substation
power system equipment.
b)
Installation of all RTUs, Multi Function Meters transducers, interface

cabinets and associated equipment.
c)
Sizing of all cables and wiring to meet the specified requirements and meet
standards.
399
RTU
7.1
d)
Installation of all signal, communication and power cables required to

interface the RTUs, interface cabinets and transducers with Employers
substation facilities.
e)
Wiring and termination of all power, communication and signals in the

RTUs, in the interface cabinets, at the transducers and on the control and
relay panels in the control house.
f)
Proper sizing and installation of grounding to the RTUs and interface

cabinets.
RTU Interfaces :
The Contractor shall locate and install the RTUs in the employer substation control
houses. All cabling shall be run and wiring connected to the power source and
communication interface. Cables shall be run and connected to the interface cabinets for
the input and output signals & local interfaces.
The RTU cabinet shall be properly grounded to the substation grounding system
through the facilities specified in Section 4.12 (f).
7.2
Interface Cabinet:
The Contractor shall locate and install the interface cabinet in the employer
substation control house. All cabling shall be run and wiring connected to the Power
source, RTU and field devices.
The interface cabinet shall gather all signals from and to the field devices located in the
substation bays and on the control board in the substation control house. Exihibit 7.1
provides a summary of the functions to be performed within the interface cabinet including:
a)
Termination of all I/O signals between the interface cabinet and field
devices.
b)
Conditioning of signals through control output interposing relays, isolating

transducers and signal transducers.
c)
Housing all signal conditioning, decoupling and transducer& MFM

equipment.
d)
Grouping of signals by equipment bays for routing to the control and relay
panels by signal types for routing to the RTU I/O points.
e)
Termination of all I/O signals between the RTU and interface cabinet.
The interface cabinet shall be properly grounded to the substation grounding system
through the facilities specified in Section 4.12 (f).
400
RTU

Cabling between the RTU and the interface cabinet shall use shielded cables.
Cables to the field equipment shall use a separate cable for each bay. Cables to the field
equipment shall be armoured type with an inductive shield.
7.2.1 Interface Cabinet Signal Marshalling Requirements:

The marshalling of signals in the interface cabinet shall include:
a)
b)
c)
Routing of all I/O signals from each substation bay to a common location on
field interface terminal blocks in the interface cabinet.
Routing of all I/O signals from common termination points in the RTU
enclosure to a common location on RTU interface terminal blocks in the
interface cabinet.
Cross-connection of the above signals on a terminal block distribution
frame.
The arrangement of the interface terminal blocks shall include consideration for the
best location to pick up signals from the field devices and route them to the RTU. The
Contractor shall review the existing substation wiring and shall access the required signals
at the closest location (equipment bay, control board or other). Some of the substations
have the signals available on terminal blocks in anticipation of the addition of RTU to the
substation. These should be used where available.
8.0
INSPECTION AND TEST :
All material, hardware and software to be furnished and all work to be performed
under this Specification shall be subject to inspections and tests. No equipment shall be
shipped until all required inspections and tests have been made, demonstrating that the
equipment conforms to the Specification and that the hardware and software have been
approved for shipment by employer.
Approval of inspection and test results, acceptance of hardware and software or the
waiving of inspection and tests thereof, shall in no way relieve the Contractor of the
responsibility for furnishing equipment which meets the requirements of this Specification,
nor shall such actions invalidate any claim which employer may make because of defective
or unsatisfactory hardware and software, employer reserves the right to request additional
tests on the equipment at no extra charge on any work employer determines not to be in
accordance with this Specification.
Whenever the results of any inspections or tests performed or requested by
employer in accordance with the requirements of this section indicate that specific
hardware, software or documentation does not meet the specification requirements, the
Contractor shall replace, modify or add at no cost to employer, hardware, software, or
documentation as necessary to correct the noted deficiencies.
8.1
Inspection :
401
RTU
Representatives of employer shall have free entry into the shops of the
manufacturer at any time while design, fabrication or testing of the equipment is taking
place and into any mill, shop or factory where the hardware or software described in this
specification is being produced.
The Contractor shall provide to Employers representatives, free of cost, all
reasonable facilities, equipment and documentation necessary to satisfy Employers
representatives that the hardware is being fabricated in accordance with the Specification.
The inspection rights described above shall apply to the facilities of the Contractor or the
Contractors subcontractor where the hardware is being manufactured. The inspection
rights shall not apply to the facilities of subcontractors supplying unit components to the
manufacturer. Such items will be inspected and tested by Employers representatives at the
manufacturing site.
Inspections by employer will include visual examination of the physical appearance
of the hardware, cable dressings and equipment and cable labeling. Contractor
documentation will also be examined to verify that it adequately identifies and describes all
hardware, software and spare parts, employer shall have access to inspect the Contractors
and manufacturers quality assurance standards, procedures, and records which are
applicable to this project. Inspection shall not relieve the Contractor of the responsibility
for furnishing material and equipment conforming to the requirements of the Specification,
nor shall such inspection invalidate any claim which employer may make because of
defective or unsatisfactory hardware or software.
The Contractor shall keep the Purchaser informed in advance of the time of starting and
of the progress of manufacture of equipment in its various stages, so that arrangements
could be made for inspection.
No material shall be dispatched from the works of manufacturer unless the material
The acceptance of any quantity of the equipment shall in no way relieve the Contractor
of his responsibility for meeting all the requirements of this specification and shall not
8.2
Test Procedures :
The Contractor shall submit the test procedures for approval twelve weeks prior to
the start of factory tests. Fully approved test procedures shall be submitted to employer at
least four weeks prior to the documentation of the tests employer will only approve test
procedures if they are inclusive thoroughly testing each section of the equipment. The
Contractor shall use IEC standards as a guide in preparing the test procedures. The test
procedures shall include the following :
a) The test schedule, including provision for eight hours of unstructured tests to be
performed by employer.
402
RTU

b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
8.3
The purpose of each test

The function to be tested
The plans / procedures to be followed
Specific references to project documentation for correlation with the
procedures and for verification of the documentation.
The test setup, equipment and conditions for each part of the test
All test inputs and outputs
Test software descriptions and listings
A copy of any certified test data to be used in lieu of testing
Expected results
The acceptance criteria
A procedure for handling the variances that are identified during testing
Test Records :
The Contractor shall maintain a complete record of the results of all tests. This
record shall be keyed to the steps enumerated in the previously approved test procedures.
The record shall include the following items :
(a)
Reference to the appropriate section of the test procedure
(b)
Description of any special test conditions or special action taken
(c)
Test results, passed / failed
A copy of the test records shall be delivered to employer and cabling elements of
the RTU procurement shall be tested in two parts :
1)
Type Testing :
The Tenderer must give the Type test report of complete integrated units
shall be fully tested to assure full compliance with the functional and
technical requirements of the Specification. The testing report shall include
one of each of the device types (transducers, MFT, modems, relays etc.)
2)
Routine Testing :
Each complete RTU / interface cabinet unit shall undergo functional and
sample point testing.
All hardware and software shall successful pass testing before being accepted. In
the event the hardware is delivered in stages (more than one delivery date), employer shall
have the option to require complete testing on all hardware for each delivery. This
complete testing shall include both Type and Routine testing.
8.4.1
Type Testing :
Type testing certificate must be submitted to the employer. Contractor shall

commence commercial production of RTUs / SICs after showing type test report and
approval from Employer.
403
RTU

The Type Testing certificate shall include testing of complete RTU and interface
cabinet hardware, software and functionality (Clause 4), transducers, Multi Function
Meters and cables (Clause 5) and standard software (clause 6) to demonstrate full
compliance with all specified requirements, standards and functional capabilities including:
(a)
Inventory check and inspection for general construction, cabling,

connectors, drawing conformance and labeling.
(b)
Tests of proper functioning of all hardware and software by a thorough

exercising of all RTU functions both individually and collectively.
(c)
Test operation of all RTU analog inputs including using convenient test
panels, which allow each input to be varied over its entire range.
(d)
Test operation of all RTU digital input points.
(e)
Test operation of all RTU control outputs.
(f)
Test SOE and RTU time synchronization and accuracy with multiple master
stations.
(g)
Test power supply voltage margins, ripple levels and short circuit
protection.
(h)
Tests analog accuracy, temperature coefficient, noise rejection and overvoltage protection on 10% of all analog points.
(i)
Test of RTU power failure and recovery
(a)
Test the operation and accuracy of all transducer devices
(b)
Test the operation and accuracy of Multi Function Meter devices
(k)
Test overload protection, impulse withstand capability and protection from

electromagnetic fields as specified for all RTU and interface cabinet wiring
termination types, including transducers, RTU I/O points, communication
channels, input power and field interface terminal blocks.
(l)
Tests of communications, including all communications ports, modems,

local interfaces and communications with multiple master stations.
(m)
Test of equipment spares through substitution
(n)
Verify completeness and accuracy of hardware and software documentation.
(o)
Test the operation of all functions of the configuration and maintenance

terminal with the RTU including verification of the communication protocol
capabilities and modification of the database, point configuration, point
404
RTU

additions and point deletions. Test operation of all diagnostic software and
confirm issuance of meaningful messages for all type of error condition.
(p)
Test under full-power, simulated environmental conditions and operation for

48 hours. Twelve hours of this test shall be at the specified high temperature
limit. The RTU shall demonstrate continuous operation without any failures.
This operation shall include periodic scanning of all points and
demonstration that all RTU functions operate properly.
RTU shall successfully pass the following tests in which all functionally is
demonstrated using a test set. The following functional tests shall demonstrate the
capabilities and features of RTU and RTU test set :
(q)
Verification of RTU Test Set capabilities
(r)
Verification of Field Device Simulator capabilities
(s)
Verification of Maintenance RTU configuration and capabilities
(t)
A test verifying that the RTU is capable of the ultimate point count
specified.
(u)
One RTU shall be temperature tested over the RTU defined temperature
range.
(v)
A configuration test where by additional I/O cards will be added and

verified that they work.
(w)
A test to show changing of the protocol prom ICs, inserting an alternate

protocol and that the RTU functions per the alternate protocol.
(x)
IEEE Surge Withstand Capability (SWC) tests shall be performed on all

field-wiring terminals of the RTU to be protected against surges with the
equipment energized and de-energized. This test shall neither cause
erroneous operations nor erroneous input date readings, any component
failures, nor shall any stored data values be modified. One complete SWC
test shall be performed. The Purchaser will select the RTU that shall be
tested.
(y)
Dielectric Test as per IEC-65.
(z)
Insulation Resistance Test as per IEC-255, 50 Hz Voltage withstand test for

60 seconds at 2 KV.
(aa)
One RTU shall be placed in a room having an ambient temperature of 55 C

with the RTU connected to a data channel and to equipment simulating
actual field equipment to be monitored or controlled. It shall remain
405
RTU

energized at this temperature for a minimum period of 48 hours. During this
48-hour burn-in period the RTU shall have its various modes of operation
exercised periodically. At the completion of the 48-hour period and with the
RTU shall energized and subjected to the ambient temperature of 55 C, the
functional tests described shall be performed at normal power supply
voltages. After completion of the burn-in at 55 C the RTU shall be
operated at normal ambient temperatures for an additional continuous period
of 240 hours. The functional tests shall be performed at least once in each
80-hour period to demonstrate that the RTU is functioning correctly. If any
failures occur, the failures shall be corrected, using modules that have been
burned-in as specified and the test restarted until 240 hours of continuous
operation is achieved.
If failures, occurring during functional testing, indicate that temperaturerelated design problems exist, the Purchaser shall have the right to insist on
complete temperature testing of the RTU type, even if the requirement has
been waived.
(bb)
Fast Transient Burst Test as per IEC-870-2-1 level-3.
(cc)
Damped Oscillatory Wave Test as per IEC-870-2-1 level 3-4.
(dd)
(ee)
Electrostatic Discharge test as per IEC-870-2-1 level-4

The RTUs and associated equipment installed in their enclosures, shall
operate without disruption in the presence of the following electromagnetic
fields :
(1)
Power Frequency Magnetic Field and Damped Oscillatory Magnetic

Field Test as per IEC-870-2-1 level-3.
(2)
Radiated Electromagnetic Field Test as per IEC-870-2-1 level-3.
(ff)
The supplier shall demonstrate all functions on the IEC-870-5-101 RTU

protocol at the latest revision level using the system and the RTU test set.
(gg)
Connection of high-voltage sources to input and output terminals may occur

during the life of the equipment. No damage shall occur to any input or
output due to continuous normal mode overload of upto 250 V DC or 250 V
DC peak at 50 Hz or due to imposition of upto 300 V DC or 300 V DC peak
at 50 Hz, between any terminal and ground. Recovery from either type of
overload to nominal accuracy shall require less than 5 minutes. The effect
on analog accuracy of either type of overload on any adjacent analog
channel shall be less than 0.1% of full scale.
Overloads greater than specified above, but less than 600 V DC or 600 V
DC peak at 50 Hz, may damage some components but shall not result in
406
RTU

propagation of any damage beyond the single input, output or
communications circuit at which the overload has occurred.
8.4.1.1
Type Testing of other Components :
The contractor shall submit type test certificate and published specifications of
the transducers, Multi Function Meters, Modems and interposing relays for review and
approval by MPPTCL. In the event, the type test reports for Multi Function Meters
transducers, modems, interposing relays etc. are not meeting the requirements as per
RTU specification, the Employer may ask for the type testing of any or all of the above at
no additional cost.
8.4.2
Routine Testing :
The Routine Testing shall include testing of employer selected RTU hardware,
interface cabinet hardware, Multi Function Meters and transducer to demonstrate
compliance with specified requirements, standards and functional capabilities including:
(a)
Inventory check and inspection for general construction, cabling, connections,

drawing conformance and labeling.
(b)
Tests of proper functioning of hardware and software by a thorough exercising of

all RTU functions, both individually and collectively.
(c)
Test operation and accuracy of all RTU analogue inputs including using convenient
test panels, which allow each input to be varied over its entire range.
(d)
Test operation of all RTU control outputs.
(e)
Test SOE and RTU time synchronization and accuracy.
(f)
Test power supply voltage margins, ripple levels and short-circuit protection.
(g)
Test of RTU power failure and recovery.
(h)
Test the operation and accuracy of all transducer devices.
(i)
Tests of communications, including all communications ports, modems and local

interfaces.
(j)
Test of equipment spares through substitution.
(k)
Test operation of all RTU digital input output points
(l)
Verify completeness and accuracy of hardware and software documentation.
(m)
Test the operation of the configuration and maintenance terminal with the RTU.
407
RTU

For any variations in the configuration, hardware components used or variations
from the Type accepted equipment, Employer has the right to perform any of the
Type Testing before successful completion of the Routine Testing.
8.4.3
Field Performance Tests :
The Contractor shall be responsible for providing field installation and testing. All
hardware will be installed, aligned and adjusted, interfaces to all employer field inputs and
outputs established, operation, verified and all test readings recorded. Upon completion, a
field performance test shall be performed to exercise all functions of the RTUs and
duplicate selected factory acceptance tests to the extent possible. This testing will include,
but not be limited to the following test :
a)
b)
c)
d)
e)
f)
RTU initialization
Proper functioning of hardware and software by exercising of selected RTU
functions using the master plan
Proper RTU communications interface.
Test operation of all diagnostic software and confirm issuance of
meaningful messages for all types of error conditions.
Test time synchronization and accuracy of the RTU from the master plan.
RTU database verification including point-to-point operation and scaling
accuracy using the master station.
The test procedures shall be submitted at least 12 weeks prior to installation of

RTUs.
9.0
TRAINING AND SUPPORT SERVICES :
The Contractor shall provide training and support services to create Employers inhouse maintenance and support capabilities for the hardware and software. The training
program shall be comprehensive and provide for interdisciplinary training hardware and
software. The required training of Employers personnel shall be conducted by the
Contractor in English.
9.1
FREE RTU Maintenance Training :
The Contractor shall provide RTU hardware, software and operation maintenance
training. The courses shall familiarize Employers course participants with RTU
installation, card/circuit board level troubleshooting and repair procedures, and the
recommended preventive maintenance procedures for the RTU equipment. Courses shall
include use of the RTU configuration and maintenance terminal and shall demonstrate all
facets of its operation. Courses shall also include hands-on trouble-shooting experience
with the RTUs supplied by the Contractor and shall cover any special equipment required
for maintenance. Actual RTUs to be supplied under this procurement shall be used for
training.
The Contractor shall also provide RTU software training in the following areas:
408
RTU

a) RTU configuration, modification and expansion
b) RTU database generation and maintenance
c) RTU software and operation including data flow.
9.1.1
Attendance :
RTU maintenance training course participants details shall be furnished to the

purchaser .
9.1.2 Training Schedule :
The training schedule shall coincide with the delivery of the RTUs to employer.
Training shall be provided in at least three different sessions to accommodate personnel
attendance. The training course shall be an optimum mix of classroom and laboratory
training.
9.1.3
Training course Requirement :
Employers Training course requirement are described below in terms of the

contents of each course to be provided. Training shall be provided on MPPTCL Data base
for the application of soft ware course, the dispatchers training course and the associate
training course.
9.1.3.1. Data base and Display building course :
The Data base and display building course shall be first course to be given in the
overall training sequence, it shall be a hands-on course using the development systems
(DS). The course shall be given immediately following delivery and installation of the DS.
The course shall be designed to train employer personnel in how to use the DS to
development the data bases, displays, reports for each SC & C computer system.
Course objectives shall include :a.
b.
c.
d.
e.
f.
g.
h.
How to set up a display development system.

How to identify data base fields , entries, records , table and contents.
How to structure RTU table defination.
How to build table , arrays and reports formats.
How to build displays.
How to perform data base maintenance.
How to generate data base from source information.
How to maintain symbol libraries, display colour group and display string
lists.
On course completion, all participants shall be able to prepare the necessary in put
data to define the system operating environment, build the system data base and displays,
and prepare the data base administrator to maintain and modify the data base and its
structures.
409
RTU

9.1.4
RTU Course :
The contractor shall provide an RTU course that covers the following subjects as a
minimum:
a.
Theory of operation of all RTUs function.
b.
c.
Operational procedures for various mode of operation, including diagnostic

tests and interpretation of the associated tests results.
Implementing and maintaining multiple communication course.
d.
Converting an RTU from one protocol to a different protocol.
e.
Demonstration of complete RTU tests set use, including tests sets

connection and set up for all possible modes of operation, all operational
procedures, the exercise of each command or feature associates with each
mode of operation the interpretation of results , and how to use the tests set
to diagnose and isolate RTU problems.
f.
Disconnection and replacement of all RTU equipment, including all

modules within the RTU.
g.
Diagnosing and isolating problems in contractor provided hard ware

associated with RTUs example transducers , multifunction meters and
marshalling cabinet wiring.
9.1.5 Training Location and Classrooms :

The RTU maintenance courses shall be given at the Contractors facility in India, or
optionally at Employers facility. The Contractor shall provide training to minimum 16
Participants in two batches.
9.2
Manuals, Equipment and Audio / Video Recordings :
Training manuals shall be prepared by the Contractor and submitted to employer at

least 30 days prior to the start of any course. It is desirable that the manuals used for
training be prepared for use at training aids. The use of maintenance or reference manuals
as the only training manuals is unsatisfactory, although their use as supplementary material
is encouraged.
Each course participant shall receive an individual copy of the training manuals and
other pertinent material. One additional master copy of all training manuals and materials
shall be provided to employer at the time of training. The master copy shall be suitable for
reproduction by employer. Upon completion of each course, training manuals shall become
the property of employer. The contractor shall also provide softcopy of the study material.
The Contractor may utilize prerecorded lectures as supplemental training material.
These lectures shall not use serve as a replacement for the classroom instructor or as a
primary training material. A copy of any course material on audio or video tape shall be
410
RTU

provided by the Contractor to employer for retention, playback and reference
documentation.
The Contractor shall provide all special tools, equipment, training aids, and any
other material required to train Employers participants effectively. The number of special
tools and other training equipment shall be adequate for the number of participants
attending the course.
9.3
Continuing Support Services:
All training courses shall be available to employer from the Contractor for a
minimum of ten years after RTU delivery. Subsequent to final acceptance, the Contractor
shall provide continuing technical support of the RTUs for a minimum ten-year period.
This requires that both consultation with knowledgeable Contractor technical personnel and
support by trained field service personnel be readily available to assist employer engineers
in correcting difficult RTU malfunctions.
10.0
DOCUMENTATION :
This Section describes the requirements for design approval and documentation.
10.1
Substation Design Document:
The supplier shall provide an engineer with substation design experience to work
with the Purchasers personnel to develop a Substation Design Document. This document
shall be completed before the Supplier orders any RTU materials. The Substation Design
Document shall include:
(a)
Wiring practices to be adhered to for all wiring (location, markings,

connection methods etc.)
(b)
Equipment installation method and order of installation identification of

each equipment as to where it should be placed.
(c)
A scaled drawing showing the location of CTs and PTs per substation and
expected wire runs to the transducer cabinets, Multi function Meters,
trenching methods and placement practice of wires.
(d)
A total installation program with approval as key milestones is completed.
(e)
Verify the wire types to purchase the quantity.
(f)
Verify the interposing relay configuration to be purchased.
The supplier shall provide the engineer for a length of time to complete this
evaluation to prepare the document and to obtain concurrence from the Purchaser.
411
RTU
10.2
Documentation Approval :
To ensure that all RTUs, interface cabinets and interconnecting wiring (cables) to
be supplied for each remote site conform to the specific provisions and general intent of the
Specification, the Contractor shall submit hardware and software documentation to
employer for review and approval. Employer will document their approval or submit
comments to the Contractor within thirty working days after receipt of the documents.
Corrected documents must be resubmitted by the Contractor to employer for approval as
soon as possible. Employer will review the resubmitted documents and record their
approval or submit additional comments to the Contractor within thirty working days after
receipt of the resubmitted document.
Documentation for the Contractors standard hardware and standard software shall
be furnished to employer for review and approval by employer only to determine that this
standard hardware and standard software is in full conformance with the Specification, that
it is consistent with other hardware and software being provided and that the
documentation is complete and correct in all respects. In cases where the Contractors
standard hardware or standard software does not conform to the requirements of this
Specification and modifications are required, the standard documentation along with
documentation of the modification shall be submitted for Employers approval.
Any purchasing, manufacturing, or programming implementation initiated prior to
Employers approval of the relevant documents of drawings shall be performed at the
Contractors risk. Employer shall have the right to request additional support documents,
and require the Contractor to make any necessary changes to construct the RTUs in
conformance with the provisions and intent of the Specification without additional cost to
employer. Review and approval by employer does not relieve the Contractor of the overall
responsibilities to satisfy Specification requirements.
10.3 Documentation :
The Contractor shall provide complete documentation for the equipment. The
following documentation requirements shall pertain to all documentation, including
documentation produced by subcontractors. All documentation is subject to review and
approval by employer, as described in clause 10.2.
10.3.1 Hardware Documentation:

The Contractor shall provide documentation for all hardware supplied to employer.
Documentation describing the circuitry, operation of the circuitry and troubleshooting and
maintenance procedures shall indicate the revision level of the hardware to which the
documentation applies. General manuals are not acceptable unless they clearly show what
is supplied and what is not supplied. This documentation shall satisfy the following
requirements :
(a)
An inventory of the hardware to be supplied, including the manufacturers
412
RTU

Name, model number, serial number and other pertinent data.
(b)
The physical planning/site-preparation documents, containing detailed mechanical

drawings of all cabinets and related hardware. Information shall be provided on
size and weight, detailed installation instructions and mounting details, clearance
requirements and environmental restrictions, as well as the electrical requirements
of the hardware.
(c)
The installation, wiring and cabling diagrams. Terminations for all connections
shall be clearly identified with adequate space for employer cable and wire
identifiers. Any special precautions associated with cabling shall be identified on
this drawing.
(d)
The internal wiring diagrams, oriented toward input and output wiring termination
points.
The drawing shall include:
1.
2.
3.
4.
5.
6.
7.
The identification of the terminal block and pin numbers

Space for employer to add the point name for each input and output
point (at least twenty characters).
Point type
The points I/O card location
The points address within the protocol
The points signal conditioning (filtering, scaling, isolation etc.) and
the location of the conditioning (if not on the points I/O card)
All jumper / strap positions.
(e)
The enclosure assembly drawings showing the locations of the components, such as
power supplies, transducers, Multi Function Transducer, interposing relays,
termination facilities, printed - circuit card chassis, and the sub assembly
comprising the components to the level of printed circuit card. The drawings shall
identify each component and sub assembly by part number and revision level. An
individual drawing shall be produced for each enclosures equipment and a copy of
the appropriate drawing shall be stored in side each enclosure, preferably on the
enclosures door.
(f)
All maintenance documentation, including manuals and other descriptive material,

which will enable employer personnel to maintain all contractor- supplied
equipment.
The maintenance documentation shall include description, specifications, theory of
operation (including software listing where applicable), printed circuit module
schematic and lay-out drawings showing components and position, mother board
schematic showing inter-module-connections, back-panel and assembly wiring
diagrams, pin lists, and other data on all electrical, electronic and mechanical
hardware. All schematic diagrams show signals sources and destinations by
413
RTU

drawing number and area. All schematic (including back panel wiring) shall
include a signal name list alphabetically listing each signal, its source, normal
waveform and value, and all destinations.
Instructions shall be included for preventive maintenance procedures
consisting of examinations, tests, adjustments and cleaning that should be
performed periodically under normal operating conditions for the purpose of
preventing failure or impairment of the equipment.
The manuals shall provide guidelines for isolating the cause of the hardware
mal-function. The discussions should contain concise information on how the
hardware operates, trouble shooting guides for localizing fault, listing of possible
sources of trouble, symptoms, probable causes, use of test equipment, use and
interpretation of built-in RTUs test functions, and instructions remedying faults.
User configuration options must be described as well as their normal position.
Instructions shall be provided for the removal, repair and replacement of all
hardwares.
Complete parts list and breakdowns, description sufficient to identify each
component and altering information for these parts, shall be provided in conjunction
with maintenance manuals. Every component sub-assembly and assembly shall
have a unique part number assigned to it. This part number shall co-inside with the
marking on the hardware itself and shall be used in the documentation whenever the
hardware element is referenced. Where standard components are used, standard
part number or the identification used by the components supplier shall be shown.
Alternate sources and part numbers shall be supplying for non-standard
components. Where applicable, the characteristics of a component shall also be
shown to aid in obtaining substitute parts (such as the value and rating resistors).
(g)
A thorough description of the RTUs communication protocol including sequential

procedure as implemented for the project. The data formats used and the
relationship of I / O card location / addresses to message fields must be clearly
presented.
(h)
Operation & maintenance documentation for the portable RTU configuration and
maintenance terminal, similar in content and detail to the above specified
documentation.
The documentation described by item (a) through (e) above is required by the
employer for RTU installation and shall be provided within two months after
contract award.
(i)
A proforma / recommended procedure for keeping performance record of the

equipment by the user shall be provided with the documents.
414
RTU

10.3.2 Software documentation :
The contractor shall supply documentation for all software provided with the RTUs.
This documentation shall include the following documentation as a minimum :
(a)
An inventory of all programs and modules to be provided and a cross

reference Index to the software documentation.
(b)
A functional overview document which describes the software on a subsystem basis and include a brief description of the hardware interfaces. This
document shall functionally describe all software to be provided with
simplified block and data flow diagram. The relationship among each
problem, the database and the system hardware shall be included. This
document shall be provided within four months after contract award and
prior to the issuance of any individual software document.
(c)
Software documentation standards, manuals which define in details the

documentation format for items (d) and (e) below. Within four months after
the contract award, the contractor shall provide the documentation standards
for employers review.
(d)
Existing design documentation and users manual for the contractors

standard software that satisfies the requirements of the specification
submitted to employer in their existing form.
Standard software which requires some modification to fulfill employers

requirement shall be subject to employers review and approval. The standard
documentation and the changes documents shall be submitted prior to the implementation
of the changes by the contractor. All changes to the contractors software shall be
identified.
10.3.3 Test documentation :
The contractor shall provide documentation for all factory and field tests. clause
8.2 describes the test documentation requirements.
10.3.4
Final documentation :
Final documentation shall consist of the documents necessary to the satisfy the
requirements in clause 10.3.1, 10.3.2, 10.3.3 and the other documents described herein or
requested by the employer. The documents will be used by the employer personnel for the
RTUs operation and maintenance after their acceptance. Final documentation must be
delivered within three weeks after the RTUs are shipped. The final hardware
documentation shall include one set of reproducible tracing of all RTUs drawing and
external connection diagram prepared specifically for employers RTU.
415
RTU

Each document shall be identified by a contractor document number. Where a
document is revised due to change in design (or for any other reason), each revision shall
be indicated by a number, date, subject in a revision block and some indication of approval
by the contractors project manager. Additional notation shall be made on the document to
permit rapid location of the revision. A final Index of system documentation shall be
included. All final documentation supplied by the contractor shall be easily reproducible
by the employer.
All final documentation shall also be provided on magnetic media in the file format
on the latest version of Microsoft Word Software. Alternately, if another word processing
system is used by the contractor, the final documentation shall be provided in the contractor
word processing format alongwith word processing software and documentation.
All drawing larger than A3 size (297 mm x 420 mm) shall be supplied as Mylar
reproducible tracings in addition to the paper prints. All drawings prepared specifically for
employer shall also be provided on floppy disk media in the DXF format of the latest
version of the AutoCAD software.
The contractor shall be responsible for supplying documentation revisions or
changes due to inaccuracies, installation requirement, omission determined by usage, and
design or production alternations of the RTUs. Changes shall be issued in the form of
replacement for the effected drawings, diagrams, charts, graphs, table, list and pages in the
various manuals prior to the start of the field performance test.
10.4
Document quantities :
The quantity to be supplied for each document is shown exhibit 10-1. Copies of
documentation provided at training courses are in addition to these quantities.
Where the contractor supply documentation organization defers from the items in
the list, the contractor shall provide the maximum quantity of documents for the
functional area covered by the document.
11.0
11.1
The Contractor must establish that they are following a proper quality assurance
program for manufacture of equipments. The Contractor shall invariably furnish following
information along with his offer. Information shall be separately given for individual type
of equipment offered.
a)
b)
Statement giving list of important raw materials, names of sub

supplier for the raw material, list of standards according to which the
raw material are tested, list of tests normally carried out on raw
material in presence of Bidders representative and copies of test
certificates.
Information and copies of test certificates as mentioned in (i) above
in respect of bought out items.
416
RTU

c)
d)
e)
f)
g)

processing exists.
inspection.
Special features provided in the equipment to make it maintenance
free.
List of testing equipment available with the Bidder for final testing
of equipment specified and test plant limitations, if any, vis--vis
type tests, acceptance and routine tests specified in the relevant
Indian Standards or equivalent international standard. These
limitations shall be very clearly brought out in schedule of
deviations from specified test equipments.
11.2 The successful Bidder shall within 30 days of placement of order submit following
information to the Purchaser.
a)
b)
c)

offer.
finalized.
11.3 The successful Bidder shall submit the routine test certificates of bought out items
and for raw material at the time of routine testing of the fully assembled equipment.
12.0
12.1 The details such as order no. and date, year of manufacture and MPPTCL should
be engraved on each and every equipment. The equipment shall be packed in crates
suitable for vertical/horizontal transport, as the case may be and suitable to withstand
handling during transport and outdoor storage during transit. The Bidder shall be
responsible for any damage during transit, due to improper and inadequate packing and
handling. The easily damageable material shall be carefully packed and marked with the
appropriate caution symbols. Wherever necessary, proper arrangement for lifting, such as
lifting hooks etc. shall be provided. Bidder shall supply, any material, found short inside
the packing cases without any extra cost.
417
RTU
12.2
a)
b)
c)
d)
e)
f)

Destination
12.3 The Bidder shall ensure that the packing list and bill of material is approved by the
418
RTU
EXHIBIT-10.1
RTU DOCUMENT QUANTITIES
S.No.
Document
Review of approval Final Document

quantities
quantities
HARDWARE DOCUMENTATION
1.
Inventory of Hardware
2.
Site preparation manual
3.
Installation, wiring & cabling
diagram
4.
Internal wiring diagram
5.
Assembly Drawings
6.
Maintenance Manuals for RTUs
7.
Test set Documentation
SOFTWARE DOCUMENTATION
1.
Inventory of software
2.
RTU Functional Overview
3.
Software Documentation standard
4.
Standard software
5.
Modified Standard software
TEST DOCUMENTATION
1.
Testing Plans
2.
Test Records
4
4
4
4 per RTU
4 per RTU
4 per RTU
4
4
4
4
4 per RTU
4 per RTU
4 per RTU
4 per RTU
4
4
4
4
4
4 per RTU
4 per RTU
4 per RTU
4 per RTU
4 per RTU
4
4
4 per RTU
4 per RTU
Note: One set of document shall be delivered at RTU site, concerned T&C circle, sub LDC
&SLDC.
419
RTU
Appendix A
RTU CONFIGURATION AND POINT COUNT
Legend
RTU Name
Data Rate
DO PLSE
The site name of the substation and RTU.

RTU communication channel data rate (300 to
1200 bits per second).
The RTU to Master Station Communication
channel requirements:
NCr =
Single channel to the master station
(Non-critical RTU)
Cr = Dual-redundant channel to the master station
(Critical RTU).
The number of analog input points
The number of single contact digital status input
points (without momentary change detection).
The number of double contact digital status input
point.
The number of double contact digital status input
points (with momentary change detection).
The number of sequence of events (SOE) digital
status input points (in addition to DI-2 bit point
counts).
The number of raise / lower pulse output points.
AO
The number of set point analog output points.
Comm Type
AI
DI 1 Bit
DI 2 Bit
DI 2MCD
DI 1 bit
420

ANNEXURE-I
TECHNICAL PARTICULARS FOR REMOTE TERMINAL UNIT(RTUs)
Sl.
Item Description
no.
1 Data transmission rate
2
3
4
5
6.
7
8
9
10
11
12
13
14
15
16
17
18
Communication ports
Communication protocol
with Master stations
Communication Protocol
with MFTs / Energymeters
Analog accuracy of the
RTU
Maximum limit for mean
accuracy drift
Analog-to-digital converter
resolution
No. of Scan Group Support
Event buffer size
Value
300 to 9600 bps for
serial port
As required
IEC 60870-5-101
Remarks
As per specification
MODBUS
atleast 99.8%
at 250 C
Less than 0.002% per

degree centigrade
+/- 2048 counts(sign
plus 11data bits)
16
atleast 300 events
Within the range of-50 to

550 C
Analog/Status data transfer

to Master station
Analog input impedance
(for current inputs)
By exception
Analog input overload

withstand capability
RTU shall be set to capture
contact operations
SOE buffer size
Time stamping accuracy
for SOE points
Up to 150% of the
input
of 20 ms or more duration.
2048.
1 millisec
Supporting Control of
Devices
RTU internal clock stability
Nominal Power supply
voltage
Two state
Less than 250.
Atleast 1 ppm
48V DC(+ve Earthed)
421
No. of events store equal

to atleast three times the
no. of SOE points
Shall support periodic
polling & on demand

SCHEDULE-II
Guaranteed Technical Particulars of RTU

Sl.No.
1
2
3
4
7
8
9
10
11
Item Description
Data transmission rate
Communication ports
Communication protocol with Master stations
Communication Protocol with MFTs / Energymeters
Analog accuracy of the RTU at 250 C
Maximum limit for mean accuracy drift (Within the
range of-50 to 550 C)
Analog-to-digital converter resolution
No. of Scan Group Support
SOE buffer size
Analog/Status data transfer to Master station
Analog input impedance (for current inputs)
12
13
14
15
16
17
18
Analog input overload withstand capability

RTU shall be set to capture contact operations
SOE buffer size
Time stamping accuracy for SOE points
Supporting Control of Devices
RTU internal clock stability
Nominal Power supply voltage
5
6.
Value
SIGNATURE OF TENDERER
422

VOLUME II
PART-2
BOOK III OF III


MPPTCL, JABALPUR
Description
Technical Book
Serial No.
Part-1

POWER TRANSFORMERS
Part-2
Book I
of III

MATERIALS
Part-2
Book II
of III

MATERIALS
Part-2
of III
MATERIALS

PART-2(BOOK III OF III)

Tender document.
INDEX
VOLUME-II, PART-2
Part 2
consist of
BOOK-I of III
S. No.

1.1
1.2
1.3
2.1
2.1.1
Circuit Breakers
BOOK-II of III
25
26
26
27
62
2.1.2
63
199
2.1.3
200
241
2.1.4
Lightning Arresters
242
254
2.1.5
Isolators
255
276
2.1.6
277
282
2.1.7
283
302
2.2
2.2.1
303
318
2.2.2
Wave Traps
319
332
2.2.3

333
351
2.2.4
352
361
2.2.5
362
372
2.2.6
RTU
373
422

Equipments
2.3.1
423
470
2.3.2
471
505
2.3.3
506
529
2.3.4
530
538
2.3.5
539
539
540
555

Cables & Hardwares
2.5.1
556
580
2.5.2
581
584
2.5.3
585
592
2.5.4
Clamp & Connectors.
593
612
2.5.5
Substation Hardware
613
633
2.6
634
644
2.7
645
667
2.3
2.4

2.4.1
BOOK-III of III
Page No.
From To
2.5
Structures
Volume-II, Part-2, Book III of III
2.3.1(A) TECHNICAL SPECIFICATION FOR 33/0.4 kV, 200 KVA STATION

TRANSFORMERS
1.0
SCOPE:
1.1
Volume-II. The bidder mentioned in this Section of the Technical Bid means Original
Equipment Manufacturer (OEM). The purchaser means the MPPTCL.
1.2
1.2.1
SYSTEM REQUIRMENTS WHICH ARE TO BE CONSIDERED FOR DESIGN OF

STATION TRANSFORMERS
CLIMATIC CONDITIONS
Applicable climatic conditions shall be as per Volume-II of this bid.
1.2.2
STANDARDS
Applicable Standards for the offered equipments/items shall be as per Volume-II.
1.3
DEVIATION FROM TECHNICAL PARTICULARS

1.4
STANDARD RATING
Standard ratings shall be 33/0.4 KV, 200KVA Station Transformer with off circuit taps
on HV winding for variation of HV Voltage.
1.5
CONTINUOUS MAXIMUM RATING AND TEMPERATURE RISE
Station transformers shall have a continuous maximum rating at the specific normal
pressures, ratio, frequency and temperature rise.
A)
All transformers shall be capable of operation continuously in accordance with IS

loading guide at their C.M.R. at any ratio.
B)
Transformer having tapping range extending not more than 5% below the normal
voltage shall operate on the principal tapping without exceeding the limits laid
down in IS 2026 for oil temperature rise and winding temperature rise as
measured by resistance. On other tappings, transformer shall operate continuously
without injurious heating.
C)
Transformers with tapping ranges extending more than 5% below normal voltage,
shall meet the temperature rise limits specified in IS 2026 on all tappings on which
the rated current is not more than 95% of the maximum rated current on the lowest
voltage tapping. On other tappings transformer shall operate continuously without
423
Station Transformers, LT Distribution Box & DO fuse

injurious heating. The loading of the transformers is to be in accordance with IS 6600guide for loading of oil immersed transformers natural cooled units.
D)
Station transformers shall be capable of operation without danger on any particular

tapping at the rated voltage in KV provided that the voltage does not vary by more
than + 10% of the voltage corresponding to the tapping.
Maximum temperature rise in each transformer when tested at its continuous

maximum KVA rating shall not exceed the following limits at the reference ambient air
temperature of 50 deg.C.
i.
ii.
1.6
Temp. of oil by thermo-meter above 50

deg.C. ambient
Temp. of winding by test resistance
above ambient
45 deg. C.
50 deg. C.
NORMAL NO LOAD VOLTAGE RATIO
Normal voltage ratio corresponding to the principal tapping shall be 33,000/433 volts
for 200KVA transformers.
1.7
a. Important technical particulars for 200KVA transformer, have been brought out in
Appendix-A1, which may please be noted carefully.
High voltage windings of the station transformers shall be designed to withstand

voltage as under:
Highest System
voltage
Lightening Impulse
withstand voltage
Power frequency
withstand voltage
36KV
170KV peak
70KV rms
Bidder shall state the impulse strength of winding guaranteed by them with the bid.
Reports and oscillographic records of tests carried out by them shall be enclosed with
the bid. If called for, the Bidder shall agree to test or make arrangement for testing
one prototype limb of 33/0.433KV windings at their cost or otherwise, they will have to
furnish impulse test certificate for transformer of similar design at their cost.
b.
Transformers shall be capable of withstanding the power frequency test
voltage as specified above as per IS:2026(latest issue).
1.8
OIL
Insulating oil used should be conforming to IS 335 (Latest issue). Station

transformer will be transported with the initial filling of insulating oil. Important characteristics
of insulating oil are shown in AppendixA2.
1.9
TAPS
1.9.1
Each transformer shall be provided with an off- circuit tap changing switch for
varying its effective ratio of transformation whilst the transformer is de-energised and
without providing phase displacement. Off circuit taps of transformer shall have tap
range of (+) 5% to (-)5% in steps of 2.5% each on HV winding for HV variation to give
normal voltage on LV side at each tap.
424
1.9.2
Tap changing switch shall be located in a convenient position so that it can be
operated easily. Switch handle will be provided with a locking arrangement alongwith tap
position indicator and direction for operation, thus enabling the switch to be operated and
locked in position. Operation shall result in simultaneous position change on all three phases,
with spring loaded snap action and ensure positive pressure contact.
1.10
WINDING CONNECTIONS AND VECTORS
1.10.1
Primary winding shall be connected in delta and secondary winding in star as
per vector symbol DY 11 in accordance with IS:2026, so as to produce a positive
displacement of 30 deg. from the primary to the secondary vectors of the same phase
(vector rotation assumed counter-clock-wise).
1.10.2
Neutral point on the secondary (LV) winding shall be extended for connection with
solidly earthed system and should be brought out to a separate insulated terminal enabling
external insertion of current transformer in the earth lead to be connected wherever
required.
Insulation and magnetic induction shall be suitable for operating transformer
continuously at a voltage 10% more than those specified in Appendix-A1. Windings of the
transformers should be fully insulated.
1.11
IMPEDANCE VALUE
Percentage impedance at 75 deg. C shall be 4.5% for 200 KVA Station Transformers.
The impedance values relate to the principal tapping and are subject to a tolerance of + 10%.
Impedance value measured on any other tapping shall not exceed the reference value
measured on the principal tapping by more than + 10%.
1.12
TRANSFORMER LOSSES
Transformers covered in the specification are required to be offered with no load and
load losses figures. Bids with lower losses will be given preference. Bidders must indicate no
load loss in Kilowatts at rated voltage and rated frequency. Also load losses at 75 deg. C
should be offered in Kilowatts. It may be noted that the offered values of no load and
load losses must be on FIRM basis and no positive tolerance in the transformer losses
will be allowed. In case after actual manufacture, if the no load and load losses are
found lower than the offered values, no financial benefit will be passed on to the
Bidder.
1.13
DESIGN & STANDARDISATION
A.
Station transformer and accessories shall be designed to facilitate

operation,
inspection, maintenance and repairs. All apparatus shall also be designed to ensure
satisfactory operation under such sudden variation of load and voltage as may be met
with under working conditions on the system including those due to short circuit.
Design shall incorporate every reasonable precaution and provision for the safety of
all those concerned in the operating and maintenance of the Transformer keeping in
view the requirements of Indian Electricity Rules.
All material including bought out item like bushings, oil, radiators and terminal
connectors etc. shall be of the best quality and of the class most suitable for working
under the conditions specified and shall withstand
the
variations of
temperatures and atmospheric conditions arising under working conditions without
B.
C.
425
D.
E.
F.
G.
undue distortion or deterioration or the setting up of undue stresses in any part,

and also without affecting the strength and suitability of the various parts of the
work which they have to perform.
Corresponding parts liable to replacement shall be inter-changeable.
Cast Iron shall not be used for chambers of oil filled apparatus or for any part of the
equipment which is in tension or subject to impact stresses or where erosion due to
acidity or sludging is likely to occur. This clause is not intended to prohibit the use of
suitable grades of cast iron for parts where service experience has shown it to be
satisfactory, e.g. large valve bodies.
All out door apparatus including bushing, insulators with their mountings etc. shall
be designed so as to avoid external pocket in which water can collect and
internally where air trap could occur.
All mechanism shall, where necessary, be constructed of stainless steel, brass or gun
metal to prevent sticking due to rust or corrosion.
H.
All taper pins used in any mechanism shall be of the split type complying with IS 2393
for these items.
I.
All connections and contacts shall be made of adequate section and contact surface
for carrying continuously the specified currents without undue heating and fixed
connection shall be secured by bolts or set of screws of ample size adequately
locked, with locking nuts used on stud connections carrying current.
J.
All
apparatus shall be designed to minimise the risk or accidental short circuit
caused by animals, birds or vermin.
1.14
GALVANISING
A.
Galvanising, where specified, shall be applied by the dipped process or by electrogalvanising process and for all parts other than steel wires, shall consist of thickness
of zinc coating equivalent to not less than 6610 gm of zinc per sq. meter of surface.
Zinc coating shall be smooth, clean and of uniform thickness and free from defects.
Preparation of galvanising itself shall not adversely affect the mechanical properties
of the coated material. Quality will be established by tests as per IS 2633.
B.
All drilling, punching, cutting, bending and welding of parts shall be completed and all
burrs shall be removed before the galvanising process is applied.
C.
Galvanising of wires shall be applied by the hot-dipped process and shall meet the
requirements of the relevant Indian Standard.
D.
Surface, which is in contact with oil, shall not be galvanised or chromium plated.
1.15
CLEANING, PAINTING & FINISHING
A.
Before painting or filling with oil or compound, all ungalvanised parts shall be
completely clean and free from rust, scale and grease, and all external surface
cavities on casting shall be filled by metal deposition.
B.
Interior of transformer tanks, and other oil filled chambers and internal structural
steel work shall be cleaned of all scale and rust by shot-blasting or other approved
method. These surfaces shall be painted with oil resisting varnish or paint.
426

C.
Except for nuts, bolts and washers, which may have to be removed for
maintenance purposes, all external surface shall be given a minimum of three
coats of paint whereas all nuts, bolts and washers shall be given minimum of one
coat paint after erection.
D.
Primary coat shall be applied immediately after cleaning. Second coat shall be of
an oil and weather resisting nature and preferably of a shade of colour easily
distinguishable from the primary and final coats and shall be applied after the
primary coat has been touched up where necessary. Final coat shall be of a
glossy oil and weather resisting nonfade paint of shade no. 631 (light grey) of
IS:5. Primer paint shall be ready made zinc chrome as per IS:104, intermediate and
final coats of paint shall be as per IS 2932.
E.
All interior surface, except those which have received anticorrosion treatment, shall
receive three coats of paint applied to the thoroughly cleaned metal surface. The
final coat shall be of a light coloured anticondensation mixture.
F.
Spacings of the bolts centres on the tank and its cover should be so designed that
the gaskets when pressed after bolting leave no room for either ingress of moisture
or leakage of oil during transport, normal service under full load and guaranteed
temperature rise conditions.
G.
One coat of additional paint shall be given at site by the purchaser and for this
purpose, supplier shall supply the requisite quantity of paint to the purchaser.
1.16
CORE
Cores shall be constructed from high grade, cold rolled, non ageing, grain oriented
silicon steel laminations, HI-B grade or better grade modern core material with lower core
losses.
1.16.1 MAGNETIC CIRCUIT
A.
Design of the magnetic circuit shall be such as to avoid static discharges,

development of short circuit paths within itself or to the earthed clamping
structure and the production of flux components at right angle to the plane of the
laminations which may cause local heating.
B.
Every care shall be exercised in the selection, treatment and handling of core
steel to ensure that as far as practicable the laminations are flat and the finally
assembled core is free from distortion, burrs or sharp edge.
C.
Although the oxide/silicate coating given on the core steel is adequate, however,
laminations can be insulated by the manufacturers if considered necessary.
D.
Oil ducts shall be provided where necessary to ensure adequate cooling and efficient
heat transfer. The winding structure and major insulation shall not obstruct the
free flow of oil through such ducts. Where magnetic circuit is divided into
pockets by cooling ducts parallel to the panels of the laminations or by insulating
material above 0.25 mm thick tinned copper bridging strip pieces shall be
inserted to maintain electrical continuity between pockets.
E.
Frame works and clamping arrangements shall be earthed in accordance with clause1.22.II.
427

F.
Insulation structure for the core to bolts and core to clamp plates shall be such as to
withstand a voltage of 2000 V AC for one minute.
1.17 MECHNICAL CONSTRUCTION OF CORE

A.
All parts of the cores shall be of robust design capable of withstanding any
shocks to which they may be subjected during lifting, transport, installation and
service.
B.
All steel sections used for supporting the core shall be thoroughly sand blasted or
shot blasted after cutting, drilling and welding. Any non-magnetic or high
resistance alloy shall be of established quality.
C.
Adequate lifting lugs shall be provided to enable the core and windings to be lifted.
D.
Adequate provision shall be made to prevent movement of the core and winding
relative to the tank during transport and installation or while in service.
E.
Supporting frame work of the core shall be so designed as to avoid the presence
of pockets which would prevent complete emptying of the tank through the drain
valve, or cause trapping of air during filling.
1.18
TERMINAL ARRANGEMENTS
1.18.1 Station transformers shall be fitted with shedded porcelain bushings or outdoor
type suitable for aluminium solderless connectors both on HV as well as LV side.
Aluminium bushings stems and aluminium metal parts will not be accepted.
1.18.2 HV bushings shall be 52 KV class porcelain standard transformer bushings
whereas LV bushing shall be 1.1 KV class non-oil communicating type.
The HV bushings shall have following parameters
i)
Minimum creepage distance
840mm
ii) Basic impulse level
250KVP
iii) Voltage class
52KV
iv)
Type of bushings
Non-oil
communicating
porcelain
transformer
bushings
Electrical characteristic of bushing insulators shall be in accordance with

IS:2099/ IS:3347 as amended from time to time. All type routine tests shall be carried
out in accordance with IS: 2099/ IS:3347.
1.18.3 Dimensions of the LV side transformer bushing including the neutral side shall
conform to relevant IS and those of the 52 KV bushings for 33 KV side shall conform to IS
3347.
1.19
VIBRATION AND NOISE
428

A.
Every care shall be taken to ensure that the design and manufacture of all
transformers and accessories shall be such as to reduce noise and vibration to the
level obtained as per the modern practice.
B.
Manufacturers will ensure that the noise level shall be according to the NEMA
standard publication TR-I.
1.20
FLUX DENSITY AND OVERFLUXING
A.
Maximum flux density in any part of the core and yokes at normal voltage and
frequency of each transformer shall be such that the flux density under over
voltage condition as per clause-1.5 D shall not exceed 1.75 Tesla.
B.
Over fluxing of the core shall be limited to 12.5%.
1.21 INTERNAL EARTHING ARRANGEMENTS

I.
GENERAL
All metal parts of the transformer with the exception of the individual core bolts and
associated individual clamping plates shall be maintained at some fixed potential.
II.
EARTHING OF CORE CLAMPING STRUCTURE
Top main core clamping structure shall be connected to the tank body by a copper
strip. The bottom clamping structure shall be earthed by one or more of the following
methods.
A.
By connection through vertical tie rods to the top structure
B.
By direct metal-to-metal contact with the tank base maintained by the weight of the
core and windings.
C.
By a connection to the top structure on the same side of the core as the main earth
connection to the tank.
III
EARTHING OF MAGNETIC CIRCUIT
A.
Magnetic circuit shall be earthed to the clamping structure at one point only
through a disconnectable link placed on an accessible position beneath an
inspection opening in the tank over. Connection to the link shall be on the same side
of the core as the main earth connection.
B.
Magnetic circuits having an insulated sectional construction shall be provided with a

separate link for each individual section. When oil ducts or insulating barriers
parallel to the plane of the laminations divide one magnetic circuit into two or
more electrically separate parts the ducts or barriers shall be
bridged in
accordance with Clause-1.17.
C.
Magnetic circuit shall not be regarded as being of sectional construction.
IV
SIZE OF EARTHING CONNECTIONS
429

All earthing connections with the exception of those from the individual coil
clamping rings shall have a cross sectional area of not less than 0.8 sq.cm. connections
inserted between laminations of different section of core as per Clause-1.22-III(B) shall
have a copper sectional area of not less than 0.2 sq.mm.
V
LEADS FROM WINDING TO BUSHING AND INTERCAKE CONNECTIONS
Leads from winding to bushing and intercake connections should be rigid enough
to withstand normal vibration and transportation shocks and short circuit stresses. They
should be spaced in such a way that necessary clearances are maintained not only in
air, but with oil medium at the lowest permissible electrical strength as per relevant ISS over
the period of normal services.
1.22
TRANSFORMER TANK
1.22.1 Main tank of the transformer shall be made of good quality sheet steel of adequate
thickness to provide sturdy and robust construction to withstand extreme pressure
conditions. Interior of the transformer tank shall be thoroughly cleaned by sand or shotblasting so as to produce a smooth and clean surface free of scale, grease and rust. Interior
of transformer tank shall be painted with insulating oil resistance paint. Thickness of the Top
and Bottom plate of tank shall be minimum 6mm, while that of side wall should be minimum
4mm.
1.22.2 OIL LEAKAGE TEST
All tanks and oil filled compartments shall be tested for oil tightness by being
completely filled with air/oil of viscosity not greater than that of insulating oil of IS 335 at
ambient temperature and subject to a pressure equal to the normal pressure plus 35
KN/sq.meter measured at the base of the tank. This pressure shall be maintained for a
period of not less than 12 hours for oil and one hour for air during which time no leakage
shall occur.
1.23
BOLTS & NUTS
A.
Steel bolts and nuts exposed to atmosphere with suitable cadmium plated or zinc
plated passivity shall be used for diameters above 6mm.
B.
All nuts, bolts and pins shall be locked in position with the exception of these
external to the transformer.
C.
On outdoor equipment, all bolts, nuts and washers in contact with non-ferrous
parts which carry current shall be of phosphor bronze, where the transformer of
current is through the bolts.
D.
If bolts and nuts are placed so that these are inaccessible by means of
spanners, suitable special spanners shall be provided by the supplier.
1.24
TERMINAL CONNECTORS
ordinary
Universal bi-metallic terminal connector for HV bushings shall have horizontal take off
arrangement and shall be suitable to receive single `ZEBRA' ACSR conductor and vertical
take off arrangement shall be suitable for 0.1 sq.mm. ACSR conductor. Minimum thickness
of clamp shall be 12mm at any part of the body. Thickness of bi-metallic liner shall be
430

minimum 2mm. Terminal connectors shall be made out of pressure / gravity diecasting process only. Stud conductor hold length shall be 100 mm (min.). Suitable terminal
connectors (4 nos.) for each transformer for LV shall also be included in the scope of supply.
1.25
PARALLEL OPERATION
Transformers of the same service voltage shall be suitable for parallel operation, the
load being shared in proportion to the capacities and percentage impedance volts which will
be within the limits specified in the relevant IS.
1.26 OVERLOAD CAPACITY
A.
Each transformer shall be capable of carrying sustained over loads as stated in

IS:6600.
B.
Type of Load: Station transformers will supply a mixed power and lightning load, with
varying power factors from 0.6 lag to 0.8 lead due to capacitors.
1.27
GUARANTEE
Manufacturer shall guarantee the following:
i.
Quality and strength of material used, both electrical and mechanical.
ii.
Performance Guarantee period for satisfactory operation of Station Transformers

shall be strictly as per clause no 9.0 of Part-2, Book I of III of Volume-II of the
specification. This period will be reckoned from the day on which last of all
accessories are received, enabling assembly testing commissioning and commercial
operation of transformers.
iii.
Performance details are to be supplied by Bidder with the bid.
1.28
TOLERANCES
Tolerances of guaranteed performance figures shall be as specified in the latest

version of IS 2026.
1.30
ROLLERS
Station Transformers shall be provided with bi-directional float rollers.
1.31
FITTINGS & ACCESSORIES
Unless otherwise specified in the order, the following standard fittings shall be
provided. The fittings shall be in accordance with the details to the extent these are specified
in IS:2026.
a.
Rating & diagram plate with purchaser's order number and date, tap position and
relative HV/LV voltage.
b.
4 Nos pulling lugs of 8mm thickness.
c.
Two earthing terminals with lugs.
d.
4 Nos. Lifting lugs of 8 mm thickness.
431

e.
4 nos. bi-directional float rollers (150mm dia and 50mm wide).
f.
Conservator with top filler cap and bottom drain valve and oil level guage.
g.
Aluminium die cast Silicagel dehydrating breather having minimum 0.5kg. silicagel
h.
HV-3 nos. 52 KV bushings, LV 4 nos. 1.1 KV bushings, Arcing horn for HV

bushings
i.
Off circuit tap switch with indicator handle, lock and 2 keys.
j.
Thermometer pocket
k.
Air release device with cap on tank top.
l.
Explosion vent diaphragm.
m.
2 filter valves (top valve, lower valve to be used also as drain valve).
n.
Bimetallic terminal connectors for each HV, LV & LV neutral bushings.
1.32
FINISHING
Exterior of the transformer and other ferrous fittings shall be thoroughly cleaned,
scraped and given primary coat and the two finishing coats of durable oil and weather
resistant paint of enamel. Colour of the finishing coats shall be DARK GREEN conforming to
IS: 5 of 1961 (colours for ready mixed paints) with conservator painted with white colour OR
any equivalent acceptable International Standards.
1.33
TESTS & TEST CERTIFICATES FOR TRANSFORMER
1.33.1 TYPE TESTS

1.33.1.1 All the equipments offered shall be fully type tested as per relevant ISS or any
equivalent acceptable International Standard & technical specification. The following type
tests shall be carried out on the transformers in accordance with ISS: 2026/1977 as
amended from time to time or any equivalent acceptable International Standard:
(i)
Short Circuit test
(ii)
Lightening Impulse Voltage withstand test.
(iii)
Heat run test
(iv)
Loss measurement
1.33.1.2 In case the transformers offered are as per purchasers technical specifications and
are already type tested in an independent test laboratory, the Bidders shall furnish four
sets of tests reports along with the offer. These tests must not have been conducted earlier
than five years from the date of opening of Bids. Purchaser reserves the right to demand
repetition of some or all the type tests in the presence of owners representative. For this
purpose, the Bidders may quote unit rates for carrying out each type test. These prices shall
be taken in to consideration for bid evaluation.
1.33.1.3 In case there is any deviation in the type tested design, from the purchasers
technical specification, the type tests have to be conducted afresh by the
manufacturer at their cost in accordance with the purchasers specification. Tests shall
be carried out immediately and detailed type test reports submitted within ONE MONTH
432

from the date of issue of Letter of Intent. Please note that no separate time shall be permitted
for this purpose.
1.33.1.4 Type tests on randomly selected unit
Suppliers may carefully note our following specific requirements of Short
Circuit, Impulse Voltage Withstand, Heat Run & Loss Measurement Tests
It may be noted that the MPPTCL reserve the right to conduct all or any of the test
mentioned under clause- 1.33.1.1. in accordance with the ISS or any equivalent acceptable
International Standard afresh on each ordered rating at MPPTCLs cost, even if the
transformers of the same rating and similar design are already type tested. This test shall be
carried out on a transformer to be selected by the MPPTCL either at supplier works when
they are offered in a lot for supply or random sample from the supplies already made to
MPPTCLs Transmission Stores. The findings and conclusions of these tests shall be
binding on the supplier.
In case the transformer does not pass 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.
(ii) For transformers already supplied, the guarantee period shall stand twice the normal
guarantee period incorporated in the order and the period of performance Security
Deposit shall be suitably extended to cover the extended guarantee period.
Further, the supply of balance quantity of transformers will not be accepted by the
MPPTCL, till another transformer from the manufactured batch is satisfactorily tested (Or
transformers are modified according to the tested design) for any or all the tests as per
clause-1.33.1.1 above at suppliers cost and consequent to this, if there is any delay in
executing the order, the same shall be to the suppliers account. MPPTCL reserves the right
to take action as per terms and conditions of the order.
(iii)
The test charges shall be borne by the firm.
1.33.2 ROUTINE TESTS

Before despatch each of completely assembled transformer shall be subjected to the
following routine tests at the manufacturers works in accordance with the details specified in
IS:1180/2026 Or any equivalent acceptable International Standards and as detailed below: -.
a.
Measurement of winding resistance.
b.
Ratio, polarity and phase relationships.
c.
Impedance voltage.
d.
No load loss and No load current.
e.
Load loss
f.
Insulation resistance.
g.
Separate Source voltage withstand.
433

h.
Induced over voltage withstand.
1.33.3. ACCEPTANCE TESTS TO BE CARRIED OUT BEFORE DESPATCH

Following tests shall be witnessed by the Purchasers representative at the works of
the supplier.
1.33.4 All the routine tests as mentioned in 1.33.2 above shall be performed on minimum
10% quantity of offered lot.
Besides above, following tests are to be performed on one unit of each lot offered
for inspection.
a.
Verification of active parts alongwith weighment of unit.
b.
Spill Current measurement test
c.
Test for Magnetic Balance shall be conducted by connecting the LV phase by

phase to rated phase voltage and measurement of an, bn, cn voltage will be
carried out.
d.
Test for Over fluxing of core.
e.
Pressure test performed on one tank.
f.
Breakdown voltage test of transformer Oil.
g.
Heat run test - One unit of the ordered quantity.
Heat run test shall have to be conducted at suppliers cost on one transformer from
first offered lot, during the course of supplies. This test shall be conducted on lowest tap by
feeding corresponding losses at 750 C. The measured losses at lowest tap at ambient
temperature shall be specifically indicated in the inspection report.
To facilitate conduction of heat run test on any unit of any lot at any point of time
during the supplies, the manufacturer 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,
whenever required and 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 fringe with electrical
clearance nor obstruct the un-tanking of the active part.
1.34 TESTING FACILITIES
Bidders should have adequate testing facilities for all routine and acceptance tests as
described above and also arrangement for measurement of losses, resistance etc.
1.35
INSPECTION
To ensure about the quality of transformers, the inspection shall be carried out by
the MPPTCLs representative at following two stages.
1.35.1 When the raw-material is received, and the assembly is in process in the shop
floor.
434
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 Executive Director (T&P), MPPTCL, Jabalpur in
this regard, so that an Officer for carrying out such inspection could be deputed, as far as
possible within seven days from the date of intimation. During the stage inspection,
1.35.1.1 A few assembled core shall be dismantled to ensure that the CRGO laminations
used are of good quality.
1.35.1.2 Dimensional details of construction of transformers as per the guaranteed technical
particulars offered by the manufacturer and approved by the Purchaser shall be verified.
1.35.1.3 Pressure and vacuum test: Tank shall be fixed with a dummy cover with all fittings
including bushings in position and shall be subjected to following pressure/vacuum created
inside the tank: i)
0.8 Kg./cm sq. above atmospheric pressure for 30 minutes.
ii)
A vacuum corresponding to (-) 0.7 Kg./cm sq. for 30 minutes.
Permanent deflection of tank plate, after pressure has been released, shall not
exceed the values given below: Length of plate
Deflection
Up to 750 mm
5mm
751 to 1250 mm
6mm
251 to 1750 mm
8mm
In case of any defect/defective workmanship observed at any stage during stage

inspection by the MPPTCLs 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 O/o Executive Director (T&P), MPPTCL, Jabalpur.
1.35.1.4 Supplier shall provide to the purchaser, complete invoice of procurement of rawmaterials i.e. core, winding material, insulation material, bushings, transformer oil, tanks etc.,
at the time of stage inspection.
If at any stage it is found that transformer is not manufactured out of the rawmaterial for which invoices have been furnished, the transformer shall be liable for rejection
by purchaser and the transformer shall be replaced by the manufacturer at no extra cost to
the purchaser.
1.35.2
At finished stage i.e. transformers are fully assembled and are ready for
despatch.
As and when the transformers are ready for despatch, an offer intimating about the
readiness of transformers, for final inspection for carrying out acceptance tests as per
relevant ISS Or any equivalent acceptable International Standards and as in clause 1.33.3
above, shall be sent by the firm alongwith Routine Test Certificates. The inspection shall
435

normally be arranged by the MPPTCL at the earliest after receipt of offer for pre-delivery
inspection.
All tests and inspection shall be carried out at the place of manufacturer unless
otherwise specifically agreed upon by the manufacturer and purchaser at the time of placing
of purchase order. The manufacturer shall offer the Inspector representing the Purchaser, all
reasonable facilities, without charges, to satisfy him that the material is being supplied in
accordance with this specification. This will include stage inspection during manufacturing
stage as well as active part inspection during acceptance tests.
Random sample checking and testing of the transformer selected at random
from the lot offered for pre-despatch inspection 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.
Purchaser has all the rights to conduct the test including type tests, at its own
cost by an independent agency whenever there is a dispute regarding the quality of
supply or interpretation of test results. In the event of failure of transformer(s) in
such tests, the expenses incurred in testing shall be to the Suppliers account as
already mentioned above in case of random testing.
1.36
TEST CERTIFICATES OF BOUGHT OUT ITEMS
To ascertain the quality of the transformer oil, the original manufacturers test 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.
1.37
TEST REPORTS ON THE ANALYSIS OF RAW MATERIALS
Bidders shall furnish details of source(s) of raw-materials, test certificates and report
on the analysis of electrolytic copper used for the winding and the steel used for core,
insulation material and also other bought out items from sub-suppliers.
1.38 QUALITY ASSURANCE PLAN:
1.38.1 Bidders must establish that they are following a proper quality assurance programme
for manufacture of Materials. Bidders shall invariably furnish following information along with
their offer.
(i)
Statement giving list of important raw materials, names of sub-suppliers for the raw
material, list of standards according to which the raw material is purchased and
copies of test certificates thereof.
(ii)
Information and copies of test certificates as in (i) above in respect of bought out
items.
(iii)
(iv)
Levels of automation achieved and list of areas, where manual processing exists.
(v)
List of areas in manufacturing process, where stage inspections are normally carried
out for quality control and details of such tests & inspections.
436

(vi)
List of testing equipment available with the Bidders for final testing of material
specified and test plant limitation, if any, vis--vis type, special, acceptance and
routine tests specified in the relevant standards. These limitations shall be very
clearly brought out in schedule of deviations from specified test equipments.
1.38.2
Successful Bidder shall within 30 days of placement of order, submit following
information to the Purchaser:
(i)
List of raw material as well as bought out accessories and the names of sub-suppliers
selected from the lists furnished along with Bid.
(ii)
Type test certificates of the raw material and bought out accessories.
(iii)
Quality Assurance Plan (QAP) with hold-up points for purchasers inspection. The
quality assurance plans and hold-up points shall be discussed between the
Purchaser and supplier before the QAP is finalized.
1.39 DRAWINGS
General Arrangement, Core-Coil Assembly and Name Plate detail drawing of each
rating of transformer offered along with guaranteed technical particulars, should be submitted
with the offer.
After award of contract four sets of drawing, Guaranteed Technical Particulars
and type test certificate of transformer with duly stamped drawing from independent
testing laboratory shall be submitted for approval.
1.40 Please ensure that bid document containing number of pages have been
properly numbered and signed by the Bidder. Bid document including all schedules
and Annexures should be indexed properly and Index of the document should be
enclosed/placed at the beginning of the bid document.
437

APPENDIX-A1
PRINCIPAL PARAMETERS OF 33/.4 kV, 200KVA STATION TRANSFORMERS
The transformers shall conform to the following specific parameters described here under:-
S. No.
1
2
3
4
5
6
7
8
9
10
Particulars
Voltage rating
Rated KVA
Type of cooling
Vector group HV/LV
Maximum flux density in iron at normal
voltage & freq. and/at 10% over voltage
Max. current density in winding HV/LV
Max. no load losses at normal ratio
without positive tol.
Max. load losses at 75 deg.C. and at
normal ratio without positive tol.
%impedance at 75 deg.C. & normal
ratio
Details of bushing rating & type
HV
LV
11
12
13
14
15
16
17
BIL level of HV winding

BIL level of HV bushing
One minute P.F. withstand voltage
(HV bushing/winding)
Electrical clearance
i/ Phase to phase
ii/ Phase to Earth
Max. temp. rise over max. ambient
temp.
a. OIL above 50 deg.C amb.
b. Winding above 50 deg.C.amb.
Continuous over voltage rating
Terminal connector
HV
300 to 330A/cm2
400W
2100W
4.5%
52 KV class porcelain standard

X-mer bushing
1.1 KV class bushing (non oil
communicating type)
170 KV peak
250 KV peak
70 KV rms.
33KV 0.4 kV
350mm
75mm
320mm
55mm
45 deg C.
50 deg.C
10% above at each tapping
on continuous basis
Horizontal/vertical take off
suitable to receive single
ACSR Zebra conductor
Suitable for power cable
connection
LV
Station Transformer
33/0.4 kV
200
ONAN
DY11
1.7 to 1.75 Tesla
438

APPENDIX A2
GUARANTEED TECHNICAL PARTICULARS OF EHV GRADE OIL
S.No.
1
2
3
4
5
6
(a)
(b)
(c)
(d)
(e)
(f)
(g)
The important characteristic of new oil shall be as under:

Characteristics
Requirements
Flash point Pensky Marten (closed) min.
140 deg.C.
Neutralisation value
a/ Total acidity max.
0.03 mg. KOH/g
b/ Inorganic acidity alkalinity
NIL
Corrosive sulphur
Non- corrosive
Electrical strength (Break down voltage) min.
a/ New unfiltered oil
30 KV (rms)
b/ New oil after filtration
60 KV (rms)
Di-electric dissipation factor (Tan Delta) at 90
0.002
deg.C. max
Specific resistance (resistivity)
a/ At 90 deg.C. Min.
35x10 12 Ohm-cm
b/ At 27 deg.C. Min.
1500x10 12 Ohm-cm
Oxidation stability
a/ Neutralization value after oxidation(max)
0.40 mg. KOH/g
b/ Total sludge after oxidation max.
0.10% by weight
c/ S.K. Value
4 to 8%
Ageing characteristics after accelerated ageing
(open breaker method with copper catalyst)
a/ Specific resistance (resistivity)
i/ at 27 deg.C. min.
2.5 x 10 12 Ohm-cm
ii/ at 90 deg.C. min.
0.2 x 10 12 Ohm-cm
b/ Di-electric dissipation factor (Tan Delta) at 0.2
90 deg.C. Max.
c/ Total acidity Max.
0.05 mg. KOH/g
d/ Total sludge value max.
0.05% by weight.
Characteristics of oil in the transformer
The important characteristics of the transformer oil after it is filled
in the transformer (within three months of filling) shall be as
follows:Electrical strength (breakdown voltage)
Di-electric dissipation factor (Tan Delta) at 90
deg. centigrade
Specific resistance (resistivity) at 27 deg.
centigrade.
Flash point Pensky Marten (closed)
Interfacial tension at 27 deg. centigrade
Neutralisation value (total acidity)
Water content
439
40KV / Min.
0.01 max.
10 x 10 12 Ohm-cm
140 deg. centigrade (Min.)
0.03 N/m. (Min.)
0.05 mg KOH/g. (Max.)
35 PPM (Max.)
APPENDIX-A3
LIST OF FITTINGS AND ACCESSORIES
The transformers to be supplied shall be provided with following fittings &
accessories
1.
Rating & terminal marking plate.

i/
Purchase order No. & date to be indicated on rating plate.
ii/ Serial number of transformer to be indicated on rating plate.

iii/ Please confirm copper windings
iv/ Rating & diagram plate with tap position & relative HV/LV voltage
2.
Three nos. 52 KV class porcelain standard transformer HV bushings.
3.
4 nos. 1.1 KV Grade oil filled non communicating type LV bushings.
4.
Earthing terminals
- 2 nos.
5.
Tank lifting lugs
- 4 nos.
6.
Jacking pads
- 4 nos.
7.
Silicagel dehydrating
8.
Conservator with oil filling cap, drain valve with plug and oil level gauge.
9.
Pressure relief device (explosion vent)
10.
Filter valves (Lower valve to be used as drain valve which should be capable to
drain oil completely)
11.
Air release device with cap on tank top.
12.
4 nos. Bi-directional float rollers (150 mm dia and 50 mm wide).
13.
Thermometer pocket.
14.
Off-circuit tap changing switch with indicator locking arrangement.
15.
Terminals connector for HV & LV bushings
breather having minimum 0.5 kg. silicagel.
440
SCHEDULE-I (A)
IN VOLUME-VI

Supply of 33/0.4 kV., 200KVA, 3-Phase,
Copper
Wound, Naturally Air Cooled (ONAN type) Station
Transformers fitted with all accessories & fittings as
described in the specification complete with first filling of
Oil etc. conforming to all technical requirements.
Qty.
S.
No.
1.
NOTE:1. The above description of the equipment is given for the purpose of offering the
prices and to mention description of equipment in invoice for claiming payment.
2. The quantity of above equipments has been mentioned in Volume-VI
441
2.3.1(B) TECHNICAL SPECIFICATION FOR LT DISTRIBUTION BOX SUITABLE

FOR 33/0.4kV 200KVA STATION TRANSFORMER
1.0
SCOPE:

equipment as per Volume-II. The bidder mentioned in this Section of the Technical
Specification means Original Equipment Manufacturer (OEM). The purchaser means the
MPPTCL.
1.1
It is not the intent to specify all details of design and construction of the LT
Distribution Box Suitable for 33/0.4kV 200KVA Station Transformer here. However, LT
Distribution Box shall conform in all respects to the high standard of engineering design and
workmanship. LT Distribution Box offered shall be complete with all components necessary
for their effective and trouble free operation. Such components shall be deemed to be
within the scope of supply of the tender irrespective of whether these are specifically
brought out in this specifications or not.
1.2
LT Distribution Box Suitable for 33/0.4kV 200KVA Station Transformer included in
the tender are required for installation in various 220KV and 132 KV EHV substations of
Madhya Pradesh Power Transmission Company located within the state of Madhya
Pradesh.
2.0
STANDARDS:
Applicable Standards for the offered equipments/items shall be as per Section-I

Volume-II of this bid.
3.0
CLIMATIC CONDITION:
Applicable climatic conditions shall be as per Section-I Volume-II of this bid.
4.0
GENERAL DESCRIPTION AND SPECIFICATIONS OF EQUIPMENT AND

QUANTITY REQUIRED:
4.1.
In the following paragraphs, General description and technical requirement of LT
Distribution Boxes have been described;
S.
No.
Particulars
Rating 200 KVA
Scope
Manufacture & Testing of L.T. distribution Boxes
System
AC 3 Phase, 4Wire 50 C/S
442
S.
No.
Particulars
Rating 200 KVA
Material should be suitable in the weather conditions as below:
a.
Temperature Range
0 0 to 50 0 C
b.
Relative Humidity
20% to Max.100%
c.
Altitude
0 to 1000 Meters
System Details
a.
K.V.A.
Suitable for use with 200 KVA Station Transformer
b.
Voltage
400 VAC
c.
Frequency
50 C/s
d.
Approximate full load

current
300 A
e.
No of outgoing circuit
per phase.
2 Nos. (with a provision of 3rd circuit on the back side)
Applicable Standards Amended Upto Date
a.
Switch Dis-connector
b.
LT MCCBs
c.
d.
e.
6
7
a.
IS:13947(Pt-III)/
1993 or to any equivalent
International Standards
IS:13947(Pt-II)/ 1993 or to any equivalent International

Standards
Enclosure Box
IS:2147/1962 or to any equivalent International
Standards
General Regulator
IS:4237/1992 or to any equivalent International
Standards
LT Switch-gear used
IS:8623(Pt-I)/ 1993 or to any equivalent International
in Box
Standards
Manufacturing/
One Triple Pole Switch Dis-connector of 400A rating
Contructional
on in coming side with 6 Nos. Single pole MCCBs for
Details
two circuits on the outgoing side, as follows:(i) Circuit-I:- 3 Nos. single pole MCCBs, nominal
current rating-200 Amps O/L
current setting- 160
Amps.
(ii) Circuit-II:- 3 Nos single pole
MCCBs, nominal current rating 200 Amps O/L current
setting-160 Amps The interconnection and links shall
be as per the enclosed drawings Adequate space
shall be provided for incorporating an additional circuit
in the dist. box.
Details Of Incoming Circuit With Triple Pole Switch Disconnector (Handle
Should Be Detachable)
Rated Insulation VAC
voltage
Should be more than 660 volts
443
S.
No.
Particulars
Rating 200 KVA
b.
Utilization category
AC 23 A
c.
Rated Impulse
withstand voltage
12 KV
d.
Rated Thermal
current
400 Amps
e.
Rated Operational
current at 240 V
400 Amps
f.
Short withstand
current for one
second
10 KA
g.
Rated making
capacity at 415 VAC
at 0.45 PF
As per relevant clause of IS No.13947 (Pt-III) or to any

equivalent International Standards i.e. 10 times of the
rated operational current of S.D.
h.
Rated breaking
capacity 415 VAC at
= 0.45PF
As per relevant clause of IS No.13497 (Pt-III) or to any

equivalent International Standards i.e. 8 times of rated
operational current of S.D.
i.
Mechanical
Endurance
(Operating Cycles)
(nos)
As per relevant Clause of IS No.13947(Pt-III) or to

any equivalent International Standards
j.
(j) Electrical
Endurance
(Operating
Cycles)
As per relevant Clause of IS No.13947(Pt-III)or to any

equivalent International Standards
k.
Cross
section
of
terminal
strips
of
switch dis-connector
in coming side &
outgoing side
50 x 6 Sq.mm. (As per drawing no.63.722 E)
l.
Length of terminal on
incoming side
80 mm
m.
Length of terminal on
out-going side
60 mm
n.
Material
of
the
terminal strips (incoming & out-going)
Tinned Electrolytic Copper
o.
Length of Operating
Handle and position
of handle.
Switch Disconne-ctor should be front operated &

length should be at-least 80mm
444
S.
No.
Particulars
Rating 200 KVA
p.
Body
material
of
Switch Disconnector
Body of the Switch Disconnector should be made of

DMC compound
q.
Applicable
type test
The Switch Disconnector, to be used in the Distbn.

Box should be type tested as per IS:13947-III)/1993 for
Seq.I, II & III or to any equivalent International
Standards. The type test should be conducted by
CPRI/ EREDA or other recognized and reputable
International Laboratory or Institutions.
Outgoing Circuit Details Single Pole MCCB Shall Be Provided As Per Details
Given Below :-
a.
No. of CKTS on Outgoing side per phase.
2 nos./ phase
b.
Nominal current
200 Amps
c.
Current setting
(Fixed over load)
160/160 Amps/ phase Two Ckt./ phase
d.
No. of pole
Single Pole
e.
Rated Short-circuit
breaking capacity in
KA as per IS:13947
(Part-III)/1993
10 KA at 0.4 PF (LAG)
f.
The sequence of
operation for MCCB
As per Clause 8.3.4 of IS:13947 (Pt-II) or to any

equivalent Inter-national Standards
g.
Utilization Category
(A)
h.
Power factor for

short CKT Test
0.4 (LAG)
i.
Colour of MCCB
Black
j.
Arrangement of
terminal strip of
MCCB
As per drawing No. 63.606 A
k.
Projections of
terminal strips of
MCCB on :-
(i)
Bus-bar
60 mm
(ii)
On outgoing(Cable
side)
80 mm
Size of terminal strips
30 x 5 Sq.mm.
l.
ISS
for
445
S.
No.
Particulars
Rating 200 KVA
m.
Material of the busbar

strips
Continuous tinned copper strip from the point of

contact.
n.
Details of Type tests

for MCCB
MCCB to be used in the distbn. box must be type

tested for Seq-I, Seq-II & Seq.III as per IS:13947 (PtII)/ 1993 / or to any equivalent International Standards
/ done by CPRI Bhopal, Banglore or EREDA and
other recognized and reputable International
Laboratory or Institutions.
o.
Type of MCCBs to be
used
Fully magnetic
p.
LT MCCB SHALL HAVE TIME CURRENT CHARACTERISTICS AS

INDICATED BELOW:
SETTING
TRIPPING TIME
1.05
More than
2.5 Hrs
1.2
More than 10 minutes & less than 2 hrs.
1.3
Less than 30 minutes
1.4
Less than 10 minutes
2.5
Less than 1 minute
Not less than 2 secs
Not less than 5 secs
12
Instantaneous (< 40 m.secs)
DETAILS OF BUS-BAR & LINKS:
a.
Material
Electrolytic tinned copper (As per drawing)
b.
Size of main Bus-bar
50 x 6 Sq.mm.
c.
Size inter-link
30 x 5 Sq.mm.
d.
Insulations over
the Bus-bar & links
PVC Insulation of standard colour

Yellow, Blue for R, Y & B Phase
e.
10
a.
Minimum Clearance
between Busbar
Box and terminals of
Switch Disconnector
& MCCBs
As per drawing no.63.606 D)

code i.e. Red,
As per drawing no.021 dt.Feb' 2001 as per IS:4237

amended upto date or to any equivalent International
Standards
Enclosures
Size
(1200 x 1100 x 470 mm) (1000 x 1000 x 400 mm) As

per drawing 021 dt.Feb'2001 (Revised)
446
S.
No.
Particulars
Rating 200 KVA
b.
Material
CR/MS Sheet
c.
Thickness
2 .0 mm
d.
Arrangement for Pad

lock
Arrangement to be provided for padlock as per

drawing no.021 dt.Feb'2001 (R)
e.
Weather Auto lock is

to be provided on
front of door
Auto lock is to be provided in such a manner that the

cover of the box can not be left open and it gets
latched automatically when closed manually. Latch
should be provided with master key for opening of the
door.
f.
Slopping of Roof
As per drawing no.21 Feb'2001 (Revised)
g.
Front door of the Box
A sticker written with

"PROPERTY OF MPPTCL "
Size of Bottom plate

perforated.
As per drawing 021 dt.Feb'2001 (Revised)
a.
Thickness of bottom
plate
2 mm
b.
Material of the bottom

plate
Perforated sheet
c.
Fixing arrangement of
the bottom plate
Should be detachable
d.
Knock out holes in

the bottom plate
3 Nos. with PVC glands suitable for the required size

of cable and additional 2 mm thick sheet of suitable
width to be provided to hold the cable glands.
e.
Additional Supports of
the Bottom Plate
2 mm thick perforated sheet
f.
Bottom Cleats of Box
Bottom cleat of 80 x 110 x 3 mm thick sheet to be

provided below the box on both side, so that box does
not come in direct contact with ground when stored.
g.
Air Circulation &

clearance in the Box.
Both side louvers with wire mesh, vermin proof

ventilation.
h.
clearance between
the terminals of bus
bar switch disconnector and
MCCB
Creepage should be as per IS:4237 or to any

equivalent International Standards
Instructions to
Lineman
Instruction printed in Hindi to be provided as per

drawing No.03 (B) in side each box.
11
i.
447
S.
No.
Particulars
Rating 200 KVA
j.
Danger Board
Identification Plate
To be provided as per drawing No.62.70 and each

box must have identification plate on the front cover.
a/ Name of the firm
b/ Rating Box
c/ Serial No.
d/ Date of Manufacture
e/ Order No. & date
k.
Hinges
As per drawing no. 6.606(c) out side.
l.
Other parts such as

Nuts, and Bolts
Washers etc.
All Nut, Bolts & Washers used in

current carrying
parts should be of good quality stain less steel (As per
drawing no.63.606 & 63.722)
12
EARTHING BOLTS
a.
Required No
b.
c.
Fixing
Size
d.
Others
Two (one on each side)

Earthing should be welded.
As per drawing
a.
One spring washer and two plain washers should be

provided on the earthing bolt.
PAINTING & FIXING ARRANGEMENT FOR BOX:
Process No.
3 Tank process
b.
Painting
c.
(i)
Colour outside &

Fixing Arrangement
for Box
Size
(ii)
Fixing
As per drawing
(iii)
Lugs
Double hole
per drawing.
14
Neutral busbar
a. Size
50x6 sq.mm or equivalent
b. Fixing
As per drawing
c. Lux
Double hole bimetallic lux of adequate size as per drg.
LUGS ON INCOMING AND OUTGOING TERMINALS
13
d.
15
With
synthetic
good quality.
Brown / White
enamel
Suitable arrangement on a double

per drawing
50 x 6 Sq.mm or equivalent
bimetallic
lugs
paint
of
pole structure as
adequate
size
as
a.
Size of Incoming side

cable & lugs.
95 Sq.mm. Single LT XPLE Cable with suitable single

holes lug.
b.
Size of Outgoing
cable & lugs
70 Sq.mm. XLPE Single core Cable suitable single

hole size lugs
448
S.
No.
Particulars
Rating 200 KVA
16
CABLE HOLDING
CLAMP
Cable holding clamp be made of 2mm thick strip with

4mm base to be provided on in coming side and
outgoing side as per drg. No.63.606 (R-2)
17
OTHER
REQUIREMENTS
There should be free circulation of Air between Switch

Dis-connector busbar & SP MCCB at back and front so
that the inside temp. does not exceed beyond
permissible limits.
18
APPLICABLE
STANDARDS FOR
BOX
IS:2147/1962 with latest amendments or to any

equivalent International Standards.
B. IP-20 IS:8623 (Pt-I)/1993 or to any equivalent
International Standards
19.
Provision of cut-outs
If needed, MPPTCL will provide cutout in distribution

boxes for which tender will provide space and plate as
per enclosed drawing No.
20
TEST & TEST CERTIFICATE
a.
Type Test Certificate
(A) Temperature rise test as per IS:8623/Pt-I/ 93 or to

any equivalent International Standards
(B) High Voltage Test should be done at 3.00 KV for
one minute
(C) 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 Circuit. independently, after by passing the MCCBs.
b.
Routine Test
Certificate:-
Each Distbn. Box should be tested for the routine test

as indicated. The routine test report indicating S. 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 and S.D. Separately.
c.
Acceptance Test On
Complete Box
(These test 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.)
TEMPERATURE RISE TEST

For this test, the Box should be kept in an enclosure
that the temp. is maintaining at 50C and the full load
current of MCCB setting i.e. 160 Amps. is passed in
all circuit and maintained till the temp. is established
and max temp. rise is recorded. (These tests should
be carried on box and MCCB separately.
449
S.
No.
5.0
Particulars
Rating 200 KVA
d.
Time Current
Characteristic Test
With the established 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 it should pass the
requirement given as per Cl.-8(p) above.
e.
Instruction for
submission of Type
Test Certificates:
The type test of the distribution box (as per relevant

ISS or to any equivalent International Standards)
should be carried out by reputed national Laboratory /
test houses such as CPRI Bangalore/ Bhopal/ and
other recognized and reputable International
Laboratory or Institutions.
INSPECTION:
5.1
The purchaser's representative shall at all times be entitled to have access to
the works and all places of manufacture where equipment/ material shall be manufactured
and the representative shall have full facilities for unrestricted inspection of the suppliers
works, raw materials and process of manufacture for conducting necessary tests as detailed
herein.
5.2
The supplier shall keep the purchaser informed in advance of the time of starting
and of the progress of manufacture of equipment/material in its various stages so that
arrangements can be made for inspection.
5.3
No material shall be dispatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the purchaser in
writing. In the later case also, the equipment/material shall be dispatched only after
satisfactory testing for all tests specified herein has been completed.
5.4
The acceptance of any quantity of material shall in no way relieve the supplier of
any of his responsibilities for meeting all requirements of the specification, and shall not
prevent subsequent rejection if such material is later found to be defective.
5.5
The number of sample selected to carryout the acceptance test shall be as per
provision in the respective IS or any equivalent International Standards.
5.6
The purchaser has the right to have the tests carried out by an independent
Agency subject to recovery of testing expenditure in case of failure, whenever there is
dispute regarding the quality of supply.
6.0
6.1
The supplier shall invariably furnish following information along with his offer,
failing which his offer shall be treated as non responsive. Information shall be separately
given for individual type of equipment offered.
(i)
Statement giving list of important raw materials, names of sub supplies for
the raw materials, list of standards according to which the raw materials are
450

tested, list of tests normally carried out on raw materials in presence of
suppliers representative copies of test certificates.
(ii)
Information and copies of test certificates as in above in respect of bought

out accessories.
(iii)
(iv)
Level of automation achieved and list of areas where manual process

exists.
(v)
List of areas in manufacturing process, where state inspections are

inspections.
(vi) Special features provided in the equipments to make it maintenance free, if

any.
(vii) List of testing equipments available with the supplier for final testing of
equipment specified and test plant limitation. If any, vis--vis the type,
special, acceptance and routine tests specified in the relevant standards.
These limitations shall be very clearly brought out in schedule of deviation
from specified test requirements.
6.2
The successful supplier shall within 30 days of placement of order submit
following information to the purchaser.
7.0
(i)
List of raw material as well as bought out item accessories and the names
of sub-suppliers selected from those furnished along with offer.
(ii)
Type test certificate of raw material and bought out accessories, if any.
(iii)
Quality assurance plan (QAP) with hold points for purchasers inspection.
The quality assurance of plan and Purchasers hold points shall be
discussed between the Purchaser and supplier, before QAP is finalized.
DOCUMENTATION:
7.1
One set of type tests reports, duly approved by the Purchaser shall be submitted
by the supplier for distribution, before commencement of supply. Adequate copies of
acceptance and routine test certificates, duly approved by the purchaser shall accompany
the dispatched consignments.
7.2
Purchaser. All manufacturing and fabrication work in connection with the equipment prior to
the approval of the drawing shall be at suppliers risk.
7.3
Approval of drawing/work by purchaser shall not relieve the supplier of his
451

revision of applicable standards, rules and codes of practices. The equipment shall conform
in all respect to high standards of engineering, design, workmanship and latest revisions of
relevant standards at the time of ordering. Purchaser shall have the power to reject any
ordered material which in his judgment is not in full accordance therewith.
8.0
8.1
The equipment shall be packed in crates suitable for vertical/horizontal transport,
as the case may be and suitable to withstand handling during transport and outdoor storage
during transit. The supplier shall be responsible for any damage to the equipment during
transit, due to improper and inadequate packing. The easily damageable material shall be
carefully packed and marked with the appropriate caution symbols. Wherever necessary,
proper arrangement for lifting, such as lifting hooks etc. shall be provided. Any material
found short inside the packing cases shall be supplied by supplier without any extra cost.
8.2
the following information.
(a)
Name of consignee.
(b)
(c)
Destination.
(d)
(e)
(f)
8.3
On each package / crates containing the material / equipment following
information shall be distinctly stenciled on it in indelible Ink along with other essential data:(i)
Contact Award letter number
(ii)
Name and address of consignee
(iii)
Manufacturers name and address
(iv)
Name of item
(v)
Quantity
(vi)
Gross weight
(vii)
Arrow Marking for stacking/opening.
8.4
The supplier shall ensure that the packing list and bill of material are approved
by the owner before despatch.
9.0
QUANTITY AND DELIVERY REQUIREMENTS:

(i)
This is set out in this specification.
(ii)
The scope of supply shall include supply of 2.5% extra quantity of bolts,
nuts, washers, split pins, cotter pins and such other small loose items free
of cost.
452

10.0 COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS:
Bidders must furnish the following information along with technical Bid:
10.1 Complete details of all the accessories which will be supplied with the LT distribution
box should be furnished.
10.2 It is obligatory on the part of Bidder to ensure that supply of all accessories along
with Main equipment are simultaneously delivered to avoid any holdup in erection and
commissioning. The responsibility for obtaining timely supplies of bought out items will rest
on Bidders and only on this basis, delivery period will be offered in the Bid.
10.3
other negligence, replenishment shall be arranged within one month time. For bought out
items, responsibility for guarantee and obtaining immediate replacement in case any
defects are noticed and also in case defective supply of any item is reported, will rest with
the Bidder. In case for attending to defects in any accessory or inspection/ replacement of
the accessory, which may be bought out item for the Bidder; if services of engineer of
original manufacturer is required, the same will be organized on immediate basis by Bidder
at his cost.
11.0
Please ensure that Bid document containing number of pages have been
properly numbered and signed by the Bidder. Bid document including all schedules
and Annexures should be indexed properly and Index of the document should be
enclosed / placed at the beginning of the Bid document.
453
APPENDIX-B
DRAWINGS
S.
No.
Description
General Arrangement Drawing for Danger Board
General Arrangement Drawing for Long Palm Double Stud Cable Lug
General Arrangement Drawing for MCCB/ Switch Disconnector

Terminal connection
General Arrangement Drawing for Cable Terminal Connection/ Cable

Holding
General Arrangement Drawing for L.T Distribution Box of 200 KVA

Xmer
454
1
k[ kk
440
o
YV~
l
N O T E S A N D R E F E R E N C E S :A.
S P E C IF IC A T IO N F O R T H E B O A R D
1.
M A T E R IA L
2.
S IZ E
1 8 G A U G E M .S . S H E E T .
200M M x 150M M
3.
F R O N T S ID E
(B A C K G R O U N D ) E N A M A L L E D W H IT E .
L E T T E R IN G F IG U R E S O F V O L T A G E , P A IN T IN G O F S K U L
A N D B O N E S S H A L L B E IN S IG N A L R E D C O L O U R
4.
B A C K S ID E
ENAM ELLED
5.
BO LT HOLES
2 Nos
N O T E :-
A S P E R IS :2 5 5 1
7 M M D IA . F O R 6 M M D IA . G .I. B O L T S .
C O R N E R S O F P LA T E S H ALL BE R O U N D ED &
A L L L E T T E R IN G S H A L L B E C E N T R A L L Y S P A C E D .
F O R 2 0 0 K V A L . T . D IS T R IB U T IO N B O X
D A N G E R B O A R D H IN D I
M P P T C L
JA BA LP U R
D R A W IN G N o .-
J IC A /M P P T C L /T R -1 0 2
T O 1 0 7 /G A D B
455
LO N G PALM . D O UBLE STUD
M P P T C L
CABLE LUG S
JABALPU R
D R A W IN G N o .-
J IC A /M P P T C L /T R -1 0 2
T O 1 0 7 /G A C A B L E L U G
S E C T IO N II
2 0 0 K V A L T D IS T R IB U T IO N B O X
456
GENERAL ARRANG EM ENT FOR M.C.C.B. / SW ITCH

DISCONNECTOR TERM INALS CONNECTION
FOR 200KVA L. T. DISTRIBUTION
M P P TCL
JABALPUR
DRAW ING No.-
JICA/M PPTCL/TR-102
TO 107/GA M CCB/DS
457
E Q U IP M E N T (M C C B )
D E T A IL S O F M C C B T E R M IN A L S A T
"A "
"B "
C A B L E H O L D IN G C L A M P
D E T A IL S A T H IN G E S
"C "
D E T A IL S A T
"D "
FO R 200KVA BOX
B U S B A R L IN K
GENERAL ARRANGEMENT FOR

C A B L E T E R M IN A L C O N N E C T IO N / C A B L E H O L D IN G
FO R 200KVA
M P P T C L
JA B A LP U R
D R A W IN G N o .-
J IC A /M P P T C L /T R -1 0 2
T O 1 0 7 /G A C .C
458
459
JICA/MPPTCL/TR-102
TO 107/GA LTDB
DRAWING No.-
L. T. DISTRIBUTION BOX FOR 200KVA TRANSFORMER
MODIFIED GENERAL ARRANGEMENT OF
OFFICE OF THE E. D. (T & P), JABALPUR
MPPTCL
SCHEDULE-I (A)
IN VOLUME-VI
1.

200 KVA LT Distribution Boxes suitable for 33/0.4 kV
200KVA Station Transformers
Qty.
S.No.
NOTE:1. The above description of the equipment is given for the purpose of offering
payment.
460
2.3.1(C) TECHNICAL SPECIFICATION FOR 33KV DO FUSE UNITS

1.0
SCOPE:

equipment as per Section-I Volume-II. The bidder mentioned in this Section of the
means the MPPTCL.
2.0
SYSTEM CONDITIONS:
Applicable climatic conditions shall be as per Section-I Volume-II.
2.1
STANDARDS:
Applicable Standards for the offered equipments/items shall be as per Section-I

Volume-II.
3.0

4.0
STANDARD RATING
Standard ratings shall be 33/0.400 kV, 500KVA Station Transformer with off circuit
taps on HV winding for variation of HV Voltage.
5.0
DROP OUT FUSES:
The drop-out fuses (D.O.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 plane.
5.1
The equipment offered by the Bidder shall be suitable for 33KV three phase 50 Hz
solidly grounded earthed neutral systems. The DO set unit shall be designed designed for a
normal current rating of 200 Amps. Whereas the rating of fuse unit shall be 15 Amp.
5.2
The drop out fuses are required with Post Insulators. These shall be suitable for
mounting on the structure. The bracket /channel hardwares for DO Fuses shall be provided
with adequate sizes of nuts, bolts and washer for mounting on the structures of the
purchaser.
6.0
POST INSULATORS:
461
Each 33KV DO Fuse Units shall have two nos 33KV Post insulator. 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
effect 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 porcelains 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
affect the electrical or mechanical strength and rigidity. Each cap and base pin shall be
made of 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.
6.1
Type Test Certificate:
The Bidder shall invariably enclose with the offer, the type test certificate of
MPSEB Design DO Fuses alongwith certified copy of the drawing and other guaranteed
technical particulars. Please note that offers without type test certificate will not be
entertained and would be out rightly rejected.
The type test report of the supplier shall also be acceptable if the supplier's
manufacturing unit, including the testing laboratory has ISO 9000 (or its equivalent)
certification and type tests has been witnessed by the representative of any of the utilities.
The type test should not be older than 5 (five) years from the date of opening of
Bid.
6.2
Each 33KV Post Insulators should have technical particulars as detailed below:S.No.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
Description
Nominal system voltage KV (rms)
Highest system voltage KV (rms)
Dry Power Frequency one minute withstand
voltage KV(rms)
Wet one minute power frequency withstand
voltage KV (rms)
Power Frequency puncture with stand
dry
voltage. KV (rms)
Impulse withstand voltage KV (peak)
Visible discharge voltage KV (rms)
Creepage distance in mm (minimum)
Cantilever strength (KN)
462
33KV
33
36
75
75
1.3 times the
actual flashover
voltage.
170
27
580
10

7.0
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 or any equivalent
International Standards.
7.1
Rated Voltage:
The rated voltage shall be 33KV for 33KV DO Fuse Units.
7.2
Rated Current:
The DO Fuse Unit components shall be suitable for 200 Amp. Current whereas the
rating of fuse unit shall be 15 Amps.
7.3
base:
Rated Lightning impulse withstand voltage values for the fuse
The rated lightning impulse withstand voltage both for positive and negative
polarities shall be as given below:
S.No.
a
b
7.4
S.No.
a
b
7.5
S.No.
a
b
c
8.0
Description
To earth and between poles
Across the isolating distance of fuse
33KV
170 KV Peak
195 KV Peak base.
Rated one minute power frequency withstand voltage (dry and wet)
values for the fuse base:
Description
To earth and between poles
Across the isolating distance of fuse
33KV
75 KV Peak
80 KV Peak base.
Temperature Rise Limit in Air Above Ambient Temperature ( 0 C ):

Description
Brass contacts silver faced
Terminals
Metal parts acting as spring
33KV
650C
500C
The temperature shall not reach such a value
that elasticity of the metal is changed.
MAIN CONTACTS:
The main contacts of the D.O.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.
Electro-dynamic withstand ability during short circuit without any risk of

repulsion of contact.
ii.
Thermal withstand ability during short circuits.
463
9.0
iii.
Constant contact pressure even when the lower parts of the insulator stacks
are subjected to tensile stresses due to linear expansion of connected
busbar or flexible conductors either because of temperature variation or
strong winds.
iv.
Proper alignment to ensure smooth operation of D.O.Fuse without

adjustment.
CONNECTORS:
The connectors shall be made from Brass suitable to receive single Zebra
conductor. 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.
10.0
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 25mm dia. The arrangement
shall be made to ensure that the fuse wire runs centrally inside the SRBP tube after
tightening.
11.0
SPRING STRIPS:
The spring strips shall be of phosphore bronze multiline brush type having a high
pressure contacts and should retain its tension under minimum continuous service
current of 200 Amps at 900C.
12.0
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 out 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.
13.0
D.O.BARRELS:
The D.O. Fuse Barrels shall be made from SRBP and shall conform 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 to the inspecting officer. The test
certificates of SRBP barrel should indicate the following test results:-
i.
ii.
Dimension:
(a) External dia
(b) Wall thickness
(c) Internal dia
Max. wraping in 12" length of the tube.
464
iii.
Axial electric strength (Proof test in oil at The barrel should with
900C at 25KV rms 50 C/s.)
stand this test satisfactorily
for one minute
iv.
Radial electric strength (Proof

at 900C at 19 KV rms 50 C/s.)
v.
Surface electric strength (Proof test in air at The barrel should withstand
room temp.(320C) at 14 KV rms at 50 C/s)
this test satisfactorily for
one minute.
vi.
Water absorption in 14 hours
vii.
Resistance to Hot Oil
viii.
Cohesion between layers (Proof test)
ix.
test in oil The barrel should with

stand this test satisfactorily
for one minute
Machineability
13.1
The Bidder should indicate the name of manufactures of SRBP tube from where
they will purchase the Barrel to make available the above test certificate. The barrels
should have the property 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.
14.0
DESIGN, MATERIALS AND WORKMANSHIP:
The successful Bidders shall assume full responsibility for co-ordination and
adequate design. All materials used in the construction of the equipment shall be of the
appropriate class, 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 0 kind of loosening. After cementing the insulator should be
cured adequately in water to attain good gripping.
15.0
GUARANTEED DATA & OTHER TECHNICAL PARTICULARS:
Guaranteed data and other technical particulars of the D.O. Fuse should be given
with the bid.
16.0
TESTS:
Each D.O.Fuse shall strictly comply with 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 Bidder should note that alongwith the Bid, the following type test certificate as
per ISS:9385 Part-II-1980 (with latest amendment) or any equivalent International
Standards must be furnished on MPPTCL design D.O. fuses. The type test should not be
older than 5 (five) years from the date of opening of Bid and should be performed in the
Govt. recognized Lab.
(i)
Impulse voltage withstand test,
465

(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
furnish Routine Test certificate of DO Fuse barrels & Post Insulator of their
manufacturers.
17.0
IMPORTANT REQUIREMENTS TO BE NOTED BY THE BIDDER:

The suppliers should carefully note the following requirements and comply the
same.
i.
All the accessories of D.O. Fuse Unit should be listed out clearly and
despatch with DO Fuse Units.
ii.
Technical particulars of D.O. Fuse Units should be as given in the

specification.
18.0
Each D.O. Fuse shall be provided with name plate of size 4"x 2" on steel channel
in case of 33KV DO Fuse and shall be either revitted/bolted.
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 MPPTCL.
Please note paper sticker should not be used for name plate. The material should
be packed in appropriate Wooden cartoons, so as to sustain transport hazards.
19.0

The following drawing of 33KV DO Fuses are enclosed herewith:(i)
EB/P6/MPEB/6 (revised) dt.14.1.88 for 33KV DO Fuse Unit.
The Bidder shall ensure that the design of their equipment is as per the drawing
enclosed and specification of the Bid. The main dimensions are given here as under:-
2.
DIMENSION OF D.O.FUSE UNITS IN MM

Particulars
33KV
Drawing No.
EB/P6/MPEB/6/(revised)
Dated 14.1.88
M.S. Flat
600x50x6
3.
M.S. Channel
600x100x50x6
4.
Fuse Barrels
510x25x14
5.
Lower Contact Hinge of Barrel:(i)

Connectors
S.No.
1.
(ii)
Hinge Contact Length
60x60x6
95
466

S.No.
(iii)
(iv)
6.
Particulars
Hinge Contact Width
Thickness of Hinge
(i)Outer
33KV
85
(ii) Inner
5
4
Barrel take out hook:Width
25
ii
Thickness
iii
Length
30
iv
Inner dia meter
25
Thickness between inner outer dia
3 mm
7.
Operating Hook:-
Width
18
ii
Thickness
iii
Inner Radius
20
iv
Outer Radius
25
8.
Female contact :-
Main Contact Width
70
ii
Strip thickness
1.5
iii
Strip length
100
iv
Width
20
Female contact height
75
9.
Female Contact Holder:-
Length
74
ii
Upper width
34
iii
Lower width
40
10.
Creepage of Insulator
580
Note: Normally Post Insulators of following standard makes should be used for
manufacturing of D.O. Fuses. The successful bidder shall required to submit the type test
certificate and obtain its approval before commencing production.
(i)
M/s Allied Ceramics Pvt. Ltd. Calcutta
(ii) M/s Birla NGK Insulators, Rishra
(iii) M/s India Potteries Ltd. Calcutta
(iv) M/s Bharat Heavy Electricals, Banglore.
(v) M/s W.S. Industries, Chennai.
20.0
INSPECTION:
467

20.1
The purchasers representative shall at all times be entitled to have access to the
works and all places of manufacture where equipment/material shall be manufactured and
the representative shall have full facilities for unrestricted inspection of the suppliers works
raw materials and process of manufacture for conducting necessary tests as detailed
herein.
20.2
The supplier shall keep the purchaser informed in advance of the time of starting
and of the progress of manufacture of equipment/material in its various stages so that
arrangements can be made for inspection.
20.3
No material shall be despatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the purchaser in
writing. In the later case also, the equipment/material shall be despatched only after
satisfactory testing for all tests specified herein has been completed.
20.4
The acceptance of any quantity of material shall in no way relieve the supplier of
any of his responsibilities for meeting all requirements of the specification, and shall not
prevent subsequent rejection if such material is later found to be defective.
20.5
The number of sample selected to carryout the acceptance test shall be as per
provision in the respective IS or any equivalent International Standards.
20.6
The purchaser has the right to have the tests carried out by an independent
Agency subject to recovery of testing expenditure in case of failure, whenever there is
dispute regarding the quality of supply.
21.0
DOCUMENTATION:
21.1
Six sets of type test reports, duly approved by the Purchaser shall be submitted by
the supplier for distribution, before commencement of supply. Adequate copies of
acceptance and routine test certificates, duly approved by the purchaser shall accompany
and dispatched consignments.
21.2
approved drawings/specification and no deviation shall be permitted without the written
approval of the Purchaser. All manufacturing and fabrication work in connection with the
equipment prior to the approval of the drawing shall be at suppliers risk.
21.3
Approval of drawing/work by purchaser shall not relieve the supplier of his
revision of applicable standards, rules and codes of practices. The equipment shall conform
in all respect to high standards of engineering, design, workmanship and latest revisions of
work or material which in his judgment is not in full accordance therewith.
22.0
22.1
The equipment shall be packed in crates suitable for vertical/horizontal transport,
as the case may be and suitable to withstand handling during transport and outdoor storage
during transit. The supplier shall be responsible for any damage to the equipment during
transit, due to improper and inadequate packing. The easily damageable material shall be
carefully packed and marked with the appropriate caution symbols. Wherever necessary,
proper arrangement for lifting, such as lifting hooks etc. shall be provided. Any material
found short inside the packing cases shall be supplied by supplier without any extra cost.
468

22.2
(a) Name of consignee.
(b) Details of consignment.
(c) Destination.
(d) Total weight of consignment.
(e) Handling and unpacking instructions.
(f)
22.3
Marking:
On each packages / crates containing the material / equipment following

information shall be distinctly stenciled on it in indelible Ink alongwith other essential data:
(i)
Contract Award letter number
(ii) Name and address of consignee
(iii) Manufacturers name and address
(iv) Name of item
(v) Quantity
(vi) Gross weight
(vii) Arrow Marking for stacking/opening.
22.4.
The supplier shall ensure that the packing list and bill of material are approved by
the owner before despatch.
469
SCHEDULE-I (A)
IN VOLUME-VI

33 KV Drop Out Fuse Units of current carrying
capacity of 200 Amps. With fuse of 15 Amp. Rating.
(each unit having 2 nos. of 33 KV Post Insulators
fitted on channel base with fuse barrel as per BSS1314) as per technical requirement as described in
Section-C in the Bid Document.
Qty.
S.No.
1.
NOTE:1. The above description of the equipment is given for the purpose of offering
payment.
470
2.3.2(A) TECHNICAL SPECIFICATION FOR 110V 300/200AH &

48V 300/200 AH STATION BATTERIES
1.0
SCOPE:
1.1
equipment as per Volume-II. The bidder mentioned in the Section of the Technical
the MPPTCL.
1.2.
SYSTEM REQUIRMENTS WHICH ARE TO BE CONSIDERED FOR DESIGN

OF BATTERIES:
1.2.1
1.2.2
STANDARDS:

Volume-II.
1.2.3
OPERATING CONDITIONS:
Batteries shall be designed to render highest efficiency for the duties specified
and shall be capable of operating continuously without the need for any shutdown.
Design shall be such as to ensure trouble free operation.
1.3.
GENERAL AND CONSTRUCTIONAL REQUIREMENTS FOR STATION

BATTERIES:
General description of Batteries of capacity 110V, 300AH/200AH & 48V,

300AH/200AH shall be as under:
1.3.1 Cells shall be supplied in glass boxes or hard rubber boxes and ample space
must be provided below the plate for accumulation of deposit. Spray arresters shall be
provided to prevent loss of acid by spraying during charge. Improved design of tubular
type Positive plates may be offered.
1.3.2 Lead acid battery, comprising of closed type cells shall be complete with tubular
positive plate assemblies, glass boxes or hard rubber boxes, lids providing microporous
plastic separators, polystyrene dewels and buffers, inter cell connector and lead covered
bolts and nuts. Battery, shall be offered complete with (i) inter row connectors, acid jars
and packing case, (ii) stands (iii) stand insulator (iv) Cable sockets for two end cells
and four tapping connections.
471
Battery Set & Battery Charger
1.3.3 Bidders may please note that all 55 Cells of 110 Volts and 24 Cells of 48 Volts
Battery sets shall be arranged in single tier system, such that, all 55/24 Cells are placed
on one wooden stand which shall be at a height of 1 ft from ground level. The Stands
shall be constructed of selected timber and painted with three coats of acid proof paint.
This is mandatory requirement.
1.3.4
Necessary paint for this purpose shall also be supplied. No metal fastenings
shall be used in wooden stand. Stands shall be supported on insulators to obtain
necessary insulation from earth and there shall be insulators between each cell and
stand.
1.3.5 Bidders may please note that there shall be two holes per inter cell connector
and two strips (one short and one long) need necessarily be provided for connections.
Arrangement of connection shall be such that if one inter cell connector/strip is removed
for cleaning of terminal and application of petroleum jelly etc. then other strip must
remain in circuit and battery should not get open circuited. Bidders may explore
possibilities of providing this arrangement for inter cell connections and confirm.
1.3.6
One set of following accessories shall be supplied along with each battery set
i.
One battery logbook.
ii.
Two copies of printed instruction sheet.
iii.
One No. cell testing voltmeter (3-0-3 volts) complete with lead.
iv.
One no. rubber syringe.
v.
One no. rubber syringe type hydrometer suitable for specific gravity
reading.
vi.
One no. thermometer (0 to 70

scale.
vii.
One set cell bridging connectors.
viii.
Anti sulphuric enamel paint -
C min.) with specific gravity correction
(a)
red colour in required quantity, and
(b)
black colour - 2 liters.
ix.
Battery stand suitable for accommodating the cells coated with 3 coats of
anti acid paint.
x.
Hard rubber cell insulators in required quantity with 12 Nos. extra (spare).
xi.
PVC sheet stand insulators in required quantity with 4 Nos. extra (spare).
xii.
One set of cell number plates with fixing pins.
xiii.
One pair of spanners.
xiv.
One no. acid resisting funnel.
xv.
One no. acid resisting jug of 2 liters capacity.
xvi.
Requisite quantity of electrolyte with 10% extra in non-returnable

containers.
xvii.
One pair of rubber gloves.
xviii.
One pair of rubber boots.
xix
One no. rubber apron.
xx.
One set of inter tier connector.
xxi.
Cable socket for two end cells and four tapping cells.
472
1.3.7 Please note that if any of the above mentioned items are not required for the
batteries offered by you, the same shall be brought out clearly with proper justification
with drawings. Any other accessories other than those mentioned above, which you
feel necessary for the batteries offered by you, may also be mentioned and the prices of
the same should be quoted separately.
1.3.8 Battery shall comprise of 55/24 cells with capacity not
less
than 300AH
/200AH for 110 Volts and 300AH/ 200AH for 48 Volts Batteries at 10 hour discharge
rate.
1.3.9 For the purpose of confirmation to supply all the items mentioned above under
Clause 1.3.2 to 1.3.6, the Bidders shall bring out all the details in a tabular form in the
manner indicated in Schedule VIII.
1.4
It shall be Bidders responsibility to prove adequacy of its design by submitting all
technical particulars and suitable graphs to show suitability of battery for supplying
emergency load on continuous basis for few hours without getting discharged.
1.5
TYPE TEST:
1.5.1 Bidders may furnish type test reports from any Govt. test house, CPRI, NPL or
other reputed agency approved by the Statutory institutions for the type of cell offered
for each rating of the batteries. Type test report of each rating cell shall not be more
than five years old. Type test report shall be as per the requirement of IS: 1651 - 1991
(with latest amendment, if any), and shall cover the following:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
1.5.2
Verification of constructional requirement.

Verification of marking.
Verification of dimensions.
Test for capacity for voltage during discharge.
Ampere -hour and watt-hour efficiency tests.
Test for retention of charges
Endurance test.
Batteries shall be tested after manufacture as per the requirement of IS:1651 1991 (with latest amendment, if any) jointly in presence of our team of officers at the
discretion of purchaser at Bidders works. Two copies of test certificates indicating the
test results obtained during the tests shall be submitted for approval. It will be obligatory
on the part of supplier to despatch the material, only after obtaining acceptance of Test
results, strictly as per our despatch clearances.
Above and other Special Tests if any required by the purchaser or his
representative shall also be carried out, so that the purchaser and his representative is
satisfied that the offered equipment shall meet our field requirements under adverse
system conditions. All these Tests shall be carried out in presence of the representative
of the purchaser prior to dispatch, if so desired by the purchaser and the test results in
quadruplicate shall be submitted to the purchaser for approval. No material shall be
despatched by the supplier without prior approval of the test certificates by the
purchaser.
473
1.6
DOCUMENTATION, DRAWINGS AND TEST REPORTS:
1.6.1 Bidders shall submit with their offers, all such drawings, instruction manual,
descriptive literature etc. as may be necessary for the proper understanding of his BID.
In the drawings Bidder shall indicate the name, make and rating of all components used
including details of placement of battery on its stand and arrangement for cable socket
for end cells and four tapping cells.
1.6.2
Bidders may carefully go through this specification and while submitting their
BID, all requirements as described under specification shall be complied with and
complete details should be furnished. In absence of non-furnishing of any of the
confirmations or schedules or technical/commercial questionnaire, the BID shall be
treated as incomplete and may be non responsive from technical angle.
1.6.3 Successful Bidder shall, within two weeks of placement of order, submit four sets
of final version of all the above drawings for purchaser's approval. Purchaser shall
communicate his comments/approval on the drawings to the supplier within two weeks.
Supplier shall, if necessary, modify the drawings and resubmit four copies of the
modified drawings for purchaser's approval within two weeks from the date of
comments. After receipt of purchaser's approval, the supplier shall, within three weeks,
submit 4 prints per battery set and two set of good qualities reproducible of the
approved drawings for purchaser's use.
1.6.4 Successful Bidder shall also furnish two sets each of bound manuals covering
erection, commissioning, operation and maintenance instructions and all relevant
information and set of approved drawings alongwith each battery set. Marked erection
drawings shall identify the component parts of the equipment as shipped to enable
erection by purchasers own personnel. Each manual shall also contain one set of all
the approved drawings, type test reports as well as acceptance reports of the
corresponding consignment dispatched.
Manufacture of Batteries shall be strictly in accordance with the approved
drawings and no deviation shall be permitted without written approval of the purchaser.
1.6.5 Approval of drawings/work by the purchaser shall not relieve the Bidder of any
of his responsibility and liability for ensuring correctness and correct interpretation of the
drawings for meeting the requirements of the latest revision of the applicable standards,
rules and codes of practices. Battery shall conform in all respects to high standards of
engineering, design, workmanship and latest revisions of relevant standards at the time
of supply and purchaser reserves the right to reject any work or materials which, in his
judgment, is not in full accordance therewith.
1.7

Bidder must furnish following information along with technical bid.
1.7.1
Complete details of all the accessories which will be supplied with each
battery set should be furnished. While furnishing these details, items which will be
manufactured by the Bidder and balance items, which will be procured from subsuppliers should be clearly identified and indicated in the BID.
474
1.7.2
It is obligatory on the part of Bidder to ensure that supply of all accessories
along with each battery set are simultaneously delivered to avoid any holdup in erection
and commissioning . Responsibility for obtaining timely supplies of bought out items will
rest on the Bidder and only on this basis, delivery period will be offered in the BID.
1.7.3
It may be noted that in case of damages/shortages due to improper packing or
any other negligence, replenishment shall be arranged within one month time. For
bought out items, responsibility for guarantee and obtaining immediate replacement
in case any defects are noticed and also in case defective supply of any item is
reported, will rest on the Bidder. In case for attending to defects in any accessory or
inspection/ replacement of the accessory, which may be bought out item for the Bidder;
if services of engineer of original manufacturer is required, the same will be organized
on immediate basis by the Bidder at his cost.
1.8
1.9
INSPECTION:
(i)
Purchaser shall have access at all times to the works and all other places
of manufacture, where the Battery Sets are being manufactured and the
Bidder shall provide all facilities for unrestricted inspection of Bidders
works, raw materials, manufacture of all the accessories and for
conducting necessary tests as detailed in the bidding document.
(ii)
Successful Bidder shall keep the purchaser informed in advance of the

time of starting and of the progress of manufacture of Battery Sets in its
various stages, so that arrangement could be made for inspection.
(iii)
No material shall be despatched from the point of manufacture unless the

material has been satisfactorily inspected / tested and dispatch clearance
issued.
(iv)
Acceptance of any quantity of the Battery Sets shall in no way relieve the
successful Bidder of this responsibility for meeting all the requirement of
this specification and shall not prevent subsequent rejection if such
equipment are later found to be defective.
1.9.1 Bidder must establish that they are following a proper quality assurance
programme for manufacture of Battery Sets. Bidders shall invariably furnish following
information alongwith their BID. Information shall be separately given for each type of
each battery set:
(i)
Statement giving list of important raw materials, names of sub-suppliers

for the raw material, list of standards according to which the raw material
is purchased and copies of test certificates thereof.
(ii)
Information and copies of test certificates as in (i) above in respect of

bought out items.
(iii)
(iv)
Levels of automation achieved and list of areas, where manual

processing exists.
475
(v)

normally carried out for quality control and details of such tests &
inspections.
(vi)
Battery Sets and test plant limitation, if any, vis--vis type, special,
acceptance and routine tests specified in the relevant standards. These
limitations shall be very clearly brought out in schedule of deviations from
1.9.2 Successful Bidder shall within 30 days of placement of order, submit following
(i)
List of raw material as well as bought out accessories and the names of
sub-suppliers selected from the lists furnished along with bid.
(ii)
(iii)
Quality Assurance Plan (QAP) with hold-up points for purchasers

inspection. The quality assurance plans and hold-up points shall be
discussed between the Purchaser and supplier before the QAP is
finalized.
1.9.3 Successful Bidder shall submit routine test certificates of bought out items
and raw material at the time of routine testing of each battery set.
1.10
1.10.1 Battery Sets shall be packed in crates suitable for vertical/horizontal transport as
the case may be and suitable to withstand handling during transport and outdoor
storage during transit. Bidder shall be responsible for any damage during transit, due to
improper and inadequate packing and handling. Easily damageable material shall be
carefully packed and marked with appropriate caution symbols. Wherever necessary,
proper arrangement for lifting, such as lifting hooks etc. shall be provided. Bidder shall
supply any material found short inside the packing eases without any extra cost.
1.10.2 Each consignment shall be accompanied by a detailed packing list containing
the following information:
a)
b)
c)
Destination.
d)
e)
f)
g)
Bill of material indicating contents of each package
1.10.3 On each package/crate containing the Battery Sets, following information shall
be distinctly stenciled on it in indelible ink alongwith other essential data:
i)
h)
Contract Award Number

Name and address of consignee
i)
Manufacturers name and address
j)
Name of item
476
k)
Quantity
l)
Gross weight
ii)
Arrow marking for stacking/opening.
Supplier shall ensure that the packing list and bill of material are approved by the
purchaser before despatch.
1.11 SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS:
Bidder shall furnish guaranteed technical particulars for the battery sets in the format
provided under enclosed Schedule-II.
1.12

1.13
properly numbered and signed. Document including all Schedules shall be indexed
properly and Index of the document shall be enclosed/placed at the beginning of the
Bid document.
477
APPENDIX-A1
SCHEDULE OF ACCESSORIES TO BE PROVIDED
WITH EACH STATION BATTERY SET
S.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21
22.
23
24
Particulars
Qty.
One battery logbook.

Printed instruction sheet.
Cell testing voltmeter (3-0-3 volts) complete with lead.
Rubber syringe.
Rubber syringe type hydrometer suitable for specific gravity
reading.
Thermometer (0 to 70 C min.) with specific gravity correction scale.
Cell bridging connectors
Battery stand suitable for accommodating the cells in single tier in
case of 110 Volts & 48 Volts battery sets coated with 3 coats of anti
acid paint.
Anti sulphuric enamel paint
a) Red colour
b) Black colour
Hard rubber cell insulators with 12 Nos. extra (spare).
PVC stand insulators in required quantity with 4 Nos. extra (spare).
Cell number plates with fixing pins.
Spanners.
Acid resisting funnel.
Acid resisting jug of 2 liters capacity.
Electrolyte with 10% extra in non-returnable containers.
1 No.
2 Nos.
1 No.
1 No.
1 No.
Rubber gloves.
Rubber boots.
Rubber apron.
Inter tier/ row connector.
Cable socket for two end cells and four tapping cells.
Petroleum Jelly
a) 110V
b) 48V
Wall mounting holder for hydrometer and thermometer
No. of cells 110/48V
1 No.
1 set
1 set
1 litre
1 litre
As required
As required
1 set
1 pair/set
1 No.
1 No
Requisite
quantity
One pair
One pair
1 No
1 set
6 Nos
100g
50g
1 No
55/24 Nos.
Note:- The accessories to be supplied with each battery sets will be finalized at the time of
drawing approval.
478
S.
No.
1
Qty.
110 Volts, 300 AH Station batteries complete with

accessories confirming to all technical requirement as per
specification.
accessories
confirming to all technical requirement as per specification.
specification.
specification.
SCHEDULE-I (A)
IN VOLUME-VI
NOTE: 1. The above description of the equipment is given for the purpose of
offering the prices and to mention description of equipment in invoice
for claiming payment.
2. The quantity of above equipments has been mentioned in volume-VI.
479
2.3.2(B) TECHNICAL SPECIFICATION FOR 110V & 48 V BATTERY

CHARGERS
1.0
SCOPE:
1.1
equipment as per Volume-II. The bidder mentioned in the Section of the Technical
the MPPTCL.
1.2
SYSTEM REQUIRMENTS WHICH ARE TO BE CONSIDERED FOR DESIGN

OF BATTERY CHARGERS:
1.2.1 CLIMATIC CONDITIONS:

1.2.2 STANDARDS:
Volume-II.
1.2.3
FAULT LEVEL: Fault level of the auxiliary AC supply at the terminals of the
charger shall be 10 KA. All accessories shall be selected and equipment shall be
designed accordingly.
1.2.4
INPUT SUPPLY: Input supply where the chargers shall be installed shall be
433V + 10% or -15%. Accordingly suitable taps in the input transformer may be
provided for supply voltage of 433V taking into account above voltage variation.
Depending upon the supply voltage available, selection of taps shall be made by the
purchaser.
There is a possibility that variation/unbalance to the extent of 10% may be
involved in the phase voltage of different phases (R,Y & B) in the input voltage at some
of the locations. The Bidders shall finalise a design, particularly the rating of diodes and
components of control circuitry of charger such that it shall take into account such
variation of +10% in the phase voltage so that performance of battery charger is not
affected. Details of precautions taken in this regard and modifications considered
in
design may be brought out separately by the Bidders in their offer.
1.3 CONSTRUCTIONAL REQUIREMENTS FOR BATTERY CHARGERS:
1.3.1
DIMENSIONS: One single sheet steel cabinet shall accommodate both boost
and float chargers. Dimensions of battery chargers shall be as under:i.
ii.
Height
Depth
1600 mm including base channel

800 mm
480
Width may be selected as per requirement to accommodate various

components speciously keeping in view proper cooling of components
1.3.2
CONSTRUCTION:
1.3.2.1
Charger cabinets shall be sheet metal enclosed and shall be dust, weather
and vermin proof. Sheet steel used shall be atleast 2.5 mm thick and properly braced
to prevent wobbling wherever necessary. Cubicle shall be of iron angle frame, i.e. a
suitable sturdy frame shall be prepared with strong base channels, to bear the load of
heavy accessories.
13.2.2
Charger cabinet shall be free standing, floor mounting type and shall be
provided with a hinged door in the back with suitable pad locking arrangements.
1.3.2.3
All doors removable covers end plates shall be gasketed all around with
neoprene gaskets. Louvers where provided shall have screens and filters. The screen
shall be made of fine GI wire mesh.
1.3.2.4
Suitable entries for various incoming and outgoing cables shall be from
bottom and fitted with cable glands etc. Cable glands shall be "screw on" type and made
of brass.
1.3.2.5
It may be noted that all heavy components namely input transformers,
chokes and motorised variac shall be mounted on the floor of the charger such that the
load is taken by the sturdy angle frame work either in one tier or two tiers if necessary.
Cantilever type mounting arrangement for these heavy items shall not be acceptable
1.3.2.6
Axis of the cable trench in the control room shall be parallel to the width of
the charger. In view of this the two cable gland plates for input and output cable
connections to the battery charger shall be provided across the cable trench at both
ends (i.e. on 800 mm width side of the charger) to facilitate direct cable entries from the
trench of around 550 mm, width. Grouting bolts for the charger cabinet at four corners
shall be provided after keeping in view that the cable trench of 550 mm width shall be in
the centre and parallel to the width of the charger.
1.3.2.7
In order to provide neat appearance and also to protect all indicating
instruments and switches/knobs provided on the front of the panel, the upper portion of
the front of the panel accommodating these accessories shall be constructed with
suitable duct in the sheet so that the level of mounting of these accessories is lower
than the front face of the panel.
1.4 WIRING: For the wiring purpose, standard 1100 volts stranded copper conductor of
2.5 sq. mm area with minimum seven strands should only be used. Terminations shall
be crimped tag solder-less type with covering sleeves only. Colour coded wires should
be used to facilitate easy tracing of wires as detailed out here under:a.
AC circuit
- Red, yellow and blue for RYB phases
- Green for earthing
- Black for neutral
b.
DC circuit
- Red for positive
- Black for negative
481
c.
Control wiring
-
Grey for annunciation & other control circuits
1.4.1
All fuses shall be HRC type and of reputed make. All fuses shall be provided
with protective covers. Incase links are to be provided these shall also be with protective
covers. Please note that open links or fuses are not acceptable and should not be
offered.
Fuses shall be provided with visible operation indicators to show that they
have operated. All accessible live connections shall be adequately shrouded and it
should be possible to change fuses with the circuit alive, without danger of contact with
live metal. Insulated fuse pulling handle shall be supplied with each cabinet.
1.4.2
Since a number of wires will run from one point to another, it is desired that
the support arrangement should be adequate and neat. Conventional method of
bunching of wires should not be adopted since the same creates problems in case any
wire is to be removed. Wires should be accommodated in suitable plastic channels with
sliding plastic cover, which may be mounted inside the panels suitably.
Inspection/removal of wires should be possible by sliding the covers. Blank plastic
channels should be provided by the sides of the panels to accommodate the incoming
cables from switchyard through the cable glands with suitable holding arrangement so
that the cables could be rigidly fixed and jerks etc may not be transferred to the
terminals inside the cubicle.
1.4.3
All door mounted equipment as well as equipment mounted inside the
cabinet shall be provided with individual labels with equipment designation engraved.
Also the cabinets shall be provided on the front with a level engraved with designation of
the cabinet as furnished by purchaser. Labels shall be made of non-rusting metal.
1.4.4
Battery charger cabinet shall be provided with two separate earthing
terminals.
1.4.5
Input and output terminals should be neatly brought out on the back side of
charger. The terminals to be provided are 4 Nos for AC input i.e. RYBN + 2 Nos. from
load i.e. + ve & -ve, and two Nos. from battery connections i.e. +ve, -ve and all tap cell
connections. Distance between the above three groups of terminals shall not be less
than 15 cms. Distance between battery +ve, -ve and tap cell terminals shall not be less
than 20 cms. For battery connections nut/bolts and washer arrangement shall be used.
All terminals provided shall be 200 mm above the base level for ease of operation.
1.4.6
Indicating lamps shall be of low watt consumption. Lamps shall be provided
with series resistors to prevent short-circuiting of control supply.
1.4.7
Engraved core identification ferrules, marked to correspond with the wiring
diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wires,
and shall not fall off when the wire is removed. Spare auxiliary contacts of all relays,
connectors etc. shall be wired to terminal blocks. All wiring shall be terminated on
suitable terminal blocks using solder less crimping type tinned copper lugs. Insulated
sleeves shall be provided at all the wire terminations. All wiring shall be neatly bunched
and cleated without affecting access to equipment mounted within the cabinet wiring
troughs shall be provided for vertical cabinet wiring and for interconnecting wiring
between front and rear sections of the cabinet. Terminal blocks shall be numbered for
identification and grouped according to function.
482
1.4.8
Electrical indicating instruments shall be mounted flush on the front panel.
1.5
PRE-TREATMENT AND PAINTING PROCESS: Sheet
steel
fabricated
members shall be subjected to pre-treatment process before painting and the process
shall be carried out as under. Process can broadly be divided as Metal Treatment and
Painting.
1.5.1
METAL TREATMENT:
i.
Degreasing : This can be achieved either by immersing in hot alkaline

degreasing bath or in hot tri 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. Immersing in

diluted sulphuric acid (approximately 20%) at nearly unit scale and rust
are totally removed.
iii.
Rinse it in cold water in two tanks to remove traces of acids.
iv.
Treat with phosphoric acid base neutriliser 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 degree to 90 degree centigrade. The uniform
phosphate coating 4 to 6 gms per sq. meter shall be achieved.
vi.
Swill in cold water
vii.
Rinse in Deolyte bath at 70 degree to 80 degree Centigrade to

neutralise any traces of salts.
viii. Seal the above phosphate coating with hot dilute chromate solution.
ix.
1.5.2
Dry with compressed air.
PAINTING:
i.
Primer:- Spray one coat wet on wet specially developed 'High Luster'
zinc chromate primer and stove at 150 degree Centigrade to 160
degree Centigrade for 25 to 30 minutes. Alternatively, Red-oxide
primer with zinc chromate content may be used. However, former
process is preferred.
ii.
Rubbing and puttying: Apply putty to fill up the scars, if any, to

present smooth surface and stove 15 to 20 minutes. Apply putty
several times to get the perfectly smooth finish.
iii.
Surfacing: - Sand down with mechanical abrasive and stove for 20

minutes.
iv.
Immediately spray second coat of primer as per (i) above or grey primer
surfacer wet on wet and stove for 30 to 40 minutes at 125 degree
centigrade.
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 and then
spray two coats of synthetic enamel finish paint wet on wet and stove
it at 150 degree for 30 minutes.
483
1.5.3
Following shall be ensured:i.
Necessary stiffeners may be welded between large cut outs to

provide rigidity before painting process.
ii.
Painting process shall be done within 24 hours of completion of metal

treatment
iii.
Small quantity of paint shall be supplied alongwith equipment for

touching up at site.
iv.
Cold process or any other authoritative process which ensures equal

or better quality than the process mentioned above shall also be
acceptable.
1.5.4
Exterior surface colour finish shall be 'smoke grey' shade No. 692 as per IS-5
and the interior surface of the charger shall be painted with egg shell white.
1.5.5
While general constructional features have
desired that Bidders may adopt modern construction
charger cabinet is sturdy in construction with suitable
meshed so that under all weather conditions the inside
the prescribed limits.
been described above, it is

practices to ensure that the
ventilation arrangements duly
temperature does not exceed
1.5.6
On the top of the charger cabinet at the four corners, lifting hooks shall be
provided.
1.5.7
At the time of dispatch the front side of the panel where indicating instruments
and accessories are to be provided shall be covered with thermocol packing. Also the
complete charger cabinet shall be packed using suitable crate so that the equipment is
able to withstand transport hazards from manufacturer's works to Transmission Area
Store and then from Area Stores to work site. Each consignment shall be accompanied
by a detailed packing list containing the following information:
a)
b)
c)
Destination.
d)
e)
f)
g)
1.5.8
It is desired that complete schematic alongwith voltage levels marked at
important points for identification and rectification of defective components of the
charger is provided on a permanently laminated/engraved plate of suitable thickness
which has to be bolted at the four corners on the inside face of rear door. Size of the
plate shall be 400 mm x 300 mm. In addition, one more plate of similar type and
dimension shall be provided on the outside of the rear door providing guidelines and
instructions for operation of the charger. Guidelines to be provided on the plates shall be
to our approval. Also schematic to be provided on the plate shall be to our approval for
which separate drawing shall be furnished immediately after award of contract.
484
1.6.
CAPACITY AND RATING FOR CHARGERS: Battery charger capacity shall
be designed based on the requirements stated here under:
CHARGER
UNIT TYPE
Float
charger unit
Boost
charger unit
1.7
REQUIREMENTS
RATING
Load(Amps)
110V
300AH
14
110V
200AH
11
48V
300AH
32
48V
200AH
20
Trickle(mA)
300
200
300
200
Total design rating of

trickle charger
(Amps)
15
12
33
21
Load(Amps)
14
11
32
20
Boost current (Amps)
30
20
30
20
Total requirement
(Amps)
44
31
62
40
Design rating of
boost charger to be
taken
44
31
62
40
DETAILS OF DESIGN PARTICULARS FOR BATTERY CHARGERS:
1.7.1
BASIC DESIGN: Basic design of battery chargers for 110 & 48 Volt systems
shall be identical except for minor variations described below. Basic requirement to be
noted is that under all condition of failure of any component of trickle charger, boost
charger, AC supply faults during the short circuit etc., over voltage condition, and under
voltage condition etc., load and battery shall always remain paralleled. purchaser can
not afford interruption of DC supply to load under any circumstances and therefore this
requirement shall be kept in view carefully. The battery charger shall have two
independent units one for boost charging and other for the float charger. At a time only
one unit shall be in service through selector switch.
1.7.2
END CELL CUTTING: It is desired that the battery charger shall be designed
on the basis of end cell cutting principle for the purpose of providing the required voltage
to the load under the condition when boost charger is in circuit. Thus, four tap
connections shall be taken from the battery in addition to the permanent tap connection
from 44th and 19th cell as already referred to under Para 5.10.5. These four additional
tap connections will be taken from the following cells
i.
110V battery : 45th cell, 48th cell, 51st cell and 55th cell.
ii.
48V battery : 20th cell, 21st cell, 23rd cell and 24th cell.
1.7.3 SELECTOR SWITCHES: Suitable single pole, heavy duty, four way selector
switch preferably of Kaycee make of required rating shall be provided so that the
required tap connection could be selected for regulating the load voltage. Thus the
design of boost charger unit should not take into account any dropper diode since
regulation of voltage shall be made by way of cutting of battery end cell.
1.7.4
THYRISTOR CONTROL CIRCUIT: Thyristor control circuit to be provided for
float charger unit should incorporate soft start feature. Voltage should not shoot up
when the supply of the charger is switched on. Suitable filter circuit and device must be
incorporated to suppress all characteristics harmonics in DC output. Also, adequate
485
surge suppressor shall be provided in the input AC supply circuit of the charger. Main
rectifier shall be provided with suitable fuses with facility of indication of fuse failure. It
should be possible to identify the faulty rectifier to facilitate quick
replacement/rectification of faulty rectifier.
1.8
BASIC DESIGN PARAMETERS:
1.8.1
VOLTAGE REGULATION:
within the following limits.
Float charger output voltage shall be set
i.
110V charger - Output of the unit shall be 2.2 x 55 = 121 Volt which
would be supplied to the battery for trickle charging and same voltage
without any drop but with regulation of plus/minus 1% shall be
provided for the load bus. Voltage above 121 volt at load bus shall
not be acceptable. Thus unlike 48 volt charger, no dropper diodes or
voltage regulatory circuit are to be provided.
ii.
48 V charger - 48 volt plus/minus 1% on load bus. Thus the design

should be such that the bus voltage is sensed and output voltage is
regulated within plus/minus 1% range. Thus in this case the trickle
charger should simultaneously provide 2.2x 24 = 52.8 Volt output for
trickle charging of the battery as well as regulated voltage of 48 volt
plus/minus 1% at the load bus. The arrangement provided for
meeting these requirements should be explained.
1.8.2 FILTER CIRCUIT: Suitable filter circuit shall be provided in all the chargers to
limit the ripple current (Peak to Peak) in the out put voltage to 2% irrespective of the
D.C. load even when they are not connected to battery. Ripple content shall be
controlled as under ;
i
110V charger :- In this case both for trickle charger unit and boost
charger unit, ripple control shall be within limit of 1% of the output
voltage
ii
48V charger :- In this case, ripple content for both float and boost
circuit should be within maximum limit of 2 millivolt psophometric with
battery in circuit and a maximum of 4 millivolt psophometric without
battery.
1.8.3 HEAT SINKS: Wherever necessary, standard heat sinks shall be utilized for heat
conduction. In many components, the rating is specified with heat sinks only and
therefore heat sinks should be procured from the component manufacturer only.
1.9
GENERAL REQUIREMENTS FLOAT AND BOOST CHARGERS:
1.9.1
FLOAT CHARGERS: Battery charger should have two independent units one
for boost charging and another for trickle charging. Output of both the units shall
be paralleled with the battery and load to suit the technical requirements
specified, earlier.
1.9.2
Charger shall be capable of float charging the batteries at 2.15 to 2.2 volts per
cell and simultaneously supplying the continuous D.C. load of the station, and
boost charging them at a voltage of about 2.65 volts per cell and delivering
current equal to 100% of the rated 10 hours discharge current of battery plus the
continuous D.C load of the station.
486
1.9.3
During normal condition, the battery shall be floated across the float charger at
2.2 volts per cell +/- 1 % and the DC load demand during the normal state will be
met by float charger. Float charger shall be static type comprising of Silicon
Controlled Rectifiers (SCR) connected in three phase banks along-with
other necessary circuit to supply a stabilized DC out-put. Provision shall be
made to have stepless and smooth voltage setting in the auto mode and also for
adjustment in manual mode in case the automatic constant voltage controller
fails.
1.9.4
Float charger shall be able to give a DC output voltage of 2.0 to 2.25 V per cell,
with maximum variation being +/- 1% of the set value. Constant Potential
Controller Circuit shall be suitable to stabilize the output voltage within +/- 1%
from no load to full load, even when the AC input voltage to the charger varies as
already specified under Input supply. The voltage should not shoot up when
the supply of the charger is switched ON. Suitable filter circuits and devices
must be incorporated to suppress all the characteristic harmonics in DC output
also adequate suppressor shall be provided in the input AC supply to the
charger.
1.9.5
Float charger shall have built in current limiting feature to drop the output voltage
on currents more than 100% of the rated current and it should be ensured that
the output voltage of the charger across battery terminals should be below 2Volt
per cell if output current is 125% or more of the rated current.
1.9.6
One Moulded Case Circuit Breaker (MCCB) of 15 KA short time current rating
shall be provided on the AC input side of the float charger with facility to indicate
MCCB Trip condition through the annunciation scheme. The main transformer
steps down the input voltage to the desired level and the output of the
transformer shall be applied to the 3 phase, full wave thyristors bridge consisting
of three thyristors & three Diodes of the specified ratings as per Appendix B of
this document. The Bidder shall also furnish detailed calculation for fixing VA
capacity of the transformer.
1.9.7
One Moulded Case Circuit Breaker (MCCB) of at least 10 KA short time current
rating with suitable overload setting shall be provided on the DC output side of
the float charger so that any fault on the DC load will not be reflected on the
equipment but will trip the MCCB and provide an annunciation. One ammeter of
suitable range shall be provided to read the DC output current of the float
charger clearly.
1.10 BOOST CHARGERS:

1.10.1 Boost charger shall have adequate rating to quick charge the battery fully within
14 hrs. after an emergency during which complete DC load is met by the
battery.
1.10.2 Current rating of Boost charger shall be 20Amps for 200AH, 30 amps for
300AH battery sets as stated earlier.
1.10.3 In the constant current mode, it shall have a current stability of +/- 2% of the set
value. Constant current setting shall have step-less range from 20% to 100% of
full rate current. Further, the boost charger shall have a provision of manual
mode of operation.
487
1.10.4 Boost charger and float chargers shall be so interlocked electrically that during
Boost charging of the Battery, the float charger will supply the DC constant load
and at the same time will be in parallel with the battery through reverse current
blocking diode at a suitable tapping (44th cell in case of 110 Volt battery and 19th
cell in case of 48 Volt Battery). One DC contactor with normally closed (NC)
power contact may be incorporated for the above. This contactor will be
normally in de-energised condition and only during Boost charging, the same
should get energized to isolate the battery from load. Rating of the DC contactor
shall be suitable as per rating of the charger. One Ammeter of suitable range
shall be provided in the boost charger circuit to read the boost charger output
current.
1.10.5 One moulded case circuit breaker of at least 10 KA short time current rating with
suitable overload setting shall be provided on the DC output side of the boost
charger so that any fault on DC out put side of boost charger shall not reflect on
the equipment, but shall trip the MCCB and provide necessary annunciation. AC
input to the boost charger shall be through a Moulded Case Circuit Breaker of at
least 15 KA short time current rating with suitable overload setting and its trip
conditions shall be annunciated.
1.10.6 For variation of voltage from boost charger unit suitable motorized
automatic run down variac of specified rating shall be provided. This
motorized variac shall be complete with facility for manual operation and
shall be mounted on the floor with control on the front panel.
1.10.7 Output voltage of boost charger unit shall be designed on the basis of maximum
voltage of 2.7 volt (quick charge finishing rate) per cell i.e. 2.7 x 55 = 148.5 volts
for 110 volt charger and 2.7 x 24 = 64.8 volts for 48 volt charger.
1.11
FLOAT CHARGER EQUIPMENT DETAILS:

Trickle Charger shall have necessary equipment for satisfactory Operation which
shall include atleast following instruments, Relays, Control switches and other
accessories.
(A)
ONE NUMBER MOULDED CASE CIRCUIT BREAKER (MCCB):

The Battery Charger shall have 415V or 433V Triple Pole AC of MCCB suitable
capacity with Overload and Short Circuit releases and contacts for annunciation
for ON / OFF operation of the unit. The Circuit Breakers shall be liberally rated.
The continuous Current Carrying Capacity and Breaking Capacity at 415 or 433
Volts AC shall be stated with back up calculations. High Rupturing capacity
(HRC) fuses of suitable capacity for Back up Protection shall also be provided.
The opening coil shall be rated for 240 Volts AC ON & OFF Push Buttons shall
be provided for closing and opening of the Breakers Sufficient NC & NO contacts
shall be available for interlock and indications.
( B)
ONE SET OF THERMAL OVERLOAD RELAY:

A Thermal over load, relay incorporating a distinct single phasing protection
(Using Different Movement of Bimetalic Strip) shall also be provided for the AC
input. The relay shall trip the above MCCB.
488
(C)
THREE NUMBERS HRC FUSES:

Fuses shall be HRC link type. Fuses shall be mounted on fuse carriers which
are in turn mounted on fuse bases. Wherever it is not possible to mount fuses
on carriers, fuses shall be directly mounted on plug in type base. In such case
one insulated fuse pulling handle shall be supplied for each charger. Fuse rating
shall be chosen by the Bidder, depending on the circuit requirement. All fuses in
the chargers shall be monitored fuse failure annunciation shall be provided on
the failure of any fuse.
(D)
PILOT LAMPS:
Three number Pilot Lamps each to indicate Float/Boost AC Supply On / Off shall
also be provided.
(E)
RECTIFIER TRANSFORMER:
Dry type Step Down Rectifier Transformer with copper winding shall be three
phase double wound impregnated, naturally air cooled, having Class F
insulation corresponding to the rating of the Associated Rectifier Assembly. It
shall be suitable for Operation at 415 or 433 15% Volts 50 3% cycles per
second.
i)
PRIMARY WINDING OF RECTIFIER TRANSFORMER:

This shall be the Alternating Current supply. The winding shall be connected in
star connection.
ii)
SECONDARY WINDING OF RECTIFIER TRANSFORMER:

The Secondary winding of the Transformer shall be 3 Phase, double wound.
The Winding shall be delta connected. This winding of the Transformer shall be
conductively connected to Rectifier Circuit elements and shall conduct the Direct
Current of Transformer.
iii)
RATING OF RECTIFIER TRANSFORMER:

The Rectifier Transformer shall be suitably rated VA, Voltage, Current frequency
& number of phases at Terminals of alternating Current Winding based on turn
ratio of the Transformer & RMS Current & No. of phases at the terminals of the
Direct Current Winding as assigned to it by the Manufacturer, corresponding to
the Rated Load of Rectifier unit shall be clearly stated. The calculations for the
rating of the Transformer shall be furnished. Ripple contents in the output
voltage and Current shall also be clearly stated.
(F)
CONTROLLER (AUTO / MANUAL):

To stabilize the DC Voltage within 1% of the set value with an AC Voltage
variation of 15%, Frequency variation 3% and Load Variation between 0 to
110% shall be provided.
(G)
AUTO / MANUAL SWITCHES:

For selecting the mode of Operation auto / Manual, Selector Switch shall be
provided.
489
(H)
AC INSTRUMENTS:
AC Volmeter & Ammeter (with shunt) shall be provided with Selector Switch.
The instruments shall be flush mounting Type, dust/ vermin proof and moisture
resistant. The instrument shall have easy accessible means for zero adjustment.
They shall be of 0.5 Accuracy Class as per IS:1248 1988. The range of
instrument shall be as under:
S.
No.
1
2
(I)
110Volt
300AH
200AH
Particulars
AC Ammeter
Selector Switch
AC Volmeter
Selector Switch
with
with
48Volt
300AH
200AH
0-50
0-30
0-25
0-25
0-500
0-500
0-500
0-500
RECTIFIER SELECTION: Rectifier Selection will consist of:
i)
One set of Thyristor stack of compact silcon diode shall be connected in three
phases for 415 or 433V 15% Volts, 50 3% C/S Full wave Bridge Current.
Each Thyristor will be mounted on a Heat Sink made of aluminium and protected
by high speed Semi conductor fuses and RC Network against Current and Over
Voltage transients. Thyristor stack / Silcon Diode shall be liberally rated. Fuse
failure relay across each high speed semi conductor fuse shall be provided so as
to know and identify which fuse has blown off.
ii)
One set AC Damping network to protect the thyristor stack against Voltage
Surges due to Transformer switching.
iii)
One set Automatic Voltage Regulator to stabilize the output voltage within
1% of output set value against specified Main and Load variation.
iv)
One set Current Limit Circuit ensuring drooping character for the charger.
v)
One set Pulse Isolator Device.
(J)
OUTPUT SECTION:
This will consist of:
i)
One no. Iron Core Inductor and a set of professional grade capacitor to
reduce output ripple voltage to 2%, HRC Fuse will be connected in
condenser circuit.
For protection - Automatic run down circuit shall be provided in the float
charger by which excessive Inrush currents from the float charger to the
Battery at the instant of resumption of Mains Supply is avoided.
ii)
One no double Pole moulded case Circuit Breaker. On the output side of the
Charger one number double pole 250 Volts DC MCCB of suitable capacity
shall be provided with overload and short circuit releases. Suitable number
of NO & NC contacts shall be provided for Annunciation and interlocks. The
circuit breaker shall be liberally rated. The continuous Current carrying
capacity, fuses of suitable capacity surge suppression Device shall also be
490
provided for back up protection. The MCCB and HRC Fuses should be of
reputed make.
iii)
(K)
Blocking Diodes: Blocking Diode shall be provided in output circuit of each

charger to prevent current flow from the DC battery into the charger. Two
nos. out put HRC link type fuses shall be provided.
DC INSTRUMENTS:
DC Voltmeter and Ammeter (with shunt) shall be provided. The instruments
shall be flush mounting type, dust / vermin proof and moisture resistant. The
instruments shall have easy excessive means for zero adjustment. They shall
be of 0.5 Accuracy Class as per IS 1248 1968, the range of Instruments shall
be as under:
S.
No.
1
Particulars
DC Ammeter (with
centre zero for charge
/ discharger current)
DC Voltmeter
110Volt
300AH
200AH
48Volt
300AH
200AH
50-0-50
50-0-50
75-0-75
75-0-75
0-150
0-150
0-75
0-75
The bidder may please note that in addition to above 1 No. DC Ammeter of
adequate rating shall also be provided in the charger to monitor float
charging and boost charging current of chargers. The range of these
ammeters shall start from zero onward as per float and boost charging
current for each rating of charger specified elsewhere in the bid document.
(L) INDICATING LAMPS:
Pilot lamps shall be provided to show that the DC supply is available from the
Rectifier.
1.12
BOOST CHARGER EQUIPMENT DETAILS:

During Boost charge operation, there shall be no load across the Bus used for
Boost charging. The Load shall only be supplied by the Float Charger till such a
time when the Voltage of the tapped Cell exceed the Float Charger voltage.
Blocking silicon Diode shall be used in the tapped cell circuit to avoid current
flow to the tapped cell from the Float charger. Load sharing can take place
between the tapped cells and Float charger in case the capacity of the float
charger is exceeded during the time when the voltage of the tapped cell is equal
or greater than the float charger voltage.
In the event of AC mains failure during Boost charging full Battery shall get
connected to the load through NC contacts of the DC contactors.
The component details of Boost charger equipment shall be similar to those
given for the float charger but this shall be suitably rated for the Boost charger
output voltage and current. In addition to these components Boost charger shall
house the following components
1.
2.
Three nos. HRC fuses at the input

One no. AC Volt meter with HRC Fuses and selector switch
491
3.
4.
5.
6.
7.
One set Alarm annunciation

One no. DC Ammeter with shunt
One no. Blocking Diode
One set Blocking Diode mounted on Heat Sink
One no. DC contactor connected between Load Positive and full Battery
for Battery charging unit.
1.13. ALARM RELAYS AND INDICATION LAMPS AND ALARM AND INDICATION
SCHEMES:
The charger shall be provided with indication lamps on AC side as well as on the
DC outputside to indicated ON / OFF position of AC / DC supply.
For supervision of the following faults conditions, a Repeat Audio Alarm and Indication
Scheme having a common bell / buzzer with Visual Indication Lamp and Auto Reset
feature shall be provided for each charger. The arrangement shall be such that audible
Alarm can be cancelled while Visual Indication conditions continue till the abnormal
conditions persist. Repetitive Alarm Scheme shall be so provided that even during the
time when a Fault is being attended and a second fault occurs, the Alarm shall sound
and so on.
1.
AC Main Fall / AC under voltage
2.
Float charger AC MCCB Trip / Overload Alarm
3.
Boost Charger AC MCCB Trip / Over Load Alarm
4.
Float charge SCR / Diode fuse failure
5.
Boost charger SCR / Diode fuse failure
6.
Float charger DC MCCB Trip / Over load alarm
7.
Boost charger DC MCCB Trip and over load Alarm
8.
Float charger DC Output voltage failure
9.
Boost charger DC Output voltage failure
10.
Load DC over voltage
11.
Load DC under voltage
12.
Earth leakage (+ve) OR Earth leakage (-ve)
13.
Capacitor fuse failure
In the event of Battery Earth Leakage Current exceeding 50 mA the Earth
Leakage Relay provided on DCDB should operate.
1.14
a)
PROTECTION OF RECTIFIER UNIT:

In order to minimize the duty on Rectifier unit and Power System from
disturbances arising from Diode Failures and Current short circuits,
Protective switch gear and other protective equipment shall be adjusted for
the shortest possible operating time consistent with selectively. The first
consideration must be rectifier devices because of their small thermal
capacity. In addition to the protection against the over loads and faults
currents the individual diode of the semi conductor rectifier must be protected
against the voltage surges caused by lighting Diode used in semi
conductor power rectifier. It shall have a repetitive peak reverse voltage
(PRV) rating greater than the normal working voltage which appears across
them. The fault current must be interrupted very quickly to prevent extensive
damages. The protection either be provided by fast acting current limiting
fuses in series with semi conductor device or with some other suitable
arrangement.
492
b)
SINGLE PHASING IN INPUT AC SUPPLY: Since the input supply to

charger is 3 phase, 415/433 volts, 50 Hz supply, there is a possibility of
single phasing, which may result into overloading of charger and may
damage charger components. This may lead to un-wanted overloading on
batteries also. To avoid such conditions, single phase preventer should be
provided which should be able to cut off the AC supply and give visual
indication and audible alarm as well. The design of single phase preventer
shall be either current operated type or voltage operated type. This will
ensure protection of variac/transformer and rectifiers etc. against unbalanced
overloads. The single phase preventer should receive supply from all the
three phases. Scheme for automatic switch off of the charger at the time of
AC failure or single phasing should be such that even if any one of the three
phases is switched off the whole supply should get disconnected.
Note: - Rating of different components to be selected for different rating chargers

covered under this specification have been detailed out in Appexdix-B enclosed.
However Bidder may select higher rating components in case specified rated
components are not available. Please note that under rated components shall not
be accepted by purchaser.
1.15
SCEHDULE OF EQUIPMENT, ACCEPTABLE MAKES OF COMPONENT

AND ACCESSORIES:
1.15.1
Schedule-IX enclosed brings out schedule of major components /
equipments, rating of various major components. Photocopy of the same should be
submitted with offer with addition/comments if any so that the purchaser may ensure of
compliance of these requirement. No other format should be used.
1.15.2
Each rating of charger should be complete and include all such minor
accessories also which may not be specifically mentioned in the Schedule-VIII but are
essential for satisfactory operation of equipment. Bidders shall not be entitled for any
additional cost in respect of such minor accessories though not specifically brought out
in the bid.
1.15.3
Bidders shall furnish guaranteed technical particulars for the battery chargers
in the format provided under enclosed Schedule-II.
1.16
TESTS: Following tests shall be carried out on the battery chargers at the
manufacturers works before dispatch.
(i)
AUTOMATIC VOLTAGE REGULATION AND LOAD TESTS:

This test is carried out on the Float charger. The load shall be
increased gradually from zero to 100% and the DC output voltage
and the power shall be measured. The ripple factor is also measured.
Both the voltage and the ripple factor should be within the specified
limits as mentioned in clauses 5.8.1 & 5.8.2 above.
(ii)
BOOST CHARGER OUTPUT TEST.
(iii)
INSULATION TESTS
(iv)
ANNUNCIATION TEST.
(v)
TEMPERATURE RISE TEST: Temperature rise test on both float

charger and boost chargers shall be conducted. The temperature rise
493
is to be measured on the following equipments (a) Diodes(b) SCRs

(c) Transformers (d) Inductors (chokes) etc.,
(vi)
CALIBRATION TESTS: Calibration tests

instruments i.e. Ammeters and Voltmeters.
on
the
indicating
All these tests described above and other Special Tests if any required by
the purchaser or his representative shall also be carried out, so that the purchaser and
his representative is satisfied that the offered equipment shall meet our field
requirements under adverse system conditions. All these Tests shall be carried out in
presence of the representative of the purchaser prior to dispatch, if so desired by the
purchaser and the test results in quadruplicate shall be submitted to the purchaser for
approval. No material shall be dispatched by the supplier without prior approval of the
test certificates by the purchaser.
1.17
DOCUMENTATION, DRAWINGS AND TEST REPORTS
1.17.1
Bidders shall submit with their bid all such drawings, instruction manuals,
descriptive literature etc. as may be necessary for the proper understanding of his offer.
Detailed write up describing the functioning of charger used, shall also be submitted.
Write up shall include the following:i.
Technical specification of the charger.
ii.
Detailed circuit description of the charger. It shall also include the

functions of various components, various protections circuits/cards,
various relays along with individual brief write-up/ leaflets.
iii.
Description on installation, commissioning and operation and

maintenance of the charger.
iv.
List of the main components of the charger - separately for Boost and
Float charger section.
v.
Circuit diagram of the complete charger shall be shown in a single

sheet. The circuitry of various protection cards/relays should also be
incorporated in the same sheet. Following details are to be clearly
indicated in the circuit diagram.
a.
Make of components used.
b.
Ratings of the components.
c.
All fuses for AC and DC circuits should be numbered and

individual rating should be indicated.
vi.
Various Test point voltage levels for control cards and other specific
points in the circuitry of the charger.
1.17.2
Bidders may please note that they shall carefully go through our specification
and while submitting their offers, all requirements as described under specification
should be complied with and complete details should be furnished. In absence of nonfurnishing of any of the confirmations or schedules or technical/commercial
questionnaire, the offers shall be treated as in-complete and may be non
responsive from technical angle.
1.17.3
Successful Bidders shall, within two weeks of placement of order, submit four
sets of final version of all the above drawings for purchaser's approval. The purchaser
shall communicate his comments/approval on the drawings to the supplier within two
494
weeks. The supplier shall, if necessary, modify the drawings and resubmit four copies of
the modified drawings for purchaser's approval within two weeks from the date of
comments. After receipt of purchaser's approval, the supplier shall, within three weeks,
submit 4 prints per charger and two set of good qualities reproducible of the approved
drawings for purchaser's use.
1.17.4
Successful Bidders shall also furnish two sets each of bound manuals
covering operation and maintenance instructions and all relevant information and
drawings pertaining to the main equipment as well as auxiliary devices alongwith each
charger. Marked erection drawings shall identify the component parts of the equipment
as shipped to enable erection by purchasers own personnel. Each manual shall also
contain one set of all the approved drawings, type test reports as well as acceptance
reports of the corresponding consignment dispatched. Manufacture of equipments shall
be strictly in accordance with the approved drawings and no deviation shall be permitted
without the written approval of the purchaser.
1.17.5
Approval of drawings/work by the purchaser shall not relieve the
Bidders of any of his responsibility and liability for ensuring correctness and
correct interpretation of the drawings for meeting the requirements of the latest
revision of the applicable standards rules and codes of practices. The equipment
shall conform in all respects to high standards of engineering, design,
workmanship and latest revisions of relevant standards at the time of supply and
purchaser reserves the right
to reject any work or materials which, in his
judgment, is not in full accordance therewith.
1.18
COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS :

Bidders must furnish following information along with technical Offer.
1.18.1
Complete details of all the accessories which will be supplied with the battery
charger should be furnished. While furnishing these details, items which will be
manufactured by the Bidders and balance items, which will be procured from subsuppliers should be clearly identified and indicated in the bid.
1.18.2
It is obligatory on the part of Bidders to ensure that supply of all accessories
along with Main equipment are simultaneously delivered to avoid any holdup in erection
and commissioning. Responsibility for obtaining timely supplies of bought out items will
rest on the Bidders and only on this basis, delivery period will be offered in the Bid.
1.18.3
It may be noted that in case of damages/shortages due to improper packing
or any other negligence, replenishment shall be arranged within one month time. For
will rest on the Bidder. In case for attending to defects in any accessory or inspection/
replacement of the accessory, which may be bought out item for the Bidder; if services
of engineer of original manufacturer is required, the same will be organized on
immediate basis by the Bidder at his cost.
1.19
EXPERIENCE: Bidder may please note that they should have
adequate experience of offered equipment/ material as per Volume-I.
495
1.20
INSPECTION:
(i)
Purchaser shall have access at all times to the works and all other
places of manufacture, where the Materials are being manufactured
and the Bidder shall provide all facilities for unrestricted inspection of
Bidders works, raw materials, manufacture of all the accessories and
for conducting necessary tests as detailed in the bidding document.
(ii)
Successful Bidder shall keep the purchaser informed in advance of

the time of starting and of the progress of manufacture of Materials in
its various stages, so that arrangement could be made for inspection.
(iii)
No material shall be dispatched from the point of manufacture unless

the material has been satisfactorily inspected and tested.
(iv)
Acceptance of any quantity of the material shall in no way relieve the

successful Bidder of this responsibility for meeting all the requirement
of this specification and shall not prevent subsequent rejection if such
1.21
QUALITY ASSURANCE PLAN: Bidders must establish that they are
following a proper quality assurance programme for manufacture of Materials. Bidders
shall invariably furnish following information alongwith his bid. Information shall be
separately given for each type of Charger:
(i)
Statement giving list of important raw materials, names of subsuppliers for the raw material, list of standards according to which the
raw material is purchased and copies of test certificates thereof.
(ii)

bought out items.
(iii)
(iv)

processing exists.
inspections.
(v)
(vi)
material specified and test plant limitation, if any, vis--vis type,
special, acceptance and routine tests specified in the relevant
standards. These limitations shall be very clearly brought out in
schedule of deviations from specified test equipments.
Successful Bidder shall within 30 days of placement of order, submit following

(i)
List of raw material as well as bought out accessories and the names
of sub-suppliers selected from the lists furnished along with Bid.
(ii)
(iii)

496

finalized.
1.21.1
Successful Bidder shall submit the routine test certificates of bought out
items and raw material at the time of routine testing of charger.
1.22

1.23
Bidder may please also note that any other accessories which are not included
in the specification, but may be necessary for satisfactory and trouble free operation of
the equipment as per standard design specified in the bid document, the same should
also be included in the schedule of equipments and cost of chargers should take into
account all such items, if any.
2.0
It is obligatory on the part of Bidders to furnish Guaranteed Technical Particulars

enclosed with the Bid document duly filled in complete in all respects. In case
Guaranteed Technical Particulars duly filled in complete in all respects is not furnished,
the Bid may be treated as non-responsive
3.0
SCHEDULE OF REQUIREMENT OF ACCESSORIES ETC. :
It is obligatory on the part of Bidders to furnish Schedule of Requirement of

Accessories provided with equipment with the bid.
4.0
properly numbered and signed by the Bidder. Bid document including all
schedules and Annexures should be indexed properly and Index of the document
should be enclosed / placed at the beginning of the Bid document.
497
APPENDIX- B1
SCHEDULE OF TECHNICAL REQUIREMENTS OF
BATTERY CHARGERS
S.
No.
1
2
4
5
6
7
8
10
Particulars
Input AC supply Voltage(volts)
Rated DC volts.
Float charger Voltage
Boost charger Voltage
Rated output DC current
a)Trickle charging current
b) For float charging (Load Current)
c) For Boost charging current
Total DC current (Load + Boost)
Rating class(As per IS- 4540)
Rated 2 Hr overload capacity.
Rated 1 min overload capacity.
Rated continuous overload capacity.
Class of insulation for:
a. Float Rectifier transformer
b. Boost Rectifier transformer
c. Milking Rectifier transformer
d. Reactors/Chokes
Xmer ratings for float charging
a) DC out put voltage (float charging
voltage)
b) DC current rating (Float + Trickle)
c) DC output VA rating
(a x b)
d) Current through each cell of rectifier
bridge
e) Float main Xmer burden (VA)
f) Primary line current of Xmer at 360V
line voltage & 60% efficiency
g) AC contactor rating
h) Rectifier Diodes & thyristars rating
(Amps)
i) Filter condenser
Xmer rating for Boost Charging
a) DC out put voltage (Boost charging
voltage)
b) DC current rating
c) DC output VA rating(a x b)
d) Current through each cell of rectifier
bridge
498
Battery Charger
110V
48V
300AH 200AH 300AH 200AH
400 Volts
110
110
48
48
121
121
52.8
52.8
148.5
148.5
64.8
64.8
1
14
30
44
1
1
11
32
20
30
31
62
Class A Air Cooled
105%
110%
100%
1
20
20
40
Class B
Class B
Class B
Class B
121
121
52.8
52.8
15
1815
12
1452
33
1742
21
1109
11
1906
1525
1830
1164
15
10
15
10
20
16
44
28
250
250
110
110
148.5
148.5
64.8
64.8
44
6534
31
4604
62
4018
40
2592
14.67
10.33
20.67
13.33
S.
No.
11
12
13
14
15
16
17
18
19
20
21
Battery Charger
110V
48V
300AH 200AH 300AH 200AH
6861
4834
4218
2722
4574
3223
2812
1815
Particulars
e) Total Burden of main & series Xmer

f) Rating of main boost Xmer (VA)
g) Primary current of main Boost Xmer
12.71
8.95
7.81
5.04
at 360V and 60% efficiency
h) Rating of series boost Xmer (VA)
2287
1611
1406
907
i) Primary current of series boost Xmer
6.35
4.48
3.91
2.52
at 360V line voltage & 60% efficiency
j) Total primary AC current of boost
19
13
12
8
charger
k) Rectifier Diodes & thyristors
59
41
83
53
l) AC contactor rating
50
30
30
30
Total line current (AC)
24
17
17
11
Type of connections of transformers for
i. Boost Xmer
Double Wound, Star Delta X-mer
ii. Float Xmer
Double Wound, Star Delta X-mer
iii. Milking transformer
Double Wound, single phase
Taps for primary voltage selections to be provided on Xmer for
i. Boost transformer
(+) 10% and ( )15%
ii. Float transformer
(+) 10% and ( )15%
iii. Milking transformer
No tapping
Maximum charging current that can be fed to battery through
a. Float charging (Float +Trickle)
15
12
33
21
b. Boost charging (including float
44
31
62
40
charging) (Load + Boost)
c. Milking charging (Amps)
15
Details of variac
Motorised variac complete with run
a) Type
down facility for manual operation to
be provided as per specification
b) Variac rating in Amps
11
8
7
4
Boost charging voltage after ten hours
operation at rated voltage
Inherent voltage regulations
a. From no load to rated load
b. From light load (20%) to rated load
voltage regulation
Percentage regulation with AVR.
Safety device to avoid voltage rise
during no load.
Efficiency at normal output voltage
149
149
65
Better than 1 %
Better than 1 %
Automatic voltage regulation to be
offered
Less than 1%
Thyristor controlled automatic
voltage regulator
100% full load
60% to 80%
75% full load
60% to 80%
50% full load

25% full load
60% to 80%
65
60% to 80%
499
S.
No.
22
23
Battery Charger
110V
48V
300AH 200AH 300AH 200AH
Particulars
Efficiency at max. output voltage
100% full load
60% to 80%
75% full load
60% to 80%
50% full load
60% to 80%
25% full load
60% to 80%
Power factor
a. rated load.
0.85
b. light load (20%)
0.7
24
Type of rectifier cell

Method of cooling for
Stacks
25
Method of cooling for transformer
26
Mounting of boost and float rectifier Boost & float rectifier X-mer to be
transformers
mounted side by side
Battery charger cubicle
a. Thickness of sheets steel
2 mm
b. Overall dimension
1600x800xAs per requirement
(H x D x W)
c. Degree of protection
As Per IS 2147
Out side smoke grey & inside egg
d. Colour of finished paint(IS-692)
shall white as per IS 692
e. Type of paint (enamel/epoxy paint)
Enamel
Smoothing filter
To be offered by Bidder
FC-3 phase bridge,
Method of voltage controls
BC- motorized variac
Maximum permissible temp rise.
i. Rectifier transformers
< 65 deg C
ii. Reactors
< 65 deg C
iii. Rectifier cells.
< 55 deg C
iv. PCBs
<10 deg C over ambient
Ripple at rated load.
a. with battery
1%
1%
2MV
2MV
b. without battery
5%
5%
4MV
4MV
Rating of diodes/SCR
a. Type
Mono Crystalline silicon
b. RMS current rating
As per requirement
c. One cycle surge current.
As per requirement
d. Repetitive surge current
As per requirement
e. Peak inverse voltage continuous
600V
600V
400V
400V
f. Peak inverse voltage surge
As per requirement
Surge suppressor across each
g. Type of protection.
device
Rating and make of tap cell Diode
As per requirement
Range of voltage variation
27
28
29
30
31
32
33
34
Silicon
rectifier cell &
Natural Air cooled

Natural Air cooled
500
S.
No.
Battery Charger
110V
48V
300AH 200AH 300AH 200AH
48
110 to 110 to
48 to
to
154
154
67
67
110
110
48
48
to
to
to
to
127
127
55
55
Particulars
i. Boost (Rated Voltage x 1.4)
ii. Float (Rated Voltage x 1.15)

35
36
37
38
Range of current variation

i. Boost
ii. Float
Rating of DC contactor.
Rating of end cell cutting switch.
Rating of milking boost charger
i. Continuous current rating
ii. Output voltage
25% to 110% of Rated Current

25% to 110% of Rated Current
75
50
120
75
As per requirement
15 (Amps)
3V
iii. Dead short ckt. Protection

39
By MCCB and HRC fuses
Rating of MCCB to be provided for protection purpose

a) AC circuit protection for Boost
Charging
b) AC circuit protection for Float
Charging
c) Boost Charger DC circuit Isolation
d) Float Charger DC circuit Isolation
e) Milking Charger circuit Isolation
40
Rating of HRC Fuses

a) For protection of rectifier Diodes in
Boost charger circuit
b) For protection of rectifier Diodes &
Thyristors in Float charger circuit
c) For protection of rectifier Diodes in
Milking charger circuit
d) Rating of HRC Fuses / Glass Fuses
required for other circuits
38
26
24
16
10
10
88
30
62
24
124
66
80
42
30
30
20
40
30
10
22
14
30
As per requirement
NOTE:(a) Bidders may please note that any other accessories which are not
included in the above list, but may be necessary for satisfactory and trouble
free operation of the equipment as per standard design specified in the bid
document, the same should also be included in the schedule of equipments
and cost of chargers should take into account all such items, if any.
(b) Bidder may select higher rating components in case of non availability of
above rated items. Please note that under rated components shall not be
accepted by purchaser.
501
APPENDIX-B2
DETAILS OF FITTING & ACCESSORIES TO BE PROVIDED WITH EACH
TYPE OF BATTERY CHARGERS
The charger should be housed in sheet steel cubicle as per design and dimensions
indicated in the specification, suitable for natural air cooled operation. The unit shall
comprise of;
Sl.
No.
A
1
Rating/Make
of
equipment
offered by the Bidders
Particulars
110V
48V
Qty Rating
300AH 200AH 300AH 200AH
COMMON EQUIPMENTS FOR BATTERY CHARGER
Blocking diode for tap One
As per
cells connection from 44th
Appendix-B1
& 19 cell for Chargers
Purchasers
Requirement
Center zero ammeter for One

battery charge/ discharge
current.
(CL 1.11 (k))
DC volt meter with selector One

switch for float/boost/load/
&
battery/battery
taps
voltage
(CL 111 (k))
AC voltmeter with selector One

switch for 3 phase input
voltage
(CL 1.11 (h))
Trickle charge indication One

lamp/LED
Standard
Single phasing preventor, One

over voltage, under voltage
earth,
leakage,
short
circuit, input , rectifier fuse
fail, O/L
Standard
AC Contactors for cutting Two

off AC supply
Standard
Annunciation facia with

accept reset and test
facility. This should have
audio/visual alarms for
various protections & also
two spares
One
Standard
Bell for alarm
One
Standard
10
Input switch
One
Appendix B1
11
DC contactor for change

over of load to boost
charger
during
float
failure.
One
-Do-
12
RF filter (1000V rating) for
One
-Do-
502
Sl.
No.
Particulars
Purchasers
Requirement
Qty
Rating
Rating/Make
of
equipment
110V
48V
300AH 200AH 300AH 200AH
Float Charger
13
RF filter (1000V rating) for

Boost Charger
One
-Do-
14
AC surge suppressor
One
-Do-
15
DC
contactor
for
automatic by pass of tap
cell in the event of supply
failure
One
-Do-
16
Four position single pole

selector switch for end cell
cutting
Set of indicators for
i. Main incoming AC
supplyÒN'
ii. AC supply to boost
chargerÒN'
iii. AC supply to float
charger ON
iv.
DC output from
boost charger ÒN'
v.
DC Output from
float
charger ÒN"
DC
contactor
for
automatic by pass of tap
cell in the event of supply
failure
One
-Do-
One
-Do-
One
-Do-
19
Four position single pole

selector switch for end cell
cutting
One
-Do-
20
Floor mounted motorised

variac
with
automatic
rundown facility complete
with provision for manual
operation for boost circuits
One
-Do-
EQUIPMENTS FOR BOOST CHARGING UNIT
Input transformer VA
rating
AC Contractor rating
Rectifier Diodes &

thyristors rating
MCCB rating AC circuit
Rating of DC contractor
HRC Fuses
Three
-Do-
Lamp to indicate boost on.
One
-Do-
17
18
One As per
Annex-B1
503
Sl.
No.
Particulars
Purchasers
Requirement
Qty
One
Rating
-Do-
Silicon rectifier stack for 3

phase full wave
rectification
HRC Fuses at DC output
Two
-Do-
10
Switch for energizing

circuit
ONE
-Do-
EQUIPMENTS FOR FLOAT CHARGING UNIT
Input transformer VA
rating
AC Contractor rating
Rectifier Diodes &

thyristors rating
MCCB rating AC circuit
Rating of DC contractor
HRC Fuses
One
As per
Annex-B1
Three
-Do-
Lamp to indicate float on
One
-Do-
Silicon rectifier stack for 3

phase full wave
rectification, complete with
thyristor circuit for
automatic voltage control
One
-Do-
Ammeter to indicate
output current(96 sqmm)
One
-Do-
10
Switch for energising

circuit
One
-Do-
11
Fuses HRC type, at DC

output
Two
-Do-
Rating/Make
of
equipment
110V
48V
300AH 200AH 300AH 200AH
Note:1) All the information in this schedule is essentially required to be mentioned.

2) The Bidders may also mention the name of other items, if any, required for satisfactory
operation of offered chargers
504
SCHEDULE-I (A)
IN VOLUME-VI
3
4

110 Volts, 300 AH Battery Charger Complete with
specification
110 Volts, 200 AH Battery Charger Complete with
specification
48 Volts, 300 AH Battery Charger Complete with accessories
48 Volts, 200 AH Battery Charger Complete with accessories
Qty.
S.
No.
1
NOTE:1. The above description of the equipment is given for the purpose of
505
2.3.3(A) TECHNICAL SPECIFICATION FOR AC & DC

DISTRIBUTION BOARDS
1.0
SCOPE:
1.1
Specification means Original Equipment Manufacturer (OEM). The purchaser
means the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipments/material
1.2
SYSTEM PARTICULARS:
Supply Boards offered under this specification shall be utilized at EHV substations having following parameters. Bidders may please note that Neutrals at
these sub-stations are solidly or effectively earthed.
S.
PARTICULARS
No.
1
SYSTEM PARAMETERS
400KV 220KV 132KV 33KV
420KV 245KV 145KV 36KV
Frequency
50 Hz
Earthing
Basic insulation level (KV peak)
1.3
50 Hz
50 Hz
50 Hz
Effectively Earthed
1425
1050
650
250
Applicable climatic conditions shall be as per Volume-II of this bid.
1.3.1
STANDARDS -

Volume-II.
1.3.2
ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS -
In the paragraph 1.3.1 above relevant Indian Standard have been mentioned.
However, the Materials meeting any other authoritative International Standard, which
ensures equal or better quality than the standards, mentioned shall also be
acceptable. Please attach photocopy of all such standards according to which the
Material has been offered.
1.3.3 In this Bid, the Bidders will have to furnish confirmation in regard to compliance
of our entire technical requirement. The Bid should clearly describe various technical
particulars of the Materials as per details given in this specification.
506
AC/DC Board / Junction Boxes

1.4
GENERAL REQUIREMENT:
1.4.1
AC Boards shall be provided with incoming supply of 3 phase, 4 wire,
415Volts AC through MCCB and bus bar/bus section of adequate rating. Distribution
of single/three phase shall be arranged through MCCBs to various load points in the
substation.
1.4.2 220V & 110V DC distribution boards shall comprise of MCCB, bus section
of busbars of adequate ratings suitable for 220V & 110V DC, two wire, ungrounded
supply from the battery charger.
1.5
CONSTRUCTIONAL REQUIREMENTS FOR AC / DC DISTRIBUTION

BOARDS:
1.5.1 AC/DC Boards shall be metal enclosed and floor mounted. Boards shall be
provided with metal frame made of structural steel channel section properly drilled for
mounting the switchgear. These shall be of single front execution with a height (H x
B x D) not exceeding 2000 x 1600 x 400 (H x B x D) and having provisions for cable
entry from the bottom with removable gland plate. Provision shall also be available
for putting labels on the front doors indicating the switchgear designation. Suitable
gaskets shall be provided all round the perimeter of covers, gland plates, door etc.
Tentative drawing of the AC/DC Boards have been enclosed at end of this Section.
1.5.2 Boards shall have two doors, one at the front and other at the backside. Both
the doors shall have pistol grip or allenkey operated door shuttering arrangement.
1.5.3 AC/DC distribution boards shall have an equipment mounting plate provided
at suitable position between the doors. All equipments shall be mounted on front side
of this plate and busbars on its back side. Boards shall be painted in accordance with
the pre-treatment and painting process as per clause 3.0. Each board shall be
given two coats of zinc chromate primer, followed by two finishing coats of shade of
IS:5 (i.e. light grey) for exterior and glossy white for the interior surfaces.
1.5.4
Switchgear shall be divided into distinct vertical sections each comprising of:
i.
Individual feeder modules arranged in the multitier formation vertically

on both sides of the Bus.
ii.
Enclosed vertical busbar running in vertical section in the middle.
iii.
Vertical cable alley covering the entire height on the sides.
iv.
Metal sheets shall be provided between two adjacent vertical sections

running to the full height of the switchgear.
1.5.5 Incoming and the outgoing feeders of the AC/DC Boards shall be provided
with label inserting blocks in front of the MCCB Chamber, so that the destiny of the
feeders could be inscribed by the purchaser.
Note:- On the basis of above arrangement successful Bidders will submit drawings
for approval of MPPTCL.
507

1.5.6 CABLE TERMINATIONS:
1.5.6.1 Suitable double compression type of brass cable glands mounted on a
removable gland plate shall be provided to support all 2.5 sq mm and copper control
cable of 19,4 & 2 Cores cables entering the switchgear. Cable glands shall
incorporate built in facilities for earthing the wire armour of cables. All cable cores
shall be adequately supported at regular interval inside the cable alleys by means of
suitable rubber lined clamps upto the respective terminal blocks. Necessary crimping
type of cable lugs for connecting the individual cores to the respective terminals shall
be provided.
1.5.6.2 Cable alley shall be provided with suitable doors or removable covers. It shall
be possible to safely carry out maintenance and rectification works on cable
connection to any CIRCUIT with the busbars and adjacent circuits live.
1.5.6.3 AC/DC boards shall have provision of multiple cable entries from the
bottom. Cable entry shall be from the bottom and suitable removable gland plates
shall be provided on the cabinet for this purpose. Necessary number of cable glands
shall be supplied duly fitted on the removable gland plate. Cable glands shall be
screw on type, made of brass and shall be of excellent quality. Number of cable
glands required for AC & DC Boards have been mentioned in clause No. 1.5.12 of
specification.
1.5.6.4 Cable lugs for copper cables shall be of tinned copper only and shall be
double compression brass nickel plated type. Suitable washers shall be provided with
lock nuts to tighten the lugs on the terminal block.
1.5.7
Cabinet shall have one space heater with switch.
1.5.8 TERMINAL BLOCKS:

1.5.8.1 All terminal blocks (both for power and control circuits ) shall be of the
1100V grade stud type comprising finely threaded pairs of brass studs of
atleast 6mm diameter, links between each pair of studs, washers, nuts and locknuts. The studs shall be securely locked within the mounting base to prevent turning.
Insulated barriers shall be provided between adjacent terminals.
1.5.8.2 All terminal shall be shrouded. The screw terminal block shall be
manufactured as per IEC60947-7-1. The insulating material of the terminal block
shall be polyamide 6.6 meeting V0/V2 inflammability class as per UL94. All metal
parts including screws shall be copper of alloy. The terminal block shall be suitable
for mounting on both DIN as well as G type rail. All the metal parts shall be captive
and touch proof. The terminal block shall have screw locking design so that it can
withstand vibration level upto 5kg and also prevent accidental loosening of
conductors.
1.5.8.3 Terminal blocks shall be adequately rated to carry the current of associated
circuit. Minimum rating of the terminal blocks is 10Amp.
1.5.8.4 Where duplication of a terminal block is necessary, it shall be achieved by
solid bonding links.
1.5.8.5 Terminal blocks shall be arranged in such a way that atleast
clearance is maintained between two sets of terminal blocks.
508
100mm

1.5.8 .6 Each terminal point shall be marked with relevant designations.
1.5.8 .7 Bottom of terminal blocks shall be spaced atleast 200mm above the cable
glands.
1.5.9
SHEET METAL WORKS:
1.5.9.1 Switchgear frame shall be fabricated using suitable mild steel structural
section or pressed and shaped cold rolled sheet of adequate thickness not less than
2.5mm
1.5.9.2 Steel enclosure shall be smoothly finished, levelled and shall be free from
flaws. The thickness of sheet steel shall be 2.5 mm. Doors shall be made of cold
rolled sheet of thickness of 2.5mm. Suitable stiffners shall be provided wherever
necessary.
1.5.9.3 All panels edges and door edges shall
distortion, bending etc.
be adequately reinforced to avoid
1.5.9.4 All cut-outs shall be true in shape and shall be free from sharp edges.
1.5.9.5 Complete structure shall be rigid, self-supporting and free from vibrations,
twists and bends.
1.5.10 MAIN BUSBARS :
1.5.10.1 Switchgear shall be provided with three phase and a neutral busbars for
AC distribution boards and two busbars for DC distribution boards and shall be
suitable for carrying continuous current and short circuit current as indicated
in the drawings appended to this specification .
1.5.10.2 Busbar shall be of uniform cross section throughout the length of the
switchgears.
1.5.10.3 All busbars shall be made of Electrolytic copper Grade Copper Bars having
size not less than 25x8 sq.mm.
1.5.10.4 Minimum clearance in air between busbars shall be maintained as
specified in IS:4237 for 500V, 3 phase AC system & 110V DC system. All busbars,
bus-taps and joints shall be PVC taped.
1.5.10.5 Busbar shall be adequately supported and braced to withstand the
stresses due to the specified short circuit currents for the associated switchgear.
Busbar supports shall be made of hylam sheets, moulded plastic material,
permaliwood or porcelain. Separate supports shall normally be provided for each
phase of the busbars. If however, the Bidder chooses to provide a common
support for all the three phases, anti tracking barriers shall be incorporated.
1.5.10.6 Busbar joints shall be of bolted type complete with believille washers,
Busbars shall be thoroughly cleaned at the joint locations and suitable contact
grease shall be applied before making a joint. The interconnection between main
bus bar and incoming/outgoing MCCBs shall be done with copper links of adequate
ratings.
509

1.5.10.7 In case of DC switch-boards, positive and negative busbars shall be
completely separated from each other by sheet steel partition. Separate supports
shall be provided for DC Busbar of each polarity. If however, the Bidder chooses to
provide a common support for both the busbars, anti tracking barriers shall be
provided.
1.5.10.8 Maximum temperature of the busbars when carrying rated current under
operating condition shall not exceed 45 deg. centigrade above ambient.
1.5.11 MOULDED CASE CIRCUIT BREAKERS:
1.5.11.1
Moulded case circuit breakers shall be quick acting, preferably with a
total arc extinction time of not less than 25 milliseconds, trip-free, and should be
able to operate satisfactorily under, (i) over load and (ii) short circuit conditions.
1.5.11.2
Moulded case circuit breakers shall be provided with arrangement of
separate tripping system for over load and short circuit conditions. For instance,
over-load tripping could be provided through a suitably calibrated bimetallic strip
and tripping under short circuit conditions could be achieved through a solenoid coil.
Any other arrangement of tripping, reliable and sturdy in design, would be
acceptable.
1.5.11.3 In case of AC Boards the MCCB shall be provided with a common trip bar
for 3 phase supply, so as to ensure opening of all threephase even when fault
occurs in only one phase.
1.5.11.4 Current carrying contact of the MCCB shall be silver plated and sturdy in
design. MCCBs should be housed in a heat resistant moulded insulated housing.
1.5.11.5
Following information regarding MCCBs of various
furnished alongwith the offer.
rating shall be
i.
Make of MCCB offered and experience of the manufacturer.
ii.
A copy of type test report in regard to short time current rating of the
MCCB should be furnished.
iii.
Complete
constructional details of the
MCCB illustrated in
suitable cross sectional drawings should be furnished indicating type
of housing, type of contacts, type and arrangement of various types
of operating mechanism, arrangement
of quenching of arc,
mounting details etc.
iv.
Suitable pamphlet explaining the working of MCCB.
1.5.12
RATING & POSITIONING OF INCOMING & OUTGOING FEEDERS:
1.5.12.1
415 VOLTS AC BOARDS:

i.
One set of 3 phase, 4 wire, 50 Hz, 400Amps busbar of the size not
less than 25x8 sqmm electrolytic grade copper for AC Boards.
ii. One number incoming feeder shall be provided with 300Amp phase
MCCB. The size of cable gland at the bottom shall be suitable for 31/2 core 300sqmm aluminium cable.
iii.
Outgoing feeders will be provided with MCCB as per the following

details:-
510
S.
NO.
Ampere
rating
300 Amps.
Three phase
3 Core 300 sq.mm

Incoming Feeder
50 Amps.
Three phase
20 Amps.
Three phase
16 Amps.
Three phase
2.5 sq mm 19 core
copper control cable. All
out going feeders.
10 Amps.
Single phase
Type of
MCCB
Number
of feeders
Size of cable to be used
iv. A total of 18 Nos. cable glands for Cable entry from the bottom
suitable for 2.5 sq.mm 19 core copper control cables shall be provided
for out going feeders from Board, whereas 1 no. incoming cable gland
shall be suitable for 300 Amps, 3 core 300 sq.mm.
v.
One number AC voltmeter, 0-500V range, with selector switch to

measure all the 3 phase voltages separately, shall be provided.
This will be mounted on top but in the middle as shown in Appendix-A.
vi. One number AC ammeter connected to LTCT ratio 300-150/5 amps.

with selector switch to measure the phase currents shall be
provided. Ammeter shall be mounted as indicated in Appendix-A. The
accuracy of ammeter should not be less than 1.0
1.5.12.2
DC BOARDS:
i.
One set of busbars of rating 200 amps DC of the size not less than
25x8sqmm electrolytic grade copper.
ii.
One number incoming feeder 200 amps with two phase 220V/110V
MCCB shall be provided. The size of the cable gland shall be
suitable for 2.5 sqmm 19 core copper control cable sq mm cable each
for positive & negative terminal
iii.
Details about Incoming and outgoing feeders to be provided on DC

distribution Board shall be as under :
S.No.
Feeders
Quantity
Ratings
Size of cable
Incoming
1 no.
200 Amps
2.5 sq mm 19 core
copper
control
cable
Outgoing
5 nos.
60 Amps
Outgoing
8 nos.
40 Amps.
4.
Emergency
Lighting
1 no.
10 Amps.
2.5 sq mm 2 core
or 4 core control
cable
Note: Disposition of feeders indicated above shall be identical for 600 Ah, 300 Ah.
as well as 200 Ah Batteries. Bidders shall make use of appropriate size of
two core cables and indicate their sizes in their offer.
iv. A total of 18 Nos. Cable glands for cable entry from the bottom for out
going feeder shall be provided for 2.5 sq.mm copper control cable and
511

2 nos, cable glands suitable for 2.5 sq mm 19 core copper control
cable for incoming supply from battery
1.6
TESTS:
Type and routine tests shall be carried out on all equipment as per relevant
Indian Standards.
1.6.1
AC/DC Boards shall be subjected to following tests (i)
Temperature rise test on power circuits.
(ii)
Short time current tests on power circuits.
(iii)
(iv)
Verification of the degrees of protection as per IS:2147.
(v)
Electrical control interlock and sequential operation tests.
(vi)
High voltage test (2KV for 1 minute).
(vii)
1.6.2 Certified copies of all type and routine test certificates shall be submitted for
purchaser's approval before despatch of the equipment.
2.0
SUBMISSION OF DESIGN DETAILS:
2.1
Requirements for participating in this Bid are as under:-
3.0
a.
Bidders must have established manufacturing facility in his factory to

manufacture the materials as specified in this Bid. The Bidders shall
clearly state his experience and capability to undertake the
manufacture of these items. Minimum acceptable experience is
specified in Volume-I.
b.
Details of such manufacture specified above and supply including

type, quantity, date of order, date of commencement and completion
of supplies, name of purchaser shall be furnished with the Bid
alongwith his full address.
c.
Bidders should have adequate testing facilities to test the product

offered in his factory to the satisfaction of the purchaser. Bid shall
include complete details of testing facilities available in manufacturer's
works.
PRE-TREATMENT AND PAINTING PROCESS -
Sheet steel fabricated members for Distribution Boards shall be subjected to

pretreatment process before painting. The process shall be carried out as under. It
can broadly be divided as `Metal treatment and painting'.
3.1
METAL TREATMENT:
i.

degreasing bath or in hot dry chlorothelence solution. In case
degreasing is done by alkaline bath rinse with cold water thoroughly.
512
3.2
ii.
Pickling : This is to remove rust and metal scales. Immersing in

diluted sulphuric acid (approximately 20%) at nearly 60 deg.
Centigrade. Unit scale and rust are totally removed.
iii.
Rinse it in cold water twice to remove traces of acids.
iv.
Treat with phosphoric acid base neutraliser for removal of chlorine

from the above acid pickling and again wash with running water.
v.
Phosphating : Immerse in grenodine `zinc phosphate solution for

about 20 minutes at 80 to 90 deg. centigrade. The uniform
phosphate coating of 4 to 5 gms per sq.meter shall be achieved.
vi.
vii.
Rinse in Deorylyte bath at 70 to 80 deg. centigrade to neutralise any

traces of salts.
viii.
Seal the above phosphate coating with hot/dilute chromoto solution.
ix.
PAINTING:
i.
Primer : spray one coat wet on wet specially developed `High

lusture' zinc chromote primer and stove at 150 deg. centigrade to 160
deg. centigrade for 25 to 30 minutes. Alternatively red-oxide primer
with zinc chromate contents may be used. However, former process is
preferred.
ii.
Rubbing and puttying : Apply putty to fill up the scars if any to

present smooth surface and stove 15 to 20minutes. Apply putty
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 20 to 40 minutes at 150 deg.
centigrade.
v.
Finish paint: Rubbing down dry and spray first coat of

enamel finish paint wet on wet and stove for 30 minutes.
vi.
Surfacing: Sand down or rub dry to prepare for final finish spray.
Final finish shall be obtained after spraying 2 Coats of synthetic
enamel finish paint wet on wet and stove it at 150 deg. centigrade for
30 minutes.
vii.
Colour of finishing paint for AC/DC Boards & Junction Boxes shall be
light grey shade as per 631 of ISS. On the interior surface, the
finishing coat shall be of glossy white colour.
i.
Necessary stiffners may be welded between large cut outs to provide

ii.
Painting process shall be done within 24 hours of completion of

treatment.
iii.
Small coating paint shall be supplied alongwith equipment for touching

up at site.
synthetic
NOTE:
513

4.0
DATA AND DRAWINGS:
Bidders shall furnish one set of following drawings and data alongwith the Bid
for preliminary study:i.
Complete assembly drawings of the switchgear showing plan,

elevation and typical sectional views and locations of terminal blocks
for external wiring connections.
ii.
Foundation plan showing location of channels sills, anchor bolts etc.
iii.
General arrangement drawing of each switchgear showing the

equipment mounted.
iv.
Time- current characteristics curves for each type and rating of

MCCBs.
v.
Developed diagram of electrical switches,
vi.
Outline drawings of cable pot heads showing dimensions and rating.
vii.
Item wised bill of material listing all devices mounted or otherwise

furnished indicating manufacturers type.
viii.
Operation and maintenance manual for individual equipment and

complete switchgear.
ix.
Illustrated literature/write-up for each equipment i.e. CTs, Voltmeter,

ammeter, switches, lamps, MCCB etc.,
Please note that above mentioned drawing/literature etc., shall be
accompanied along-with the offer, otherwise the offer shall be treated as non
responsive.
5.0
PACKING AND TRANSPORT:
5.1 All equipments/material shall be protected for transport carriage at site and
5.2
Supplier shall be responsible for any damage to the equipment during transit
due to improper and inadequate packing.
5.3
Only packages constructed out of wooden material and of dimensions
proportional to the size and weight of contents shall be used.
5.4
Bundled materials shall be rigidly steel strapped over the protective covering
such as gunny bags.
5.5
Fragile materials shall be securely braced within the container or
otherwise amply fastened and packed to prevent shifting of ratting soft nonhygroscopic packing materials shall be
placed between the hard packing
materials and the fragile equipment.
5.6
Loose material e.g. bolts, nuts etc., shall be packed in gunny bags and
sealed in polythene bags with proper tagging.
5.7
All opening in the equipment shall be tightly covered, plugged or capped
to prevent foreign material from entering.
5.8
Proper arrangements for attaching slings for lifting shall be provided.
5.9
Each package shall be clearly, legibly and durably marked on both sides as
follows:-
514
6.0
a.
Name & designation of the consignee

purchaser.)
b.
Ultimate destination (as required by the
c.
Items and respective quantities contained in the package to be

furnished by the purchaser.)
d.
Net and gross weight of the material.
e.
Gross weight of each package
be
furnished by the
purchaser)
INSPECTION:
(i)
Purchaser shall have access at all times to the works and all other
places of manufacture, where the Material are being manufactured
Bidders works, raw material, manufacture of all the accessories and
for conducting necessary tests as detailed in the bidding document.
(ii)
Successful Bidder shall keep the purchaser informed in advance of

the time of starting and of the progress of manufacture of Material in
its various stages, so that arrangement could be made for inspection.
(iii)

the material has been satisfactorily inspected / tested and despatch
clearance issued.
Acceptance of any quantity of the material shall in no way relieve the
successful Bidder of his responsibility for meeting all the requirement
of this specification and shall not prevent subsequent rejection if such
(iv)
7.0
(to
7.1
Bidders must establish that they are following a proper quality assurance
programme for manufacture of Material. They shall invariably furnish following
information along with their Bid. Information shall be separately given for AC and DC
supply Boards.
7.2
(i)
(ii)

bought out items.
(iii)
(iv)

inspections.
(v)
List of testing equipment available with the Bidders for final testing of
Successful Bidders shall within 30 days of placement of order, submit

following information to the Purchaser:
515
8.0
(i)
List of raw material as well as bought out items/accessories and the

names of sub-suppliers selected from the lists furnished along with
Bid.
(ii)
(iii)

inspection. Quality assurance plans and hold-up points shall be
finalized.
SCHEDULE:
Schedules and annexure attached with this specification are the integral part
of the specification and shall be submitted duly filled in by the Bidders alongwith the
offer.
Bill of material for each equipment shall be submitted by the Bidder
separately. Makes of the equipment shall be clearly indicated. Bidders may please
note that a general mention that the components shall be of reputed make will not be
acceptable.
9.0

10.0
10.1 Bid shall be complete in all respects and shall include all minor accessories,
small wiring etc., not specifically mentioned in the Schedule, specifications etc;
but essential for the completeness of the system. Bidders shall not be eligible for
extra charges in respect of such minor accessories, small wiring etc., though not
included specifically in this specification but requires for satisfactory operation of
equipment offered.
10.2
10.2.1
Complete details of all the accessories which will be supplied with
Distribution Boards.
10.2.2
It is obligatory on the part of Bidders to ensure that supply of all
accessories along with Main equipment are simultaneously delivered to avoid any
holdups. Responsibility for obtaining timely supplies of bought out items will rest on
the Bidders and only on this basis, delivery period will be offered in the Bid.
10.2.3
It may be noted that in case of damages/shortages due to improper
packing or any other negligence ,replenishment shall be arranged within one
months time. For bought out items, responsibility for guarantee and obtaining
immediate replacement in case any defects are noticed and also in case
defective supply of any item is reported, will rest on the Bidders.
516
APPENDIX-A
DRAWINGS
S.No.
Description
General Arrangement Drawing for 415V AC

Distribution Board
General Arrangement Drawing for 220/110V DC

Distribution Board
517
2 000
518
Y
4 00
BUS BARS
BOTTOM VIEW
1600
1100
FRONT VIEW
400
ASS
350
Y1
C AB LE A LLE Y
MCCB
250
250
50
600
400
A
(0-300A)
1 00
4 00
MCCB 20A TP
5 Nos.
MCCB 15A TP
3 Nos.
N.T.S.
SCALE
NAME
DATE
JICA/MPPTCL/TR-101 TO 107/ GA 415V

AC BOARD
DRAWING NUMBER
APPROVED
CHECKED
PREPARED CAD-CELL
DRAWN
MCCB 16A TP
3 Nos.
415 VOLTS A.C. DISTRIBUTION BOARD

G.A. DRAWING
SINGLE LINE DIAGRAM
MCCB 50A TP
4 Nos.
CABLE
GLANDS
TERMINALS
TERMINALS
SECTIONAL VIEW Y1-Y1
700
400
BUS BAR COPPER (25x8) mm. SINGLE LINE DIAGRAM
8. CABLE GLANDS SHALL BE PROVIDED AS PER SPECIFICATION
7. BUS BAR-25x8 MM. EC GRADE COPPER
6. BASE CHANNEL-100x50 MM.
700
400
SECTIONAL VIEW Y-Y
SUPPORTS
SUPPORTS
BUS BAR
SELECTOR
SWITCH
METER
5. COLOUR FINISH (EXTERIOR-LIGHT GREY)(INTERIOR-WHITE)
4. TOLERANCE 10%
3. SHEET THICKNESS 2.5 MM.
2. SCALE N.T.S.
ASS
VSS
C.F.
2A
C.T. 300/5
50
(0-500V)
1. DIMENSION IN MM.
MAINS
ON O/L
SIDE VIEW
NOTES:-
INCOMER
MCCB
300A TP
INCOMER
SUPPLY
BASE
CHANNEL
OUT GOING
MCB
CHAMBER
TERMINALS
HINGES
1 00
SECTIONAL VIEW X-X
350
MCCB
INCOMER
VSS
M ONOGRAM
Y1
2 00
250
250
C AB LE A LLE Y
CABLE ALLEY
MCCB
INCOMER
M ONOGRAM
BUS BAR
CHAMBER
FRONT VIEW
BOTTOM VIEW
BUS BARS
SECTIONAL VIEW X-X
MCCB
V2
V2
HINGES
X
OUT GOING
MCCB
CHAMBER
BASE
CHANNEL
CABLE GLANDS
TERMINALS
SIDE VIEW
MCCB 60 ADP
5 Nos.
METER
BUS BAR
SUPPORTS
SUPPORTS
SECTIONAL VIEW Y-Y
MCCB 40 ADP
8 Nos.
TERMINALS
TERMINALS
CABLE
GLANDS
SECTIONAL VIEW Y1-Y1
N.T.S.
SCALE
220/110 V D.C. DISTRIBUTION

BOARD G.A. DRAWING
SINGLE LINE DIAGRAM
MCCB 10ADP
1 No.
BUS BAR COPPER(25X8)mm SINGLE LINE DIAGRAM
INCOMER
MCCB
200A TP
INCOMER
SUPPLY
1. DIMENSION IN MM.
NOTES:-
COLOUR FINISH (EXTERIOR-LIGHT GREY)(INTERIOR-WHITE)

BASE CHANNEL-100x50 MM.
BUS BAR-25x8 MM. EC GRADE COPPER
ALLCOMPONENTS AS PER DETAILS BILL OF MATERIAL ENCLOSED
CABLE GLANDS SHALL BE PROVIDED AS PER SPECIFICATION.
2. SCALE N.T.S.
3. SHEET THICKNESS 2.5 MM.
4. TOLERANCE 10%
5.
6.
7.
8.
9.
DRAWN
CHECKED
NAME
DATE
PREPARED CAD-CELL 18-07-09
DRAWING NUMBER
APPROVED
JICA/MPPTCL/TR-101 TO 107/ GA
220/110V /DC BOARD
519
CABLE ALLEY
SCHEDULE-I (A)
IN VOLUME-VI
Qty.
1
Supply of 415V AC Distribution Board meeting all Technical

requirements as prescribed in Bid document.
110V DC Distribution Board meeting

all
Technical
As per Price
Schedule
S.No.
offering the prices and to mention description of equipment in
520
2.3.3(B) TECHNICAL SPECIFICATION FOR JUNCTION BOXES

1.0
SCOPE:
1.1
Specification means Original Equipment Manufacturer (OEM). The purchaser
means the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipments/material
1.2.1
STANDARDS -

Volume-II.
1.2.2
ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS
In the paragraph 1.2.1 above relevant Indian Standard have been mentioned.
However, the Materials meeting any other authoritative International Standard, which
ensures equal or better quality than the standards, mentioned shall also be
acceptable. Indian Standards for which are not available, the relevant equivalent
International Standards will be applicable. Please attach photocopy of all such
standards according to which the Material has been offered.
1.2.3 In this bid, the Bidders will have to furnish confirmation in regard to compliance
of our entire technical requirement. The bid should clearly describe various technical
particulars of the Materials as per details given in this specification.
1.2.4
CLIMATIC CONDITIONS Applicable climatic conditions shall be as per Volume-II.

SYSTEM PARTICULARS -
1.2.5
Materials offered under this specification shall be utilized at EHV sub-stations

having following parameters. Bidders may please note that Neutrals at these substations are solidly or effectively earthed.
S.
PARTICULARS
No.
1
2.0
SYSTEM PARAMETERS
400KV 220KV 132KV 33KV
420KV 245KV 145KV 36KV
Frequency
50 Hz
Earthing
Basic insulation level (KV peak)
50 Hz 50 Hz 50 Hz
Effectively Earthed
1425
1050
650
250
CONSTRUCTION -
Junction (Marshalling) boxes shall be made of MS sheet steel of thickness 2.5

mm. with suitable rubber beading and gaskets so as to make the box completely
521

water proof and suitable for outdoor installation. Quality gaskets shall be utilized to
prevent ingress of rain water inside the box.
2.1.1. Suitable mounting arrangement shall be provided for the Junction (Marshalling)
boxes.
2.1.2 Boxes shall be suitable for outdoor mounting as stated above and shall
be provided with knock-outs both in top and bottom plated for cable/conduit
connectors. The box cover should be hinged at one end in addition nuts/bolts shall
be provided in all four corners for tightening the box cover. All hardwares used in
junction boxes shall be zinc passivated.
2.1.3 Junction (Marshalling) boxes shall be provided with two earthing terminals
and shall be complete with end plate, end clamps, fixing channels, flange,
covers and brass cable glands etc.
2.1.4 Box shall be painted in accordance with the pre-treatment and painting
process as per clause 3.0. Each box shall be given two coats of zinc chromate
primer, followed by two finishing coats of shade of IS:5 (i.e. light grey) for exterior and
glossy white for the interior surfaces.
2.1.5
Moulded barriers of suitable size shall be provided between terminals to
prevent flashover. The terminals shall have a voltage withstand capability of at least
5KV between phase to earth as well as between two adjacent blocks for one
minute. Each junction (marshalling) box shall have provision of addition of one more
row terminal blocks in future and each row shall have provision for 5 to 10 terminal
blocks, if required.
2.1.6 Terminal blocks shall be Elmex reputed make and shall be of
the
disconnectable type only. Our approved type of terminal connector is ELMEX make
KLTDM4. Please
note
that non disconnecting type terminal blocks are not
required and all such Boxes shall not be accepted.
2.1.7 All terminals shall be complete with insulated barriers, terminals, studs,
washers, nuts, lock nuts & identification strips and shall have facility for
measurement of voltage/current using banana pins.
2.2
IMPORTANT DESIGN REQUIREMENT Following should be kept in view while designing the box:-
2.2.1
Terminal blocks should necessarily be of disconnecting type only.
2.2.2 The cover of the box should cover the complete surface of the box, so that
installation may be water proof. A stopper should be provided so that at the times of
opening full load may not come on the hinges.
2.2.3 It may be ensured that the Junction/Marshalling box is manufactured in the
best possible way to ensure that the box is completely dust and water proof. For this
purpose it may be noted that all joints in the boxes should be of "TONGUE
GROOVE" type.
2.2.4
Earthing arrangement for the box should be provided.
522

2.2.5 A small copper strip of adequate size with three or five nuts should be
provided inside the box so that earthing of three or five star points of CT secondary
could be possible without any difficulty.
2.2.6
Terminal blocks should be numbered serially.
2.2.7 Double compression type Brass cable glands, rubber gaskets and Elemex
make terminal blocks should be of best quality.
2.2.8
Suitable handle type looking arrangement shall be provided for the box.
2.2.9
Thickness of the sheet metal should not be less than 2.5 mm.
2.2.10 Junction boxes shall be made by using 4 pieces of sheet metal only. Out of
these 4 pieces, one shall be used for three sides of the box, another one for
cover and two pieces shall be used for balance two sides of the box.
2.2.11 Junction Boxes in which more than 4 pieces of sheet metal will be used shall
not be acceptable.
2.2.12 A small circular plate should be provided with each of the cable gland, so
that the gland not in use may be closed properly, so as to avoid entry of rain
water in the box.
2.3.0
GENERAL REQUIREMENT -
2.3.1
Requirement of 128 Ways, 64 Ways and 36 Ways Junction boxes shall

be as per price schedule.
2.3.2 Number of ways required for different types of Junction (Marshalling) boxes
and the inside clear dimensions in these boxes shall be as follows:S.No
1
2
2
Particulars
Width
128 ways (64 terminal

blocks)
blocks)
blocks)
(mm)
700
Depth
(mm)
300
Height
(mm)
800
700
300
800
410
100
340
2.3.3 Terminal blocks shall be mounted in 2 rows of 64ways for 128 ways box, 2
rows of 32 ways for 64 way box and 1 row of 36 ways for 36 way box. The box
shall, however, have a provision for one additional row of terminal blocks to be
added in future. The row of terminal blocks shall be on Cadmium passivated
slotted steel channels of 14 SWG size and each row shall have provision for
addition of 5 to 10 terminal blocks, if required.
2.3.4 CABLE ENTRY AND GLANDS In all the Junction (Marshalling) box cable entry shall be from bottom and
cable gland fixing plate shall be removable type. The 128 Ways Junction boxes
shall have 20 Nos. brass, cable glands, suitable for 4 core, 10 sq.mm. PVC insulated
523

armoured cables and 64 ways Junction (Marshalling) box shall have total 16 nos.
brass cable glands out of which 8 nos. brass cable glands suitable for 4 core, 4
sq.mm.PVC insulated unarmoured cables and 8 Nos. glands for 8 core, 4 sq. mm.
PVC insulated unarmoured cable. The 36 ways box shall have 9 No. brass cable
glands suitable for 4 core , 2.5 sq.mm. PVC insulated unarmoured cables. Brass
cables glands shall be of double compression type and preferably of COMET make.
2.4
SUBMISSION OF DESIGN DETAILS -
2.4.1 Requirements for participating in this Bid are as under:-
3.0
a.
Bidder must have established manufacturing facility in his factory to

manufacture the materials as specified in this Bid. The Bidder shall
clearly state his experience and capability to undertake the
manufacture of these items. The minimum acceptable experience is
specified in Volume-I.
b.
Details of such manufacture specified above and supply including

type, quantity, date of order, date of commencement and completion
of supplies, name of purchaser shall be furnished with the Bid
alongwith his full address.
c.
Bidder should have adequate testing facilities to test the product

offered in his factory to the satisfaction of the purchaser. The Bid shall
include complete details of testing facilities available in manufacturer's
works.
Sheet steel fabricated members for Junction Boxes shall be subjected to

pretreatment process before painting. The process shall be carried out as under.
The process can broadly be divided as `Metal treatment and painting'.
3.1
METAL TREATMENT i.

degreasing bath or in hot dry chlorothelence solution. In case
degreasing is done by alkaline bath rinse with cold water thoroughly.
ii.
Pickling: This is to remove rust and metal scales. Immersing in diluted

sulphuric acid (approximately 20%) at nearly 60 deg. Centigrade. Unit
scale and rust are totally removed.
iii.
iv.
Treat with phosphoric acid base neutraliser for removal of chlorine

from the above acid pickling and again wash with running water.
v.
Phosphating : Immerse in grenodine `zinc phosphate solution for

about 20 minutes at 80 to 90 deg. centigrade. The uniform
phosphate coating of 4 to 5 gms per sq.meter shall be achieved.
vi.
vii.
Rinse in Deorylyte bath at 70 to 80 deg. centigrade to neutralise any

traces of salts.
viii.
524

ix.
3.2
PAINTING i.
Primer : spray one coat wet on wet specially developed `High

lusture' zinc chromote primer and stove at 150 deg. centigrade to 160
deg. centigrade for 25 to 30 minutes. Alternatively red-oxide primer
with zinc chromate contents may be used. However, former process is
preferred.
ii.
Rubbing and puttying : Apply putty to fill up the scars if any to

present smooth surface and stove 15 to 20 minutes. Apply putty
Surfacing: Sand down with mechanical abrasive and stove for 20
minutes.
iii.
iv.
Primer: Spray second coat of primer as per (i) above or grey primer
surface wet on wet and stove for 20 to 40 minutes at 150 deg.
centigrade.
v.
Finish paint: Rubbing 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. Final
finish shall be obtained after spraying 2 Coats of synthetic enamel
finish paint wet on wet and stove it at 150 deg. centigrade for 30
minutes.
vii.
Colour of finishing paint for Junction Boxes shall be light grey shade
as per 631 of ISS. On the interior surface, the finishing coat shall be
of glossy white colour.
NOTE -
4.0
i.
Necessary stiffners may be welded between large cut outs to provide

ii.
Painting process shall be done within 24 hours of completion of

treatment.
iii.
Small coating paint shall be supplied alongwith equipment for touching

up at site.
DATA AND DRAWINGS -
Bidders shall furnish one set of following drawings and data alongwith the Bid
for preliminary study:i.
Complete assembly drawings of the Junction boxes showing plan,

elevation and typical sectional views and locations of terminal blocks
for external wiring connections.
ii.
Foundation plan showing location of channels sills, anchor bolts etc.
iii.
General arrangement drawing of each rating Junction box showing the

terminal connectivity mounted.
iv.
Outline drawings of cable pot heads showing dimensions and rating.
v.
Itemised bill of material listing all devices mounted or otherwise

furnished indicating manufacturers type.
525

Please note that above mentioned drawing/literature etc., shall be
accompanied alongwith the offer, otherwise the offer may be treated as non
responsive.
5.0
PACKING AND TRANSPORT -
5.1
All equipments/material shall be protected for transport carriage at site and
5.2
Supplier shall be responsible for any damage to the equipment during transit
due to improper and inadequate packing.
5.3
Only packages constructed out of wooden material and of dimensions
proportional to the size and weight of contents shall be used.
5.4
Bundled materials shall be rigidly steel strapped over the protective covering
such as gunny bags.
5.5
Fragile materials shall be securely braced within the container or
otherwise amply fastened and packed to prevent shifting of ratting soft nonhygroscopic packing materials shall be
placed between the hard packing
materials and the fragile equipment.
5.6
Loose material e.g. Bolts, nuts etc., shall be packed in gunny bags and
sealed in polythene bags with proper tagging.
5.7
All opening in the equipment shall be tightly covered, plugged or capped
to prevent foreign material from entering.
5.8
Proper arrangements for attaching slings for lifting shall be provided.
5.9
Each package shall be clearly, legibly and durably marked on both sides as
follows:a.
Name & designation of the consignee (to be furnished by the

purchaser.)
b.
Ultimate destination (as required by the
c.
The items and respective quantities contained in the package to be

furnished by the purchaser.)
b.
Ultimate destination (as required by the purchaser)
c.
The items and respective quantities contained in the package.
d.
The net & gross weight of the materials
e.
Gross weight of each package
5.10 Successful Bidder

purcharsers approval.
6.0
shall
furnish
detailed
purchaser)
dimensioned
drawings
for
INSPECTION
(i)
The purchaser shall have access at all times to the works and all other
places of manufacture, where the Materials are being manufactured
526

Bidders works, raw materials, manufacture of all the accessories and
for conducting necessary tests as detailed in the Bid document.
7.0
(ii)
The successful Bidder shall keep the purchaser informed in advance

of the time of starting and of the progress of manufacture of Materials
in its various stages, so that arrangement could be made for
inspection.
(iii)

(iv)
The acceptance of any quantity of the material shall in no way relieve

the successful Bidder of this responsibility for meeting all the
requirement of this specification and shall not prevent subsequent
rejection if such equipment are later found to be defective.
QUALITY ASSURANCE PLAN -
7.1
The Bidders must establish that they are following a proper quality assurance
programme for manufacture of Materials. The Bidder shall invariably furnish following
information along with their bid. Information shall be separately given for each type of
cable:
7.2
(i)
(ii)

bought out items.
(iii)
(iv)

processing exists.
(v)

inspections.
(vi)

(i)
of sub-suppliers selected from the lists furnished along with Bid.
(ii)
(iii)

finalized.
527
8.0
SCHEDULE -
The Schedules and annexure attached with this specification are the integral
part of the specification and shall be submitted duly filled in by the Bidders alongwith
the offer. The bill of material for each equipment shall be submitted by the Bidders
separately. The makes of the equipment shall be clearly indicated. A general
mention that the components shall be of reputed make will not be acceptable.
9.0

10.0
COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS -
10.1 The Bid shall be complete in all respects and shall include all minor
specifications etc; but essential for the completeness of the system. The Bidders
shall not be eligible for extra charges in respect of such minor accessories, small
10.2
The Bidders must furnish the following information along with technical bid.
10.2.1 Complete details of all the accessories which will be supplied with Junction
Box should be furnished.
10.2.2 It is obligatory on the part of Bidders to ensure that supply of all accessories
along with Main equipment are simultaneously delivered to avoid any holdup in
erection and commissioning. The responsibility for obtaining timely supplies of
bought out items will rest on the Bidders and only on this basis, delivery period will be
offered in the Bid.
10.2.3 It may be noted that in case of damages/shortages due to improper packing
or any other negligence, replenishment shall be arranged within one month time. For
bought out items, responsibility for guarantee and obtaining immediate replacement
in case any defects are noticed and also in case defective supply of any item is
reported, will rest on the Bidders.
528
SCHEDULE-I (A)
IN VOLUME-VI
Supply of 128 ways (64 terminal blocks)

Junction Boxes meeting all Technical
64 ways (32 terminal block) Junction Boxes

meeting all Technical requirements as
prescribed in Bid document.
36 ways (18 terminal block) Junction Boxes

meeting all Technical requirements as
prescribed in Bid document.
Qty.
S.No.
529
2.3.4 TECHNICAL SPECIFICATION FOR LIGHTING EQUIPMENTS

1.0
SCOPE:
1.1
the MPPTCL.
1.2
SYSTEM REQUIRMENTS WHICH ARE TO BE CONSIDERED FOR

DESIGN OF LIGHTING EQUIPMENTS
NOTE :
In this part of specification we have brought out details of climatic conditions

and system requirements which have to be taken into account for the
purpose of design of Lighting Equipments. Also in this section various
standards have been detailed out which are to be followed and confirmed by
the bidders for selecting various components in designing the equipment:
1.2.1
Climatic conditions at site under which the equipments shall be guaranteed

to operate satisfactorily are as under:-
S.
No.
i
ii
iii
iv
v
vi
Particulars
Conditions
Location
Maximum ambient air temp
Minimum ambient air temp
Average daily ambient temp
Maximum Relative humidity
Indoor
500 Centigrade
10 Centigrade
350 centigrade
95% (sometime
saturation)
1000 (Meters)
Maximum altitude above mean sea level
approaches
vii
Average Annual rainfall
1250 (mm)
viii
Maximum wind pressure
150 Kg/m2
ix
Isoceraunic level
90 days per year
x
Seismic level (Horizontal acceleration)
0.3
Moderately hot and humid tropical climate, conducive to rust and fungus growth.
1.2.2
STANDARDS:
Offered Lighting Equipments shall be manufactured tested and supplied

with all guaranteed technical particulars generally confirming to meet the requirement of
the latest revisions of relevant standards of international Electro-technical commission
or equivalent national standards of India with latest amendments of relevant standards,
530
Lighting Equipments

rules and codes. Unless otherwise specified, the equipment shall conform to the latest
applicable Indian, IEC, British or any other authoritative standards, and in particular to
the following standards:
IS No.
IS:1913
IS:3287-1965
IS:1777-1978
IS:9974-1981
(Part-I & II)
IS:8019
IS:10322-1987
(Part-I to V)
IS:3528
IS:4013
IS:3480
IS:1653
IS:2147
IS:1034-1990
IS:6616-1982
Particulars
General and safety requirements for electric lightning fittings
Industrial Lighting fitting with plastic reflectors
Industrial Luminaries with metal reflectors
High Vacuum Sodium Vapour Lamp
Vitreous enamelled reflectors for use with illuminating device.
Luminaries
Water Proof electric lightning fitting
Dust proof electric lightning fitting
For flexible conduits
Steel conduit
Degree of protection for Switchgear and control gear
Electric Ballast
Ballast for Lamps
Bidders shall clearly state the standards to which the equipment offered by
him conforms. In the event of offering of equipment conforming to standards other than
IS, the salient points of comparison between standards adopted and the relevant IS shall
be indicated in the proposal alongwith copies of adopted standards. It will be sole
responsibility of the bidder to prove that the salient features of offered equipment are
equivalent or better than standards specified above.
1.3
SYSTEM DETAILS
Frequency
50 Hz
No. of phases
Earthing
AC SUPPLY SYSTEM
Nominal supply voltage
3
Effectively earthed
240 Volts, single phase
415 Volts, 3 Phase, 4 wire,
Neutral grounded system
50 Hz
10%
15%
Nominal frequency
Variation in supply voltage
Combined Voltage and frequency
variation
Variation in frequency
1.4
5%
FLOOD LIGHTING LUMINARIES
Luminaire shall comprise of die-cast aluminium alloy housing with low copper
content, high degree of corrosion resistance. The housing should be provided with
cooling fins for effective heat dissipation. The optical system (reflector) should be made
531
Lighting Equipments

from high purity aluminium electro chemically brightened and anodized. The front
closing of housing should be by a heat resistant toughened glass and a profile gasket.
For rigidity to glass four clamps shall be provided. For aiming light in the proper
direction, a graduation disc should be provided.
Rear cover made of cast aluminium alloy and also provided with cooling fins
shall be fixed to main housing by two knurled headed loss proof stainless steel screw.
The alignment of rear cover shall be achieved by two guide fins. The material & finish of
various items shall be as follows :Housing
Gravity Die cast aluminium, LM Aluminium,

Hammer tone Grey
Front clamps
Stainless steel
Mounting bracket
MS Hot dip galvanized
Reflector
High purity aluminium electro-chemically

brightened and anodised
Gasket
Ethylene propylene
Electrical &
mechanical data
Suitable for use with single 250 Watts High

Pressure Sodium Vapour (HPSV) lamp/ High
Pressure Metal Helaid (HPMH)
220/240 Volts Nominal p.f. 0.9
Lamp Voltage
1.5
HIGH PRESSURE SODIUM VAPOUR LAMPS
HPSV Lamp of 250 Watts shall be polycrystalline, translucent, aluminium

oxide discharge tube. The inside of tubular clear lamp avoid shell shall be coated with a
film of uniform layer of diffusing powder (which shall be applied electro statically).
Discharge tube shall contain an amalgam of mercury sodium along with
xenon gas as starter. The outer shell shall be evacuated. The accessories for optimum
performance needed are ballast, an electronic igniter and a capacitor. The lamp shall
have diameter 47mm, base E40. The 250 Watts lamp shall have nominal lamp current
of 3.0 Amps. The 100 hours luminous flux shall be 27,000 Lumens for 250 Watts lamps.
The lumen maintenance at the end of 12000 Hours shall be above 78%.
1.6.0
GENERAL REQUIREMENT
LIGHTING LUMINARIES
OF
OUTDOOR
TYPE
FLOOD
1.6.1
Equipments in all respect shall incorporate highest quality of modern
engineering and workmanship. Collaboration arrangements with reputed supplier, if any,
may be clearly stated.
1.6.2
Materials offered shall be complete with all components and accessories,
which are necessary or usual for their satisfactory performance and efficient
maintenance. Such parts or accessories shall be deemed to be within the scope of the
specification.
1.6.3
Design, manufacturing process and individual control of all the fixtures shall
be such as to give maximum factor of safety with minimum weight in respect of
532
Lighting Equipments

maximum working load, highest mobility, complete elimination of sharp edges and
corners, best resistance to corrosion and good finishing, and suitable for outdoor
execution, in respect of switchyard fixtures.
1.6.4
All castings shall be free from shrinkages, below holes, cracks and other
defects and quality of the product shall be uniform throughout.
1.6.5
All AC outdoor lighting fixtures shall be suitable for operation on single phase
2 Wire AC supply specified under clause 5.3.
1.6.6
Fixtures shall be designed to have low temperature rise, and suitable heat
radiation devices. The protective glass wind shields shall be fixed at proper distance to
avoid localised intensive heat and also cracking due to extreme temperature differential
inside and out side the fixtures.
1.6.7
Lighting fixtures shall be designed for minimum glare. Finishing of fixtures
shall be such that no bright spots are produced either by direct light sources or by
reflection.
1.6.8
All fixtures shall be complete with accessories like Ballast, power factor
improvement capacitors etc. It is desired to mount these fixtures on the sub-station
structures only and accessories listed above should be part of fitting assembly. If,
however, the accessories can not be accommodated inside, then a separate metal
enclosed water proof box shall be included in the scope to accommodate these
accessories along with a fuse and a set of terminal blocks suitable for loop-in and loopout connections. The fixtures shall be provided with weather proof and vermin proof
boxes.
1.6.9
Each fixture shall have a terminal block suitable for loop-in, loop-out and Toff connection by cable, type and size of which shall be as specified. Internal wiring
should be completed by manufacturer by means of stranded copper wire of adequate
size and terminated on the terminal block.
1.6.10
Each lighting fixtures shall be provided with an earthing terminal suitable for
connection to purchasers earthing conductor (SGW-12).
1.6.11
All metal or metal enclosed parts of the housing shall be bonded and
connected to the earthing terminal so as to ensure satisfactory earthing continuity
through out the fixtures.
1.6.12
Mounting facility and conduit knock-outs for the fixtures shall be specified.
1.6.13
On completion of the manufacture, all surface of the fixtures shall be
thoroughly cleaned and degreased. The fixtures shall be free from scales, rust, sharp
edges, and burrs.
1.6.14
Where enamel finish is specified, it shall have a minimum thickness of 2
mills for outside surface and 1.5 mills for inside surface. The finish shall be highly
polished, nonporous and free from blemishes, blisters and fading.
1.6.15
Housing shall be stove-enamelled or anodised aluminium or epoxy coated
aluminium.
1.6.16
Surface shall be scratch resistant and shall show no signs of cracking or
flaking when bent through 90oC over dia mandrel.
1.6.17
All lightning reflecting surfaces shall have optimum light reflecting coefficient, so as to ensure the overall light output as specified by the manufacturer.
533
Lighting Equipments
1.7.0
ACCESSORIES FOR LIGHTING LUMINARIES
1.7.1
REFLECTORS
Reflectors shall be manufactured from sheet steel or aluminium of not less

than 20 SWG thickness. They shall be readily removable from the housing for cleaning
and maintenance without disturbing the lamps and without use of tools. They shall be
securely fixed to the housing by means of positive fastening device of captive type.
1.7.2
BALLASTS
Ballasts shall be designed, manufactured and supplied in accordance with

the relevant standard and function satisfactorily under site conditions specified in this
specification. The ballasts shall be designed to have a long service life and low power
loss. Ballasts shall be mounted using self locking, antivibration fixings and shall have
ease of removal without dismouting the fixtures. They shall be totally enclosed units.
The ballasts shall be of the inductive, heavy duty type filled with thermosettings,
insulating, moisture repellent, polyester compound filled under pressure or vacuum.
Ballasts shall be provided with 2 tappings to set the voltage within the range of 220 or
240 volts. End connections and taps shall be brought out into a suitable terminal block,
rigidly fixed to the ballast enclosure. The ballast wiring shall be of copper wire. They
shall be free from hum and vibration. Ballasts, which produce humming, shall be
replaced free of cost by the supplier.
1.7.3
1.7.4
CAPACITORS
i.
Capacitors shall have a constant value of capacitance and shall be

connected across the supply of individual lamp circuits.
ii.
Capacitors shall be suitable for operation at supply voltage as specified

and shall have a value of capacitance so as to correct the power factor
of its corresponding lamp circuit to the extent of 0.98 lag.
iii.
Capacitors shall be hermetically sealed preferable in a metal enclosure

to prevent seepage of impregnent and ingress of moisture.
FUSES AND FUSE HOLDERS (FOR FLOOD LIGHT FIXTURES)
Fuse shall be housed in non-hygrosopic insulated housing of totally enclosed

dead front type provided with a pull out type fuse carrier. The fuse holder shall be
mounted within the fixture housing, remote from other control gear as ballast etc. and
accessible from the outside of the fixtures. It shall be possible to replace the fuse
without disturbing the reflector or lamp and without demounting the fixture. The fuse
shall be non-deteriorating, high conductivity, high repturing capacity type and suitable
for operation on a supply voltage as specified.
1.8

1.9.
DRAWING AND LITERATURES
Bidders shall furnish relevant descriptive and illustrative literature

on lighting fixtures and accessories and following drawings/data for
the respective lighting fixtures :-
534
Lighting Equipments

1.9.2
Six sets of dimensional drawing
1.9.3
Mounting details, cable entry facility and weights.
1.9.4
Light distribution diagrams (Zonal and iso candela).
1.9.5
Lamp output vs. temperature curve.
Six sets of complete final drawings, instructions manuals and test report of
each type of luminaries shall be furnished by the successful bidder one month prior to
the commencement of actual supply of equipments.
1.10
QUALITY ASSURANCE PLAN
Bidders shall invariably furnish following information along with his offer,
failing which his bid may be treated as non responsive. Information shall be separately
given for individual type of equipment offered.
1.11
i)
Statement giving list of important raw materials, names of sub

supplies for the raw materials, list of standards according to which the
raw materials are tested, list of tests normally carried out on raw
materials in presence of bidders representative copies of test
certificates.
ii)

bought out accessories.
iii)
iv)
Level of automation achieved and list of areas where manual process

exists.
v)

inspections.
vi)
List of testing equipments available with the bidder for final testing of
equipment specified and test plant limitation. If any, vis--vis the type,
schedule of deviation from specified test requirements.
TEST AND TEST REPORTS
1.11.1
Type tests, acceptance test and routine test for the lighting fixtures and
accessories covered by this specification shall be carried out as per the relevant Indian
Standards/British Standards for the respective fixtures and their accessories.
1.11.2
Manufacturers type and routine test certificates shall be submitted for tests
conducted as per relevant IS for the fixtures and accessories.
1.12
INSPECTION
Equipment shall be subject to inspection by a duly authorised representative

of purchaser. Inspection may be made at any stage of manufacture at the option of
purchaser. The equipment if found unsatisfactory in regard to material or workmanship
is liable for rejection. Bidder shall grant free access to the places of manufacture to
535
Lighting Equipments

purchasers representative at all reasonable times when the work is in progress.
Inspection by the purchaser or his representative shall not relieve the bidder of his
obligation of furnishing materials in accordance with the specification.
1.13
SAMPLES
Bidders shall supply, without extra cost, one sample of Flood lighting
luminaries complete with fixture & high pressure sodium vapour lamp of 250 watts.
Sample shall necessarily be engraved with manufacturers identification
mark and type designation of the item. The purchaser shall be at liberty to subject these
samples to any tests which he may deem fit. The purchaser shall not be responsible for
any damage, which may occur to these free samples during such testing. The samples
shall not be returned to the Bidder.
All Bidders shall meet this requirement of submission of samples of specified
items, irrespective of whether they had earlier supplied these items to the purchaser in
the past or not.
1.14
COMPONENTS OF EQUIPMENTS
Each equipment should be complete and include all minor accessories and
fixing devices etc. though not specifically mentioned in this specification but which is
essential for the mounting and use of equipments.
1.15
MARKING
Equipment shall be legibly and identibly marked with trade mark or name of
manufacture, country of manufacture and month and year of manufacture and
certification mark. All labels to be used on wooden boxes are tin tags, containing the
fitting shall be tin securely bond with the wire and shall have the descriptive marking
stamped thereon.
1.16
PACKING
All accessories shall be supplied in strong wooden boxes crates of approved

design with steel loop and strap bands for strength and durability withstand rough
handling during transportation handling and also during storage. The gross weight of
packing shall not normally exceed 50 Kgs. Different fittings shall be packed in different
cases and shall be complete with their minor accessories fitted in place. All fragile,
fixtures of glass, Perspex or other items shall be properly and securely packed to
prevent, oscillation in transit, or even two units striking each other. All nuts shall be hand
tightened over the bolts upto farthest point. All packages shall be marked on the side as
follows:Each consignment shall be accompanied by a detailed packing list
containing the following information:
a)
b)
c)
Destination.
d)
e)
f)
g)
536
Lighting Equipments

Bidder shall ensure that the packing list and bill of material are approved by
the purchaser before despatch.
2.0
Please ensure that bid document containing number of pages have
been properly numbered and signed by the bidder. Bid document including all
schedules and Annexures should be indexed properly and Index of the document
should be enclosed / placed at the beginning of the bid document.
537
Lighting Equipments
SCHEDULE-I (A)
IN VOLUME-VI
250 Watt HPSV Flood lighting luminaries

complete with lamp and fixture
Qty.
S.No.
538
Lighting Equipments
2.4.1 TECHNICAL SPECIFICATIONS FOR 220 KV, 132 KV AND 33 KV

SUBSTATION SWITCHYARD STRUCTURES
1.0
SCOPE This scope of this specification covers design, manufacturing supply of 220 KV,
132 KV and 33 KV Substation Switchyard Structures as per Volume-II. The bidder
mentioned in the Section of Technical specification means Original Equipment
Manufacturer (OEM). The purchaser means the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipment / material of
2.0
STANDARDS Applicable standards for offered equipment / material shall be as per Volume-II.
3.0
CLIMATIC CONDITIONS
4.0
SYSTEM PARTICULARS Applicable system particulars shall be as per Volume-II.
5.0
BREAK-UP OF OFFERED PRICES The Bidders may please note the following:
6.0
(i)
While exact weight of different type of Structures required under Bid

Specification have been furnished for the purpose of offering prices by the
Bidders, a situation may arise wherein due to approved design of prototype
structure, minor variation in weight of structure as compared with unit weight
specified in bid document may take place. Under such circumstances, the
payment will be made to the supplier based on BOM Weights as per approved
design or Unit Weight as specified in Bid Document which ever happens to be
less. Further, the structures shall be supplied as per approved drawings/Bill of
Material and the payment will be restricted to the extent mentioned above.
(ii)
The bidders may furnish break-up of offered prices of Structures into following
elements:
(a)
Price of fabricated, galvanized M.S. steel sections per Metric Tonne.
(b)
Price of galvanized foundation bolts alongwith accessories per per Metric

Tonne.
(c)
Price of galvanized nuts, bolts, washers and other accessories per Metric
Tonne.
DRAWING AND DESIGN -
The successful bidder will be required to supply Structures as per the

details
furnished by the MPPTCL. In order to facilitate, preparation of shop drawings and taking up
the fabrication work, the detailed drawings of each type of Structure and all other relevant
details will be made available by the MPPTCL alongwith the contract. By and large, steel
540
Switchyard Structures

sections like; Channels, Angles, Flats, Plates and RS Joists would be required for fabrication
of various Structures covered in this specification.
7.0
SHOP DRAWINGS -
The successful bidder shall prepare shop drawings for fabrication of Structures and 4
sets of Structural drawings of each type of Structure shall be made available to the MPPTCL
for its record. Soft copy of the drawings developed in Auto CAD are also required to be
furnished immediately after approval of drawings of all the structures for which orders are
placed.
8.0
9.0
PROTOTYPE OF STRUCTURES i.
Prototype of each of the lattice / non lattice type Structure covered in Bid
Specification shall be offered by the successful bidder for inspection within 60
days from the date of issue of the detailed order. Failure to offer the proto-type
for inspection within the period specified could be construed as unsatisfactory
performance under the contract and in such an eventuality, the performance
security may be forfeited without giving any notice.
ii.
Notwithstanding anything covered in the drawings and other details furnished

by the MPPTCL, the supplier may make minor modification (if any) in length
and size of Structure member, quantity and size of nuts, bolts, washers etc,
which could be considered essential for ensuring completeness and
satisfactory operation of Structures.
INTERCHANGEABILITY OF STRUCTUERES-
In Structures, any change in design of any structure / change in quantity is felt

necessary the same will be intimated to the successful bidders/ firms one month prior to
contractual delivery of the respective structure.
10.0
MATERIAL -
The Structures shall be of structural steel quality conforming to latest version of IS:
2062. Structural steel sections manufactured according to latest IS: 808 shall be taken into
consideration for fabrication of Structures. Tested steel sections having its yield strength not
less than 2550 kg/sq cm shall be used.
11.0
PROCUREMENT OF STEEL BY THE BIDDER The following provisions shall apply in connection with the procurement of steel by the
bidder:
(i)
The steel used for the fabrication of Structures shall be mild-steel of tested
quality as per latest version of IS: 2062 Gr.-A quality.
(ii)
The steel shall generally be procured from the main Steel Producers. However,
in case of sections not rolled/ available from the main producers, the same
could be procured from re-rollers as per quality conforming to relevant IS,
provided:
(a)
Re-rolling of structural steel sections is done from billets/ingots of tested

quality only.
541

(b)
12.0
(iii)
The bidders should take into account the fabrication wastage while offering the
prices. The MPPTCL shall not accept any liability in connection with the actual
wastage of steel during fabrication or otherwise and no additional cost will be
allowed on this account.
(iv)
Substitutions, if any, of steel sections of the Structure parts by higher size, due
to their non-availability or otherwise shall be to the suppliers account. The
MPPTCL shall not accept any liability on this account.
FABRICATION WORKMANSHIP (i)

(ii)
13.0
Re-rolled sections are duly tested as per relevant IS. It may, however,
be noted that additional cost, if any, on account of procurement of steel
sections from re-rollers shall not be payable.
Except where hereinafter modified, details of fabrication shall conform to latest

version of IS:802.
The fabrication shall be done strictly in accordance with the drawings made
available by the MPPTCL.
(iii)
The Structures shall be accurately fabricated to bolt together easily at site

without any undue strain on the bolts.
(iv)
The diameter of the hole shall be equal to the diameter of the bolt plus 1.5 mm.
(v)
Necessary drain holes shall be provided at all points of the Structures where
pockets of depressions are likely to hold water.
(vi)
All similar parts shall be made strictly interchangeable. All steel sections
before any work is done on them, shall be carefully leveled, straightened
and made true to detailed drawings by methods which should ensure that
granual configuration of steel is not distorted. Further, while assembly the
adjacent matching surfaces should be in close contact throughout. No rough
edges shall be permitted in the entire Structures. Hammering is not permitted
for straightening.
(vii)
Cutting may be done by shearing, cropping, flame cutting or sawing. The

surface so cut shall be cleaned smooth, reasonably square and free from
deformation and distortion.
DRILLING AND PUNCHING (i)
The holes in the member shall either be drilled or punched with a jig, the former
process will be preferred.
(ii)
Punching may be adopted for providing holes in steel sections up to 12 mm

thickness. For thicker sections, drilling shall be done.
(iii)
The holes shall be punched/drilled after bending and relative position of these
holes shall be maintained with the use of proper templates/jigs and fixtures.
(iv)
The holes shall be perfectly circular and no tolerance in this respect is

permissible. The holes shall be perpendicular to the Steel sections.
(v)
All burrs left by drills or punch shall be removed completely. When the
Structure members are in position, the holes shall be truly opposite to each
other. Drilling or ramming to enlarge defective holes shall not be permitted.
542

(vi)
(vii)
14.0
(a)
For 16 mm diameter bolt, edge distance of 20 mm from hole centre to

rolled or swanked edge and 23 mm from hole centre to sheared or
flame cut edge.
(b)
The gap between the edges of the connected members in butt joint
shall not be more than 6 mm and less than 4 mm.
The bolt gauge distance in flanges of angle sections shall generally be in

accordance with "Hand Book for structural Engineers-Structural Steel Sections
Revised."
GALVANIZING (i)
(ii)
15.0
The minimum spacing of bolt and edge distance shall be as under:
All structural steel shall be galvanized after fabrication. Galvanizing of Steel

section conform to latest version of IS: 2629 & IS:4759 All galvanized members
shall withstand tests as per IS:2633. For fasteners, the galvanizing shall
conform to latest version of IS: 1367.
The galvanizing shall be done after all fabrication work is completed, except
that the nuts may be tapped or re-run after galvanizing. Threads of bolts and
nuts shall have a net fit and shall be such that they can be turned with finger
throughout the length of the threads of bolt and they shall be capable of
developing full strength of the bolts. Spring washers shall be electro-galvanized
as per latest version of IS: 1573.
GALVANISED BOLTS, NUTS AND WASHERS (i)
The bolts (5.6 quality) and nuts (5.0 quality) shall be of HRH mild steel and hot
dip galvanized. Spring washers shall be supplied for insertion under all nuts.
These washers shall be of steel, electro galvanized, positive lock type and of
3.5 mm thickness. Bolt heads and nuts shall be of hexagonal shape.
(ii)
The nuts shall be forged and tapped after galvanizing and then lubricated.
The nuts shall be chamfered on one face only, the other face shall be
machined.
(iii)
The bolts shall be manufactured by cold/hot forging process and the threads
shall be rolled.
(iv)
The bolts and nuts shall be free from forging and threading defects such as
cuts, splits, burrs, bulging, taper, eccentricity, loose fit etc. The bolts shall be
threaded upto standard length only as per relevant Indian Standard and not to
full length.
(v)
The bolts and nuts shall conform to IS:1967, IS:12427, IS:1363,

with latest amendment.
(vi)
The spring washers suitable for diameter of the bolts shall be manufactured out
of rectangular section with tolerances as per IS:3063 with latest amendments.
The spring washer steel shall conform to IS:4072 with latest amendments. The
spring washers after coiling shall be suitably heat treated so as to result in the
finished washer having hardness 43 to 50 HRC when tested in accordance with
latest version of IS:1586. Surface of the washers shall be free of scales and
burrs. The washers shall be coiled without any kinks (except for the shape with
turned-up ends). The ends of the washer shall not abut when the washers are
compressed. The ends shall be so served as to prevent tangling.
543
IS:1367
16.0
17.0
18.0
(vii)
The spring washer shall be electro galvanized with chromate passivation. The
electro galvanizing of washers should conform to 'severe' grading service
conditions incorporated in IS:1573 with latest amendments. The local thickness
of zinc coating should be minimum 25 microns and average thickness 38
microns. It should be further suitably heat-treated to avoid any danger of
hydrogen embitterment.
(viii)
Plain/pack washers shall be 4 mm thick and shall be suitable for diameter of

respective bolts.
QUANTITY OF BOLTS, NUTS AND WASHERS (i)
Quantity and Size of Nuts and Bolts required alongwith each Structure has
been detailed out in the Appendix-A1, A2 & A3 of this bidding document.
(ii)
A set of one bolt and one nut required for assembly of Structure shall have one
number spring washer and one number plain washer.
(iii)
Since the structures are of bolted type, every foundation bolt shall have three
numbers nuts, one number anchor plate and one number plain washer as
indicated in the drawings. The anchor plate shall have a hole at the centre
suitable for diameter of the foundation bolt.
TOLERANCES (i)
The maximum allowable difference in the diameter of the hole on the two sides
of the plate or angle shall not exceed 0.8 mm.
(ii)
The tolerance cumulative or between consecutive holes shall be within + 0.5

mm.
(iii)
The tolerance on the overall length of member shall be within
(iv)
The tolerance on gauge distance shall be within + 0.5 mm.
(v)
Rolling and weight tolerance of steel sections shall be as per latest version of
IS: 1852 and IS: 808.
+ 1.6 mm.
MARKING -
Every member of the Structure shall be distinctly given punch mark as per structural
drawings. Type of Structure (e.g. AGT, 1GO3 etc.) and suppliers identification mark shall also
be punched. The marking shall be done with marking dies of minimum 18 mm size and this
mark shall be in "legible English letters".
19.0
PACKING AND MARKING i.
The material shall be boxed or bundled for transport preferably in the following
manner:
a.
Large members like angles, channels etc., shall be packed in bundles

securely wrapped four times around each end and over 900 mm with
steel wire of 3.55 mm diameter with ends twisted tightly. As far as
practicable, a bundle shall consist of all the large members of one
Structure only.
544
b.
Small loose pieces shall be nested and bolted together holes wrapped
round at least four times with steel wire of 3.55 mm diameter and its
ends twisted tightly or packed in wooden crates. Gross weight of each
bundle shall not exceed 200 Kgs.
c.
Bolts, nuts and washers required for Structures shall be packed in

heavy gunny bags accurately tagged in accordance with the contents
and a number of bags packed in a solid box of 22mm thick lumber with
paneled ends to be accurately nailed and further reinforced with 22mm
x 75mm buttons round the sides at the ends with 25 mm x 1.26 mm
iron band stretched entirely around the buttons with ends overlapping at
least 150 mm. Gross weight of each box shall not be exceed
approximately 200 Kgs.
Packing list incorporating all relevant details e.g., quantity of Structures,
number and size of steel sections, quantity of nuts, bolts, washers etc.,
shall be forwarded alongwith each consignment.
d.
e.
ii.
In the nut shell the packing arrangement should be such that all
packages of one particular type of Structure are identifiable at site for
the purpose of allocation for a particular work. In case more than one
Structure of a particular type is delivered in area stores/work site,
combined packing arrangement by way of clubbing members of similar
type (for more than one Structure) in a combined package should not
be done. Unified packing procedure for each Structure should be
adopted.
Each bundle or packing shall be marked in "legible English letters" in the

following manner.
a.
Reference of purchase order.
b.
The name of the consignee (as per dispatch instructions given by the
MPPTCL).
c.
Ultimate destination (if any) as required by the MPPTCL.
d.
The relevant marks and number of Structure members or reference or

bolts, nuts and small components for easy identification.
e.
Suppliers identification:
The marking shall be stenciled and indelibly inked on the top members
in the bundles, on wooden boxes and also on gunny bags containing
smaller components.
20.0 GENERAL GUIDE-LINES FOR INSPECTION i.
FOR FABRICATED STRUCTURE MEMBERS a.
b.
Sample selection from the offered lot at a ratio of 50 MT (or part

thereof) 1 no. each for all tests.
545
ii.
21.0
c.
Dimension, fabrication and trueness verification of Structure members

from shop drawing.
d.
Galvanizing test of each sample i.e., dip test, hammer test and mass of
Zinc test.
e.
Random verification Zinc coating over galvanized surface by Alko

meter.
f.
Tensile test and bend test of each sample.
g.
Chemical composition test of at least two samples per offered lot.
h.
Verification of manufacturers test certificate for mild steel used in

Structure members.
FOR BOLTS, NUTS AND WASHERS a.
b.
Sample selection from the offered lot as per relevant IS for each items.
c.
Dimension, fabrication and trueness verification.
d.
Galvanizing test of each sample.
e.
Other acceptance tests for respective items as per relevant IS.
INSPECTION AND TEST CERTIFICATES (i)
All Structures to be supplied will be subject to inspection and approval by

the MPPTCL 's representative before dispatch and / or on arrival at the
destination. Inspection before dispatch shall not, however, relieve the supplier
of his responsibility to supply the Structures strictly in accordance with the
specification.
(ii)
The successful bidder shall abide by all the statutory provisions, acts such as
the Indian Electricity Act, Indian Factory Act, Indian Boiler Act etc., and
corresponding rules and regulations as may be applicable and as amended
from time to time.
(iii)
The MPPTCL's representative shall be entitled at all reasonable time during

manufacture to inspect, examine and test at the supplier premises the
materials and workmanship of the material to be supplied.
(iv)
As soon as the Material is ready for testing, the supplier shall intimate the
MPPTCL well in advance, so
that action could be taken for getting the
material inspected. The material shall not be dispatched unless waiver of
inspection is obtained or inspected by the MPPTCL's authorized
representative. When the material has passed the specified tests, the
MPPTCLs representative shall furnish a certificate to this effect in writing to the
supplier. The Structures shall not be dispatched unless the test certificates are
approved.
(v)
Test certificates shall be in accordance with latest version of the relevant Indian
Standards.
546
22.0
(vi)
The supplier shall keep the MPPTCL informed in advance about the time of
starting and of the progress of manufacture of Structures in various stages.
(vii)
The acceptance of any batch shall in no way relieve the supplier of any of
his responsibilities for meeting all the requirements of the specification and
shall not prevent subsequent rejection at any item if the same is later found
defective.
(viii)
In case, any member of the Structure is not found as per the relevant drawing,
it shall be liable for rejection even after receipt.
(ix)
Defects which may appear during fabrication shall be made good. Any member
of the Structure, once rejected, shall be destroyed.
The Bidder must establish that he is following a proper quality assurance Programme
for manufacture of Substation Structures. The Bidder shall invariably furnish following
information alongwith his bid:
23.0
(i)
Statement giving list of important raw materials, names of sub-suppliers for the
raw material, list of standards according to which the raw material is purchased
and copies of test certificates thereof.
(ii)

out items.
(iii)
List of machines and manufacturing facilities available.
(iv)

exists.
(v)

carried out for quality control and details of such tests and inspections.
(vi)
List of testing equipment available with the Bidder for final testing of Structures
specified and test plant limitation, if any, vis--vis type, special, acceptance and
routine tests specified in the relevant standards. These limitations shall be very
clearly brought out in schedule of deviations from specified test equipments.
INFORMATION TO BE FURNISHED AFTER PLACEMENT OF ORDER -
The successful Bidder shall within 30 days of detailed order, submit following
information to the MPPTCL:
24.0
(i)
List of raw material as well as bought out accessories and the names of subsuppliers selected from the lists furnished along with Bid.
(ii)
(iii)
Quality Assurance Plan (QAP) with hold-up points for MPPTCLs inspection.
The quality assurance plans and hold-up points shall be discussed between the
MPPTCL representative and supplier before the QAP is finalized.
ROUTINE TEST CERTIFICATES -
for raw material at the time of routine testing of Substation Structures.
547
APPENDIX-A1
DETAILS OF NUTS, BOLTS, WASHERS AND
THEIR QUANTITY REQUIRED ALONGWITH EACH 220 KV STRUCTURE
Sizes of Nuts and Bolts

Pack Washers
for 16mm
dia bolt
Thickness
16 mm dia
Type of
Structure
Step
bolts
175
mm
long
Length
60
mm
55
mm
50
mm
45
mm
40
mm
10
mm
8
mm
6
mm
Plain
Washe
rs
for
16mm
dia bolt
20 mm dia
Length
70
mm
55
mm
45
mm
Plain
Washe
rs
for
20mm
dia
bolt
24 mm dia
Length
75
mm
70
mm
Plain
Wash
ers
for
24m
m dia
bolt
<---------------------------QUANTITY (Nos.)------------------------------->
Gantry
Column
(AAGT)
Found
ation
Bolts
Size
(dia X
length
) mm
and
quanti
ty
(Nos)
30 X
1350
12
Nos
30 X
1350
8 Nos
56
50
120
217
98
180
18
97
665
NIL
NIL
NIL
NIL
144
NIL
144
NIL
NIL
NIL
260
146
86
34
32
112
492
NIL
NIL
96
32
128
NIL
NIL
58
80
210
NIL
NIL
28
351
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
36
52
58
490
NIL
NIL
30
636
NIL
96
NIL
96
NIL
NIL
NIL
24 X
1200
8 Nos
NIL
NIL
28
60
194
372
NIL
NIL
110
654
NIL
96
NIL
96
NIL
NIL
NIL
24 X
1200
8 Nos
NIL
NIL
NIL
NIL
28
24
NIL
NIL
12
52
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
12
16
NIL
NIL
NIL
28
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
NIL
44
16
NIL
NIL
NIL
60
NIL
NIL
NIL
NIL
NIL
NIL
NIL
Isolator
Structure
(AITCH)
NIL
NIL
144
96
88
100
NIL
NIL
96
428
NIL
NIL
NIL
NIL
NIL
NIL
NIL
PT/CVT
Structure
(APT)
NIL
NIL
NIL
NIL
28
24
NIL
NIL
12
52
NIL
NIL
NIL
NIL
NIL
NIL
NIL
Gantry
Column
(AGT)
Gantry
Beam
(AGB)
Main Bus
Structure
(ABM)
Auxilary
Bus
Structure
(ABA)
CT
Structure
(ACT)
LA
Structure
(ALA)
Post/Solid
core
Insulator
Structure
(API)
20 X
450
4 Nos
20 X
450
4 Nos
20 X
900
4 Nos
20 X
900
24
Nos
20 X
450
4 Nos
NOTE:
(i) A set of one bolt and one nut required for assembly of structure shall have one number spring Washer.
(ii) Each foundation bolt shall have three numbers nuts, 1 No. Anchor Plate & Plain Washer.
(iii) The step bolt shall have two nuts & one number spring washer.
(iv) Accessories, which are not indicated in above tables but are necessary for completeness and satisfactory operation of Structures shall be deemed to
have been included in the scope of supply of this contract.
548
APPENDIX-A2
THEIR QUANTITY REQUIRED ALONGWITH EACH 132KV STRUCTURE
Sizes of Nuts and Bolts
16 mm dia
Plain
Washers
for
16mm
dia bolt
Foundation
Bolts
Size (dia X
length) mm
and
quantity
(Nos)
Sr.
No.
Type of
Structure
GANTRY
COLUMN (3GO2)
NIL
50
15
350
102
505
20X1240
16 Nos.
GANTRY BEAM
(3GO2)
56
NIL
NIL
142
40
220
NIL
Length
55
50 mm 45 mm 40 mm 35 mm
mm
<---------------------------QUANTITY (Nos.)------------------------------>
MAIN BUS BAR

STRUCTURE
(3BO4)
AUXILARY BUS
BAR
STRUCTURE
(3BO3)
ISOLATOR
STRUCTURE
(3D02)
NIL
NIL
NIL
150
325
475
25X1200
8 Nos.
NIL
NIL
NIL
190
150
340
20 X 540
32 Nos
NIL
NIL
NIL
56
NIL
56
20 X 940
16 Nos.
PT STRUCTURE
(3VO4)
NIL
NIL
25
20
NIL
45
20 X 500
4 Nos.
CT STRUCTURE
(3CO5)
NIL
NIL
NIL
NIL
NIL
25 X 600
4 Nos.
LA STRUCTURE
(3LO4)
NIL
NIL
NIL
30
20
50
20 X 500
4 Nos.
10
COUPLING
20 X 540
CAPACITOR
NIL
NIL
NIL
26
NIL
26
4 Nos.
STRUCTURE
(3KO2)
POST/SOLID
25 X 600
CORE
NIL
NIL
NIL
NIL
NIL
0
4 Nos.
STRUCTURE
(3PO2)
NOTE:
(i) A set of one bolt and one nut required for assembly of structure shall have one
number spring washer.
(ii) Each foundation bolt shall have three numbers nuts, one no. plane washer & Anchor
plate.
(iii) Accessories, which are not indicated in above tables but are necessary for
completeness and satisfactory operation of Structures shall be deemed to have been
included in the scope of supply of this contract.
549
APPENDIX-A3
THEIR QUANTITY REQUIRED ALONGWITH EACH 33KV STRUCTURE
Sr.
No
Type of
Structure
ISOLATOR
STRUCTURE
(1D03)
CT/PT/LA/PI
STRUCTURE
(1VO2)
NOTE:
Sizes / Unit Weight of Nuts and Bolts

16 mm dia
Pack Washers
for 16mm
dia bolt
Plain
Washers
for
16mm
dia bolt
Length
55
50
45
40
8 mm
6 mm
mm
mm
mm
mm
<---------------------------QUANTITY (Nos.)------------------------------>
NIL
NIL
NIL
42
NIL
NIL
42
NIL
NIL
28
NIL
NIL
32
Foundation
Bolts
Size (dia X
length) mm
and
quantity
(Nos)
25X1200
8 Nos.
20X815
4 Nos.
(i) A set of one bolt and one nut required for assembly of structure shall have one number spring
washer.
(ii) Each foundation bolt shall have three numbers nuts, one no. plane washer & Anchor plate.
(iii) Accessories, which are not indicated in above tables but are necessary for completeness and
satisfactory operation of Structures shall be deemed to have been included in the scope of supply of
this contract.
550
APPENDIX-B
DRAWINGS
S.
no.
Description
220 KV Isolator Structure
33 KV Isolator Structure
Foundation Bolt
Foundation Bolt
551
552
553
554
555
Volume-II, Part-2, Book-III of III
2.5 TECHNICAL SPECIFICATION FOR BUSBAR MATERIALS, EARTHING

MATERIALS, CABLES & HARDWARES
2.5.1 (A) TECHNICAL SPECIFICATIONS FOR ACSR CONDUCTOR
Technical specifications for ACSR conductor are given in the Section 3 of

Vol.- V, Book - I
556
ACSR Conductor, Screening Conductor & Disc Insulator

2.5.1 (B) TECHNICAL SPECIFICATIONS FOR SCREENING CONDUCTOR
(HIGH TENSILE GALVANISED STEEL EARTH WIRE)
Technical Specifications for Screening Conductor (High Tensile Galvanized

Steel Earth wire are giving in Section- 5 of Vol. V, Book- I.
557

2.5.1 (C) TECHNICAL SPECIFICATIONS FOR 70 KN, 90 KN, 120 KN & 160 KN EMS
PORCELAIN DISC INSULATORS
1.0
SCOPE:
The scope of this bid covers design, manufacturing supply of equipments/

material as per Volume-II, Part-2, Book-I. The bidder mentioned in the Section of
Technical Bid means Original Equipment Manufacturer (OEM). The purchaser means
the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipments/ material of
2.0
STANDARDS:
Applicable standards for offered equipment/ material shall be as per Volume-II,

Part-2, Book-I.
3.0
4.0
SYSTEM PARTICULARS:
Applicable system particulars shall be as per Volume-II, Part-2, Book-I.
5.0
GENERAL TECHNICAL REQUIREMENTS
5.1
PORCELAIN
The porcelain used in the manufacture of the shells shall be ivory white,
nonporous of high dielectric, mechanical and thermal strength, free from internal
stresses, blisters, laminations, voids, foreign matter, imperfections or other
defects which might render it in any way unsuitable for insulator shells. Porcelain
shall remain unaffected by climatic conditions, ozone, acid, alkalizes, zinc or
dust. The manufacturing shall be by the wet process and impervious character
obtained by thorough verification.
Porcelain Glaze
Surfaces to come in contact with cement shall be made rough by sand glazing.
All other exposed surfaces shall be glazed with ceramic materials having the
same temperature coefficient of expansion as that of the insulator shell. The
thickness of the glaze shall be uniform throughout and the colour of the glaze
shall be brown. The glaze shall have a visible luster, smooth on surface and be
subject to satisfactory performance under extreme tropical climatic weather
conditions and prevent ageing of the porcelain. The glaze shall remain under
compression on the porcelain body throughout the working temperature range.
558

5.2
METAL PARTS
5.2.1
Cap and Ball Pins

Ball pins shall be made with drop forged steel and caps with malleable cast iron.
They shall be in one single piece and duly hot dip galvanized. They shall not
contain parts or pieces joined together, welded, shrink fitted or by any other
process from more than one piece of material. The pins shall be of high tensile
steel, drop forged and heat-treated. The caps shall be cast with good quality
black hearth malleable cast iron and annealed. Galvanising shall be by the hot
dip process with a heavy coating of zinc of very high purity. The Supplier shall
specify the grade, composition and mechanical properties of steel used for caps
and pins.
5.2.2
Security Clips
The security clips shall be made of phosphor bronze or of stainless steel.2.5%
extra security clip shall be provided.
5.3
FILLER MATERIAL
Cement to be used as a filler material shall be quick setting, fast curing Portland
cement. It shall not cause fracture by expansion or loosening by contraction. Cement
shall not react chemically with metal parts in contact with it and its thickness shall be as
small and as uniform as possible.
The insulator design shall be such that the insulating medium shall not directly
engage with hard metal. The surfaces of porcelain and hard metal should be coated with
resilient paint to offset the effect of difference in thermal expansions of these materials.
5.4
MATERIAL DESIGN AND WORKMANSHIP
5.4.1
GENERAL
5.4.2
(i)
All raw materials to be used in the manufacture of these insulators shall

be subject to strict raw material quality control and to stage testing/quality
control during manufacturing stage to ensure the quality of the final end
product. Manufacturing shall conform to the best engineering practices
adopted in the field of extra high voltage transmission. Bidders shall
therefore offer insulators as are guaranteed by them for satisfactory
performance on 220KV/132KV Transmission lines.
(ii)
The design, manufacturing, process and material control at various

stages be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish, elimination of sharp edges and
corners to limit corona and radio interference voltages.
INSULATOR SHELL
The design of the insulator shells shall be such that stresses due to expansion
and contraction in any part of the insulator shall not lead to deterioration. Shells with
cracks shall be eliminated by temperature cycle test followed by mallet test. Shells shall
be dried under controlled conditions of humidity and temperature.
559

5.4.3
METAL PARTS
(i)
The pin and cap shall be designed such that it will not transmit the mechanical
stresses to the shell by compression and develop uniform mechanical strength in
the insulator. The cap shall be circular with the inner and outer surfaces
concentric and of such design that it will not yield or distort under loaded
conditions. The head portion of the pin ball shall be suitably designed so that
when the insulator is under tension the stresses are uniformly distributed over the
pinhole portion of the shell. The pin ball shall move freely in the cap socket either
during assembly of a string or during erection of a string or when a string is
placed in position.
(ii)
Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes and
rough edges. All metal surfaces shall be perfectly smooth with no projecting parts
or irregularities, which may cause corona. All load bearing surfaces shall be
smooth and uniform so as to distribute the loading stresses uniformly. Pins shall
not show any microscopically visible cracks, inclusions and voids.
5.4.4
GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the latest edition
of IS:2629. The zinc to be used for galvanizing shall conform to grade Zn 99.5 as per
IS:209. The Zinc coating shall be uniform, smoothly adherent, reasonably bright,
continuous and free from impurities such as flux, ash, rust stains, bulky white deposits
and blisters. Before ball fittings are galvanized, all die flashing on the shank and on the
bearing surface of the ball shall be carefully removed without reducing the designed
dimensional requirements.
5.4.5
SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as a locking device for ball and socket coupling
shall be R shaped hump type to provide for positive locking of the coupling as per
IS:2486 (Part IV). The legs of the security clips shall allow for spreading after installation
to prevent complete withdrawal from the socket. The locking device shall be resilient,
corrosion resistant and of sufficient mechanical strength. There shall be no possibility of
the locking device to be displaced or be capable of rotation when placed in position and
under no circumstances shall it allow separation of insulator units and fittings. W type
security clips are also acceptable. The hole for the security clip could be countersunk
and the clip shall be of such design that the eye of the clip may be engaged by a hot line
clip puller to provide for disengagement under energized conditions. The force required
for pulling the clip into its unlocked position shall not be less than 50 N (5 kgs) or more
than, 500 N (50 kgs).
5.5
BALL AND SOCKET DESIGNATION
The dimensions of the balls and sockets for 70 KN & 90 KN discs shall be of 16
mm and for 120KN/160KN discs shall be of 20 mm designation in accordance with the
standard dimensions stated in IS:2486 (Part II).
560

5.6
DIMENSIONAL TOLERANCE OF DISC INSULATOR
It shall be ensured that the dimensions of the disc insulators are within the limits
specified below:
a. Diameter of Disc (mm)
Rating
Standard
Maximum
Minimum
160 KN Disc
280
293
267
120 KN Disc
255
266
244
90 KN Disc
255
266
244
70 KN Disc
255
266
244
b. Ball to Ball Spacing between Discs (mm)

Rating
5.7
Standard
Maximum
Maximum
160 KN Disc
170
175
165
120 KN Disc
145
149
141
90 KN Disc
145
149
141
70 KN Disc
145
149
141
INTERCHANGEABILITY
The insulators inclusive of the ball and socket fittings shall be of standard design
suitable for use with hardware fittings of any make conforming to relevant Indian
Standards.
5.8
CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) PERFORMANCE
All surfaces shall be even, smooth, without cuts, abrasions or projections. No

part shall be subjected to excessive localized pressure. The metal parts and porcelain
shall not produce any noise generating corona under all operating conditions.
5.9
SUITABILITY FOR LIVE LINE MAINTENANCE
5.9.1
The insulators shall be compatible for use with hot line or live line maintenance
techniques so that usual hot line operations can be carried out with ease, speed
and safety.
5.9.2
Suppliers shall indicate the methods generally adopted in routine hot and cold
line maintenance of EHV lines for similar insulators supplied by them. Suppliers
shall also indicate the recommended periodicity of such maintenance.
561

5.10
FREEDOM FROM DEFECTS

Insulators shall have none of the following defects:
5.11
i)
Ball pin shake
ii)
Cementing defects near the pin like small blow holes, small hair cracks,
lumps, etc.
iii)
Sand fall ferro particle defects on the surface of the insulator.
iv)
Shell eccentricity
INSULATOR STRINGS
5.11.1 TYPE AND RATING

The insulator strings shall be formed with standard discs described in this
specification for use on 3 phase, 400kV/220kV/132kV, 50Hz effectively earthed systems
in a moderately polluted atmosphere. Suspension insulator strings for use with
suspension towers are to be fitted with discs of 70 kN & 120KN EMS rating while tension
insulator strings for use with Anchor/Tension towers are to be fitted with discs of 90 kN &
160 kN EMS rating.
5.11.2 STRING SIZE
The size of the disc insulator, the number to be used in different types of strings
and their electro-mechanical strength shall be as follows:
S.No.
Size of
disc
insulator
(mm)
No. of
standard
discs
Electro
mechanical
strength of
insulator
string (kN)
160
2x160
70
a)
b)
Single Tension for 220 KV

Double Tension for 220 KV
280x170
280x170
14
14
c)
Single Suspension for 220/132KV
255x145
13/9
255x145
2x13/2x9
2x70
255x145
255x145
10
2x10
90
2x90
d)
e)
f)
5.12
Type of String
Double Suspension for 220KV/

132KV
Single Tension for 132KV
Double Tension for 132KV
STRING CHARACTERISTICS
5.12.1 The characteristics of the complete string shall be as follows :
562
S.
No
Particulars
Single / Double
Suspension
Single / Double
Tension
220KV
132KV
220KV
132KV
i.
Switching surge withstand

voltage (dry & wet) KV peak
900
350
900
350
ii
Lightening Impulse withstand

voltage (dry) KV peak
1200
800
1200
800
iii
Power frequency withstand

voltage (wet) KV r.m.s
460
280
490
300
iv
Mechanical failing Load - kgf
7000/
14000
7000/
14000
16500/
33000
9000/
18000
4690/
9380
4690/
9380
11055/
22110
6030/
12060
No deformation load-kgf
vi.
Corona Extinction Voltage KV

rms
vii.
Max. RIV for complete string at

266KV (rms) line to ground
voltage (micro volt)
viii.
Max. voltage across any disc
5.12.2 Insulator units after assembly shall be concentric and coaxial within limits as
permitted by Indian standards.
5.12.3 The string design shall be such that when units are coupled together there shall
be contact between the shell of one unit and metal of the next adjacent unit.
5.12.4 It may please be noted that in the BOQ hardwares required for insulator string is
integral part of string. Bidder shall quote the price of insulator string with suitable
hardware.
5.12.5 The bidder may please also use Long rod porcelain insulator string or long rod
polymer insulators in place of Disc insulator string. The Long rod Porcelain
insulators or Long rod polymer insulator shall have technical specification
equivalent or better than the technical specification of Disc insulator string. It may
please be noted that in a particular work, the bidder will have to use only one
type of insulators and combination of different types of insulators in one particular
work will not be allowed.
563

6.0
TESTS
The following tests shall be carried out on the insulator string and also on unit
disc insulators.
6.1
TYPE TESTS
This shall mean those tests which are to be carried out to prove the design,
process of manufacture and general conformity of the material and product with the
intents of this specification. These tests shall be conducted on a representative number
of samples prior to commencement of commercial production. The successful supplier
shall indicate his schedule for carrying out these tests.
6.2
ACCEPTANCE TESTS
This shall mean those tests which are to be carried out on samples taken from
each lot offered for pre-despatch inspection for the purpose of acceptance of the lot.
6.3
ROUTINE TESTS
This shall mean those tests, which are to be carried out on each insulator to
check the requirements which are likely to vary during production.
6.4
STAGE TESTS DURING MANUFACTURE
Stage tests during manufacture shall mean those tests which are to be carried
out during the process of manufacture to ensure quality control such that the end
product is of the designed quality conforming to the intent of this specification.
6.5
TEST VALUES
For all type and acceptance tests, the acceptance values shall be the value
guaranteed by the Supplier in the guaranteed technical particulars or the acceptance
value specified in this specification or the relevant standard whichever is more stringent
for that particular test.
6.6
TEST PROCEDURES AND SAMPLING NORMS
The norms and procedure of sampling for the above tests shall be as per the
relevant Indian Standard or other Internationally accepted standards. This will be
discussed and mutually agreed to between the successful Supplier and Purchaser
before placement of order. The standards and norms according to which these tests are
to be carried out are listed against each test. Where a particular test is a specific
requirement of this specification, the norms and procedure for the same shall be as
specified in Appendix-A1 attached hereto or as mutually agreed to between the
successful Supplier and the Purchaser in the Quality Assurance Programme. The
supplier shall offer at least three times the quantity of materials required for conducting
all the type tests for sample selection. Before sample selection, the supplier shall be
required to conduct all the acceptance tests successfully in presence of Purchasers
representative.
564
6.7
DETAILS OF TYPE TESTS
6.7.1
The material offered shall be fully type tested as per this specification and the
Supplier shall furnish four sets of type test reports alongwith the offer. These
tests must not have been conducted earlier than five years.
6.7.2
Following type tests shall be conducted on string insulators/unit disc insulators

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Visible discharge test

Impulse voltage withstand test
Wet power frequency voltage withstand test
Verification of dimension test
Temperature cycle test
Electro-Mechanical failing load test
Puncture test
Porosity test
Galvanising test
24 hours mechanical failing load test
Metallurgical test
IS:731
IS:731
IS:731
IS:731
IS:731
IS:731
IS:731
IS:731
IS:731
IS:731
IS:2108 & IS:2004
6.8
DETAILS OF ACCEPTANCE AND ROUTINE TESTS
6.8.1
All Acceptance and Routine tests as stipulated herein shall be carried out by the
Supplier in the presence of Purchasers representative.Immediately after
finalisation of the programme of acceptance/routine testing, the Supplier shall
give sufficient advance intimation to the Purchaser, to enable him to depute his
representative for witnessing the test.
6.8.2
For String Insulator Units following Acceptance & Routine tests shall be
conducted:
(A)
Acceptance tests:
a)
b)
c)
d)
e)
f)
g)
h)
i)
(B)
a)
b)
c)
Verification of dimensions
Temperature cycle test
Galvanising test
Mechanical performance test
Test on locking device for ball and
socket coupling
Eccentricity test
Electro-mechanical strength test
Puncture test
Porosity test
IS:731
IS:731
IS:731
IEC:575
IEC:372/IS-2486(part-IV)
As per Specification
IS-731
Routine tests:
Visual Inspection
Mechanical routine test
Electrical routine test
565
IS-731
IEC:383
6.9
Tests during Manufacture (STAGE TESTS)

On all components as applicable
6.10
a)
Chemical analysis of Zinc used for

galvanizing
b)
Chemical analysis, mechanical and

metallographic test and magnetic
particle inspection for malleable As per this Specification
castings
c)
Chemical analysis, hardness test

and magnetic particle inspection for
forgings
d)
Crack detection test for metal parts
ADDITIONAL TESTS
The purchaser reserves the right for carrying out any other tests of a reasonable
nature at the works of the Supplier/laboratory or at any other recognized laboratory /
research institute in addition to the above mentioned type, acceptance and routine tests
at the cost of the Purchaser to satisfy that the material complies with the intent of this
specification.
6.11
COORDINATION FOR TESTING:
For 400KV/220KV/132KV insulator strings, the Supplier is required to produce

type test reports to the satisfaction of the Purchaser. However, in case the Purchaser
desires, the Supplier shall conduct all the type tests on the complete string with relevant
hardware fittings. Responsibility of arranging required hardwares for the purpose of type
testing will remain with the insulator Supplier.
7.0
INSPECTION
7.1
i)
Purchaser and its representatives shall at all times be entitled to have

access to the works and to all places of manufactures where insulators are
manufactured and the successful Supplier shall afford all facilities to them for
unrestricted inspection of the works, inspection of material, inspection of
manufacturing process of insulators and for conducting necessary tests as
specified herein.
ii) The successful Supplier shall keep the Purchaser informed in advance of the
time of starting and progress of manufacture of insulators in its various stages
so that arrangements could be made for inspection.
iii) No material shall be despatched from its point of manufacture unless the
iv) The acceptance of any quantity of insulators shall in no way relieve the
successful Supplier of his responsibility for meeting all the requirement of this
specification and shall not prevent subsequent rejection, if such disc
insulators are later found to be defective.
566
7.2
IDENTIFICATION MARKING
7.2.1
Each disc insulator shall be legibly and indelibly marked with the trade mark of
the manufacturer, the month and year of manufacture, the guaranteed combined
mechanical and electrical strength in kilo-newtons abbreviated by KN to
facilitate easy identification and proper use.
7.2.2
The marking shall be on porcelain shell of insulators. The marking shall be

printed and not impressed/embossed and same shall be applied before firing.
7.2.3
One 10mm thick ring of good quality paint shall be marked on the cap of each
insulator of particular strength for easy identification of the type of insulator. The
paint shall not have any deteriorating effect on the insulator performance.
Following codes shall be used as identification mark:For 70kN disc insulator Green
For 90kN disc insulator Blue
For 120kN disc insulator- Yellow
For 160kN disc insulator Red
8.0
QUALITY ASSURANCE PLAN
8.1
The Supplier hereunder shall invariably furnish following information alongwith

his offer, failing which the offer shall be liable for rejection. Information shall be
separately given for individual type of material offered.
i)
Statement giving list of important raw materials, names of sub-suppliers

for the raw material, list of standards according to which the raw material
are tested, list of tests, normally carried out on raw material in presence
of Suppliers representative, copies of test certificates.
ii)

bought out items.
iii)
iv)
Level of automation achieved and list of areas where manual processing

exists.
v)

normally carried out in quality control and details of such test and
inspections.
vi)
Special features provided in the insulators to make it maintenance free.
vii)
List of testing equipment available with the Supplier for final testing of
insulators specified and test plant limitation, if any, vis-a-vis the type,
special, acceptance and routine tests specified in the relevant standards.
567
8.2
The successful Supplier shall within 30 days of placement of order submit the
i)
List of raw material as well as bought out accessories and the name of
material as well as bought out accessories and the names of subsuppliers selected from those furnished alongwith the offer.
ii)
Type test certificates of the raw material and bought out
iii)
Quality assurance plan (QAP) with hold points for Purchasers inspection.
The QAP and Purchasers hold points shall be discussed between the
Purchaser and the Supplier before the QAP is finalized.
accessories.
8.3
The successful Supplier shall submit the routine test certificates of bought out
items and raw material at the time of routine testing of the insulator.
9.0
DOCUMENTATION
9.1
The Supplier shall furnish full description and illustrated catalogues of insulators
offered, alongwith the bid. The supplier shall also furnish alongwith the bid the
outline drawing of each insulator unit including cross-sectional view of the shell.
The drawing shall include the following information :
9.2
i)
Shell diameter and unit spacing with manufacturing tolerance.
ii)
Creepage distance.
iii)
Unit mechanical and electrical characteristics as also for the complete

string-suspension and tension.
iv)
Size and weight of ball and socket part.
v)
Weight of unit insulator disc.
vi)
Materials for the disc, cap and pin.
vii)
Identification mark.
viii)
Manufacturers catalogue number.
ix)
Brief installation instructions.
x)
Relevant technical details of significance.
TEST REPORTS
i)
ii)
Four copies of type test reports shall be furnished to the Purchaser within
one month of conducting the tests. One copy will be returned duly
certified by the Purchaser to the Supplier within three weeks thereafter
and on receipt of the same Supplier shall commence with the commercial
production of the insulators.
Four copies of acceptance test reports shall be furnished to the
Purchaser. One copy will be returned, duly certified by the Purchaser and
only thereafter shall the materials be despatched.
568
10.0
11.0
iii)
All records of routine test reports shall be maintained by the Supplier at

his works for periodic inspection by the Purchaser.
iv)
All test reports of tests conducted during manufacture shall be maintained

by the Supplier. These shall be produced for verification as and when
requested for by the Purchaser.
PACKING & FORWARDING

i)
All disc insulators shall be packed in strong seasoned wooden crates.

The gross weight of the crates alongwith disc insulators shall not normally
exceed 100 kg. to avoid handling problem.
ii)
The packing shall be of sufficient strength to withstand rough handling

during transit, storage at site and subsequent handling in the field.
iii)
Suitable cushioning, protective padding, or dunnage or spacers shall be

provided to prevent damage or deformation during transit and handling.
iv)
All packing cases shall be marked legibly and correctly so as to ensure

safe arrival at their destination and avoid the possibility of goods being
lost or wrongly dispatched on account of faulty packing and faulty or
illegible markings. Each wooden case/crate shall have all the markings
stenciled on it in indelible ink.
SPECIFICATION DRAWINGS
The specification drawing in respect of the disc insulators indicated above is

attached with this specification. The specification drawing is attached herewith for
information and guidance of the Supplier only. The drawings to be furnished by the
Supplier shall be as per his own design and manufacture and shall be distinct and
separate from these specification drawings.
The drawing shall include but not limited to the following information :a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Shell diameter and ball to ball spacing with manufacturing tolerances.

Minimum creepage distance with positive tolerance.
Protected creepage distance
Eccentricity of the disc
i) Axial run out
ii) Radial run out
Unit mechanical and electrical characteristics
Size and weight of ball & socket parts
Weight of unit insulator disc
Materials
Identification mark
Manufacturers catalogue number.
After placement of award, the supplier shall submit full dimensioned

manufacturing drawing of insulator cap, pin & insulator shell in six copies to the
purchaser for reference & record.
569
Appendix-A1
TEST DETAILS
1.
Voltage Distribution Test:
The voltage across each insulator unit shall be measured by sphere gap method.
The result obtained shall be converted into percentage and proportionate correction be
applied so as to give a total of 100% distribution. The voltage across any disc shall not
exceed 9% for suspension insulator strings and for double tension insulator strings. The
total of the voltage distribution of all discs so computed shall be within 95% and 105%. If
not, the test shall be repeated. The proportions correction shall be made on the values
so as to give a total of 100% distribution.
2.
Mechanical Strength Test:
The complete insulator string alongwith its hardware fittings excluding arcing
horn, corona control ring/grading ring and suspension assembly/dead end assembly
shall be subjected to a load equal to 50% of the specified minimum ultimate tensile
strength (UTS) which shall be increased at steady rate to 67% of the minimum UTS
specified. The load shall be held for five minutes and then removed. After removal of the
load, the string components shall not show any visual deformation and it shall be
possible to disassemble them by hand. Hand tools may be used to remove cotter pins
and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of
UTS and the load shall be further increased at a steady rate till the specified minimum
UTS and held for one minute. No fracture should occur during this period. The applied
load shall then be increased until the failing load is reached and the value recorded.
3.
Vibration Test:
The suspension string shall be tested in suspension mode, and tension string in
tension mode itself in laboratory span of minimum 30 metres. In the case of suspension
string a load equal to 600 kg shall be applied along the axis of the suspension string by
means of turn buckle. The insulator string alongwith hardware fittings and two subconductors (each tensioned at 4500 kg) shall be secured with clamps. The system shall
be suitable to maintain constant tension on each sub-conductors throughout the duration
of test. Vibration Dampers shall not be used on the test span. Both the sub-conductors
shall be vertically vibrated simultaneously at one of the resonance frequencies of the
insulator string (more than 10 Hz) by means of vibration inducing equipment. The
amplitude of vibration at the antinode point nearest to the string shall be measured and
the same shall not be less than + 120/f , f being the frequency of vibration. The insulator
string shall be vibrated for five million cycles then rotated by 90 deg. and again vibrated
for 5 million cycles without any failure. After the test, the disc insulators shall be
examined for looseness of pins and cap or any crack in the cement. The hardware
fittings shall be examined for fatigue failure and mechanical strength test. There shall be
no deterioration of properties of hardware components and disc insulators after the
vibration test.
570

The disc insulators shall be subjected to the following tests as per relevant
standards:
Test
Percentage of
discs to be tested
Temperature cycle test followed by mechanical

performance test
60
Puncture test (for porcelain insulator only)
40
If the results of the second test show a porcelain shell rupture, the production
does not comply with this specification.
4.
Chemical Analysis of Zinc used for Galvanising:
Samples taken from the zinc ingot shall be chemically analysed as per IS:209.
The purity of zinc shall not less than 99.95%.
5.
Tests for Forgings:
The chemical analysis, hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognized procedures for these tests. The
sampling will be based on heat number and heat treatment batch. The details regarding
test will be as discussed and mutually agreed to by the Supplier and Purchaser in
Quality Assurance Programme.
6.
Test on Castings:
The chemical analysis, mechanical and metallographic tests and magnetic

particle inspection for castings will be as per the internationally recognized procedures
for these tests. The samplings will be based on heat number and heat treatment batch.
The details regarding test will be as discussed and mutually agreed to by the Supplier
and Purchaser in Quality Assurance Programme.
7.
Eccentricity Test:
The insulator shall be vertically mounted on a fixture using dummy pin and
socket. A vertical scale with horizontal slider shall be used for the axial run out. The
pointer shall be positioned in contact with the bottom of the outermost petticot of the
disc. The disc insulators shall be rotated with reference to the fixture and the slider shall
be allowed to move up and down on the scale but always maintaining contact with the
bottom of the outer most petticot. After one full rotation of the disc, the maximum and
minimum position the slider has reached on the scale can be found out. Difference
between the above two readings shall satisfy the guaranteed value for axial run out.
Similarly using a horizontal scale with vertical slider the radial run out shall be measured.
The slider shall be positioned on the scale to establish contact with the circumference of
the disc insulator and disc insulator rotated on its fixture always maintaining the contact.
After one full rotation the maximum and minimum position of the slider reached on the
scale are found out. The difference between the above readings shall satisfy the
guaranteed value for radial run out.
571
8.
Crack Detection Test:
Crack detection test shall be carried out on each ball and pin before assembly of
disc unit. The manufacturer shall maintain complete record of having conducted such
tests on each and every piece of ball pin. The supplier shall furnish full details of the
equipment available with him for crack test and also indicate the test procedure in detail.
SYSTEM PARTICUALRS
S.No. PARTICULARS
1
System
Electrical System Data

A.C.
3phase
A.C.
3phase
A.C.
3phase
Line voltage (kV rms)
220
132
400
Max.voltage (kV rms)
245
145
420
Frequency
50Hz.
50Hz.
50 Hz
Neutral grounding system
Lightning impulse with-stand

voltage(dry & wet)(kVp)
1050
550
1425
Power frequency withstand

voltage (wet) (kVp)
395
230
630
Switching surge withstand

voltage (wet) (kVp)
650
325
1050
Short circuit level (kA)
40
40
40
effectively
earthed
effectively
earthed
effectively
earthed
10.
Minimum corona extinction

voltage at 50 Hz AC system
dry condition (Kv rms)
320
11.
Radio interference voltage at

one MHz for phase to earth
voltage of 266KV dry
conditions(Microvolt)
500
572
APPENDIX A2
PRINCIPLE PARAMETERS AND OTHER REQUIREMENT FOR ACSR
CONDUCTOR
Principal Parameters of Stranded Conductor:
S.No
ACSR Zebra
ACSR Panther
Aluminium-54
Steel 7
Aluminium-30
Steel-7
ii. 1 Steel Layer
iii. 1st Aluminium Layer
12
12
18
18
24
428.9
212.10
a)
Details of Stranded Conductor

No. of Strands
i. Steel Centre
st
nd
iv. 2 Aluminium Layer

v. 3rd Aluminium Layer
b)
Sectional Area of Aluminium (mm )

2
c)
Total Sectional Area (mm )
484.50
261.60
d)
Overall diameter(mm)
28.62
21.00
e)
Approximate weight (Kg/Km )
1621
976
0.06915
0.139
130.32
89.67
0.686 x 106
0.787 x 106
f)
g)
Calculated D.C. Resistance at 20 C

(Ohm/Km)
Minimum UTS (kN)
h)
Modulus of Elasticity (Kg/cm2)
The details of aluminium strand are as follows:

S.
Details of Aluminium Strands
No.
i)
Minimum breaking load of strand
Before stranding (kN)
ACSR Panther
1.29
1.17
1.23
1.11
3.651
4.107
j)
Minimum breaking
after stranding (kN)
k)
Maximum D.C. resistance of

at 20oC (Ohm/Km)
l)
Nominal Strand Dia
3.18
3.00
m)
Max. Strand Dia
3.21
3.03
n)
Min. Strand Dia
3.18
3.00
o)
Mass (Kg/Km) of Strand at Nominal

Dia
21.47
19.11
load of strand
ACSR Zebra
573
strand

The details of steel strand are as follows:
S.
No
Details of Steel Strands
ACSR Zebra
ACSR Panther
p)
Minimum breaking load of strand

Before stranding (kN)
10.43
9.29
q)
Minimum breaking
after stranding (kN)
9.91
8.83
r)
Nominal Strand Dia
3.18
3.00
s)
Maximum Strand Dia
3.24
3.06
t)
Minimum Strand Dia
3.18
3.00
u)
Mass (Kg/Km) of
Dia
61.95
55.18
v)
Zinc coating testing
3 dips of 1
min. each
3 dips of 1 min.
each
w)
Wt. of Zinc Coating (gms./m2)
260
260
load of stran
Strand at Nom.
574
APPENDIX A3
PRINCIPLE PARAMETERS AND OTHER REQUIREMENT FOR SCREENING
CONDUCTOR (HIGH TENSILE GALVANISED STEEL EARTH WIRE)
PRINCIPAL PARAMETERS OF EARTH WIRE:
The standard technical particulars of 7/3.66mm galvanized steel earth wire shall
be as follows:a.
The details of Steel strand:
Sr. No.
Details of steel strands
Earth Wire
a)
Material
Steel
b)
Stranding
c)
Weight per Km
583 Kgs
d)
Dia. of wire
3.66 mm
e)
Tolerance
2%
f)
Minimum elongation in 100 mm length
5 mm
g)
Minimum breaking strength per strand
1000 Kg
h)
Minimum tensile strength
95 Kg./mm2
i)
D.C. resistance at 20oC
17.15 Ohms/Km
b.
Sr. No.
The details of Stranded Earth Wire :

Details of Stranded Earth Wire
Earth Wire
i.
Maximum Length of Lay
198
ii.
Minimum Length of Lay
165
iii.
Minimum breaking load
6972 Kgs
iv.
Overall diameter
10.98mm
Modulus of elasticity
1.933 x 106 Kg./cm2
vi
Co-efficient of linear expansion
11.50 x 10- 6 per oC
vii
Weight of zinc coating on wire
260 gms./m2 (Min.)
viii
No. of one minute dip and half minute dip 3 one minute and
respectively
1 half minute
ix
Calculated d.c. Resistance at 20 oC
575
2.5 Ohms per Km
APPENDIX A4
PRINCIPLE PARAMETERS AND OTHER REQUIREMENT FOR 70 KN, 90 KN,
120 KN & 160 KN EMS PORCELAIN DISC INSULATORS
1.
DETAILS OF DISC INSULATORS
1.1
The insulator strings shall consist of standard discs for a three phase 50 Hz,
effectively earthed 400KV/220KV/132KV transmission system in a moderately
polluted atmosphere. The discs shall be cap and pin, ball and socket type.
1.2
The specified values and disc dimensions, impulse and power frequency
voltages, electromechanical strength [EMS] of individual insulator units are as
under. The values given are minimum which apply to all cases. Specified
withstand and flashover voltages are referred to standard atmospheric condition.
2.
CHARACTERISTICS OF DISC INSULATORS
The disc insulators should have the following particulars and characteristics:
S.No
Particulars
Disc Insulators
70KN
EMS
90kN
EMS
120kN
EMS
160kN
EMS
Diameter of the disc (mm)
255
255
255
280
ii
Spacing of the disc (mm)
145
145
145
170
iii
Size and designation of pin-ball

shank
16 mm
16 mm
20mm
20 mm
iv
Creepage
(minimum)
(mm)
320
320
320
330
Power frequency one minute dry

withstand voltage kV (rms)
70
75
75
75
vi
Power frequency one minute wet

40
45
45
45
vii
Power
frequency
puncture
120
125
125
125
viii
Minimum dry impulse withstand

voltage 1.2x50 micro second
wave, positive and negative Kv
Peak)
110
110
110
120
ix
Maximum Radio interference

voltage with 10 kV RMS to
ground. (microvolts)
50
50
50
50
Minimum
corona
voltage kV (rms)
18
18
distance
extinction
576
APPENDIX-A5
DRAWINGS
S.
No.
Description
Drawing for 70KN, 90KN and 160KN Disc Insulator
Drawing for 120KN Disc Insulator
577
ITEM DESCRIPTION
MATERIAL
1. SHELL
2. SECURITY CLIP
PORCELAIN
PHOSPHOR BRONZE/STAINLESS
STEEL
MCI
FORGED STEEL
3. CAP
4. BALL PIN
PARTICULARS:S.NO.
EMS OF DISC
INSULATOR
1.
2.
3.
70 KN
90 KN
160 KN
DIAMETER
(A)
200
200
280
SPACING
(B)
145
145
170
MINIMUM SIZE OF
CREEPAGE BALL
DISTANCE SOCKET
320
16
320
16
330
20
NOTE. (1) TOLERENCE AS INDICATED IN THIS SPECIFICATION

(2) ALL DIMENSIONS IN MM
160 KN DISC INSULATOR OF

BALL & SOCKET TYPE
FOR TENDER PURPOSE ONLY
578
ITEM DESCRIPTION
MATERIAL
1. SHELL
2. SECURITY CLIP
PORCELAIN
PHOSPHOR BRONZE/STAINLESS
STEEL
MCI
FORGED STEEL
3. CAP
4. BALL PIN
PARTICULARS:S.NO.
EMS OF DISC
INSULATOR
DIAMETER
(A)
SPACING
(B)
1.
120 KN
255
145
MINIMUM
CREEPAGE
DISTANCE
320
SIZE OF
BALL
SOCKET
20
NOTE. (1) TOLERENCE AS INDICATED IN THIS SPECIFICATION

(2) ALL DIMENSIONS IN MM
120 KN DISC INSULATOR OF

BALL & SOCKET TYPE
FOR TENDER PURPOSE ONLY
579
SCHEDULE I (A)
S.No.
1
Material Particulars
Quantity
ACSR Conductors
Supply of 30/7/3.00mm ACSR Panther Conductor

2
Supply of Screening Conductor (7/3.66 mm Earthwire)
Disc Insulators
Supply of 70 KN EMS Porcelain Disc Insulator
Supply of 90KN EMS Porcelain Disc Insulator
Supply of 54/7/3.18mm ACSR Zebra Conductor

580
2.5.2 TECHNICAL SPECIFICATION FOR MS FLATS

1.0
SCOPE This scope of this specification covers design, manufacturing supply of

MS Flat for EHV substations as per Volume-II, Part-2, Book-I. The bidder
mentioned in the Section of Technical specification means Original
In case bidder is not OEM, sole responsibility of offering equipment /
material of manufacturer as per this specification requirement shall rest on the
bidder.
2.0
STANDARDS Applicable standards for offered equipment / material shall be as per

3.0
CLIMATIC CONDITIONS
4.0
SYSTEM PARTICULARS Applicable system particulars shall be as per Volume-II, Part-2, Book-I.
5.0
SIZE OF MS FLATS
The following sizes of MS Flats are covered in this specification:S. No.
A
1
2
3
6.0
MS Flats
75X8 mm
50X6 mm
65x8 mm
MATERIAL The MS Flats should be conforming to latest version of IS: 2062. Tested MS
Flats having its yield strength not less than 2550 kg/sq cm shall be used. If rerolled materials are supplied, then it must be ensured that Re-rolling of MS
Flats is done from billets/ingots of tested quality only and re-rolled sections
are duly tested as per relevant IS.
7.0
WEIGHMENTThe Weighment shall be witnessed by the consignee at the time of taking

delivery. The Weighment recorded in the Material Receipt Certificate (MRC)
issued by the consignees shall be final. The bidder / manufacturer is
exclusively responsible for any loss in transit.
8.0
LENGTHThe MS Flats shall be supplied in following lengths:

i.
M.S.Flats
5.5 Mtrs. to 15 Mtrs.

581
MS FLATS

Any tolerance on negative side shall not be accepted.
9.0
PACKING & MARKINGEach bundle or packing shall be marked in legible English letters in the
following manner.
i.
ii.
iii.
Reference of purchase order

The name of the consignee
Manufacturers identification.
The marking shall be stenciled and indelibly inked on the each member in the
bundles.
10.0
GENERAL GUIDE-LINES FOR INSPECTIONFOR MS FLATS
11.0
i.
ii.

One no. sample shall be selected from the offered lot of every 50 MT
or part thereof for each Size.
iii.
Dimensional verification of MS Flats.
iv.
Tensile test and Bend test of each sample.
v.
Chemical composition test of one sample of every 50 MT or part

thereof.
vi.
Verification of manufacturers test certificate for billets/ingots used in

rolling of MS Flats.
INSPECTION AND TEST CERTIFICATES (i)
MS Flats to be supplied will be subject to inspection and approval

by the MPPTCL 's representative before dispatch and / or on arrival
at the destination. Inspection before dispatch shall not, however,
relieve the supplier of his responsibility to supply the MS Flats strictly
in accordance with the specification.
(ii)
The successful bidder / manufacturer shall abide by all the statutory

provisions, acts such as the Indian Electricity Act, Indian Factory Act,
Indian Boiler Act etc., and corresponding rules and regulations as may
be applicable and as amended from time to time.
(iii)
The MPPTCL's representative shall be entitled at all reasonable time

during manufacture to inspect, examine and test at the bidders
premises the materials and workmanship of the material to be
supplied.
(iv)
As soon as the material is ready for testing, the supplier shall intimate
the MPPTCL well in advance, so that action could be taken for getting
the material inspected. The material shall not be dispatched unless
waiver of inspection is obtained or inspected by the MPPTCL's
authorized representative. When the material has passed the specified
582
MS FLAT

tests, the MPPTCLs representative shall furnish a certificate to this
effect in writing to the supplier. The MS Flats shall not be dispatched
unless the test certificates are approved.
12.0
(v)
Test certificates shall be in accordance with latest version of the

relevant Indian Standards.
(vi)
The acceptance of any batch shall in no way relieve the supplier

of any of his responsibilities for meeting all the requirements of the
specification and shall not prevent subsequent rejection at any item
if the same is later found defective.
(vii)
In case, MS Flats is not found as per the relevant specification, it shall

be liable for rejection even after receipt.
(viii)
Defects which may appear during manufacture shall be made good.
(ix)
Testing charges shall be born by the bidder.
ROUTINE TEST CERTIFICATES The successful Bidder/ Manufacturer shall submit the routine test certificates
of raw material at the time of routine testing of MS Flats.
13.0
IMPORTANT NOTE FOR BIDDERS-
In this bid, the Bidders will have to furnish confirmation in regard to

compliance of our entire technical requirements. The bid should clearly describe
various technical particulars of the MS Flats as per details given in this specification.
583
MS FLAT
SCHEDULE I (A)
DESCRIPTION OF MATERIAL FOR SCHEDULE OF RATES AND PRICES
TO BE FURNISHED IN VOLUME -VI
S.No.
1
a.
b.
c.
Particulars
MS Flats
75X8 mm
50X6 mm
65x8 mm
Qty
Note :
1.
The above description of material is given for the purpose of offering the
prices and to mention description of material in Invoice for claiming payment.
2.
The quantity of above material has been mentioned in Volume-VI
584
MS FLAT
2.5.3
1.0
TECHNICAL SPECIFICATIONS FOR POWER AND COPPER

CONTROL CABLES
SCOPE:
This scope of this specification covers design, manufacturing supply of Power

and Copper Control Cables as per Volume-II, Part-2, Book-I. The bidder mentioned in
the Section of Technical specification means Original Equipment Manufacturer
(OEM). The purchaser means the MPPTCL.
In case bidder is not OEM, sole responsibility of offering equipment / material of
2.0
STANDARDS Applicable standards for offered equipment / material shall be as per Section-I,
Volume-II.
3.0
CLIMATIC CONDITIONS
4.0

5.0
GENERAL TECHNICAL REQUIREMENTS & CONSTRUCTIONAL DETAILS:
The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
underground buried installation with chances of flooding by water. Cables shall be
designed to withstand mechanical, electrical and thermal stresses developed under
steady-state and transient operating conditions as specified elsewhere in this
specification.
5.1
CONTROL CABLES:
Control cables shall be of 1.1 KV grade, multicore (as specified in Clause 1.3
above), PVC insulated, PVC inner sheathed, Armoured, PVC outer sheathed with Solid
copper conductor for cables of 2.5 sq.mm and 4 sq. mm sizes and Stranded copper
conductor for cables of 10 sq.mm size conforming to latest version of IS:1554 or
5.1.1
CONDUCTOR:
The conductor shall be made from high conductivity copper rods complying with
latest version of IS:613 or equivalent International Standards. The conductor shall
consist of annealed copper wires complying with IS:8130 with latest amendments or
5.2
INSULATION:
The conductor shall be provided with PVC insulation applied by extrusion in

accordance with latest version of IS:5831 or equivalent International Standards. The
average thickness of insulation shall be in accordance with the IS:1554 (Part-I) with
latest amendments or equivalent International Standards.
The insulation shall be so applied that it fits closely on the conductor and
shall be possible to remove it without damages to the conductor.
585
Control & Power Cable

5.3
CODE IDENTIFICATION:
Colouring of insulation shall identify cores of the cables of upto 5 cores.

Following colour schemes shall be adopted:
S.
No.
Number
of Cores
Colour Scheme
1 Core
Red, Black, Yellow or Blue
2 Cores
Red and Black
3 Cores
Red, Yellow and Blue
4 Cores
Red, Yellow, Black and Blue
5 Cores
Red, Yellow, Black, Blue and Grey
6 Cores
and
above
Two adjacent cores (counting and direction core) in each

layer, Blue and Yellow, remaining cores Grey or in
accordance with the scheme given in IS: 1554 Clause 10.3
The cables having more than 5 cores, as an alternate to the provision of (6)
above, the core identification may be done by numbers as indicated in latest version
of IS :1554 (PART-I) Clause 10.3.
5.4
LAYING UP OF CORES:
In multi-core cables, the cores shall be laid up together with a suitable lay, the
outer most layer shall have right-hand lay and successive layer shall be laid with
opposite lay, where necessary, the interstices shall be filled with non hygroscopic
materials.
5.5
INNER SHEATH:
The laid up cores shall be provided with inner sheath applied by extrusion. It
shall be ensured that the shape be as circular as possible. The inner sheath shall be so
applied that it fits closely on the laid up cores and it shall be possible to remove it
without damage to the insulation. The thickness of inner sheath shall be conforming to
latest version of IS:1554 (Part-I) or equivalent International Standards.
5.6
FILLER AND INNER SHEATH:

The filler and inner sheath shall be of the following:
(i)
Unvulcanised rubber, or
(ii)
Thermoplastic materials
Unvulcanised rubber or thermoplastic material used shall not be harder than

PVC used for insulation and outer sheath. The material shall be chosen to be
compatible with temperature ratings of the cable and shall have no deterious effect on
any other component of the cable.
5.7
ARMOURING:
Armouring shall be of the following:
(i) Galvanized round steel wires, or
(ii)
Galvanized steel strip.
586

The galvanized steel wires/ strips shall comply with the requirements of
latest version of IS:3975 or equivalent International Standards. The armouring shall be
of galvanized steel, as follows:
S.
No.
Type of armour and size

Steel strip/Round wire
Calculated nominal size

of Cable under armour
Upto 13 mm.
1.4 mm. dia GS wire
Above 13 upto 25 mm.
0.8 mm. thick GS strip/1.6 mm. dia GS wire
Above 70 mm.
The gap between armour wire/strip shall not exceed one armour wire/strip
space and there shall be no cross over/over- riding of armour wire/strip. The minimum
area of coverage of armour shall be 90%. The breaking load of armour joint shall not be
less than 95% of that of wire/strip. Zinc rich paint shall be applied on armour joint
surface.
5.8
OUTER SHEATH:
The outer sheath shall be applied by extrusion. It shall be applied:
(i)
Over the inner sheath in case of unarmoured multicore cables.
(ii)
Over the armouring in case of armoured multicore cables.
The outer sheath shall be applied by extrusion. It shall be applied over the
armouring in case of armoured multicore cables.The outer sheath shall be so applied
that it fits closely over armouring. It shall be possible to remove it without damage to
the insulation/inner sheath. The colour of the outer sheath shall be black.
The thickness of outer sheath insulation shall conform to latest version of
IS:1554 Part-I or equivalent International Standards.
6.0
ALUMINIUM POWER CABLES:
Power cables shall be of 1.1 KV grade, multicore (as specified above), PVC
insulated, PVC inner sheathed, armoured, PVC outer sheathed with stranded
Aluminium conductor and Heavy duty Galvanized Single Flat Steel armoured
confirming to IS 1554 or equivalent International Standards.
6.1
CONDUCTOR:
Aluminium conductor used in power cables shall comply with latest version
of IS:8130 or equivalent International Standards.
7.0
IDENTIFICATION:
In addition to Manufacturers identification on cable as per Clause-17.1 of

IS:1554 (Part-I) with latest amendments, following marking shall also be embossed
over outer sheath at every three meters:
(i)
Cable size and voltage grade.
587

(ii)
Word PROPERTY OF MP POWER TRANSMISSION COMPANY

and Name of manufacturer.
Besides above Marking for length of Cable at every one meter shall also
be done on outer sheath of cable.
The embossing shall be increasive, automatic in line throughout the length
of the Cable and shall be legible and indelible.
8.0
PACKING AND MARKING:
Cables shall be supplied in non-returnable wooden drums or steel drums of

heavy construction. The surface of the drum and outer most cable layer shall be
covered with waterproof layer. Both the ends of the cables shall be properly sealed with
heat shrinkable PVC or rubber caps, secured by Ù nails so as to eliminate ingress of
water during transportation storage and erection. Wooden preservative antitermite shall
be applied to the entire drums. Wooden drums should comply with latest version of
IS:10418 or equivalent International Standards. The following information should be
stenciled on the drum:
9.0
(i)
Reference to relevant Indian or International Standard.
(ii)
Manufacturers name, brand name or trade mark.
(iii)
Type of cable and voltage grade.
(iv)
Number of cores.
(v)
Nominal cross-sectional area of the conductor.
(vi)
Cable code.
(vii)
Colour of cores.
(viii)
Length of cable on the drum.
(ix)
Number of lengths on drum (if more than one).
(x)
Direction of rotation of drum by means of an arrow.
(xi)
Approximate gross weight.
(xii)
Running end of cable.
(xiii)
Country of manufacturer and Year of manufacture.
STANDARD DRUM LENGTH:
The control cable should be joint less in each drum. The standard drum
length for Copper Control cables shall be as follows;
For
220
and
Substation work
Power cable
10.0
132
KV
500 Mtrs
500 Mtrs
TOLERANCE:
(i)
Tolerance on the overall diameter of the Cable shall be +2 mm over

the declared value in the technical data sheets of Guaranteed
Technical Particulars.
(ii)
The length per drum shall be subjected to maximum tolerance of +5%

of the standard drum length. The purchaser shall have option to reject
cable drums with shorter length.
588

(iii) Over all tolerance in total quantity for each type and size of cables
shall be +2%
11.0
TESTS:
All types and sizes of cables being supplied shall be subjected to Type
tests, Additional test, Routine tests and Acceptance tests as specified below at the
expense of Supplier and according to relevant standards.
11.1
TYPE TESTS AND ADDITIONAL TESTS:
It is essential to furnish all the type test reports for each type and size of
cable as stipulated in latest version of IS:1554 (Part-I) and following Additional tests
alongwith the tender:
(i)
Loss of mass test
(ii)
Heat shock test
(iii)
Thermal stability test
(iv)
Accelerated water absorption test
(v)
Dielectric strength retention test
Above Type/Additional Tests shall be conducted in Government / Reputed

Testing Laboratories and shall not be older than 5 Years.
For any change in the design/type, already type tested/tested for additional
test and the design/type offered against this tender, the purchaser reserves the right to
demand repetition of some or all type tests and additional tests without any extra cost
on the first or any one lot of any rating included in the package.
11.2
ACCEPTANCE TEST:
Acceptance tests shall be carried out on each type and size of cables on
cable drums selected at random as per following plan:
S. No.
1
Numbers of drums
offered for inspection
Upto 50
Number of drums to be
taken as samples
2
Upto 51 to 100
From 101 to 300
13
From 301 to 500
20
Above 501
32
The following shall constitute acceptance tests :

(i)
Annealing test (for copper)
(ii)
Conductor Resistance test
(iv)
Test for thickness of insulation and sheath.
(v)
Tensile strength and elongation test at break of insulation and
sheath.
(vi)
High voltage test (Water immersion test) a.c. test only
(vii)
High Voltage test at room temperature and
(viii) Insulation Resistance test
589

11.3
ROUTINE TESTS
Routine tests shall be carried out for each drum of cables of all types and
sizes. Following shall constitute routine tests :
12.0
13.0
(i)
Conductor Resistance test
(ii)
High Voltage Test at room temperature
INSPECTION:
(i)
The purchaser shall have access at all times to the works and all
other places of manufacture, where the Cables are being
manufactured and the successful Tenderer shall provide all facilities
for unrestricted inspection of works, raw materials, manufacture of
all the accessories and for conducting necessary tests as detailed in
the tender document.
(ii)
The successful Tenderer shall keep the purchaser informed in

advance of the time of starting and of the progress of manufacture of
Cables in its various stages, so that arrangement could be made for
inspection.
(iii)

the material has been satisfactorily inspected and tested or predespatch inspection has been waived.
(iv)
The acceptance of any quantity of the material shall in no way relieve

the successful tenderer of his responsibility for meeting all the
rejection if such Material are later found to be defective.
INSPECTION PROGRAMME
13.1
Successful Tenderer shall chalk out a detailed inspection and testing
programme for various manufacturing activities. The Purchaser also reserves the
right to carryout any tests by a third party at its sole discretion. All Costs of
inspection/tests shall be borne by you.
13.2
STAGE INSPECTIONS:
Successful Tenderer shall intimate the detailed manufacturing programme

within 30 days from the date of placement of order. The MPPTCL will have a right to
depute its inspecting officers during the manufacture of the cable at various stages of
manufacturing for Stage Inspections. Purchaser shall normally depute its representative
to carry out stage inspections at following stages of manufacturing of cables : i.
ii.
iii.
before drawing of conductor

before application of insulation on conductor
before application of inner sheath over laid up cores
Intimation for stage inspections as above for various lots shall be given by you
one week in advance to organize deputation of inspecting officer. During stage
inspections, the inspecting officer shall verify the sources of raw material, its quality etc.
During this stage, following documents shall be verified by our inspector as a proof
towards use of raw material for manufacture of Cables ordered by us.
590

i.
ii.
iii.
iv.
v.

Factory test certificate
Packing list
Bill of lading, if applicable
Bill of entry certificate by customs, if applicable
The Purchaser also reserves the right to carry out stage inspections at other
stages also, for which advance intimation shall be given and all necessary cooperation
shall be rendered by the manufacturer. Only after approval of the purchaser, the
supplier shall proceed ahead for manufacturing of the cable. During stage inspection,
adherence to the approved Quality Assurance Plan will also be checked.
A complete record of stage inspection shall be kept by you and this record
shall be made available for inspection by the representative of the MPPTCL.
14.0
14.1
The Tenderer must establish that they are following a proper quality
assurance programme for manufacture of Cables. The Tenderer shall invariably furnish
following information alongwith his tender. Information shall be separately given for
each type of cable:
(i)
Statement giving list of important raw materials, names of subsuppliers for the raw material, list of standards according to which
the raw material is purchased and copies of test certificates thereof.
(ii)

bought out items.
(iii)
(iv)

processing exists.
(v)

inspections.
(vi)
List of testing equipment available with the Tenderer for final testing
of cable specified and test plant limitation, if any, vis--vis type,
14.2
The successful Tenderer shall within 30 days of placement of order, submit
(i)
of sub-suppliers selected from the lists furnished along with Tender.
(ii)
Type test certificates of the raw materials and bought out

accessories.
(iii)

finalized.
14.3
The successful Tenderer shall submit the routine test certificates of bought
out items and for raw material at the time of routine testing of cable.
591
SCHEDULE I (A)
DESCRIPTION OF MATERIAL FOR SCHEDULE OF RATES
AND PRICES TO BE FURNISHED IN VOLUME - VI
S.No.
Particulars
Qty
1.
1.1KV UNARMOURED COPPER CONTROL CABLES
a.
19 Core 2.5 Sq mm
b.
12 Core 2.5 Sq mm
c.
8 Core 2.5 Sq mm
d.
4 Core 2.5 Sq mm
e.
2 Core 2.5 Sq mm
2.
1.1 KV ARMOURED COPPER CONTROL CABLES:
a.
19 Core 2.5 Sq mm
b.
12 Core 2.5 Sq mm
c.
4 Core 2.5 Sq mm
d.
4 Core 4 Sq mm
e.
4 Core 10 Sq mm
f.
2 Core 2.5 Sq. mm
3.
ARMOURED ALUMINIUM POWER CABLE:
a.
3.5 Core 1.5 Sq mm
Note :
1.
The above description of material is given for the purpose of offering the prices
and to mention description of material in Invoice for claiming payment.
2.
The quantity of above material has been mentioned in Volume-VI
592
2.5.4 TECHNICAL SPECIFICATION FOR CLAMPS & CONNECTORS

1.0

Clamps & Connectors/ Spacers manufactured through Pressure Die Casting
process for EHV substations as per Volume-II, Part-2, Book-I. The bidder
bidder.
2.0
STANDARDS Applicable standards for offered equipment / material shall be as per Volume-II,
Part-2, Book-I.
3.0
CLIMATIC CONDITIONS
4.0
5.0
GENERAL TECHNICAL REQUIREMENTS FOR CLAMPS & CONNECTORS:
5.1
This section covers the design of current carrying type Clamps and Connectors
for use in the 200 KV and 132 KV Switchyard . The connectors required would
include those required for connections from terminals of equipments to
conductors. Certain quantity of non-current carrying type clamps are also
included. The scope of supply would include Clamps and Connectors/Spacers
complete with associated bolts, nuts, Belleville /spring washers and flat washers
as specified.
5.2
For each of the item, a drawing has been enclosed and all the items of
Clamps & Connectors/Spacers should be offered strictly on the basis of
above drawings.
5.2.1
All the current carrying parts shall be so designed and manufactured to have
minimum contact resistance. The maximum tension per conductor is expected to
be 2000 Kgs.
5.2.2
The clamps shall so be designed that insulators shall not be subject to any
abnormal stresses due to thermal changes in conductor.
5.2.3
All the clamps shall enable the connection to be as short as possible. Wherever
possible the clamps shall be two separate halves.
593
Clamps and Connector
5.2.4
Spacer shall prevent clashing of the T clamps and minimize effects of short
circuit forces between bundle conductors on structures. They shall be capable of
withstanding electro-magnetic and electrostatic forces during short circuit without
deformation or damage to the conductor or spacer.
5.2.5
Spacers shall permit the relative axial and torsional movement of sub-conductors
and maintain their correct separation without lubrication or maintenance.
5.2.6
All nuts, bolts & washers shall be made of hot dip galvanized Mild Steel
conforming to relevant IS only.
5.2.7
The Material in all respect shall incorporate highest quality of modern

engineering design and workmanship. The specification is merely for the
guidance of the Bidder as has been clearly stated earlier and it is not the
intention to specify the details of design and workmanship. The Clamps/ Spacers
shall be designed and manufactured in accordance with the Bidders standard
practices, when such practices do not conflict with this specification.
5.2.8
There shall not be any sharp edges which may lead to accumulation of charge &
electrical breakdown. All corners/ edges shall be rounded.
5.2.9
The Material offered shall be complete with all components and accessories
which are necessary or useful for their satisfactory performance and efficient
maintenance. Such parts shall be deemed to be within the scope of this
specification whether specifically included or not.
5.2.10 The design should be such that adequate clamping pressure is obtained with the
tightening of the nuts and the pressure should be maintained throughout the
service of the connector. In order to provide for creep of Aluminium under
pressure, it is essential that only Belleville washers are used. This should be
specifically confirmed and should also indicate tightening torque required.
5.2.11 All connectors and clamps shall be suitable to carry safely the maximum
allowable current in the associated conductor and to withstand the maximum
loads occurring under adverse circumstances and operating conditions. The
maximum fault current is 40 KA rms for a period of 3 seconds. The temperature
of the clamps and fittings shall never exceed that of the associated conductor.
5.2.12 The short circuit current shall be of the order of 40 KA rms for
3 seconds. The Clamps & Connectors/ Spacers should be suitable to withstand
the short circuit forces corresponding to this current.
5.2.13 The design of Clamps should be such that proper space for movement of normal
quality single head spanner during tightening is available. This is an important
requirement and should be confirmed by the Bidder.
5.2.14 Materials:
The Clamps & Connectors/ Spacers shall be made of materials listed below: -
i.
For connecting ACSR conductor Aluminium alloy casting conforming to

designation A6 of IS:617.(Redesignation 4600)
594
ii.
Bolts, Nuts, plain washers and spring washers for above items shall
be made of hot dip galvanized Mild Steel conforming to relevant IS
only.
iii.
The Bidder shall ensure that the Alloy used assures good stability and
sound casting by proper fluidity. Proper mechanical and physical strength
characteristics should be obtained corresponding to the standard
requirements of the Alloy specified.
5.2.15 For Clamps and Connectors used in 220 KV, 132 KV & 33 KV switchyard
should be made by Pressure Die-Casting Process and thereafter given
appropriate treatment. Clamps bodies made by Sand casting shall not be
accepted in any case.
5.2.16 Castings :
All casting shall be free from blow holes, surface blisters and shall be rounded
off.
5.2.17 Constructional Details :
i.
All sharp edges and corners shall be blurred and rounded off.
ii. Minimum thickness of any part of the Clamps and Connectors/ Spacers shall
not be less than 12 mm.
iii. Bolts and nuts shall have hexagonal heads and threads as per Indian
Standard.
iv. Flexible connectors, braids or laminated straps shall be made from tinned
copper strips or aluminium laminates depending upon the clamp.
v.
Size of terminal/conductor for which the Clamps/ Spacers are suitable shall
be embossed on each component of the clamp.
vi. Casting should be such that adequate free space for placement and
movement of double ended spanners for tightening of nuts is available.
Further, for adequate strength, clear distance of minimum 6 mm shall be
available between the edges of the holes meant for Nuts/Bolts and any
corner of the Clamps & Connectors/ Spacers.
5.2.18 Bolts, Nuts & Washers :
These shall be as per Indian Standard and shall have tensile strength and
elongation as per grade 5.6P. The Bidder should ensure proper tightening either
by use of Belleville or by the use of torque wrenches.
5.2.19 Interchangeability :
All components of like design shall be inter-changeable.
6.0
Tests :
All types of Material being supplied shall be subjected to Type tests, Routine
tests and Acceptance tests as specified below at the expense of Bidder and
595
according to relevant standards. The following tests shall be carried out on the
Clamps & Connectors/ Spacers :
6.1
Type Tests :
This shall mean those tests which are to be carried out to prove the design,
process of manufacture and general conformity of the material and product with
the intents of this specification. The equipment / materials offered shall be type
tested as per the relevant International/Indian Standard and as required under
the technical specification.
All the clamps covered in the bid identification should be Type Tested as
detailed below :a.
All type tests are required to be conducted in respect of following items as

per relevant IS/ Technical Specification:i. T Clamp for Twin Moose Run & Single Moose Tap
ii. T Clamp for Twin Zebra Run & Single Zebra Tap
iii. PG Clamp for Zebra ACSR
iv. Pad Clamp for Twin Zebra ACSR
b.
For remaining items, all the type tests excepting short time current test
are required to be conducted.
The Type test reports for all the clamps as detailed above are required to
be furnished with the Bid. If the type tests on these Clamps are older than 5
years or are yet to be carried out, the successful Bidder will be required to
furnish the requisite test report for successful conduction of type tests within 60
days from the date of detailed order.
6.2
Acceptance Tests :
This shall mean those tests which are to be carried out on samples taken from
each lot offered for pre-despatch inspection for the purpose of acceptance of the
lot.
6.3
Routine Tests :
This shall mean those tests, which are to be carried out on each Clamp &
Connector/ Spacers to check the requirements which are likely to vary during
production.
6.4
Stage Tests During Manufacture :

Stage tests during manufacture shall mean those tests which are to be carried
out during the process of manufacture to ensure quality control such that the end
product is of the designed quality conforming to the intent of this specification.
6.5
Test Values :
For all type and acceptance tests, the acceptance values shall be the values
guaranteed by the Bidder in the guaranteed technical particulars or the
acceptance value specified in this specification or equivalent International
Standards whichever is more stringent for that particular test.
596
6.6
Test Procedures and Sampling Norms :

The norms and procedure of sampling for the above tests for Clamps &
connectors/ Spacers shall be as per the relevant Indian Standard or equivalent
International Standards.
7.0
Clamps & Connectors:
7.1
Type Tests :
It is essential to furnish following type test reports in respect of Clamps covered
in clause 2.1 above as stipulated in latest version of IS: 5561:
7.2
i.
Tensile Test
ii.
Resistance Test
iii.
Temperature rise Test
iv.
Short time current Test
v.
Dimensional Check
vi.
Galvanizing Test, if applicable
Acceptance and Routine Tests :

For Clamps & Connectors following Acceptance & Routine tests shall be
conducted:
(A)
Acceptance test :
i.
ii.
iii.
iv.
v.
(B)
Visual check
Tensile Test
Resistance Test
Dimensional Check
Routine Test :
i.
ii.
7.3
SPACERS:
7.3.1
Type test:
Visual inspection
Dimensional Check
It is essential to furnish following type test report for Spacers (also covered in
clause 2.1) as stipulated in latest version of IS: 10162 :
i.
ii.
iii.
iv.
v.
Visual examination
Clamp slip test
Resilience test
Clamp bolt torque test
597
vi.
vii.
viii.
ix.
x.
Assembly torque test

Tensile load test
Compression and pull off test
Magnetic power loss test and
7.3.2 Acceptance and Routine Tests :

For Spacers following Acceptance & Routine tests shall be conducted:
(A)
Acceptance test:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
(B)
Visual examination
Clamp slip test
Clamp bolt torque test
Assembly torque test
Tensile load test
Compression and pull off test
Routine test :
i.
ii.
8.0
Visual examination and

MARKING:
Each Clamps & Connectors / Spacers shall be marked with the trade mark of the
manufacturer and year of manufacturing. Marks shall be forged or stamped with a steel
die before galvanizing. The mark shall be distinct, durable and conspicuous.
9.0

(i)
All Material and associated fittings e.g., nuts, bolts and washers etc
shall be packed in suitable sized strong and weather resistant
wooden cases/crates. The gross weight of the packing shall not
normally exceed 50 Kg. to avoid handling problems.
(ii)
The packing shall be of sufficient strength to withstand rough

handling during transit, storage and subsequent handling in the field.
(iii)
Suitable cushioning, protective padding or spacer shall be provided to

prevent damage or deformation during transit and handling.
(iv)
All identical items shall be dispatched to destination duly assembled

and packed. Bolts, nuts, washers and pins etc. shall be packed duly
installed and assembled with the respective parts and suitable
measures shall be taken to prevent their transit loss/damage.
(v)
All packing cases shall be marked legibly and correctly so as to

ensure their safe arrival at their destination and to avoid the
possibility of goods being lost or wrongly dispatched on account of
598
faulty or illegible markings. Each wooden case / crate shall have all
the markings stenciled on it in indelible ink.
(vi)
10.0
The list showing quantity of components, product drawing and

assembly / maintenance instructions for the users should be sent with
each consignment.
DRAWINGS:
We have standardized our technical requirements for Clamps &
Connectors/ Spacers. Accordingly drawing for each item is attached with
the Bidding Document. Bidder will have to offer material exactly as per
these drawings. Any change in design/dimension will lead to rejection of
bid.
The Bidder shall submit following information / drawings for each item,
with the Bid:
(i)
Fully dimensioned drawings giving as assembly and details of each type

of items with bill of material and weight.
(ii)
Technical details with descriptive literature/catalogue and photograph for

each items.
(iii)
The nature of the material used for various parts shall be clearly
specified in the drawings.
(iv)
Weight of individual components and total assembled weight.
The successful bidder is required to furnish fully dimensional drawings of offered

material within 15 days from the date of issue of the order for its approval.
11.0
INSPECTION :
(i)
Purchaser and its representatives shall at all times be entitled to

have access to the works and to all places of manufacturing where
Clamps & Connectors/ Spacers are manufactured and the Bidder shall
afford all facilities to them for unrestricted inspection of the works,
inspection of raw material, inspection of manufacturing process of
Clamps & Connectors/ Spacers and for conducting necessary tests as
detailed in the Bidding document.
(ii)
The successful Bidder may keep the Purchaser informed in advance of

the time of starting and progress of manufacture of Clamps &
Connectors/ Spacers in its various stages so that arrangements could be
made for stage inspection.
(iii)
No material shall be dispatched from its point of manufacture unless the

material has been satisfactorily inspected and tested or inspection waiver
is granted.
(iv)
The acceptance of any quantity of Clamps & Connectors/ Spacers shall

in no way relieve the Bidder of his responsibility for meeting all the
599

rejection, if such materials are later found to be defective.
12.0
(v)
Immediately after finalization of the programme of acceptance / routine

testing, the successful Bidder shall give advance intimation in writing
intimating the date and the place at which the materials shall be ready for
inspection and testing. All acceptance tests shall be carried out in
presence of Purchasers representative. They will also provide such
assistance as may be required for or as may be reasonably demanded
by Purchasers representative to carry out such tests efficiently. The
material shall not be dispatched unless the same is inspected and
approved or the waiver of inspection is granted.
(vi)
When the specified tests are conducted successfully in presence of

Purchasers representative, the successful Bidder shall submit the test
certificate in duplicate duly witnessed by representative to Purchasers for
approval. The material shall not be dispatched until these certificates are
approved.
(vii)
Successful Bidders request for pre-despatch inspection waiver should

invariably accompany with the test certificate in duplicate as per the
relevant IS and guaranteed technical particulars of the order, for
Purchasers approval.
12.1 The Bidder must establish that they are following a proper quality assurance
programme for manufacture of Materials. The Bidder shall invariably furnish following
information alongwith his Bid;
i.
Statement giving list of important raw materials, names of vendors for the
raw material, list of standards according to which the raw material is
purchased and copies of test certificates thereof.
ii.

bought out items.
iii.
iv.

exists.
v.

inspections.
vi.
material specified and test plant limitation, if any, vis--vis type, special,
acceptance and routine tests specified in the relevant standards. These
limitations shall be very clearly brought out in schedule of deviations from
600
12.2

i.
List of raw material as well as bought out accessories and the names of
sub-suppliers selected from the lists furnished along with Bid.
ii.
iii.

finalized.
12.3 The successful Bidder shall submit the routine test certificates of bought out
items and raw material at the time of routine testing.
13.0
STAGE INSPECTION:
Successful Bidder shall strictly adhere to the approved detailed manufacturing

and quality assurance Programme. The MPPTCL have right to depute its officer during
the manufacture of the Clamps & Connectors/ Spacers at various stages of
Manufacturing for Stage Inspection. Purchaser shall normally depute its representative
to carryout Stage Inspection at the time of Gravity Die Casting of Clamps & Connectors/
Spacers.
Intimation for stage inspections as above for various lots shall be given by you
one week in advance to organize deputation of inspecting officer. During stage
inspections, the inspecting officer shall verify the sources of raw material, its quality etc.
During this stage, following documents shall be verified by our inspector as a proof
towards use of raw material for manufacture of Clamps & Connectors/ Spacers ordered
by us.
i
ii
iii
iv
v

Factory test certificate
Packing list
Bill of lading, if applicable
Bill of entry certificate by customs, if applicable
The Purchaser also reserves the right to carry out stage inspections at other
stages also, for which advance intimation shall be given and all necessary cooperation
shall be rendered by the manufacturer. Only after approval of the purchaser, the
supplier shall proceed ahead for manufacturing of the Clamps. During stage inspection,
adherence to the approved Quality Assurance Plan will also be checked. In case the
inspecting officer does not visit the works for stage inspection, the supplier may proceed
ahead as per their standard manufacturing process.
A complete record of stage inspection shall be kept by you and this record shall
be made available for inspection by the representative of the MPPTCL.
601
APPENDIX - A
List of Drawings
T clamps for
Twin Zebra ACSR run and single Zebra ACSR tap
Zebra ACSR run and Zebra ACSR tap
Parallel Groove (PG) Clamps for ;
Zebra ACSR and Zebra ACSR
Zebra ACSR and Panther ACSR
Post Insulator (PI) Clamps for ;
Single Zebra ACSR
Twin Zebra ACSR
Rigid Type Spacers for ;
Twin Zebra ACSR
602
603
604
605
606
607
608
609
610
611
SCHEDULE I (A)
DESCRIPTION OF MATERIAL FOR SCHEDULE OF RATES AND PRICES TO
BE FURNISHED IN VOLUME VI
S.No.
1
Particulars
T clamps for
Twin Zebra ACSR run and single Zebra ACSR tap
Zebra ACSR run and Zebra ACSR tap
Parallel Groove (PG) Clamps for ;
Zebra ACSR and Zebra ACSR
Zebra ACSR and Panther ACSR
Post Insulator (PI) Clamps for ;
Single Zebra ACSR
Twin Zebra ACSR
Rigid Type Spacers for ;
Twin Zebra ACSR
Qty.
As per Price
Schedule
Note :
1.
The above description of material is given for the purpose of offering the prices
and to mention description of material in Invoice for claiming payment.
2.
The quantity of above material has been mentioned in Volume-VI.
612
2.5.5 TECHNICAL SPECIFICATIONS FOR SUBSTATION TYPE HARDWARE

1.0
SCOPE:
The scope of this bid covers design, manufacturing supply of material as per VolumeII, Part-2, Book-I. The bidder mentioned in the Section of Technical Bid means Original
In case bidder is not OEM, sole responsibility of offering material of manufacturer as
per this bid requirement shall rest on the bidder.
2.0
STANDARDS:
Applicable standards for offered material shall be as per Volume-II, Part-2, Book-I.
3.0
4.0
SYSTEM PARTICULARS:
Applicable system particulars shall be as per Volume-II, Part-2, Book-I.
5.0
BALL AND SOCKET DIMENSIONS:
The Ball and Socket for Hardware fittings shall necessarily conform to the dimensions
as stipulated in the Indian Standards. The Ball and Socket dimensions of the Hardware sets to
be used with 7000 kg and 9100 kg Electro Mechanical strength Disc Insulators shall conform to
designation 16mm/16mm-B in accordance with IS:2486(Part-II) or equivalent International
Standard. The Ball and Socket dimension of Hardware to be used with 11500 Kg & 16,500 kg
Electro Mechanical strength disc insulator shall conform to designation 20mm in accordance
with IS-2486:(Part-II) or equivalent International Standard. The Bidder shall offer full detail of
locking device in accordance with IS 2486:(Part-III) or equivalent International Standard along
with test reports, gauges and adherence to Standards for Tests on Locking Devices in line with
IS:2486 (Part-IV) or equivalent International Standard.
6.0
REQUIRED
STRINGS:
GUARANTEED
STRENGTH
OF
HARDWARE
OF
INSULATOR
The Hardwares and Clamps of 132kV/220kV single suspension and double

suspension strings suitable for Panther ACSR and Zebra ACSR and all types of suspension
and tension strings suitable for sub-station shall have the ultimate breaking strength of not
less than 7,000 kgs.
The slipping strength of the suspension clamp shall not be less than 15% and more
than 20% of the Conductor strength with which it is to be used.
613
Substation Hardware

The Hardware and Compression Clamp of single and double tension strings suitable
for Panther ACSR shall have ultimate breaking strength of not less than 9,100 kgs. The
slipping strength of Compression Clamp shall not be less than 95% of the ultimate breaking
strength of Panther ACSR.
Each individual Hardware component of double suspension and double tension strings
such as ball-clevis, socket clevis etc. shall have minimum breaking strength as specified for
respective single suspension and tension string respectively.
7.0
PARTICULARS OF HARDWARE FITTINGS:
Each Hardware fitting for the substation shall be complete in all respect and Bidder
should furnish complete drawings and technical particulars of the items quoted. The
Hardware fittings should normally comprise items conforming to enclosed drawing as under: 7.1
Single Suspension Hardware Fittings For Zebra/Twin-Zebra for Sub Station:
The 132/220kV sub stations Hardware fittings shall comprise of one Ball Hook, one
Socket Clevis Eye Horn holder, one Arcing Horn and one Suspension Clamp for respective
size of Conductors
7.2
Single Tension Hardware For Twin ACSR Zebra for substation:
Single Tension Hardware shall comprise of U Clevis, one Ball Link, Socket Clevis,
Yoke Plate, two Clevis Eyes and two Tension Clamps of bolted type suitable for ACSR Zebra.
The minimum breaking and slipping strength of single tension Hardware fitting for twin
Conductor shall not be less than 7000 Kgs. One set of additional nuts (as check nuts) should
be provided alongwith the bolts and nuts to fix the tension clamp with the conductor so as to
avoid the possibility of relative/looseness due to vibration of strings.
7.3
Single Tension Hardware for Panther/Zebra/Twin Zebra for substation:
The Single Tension Hardware shall comprise of one Anchor Shackle, one Ball link,
Socket Clevis and one Tension Clamps of bolted type suitable for respective sizes of
Conductor. The minimum breaking and slipping strength of single tension Hardware fitting
shall not be less than 7000 kgs. One set of additional nuts (as check nuts) should be provided
alongwith the bolts and nuts to fix the tension clamp with the conductor so as to avoid the
possibility of relative/looseness due to vibration of strings.
7.4
GROUNDWIRE ASSEMBLIES:
The Ground wire tension assembly shall have minimum breaking strength equal to
that of the Ground Wire. The slipping strength of the Compression Clamp shall not be less
than 95% of the breaking strength of Ground Wire. The Ground wire tension assemblies for
Sub-Stations shall be as under: The Ground wire tension assembly for Substation shall comprise of one bolted type
Clamp and one `D Shackle complete with minor accessories such as bolts, nuts pins etc. The
614
Substation Hardware

assembly shall be hot dip galvanized and made inherently resistant to the atmosphere
corrosion. The design of the bolted type clamp shall be strictly as per sketch shown in the
enclosed drawing.
8.0
DETAILS OF COMPONENTS OF HARDWARE FITTINGS:
8.1.
Socket Eye & Ball Clevis:

The Socket Eye and Ball Clevis be made of forged steel as per the drawing enclosed.
8.2.
U Clevis:
These shall be made of forged steel complete with galvanised steel rivets washer and
Phosphorus Bronze/Stainless Steel pins.
8.3.
Ball Fittings:
These shall be made of forged steel in one piece. They shall be normalized to achieve
the minimum breaking strength specified in the respective drawings. Before galvanising of
ball fittings, all die fleshing on the shank and on the bearing surface of the ball shall be
carefully removed without reducing the dimension below the requirements. The dimension of
the ball & socket shall be 16mm/20mm designation in accordance with standard dimensions
stated in IS:2486 (Part-II).
8.4.
Dimensions & Tolerances:
8.4.1. The dimensions and tolerances of pin balls and socket ends shall conform to IS 2486
Part-II/IEC-120 and shall be checked by the gauge therein after galvanizing.
8.4.2. The pin balls shall be checked with the applicable GO gauges in at least two
directions, one of which shall be across the line of die flashing and the other 90 deg. to
this line. NO GO gauges shall not pass in any direction.
8.4.3. The bearing surfaces of balls and machined sockets, before galvanizing shall not have
surface roughness more than 250 micro inches.
8.4.4. The bearing surface of socket ends shall be uniform about the entire circumference
without depressions or high spots. The internal contour of the socket ends shall be
concentric with the axis of fittings. The axis of the bearing surface of socket ends shall
be coaxial with the axis of fittings with no appreciable tilting.
8.5.
Socket Fittings:
Socket fittings shall be made of clause IV steel as per IS:2004 or steel of equivalent
grade and shall be forged in one piece. They shall be normalized to achieve the
minimum breaking strength specified on the respective drawings.
8.6.
Security clip for Socket fittings:
8.6.1. Socket fittings shall be provided with R-shaped security clip in accordance with IS:2486
(Part-III) to provide positive locking against unintentional disengagement of socket from
the ball of the insulator. The security clip shall be humped to maintain the clip in the
locked position and shall have both prongs spread to prevent complete withdrawal from
615
Substation Hardware

the socket. The clip end shall not project outside the recess of socket when the clip is in
locked position.
8.6.2. The hole for the security clip shall be on the side of the socket opposite to the socket
opening. The hole for the clip shall be counter sunk. The clip eye shall be of such
design that the same may be engaged by a hotline clip puller to provide for
disengagement under energized conditions.
8.6.3. The force required to pull the clip to its unlocked position shall not be less than 50 N or
more than 500N.
8.6.4. The security clip shall be made of stainless steel of type AISI 302 or 304 or phosphor
bronze as per IS:7814.
8.7.
Clevis-Eye:
These shall be forged steel of malleable cast iron and shall be complete with
galvanised pin with flat washer and split pin of Phosphorus Bronze/Stainless Steel.
8.8.
Yoke Plate:
8.8.1. The yoke plates/link plate shall be made of mild steel plate as per IS:226 or equivalent
standards. Shearing/cutting of the plates shall be clean without drawn or ragged edges.
If the plates are flame cut, mechanical guides shall be used. It shall be ensured that the
grain flow of the yoke plate shall be in the direction of the tensile load.
8.8.2. Holes shall be cylindrical clean cut and perpendicular to the plane of the material. The
periphery of the holes shall be free from burrs.
8.8.3. All the corners and edges should be rounded off with a radius of at least 3mm.
8.8.4. Design calculation is for bearing and tensile strength for deciding the dimensions of
yoke plate shall be furnished by the bidder. The holes provided for bolts in the yoke
plate should satisfy shear edge condition as per IS:800.
8.9.
Corona Control Ring :-
8.9.1. The corona control ring shall be provided with hardware fittings and shall be of such
design that it should cover at-least one disc insulator in insulator strings so that they will
reduce the voltage across the insulator units. It shall also improve corona and radio
interference performance of the complete insulator string alongwith hardware fittings.
8.9.2. The corona control rings shall conform to the specification drawings. The same shall be
made of aluminium alloy tube of minimum 2.5mm wall thickness of type 6063 or
equivalent. The same shall be heat treated to maintain consistency in material
properties during service.
8.9.3. Welding of corona control ring shall be done with Argon welding. The welded locations
shall be suitably grinded and shall not allow penetration of water inside the tube during
service. The mechanical strength of welded joint shall not be less than 20kN.
8.9.4. The corona control ring shall be buffed and have a brushed satin finish. No blemish
shall be seen or felt while rubbing a hand over the surface.
9.0
IMPORTANT CONDITIONS:
9.1
All Hardware items shall be complete with minor items such as security clip, bolts,
nuts, washer, split pins and inners etc.
616
Substation Hardware

9.2
9.3
9.4
Enclosed drawings show the attachment proposed to be fitted on the towers. The
Bidder shall be responsible for satisfying him that the Insulator fittings offered are
entirely suitable for the proposed attachments and for the sizes of the Conductor.
All ferrous fittings (except those specified otherwise) shall be hot dip galvanized, after
all machining and fitting has been completed, in accordance with relevant Indian
Standard. All Hardware items (other than clamps) and those specified otherwise
should be made of Drop Forged Steel. Socket items in forged steel must be forged. All
forgings supplied should be stress relieved and this treatment should be done at the
Bidder works. Forgings, which are not stress relieved, will not be acceptable. The
items like Yoke Plate, Arcing Horn, Bolts and Nuts shall be of mild steel and rest of the
items shall be of forged steel.
All Bolts, Nuts and Screw heads shall have only wide worth standard thread and of
sizes indicated in the enclosed drawing. Bolts head and Nuts shall be hexagonal.
Where required, nuts shall be locked in approved manner. The thread in Nuts shall be
over tapped after galvanizing and shall be cut before galvanizing. The threads shall not
be under cut. The Nuts should be tapped such that they are fit on the bolt threads i.e.
these should not have loose fitting.
10.0
LENGTH OF STRINGS:
10.1
The clearance to the tower steel parts under service conditions of Insulator have been
decided on the basis that the overall length of 9 Disc for 132kV line and 13 Disc for
220kV line (both of 7000 kgs EMS for single suspension string) will not exceed the
length as indicated in the attached drawings. The dimension of the Disc for Ball and
Socket type will be 255mm x145mm for 7000 kgs EMS to be used with suspension
strings on 132kV/220kV lines.
In case of 132kV tension strings, 10 Disc insulators of 9100 kg EMS of size 255mm
(dia) x 145mm (height) will be used. In case of 220kV tension strings, 14 Disc
insulators of 16,500 kgs EMS of size 280mm (dia) x 170mm (height) will be used.
In case of 400kV tension strings, 24 Disc insulators of 16500 kg EMS of size 280mm
(dia) x 170mm (height) will be used.
10.2
10.3
11.0
GALVANISING:
11.1
Hot dip galvanizing shall conform to Indian Standard specification IS-2633 or

equivalent International Standard. Galvanising shall be uniform, free from blisters, and
shall not peel off due to abrasion, Zinc coating shall be thick enough to withstand 6
one minute dips in Copper Sulphate solution (precee test) for all ferrous parts except
for threaded portions which shall withstand at least 4 one minute dips.
11.2
The Bidder must emboss/engrave their name in each forged steel item and Aluminium
castings such as Ball Hook, Yoke Plate, Socket Clevis, Clevis Eye, Clevis-Clevis,
Anchor Shackle/D-Shackle, Chain Link, Suspension Clamps of AGS type, Tension
Clamps and Arcing Horns. This is very essential. If the Bidder will not agree with this
condition, their offer will be treated as non-responsive.
12.0
TESTS
The following Type Tests, Stage Tests, Routine Tests and Acceptance Test shall be
carried out on power Conductor & Ground wire Hardware fittings.
617
Substation Hardware

12.1
Type Tests
The material offered shall be fully Type Tested as per this specification and the Bidder
shall furnish four sets of Type Test reports along with the offer. These tests must not have
been conducted earlier than five years. For any change in the design/type already Type
Tested and the design/type offered against this specification, the purchaser reserves the
Rights to demand repetition of test without any extra cost.
12.2
Stage Tests:
Stage Tests during manufacturing shall mean those test required to be carried out
during the process of manufacturing to ensure quality control such that last product is of the
designed quality conforming to the intent of this specification.
12.3
Routine Tests:
Routine Tests are those tests, which required to be carried out on each and every
finished product so as to check with requirements that are likely to vary during production.
12.4
Acceptance Tests:
Acceptance Tests shall mean those tests, which required to be carried out on
samples taken from each lot offered for pre-despatch inspection for purposes of acceptance
of that lot.
12.5
Test Values:
For all type and acceptance tests, the acceptance values shall be the value
guaranteed by the Bidder in the guaranteed technical particulars or the acceptance value
specified in this specification, the relevant Indian Standard or equivalent International
Standard.
12.6
Test Procedures And Sampling Norms:
The norms and procedure of sampling for the above tests shall be as per the relevant
Indian Standard or other internationally accepted Standards. This will be discussed and
mutually agreed to between the successful Bidder and Purchaser before placement of order.
13.0
TYPE TESTS:
13.1
a.
On Suspension Hardware fittings only.

Magnetic power loss test for suspension assembly.
b.
Clamp slip strength for AGS clamp
c.
d.
Clamp slip strength VS torque test for suspension

clamp
Test on neoprene
e.
Ozone test.
f.
Heat resistance test.
618
As per
specification
Substation Hardware

13.2
a.
b.
c.
d.
13.4.
13.5.
13.6.
13.7.
On Tension Hardware Fittings only

Electrical resistance test for dead end assembly.
Heating cycle test for dead end assembly
Slip strength test for dead end assembly.
Mechanical strength test.
IS:2486(Part-I)
As per
specification
All the type tests given under clause no 13.1 above shall be conducted separately on
single/double suspension and tension insulator string alongwith hardware fittings.
The tests specified under clause no. 13.1 e & f. (i.e. the voltage distribution test and
corona/RIV Dry test) shall also be conducted on single suspension pilot double
suspension and single tension insulator string alongwith hardware fittings.
The mechanical strength test given under clause no. 13.1 (g) above shall also be
conducted on single suspension pilot, double suspension and single tension insulator
string alongwith hardware fittings.
The magnetic power loss test specified under 13.2 (a) shall be conducted on single
suspension, single suspension pilot and double suspension assembly.
14.0 ACCEPTANCE TEST / SAMPLE TESTS:

14.1. On both suspension and tension hardware fittings:
a. Visual Examination
b. Verification of dimensions
c. Galvanising test/Electroplating
d. Mechanical strength test of welded joint
e. Mechanical strength test for corona control rings.
f. Test on locking devices for ball & socket coupling.
g. Mechanical strength test of each components
excluding corona control ring and arcing horn.
14.2. On suspension Hardware fittings only:
a. Clamp slip strength vs torque test for suspension
clamp.
b. Shore hardness test of elastomer cushion for AG
suspension clamp.
c. Bend test for armour rod set.
d. Re silence test for armour rods set.
e. Conductivity test for armour rods set
14.3. On tension hardware fittings only
a. Slip strength test for dead end assembly
14.4 Suspension hardware for groundwire.
i. Visual examination
ii. Dimensional verification.
iii. Slip strength test.
iv. Mechanical strength test on each component
v. Galvanising test
vi. Mechanical strength test of welded joint
14.5 Tension hardware for groundwire
i Visual examination
619
IS:2486 (Part-I)
IS:2486 (Part-I)
As per this specification.
BS:3288(Part-I)
IEC:372(2)
IS:2121 (Part-I)
IS:2486 (Part-I)
Substation Hardware

ii
iii
iv
14.6
i.
ii.
iii.
Dimensional verification.
Slip strength test.
Electrical resistance test.
Test during manufacture.
On all components as applicable.
Chemical analysis of zinc used for galvanizing
Chemical analysis, hardness test grain size inclusion
rating and magnetic particle inspection for
forgoing/castings.
iv. Chemical analysis and proof load test fabricated
hardware.
v. Tests on malleable castings forgings and fabricated
hardwares.
15.0
The detailed drawings of each component assembly drawings and descriptive literature
of the Hardware assembly shall be submitted along with their offer. The detailed dimension
drawings for each and all-individual Hardware items such as clamps, U Clevis, Socket Eye,
Yoke Plate and Socket Clevis etc. shall also be submitted separately. Test certificates for
different tests conducted as per relevant ISS, for all the offered items must also be submitted
essentially. The offer of such bidders who do not submit the drawings as per requirement may
be treated as rejected.
16.0
MATERIALS AND WORKMANSHIP:
16.1.
All the materials shall be of the latest design and conform to the best modern practice
adopted in the extra high voltage field. The Bidder shall offer only such equipment as
guaranteed by him to be satisfactory and suitable for 400/220/132kV Sub-stations.
The design, manufacturing process and quality control of all the materials shall be
such as to give maximum factor of safety, maximum possible working load, highest
mobility, elimination of sharp edges and corners, best resistance to corrosion and a
good finish.
All ferrous parts shall be hot dip galvanised, after all machining has been completed.
Nuts may, however, be tapped (threaded) after galvanising and the threads oiled.
Spring washers shall be electro galvanised. The bolts threads shall be under cut to
take care of increase in diameter due to galvanising. Galvanising shall be done in
accordance with IS:2629-1966 or equivalent International Standard and satisfy the
tests mentioned in IS:2633-1972 or equivalent International Standard. Fasteners shall
withstand four dips while spring washers shall be guaranteed to withstand at least six
dips each lasting one minute under the standard precee test for galvanising.
The Zinc coating shall be perfectly adhere, of uniform thickness, smooth, reasonably
bright, continuous and free from imperfections such as flux, ash, rust stains, bulky
while deposits and blisters. The Zinc used for galvanising shall be grade Zn. 99.95 as
per IS: 209-1966 or equivalent International Standard.
In case of castings, the same shall be free from all internal defects like shrinkage,
inclusion, blowholes, cracks etc.
All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum.
16.2.
16.3.
16.4.
16.5.
16.6.
620
Substation Hardware

16.7.
16.8.
16.9.
No item which would produce high electrical and mechanical stresses in normal
working shall have sharp ends or edges, abrasions or projections and shall not cause
any damage to the Conductor in any way during erection or during continuous
operation. The design of adjacent metal parts and mating surfaces shall be such as to
prevent corrosion of the contact surface and no maintain good electrical contact under
service conditions.
Particular care shall be taken during manufacturing and subsequent handling to
ensure smooth surface free from abrasion or dents.
The fasteners shall conform to the requirement of IS: 6639-1972 or equivalent
International Standard. All fasteners and clamps shall have locking arrangements to
guard against vibration loosening.
17.0
INSPECTION:
17.1.
Purchaser and its representatives shall at all times be entitled to have access to the
works and to all places of manufacturing and the successful Bidder/Supplier shall
afford all facilities to them for unrestricted inspection of the works, inspection of
material, inspection of manufacturing process and for conducting necessary tests as
specified herein.
starting and progress of manufacturing of material in its various stages so that
arrangements could be made for inspection.
No material shall be despatched from its point of manufacturing unless the material
The acceptance of any quantity of material shall in no way relieve the successful
Bidder of his responsibility for meeting all the requirement of this specification and
shall not prevent subsequent rejection, if such materials are later found to be defective.
17.2.
17.3.
17.4.
18.0
IDENTIFICATION MARKING:
The main component of the material covered in the specification shall be legibly and
indelibly marked with the trademark of the manufacturer, the month and year of manufacture,
the guaranteed combined mechanical and electrical strength in kilo-Newton abbreviated by
kN to facilitate easy identification and proper use. Marks shall be forged or stamped with a
steel die before Galvanizing. The marks shall be distinct, durable and conspicuous.
Embossing/Engraving should be done at the time of manufacturing process itself, but before
Galvanizing. Smaller component like bolts & nuts, split pin and washers etc. may be excluded
from this requirement.
19.0
19.1.
i.
The Bidder hereunder shall invariably furnish following information along with his offer.
Statement giving list of important raw materials, names of sub-suppliers for the raw
material, list of Standards according to which the raw material are tested, list of tests,
normally carried out on raw material in presence of Suppliers representative, copies
of test certificates.
Information and copies of test certificates as in (i) above in respect of bought out
items.
Level of automation achieved and lists of areas where manual processing exists.
ii.
iii.
iv.
621
Substation Hardware

v.
List of areas in manufacturing process, where stage inspections are normally carried
out in quality control and details of such test and inspections.
vi.
Special features provided in the offered material to make it maintenance free.
vii.
List of testing equipment available with the bidder for final testing of the material
specified and test plant limitation, if any, vis--vis the type, special, acceptance and
routine tests specified in the relevant Standards. These limitations shall be very clearly
brought out in schedule of deviations from specified test requirements.
19.2. The successful bidder shall within 30 days of placement of order submit the following
(i) List of raw material as well as bought out accessories and the names of sub-suppliers
selected from those furnished along with the offer.
(ii) Type test certificates of the raw material and bought out accessories.
(iii) Quality Assurance Plan (QAP) with hold points for Purchasers inspection. The QAP
and Purchasers hold points shall be discussed between the Purchaser and the
Supplier before the QAP is finalized.
19.3. The successful bidder shall submit the routine test certificates of bought out items and
raw material at the time of routine testing of the material covered in the specification.
20.0
DOCUMENTATION & LIST OF DRAWINGS:
The bidder shall furnish full description, illustrated catalogues and dimensional
drawings, along with the bid. The drawing shall include the following information:
(i)
General outline & assembly drawings of all the items /material covered in the
specification.
(ii) Dimensions, unit spacings
(iii) Unit mechanical and electrical characteristics as also for the complete assembly/set.
(iv) Weight of each component.
(v) Identification mark.
(vi) Material designation used for different components with reference to Standards.
(vii) Fabrication details such as welds, finishes and coatings
(viii) Manufacturers catalogue number.
(ix) Brief installation instructions.
(x) Reference of type testing.
(xi) Relevant technical details of significance.
622
Substation Hardware
APPENDIX-A1
TECHNICAL PARTICULARS OF CONDUCTOR AND GROUNDWIRE FOR
220/132kV SUBSTATIONS
The Hardware fitting for 132/220kV S/s shall be suitable for the following sizes Conductors.
S.N
Particulars
Material
2
3
Size
Nominal Alu.area
Stranding and wire
diameter (no./mm)
Number of strands in
each layer.
Central core
1st layer
2nd layer
3rd layer
4th layer
Sectional area of
Alu.
Total sectional area
Appr. overall
diameter
Overall diameter
when wrapped with
preformed Armour
Rod
Approximate weight
6
7
8
9
10
11
Calculated D.C.
resistance at 20 C
12
Appr. Breaking Load
13
14
Co-efficient of Linear
Expansion
Final Modulus of
Elasticity
Panther ACSR
Zebra ACSR
Ground Wire
ACSR
ACSR
Steel
130 mm Cu Eq.
207 mm
30/3.00 Alu.+
7/3.00 steel
260 mm Cu Eq.
419 mm
54/3.18 Alu.+
7/3.18 steel.
--7/3.66mm.
1 of steel
6 of steel
12 of Alu.
18 of Alu
---
1 of steel
6 of steel
12 of Alu.
18 of Alu.
24 of Alu.
212.10 mm
428.90 mm
--
261.60 mm
484.50 mm
--
21.00 mm
28.62 mm
10.98 mm
33.78 mm
44.36 mm
18.30 mm
976 Kg/ Km
1621 Kg/ Km
583Kg/ Km
0.139 Ohm/Km
0.0691 Ohm/Km
2.5 Ohm/Km
9127 Kgs.
13316 Kgs.
6972 Kgs
17.73 x 10
per C
-6
-6
19.35 x 10 per
C
0.686 X 106
0.787 X 106 kg/cm
kg/cm
623
1 of steel
6 of steel
11.5 x 10-6
per C
1.931X106
Kg/cm
Substation Hardware
APPENDIX A2
PRINCIPLE PARAMETERS FOR SUBSTATION TYPE HARDWARE
1.
PRINCIPAL PARAMETERS:
1.1.
Details of Hardware Fittings:
The Hardware fittings shall meet the technical requirement as per clause and also
general arrangement drawings of Hardware fittings attached herewith. Hardware fittings shall
be suitable for single/double suspension Insulator strings, single/double tension Insulator
strings. Each Hardware fitting shall be supplied complete in all respect and shall include all
components, which are required for making complete set.
1.2.
The hardware fittings for substation shall be suitable for ACSR Conductor and groundwire as per technical parameters indicated in Appendix-A1.
2.
INSULATOR STRING CHARACTERISTICS:
2.1
The complete insulator string including Hardware fittings shall have the following
characteristics.
S.
Characteristics
Single/ Double
Single/ Double
No.
Tension
Tension
132kV
220kV
132kV
220kV
1
No. of Standard Discs
1x13
2x13
1x9
2x9
1x14
2x14
1x10
2x10
Nominal diameter of discs
255
255
280
255
Power frequency withstand voltage

(wet) kV (rms)
460
280
490
300
Lighting impulse withstand voltage

(dry)(kVp)
1200
800
1200
800
Switching surge Withstand

voltage (Dry & wet) (kVp)
900
350
900
350
Mechanical failing Load (kgf)
7000/
14000
Pollution
16500/
9000/
33000
18000
Moderatel
y polluted
No deformation load (kgf)
Corona Extinction voltage (KV rms)
7000/
14000
Moderate
ly
polluted
4690/
9380
176
4690/
9380
-
11055/
22110
176
624
6030/
12060
-
Substation Hardware

APPENDIX A3
DRAWINGS
S. No.
Description
For 220 KV Tension fittings with Twin Moose Hardware
For 220 KV Single Tension fittings with Single Moose Hardware
For 220 KV Susp. fittings with Twin Moose with through clamp
(300 mm)
For 220 KV Susp. fittings with Twin Moose with drop clamp
(300 mm)
For 220 KV Susp. fittings with Single Moose
For 132/220 KV Substation type of Hardwares
For 220 KV Bolted type tension assembly for Earthwire
625
Substation Hardware
626
Substation Hardware
627
Substation Hardware
628
Substation Hardware
629
Substation Hardware
630
Substation Hardware
631
Substation Hardware
632
Substation Hardware

SCHEDULE I (A)
Substation Hardware
1
Single Susp. with single Zebra hardware
Single Susp. with Twin Zebra hardware
Single Tension with single Zebra hardware
Single Tension with twin Zebra hardware
Single Tension with single Panther hardware
Quantity
As Price Schedule
S. No.
NOTE: 1. The above description of the equipment is given for the purpose of offering
payment.
633
Substation Hardware
2.6 TECHNICAL SPECIFICATION OF 10 KL OIL STORAGE TANKS

1.0

Fiber Glass Oil Storage Tank as per Volume-II, Part-2, Book-I. The bidder
bidder.
1.2
STANDARDS Applicable standards for offered equipment / material shall be as per Volume-II,
Part-2, Book-I
1.3
CLIMATIC CONDITIONS
1.4
2.0
3.0
DESIGN & CONSTRUCTION OF FRP TANKS HAVING CAPACITY 10KL

2.1
FRP tanks shall be corrosion-resistant to the specified tank contents and

shall be suitable for the intended service life. FRP tanks shall have roofs
capable of withstanding an external uniformly distributed loading of 50
pounds per square foot. Flat-top tanks to have a maximum 25 pounds per
square foot. Additional loads from mixers, pumps, or catwalks shall be
supported externally from the tank.
2.2
Dimensional Requirements-Cylindrical Vessels and Tanks: Diameters shall

be measured internally. Tolerance on nominal diameter including out-ofroundness shall be plus or minus 1 percent. Measurements shall be taken
with the tank in the vertical position. Taper shall not exceed 0.25 percent
per side. The minimum knuckle radius on formed heads shall be 1-1/2
inches unless noted otherwise on the attached data sheets.
2.3
All FRP tanks shall be designed for outdoor service with direct sunlight
exposure. Tanks shall be designed to meet pressure, loading or seismic
criteria using strengthening ribs, unless otherwise indicated on the data
sheets. Where no strengthening ribs are specified, loads shall be
distributed over a uniform side shell thickness.
MATERIALS
Material of Construction :
- 634 -
Oil Storage Tank

Shell, Top, Bottom
Nozzle Neck
Nozzle Flange
Manhole Neck
Manhole Flange/Cover
Gasket
FRP
Lifting Lug
FRP
Stiffening Ring
FRP
Saddles
FRP
Barrier Plate
FRP
FRP
NEOPRENE RUBBER
Ms Painted
Is Flate 100 X 6
A. Resin:
1.
2.
3.
4.
5.
The equipment shall be fabricated using the corrosion-resistant resin

specified below. Unless otherwise specified, the resin shall be used
throughout all laminates
Catalyst/promoter/accelerators shall be commercial grade cobalt
napthenate with dimethyl aniline, benzoyl peroxide, and methyl ethyl ketone
peroxide appropriate to the resin blend, enforcement and manufacturers
equipment. Positive measurement control of catalysts, promoters, and
resins shall be maintained at all times.
No fillers, additives, or pigments shall be employed in the resin, except as
specified below. A thixotropic agent for viscosity control may be used as
recommended by the resin manufacturer. No thixotropic agent is to be used
in the corrosion liner or on surfaces to be in contact with the corrosive
environment. Use of this additive is subject to the approval of the
Contractor.
Resin putty shall be made using the same resin as was used in the
component laminates. Resin putty shall contain a minimum 15 percent by
weight of milled glass fibers. The use of silica flour, grinding dust or other
fillers is not allowed.
Resin: acceptable commercial-grade vinyl-ester resins, including Co-Rezyn
8300, Derakane 411, and Hetron 922. The manufacturer shall confirm the
recommended resin and corrosion barrier is appropriate for the specified
contents. All corrosion barrier surfaces must be fabricated from the same
resin blend.
B. Reinforcement:
1. All glass fiber reinforcing shall have epoxy compatible with silane-type
surface finish and binder that is recommended by the glass manufacturer for
the particular resin system to be used.
2. Surfacing veils on interior surfaces shall be 10-mil Nexus veil or Type Cglass veil as specified on the tank data sheets.
3. Surfacing veil used on the tank exterior (if requested) surfaces shall be 10mil Type C-glass veil.
4. Mat shall be type E glass, 1 ounces or ounce per square foot as
specified in the laminate sequence charts with nominal fiber length of 1.25
plus or minus 0.75 inch.
5. Continuous roving used in chopper gun for spray up shall be Type E glass.
6. Woven roving shall be Type E glass, nominal 24 ounces per square yard, 4
by 5 weave with silane-type finish.
7. Continuous roving used for filament winding shall be Type E glass with a
silane-type finish with a nominal yield of 110 yards or more per pound.
C. The final exterior coat shall be pigmented to form a uniform color coat. The
pigment shall be dispersed in the resin used for the final coat. Tanks shall have
- 635 -
Oil Storage tank

a UV inhibitor added to the final exterior resin coat.
submitted with bid request.
3.1
Tank colors will be
10 KL tanks should have following dimensions.

Sr.No. Capacity Length
Width
Height (Estimated)
1
10 KL
4000 mm 1750 mm
1500 mm
3.1.1
4.0
Dimensions and othjer arrangements for 10 KL capacity storage tank are

indicated in drawing no. 1. The length and width of the tank as indicated
above are not to be modified since any increase in the dimensions may
create transportation problems. Tenderers may slightly modify the height
of tank and justify the capacity by calculations.
3.2
All nuts and bolts shall be of hexagonal head and hot dip galvanized
chromium plated confirming to IS : 1367 latest revision.
3.3
Oil storage tanks shall be in accordance with the requirements specified in

the existing rules of Inspector of Explosives, Govt. of India.
3.4
Tenderers shall supply the tanks complete with all pipings, bolts, gaskets
and other accessories as indicated in enclosed drawing no. 1 & 2
ACCESSORIES :
The following accessories are required to be provided on the oil storage tanks as
indicated in the enclosed drawing No. 1 & 2. The basic offered cost must take un to
consideration cost of all he accessories, otherwise the offer will be rejected . It may
please be ensured that all the fittings and accessories offered shall be of reputed
make, which shall be to our approval.
4.1
Manhole :
Each storage tank shall be provided with a man hole of size 750mm x
750mm on top of the tank as indicated in drawings. Suitable air tight cover
with proper sealing arrangement shall be provided ensuring that oil has no
accessibility to atmospheric air. Suitable handles for lifting the cover shall
be provided. The gasket for man hole should be of best quality neoprene
material. Two spare gaskets with each tank will have to be supplied.
4.2
Silica gel Breather :

Each storage tank shall be provided with detachable Silica gel breather
having charge capacity of 2 Kg. The container of breather should be of
suitable metal with transparent window all along the periphery. It may
please be noted that plastic container for silicagel shall not be acceptable.
4.3
Valves :
Each storage tank shall be provided with following valves at various
locations as indicated in the drawing. All valves shall be made of gun metal
and wheel type (flanged) only. This requirement has to be confirmed by the
tenderers without any deviation. All valves shall have position indicator
indicating the status i.e., valves are in open or shut position.
5.3.1. Sampling Valve :
Two Nos. 15mm dia valves for taking oil sample shall be provided
one on top and other at the bottom.
- 636 -
Oil Storage tank
5.3.2. Filter Valve :

Four nos. 50 mm dia valves suitable for connecting 38mm internal
dia hose pipe shall be provided two no. each on the top and bottom
location but on diagonally opposite sides to enable cross current
circulation of oil using two filter machines.
5.3.3. Drain Valve :
At the bottom of the tank, two nos. 50mm dia valves with a plug shall
be provided for draining of the oil.
4.4
Oil Level Indicator :

A plain oil level indicator shall be provided on either side of the tank. The
indicator shall be of flush mounting type, to cover the entire height. The
arrangement should be such that the indicator does not get damaged
during handling and transportation. Oil level indicator is shown in three
pieces in the drawing. Any other suitable arrangement shall also be
accepted.
4.5
Lifting Lugs :
Four number suitable lugs (two nos. on each side) shall be provided for
lifting the complete tank without any damage or distortions .
4.6
Hoses :
4.6.1 High temperature resistant hoses made of best quality neoprene
materials with wire reinforcements are to be supplied with oil
storage tanks of each capacity covered in this specification . Two
lengths, each of 20 meters, shall be supplied with each tank.
Internal diameter of hoses shall be 38mm. The offered prices of 10
KL tanks therefore should take in to account the cost of two length
of 20 meters hose pipes.
4.6.2
These hoses shall be suitable for circulation of oil to be used in

transformers with temperature as high as 100oC . The hoses
should be suitable for suction cum pressure for very high degree
of vacuum, almost absolute vacuum and pressure. It should be
ensured that material used does not contaminate the transformer
oil passing through it.
4.6.3
The pipe flange arrangements shall be suitable to match the

arrangement provided by tenderers in storage tank for inlet/outlet
of transformer oil. The tenderers shall submit a sample of the hose
(about 0.5m length) pipe offered by them, alongwith the tender.
7.0
TESTS & TEST CERTIFICATES FOR FIBER OIL STORAGE TANK
7.1
TYPE TESTS
The tank offered shall be fully type tested as per IS 10661-1983 or any
equivalent acceptable International Standard & technical specification. In case the Oil
Storage Tanks offered are as per MPPTCLs technical specifications and are already type
tested in an independent test laboratory, the Tenderer shall furnish one set of tests
reports along with the offer. These tests must not have been conducted earlier than five
- 637 -
Oil Storage tank

years from the date of opening of Bids. MPPTCL reserves the right to demand repetition
of some or all the type tests in the presence of owners representative. For this purpose,
the Tenderer may quote unit rates for carrying out each type test. These prices shall be
taken in to consideration for bid evaluation.
7.2
ROUTINE TESTS
Before despatch each of tank shall be subjected to the routine tests at the
manufacturers works in accordance with the details specified in relevant IS Or any
equivalent acceptable International Standards .
MPPTCL has all the rights to conduct the test including type tests, at its own
cost by an independent agency whenever there is a dispute regarding the quality of
supply or interpretation of test results.
8.0
9.0
INSPECTION :
i.
The MPPTCL shall have access at all times to the works and all other
places of manufacture, where the current transformers and potential
transformers are being manufactured and the Tenderer shall provide all
facilities for unrestricted inspection of the Tenderers works, raw
materials, manufacture of all the accessories and for conducting
necessary tests as detailed herein.
ii.
The successful Tenderer shall keep the MPPTCL informed in advance

of the time of starting and of the progress of manufacture of equipment
in its various stages, so that arrangements could be made for
inspection.
iii.

iv.
The acceptance of any quantity of the equipment shall in no way relieve

the successful Tenderer of his responsibility for meeting all the
rejection if such equipment are later found to be defective.
9.1
For the purpose of supply of above equipments, you will have to follow strict
quality assurance programme, which will include thorough verification of samples of
critical assemblies and accessories by us, verification of sources of raw materials,
detailed verification of your drawing & design, checking up of all calculations regarding
size of terminals, primary winding etc, stage inspection at various critical stages of
manufacture and minor modifications consequent to such stage inspections as per our
requirements and all other related requirements, which have generally been brought out
in bidding documents and the detailed contract. It is expected that you would be very
serious and prudent in meeting these requirements without any loss of time, so that
supply of equipments in line with quality assurance programme is ensured within
targeted schedule.
The MPPTCL reserves the right to specify various stages for stage
inspections and also for manufacture of a proto type unit for inspection & testing, before
according clearance for bulk manufacturing.
- 638 -
Oil Storage tank

9.2
The Tenderer must establish that they are following a proper quality
assurance programme for manufacture of current transformers and potential
transformers.
The Tenderer shall invariably furnish following information along with his bid.
i.

presence of Tenderers representative, copies of test certificates.
ii.

bought out items.
iii.
iv.

processing exists.
v.

inspection.
vi.
vii.
List of testing equipment available with the Tenderer for final testing of
equipment specified and test plant limitations, if any vis--vis type,
special, acceptance and routine tests specified in the relevant Indian
Standards or equivalent international standard. These limitations shall
be very clearly brought out in schedule of deviations from specified test
equipments.
9.3
The successful Tenderer shall within 30 days of placement of order, submit
following information to the MPPTCL.
i.
List of raw materials as well as bought out accessories and the names
of sub supplier selected from the lists furnished along with bid.
ii.
iii.
Quality Assurance Plan (QAP) with hold points for MPPTCLs

inspection. The quality assurance plans and holds points shall be
discussed between the MPPTCL and Tenderer before the QAP is
finalized.
9.4
The successful Tenderer shall submit the routine test certificates of bought
out items and for raw material at the time of routine testing of the fully assembled
equipment.
10.0
DOCUMENTATION :
10.1
All drawings shall conform to the latest version of international standards
organization (ISO) A series of drawing sheet/ Indian Standards Specification IS-11065.
All drawings shall be in ink and suitable for micro filming. All dimensions and data shall
be in S.I. Units.
10.2

The Tenderer shall furnish four sets of following details and drawings along
with his bid :-
- 639 -
Oil Storage tank

a.
b.
c.
d.
e.
f.
g.
General outline and assembly drawings of the Tank.

i)
ii)
Details of rupture type pressure relief device with diaphragm, specifying
size of diaphragm and it's thickness.
Name plate.
Schematic drawing.
tested.
material.
10.3 The successful Tenderer shall within two weeks of placement of order, submit
four sets of final versions of all the above drawings for MPPTCLs approval. The
MPPTCL shall communicate his comments/approval on the drawings to the Tenderer
within reasonable time. The Tenderer shall, if necessary, modify the drawings and
resubmit four copies of the modified drawings for MPPTCLs approval within two
weeks from the date of MPPTCLs comments. After receipt of MPPTCLs approval,
the Tenderer shall within three weeks submit 20 prints and two good quality
reproducible of the approved drawings for MPPTCLs use.
10.4
The Tenderer for distribution, before commencement of supply, shall submit
six sets of the type test reports, duly approved by the MPPTCL. Adequate copies of
acceptance and routine tests certificates, duly approved by the MPPTCL shall
accompany the dispatched consignment.
10.5
the MPPTCL. All manufacturing and fabrication work in connection with the equipment
prior to the approval of the drawing shall be at the Tenderers risk.
10.6
Twenty (20) copies of nicely printed and bound volumes of operation,
maintenance and erection manuals in English Language, for each type and rating of
equipment supplied shall be submitted by the Tenderer for distribution, prior to the
dispatch of the equipments. The manual shall contain all the drawings and information
required for erection, operation and maintenance of the equipments. The manual shall
also contain a set of all the approved drawings, type test reports etc.
10.7
Approval of drawings/ work by MPPTCL shall not relieve the Tenderer of his
revision of applicable standards, rules and codes of practices. The equipment shall
conform in all respects to high standards of engineering, design, workmanship and latest
revisions of relevant standards at the time of ordering and MPPTCL shall have the power
to reject any work or material, which in his judgment is not in full accordance therewith.
11.0
11.1
The equipment shall be packed in crates suitable for vertical/ horizontal
transport, as the case may be and suitable to withstand handling during transport and
outdoor storage during transit. The Tenderer shall be responsible for any damage during
transit, due to improper and inadequate packing and handling. The easily damageable
material shall be carefully packed and marked with the appropriate caution symbols.
Wherever necessary, proper arrangement for lifting, such as lifting hooks etc. shall be
- 640 -
Oil Storage tank

provided. Tenderer shall supply any material found short inside the packing cases
11.2
the following information.
a.
b.
c.
Destination
d.
e.
f.
11.3
The Tenderer shall ensure that the packing list and bill of material are
approved by the MPPTCL before dispatch.
- 641 -
Oil Storage tank
APPENDIXA
TECHNICAL REQUIREMENTS OF OIL STORAGE TANK
This schedule of guaranteed technical particulars for Oil Storage Tank is to be submitted
by the Tenderers. It may be carefully noted that filling/ reply of each and every clause
described below is a must.
S. No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Particulars
Design Standard
Design Pressure
Design Temperature
Service Fluid
Type of Service
Operating Pressure
Operating Temperature
Liquid Density
Hydro Test Pressure
Volume Full
Volume Operating
Type of Tank
Size
M.O.C
Equipment Name
Thickness In Mm
Dished Ends
Shell
Barrier Plate
Finishing-Inside
Finishing-Outside
Nozzles Standard
Nozzles Projection
Colour
Empty Weight (Approx.)
Manufacturing Process
Manufacturing Technique
Lamination Swquence
Inspection
Testing
Technical Requirement
British Standard 4994-1987
Atmospheric + Static Head
700c
Transformer Oil
Storage & Transportation
Atmospheric + Static Head
600c
0.83 To 0.89
Atm Static Head Only
10,000 Litre
11,235 Litre
Horizontal, Cylindrical With Dished Ends
1650 Mm Dia X 4200 Mm Long
FRP
Oil Transportation Tank
10 Mm
8 Mm
8 Mm
Mirror
Matt-D.A Grey Pigmented Colour
Ansi B 16.5 # Asa 150
150 Mm
D.A Grey (Pigmented)
Please Furnish
Hand Lay Up Process With Atmospheric Curing
Moulding Single Part Consolidation
Please Furnish
At Our Stire Prior To Despatch
A. Physical Dimensions
B. Thickness Testing
C. Hydrostatic Testing With Full Water For 48
Hrs.
- 642 -
Oil Storage tank
- 643 -
Oil Storage tank
SCHEDULE I (A)
DESCRIPTION OF MATERIAL FOR SCHEDULE OF RATES AND PRICES TO
BE FURNISHED IN VOLUME VI
S.No.
1.
Particulars
Qty
Fiber Glass Oil Storage Tank
Note :
1.
The above description of material is given for the purpose of offering the
prices and to mention description of material in Invoice for claiming
payment.
2.
The quantity of above material has been mentioned in Volume-VI.
- 644 -
Oil Storage tank
2.7
1.0
TECHNICAL SPECIFICATION FOR FIRE FIGHTING EQUIPMENTS
SCOPE:
Volume-II, Part-2, Book-I. The bidder mentioned in this Section of the Technical Bid means
Original Equipment Manufacturer (OEM). The purchaser means the MPPTCL.
2. Technical requirements:
2.1
The fire fighting equipments (extinguishers) of various types shall be provided for
electrical installation like outdoor switchyards, live electrical equipments, control room, lead
acid battery room, stores yards, building, etc. fire fighting equipments (extinguishers) of
various types shall be supplied in following quantities strictly conforming to Indian Standards
mentioned against each:
S.
No.
Description
Capacity of
each
extinguisher
Total nos.
required.
IS
reference
Carbon Di-oxide (Co2) type

trolley mounted
22.5 Kgs
336
IS:2878
Mechanical foam type

trolley mounted
50 Ltr.
358
IS:13386
75 Kgs.
180
IS:10658
395
IS:2546
Dry chemical powder

(DCP) type trolley
mounted
Set of fire buckets
comprising of 6 buckets of
10 Ltrs. capacity each with
stand
2.2
Carbon-di-oxide type fire extinguishers shall be designed for mainly extinguishing
class-B & C fire involving inflammable liquid, gaseous substances electrical & electronic
equipments, transformer & switchgear fires. Carbon-di-oxide type fire extinguisher and
accessories shall be as per IS-2878. The CO2 type 22.5 kg. capacity fire extinguisher shall
be mounted on detachable trolley having valve bearing fitted solid rubber wheels 300 x 15
mm. The body of the extinguishers shall be of seamless steel cylinder conforming to latest IS
:2878 or of such cylinders which are approved by the Chief Controller of Explosive, Govt. of
India, with Sl. No. & certificate, fitted with ISI mark discharge wheel valve complete with 5
mtr. Length high-pressure rayon braided discharge hose with cold insulated rubber handle
and horn. The hose pipe shall have bursting pressure of 275 kgf./cm.2. The discharge
horn shall be of material, which is non-conductor of electricity. The fire extinguisher shall be
painted in accordance with IS:536 :1961. The equipment shall be completed with first
charge of CO2 gas conforming to IS:307:1966.
2.3
Mechanical foam type fire extinguishers shall be used for class-A & B fires i.e.
fires in inflammable liquids. Foam type fire extinguishers and accessories shall be as per IS13386 (for 50 ltr. Capacity). The body of the 50 ltr. Capacity fire extinguisher shall be
fabricated from M.S. steel sheet not less than 1.25 mm in thickness. It shall be welded type
constructed and painted with zinc or lead tin alloy applied by hot dipping electrolytic process
645
Fire Fighting Equipments

to withstand internal or external corrosion. The neck ring nozzle and cap shall be mounted
on solid rubber wheel 300 x 15 mm for easy portability and shall be painted with Fire Red
confirming to shade No.536:of IS:2932.
2.4
Dry power type extinguishers shall be used for B & C class fires, especially for
combating three dimensional or running fires involving inflammable liquids like transformer
oil, paints, electrical wiring, live machinery solvents or industrial gases. They shall also be
used on energized equipments. Fire extinguishers and its accessories shall be as per IS
10658 (75 kg. capacity trolley mounted). Dry powder fire extinguisher 75 kg. capacity shall
be having constructional features as per IS:10658 1983. The body of this equipment shall
be fabricated from minimum 3.15 mm thick M.S. plate. The neck ring may also be made of
stainless tube. The construction of body shall be welded type and painted with zinc or lead
tin alloy applied by hot dipping or electrolytic process to withstand external & internal
corrosion. The CO2 gas filled cylinder (confirming to IS:7285 1974) shall be fitted
externally with easily detachable type clamps support. The discharge clamps support, the
discharge hose shall be fitted with not less than 50 kg.F/cm2 the nozzle shall be trigger
controlled. The pneumatic rubber connecting to CO2 gas cylinder and main tank shall
confirm to bursting pressure 275 kgf/cm2 the equipment shall be mounted on wheeled
carriage having ball bearing fitted solid rubber wheels 300 x 15 mm size. The first charge of
chemical powder confirming to IS : 4308 1982, shall be supplied separately complete
equipments shall be painted with FIRE RED confirming to shade No: 536 of IS : 1961.
2.5
Set of fire buckets comprising 6 no. buckets of capacity10 Ltrs. each with
stand. The Bucket shall be in conical shape having dome shaped bottom, made of 1mm
thick good quality MS galvanized sheet confirming to IS 2546. The Overall height of the
bucket should be 346mm (min).The diameter at top shall be 360mm (min) & at bottom shall
be 170mm (min).It shall have Main handle of 10m dia & bottom handle of 8mm. Main handle
to be free and to lie along the edge of bucket. The internal and external surfaces of the
bucket shall be free from defects, is certified to be not less than the calculated minimum wall
thickness plus additional allowance. Outer shall of each bucket shall be painted fire red or
post office red conforming to shade No.536 or 537 or IS 5 & inside of the bucket shall be
painted with white colour. Every bucket shall be marked FIRE with white paint. The
dimensions of stand shall be 1050 mm x 750 mm (Height), should be made from 35mm X
35mm X 5mm size angle made of mild steel. Stand shall also be painted fire red or post
office red conforming to shade No.536 or 537 or IS 5.Suitable hanging arrangement should
be there to hang 6 buckets.
2.6
Design and manufacture of all equipment shall conform to the highest engineering
standard to ensure safe and reliable operation. The items shall be suitable for the respective
design pressure, temperature and service conditions as stipulated elsewhere in this
specification.
2.7
The bidders shall offer the equipment strictly as per the specification laid down in this
bid document.
The bidder shall submit the detailed BIS license with endorsement for manufacture of
Aqueous film forming foam and dry chemical powder along with the bid.
2.8
First charge of chemicals in each extinguisher shall be provided.
charges shall be refilled after testing at site.
All chemical
2.9
Spanners and other accessories as required shall be supplied with each fire
extinguisher.
2.10 Nature and charging of chemical shall be in accordance with the respective Indian
Standard. The chemicals to be used with fire extinguishers should have test certificate
646

from Govt. approved laboratory. Wherever required a certificate from Chief Explosive
Deptt. Nagpur shall be submitted.
2.11 Bidders should invariably furnish a Notarized copy of their valid BIS license with all
the enclosures of the BIS license held by the Firm using IS/BIS mark, wherever applicable.
2.12 The successful Bidder wherever possible, will require to emboss / engrave the words
Property of MPPTCL along with the purchase order number on each extinguisher and
accessories. Also suppliers should emboss / engrave / affix their company name plate with
details or manufacturers name and trade mark.
2.13
The method of sampling and criteria for conformity shall be as per the relevant ISS.
2.14 The bidder shall have to demonstrate the equipments offered to us at his own cost at
Jabalpur as and when required by the purchaser. However, it would not be binding to the
purchaser to place the order on this basis.
2.15 If required, the technical committee of MPPTCL may visit factory premises to
conform the manufacturing facilities before issuing supply order.
2.16 In the event of placement of order, the successful bidder shall have to provide
demonstration for charging of chemicals, operation of equipments, their routine maintenance
and guidelines in that respect etc. at three places in M.P. namely Jabalpur, Bhopal & Indore.
3. Detailed Technical Specification for fire fighting equipments:
3.1
Fire extinguisher, carbon-di-oxide,(CO2) type, trolley mounted:

The extinguisher shall be of following capacities:
Trolley mounted :
a. Mild steel body
3.1.1
22.5 Kg.
Rating suitability:
The rating of extinguishers shall be based on the amount of extinguishing medium

used to extinguish the fire of maximum size under the condition of the test. This amount
shall not be less than the appropriate minimum value given below:
S/N
Nominal size/ CO2

content Kg.
Discharge time
Class B rating
Fire size/ fuel

heptanes.
22.5
20-60 s
20 B, C
20 m2 (20 l)
The capacity of the extinguisher shall be the mass of carbon-di-oxide when filled in
the container. The filling ratio will not be more than 0.667 0.033 percent. The carbon
dioxide gas shall conform to IS 15222. The extinguishers shall be cleaned internally and
shall be fitted with liquefied carbon dioxide to the filling ratio mentioned above. The quantity
shall be determined by weighing. The weight of extinguisher shall not be less than 10% of
the mass marked on it for fully charged extinguisher as per IS-2190.
3.1.2 Operating temperatures:
647

[Extinguishers shall be capable of operating reliably between the following
temperatures ranges:
- 30C
to
+ 55C
The temperature range shall be marked on the fire extinguishers.

3.1.3
Material :
The material for construction of various components is given below:
S. No.
Component
1
i
2
Discharge valve
ii
Safety device
iii
Syphon tube
iv
Hose
Discharge horn
Note:
Material
3
a) Brass
b) Copper
c) Aluminium
The minimum bursting
pressure shall be 275
kgf/ cm2
in control
discharge and 140 kgf/
cm2 without control
discharge.
Non-conductor
of
electricity
like
polyethylene, fibre-glass
and similar material.
Conforming to relevant
Indian Standard
4
IS 3224 (sequence grip
valve.
IS 5903
Alloy No.2 of IS 407
IS 1545
IS 738
1-
Safety device conforming to IS 5903 shall be in-built in discharge valve

conforming to IS 3224.
2- Carbon dioxide extinguisher with metal horn does not qualify the electrical fire
rating.
3.1.4. Constructions:
3.1.4.1 The extinguishers shall be in cylindrical shape having concave base. In case of steel
body it shall conform to IS 7285. In case of aluminium, containers shall be seamless. The
composition of material and the mechanical properties of the finished container shall be as
per IS 2878.
3.1.4.2
Manufacture:
3.1.4.2.1
Process of manufacture
The container shall be made:
a)
b)
c)
d)
By cold or hot extrusion from cast or extruded billets; or

By cold or hot extrusion followed by cold drawing from cast or
Extruded billets; or
By cupping and cold drawing sheet or plate: or
By necking at both ends extruded or cold drawn tube.
648
They shall be made only by a process that has been shown to produce containers
free from cracks or other flaws that could adversely affect the safety of the containers.
The ends shall be of an approved shape and shall be formed by forgoing, swaging,
or spinning. Ends shall not be welded on and metal shall not be added in the process of
closing.
3.1.4.2.2 Examination of the cylinders before closing in operation:
Each cylinder shall be examined before final closing in operation for external and
internal surface defects, finished thickness and circularity of the cylinder shell.
a.
Surface defects:
The internal and external surfaces of the cylinder shall be free from defects, which
might adversely affect the safe shoring of the cylinder. A cylinder which has a surface defect
greater than 5 percent of the shell thickness may have the defect ground out to the
satisfaction of the inspecting is checked before closing in operation and is certified to be not
less than the calculated minimum wall thickness plus additional allowance.
b.
Finished thickness:
The agreed finished thickness shall be not less than the minimum calculated wall
thickness obtained by the formula at any point and at any transverse section of the
cylindrical portion. If required by the purchaser, suitable allowance to cover corrosion,
manufacturing tolerances and stresses due to horizontal acceleration and retardation during
transportation may also be provided.
c.
Circularity:
The difference between the maximum and minimum external diameter measured at
any cross-section of the cylindrical portion of the cylinder shall not exceed 1 percent of the
nominal internal diameter.
d.
Mass:
The minimum and maximum mass of the cylinder shall be within the limits agreed
upon between the manufacturer and the purchaser, depending on size, type and required
thickness.
e.
Water capacity:
The water capacity of the cylinders shall be such that the nominal water capacity for
the permanent gases and minimum water capacity for liquefiable gases shall be obtained.
f.
Permissible pressure:
The test pressure on which the design of the extinguisher container is based shall be
not less than:
I/0.85 x the pressure developed by the gas at the reference temperature ( for
liquefiable gases).
3.1.4.2.3
Heat treatment:
649

Each container shall be heat treated at a temperature within the range 515C to
545C and water quenched and then artificially aged at a temperature selected within the
range 150C to 200C.
Minimum values of mechanical properties required in the finished container after heat
treatment and at room temperature shall be as given in Table 4 of IS-2778.
The operations involving heat treatment shall be carried out carefully in furnaces
equipped to control temperatures accurately, and the containers shall be maintained at the
stipulated temperatures for the length of time necessary to ensure that all parts have
reached the required temperature and all necessary metallurgical changes have been
effected.
3.1.4.3. Discharge valve or operating head:
The valve shall be provided and it shall be squeeze grip type or wheel type.
3.1.4.4
Discharge fittings:
i). The hose of not less than 10mm internal diameter shall be provided for 22.5 Kg.
capacity fire extinguishers. The length of the hose shall be not less than 5 m for 22.5 kg.
capacity fire extinguishers.
ii) A discharge horn with a suitable handle shall be provided.
3.1.4.5.
Trolley:
The details of trolley shall be as given in IS-2878. The dimensions of trolley shall be
300mm x 50mm x 25mm.
3.1.5
Anti-corrosive treatment:
The external surface of the body shall be completely coated with epoxy powder of
minimum 0.050 mm thickness. The thickness of the coating shall be measured as per the
procedure given in IS 3203.
3.1.6. Painting:
i) Each extinguisher shall be painted fire red or post office red conforming to shade
No.536 or 537 or IS 5.
ii) A picture showing operation of the extinguisher in the correct manner shall be
provided on the body of the extinguishers.
iii)
The extinguisher shall be marked with the letters B and C indicating their
suitability for respective classes of fires as laid down in IS 2190. The letters B and C shall be
of 2.5 cm size printed in white colour centrally contained in a square of 4 cm size and a circle
of 2 cm radius respectively and shall be coloured black.
iv)
3.1.7
3.1.7.1
The paint shall conform to IS 2932.

Performance requirements:
Discharge duration:
The design and construction of the extinguisher shall be such that when operated
at an angle of not more than 45C from the vertical at a temperature of 27 2C, it shall
650

expel not less than 95 percent of the contents in the form of a continuous discharge within
the following period from the time of operating the valve. The body shall be weighed 30mm
after the discharge period and shall be wiped and dried before checking the contents. The
minimum effective discharge time of extinguishers shall not be less than the appropriate
value given in clause 3.1.1.
Note: Extinguisher should be conditioned for 1 h before testing.
3.1.7.2 Intermittent operation:
An extinguisher shall be capable of being operated intermittently without freeze up of
the valve seat and causing any leak when conditioned at 27 2C. The valve shall be
opened for 3 s and closed for 10 s and the cycle shall be repeated and shall discharge at
least 95 percent of the contents.
3.1.7.3
Leakage test:
The extinguisher without its attachment shall be filled with CO2 gas to the specified
filling ratio and dipped in water for 2 min. and then check that no bubbles come out or soap
solution test for leakage be carried out.
3.1.7.4
Class B Test Fire:

It shall be in accordance with IS: 2878.
3.1.7.5 Special requirements:

The extinguisher horn shall be constructed to withstand crushing when 25 kg is
applied to its extremity for 5 min. immediately after having completely discharged the
extinguisher through the horn.
Subject the horn to the following test:
a.
b.
c.
d.
Condition the horn at 55C for 18 h.

Attach the horn to a fully charged extinguisher.
Discharge the extinguisher with the valve fully open.
Subject the horn to a static load of 25 kg using a circular contact surface of 50
mm diameter for 5 min. applied at the end of the horn; and
Check that the horn does not show any evidence of cracking or breakage.
e.
3.1.8
Marking :
3.1.8.1 Every extinguisher shall be clearly and permanently marked in accordance with the
requirements.
3.1.8.2 The following information shall be marked on the extinguisher:
a.
b.
c.
d.
Manufacturers name or trade mark.

Method of operation in prominent letters.
The words CARBON DIOXIDE TYPE in prominent letters.
Capacity.
e.
f.
Year of manufacture of extinguisher and date of refilling and

Source, year of manufacture of the cylinder and its test pressure.
651

3.1.8.3 The following information to facilitate filling or recharging shall also be marked on
the head of extinguisher or on the neck of the cylinder.
a.
Empty weight of extinguisher ( to include operating head, internal discharge tube
and carrying handle but not any hose or discharge horn assembly), shown as EW: and
b.
Filled weight of extinguisher (to include operating head, internal discharge tube,
carrying handle and gas-filled contents but not any hose or discharge horn assembly),
shown as FW.
3.1.8.4
BIS certification marking:

The extinguisher may also be marked with the Standard Mark.
The use of the Standard Mark is governed by the provisions of the Bureau of
Indian Standards Act 1986 and the Rules and Regulations made there under. The details of
conditions under which a license for the use of the Standard Mark may be granted to
manufactures or producers may be obtained from the Bureau of Indian Standards.
3.2. Fire Extinguisher, Mechanical foam type, Trolley mounted
(50 ltr. Capacity):
The total liquid capacity of the extinguishers when filled with the charge, i.e. foam
concentrate liquid and water up to the specified level shall be:
i.
50 0.5 ltr.
3.2.1 Material:
The material for construction of various parts of extinguishers shall be as given
below:
S.
Component
Material
Requirements, Relevant to
No.
IS
i
Body
Mild steel sheet
Any Grade of IS 513
a) Leaded tin bronze
IS 6913
b) Mild steel pipe
IS:1239 (Part I) : 1979
Cap
a) Leaded-tin-bronze
Grade LTB 2 of IS 318
iv
Cap washer
Rubber
Spring
Spring steel
a) Brass
Conforming
to
the
requirements of hardness as
applicable to type 3 of IS 538
and also acid and alkali
resistant.
Grade I of IS 4454 (Part-I)
Alloy No.2 of IS 407
vi
Syphon tube
b) HDPE
IS 4984
c) Mild steel
IS 3601
d) Copper
a) Leaded-tin-bronze
b) Brass
IS 1545
Grade 2 of IS 291 or Type 1
of IS 319
Annex B
ii
Neck ring
iii
vii
Discharge fittings
c) Plastic (for nozzle)

652

S.
No.
viii
Component
Material
ix
x
Foam
making a) Aluminium alloy
branch pipe
b) Leaded-tin-bronze
c) Plastic
Gas Cartridge
Hose
Braded rubber plastic
xi
Snifter valve
a) Brass
b) Stainless steel
Requirements, Relevant to
IS
Grade 4450 or 4425 of IS 617
IS 7328
IS 4947
Having bursting pressure of
not less than 50 Kg/ Cm2.
Type 1 of IS 319
Grade 04 Cr 18 Ni 10 of IS
6603
3.2.2 Shape:
The shape of the body shall be cylindrical with outside diameter and thickness of mild
steel sheet as mentioned below:
i.
ii.
Dia - 300 25 mm
Thickness - 3.15 mm.
3.2.3 Construction :
3.2.3.1 General :
The top dome and bottom dish of the body shall be without reverse of curvature and
shall be dished outwards to a radius not exceeding the outside diameter of the body to which
these are fixed or of which one or both form a part if solid drawn therewith.
i.
Nonferrous metal parts shall be mechanically tightened and soldered, if needed, or
brazed to the body.
3.2.3.2
Body :
Circumferential and horizontal joints of the body shall be of welded type.
i.
The welded construction to one of the types given below and shall conform to Indian
Standard mentioned against each.
a.
b.
Spot welding (for attachment of fittings only) shall conform to IS 819: 1957, and
Metal arc welding shall conform to IS 9595 : 1980.
3.2.3.3 Carrying Handle:

The carrying handle shall be made of mild steel rod or tube of not less than 16mm
diameter. If tube, the thickness of the sheet used shall be not less than 1.25 mm.
3.2.3.4 Neck Ring:
The neck ring shall provide a clear opening of not less than 75mm diameter. It shall
have parallel screw threads conforming to class A of IS 2643 (Part 1) : 1975 for a effective
length of not less than 28mm. The neck ring shall be firmly fixed to the body by welding.
3.2.3.5 Cap:
The cap shall be threaded for not less than 25mm effective length with parallel
threads conforming to class A of IS 2643 (Part 1): 1975. At least four holes of not less than
653

2.5mm diameter each shall be drilled through threads of the cap to form vents. The centre of
the vent holes shall be 6.5 mm maximum from the face of the cap joint washer.
3.2.3.6 Snifter valve:
A snifter valve (breathing device) shall be fitted to extinguishers for upright type and
the design shall be such that when variation in atmospheric temperature is within 10C
there shall be no spouting of liquid through nozzle.
3.2.3.7 Safety Pressure Release Valve:
The cap or body should have a safety pressure release valve mechanism by which
if the pressure inside the container exceeds 25 Kgf/Cm2, the safety pressure release valve
will release the internal pressure automatically.
3.2.3.8 Liquid Level Indicator:
The 50 ltr level of the solution inside the body shall be indicated on the exterior of
the body. It shall also be permanently indicated in the interior, or means shall be provided
to demonstrate that the solution level is correct.
3.2.3.9 Hose
The discharge hose shall have a bore of not less than 12.5 mm and a length of not
less than 3m.
3.2.3.10 Foam Making Branch and other discharge fittings:
The design of the foam making branch and other discharge fittings shall be such that
when the extinguisher is set in operation, it shall be capable of discharging foam as in 9.07.
3.2.3.11 Syphon Tube:
The siphon tube shall be fitted inside the body.
3.2.3.12 Drain Plug:
At the bottom of the body a drain plug of size 25mm minimum with rubber washer
shall be fitted.
3.2.3.13 Wheeled Carriage:
The fire extinguisher shall be provided with wheeled carriage with rubber tyred
wheels of size 250 mm x 50mm x 25mm and axle of mild steel rod of 25mm minimum
diameter. Tolerance for wheeled carriage shall be 10mm. The fitting shall ensure the lowest
part of the body remains not less than 10 cm above the ground when it is in the vertical
position.
3.2.3.14 Gas Cartridge:
The capacity of gas cartridge shall not exceed 300 (+10g, -3 g).
3.2.4 Charge:
654

The charge shall consist of foam concentrate conforming to IS 4989 (Part 2): 1984
and quantity not less than 3 ltr ( 6 percent concentrate) or 1.5 ltr ( for 3 percent concentrate)
and balance quantity of water to make the foam water solution to 50 ltr.
3.2.5 Anti Corrosive Treatment:
All internal surfaces of the body be completely coated with lead-tin alloy (tin not less
than 10 percent), applied by electrolytic process or by hot dipping process to a thickness of
not less than 0.012 mm. The thickness of the coating shall be measured as given in IS
3203: 1982. The external surface of the body and both surfaces of siphon tube shall also be
subjected to this anti-corrosive treatment. There shall be no visible uncoated area both
internally or externally.
Phosphating in accordance with the provisions of IS 3618: 1966 may be applied on
the external surface of the body as an alternative to lead-tin alloy.
3.2.6 Painting:
Each extinguisher shall be painted fire red conforming to shade No.536 or 537 of IS
5:1978. Each extinguisher shall be marked with letters A and B, indicating their suitability for
respective classes of fires as laid down in IS 2190. The letters A and B shall be of 2.5 0.5
cm size printed in black colour, centrally contained in a square of 4 0.5 cm size. The
square shall be coloured cream (lemon yellow) conforming to shade No.355 of IS5. The
paint shall conform to IS 2932 : 1974.
3.2.7
Test requirement:
3.2.7.1 The extinguisher shall be discharging not less than 90 percent by mass of the actual
rated capacity of the extinguisher, when the extinguisher is set into operation under normal
temperature conditions of 27 5C, the foam solution shall be expelled in the form of a foam
jet which will maintain a throw of not less than 10m for the minimum period of 40 seconds.
The maximum period of discharge of minimum 90 percent of the liquid shall be 180 seconds.
The test shall be carried out so that the stream is discharged in horizontal direction in still air
conditions from a height of 1.25m from the ground.
3.2.7.2 The foam produced shall have minimum expansion 6 and 25 percent, drainage time
70 to 120 seconds and formation of film as per IS 4989 (Part 2): 1984.
3.2.7.3 The extinguisher body and the cap (without the safety release valve) shall be tested
separately to an internal hydraulic pressure of 3.0 MN/m2 (30 kgf/cm2) for a period of 2 min.
During this test, it shall not show any sign of leakage.
3.2.7.4 In case of hydraulic burst failure test for body, the mechanical failure shall not occur
at a pressure of less than 4.5 MN/m2 (45 kgf/cm2 ).
3.2.8
Optional requirements:
3.2.8.1 The product may carry along with instructions for proper use so as to maximize
product performance with statutory warning, if any, minimize waste and method of safe
disposal.
3.2.8.2 The material uses for product packaging (excl. refills) shall be recyclable, reusable or
biodegradable.
655

3.2.8.3 The product must display a list of critical ingredients in descending order of quantity
present in percent by weight. The list of such critical ingredients shall be identified by the
Bureau of Indian Standards.
3.2.9
Specific Requirements:
3.2.9.1 The fire extinguisher shall not contain any Ozone Depleting Substance (ODS).
3.2.9.2 Gas based extinguisher media once discharged in the atmosphere should not have
atmospheric life time of more than a year.
3.2.9.3 Chemical used should not have global warming potential.
3.2.9.4 The metallic body and other metal parts of the fire extinguishers shall be free of lead
or lead alloys.
3.2.9.5 The coating used for the metallic part shall not be formulated with mercury and
mercury compounds or be tinted with pigments of lead, cadmium, chromium VI and their
oxides. Excluded are natural impurities entailed by the production process up to the amount
0.1 percent by weight, which are contained in the raw material.
3.2.10 Marking :
3.2.10.1
information:
a.
b.
c.
d.
e.
f.
g.
h.
3.2.10.2
Each extinguisher shall be clearly and permanently marked with the following
Indication of the source of manufacture.

Method of operation in prominent letters.
The word Mechanical Foam Fire Extinguishers:
The capacity of extinguisher in litres.
The words after discharge the extinguisher must be washed out carefully with
fresh water using at least two changes in prominent letter.
A declaration to the effect that the body of the extinguisher has been tested to
pressure 3.0 MN/m2 (30 kgf/cm2) and
Year of manufacture
Class of fire that is A & B.
The extinguisher may also be marked with Standard Mark.
3.3.
FIRE EXTINGUISHER, DRY CHEMICAL POWDER (DCP) TYPE, TROLLEY

MOUNTED:
3.3.1
CAPACITY
The total capacity of the dry powder extinguisher when filled shall be as under:
75 kg + 5% ( tolerance).
3.3.2. MATERIALS
The material for construction of various parts of the extinguisher shall be as given
below:
S.
No.
Component
Material
Requirements
Relevant to IS
Body
Mild steel sheet
IS 1079 or IS 2041 or IS 2062
656
ii
Neck ring
iii
Nozzle
Leaded tin bronze
Seamless mild steel

tube
IS 1239 (Part I)
Copper
IS 6912
Brass
Grade II of IS 291 or type I of

IS 319
IS 7328
Grade 4450 of IS 617
Leaded tin bronze

Plastic
Aluminium alloy
Leaded-tin-bronze
Brass
Leaded-tin-bronze
Brass

Type I of IS 319
Type I of IS 319
Conforming to the
requirements of hardness as
applicable to type 3 of IS 5382
and also acid and alkali
resistant.
iv
Cap
Drain plug
vi
Cap washer
Rubber
vii
Syphon tube
Seamless mild steel

tube
IS 1239 (Part-I), IS 3601
viii
Discharge
valve
IS 3224
3.3.3. CONSTRUCTION
3.3.3.1 Body
The construction of the body shall be welded conforming to the requirements given
in IS 9595. The shape of the body shall be cylindrical having diameter not more than 75 cm.
The domed ends of the body shall be without reverse of curvature and shall be dished
outwards to a radius not exceeding the internal diameter of the body to which these are
fixed.
3.3.3.2
Neck Ring
The neck ring shall provide a clear opening of not less than 75 mm. It shall have
parallel screw threads for effective length of not les than 22 mm. The neck ring shall be
firmly secured to the body by brazing or welding.
3.3.3.3
Cap
The cap shall be threaded for fixing to the neck ring in the body for not less than
22 mm effective length. The parallel threads shall be in accordance with IS 2643 (Part 1).
At least 3 holes of not less than 3 mm diameter each shall be drilled through the threads of
the cap to form vents for release of any pressure remaining in the body during withdrawal of
the cap. The centres of the vent holed shall be 6.5 mm maximum from the face of the cap
joint washer. The extinguisher shall be fitted with safety valve which shall release at a
pressure of 2.5 MN/m2 (25 kgf.cm2) as per requirement of IS 5903.
3.3.3.4
Cap Joint Washer
657
The cap joint washer shall be provided in the recess in the cap.
3.3.3.5 Expansion Space
A space shall be provided above dry powder level in the body of the extinguisher.
It shall be of sufficient volume to ensure that when discharge nozzle is temporarily closed
and the extinguisher is operated at a temperature of 27 5 C, the internal pressure shall not
exceed 1.5 MN/m2 (15 kgf/cm2) and the body shall not show any sign of leakage.
3.3.3.6
Discharge Hose
Discharge hose shall be of braided rubber of PVC of nominal bore 19 mm

diameter fitted with not less than 5 m. The hose shall have bursting pressure of not less
than 50 kgf/cm2.
3.3.3.7 Cylinder
The CO2 gas cylinder shall conform to IS 7285 and shall be of capacity 3 litres and
shall be filled with carbon dioxide (IS 307) having maximum filling ratio of 0.667 which is the
ratio of mass of carbon dioxide charged in the container to the mass of water required to fill
the container at 27 C.
3.3.3.8
Copper Tubing (Required if Gas Cylinder is Used):

It shall conform to bursting pressure of 275 kgf/cm2.
3.3.3.9 Nozzle and other Discharge Fittings:

The nozzle shall be trigger controlled and shall be capable of discharging dry
powder as in 3.3.6.1, and shall be so designed as to eliminate moisture penetration.
3.3.3.10 Actuation Mechanism
The CO2 cylinder shall have wheel valve to operate and discharge gas.
3.3.3.11 Drain Plug
The drain plug of not less than 25 mm diameter shall be provided on the body
except in case of 25 kg capacity and the washer shall be provided to make the joint water
tight.
3.3.4
ANTI-CORROSIVE TREATMENT
3.3.4.1 All internal and external surfaces of the body and internal parts shall be completely
coated with zinc or lead-tin alloy (tin 10 percent minimum) applied by hot-dipping or
electrolytic process to a thickness of not less than 0.025mm. The thickness of the coating
shall be measured as given in IS 3203. There shall be no visible uncoated area both
internally and externally.
3.3.4.2
Phosphating (see IS 3618) may be applied on the external surface of the body as
an alternative to zinc or lead-tin alloy coating.
3.3.4.3 Epoxy polyester powder coating of 50-micron thickness may be applied on both
surfaces of the body as an alternative to lead -tin alloy coating
658

3.3.5.
PAINTING
Each extinguisher shall be painted fire red conforming to shade No.536 of IS 5. All
components of trolley and other items other than the fire extinguisher shall be painted with
the primer and finishing paints of two coats each. The paint shall conform to IS 2932:
3.3.6
TEST REQUIREMENTS
3.3.6.1
Performance Test
The extinguisher shall be capable of discharging minimum of 85 percent by mass

of the actual rated capacity of dry powder when the extinguisher is operated at a
temperature of 27 5 C in still weather condition. The contents shall be expelled in the
form of a continuous discharge, which shall comply with the following requirements:
Capacity of Durations
Extinguisher in see
Kg
75
3.3.7
Range of Jet Throw

(Minimum Throw)
m
50 to 60
10
WHEELED CARRIAGE
The fire extinguisher shall be provided with wheeled carriage according to IS-10658.
The fitting shall ensure that the lowest part of the body remains not less than 20 cm for 75 kg
above the ground when it is in the vertical position.
3.3.8 MARKING
3.3.8.1
Each extinguisher shall be clearly and permanently marked with the following
information.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
3.3.8.2
Name of the manufacturer or trade-mark, if any

Method of operation in prominent letter
Words 'Dry Powder Extinguishers
Capacity of the extinguisher in kg'
Words 'Recharge After Use';
A declaration to the effect that the body of the extinguisher has been
tested to a pressure of 3.0 MN/m2 (30 kgf/cm2);
Letters indicating the various classes of fires for which the extinguisher is
suitable;
Year of manufacture;
Working and design pressure;
Working and design pressure;
Capacity of gas cartridge ; and
Capacity of gas cylinder with filling ratio.
BIS Certification Marking
The product may also be marked with the Standard Mark.
3.1
Set of fire buckets comprising 6 no. buckets of capacity10 Ltrs. each with
stand
BUCKET
659

3.4.1
Material
3.4.1.1 Mild Steel Black Sheets

Mild steel black sheets used for the manufacturer of buckets shall confirm to
Grade St.34 or Grade St 42 of IS : 1979-1968.
3.4.1.2 Mild Steel Rod
Mild steel rod used for the top and bottom handles shall conform to IS : 226-1969.
3.4.1.3 Mild Steel Wire
Mild steel wire used for stiffening the top rim shall conform to IS : 280-1962.
3.4.1.4 Paints
Paints used for painting of fire buckets shall conform to the appropriate Indian
Standards given in Table-1 of IS-2546-1974. The shade of the outside colour shall
be fire red and inside shall be of the white, conforming to shade of respective IS.
3.4.2
Shape and Essential Dimensions
3.4.2.1 The shape and the essential dimensions of fire bucket shall conform to those
described in IS-2546-1974.
3.4.3
Manufacture
3.4.3.1 Body
The body shall be in two halves which shall be joined together by butt welding. The
top rim of the body shall be wired and uniformly beaded. The beading shall be fully
formed without gaps. The thickness of body shall be 1 mm and diameter of beading
wire 3.55 mm. IS-2546-1974.
3.4.3.2 Bottom
The bottom shall be dished and shall be joined to the body by butt welding so that
there is no raw edge or crevice on the inside of the bucket. The thickness of the
bottom sheet shall be 1mm.
3.4.3.3 Ears
The ears shall be made of mild steel sheet and shall be fitted to the body at the top
by means of welding with the flat head on the side. The thickness of sheet for ears
shall be 2.8mm.
3.4.3.4 Top handle
The top handle shall be of mild steel rod of 10mm in diameter with its ends bent up
as shown in Fig.1 of IS-2546-1978.
3.4.3.5 Bottom handle
The bottom handle shall be of mild steel rod of 10mm in diameter and it shall be joined
to the bottom by welding as shown in Fig.1. The grip shall have not sharp edges.
660
3.4.3.6 General
All gas welds shall be free from porosity, blow holes and brittleness.
3.4.4 Finish
3.4.4.1 All parts of the bucket shall be finished smooth and sharp edges
rounded off.
3.4.4.2 The bucket shall be galvanized after manufacturer as per IS:2629-1966, The
thickness of coating of zinc conforming to S:13229-1991 specification for zinc for
galvanizing on any portion shall be not less than 0.06g/cm2 (both sides inclusive).
Alternately, it may also be galvanized of lead tin alloy to a thickness of not less than
0.012 mm.
3.4.4.3 Bucket shall, in addition to galvanizing be painted with two coats of white paint on the
inside and two coats of red paint on the outside (see also 3.4.1.4). The handles and
the ears shall be painted with two coats of black paint.
3.4.4.4 The word FIRE shall be painted in black centrally on the outside, its letters shall be
75mm high and approximately 12mm thick.
3.4.5 PERFORMANCE REQUIREMENTS
3.4.5.1 The bucket shall be water tight and tested for leakage as given in
3.4.5.2 and 3.4.5.3.
3.4.5.2 The bucket shall be filled with water to the brim and kept for 15 minutes. The bucket
shall not show any sign of leakage during this period.
3.4.5.3 A water tank of suitable size and full of water shall be used for conducting the test.
The dry empty bucket with its top facing upwards shall be pressed down the water
vertically taking care that the top is at least 6mm above the water level. It shall be
observed whether any water gets into the bucket from the bottom or sides of the
bucket. If any water enters the bucket, it shall be considered to have failed the test.
3.4.5.4
The bucket shall be withdrawn, reversed (with top downwards) and again pressed
down the water vertically without agitating the water. Should any air bubble be seen
escaping through the water, the bucket shall be considered to have failed the test.
3.4.6
Inspection and manufacturers certificate
3.4.6.1 The purchaser or his representative shall, if desired, be granted facilities for
inspection of finished goods prior to dispatch at the manufacturers works.
3.4.7 Scale of sampling and criterion for conformity
3.4.7.1 In any consignment, all the buckets from the same batch of manufacturer shall be
grouped together to constitute a lot.
3.4.7.2 Sample size
The number of buckets to be selected from the lot shall depend on the size of the
lot and shall be in accordance with Col.(1) and (2) of Table.2 of
IS:2546 -1974.
661

3.4.7.3 Number of Test All the buckets selected as in 3.4.7.2 shall be inspected for
shape and dimensions, manufacturing defects and finish and tested for leakage. Any
bucket which fails to satisfy the requirement of any one or more of the characteristics
shall be considered as defective bucket.
3.4.7.4 Criterion for conformity - The lot shall be considered as conforming to the
requirements of this standard if the number of defective buckets among those
inspected does not exceed the corresponding number given in col.3 of table.2 of IS2546-1978, other wise it shall be considered as not conforming to the requirements
of the standard.
3.4.8
Marking and packing
3.4.8.1 Each bucket shall be stamped or embossed on its side with the manufacturers name
or trade-mark, year of manufacture and its capacity. Embossing shall be sufficiently
deep so that the marking remains quite legible after galvanizing.
3.4.8.2 The fire bucket may also be marked with the ISI certification mark.
3.4.9 STAND
3.4.9.1 Material should be made from 35mm X 35mm X 5mm size angle made of mild steel.
3.4.9.2 Paint
Stand shall also be painted fire red or post office red conforming to shade No.536 or
537 or IS 5.
3.4.9.3 Shape & Dimensions
The dimensions of stand shall be 1050 mm x 750 mm (Height), should be made from
35mm X 35mm X 5mm size angle made of mild steel. Stand shall have shape
suitable to hang 6 buckets. Suitable hanging arrangement should be there to hang 6
buckets
3.4.9.4 All parts of the bucket shall be finished smooth and sharp edges rounded off.
4
SUBMISSION OF DESIGN DETAILS -
4.1 Requirements for participating in this Bid are as under :a.
Bidder must have established manufacturing facility in his factory to

manufacture the materials as specified in this bid. The bidder shall clearly
state his experience and capability to undertake the manufacture of these
items.
b.
Details of such manufacture specified above and supply including type,

quantity, date of order, date of commencement and completion of supplies,
name of purchaser shall be furnished with the bid along with his full address.
c.
Bidder should have adequate testing facilities to test the product offered in
his factory to the satisfaction of the purchaser. The bid shall include complete
details of testing facilities available in manufacturer's works.
662

5
Sheet steel fabricated members for Fire Fighting Equipments shall be subjected to
pre-treatment process before painting. The process shall be carried out as under. The
process can broadly be divided as `Metal treatment and painting'.
5.1
5.2
METAL TREATMENT i.
Degreasing : This can be achieved either by immersing in hot alkaline

degreasing bath or in hot dry chlorothelence solution. In case degreasing is
done by alkaline bath rinse with cold water thoroughly.
ii.
Pickling: This is to remove rust and metal scales. Immersing indiluted

sulphuric acid (approximately 20%) at nearly 60 deg. Centigra de. Unit scale
and rust are totally removed.
iii.
iv.
Treat with phosphoric acid base neutraliser for removal of chlorine from
the above acid pickling and again wash with running water.
v.
Phosphating : Immerse in grenodine `zinc phosphate solution for about 20

minutes at 80 to 90 deg. centigrade. The uniform phosphate coating of 4
to 5 gms per sq.meter shall be achieved.
vi.
vii.
Rinse in Deorylyte bath at 70 to 80 deg. centigrade to neutralise any traces

of salts.
viii.
ix.
PAINTING
i.
Primer : spray one coat wet on wet specially developed `High lusture'
zinc chromote primer and stove at 150 deg. centigrade to 160 deg.
centigrade for 25 to 30 minutes. Alternatively red-oxide primer with zinc
chromate contents may be used. However, former process is preferred.
ii.
Rubbing and puttying : Apply putty to fill up the scars if any to present
get the perfectly smooth finish.
Surfacing : Sand down with mechanical abrasive and stove for 20 minutes.
iii.
iv.
Primer : Spray second coat of primer as per (i) above or grey primer
surface wet on wet and stove for 20 to 40 minutes at 150 deg. centigrade.
v.
Finish paint : Rubbing 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. Final
finish shall be obtained after spraying 2 Coats of synthetic enamel finish
paint wet on wet and stove it at 150 deg. centigrade for 30 minutes.
vii.
Colour of finishing paint for Fire Fighting Equipments shall be as described

in clause-3.1 to 3.4 of this section II.
NOTE i.
Necessary stiffeners may be welded between large cut outs to provide

663

ii.
Painting process shall be done within 24 hours of completion of treatment.
iii.
Small coating paint shall be supplied alongwith equipment for touching up at

site.
6.
TESTS:
6.1
TYPE TEST:
All the equipment offered, shall be fully type tested as per relevant Indian Standards
during the last five years from the date of bid opening. Copy of test reports shall be
enclosed with the bid. For any change in the design/type already type tested and the
design/type offered against this bid, the Purchaser reserves the right to demand repetition
of same or all type tests without any extra cost.
6.2
i.
relevant Indian Standards in presence of purchasers representative.
ii.
Immediately after finalisation of the programme of type/ acceptance/ routine testing,
the manufacturer shall give sufficient advance intimation to the Purchaser, to enable him to
6.3
The successful Bidder shall submit the routine test certificates of bought out items
and for raw material at the time of routine testing of the fully assembled equipment.
7
DOCUMENTATION:
7.1
All drawings shall conform to latest version of Indian Standards Specification. All
drawings shall be in ink and suitable for micro filming. All dimensions and data shall be in
S.I. Units.
7.2

The Bidder shall furnish four sets of following details and drawings along with his
bid:i.
ii.

Name plate.
iii.
Schematic drawing.
iv.
tested.
v.
material.
7.3
The successful Bidder shall within 15 days of placement of order, submit a set of
communicate his comments / approval on the drawings to the Bidder within reasonable
time. The Bidder shall, if necessary, modify the drawings and resubmit the modified
drawings for Purchasers approval.
7.4
Purchaser. All manufacturing and fabrication work in connection with the equipment prior to
the approval of the drawing shall be at the Bidders risk.
664

7.5
Thirty four (34) copies of nicely printed and bound volumes of operation,
maintenance and erection manuals in English Language, for each type and rating of
equipment supplied shall be submitted by the Bidder for distribution, prior to the dispatch of
the equipment. The manual shall contain all the drawings and information required for
erection, operation and maintenance of the equipments. The manual shall also contain a set
of all the approved drawings, type test reports etc.
7.6
Approval of drawings/work by Purchaser shall not relieve the Bidder of his
revision of applicable standards, rules and codes of practices. The equipment shall
conform in all respects to high standards of engineering, design, workmanship and latest
revisions of relevant standards at the time of ordering and Purchaser shall have the power
to reject any work or material, which in his judgment is not in full accordance therewith.
10
10.1 The Bidders must establish that they are following a proper quality assurance
programme for manufacture of Materials. The bidder shall invariably furnish following
information along with their bid. Information shall be separately given for each type of cable:
10.2
(i)
Statement giving list of important raw materials, names of sub-suppliers for

the raw material, list of standards according to which the raw material is
purchased and copies of test certificates thereof.
(ii)

out items.
(iii)
(iv)

exists.
(v)

carried out for quality control and details of such tests and inspections.
(vi)
List of testing equipment available with the bidder for final testing of material
specified and test plant limitation, if any, vis--vis type, special, acceptance
and routine tests specified in the relevant standards. These limitations shall
be very clearly brought out in schedule of deviations from specified test
equipments.
The successful bidder shall within 30 days of placement of order, submit following
(i)
List of raw material as well as bought out accessories and the names of subsuppliers selected from the lists furnished along with Bid.
(ii)
(iii)
Quality Assurance Plan (QAP) with hold-up points for purchasers inspection.
The quality assurance plans and hold-up points shall be discussed between
the Purchaser and supplier before the QAP is finalized.
665

11
SCHEDULE
The Schedules and annexure attached with this specification are the integral part of
the specification and shall be submitted duly filled in by the bidders alongwith the offer. The
bill of material for each equipment shall be submitted by the bidders separately.
12
DISCREPANCY IN TECHNICAL PARTICULARS -
No deviation from technical particulars of equipments and materials will be allowed ,

666
SCHEDULE-I(A)
IN VOLUME-VI
Carbon Di-oxide (Co2) type trolley mounted of 22.5 kgs

capacity
Mechanical foam type trolley mounted of 50 Ltrs capacity
Dry chemical powder (DCP) type trolley mounted of 75 Kgs

capacity
Qty.
Set of fire buckets comprising of 6 nos. buckets of 10 Ltrs.

capacity each with stand
S.No.
NOTE: 1. The above description of the equipment is given for the purpose of offering
payment.
2. The quantity of above equipments has been mentioned in Volume-VI
667

Transformer Manual

Uploaded by

Copyright:

Available Formats

Transformer Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Transformer Manual

Uploaded by

Copyright:

Available Formats

MADHYA PRADESH POWER TRANSMISSION CO. LTD.

SHAKTI BHAWAN RAMPUR: JABALPUR

TECHNICAL SPECIFICATION FOR SUPPLY

O/o CHIEF ENGINEER (PROCUREMENT)

Volume-II contains four booklets as under:Section

TECHNICAL SPECIFICATION FOR MPPTCL/TECH/

TECHNICAL SPECIFICATION FOR MPPTCL/TECH/

TECHNICAL SPECIFICATION FOR MPPTCL/TECH/

All the above four booklets are in the form of

Annexures and appendix for 132KV, 40MVA Power Transformer

Principal Technical particulars

List of Fittings and Accessories

Test certificates to be furnished for

Schedule of Inspection Windows

Annexure VI(A)- Drawings & Data to be furnished

Details of Inspection Program

List of Hand Tools and Jacks

Description of equipment for

Calculation for Hot Spot winding

- Technical particulars to be filledin by bidder

List of abbreviations used in technical specification

VOLUME II, PART-1

TECHNICAL SPECIFICATION FOR 40 MVA ,

Max. Ambient air temp. (oC)

Average annual rainfall (cm)

At various substations within

433V, 3phase, 4wire 50Hz. neutral grounded AC

250V, single phase, 50Hz. AC supply.

Bidders scope include supply of interconnecting cables, terminal

: Voltage Variation of 25% to +10%;Frequency

: Voltage Variation of -20% to + 10%.

All accessories requiring AC or DC

GENERAL TECHNICAL REQUIREMENTS

40KA for 3 secs.

Over Loading : The transformer shall be capable of being

Over Voltage : The transformers shall be capable of being

4.2 Radio Interference & Noise Level

ONAN (Air natural).

ONAF (Air forced)

No load losses (Iron losses).

b) Load(Copper losses) + Auxiliary losses. : 100 KW

Heat Run Test:

One 40 MVA 132 KV power transformer of each manufacturer (if

The tanks shall be designed to withstand the following

Mechanical shocks during transportation.

Vacuum filling of oil at 10 milli torr in transformer with

(iii) Continuous internal pressure of 35 kN/m2 over normal

Under seismic condition /events both horizontal/vertical.

Where ever possible the transformer tank and its accessories

Lifting lugs suitable for lifting the equipment complete

A minimum of four jacking pads in accessible position

Inspection cover/access windows & Manholes:

Space for free movement in Transformer Tank for

All bolted connections to the tank shall be fitted with

(K) Suitable guides shall be provided for positioning the various

The tank cover shall be sloped to prevent retention of rain

Inspection cover/man holes shall be provided as per AnnexureIV.

The tank covers shall be fitted with pockets at the position of

Bushings, turrets, covers of inspection openings, thermometer,