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Rural Electrification programme is not a viable proposition because of the highly capital intensive nature of the equipment, wide spread and scattered network leading to difficulty in maintenance, and lengthy lines and isolated and scattered loads leading to high distribution losses. Due to unremunerative and highly subsidized tariff, the RE programme is financially unviable. In such a situation, of scarce resources on the one hand, and commitment to bring electricity to all the villages on the other, the only way out was to devise ways and means of bringing out cost-effective and technically superior systems for rural electrification. With active association of the SEBs, manufacturers and research institutes, REC brought out standards and specifications for RE construction materials including conductors, transformers, insulators, circuit-breakers, energy meters etc. and evolved construction practices for laying of HT/LT lines, erection of substations etc. With the availability of such REC standards, the manufacturers were able to produce cost-effective and better equipments for adoption and use by all the SEBs in the country. However, due to financial constraints there is a huge gap between the demand and supply of power in the country. Further, a high percentage of T&D losses to the extent of 21.2% also adding to this huge shortage of power. To achieve this a great necessity was felt to standardize the various material and construction practices for carrying out rural electrification works in the country. REC with the active participation of State Electricity Boards, manufactures and various Research Institutes were able to bring out the various standards and specifications for RE construction works. This was all the more very important, in view of different climatic/field conditions existing in various parts of the country. The construction materials for carrying out rural electrification works was being used according to the local requirement of the area which used to result in costlier material procurement as manufacturers of such items used to produce the same item with different designs/standards i.e. as per the requirement of the individual customer and construction practices. Now due to the available of REC standards and construction practices of various items for RE works, there has been their uniform adoption by various State Electricity Boards and utilities, resulting into cost effective and technically superior systems for rural electrification. REC has so far issued 74 specifications, 232 Construction Standards and 14 Manuals for carrying out rural electrification works.

Implementation
The evolving of various standards and specifications by REC, has been welcomed and appreciated by the State Electricity Boards/Power Utilities and Manufacturers. There has been frequent discussions with them by REC for their up-gradation and to bring out new standards/specifications for various other items. The feed back on various difficulties of SEBs are discussed in detail and their suggestions are invited for their further improvement and better acceptability to the actual field conditions. The need for further updating/revising the existing standards & specifications is done by incorporating all their suggestions after securing consensus from all concerned in the conference being conducted by REC. This helps to keep pace with the latest development in the technology. Although the execution of RE works is the sole responsibility of SEBs/PDs, REC through its wider network in the country ensures the adoption of these Standards/Construction Practices for cost effective, qualitative and reliable power system in the rural areas.

Benefits of Standardisation in System Improvement

There had been a great need to improve the rural distribution system with its rapid expansion because of steep load growth by energizing more and more no. of agricultural pumpsets and electrifying new villages. This has resulted into poor voltage conditions and increase in distribution losses. With adoption of REC Construction standards, SEBs have been able to

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distribution losses. With adoption of REC Construction standards, SEBs have been able to improve quality of supply of power and remarkable saving of energy by reducing losses to a great extent. Further with the propagation by REC of the importance of using energy efficient modern/innovative technology equipment, SEBs have been successful in ensuring the reliable and qualitative supply of power to the rural areas.

Training of Staff by REC

REC through its Training Centre at Hyderabad (CIRE) is also conducting various training programmes/courses for the engineers of State Electricity Boards to carry out various RE works adopting REC Construction Standards and practices.

Recognition
The institution of Standard Engineer, an affiliate of the Bureau of Indian Standards, has awarded, REC the Company Standardisation Commendation Award for the year 1987 in recognition of excellent contribution of REC in the field of Standardisation.

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REC Specifications
S.No. 1 Name of the Specification Hard Drawn Stranded Aluminium and Steel Cored Aluminium Conductors for Overhead Power Lines Outdoor type three phase 11KV/433- 250V Distribution Transformers upto and including 100 KVA and including 100 KVA 11 KV Porcelain Insulators and Fittings Porcelain Insulators and Insulator Fittings for 415/240V Overhead Power Lines Single phase and Three-phase, whole Current AC Electricity Meters 415V Three phase Shunt Capacitors Three phase 33/11 KV Step Down Transformers 11 KV Oil Circuit Breakers Rubber Hand Gloves 11 KV Lightning Arresters Outdoor Type Three phase 11KV/433-250V Sealed Distribution Transformers upto and including 100 KVA 33 KV Vacuum/SF-6 Circuit Breakers Porcelain Insulators and Insulator Fittings for 33 KV Overhead Power Lines Single Wire Earth Return (SWER) Distribution Transformers Pre-stressed Cement Concrete poles (FOS 2.5) for 11 KV and LT Lines 33 KV Lightning Arresters On Load Tap Changers for 33/11KV Transformers LT Circuit Breakers 11 KV Capacitor Banks at 33/11KV Sub stations 11 KV Circuit Breakers for Controlling Capacitors Guy Strain Insulators 11 KV Vacuum Circuit Breakers Specification No. 1/1971(R-1993)

2/1971(R-1997)

3 4

3/1971(R-1993) 4/1972(R-1979)

5/1974(R-1993)

6 7 8 9 10 11

6/1974 7/1974(R-1993) 8/1975(Withdrawn) 9/1975(R-1993) 10/1976 11/1976(R-1993)

12 13

12/1979(R-1993) 13/1979

14 15

14/1979 15/1979

16 17 18 19 20 21 22

16/1981 17/1981 18/1981(R-1983) 19/1981(R-1993) 20/1981(R-1993) 21/1981 22/1983

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23 Out door type Three phase 11KV/433-250V Completely Selfprotected Distribution Transformers upto and including 100 KVA Pre-stressed Concrete Poles for 33 KV lines Helically Formed Fittings for 11 KV & LT lines PVC Insulated LT Cables PVC Insulated LT Service Cables with Embedded Bearer Wire LT Rewirable Fuses LT Line Spacers Outdoor type Three-phase 11KV/433-250V Resin Cast Dry Type Distribution Transformers upto and including 100 KVA Earth Knobs for LT Lines Aerial Bunched Cables for LT Lines Aluminium Alloy Conductors for Overhead Power Lines 24 V/110 V NICAD Batteries with chargers for 33/11 KV and 66/11 KV Sub stations 11 KV Pole Mounted Automatically Switched Capacitors Automatic Transformer Disconnection Switches 11 KV Automatic Voltage Boosters/ Regulators 11 KV Auto Reclosers Transformer Oil for power/ Distribution Transformers Fibre glass Cross Arms for 11 KV Lines. Rectangular Hollow Steel Poles Fibre glass Cross Arms for 33 KV Lines 11 KV Air Break Switches 11 KV Line Sectionalisers GI Wires GI Stay Wires Pre-stressed Concrete Spun Poles 23/1983(R-1997)

24 25 26 27

24/1983(R-1987) 25/1983 26/1983(R-1987) 27/1983

28 29 30

28/1983 29/1983(R-1987) 30/1983

31 32 33 34

31/1983 32/1984 33/1984(R-1993) 34/1984(R-1987)

35 36 37 38 39 40 41 42 43 44 45 46 47

35/1984(R-1993) 36/1984 37/1984(R-1993) 38/1984(R-1997) 39/1985(R-1993) 40/1985(R-1997) 41/1985 42/1987(R-1997) 43/1987 44/1987(R-1993) 45/1986 46/1986 47/1987

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48 49 50 51 52 53 54 55 56 12 V Batteries for Solar street Lights Single phase Dry Type Distribution Transformers Single phase Distribution Transformers(Oil Filled) Epoxy Based Protective Paint 33 KV Switch Isolators 11 KV Drop Out Fuse Cutouts 33 KV Load Break Switches 11 KV and 33 KV Metal Oxide Lightning Arresters Outdoor type three phase fail safe Distribution Transformers Danger Notice Plates Transformer Oil Testing Kit 11 KV Current Transformers 11 KV Voltage Transformers Miniature Circuit Breakers for Service Connections High Tensile Steel Wires for PCC Poles 11 KV XLPE Cables Aerial Bunched Cables for 11KV Lines Oil Filtration Set Residual Current Operated Circuit Breakers Controller cum Inverter for Solar Street Lights Switched LT Capacitors 11KV Automatically Switched Capacitor Banks at Sub Stations Outdoor type three phase 11KV/433-250V Conventional and Sealed distribution transformers with Amorphous Metal Core upto and including 100 KVA Remote Controlled Load Management Scheme Single Phase Completely Self Protected (CSP) distribution Transformers (Oil Filled) Outdoor type three phase 11 KV/433-250V completely self protected Distribution Transformers with Amorphous Metal Core upto and Including 100 KVA 48/1987 49/1987 50/1987(R-1997) 51/1987 52/1987 53/1987 54/1987(R-1993) 55/1987 56/1988(R-1993)

57 58 59 60 61 62 63 64 65 66 67 68 69

57/1993 58/1993 59/1993 60/1993 61/1993 62/1993 63/1993(R-1997) 64/1993 65/1993 66/1993 67/1993 68/1993 69/1993

70

70/1993(R-1997)

71 72

71/1993 72/1997

73

73/1997

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Core upto and Including 100 KVA 74 22 KV and 33 KV XLPE Cables 74/1997

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REC Specification 1/1971 (Revised 1993) HARD DRAWN STRANDED ALUMINIUM AND STEEL CORED ALUMINIUM CONDUCTORS FOR OVERHEAD POWER LINES FOREWORD A Conference on Standardisation of Specifications and Construction Practices in Rural Electrification was held on 4th and 5th January, 1971 in New Delhi. Besides the Rural Electrification Corporation, representatives of various State Electricity Boards, the Indian Standards Institution (BIS), Central Water & Power Commission (CEA), Central Board of Irrigation and Power and many other organisations participated in the discussions. Based on the consensus arrived at the Conference, REC Specification No. 1/1971 covering 7/2.21 mm (25 mm2 aluminium area) and 7/3.10mm (50mm2 aluminium area) AAC for use on LT lines and 7/2.59 mm (30mm2 aluminium area) and 7/3.35mm (50mm2 aluminium area) ACSR for use on 11 KV and LT lines was issued. Subsequently, the Specification was revised to incorporate an additional size of ACSR viz 7/2.11mm (20mm2 aluminium area) for use on 11 KV and LT lines and then again to incorporate three more sizes of ACSR viz. 7/3.35mm (50mm2 aluminium area), 7/4.09mm (80mm2 aluminium area) and 6/4.72mm + 7/1.57 mm (100mm 2 aluminium area) for use on 33 KV lines. Consequent upon the revision of IS:398 in 1976, it was considered necessary to bring the above mentioned REC Specification in line with the revised Indian Standards Specification. Accordingly, the required modifications were discussed by the Technical Committee on Standardisation in its meeting held in April, 1978. The Committee also considered certain suggestions made by the Conductor and Cable Manufacturers Association of India (CACMAI) for modifications in the standard lengths, short lengths, gross weight etc. This revised Specification is issued on the basis of the decisions taken by the Technical Committee, which were subsequently ratified by the Eighth Conference on Standardisation, Research & Training in Rural Electrification held in February, 1979. Subsequently, BIS has introduced Amendment No. 2 to IS:398 Part-I 1976 (for AAC) and amendment No. 4 to IS:398 part-II (for ACSR conductors), reducing the maximum resistivity from 0.02845 ohm.mm2/m to 0.028264 ohm.mm2/m, thus reducing the maximum permissible resistance of all conductors at 20oC. This revision incorporates the amended values of maximum resistance at 20oC accordingly. 1. SCOPE This Specification covers the details of the conductors for use on 33 KV, 11 KV and LT overhead lines in rural electric distribution systems. The sizes of conductors standardised for lines of different voltages are indicated below : 33KV Lines i) ii) iii) ACSR 7/3.35mm (50mm2 aluminium area) ACSR 7/4.09 mm (80mm2 aluminium area) ACSR 6/4.72 mm + 7/1.57 mm (100mm2 aluminium area)

11 KV Lines i) ACSR 7/2.11 mm (20mm2 aluminium area) ii) ACSR 7/2.59 mm (30mm2 aluminium area) iii) ACSR 7/3.35 mm (50mm2 aluminium area) LT Lines i) ii) iii) iv) v)

ACSR 7/2.11 mm (20mm2 aluminium area) ACSR 7/2.59 mm (30mm2 aluminium area) ACSR 7/3.35 mm (50mm2 aluminium area) AAC 7/2.21 mm (25mm2 aluminium area) AAC 7/3.10 mm (50mm2 aluminium area)

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2. APPLICABLE STANDARDS Except when they do not comply with the specific requirements in this specification, the conductors shall comply with the Indian Standard Specification IS:398 (Pt.I)-1976 and IS:398 (Pt.II)-1976 or the latest version thereof. SIZES The sizes and properties of Stranded Aluminium and Steel cored Aluminium Conductors shall be as under : TABLE I STANDARD ALUMINIUM STRANDED CONDUCTORS Nominal Aluminium Area 1 mm.sq. 25 50 Stranding and Wire Diameter 2 mm 7/2.21 7/3.10 Sectional Approx. Area Overall Diameter 3 mm.sq. 26.85 52.83 4 mm 6.63 9.30 Approx. Mass 5 Kg./Km 74 145 Calculated Resistance at 200 C Max. 6 Ohm./Km 1.086 0.5525 Approx. Calculated Breaking load 7 KN 4.52 8.25

3.

TABLE II STRANDED STEEL CORED ALUMINIUM CONDUCTORS Nominal Aluminium Area Stranding & Wire Diameter Sectional Area of Aluminium Total Sectional Area Approx. Overall Diameter Approx. Mass Calculated Resistance at 200C Max. 8 Ohm./Km 1.394 0.9289 0.5524 0.3712 0.2792 Approx. Calculated Breaking Load 9 KN 7.61 11.12 18.25 26.91 32.41

AL. 1 mm.sq 20 30 50 80 100 2 Mm 6/2.11 6/2.59 6/3.35 6/4.09 6/4.72

Steel 3 mm 1/ 2.11 1/ 2.59 1/ 3.35 1/ 4.09 7/ 1.57 4 mm.sq. 20.98 31.61 52.88 78.83 105.00 5 Mm.sq. 24.48 36.88 61.70 91.97 118.50 6 mm 6.33 7.77 10.05 12.27 14.15 7 Kg./Km. 85 128 214 319 394

4.

ALUMINIUM WIRES
THE PROPERTIES OF ALUMINIUM WIRES TO BE USED IN THE CONSTRUCTION OF THE UNDER STRANDED CONDUCTORS SHALL BE AS

TABLE III SOLID ALUMINIUM WIRES USED IN THE CONSTRUCTION OF STRANDED ACSR CONDUCTORS Diameter Cross Sectional Area of Nominal Diameter Wire 4 mm.sq. 3.497 3.836 5.269 Mass Resistance At 200 C Breaking Load Min.

Nominal 1 mm 2.11 2.21 2.59

Min. 2 mm 2.09 2.19 2.56

Max. 3 mm 2.13 2.23 2.62

Before Stranding 5 Kg./Km 9.45 10.37 14.24 6 Ohm./Km. 8.237 7.503 5.490 7 KN 0.63 0.68 0.89

After Stranding 8 KN 0.60 0.65 0.85

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3.10 3.35 4.09 4.72 3.07 3.32 4.05 4.67 3.13 3.38 4.13 4.77 7.548 8.814 13.140 17.500 20.40 23.82 35.51 47.30 3.818 3.265 2.194 1.650 1.24 1.43 2.08 2.78 1.18 1.36 1.98 2.64

5.

STEEL WIRES
THE PROPERTIES OF STEEL WIRES TO BE USED IN THE CONSTRUCTION OF THE STRANDED ACSR CONDUCTORS SHALL BE AS UNDER

TABLE IV SOLID STEEL WIRES USED IN THE CONSTRUCTION OF STRANDED ACSR CONDUCTORS Diameter Nominal 1 mm 1.57 2.11 2.59 3.35 4.09 6. Min. 2 mm 1.54 2.07 2.54 3.28 4.01 Max. 3 mm 1.60 2.15 2.64 3.42 417 Cross Sectional Area of Nominal Diameter Wire 4 mm.sq. 1.936 3.497 5.269 8.814 13.140 Mass Breaking Load Min. Before Stranding 5 Kg./Km 15.10 27.27 41.09 68.75 102.48 6 KN 2.70 4.60 6.92 11.58 17.27 After Stranding 7 KN 2.57 4.37 6.57 11.00 16.41

FREEDOM FROM DEFECTS The wires shall be smooth and free from all imperfections, such as spills & splits. JOINTS IN WIRES & CONDUCTORS 7.1 All aluminium conductors : No joints shall be permitted in any wire. 7.2 Aluminium Conductor Steel Reinforced :

7.

Aluminium Wires : No two joints shall occur in the aluminium wires closer together than 15 metres. Steel Wires : No joints shall be permitted in steel wires used for ACSR of Sizes 20mm2 aluminium area (7/2.11mm), 30mm2 aluminium area (7/2.59mm), 50mm2 aluminium area (7/3.35mm) and 80mm2 aluminium area (7/4.09 mm). In the case of ACSR of 100mm2 aluminium area (6/4.72mm + 7/1.57 mm) having seven galvanised steel wires, joints, in individual wires shall be permitted but no two such joints shall be less than 15 metres apart in the complete steel core. 8. STRANDING The wires used in construction of a stranded conductor shall, before stranding satisfy all the 8.1 requirements of this standard for solid wires. 8.2 (i) Lay Ratio : The lay ratio for aluminium wires in case of AAC shall be within limits given below : No. of wires in conductors 7 Min. 10 Lay Ratio Max. 14

(ii)

The lay ratio for aluminium and steel wire in case of ACSR shall be within limits given below : No. of wires Ratio Aluminium Lay ratio for Steel wire Lay Ratio for

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Al. 6 6 9. Steel 1 7 wire dia to steel wire dia 1.000 3.000 (6 wire layer) Min. 13 Max. 28 Aluminium wire Min. 10 10 Max. 14 14

TESTS The samples of individual wires for the tests shall normally be taken before stranding. The manufacturer shall carry out test on samples taken out at least from 10% of aluminium wire spools and 10% of steel wire coils. However, when desired by the purchaser, the test sample may be taken from the stranded wires. a) The wires used for all aluminium conductors shall comply with the following tests as per IS:398(Pt.I)-1976. i) Breaking load test ii) iii) Wrapping test Resistance test

b) The wires used for aluminium conductors, steel reinforced shall comply with the following tests as per IS:398 (Pt.II)-1976 i) Breaking load test ii) Ductility test iii) Wrapping test iv) Resistance test v) Galvanising test 10. PACKING & MARKING The conductors shall be wound in reels or drums conforming to IS:1778-1980 Specification for Reels and Drums for bare wire or the latest version thereof. 10.1 Packing The gross mass for various conductors shall not exceed by more than 10% of the values given in 10.1.1 the following table : Conductor Size AAC
25mm2 Al. area (7/2.21 mm) 50mm2 Al. area (7/3.10 mm)

Gross Mass
500 Kg. 500 Kg.

ACSR 20mm2 Al. area (7/2.11 mm) 30mm2 Al. area (7/2.59 mm) 50mm2 Al. area (7/3.35 mm) 1000 Kg. 1000 Kg. 1500 Kg. 1500 Kg. 2000 Kg.

80mm2 Al. area (7/4.09 mm) 100mm 2 Al. area (6/4.72mm + 7/1.57mm)

The normal length of various conductors shall be as given in the following table : 10.1.2 Conductor Size Normal conductor length AAC
25mm2 Al. area (7/2.21mm) 50mm2 Al. area (7/3.10mm) 1.0 Km. 1.0 Km.

ACSR
20mm2 Al. area (7/2.11 mm) 30mm2 Al. area (7/2.59 mm) 50mm2 Al. area (7/3.35 mm) 80mm2 Al. area (7/4.09 mm) 100mm 2 Al. area (6/4.72mm + 7/1.57mm) 2.0 Km. 2.0 Km. 2.0 Km. 1.5 Km. 2.0 Km.

10.1.3

Longer lengths shall be acceptable.

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Short lengths, not less than 50% of the standard lengths, shall be acceptable to the maximum 10.1.4 extent of 10% of the quantity ordered. 10.2 a) b) c) d) e) f) g) h) 11. Marking : The following information shall be marked on each package : Manufacturers name Trade mark, if any Drum or identification number Size of conductor Number and lengths of conductor Gross mass of the package Net mass of conductor I.S.I certification mark, if any

INSPECTION
All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this Specification.

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REC Specification-2/1971 (Revised 1997) OUTDOOR TYPE THREE PHASE 11 KV/433-250 V CONVENTIONAL DISTRIBUTION TRANSFORMERS UPTO AND INCLUDING 100 KVA. FOREWARD This specification was originally issued in 1971 on the basis of the decisions taken in the First Standardisation Conference. The specification was subsequently revised in 1972, 1976, 1979, 1981 and 1983 on the basis of the decisions taken in various Standardisation Conferences. The modifications mainly related to incorporation of 16 KVA rating, provision of special type of drain-cum-sampling valve, making the provision of silica gel breather optional, reducing limits of no-load and full-load losses, stipulation of short-circuit and unbalanced current tests etc. The Specifications had been revised in 1988 to incorporate use of improved quality transformer oil, provision for DPC and other improved insulating materials etc. as approved by 11th Standardisation Conference. Based on the recommendations of 13th Conference on Standardisation, Technical Development and Training in Rural Electrification, held on 4th-6th May, 1993, the specification has been further revised to stipulate the use of clamp type terminals as an integral part of the bushings to directly receive aluminium conductors/cables without requiring use of lugs and to eliminate the possibility of ingress of moisture through the exposed threads of the bushing stems. Another important provision made in the Specification is the use of built-in LT Circuit breakers for proper protection of transformer against overloads and system faults. This measure is expected to substantially increase the service life of transformers and reduce failures. The characteristic of transformer oil after three days filling had also been incorporated. Due to all these measures the warranty period had been increased to 2 years from the date of supply or 18th months from the date of commissioning, whichever is earlier. During the 14th Conference on Standardisation and Technical Development held on 25th April, 1997, at New Delhi, it was decided to delete for the time being, the provision of an LT Circuit Breaker from the specification, till such time suitable LT Circuit Breakers, with time current characteristics matching with that of the transformers, are indigenously developed, manufactured and made available to the transformer manufacturers at a reasonable cost. The Conference also recommended changes to be made in the material to be used for inter layer insulation. Based on the above recommendations, the specification is being revised and issued. 1. SCOPE

This specification covers oil-immersed, naturally cooled, three-phase, 50 Hz, double-wound outdoor type distribution transformers of 16, 25, 63 and 100 KVA ratings for use in system with a nominal voltage of 11 KV. 2. APPLICABLE STANDARDS

Unless otherwise stipulated in this specification, the distribution transformers shall comply with the latest version of IS:1180 (Pt.I) and IS:2026. 3. STANDARD RATINGS The standard ratings shall be 16, 25, 63 and 100 KVA. 4. NO LOAD VOLTAGE RATIO The no load voltage ratio shall be as follows: a) b) 5. TAPS No taps are to be provided in these transformers. 6. WINDINGS 11000/433-250 V for 16, 25, 63 and 100 KVA 10450/433-250 V for 100 KVA only, whenever specified

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For 16 and 25 KVA transformer ratings, thermo-mechanically treated NML PM2 designation aluminium 6.1 alloy wires should be used for HV windings for better short circuit capability and longer life. The technical properties of these wires shall be as follows: i) ii) iii) Electrical Conductivity (Percentage IACS at 20oC.) Ultimate Tensile Strength (Kg/mm2) Percentage elongation at 250 mm gauge length 61-62 10-13 27-35

NOTE: The supplier shall furnish requisite data in support of the above properties as guaranteed technical particulars and shall also satisfy the inspecting officer in this regard.

Alternatively
Since the Government of India, Minisitry of Industry, New Delhi vide its letter No.19/(53)/93-E1. India dated 13.4.94 has allowed the use of copper windings also, the SEB may specify use of either aluminium or copper winding for these transformers depending upon their economic advantage. Unless otherwise specified, DPC insulation shall be used for HV and LV winding wires and Electrical Grade 6.2 plain insulation kraft paper shall be used for inter-layer insulation of the HV and LV coils. In case PVA enamelled conductor is used for HV/LV winding, electrical grade epoxy dotted, thermally upgraded kraft paper shall be used for inter-layer insulation. Use of single coil design for HV winding shall be preferred due to its better short-circuit behaviour. Corrugated cylinder made from pre-compressed insulation board should be used between HV and LV 6.3 windings. Angle shaped End Rings made from pre-compressed board should be used between the end coil and core 6.4 (with this provisions, the purchaser should not specify any minimum clearance between end coil and core). 6.5 The primary winding shall be connected in delta and the secondary winding in star(Vector Symbol Dy 11) so as to produce a positive displacement of 30 degrees from the primary to the secondary vectors of the same phase (Vector rotation assumed counter clockwise). The neutral of the secondary winding shall be connected to a separate insulated terminal. 7. FITTINGS The following standard fittings shall be provided:a) b) Two earthing terminals Oil level gauge indicating three positions of oil marked as follows:Minimum(-50C) 300C Maximum (980C) Lifting lugs Plain breathing device comprising an inverted U-pipe with wire gauze at the open end or Silica gel breather, as required by the purchaser. Drain-cum-Sampling Valve (Steel) of the type shown in Fig.1 welded to the tank. The operating this valve shall be supplied with the transformer. Thermometer pocket for 63 and 100 KVA units. Filling hole having P 1 thread (with cover) on the transformer body/conservator special tool for

c) d) e) f) g) 8.

CONSERVATOR. On transformer of 63 and 100 KVA, provision of conservator is obligatory. For 16 and 25 KVA 8.1 transformer, the manufacturers may adopt their standard practices. The conservator shall be provided with a drain plug and a filling hole with cover. In addition, the cover 8.2 of main tank shall be provided with an air release plug to enable trapped air to be released unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank.

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The inside diameter of the pipe connecting the conservator to the main tank shall be within 20 to 50 8.3 mm and it should project into the conservator in such a way that its end is approximately 20 mm above the bottom of the conservator so as to create a sump for collection of impurities. The minimum oil level (corresponding to 50C) should be above the sump level. 9. RATING AND TERMINAL MARKING PLATE(S)

Each transformer shall be provided with non-detachable rating and terminal marking plate(s) of weather proof material, fitted in a visible position and showing complete information as given in IS:1180(Pt.I). 10. LIMITS OF TEMPERATURE RISE.

The temperature rise shall not exceed the limit of 550C (measured by resistance) for transformer windings and 450C. (measured by thermometer) in top oil when tested in accordance with IS:2026. 11. LOSSES AND IMPEDANCE VALUES. 11.1 The no-load and load-losses shall not exceed the values given in the following table.: KVA Rating 16 25 63 100 Noload losses (Fixed loss) Watts 80 100 180 260 Load losses at 750C Watts 475 685 1235 1760

The above losses are maximum allowable and there will not be any plus tolerance. The capitalisation of losses will be allowed for lower losses offered. 11.2 12. The percentage impedance at 750C shall be 4.5% subject to tolerance as per IS:2026.

PERMISSIBLE FLUX DENSITY AND OVERFLUXING.

The flux density at rated voltage and frequency shall not exceed 1.69 tesla. The no-load current at Rated Voltage and at 112.5 percent Rated Voltage shall not exceed values given below:KVA Rating 16 25 63 100 Percentage of Rated full Load Current At 100% Rated Voltage 4.0 3.5 3.0 2.5 At 112.5% Rated Voltage 8 7 6 5

13.

BUSHING TERMINALS. To avoid bimetallic action at the point of connection to the aluminium windings and to the external 13.1 aluminium cables/conductors, both HV & LV bushing stems shall be made of aluminium alloy conforming to the requirement of IS: 3347. The busing terminals shall be of clamp type to directly receive aluminium conductors/cables without 13.2 requiring use of lugs. The terminal shall be directly screwed on to the stem to secure effective sealing of the bushing. Details of the terminals are given in Appendix-II.

14.

SEALING GASKETS

All sealing washers/gaskets shall be made of oil and heat resistant nitrile rubber. Gaskets made of natural rubber or cork sheet are not permissible. 15. TRANSFORMER OIL The transformer oil shall comply with REC Specification No. 39/1985(R-1993) (AppendixI).

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16. TESTS AND INSPECTION. 16.1 Routine Tests:All transformers shall be subjected to the following routine tests at the manufacturers work in accordance with IS:2026 and IS:1180(Pt.I). a) b) c) d) e) f) g) Measurement of winding resistance Measurement of voltage ratio and check of voltage vector relationship Measurement of impedance voltage/short circuit impedance and load loss Measurement of no-load loss and no-load current Measurement of insulation resistance Induced over-voltage withstand test Separate-source voltage withstand test

16.2. Type Tests. The following type tests shall be made on the transformers as per details given in IS:2026: a) to g) as indicated under routine tests: h) Lightning impulse test i) Temperature-rise test j) Short circuit test k) Air Pressure test(IS:1180 Part-I-1989). l) Unbalance current test: The value of unbalance current indicated by the ammeter as shown in the test arrangement in Fig.2 shall not be more than 2% of the full load current. If records of a type test on a transformer which, in essential details, is representative of the one being purchased are furnished, the purchaser may accept this as evidence of the type test instead of the actual test 16.3. The supplier shall furnish calculations in accordance with IS:2026 to demonstrate the thermal ability of the transformer to withstand short-circuit. 16.4. Inspection.

16.4.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge to satisfy him that the material is being furnished in accordance with this specification. 16.4.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply. 17. WARRANTY.

The supplier shall guarantee satisfactory performance of transformers and all the associated components for a period of 2 years from the date of receipt by the purchaser or 18 months from the date of commissioning, whichever is earlier. During the warranty period, all repairs/replacements shall be carried out free of cost and the warranty shall cover all failures except those caused by deliberate interference. 18. MOUNTING ARRANGEMENT. The under-base of all transformers shall be provided with two 75 x 40 mm M.S. Channels 460 mm long with holes as shown in Fig.3 to make them suitable for fixing on a platform or plinth.

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Appendix - I REC specification 39/1985 (Revised -1993) TRANSFORMER OIL FOR POWER/DISTRIBUTION TRANSFORMERS F0REWORD There is a general complaint by the SEBs and the transformer manufacturers that the quality of transformer oil being produced in the country is not upto the mark and the insulating properties of oil deteriorate very fast. The quality of oil often deteriorates even after a short period of storage or over a short-span of service of transformer, indicating unstable characteristics of the oil. This has an adverse effect on the service life of transformers and also poses serious maintenance problems for the SEBs.

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To improve the quality and stability of transformer oil, it appears necessary to specify certain ageing characteristic. IS:335-1983 which covers the specification for transformer oil does not specify the ageing characteristics. This aspect was discussed during the 11th Standardisation Conference held on 28th & 29th September, 1984 at New Delhi and it was decided to issue a standard specification for improved quality of transformer oil taking into account the useful experimental work done by the CPRI . This specification is based on the decision taken by the Conference. During 13th Standardisation Conference held on 4th-6th May 1993, this REC Specification was further discussed as a part of revision of REC Specification for conventional transformers (2/1971) and it was decided that the oil characteristics after filling in the transformer shall be tested after 3 days instead of 3 months as the oil characteristic gets stabilised after 3days of filling. This will save time for the transformer manufacturers and will also ensure good quality oil to the purchaser. Accordingly the specification has been revised. These characteristics will be further aliened to IS:1866 which is under revision and where characteristics of oil in the transformer are under consideration. 1. SCOPE

This specification covers the requirements of insulating oil for use in distribution and power transformers used in the rural electrification system. The requirements have been given in two parts : A) For new transformer oil in drums/tankers. B) For oil after it is filled in the transformer (the values shall be applicable after 3 days from the date of filling). Note: The difference between the characteristics stipulated for 'A' & 'B' above is in recognition of the fact that the oil characteristics may undergo some change after it is filled in the transformer. 2. APPLICABLE STANDARD Except as modified in this specification, the transformer oil will comply with latest version of IS:335-1983.

A. 3.
Sl.

New Oil The important characteristics of new oil shall be as follows:

Characteristics Flash point Pensky Marten(closed), Min. Neutralization value a) Total acidity, Max. b) Inorganic acidity/alkalinity Corrosive Sulphur Electric Strength (breakdown voltage) Min. a) New unfiltered oil b) New oil after filtration Dielectric dissipation factor (tan delta) at 90oC (Max.) Specific resistance ( resistivity) a) At 900C (Min.) b) At 270C (Min.) Oxidation stability a) Neutralization value after oxidation (Max.) b) Total sludge after oxidation (Max.) 140oC 0.03mg KOH/g Nil Non-Corrosive 30KV(rms) 50KV(rms) 0.005 30x1012 ohm-cm 500x1012 ohm-cm 0.40mg KOH/g 0.10% by weight Requirement

1 2
3 4 5 6

4.

AGEING CHARACTERISTICS Ageing characteristics after accelerated ageing (open beaker method with copper catelyst).

Specific resistance (resistivity) a)

i)

at 27oC

2.5x1012 ohm-cm (Min.)

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ii) b)
c) d) B. at 90oC 0.2x1012 ohm-cm (Min.) 0.20 Max. 0.05 Max. 0.05 Max.

Dielectric dissipation factor (tan delta) at 900C Total acidity in mg KOH/g Total sludge value (%) by weight

Characteristics of oil in the transformer

The important characteristics of the transformer oil after it is filled in the transformer (after 3 days of filling) shall 5. be as follows:

S.No.

Characteristics Electric strength (Breakdown voltage) Dielectric dissipation factor (tan delta) at 90oC Specific delta resistance (resistivity) at Flash point, P.M (Closed) Interfacial tension at 27o C Neutralization value (total acidity) Water content, PPM 27oC (Ohm-cm)

Specification 30 KV Min. 0.01 Max 10x1012 140oC (Min.) 0.03 N/m (Min.) 0.05 mg KOH/g (Max.) 35 (Max.)

1 2 3 4 5 6
7

6.

TESTS

All tests to verify the characteristics as incorporated in this specification shall be carried out in accordance with IS:335-1983 or its latest version.

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REC Specification 3/1971 (Revised 1993) 11KV PORCELAIN INSULATORS AND FITTINGS FOREWORD This specification was originally issued in 1971 on the basis of the decisions taken in the First and Second Standardisation Conferences. For strain insulators, only Tongue & Clevis type were standardised at that time. The specification was subsequently revised in the Tenth Standardisation Conference held in April 1983 to specify the material, shape and dimensions of the strain clamps. In the Tenth Conference, another important decision was taken to issue a new Specification No. 25/1983 for Helically Formed Fittings keeping in view their advantages such as ease of application, better quality of construction, less wastage of conductor etc. The specification on 11KV insulators and fittings was further revised in 1984 to incorporate dimensions of 11 KV Pin Insulators to facilitate application of Helically Formed Ties in accordance with the decisions taken at the 11th Standardisation Conference. The specification was again revised in 1988 to include provision of Ball & Socket strain insulators and fittings as an alternative to Tongue & Clevis insulators and fittings as per decision taken in the Twelfth Standardisation Conference held in July, 1987. The revised specification was discussed in the 13th Standardisation Conference held on 4th- 6th May, 1993. Based on the decisions taken in this Conference the revised specification is issued. Part-I : INSULATORS 1. SCOPE This specification covers details of porcelain insulators (Pin and Strain Insulators) for use on 11 KV overhead power lines in rural electric distribution system. 2. APPLICABLE STANDARDS Except when it conflicts with the specific requirements of this specification, the insulators shall comply with IS:731 and IS:3188 as amended from time to time. 3. GENERAL REQUIREMENTS 3.1 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.

Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain 3.2 parts of insulators except those areas which serve as support during firing or are left unglazed for the purpose of assembly. The design of insulators shall be such that stresses due to expansion and contraction in any part of the 3.3 insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal. Cement used in construction of insulators shall not cause fracture by expansion or loosening by 3.4 contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as uniform as possible. The insulators should preferably be manufactured in automatic temperature - controlled kilns to obtain 3.5 uniform baking and better electrical and mechanical properties. 4. CLASSIFICATION AND DIMENSIONS

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4.1 4.2 4.3 Both pin and strain insulators shall conform to Type B of IS:731. The dimensions of pin insulators shall be as shown in Fig. 1. The strain insulators shall be of Ball and Socket type or Tongue and Clevis type, as required by the

Purchaser. The dimensions of these insulators shall be as per Fig. 2.

5. TEST VOLTAGES 5.1 Highest System voltage KV(rms) 12 The test voltages of insulators shall be as under : Visible Discharge Test KV(rms) 9 Wet Power Frequency withstand Test KV(rms) 35 Power Frequency puncture withstand test Pin Insulator KV(rms) 105 Strain Insulator KV(rms) 1.3 times of the actual dry flash over voltage of the Insulator Impulse voltage withstand Test KV (Peak) 75

6.

FAILING LOAD Mechanical Failing Load (For Pin Insulators only) The insulators shall be suitable for a minimum failing load 6.1 of 5 KN applied in transverse direction. Electro-Mechanical Failing Load (For Strain Insulators) The insulators shall be suitable for a minimum 6.2 failing load of 45 KN applied axially.

7.

CREEPAGE DISTANCE The minimum creepage distance shall be as under : Highest System Voltage KV 12 Normal and Moderately polluted atmosphere mm 230 Heavily Polluted atmosphere Pin insulator mm 320 Strain insulator Mm 400

Note : Higher value of creepage distance has been specified for strain insulators as these are normally used in horizontal position in 11 KV lines. 8. TESTS The insulators shall comply with the following tests as per IS:731 :8.1 a) b) c) d) e) f) g) h) i) j) k) l) Type Tests Visual examination Verification of dimensions Visible discharge test Impulse Voltage Withstand Test Wet Power Frequency Voltage Withstand Test Temperature cycle test Mechanical Failing load test (for Pin Insulators only) 24-hour Mechanical strength Test for Strain Insulators Puncture Test Porosity Test Galvanising Test Electro-mechanical failing load test (for Strain insulators only)

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8.2 a) b) c) 8.3 a) b) c) d) e) f) 9. a) b) c) d) ROUTINE TESTS: Visual examination Mechanical routine test (for strain insulator only) Electrical routine test (for strain insulator only) ACCEPTANCE TEST: Verification of Dimensions Temperature cycle Test Electro-mechanical failing load test (for strain insulators only) Puncture test (for strain insulators only) Porosity test Galvanising test MARKING 9.1 Each insulator shall be legibly and indelibly marked to show the following : Name or trade mark of manufacturer Month and year of manufacture Minimum failing load in KN ISI certification mark, if any 9.1.1 10. Markings on porcelain shall be printed and shall be applied before firing.

PACKING All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail transport. Where more than one insulator is packed in a crate, wooden separators shall be fixed between the insulators to keep individual insulators in position without movement within the crate.

11.

INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed 11.1 upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency 11.2 whenever there is dispute regarding the quality of supply.

Part-II : INSULATOR FITTINGS 1. SCOPE This specification covers details and test requirements for (i) Pins for 11 KV Insulators, (ii) Helically Formed Pin Insulator Ties (iii) Fittings for Strain Insulators with Helically Formed Conductor Dead-Ends and (iv) Fittings for Strain Insulators with conventional Dead-End Clamps. 2. APPLICABLE STANDARDS Pins shall comply with the requirements of IS:2486 (Pt.I & II). Helically formed fittings shall comply with IS:12048-1987. Fittings for strain insulators shall comply with the requirements of IS:2486 Pt.I to IV. 3. 3.1 PINS FOR INSULATORS General Requirements The pins shall be of single piece obtained preferably by the process of forging. They shall not be made by joining, welding, shrink fitting or any other process using more than one piece of material. The pins shall be of good finish, free from flaws and other defects. The finish of the collar shall be such that a sharp angle between the collar and the shank is avoided. All ferrous pins, nuts and washers, except those made of

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stainless steel, shall be galvanised. The threads of nuts and taped holes, when cut after galvanising shall be well oiled or greased. 3.2 Dimensions

Pins shall be of small steel head type S 165 P as per IS:2486 (Part-II) having stalk length of 165mm and shank length of 150mm with minimum failing load of 5 KN. Details of the pins are shown in Fig. 3. 3.3 Tests

Insulator pins shall comply with the following test requirements as per IS:2486 (Part-I)-1993 or latest version thereof: 3.3.1. Type Tests a) b) c) d) 3.3.2 a) b) c) 3.3.3 Checking of threads on heads Galvanising test Visual examination test Mechanical test Acceptance Tests Checking of threads on heads Galvanising test Mechanical test Routine Test Visual examination test 4. HELICALLY FORMED PIN INSULATOR TIES

Helically formed ties used for holding the conductor on the pin insulator (Fig.4) shall be made of aluminium 4.1 alloy or aluminised steel or aluminium-clad steel wires and shall conform to the requirements of IS:12048-1987. The ties shall be suitable for pin insulator dimensions as per Fig. 1 of Pt. I and conductor sizes to be 4.2 specified by the purchaser. Note : Helically formed insulators ties are made to suit specific sizes of conductors, which specified by the purchaser. should be clearly

Elastomer pad for insulator shall be used with the ties to avoid abrasion of the conductor coming into 4.3 direct contact with the insulator. 4.4 Tests The ties shall be subjected to the tests specified in IS:12048-1987. 5. FITTINGS FOR STRAIN INSULATORS WITH HELICALLY FORMED CONDUCTOR DEAD-ENDGRIPS 5.1 Fittings for Strain Insulators of Tongue & Clevis Type 5.1.1 The fittings shall consist of the following components: a) Cross arm strap conforming to IS:2486 (Pt.II)-1989. b) Aluminium alloy die cast thimble-clevis for attaching to the tongue of strain insulator on one end and for accommodating the loop of the helically formed dead-end fitting at the other end in its smooth internal contour. The thimble shall be suitable for all sizes of conductors ranging from 7/2.11mm to 7/3.35mm ACSR. The thimble clevis shall be attached to the insulator by a steel cutter pin used with a non-ferrous split pin of brass or stainless steel. The thimble shall have clevis dimensions as per IS:2486 (Pt.II)-1989. c) Helically formed dead-end grip having a pre-fabricated loop to fit into the grooved contour of the thimble on one end and for application over the conductor at the other end. The formed fitting shall conform to the requirement of IS:12048-1987.

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Note : As the helically formed fittings are made to suit specific sizes of conductors, the purchase should clearly specify the number of fittings required for each size of conductor. 5.1.2 5.2 Nominal dimensions of the T&C type insulator fittings are shown in Fig. 5.

Fittings for Strain Insulators of Ball & Socket Type 5.2.1 a) The fittings shall consist of the following components: Cross arm strap conforming to IS:2486 (Pt.II)-1989.

b) Forged steel ball eye for attaching the socket end of the strain insulator to the cross arm strap. Forgingsshall be made of steel as per IS:2004-1978. c) Aluminium alloy thimble-socket made out of permanent mould cast, high strength aluminium alloy for attaching to the strain insulator on one end and for accommodating the loop of the helically formed dead-end fittings at the other end in its smooth internal contour. The thimble-socket shall be attached to the strain insulator with the help of locking pin as per the dimensions given in IS:2486 (Pt.II)-1989 and d) Helically formed dead-end grip as per clause 5.1.1(c) above. Nominal dimensions of the Ball & Socket type insulatorfittings are shown in Fig. 6.

5.2.2 5.3

Tests

The helically formed fittings for strain insulators shall be subjected to tests as per IS:12048-1987. The other hardware fittings shall be tested as per IS:2486 (Part-I). 6. FITTINGS FOR STRAIN INSULATORS WITH FITTINGS COVERED IN CLAUSE 5) CONVENTIONAL DEAD-END CLAMPS ALTERNATIVE TO

Fittings for strain insulators with conventional dead-end clamps for use with tongue & clevis or ball & 6.1 socket type insulators shall consist of the following components : a) Cross arms strap conforming to IS:2486 (Pt.II)-1989 b) Dead-end clamp made of aluminium alloy to suit ACSR conductors from 7/2.11mm to 7/3.35mm. The ultimate strength of the clamp shall not be less than 3000 Kg. The shape and major dimensions of clamps suitable for B&S and T&C insulators are shown in figures 7 & 8 respectively. 6.2 Tests

The fittings shall be subjected to type, routine and acceptance tests in accordance with the stipulations of IS:2486 (Pt.I). Note: Fittings for strain insulators as stipulated in Clause 5 are preferable to the fittings stipulated in Clause 6 both from the point of view of better quality of construction and ease of application. 7. PACKING For packing of GI pins, strain clamps and related hardware, double gunny bags or wooden cases shall be 7.1 used. The heads and threaded portions of pins and the fittings shall be properly protected against damage. The gross weight of the packing shall not normally exceed 50 Kg. Helically formed fittings shall be 7.2 packed in card-board / wooden boxes. Fittings for different sizes of conductors shall be packed in different boxes and shall be complete with their minor accessories fitted in place and colour codes on tags/fittings shall be marked to identify suitability for different sizes of conductors as per IS:12048-1987. 8. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed 8.1 upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being

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furnished in accordance with this specification. The purchaser has the right to have the test carried out at his own cost by an independent agency 8.2 whenever there is dispute regarding the quality of supply.

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REC Specification 4/1972 (Revised - 1979)

PORCELAIN INSULATORS AND INSULATOR FITTINGS FOR 415/240V OVERHEAD POWER LINES

FOREWORD Specifications for porcelain insulators and fittings for 415/240 volt lines were issued vide REC Specification No. 4/1972. This specification was prepared on the basis of the decisions taken at the First and Second Conferences on Standardisation held in 1971 and the Third Conference in 1972. The Specification was revised in 1976 to incorporate an additional size (Type 1) for shackle insulators. The revised Specification was approved by the Technical Committee on Standardisation at its meeting held in April, 1976 and subsequently by the Seventh Conference on Standardisation held in October, 1976. A proposal to further revise this Specification was placed before the Helping Committee on Standardisation in its meeting held in October, 1977. The proposed revision envisaged inclusion of fittings for Type 1 shackle insulators and bringing all other fittings in line with the Indian Standard Specifications. This revised Specification incorporates the decisions taken by the Helping Committee and subsequent approval of the Technical Committee on Standardisation in its meeting held in April, 1978 and the Eighth Conference on Standardisation, Research & Training in Rural Electrification held on 23rd-24th February, 1979. 1. SCOPE This Specification covers the details of the porcelain insulators and insulator fittings for use on 415/240 V overhead power lines met with in rural electric distribution systems. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the insulators shall comply with IS:1445-1977 and the fittings with IS:7935-1975 or the latest versions thereof. 3. PORCELAIN INSULATORS 3.1 General Requirements 3.1.1 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.

3.1.2 The glaze, unless otherwise specified, shall be brown in colour. Except for the screw threads and the parts on which the porcelain is supported during firing, which may be left unglazed, all other surfaces of the insulator shall be effectively glazed. 3.1.3 The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to its deterioration. 3.1.4 The insulator shall be in one piece.

3.2 Type of Insulators 3.2.1 Pin Insulator : Pin insulator is an insulator consisting of a single piece of porcelain and intended to be mounted rigidly on a supporting structure by a pin, which passes up inside the insulator. The pin type insulator shall have a top groove and shall be threaded to take mild steel pins, the profile of threads being as given in Fig. 5 of IS:1445-1977. The dimensions of pin insulator shall be as shown in Fig. 1. 3.2.2 Shackle Insulator : Shackle insulator is an insulator consisting of a single piece of porcelain and intended to be mounted vertically or horizontally , between and in contact with the two ends of a U strap or a pair of straps with its axis vertical and intended to secure a line conductor in tension. The dimensions of shackle insulator shall be as shown in Fig. 3 & 4. 3.3 Basic Insulation Levels The test voltages of the insulators shall be as under : Type of Insulator Wet One-Minute Power Frequency Withstand Voltage Power Frequency Puncture Withstand Voltage

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KV (rms) Pin Shackle KV (rms)

10 10

60 60

Note : The withstand voltage in Column 2 above is referred to the Reference Atmospheric Conditions as per IS:1445. 3.4 Mechanical Loads The insulators shall be suitable for the minimum failing load specified as under : Pin Insulator KN 3.5 Shackle Insulator 11.5 (Type 1) 16.0 (Type 2) KN

3.5 Tests The insulators shall comply with the following tests as per IS:1445. 3.5.1 Type Tests

The following tests shall constitute the type tests : a) Visual examination b) Verification of dimensions c) Wet power-frequency voltage withstand test d) Temperature cycle test e) Mechanical failing load test f) Power-frequency puncture withstand test and g) Porosity test 3.5.2 Acceptance Tests

The test samples shall be subjected to the following acceptance tests in the order indicated below : a) Verification of dimensions b) Temperature cycle test c) Mechanical failing load test (subject to mutual agreement between the purchaser and the supplier) and d) Porosity test 3.5.3 Routine Test :

The visual examination shall be carried out on each insulator. 3.6 Marking 3.6.1 Each insulator shall be legibly and indelibly marked toshow the following :

a) Name or trade mark of the manufacturer b) Year of Manufacture and c) ISI certification mark, if any 3.6.2 Marking on porcelain shall be printed and shall be applied before firing.

3.7 Packing All insulators shall be packed in baskets, crates or boxes as per manufacturers standard practice but suitable for rough handling. 4. INSULATOR FITTINGS 4.1 Pins

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4.1.1 General Requirements

4.1.1.1 The pins shall be obtained by the process of forging. They shall be of good finish, free from flaws and other defects. The finish of the collar shall be such that a sharp angle between the collar and the shank is avoided. 4.1.1.2 All ferrous pins, nuts and washers except those made of stainless steel, shall be galvanised. The threads of nuts shall be cut after galvanising and shall be well oiled or greased. 4.1.2 Dimensions

Pins shall have a stalk length of 135mm, shank length of 125 mm and minimum failing load of 2.0 KN. The dimensions of the pin shall be as given in Fig. 2. 4.2 Shackle Insulator Fittings 4.2.1 General Requirements

4.2.1.1 All parts shall be of good finish and free from flaws and other defects. The edges on the outside of fittings, such as at the holes etc. shall be rounded. 4.2.1.2 All ferrous fittings and the parts other than those of stainless steel shall be galvanised. Small fittings like spring washers, nuts etc. may be electro-plated with zinc. 4.2.1.3 Strap type fittings shall consist of the following: a) A pair of MS strap b) 2 Nos. MS bolts with hexagonal head and nuts c) 2 Nos. spring washers d) Helically formed conductor dead-end fittings made of aluminium alloy or aluminium-clad steel conforming to the requirements of REC Spec. No. 25/1983. 4.2.1.4 The complete details of shackle fittings to be used with steel cross-arms are shown in Fig. 3 & 4. 4.2.1.5 Alternatively, U clamp fittings shall be required. These would consist of : a) MS U - clamp b) 1 No. MS bolt and nut c) 1 No. spring washer d) Helically formed distribution side tie made of aluminium alloy or aluminium-clad steel conforming to the requirements of REC Spec. No. 25/1983. Note : Uclamp fittings are intended only for use on tangentlocations or for service lines where load is small; the strap fittings are meant for angle and dead-end locations. 4.2.2 Tests Insulator fittings shall comply with the following tests as per IS:7935. 4.2.2.1 Type Tests : The following shall constitute the type tests : a) b) c) d) e) Visual examination Verification of dimensions Checking of threads on heads Galvanising/electroplating test and Mechanical strength test (for pin insulator fittings only)

4.2.2.2 Acceptance Tests : The following shall constitute the acceptance tests : a) b) Checking of threads on heads and Galvanising test

4.2.2.3 Routine Test : Visual examination test shall be carried out as routine test

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4.3 Packing For packing of insulator pins and shackle fittings, double gunny bags or wooden cases, if deemed necessary, shall be employed. Helically formed fittings shall be packed in card board/wooden boxes. The gross weight of each packing shall not normally exceed 50 Kg. All nuts shall be hand-tightened over the bolts and screwed up to the farthest point.

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REC Specification 5/1974 (Revised-1993)

SINGLE PHASE AND THREE PHASE WHOLE CURRENT AC ELECTRICITY METERS

FOREWORD This specification was earlier issued in 1974. It was revised in 1976 and again in 1981 based on the recommendations of Standardisation Conferences held in 1973, 1976 and 1981 respectively. The representatives of Meter manufacturers and State Electricity Boards attended the various Standardisation Conferences. The recommendations of the manufacturers and SEBs were considered for finalisation of the specification. However, lot of modifications in the IS:722 part-II & III were affected in 1990 and a new IS bearing number 130101990 was brought out, superseding IS:722 Part-II, III, VIII & IX. Apart from this CBI&P had brought out a Specification on the Energy Meters for accuracy class-2 in January, 1989. Requests for modification/revision of REC Specification were received from various SEBs and therefore the revised REC Specification is being brought out taking into account the CBI&P specification 1989 as well as the IS:13010-1990. In the revised REC Specification, the test on material used for the dial has been added; apart from Vibration, Shock, Transportation, Impulse Voltage and Driving Torque Measurement tests. The clearance between rotating disc and the glass window has been reduced from 10mm to 8mm to align with CBI&P Specification. This specification was discussed during 13th Conference on Standardisation, Technical Development and Training held on 4th-6th May, 1993 at New Delhi. Based on the decisions taken in the Conference this revised specification is issued. SCOPE This specification covers the details of newly manufactured induction type single phase and 3-phase whole-current watt-hour meters of accuracy class-2 for measurement of active energy of nominal frequency in the range of 40 Hz to 60 Hz. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the meters shall comply with Indian Standard Specification IS:722 Part-I and IS:13010-1990 or the latest version thereof. 3. FIXING ARRANGEMENT Single-phase meters shall have two fixing holes - one at the top and one at the bottom. Three-phase meter shall have fixingholes - one at the top and two at the bottom. The top screw hole shall be provided in a special clip bent towards the back of the meter so that the screw-head is not accessible after the meter is fixed. The lower screw hole (s) shall be provided inside the terminal compartment so as to make them inaccessible to un-authorised persons after the terminal cover is sealed. 4. RATINGS 4.1 Current : The basic current ratings (Ib) for a single phase whole-current meter shall be 2.5 and 10 A. The corresponding rated maximum currents (Imax) shall be 5 and 20 A. These ratings shall be marked on the name plate as 2.5 - 5A and 10 - 20A respectively. 4.2 The rated maximum currents (Imax) for three-phase meters (corresponding to 120% of basic current) shall be 10, 30 and 50A. These meters shall only be of (Ib) 3-phase 4-wire type. 4.3 Voltage : The rated voltage shall be 240 V for single-phase and 415V for three-phase meters. However, since the voltage conditions experienced in the field are different and voltage varies from 180 to 285 volts, meters shall withstand these voltage conditions. In order to check that the meters will withstand these voltage conditions, 1.25 times rated voltage shall be applied while conducting heating test. 5. TERMINAL BLOCK AND TERMINALS The terminal block which is made of an insulation material shall be enclosed in a metallic housing 5.1 (preferably steel plate) to cover its back and sides to give sufficient strength particularly for the purpose of tightening the fixing screws. The screw holes shall preferably be provided with metallic sleeves or a metallic strip moulded in the block to avoid damage to terminal block while tightening the screws. The terminal block and its cover shall be such as to completely enclose the terminal compartment except 5.2 for the provision of conduit entry at the bottom for incoming and outgoing leads. The size of the holes for conduit entry shall be as specified by the purchaser. 1.

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The diameter of terminal holes for introducing the external conductor shall be 5.5mm for meters upto 30A 5.3 and 9.5mm for meters of 50A rating. Each terminal shall have two fixing screws. The terminals shall be made of electroplated brass and shall be made of replaceable type. The meter 5.4 chamber shall be made dust-proof and moisture-proof by providing suitable gaskets over the rear end of the terminals. The terminal screws (both for single phase and three-phase meters) shall not have a thread size less than 5.5 M-4 and head less than 5mm dia. The screws shall not have a pointed end at the bottom. Crimping pins (aluminium) generally conforming to IS:8309 shall be provided on the incoming and 5.6 outgoing terminals to facilitate proper cable termination at site. The sizes of crimping pins shall be as shown in the drawing enclosed. The minimum centre-to-centre clearance between the adjacent terminals shall be 13mm for meters up to 5.7 30A and 15mm for 50A meters. 6. ENERGY REGISTER The energy register shall only be of cyclo-meter type and shall comply with the requirements of the Indian 6.1 Standards. The register shall be capable of registering upto 9,999.9 units for single-phase meters and 99999.9 units for three phase meters. Both single-phase and three-phase meters shall be provided with a reverse running-stop to prevent the 6.2 meters from running in reverse direction. The material of drums shall be metallic/special synthetic material. The later material shall withstand 6.3 temperature ofboiling water for 5 minutes continuously without distortion or softening. The manufacturers shall supply type test certificate indicating the quality of material used for dial assembly; as per IS:13010-1990 Clause 11.18. 6.4 7. The ratio gear wheels shall be made only of metal.

DISCONNECTION DEVICE FOR THE METER VOLTAGE CIRCUIT

The disconnecting device for the voltage circuit shall be located inside the meter case and not in the terminal compartment. The device shall not be accessible when the meter case is sealed. 8. SEALING ARRANGEMENT At least two sealing screws shall be provided in the case of single-phase meters and three in the case of 38.1 phase meters for proper fixture of the meter cover. 8.2 The sealing screws shall have two independent sealing holes so that two separate seals can be provided.

The sealing screws used for the meter cover shall be fixed upside down so that these are tightened from 8.3 the rear side. 9. POWER LOSS

The maximum permissible power loss in potential coil shall be 1.5 watts. No weightage in price shall be given for offers with lower losses. 10 GENERAL REQUIREMENTS 10.1 10.2 10.3 10.4 10.5 10.6 A minimum of 8mm clearance shall be kept between window glass and disc. Rivets shall not be used in the arrangement adopted for fixing the window glass. The current and potential coils shall be made of enamelled copper wire. The dia of steel wire used as the top pivot pin of the disc assembly shall be of 0.5mm minimum. All electrically alive screws shall be of electroplated brass. All other screws shall be electroplated. Rubber or any other non-hygroscopic material shall be used for the gasket used for fixing the meter cover

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over the body. In the case of single phase meters, the magnet and phase adjustments shall be capable of being 10.7 operated either from the top or from the front. 10.8 The resistance wires of the power factor adjustment device shall have adequate tension to permit smooth and easy adjustments. A clear distance not less than 2mm shall be maintained between the resistance wire and the frame. If a press pahn insulation covering is used over the potential coil, it should be securely bound to avoid 10.9 loosening and consequent fouling with the meter mechanism. 10.10.1 The material for meter frame shall be of Die Cast Aluminium alloy with holes drilled in one setting or made out of steel sheet of minimum thickness of 18 SWG which will provide high mechanical strength and rigidity to the frame. 10.10.2 Suitable arrangement of earthing the meter shall be provided; as per clause 6.4.4 of IS:13010-1990. 11. MARKING & NAMEPLATES Every meter shall be marked with the information as per clause 8 of IS:13010-1990 and the marking shall be indelible, distinct and readable from outside. 12. TESTS 12.1 All type and routine tests laid down in IS:13010 shall be carried out. In addition to the above, the following 12.2 manufacturers on both single and 3-phase meters. type/acceptance/routine tests shall be carried out by the

12.2.1 Sustained Accuracy (Type Test) (i) An initial test for accuracy shall be carried out at the rated voltage and frequency at unity power factor at the following loads and the percentage errors noted :

Single-Phase a) b) c) 200% basic current 100% basic current 10% basic current

3-Phase 120% basic current 100% basic current 10% basic current

(ii) After the initial test, the meter shall be run preferably continuously at approximately the current stated at (a) above at rated voltage and unity power factor up to a registration in KWh numerically equivalent to 1000 Hrs. running at the current at (a) above, rated voltage and UPF. On completion of this run, the meter shall be re-tested as in 12.2.1(i) and the percentage errors shall not differ by more than 1% from the error of the meter under initial test for the test condition 12.2.1(a) and (b) and 2% for test conditions 12.2.1(c). (iii) The condition of the bottom bearing shall be examined after completion of the test, as specified in IS:13010. 12.2.2 Running at Low Load (Type Test) The energy registration mechanism of the meter shall be tested for satisfactory working at the point of maximum torque i.e. when all the drums are indicating digit 9. The test shall be carried out with 10% of the rated basic current and unity power factor. When so tested, the gearing mechanism should integrate continuously without any stoppage or slippage up to 0000.1 or 00000.1 as the case may be. 12.2.3 Transportation Test (Acceptance Test) At least 50% of the samples of the meters be tested for error at Imax, Ib and 5% Ib at Unity Power Factor and 50% Imax and 10% Ib at 0.5 Power Factor besides checking them for starting current and creep test. These meters should be tested with meters cover duly tightened and after these have been sealed properly. After recording these errors the meters be put in their normal packing i.e. card board boxes without blocking the rotor disc and transported for at least 50 km. in any transport vehicle such as pick up van, jeep etc. on uneven roads and then retested at all these loads after transportation. The variation in errors recorded before/after transportation should not exceed 1% at higher loads and 1.5% at low loads.

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13. PACKING Before despatching meters, the manufacturers should insert suitable temporary supports to block the movement of the disc, so as to avoid damage to delicate parts like pivots and bearings. All other recommendations made in the Indian Standard (IS:13010-1990 Annexure E) on packing of meters shall be adhered to. 14. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification.

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REC Specification 6/1974 415 V THREE PHASE SHUNT CAPACITORS FOREWORD In the Fourth Conference on Standardisation of Specification and Construction Practices in Rural Electrification held in New Delhi in April, 1973, it was decided that a Committee consisting of representatives of Andhra Pradesh, Haryana, Mysore, Punjab, Tamil Nadu and Uttar Pradesh State Electricity Boards, Central Board of Irrigation & Power and Rural Electrification Corporation should discuss in full detail the question of large scale application of LT Capacitors in rural electrification systems and recommend appropriate measures. The Committee held a meeting in New Delhi in July 1973 and all the important aspects of the matter were discussed. The Committee considered the application of shunt capacitors directly on the consumers' motors as one of the most practicable and economical methods of reducing the losses and improving the voltage conditions in the rural electrification systems. The Committee also discussed the ratings and other technical aspects of the capacitors to be used with general purpose induction motors commonly used for agricultural and small industrial connections. This Specification is based on the decisions taken at the meeting and subsequent discussions in the Fifth Conference on Standaradisation of Specifications and Construction Practices in Rural Electrification held in New Delhi in May 1974. 1. SCOPE This Specification covers 415 V, three-phase, 50 Hz, outdoor type capacitor units intended for power factor improvement of general purpose induction motors upto and including 7.5 KW (10 H.P.) output. 2. APPLICABLE STANDARDS Unless otherwise modified in this Specification, the shunt capacitor units shall comply with the Indian Standard Specifications IS:2834-1986 or the latest version thereof. 3. STANDARD RATINGS 3.1 The standard ratings of capacitor units shall be 1 KVAR, 2 KVAR, 3 KVAR and 4 KVAR for 50C temperature (IS:2834). 3.2 The recommended capacitor ratings to be used with small motors of various rated outputs are as follows : Motor rated output 2.2 KW (3 HP) 3.7 KW (5 HP) 5.5 KW (7.5 HP) 7.5 KW (10 HP) 4. RATED VOLTAGE The rated voltage of the capacitors shall be 415 V. 5. REACTIVE OUTPUT The maximum continuous reactive output of a capacitor (including any due to the flow of harmonic currents) shall not exceed 30 percent over the rated reactive output of the capacitor. 6. RATING PLATE A rating plate shall be provided on each capacitor unit containing the information specified in IS:2834. 7. CONNECTIONS AND TERMINALS The capacitor phase units shall be connected in delta internally and encased in hermetically sealed metal 7.1 container. 7.2 The three terminals shall be brought out in a terminal box which shall have a suitable water proof cover. Capacitor rating 1 KVAR 2 KVAR 3 KVAR 4 KVAR

7.3 Mode of connections of 3-terminal capacitor to a motor having a star-delta starter with six terminals in shown in REC Construction Standard H-9. 8. EARTH CONNECTION The capacitor container shall be provided with a suitable earthing terminal clearly marked as . 9. DISCHARGE DEVICE 9.1 Suitable discharge device shall be connected in the terminal box across the capacitor terminals.

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9.2 The discharge device shall reduce the residual voltage from the crest value of the rated voltage to 50 V or less within one minute after the capacitor is disconnected from the source of supply. 10. OTHER SAFETY REQUIREMENTS Capacitors shall comply with all the relevant safety regulations as per I.E. Rules 1956 and provisions of IS:2834.

11.

TESTS AND INSPECTION

11.1 Routine Tests : All capacitor units shall be subjected to the following routine tests at the manufacturers works in accordance with the details specified in IS:2834. a) b) c) d) e) f) Test for Output and/or Capacitance Voltage Test Between Terminals Voltage Test Between Terminals and Container Insulation Resistance Test Test for Efficiency of Discharge Device, and Test for Output and/or Capacitance ( the repetition of this test is necessary after the voltage and other tests in order to verify that no breakdown of any part of the capacitor has occurred during those tests )

In addition to the routine tests, the following tests (besides any other test especially prescribed by the 11.2 purchaser) shall be carried out only once by the manufacturer to rove that the design of capacitors complies with the requirements of this Specification and IS:2834: a) b) c) Test for Dielectric Loss Angle (Power Factor) Test for Capacitor Losses and Stability Test

Certificates of type tests carried out on a capacitor identical in all essential details with that being supplied 11.3 may be furnished by the manufacturer as evidence of compliance with this Specification. 11.4 Inspection

11.4.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 11.4.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply

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REC Specification 7/1974 (Revised - 1993) THREE PHASE 33/11KV STEP DOWN TRANSFORMERS FOREWORD This specification was originally issued in 1974 on the basis of the decisions taken at the Fifth Conference on Standardisation of Specifications and Construction Practices in Rural Electrification held in New Delhi in May, 1974. This Specification was revised in 1979 and again in 1981 on the basis of the decisions taken by the 8th and 9th Conference on Standardisation, Research and Training in Rural Electrification held in February, 1979 and April, 1981 respectively. Further proposals to revise the specification were discussed by the Helping Committee on Standardisation in its 7th Meeting held in April, 1982 and subsequently by the 10th Conference on Standardisation, Research and Training in rural electrification held in April, 1983. These proposals related to the modification in the value of the percentage impedance of 630 KVA power transformers, provision of short-circuit and vacuum tests. However, in 1986 the values of electrical characteristics of bushing insulators were revised (refer IS:2099-1986). The visible discharge test for bushing insulators was deleted altogether. These changes have been incorporated in the present revision of REC Specification. The revised specification is based on the discussions held in the 13th Conference on Standardisation, Technical Development and Training held on 4th-6th May 1993 at New Delhi.

1.

SCOPE This specification covers oil-immersed, naturally air-cooled (type ON) outdoor type, three-phase, 50Hz, 33/11KV step down power transformers of capacities up to and including 5000 KVA for use in rural electrification system.

APPLICABLE STANDARDS Unless otherwise modified in this Specification, the transformers shall comply with the latest version of Indian Standard Specification IS:2026.

STANDARD RATINGS The standard ratings shall be 630 KVA, 1600 KVA and 3150 KVA for transformers with off-circuit taps and 3150 KVA and 5000 KVA for transformers with on-load taps.

CONTINUOUS MAXIMUM RATING AND TEMPERATURE RISE As regards rating and temperature rise, all transformers shall comply with the appropriate requirements of IS:2026.

NO-LOAD VOLTAGE RATIO The no-load voltage ratio corresponding to the principal tapping shall be 33,000/ 11,000 V.

TAPS Off-circuit taps : Transformers with off-circuit taps shall have taps ranging from (+) 2.5% to (-) 10% in steps 6.1 of 2.5% each on HV winding for HV variation. The tap changing switch shall be located in a convenient position so that it can be operated from 6.1.1 ground level. The switch handle will be provided with a locking arrangement along-with tap position indication, thus enabling the switch to be locked in position. On-load taps : Transformers with on-load taps shall have taps ranging from (+) 5% to (-) 15% in steps of 6.2 2.5% each on HV winding for HV variation. 6.2.1 Equipment for only local electrical and local hand operation shall be provided. 6.2.2 The circuit arrangement shall be flexible to provide for addition of a transformer at a later date.

6.2.3 An out-of-step device shall be provided for each transformer which shall be arranged to prevent further tap changing when transformers in a group, operating in 'parallel control', are one tap out-of-step.

7.

WINDING CONNECTIONS AND VECTORS

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The primary winding shall be connected delta and secondary winding star as per vector symbol Dy11 7.1 (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). The neutral point of the secondary (L.V.) winding shall be solidly earthed and should be brought out to a 7.2 separate insulated terminal, enabling a current transformer for an earth leakage relay to be connected wherever required.

8. IMPEDANCE VALUES The percentage impedance at 75oC shall be 5% for 630 KVA transformers, 6.25% for 1600 KVA and 3150 KVA transformers and 7.15% for 5000 KVA transformers. The impedance values refer to the principal tapping and are subject to a tolerance of ()10%. The impedance values measured on any other tapping shall not exceed the value measured on the principal tapping by more than ()10%.

9. LOSSES The losses shall not exceed by more than 10% the values given below : 9.1 KVA Rating 630 1600 3150 5000 9.2 No Load Losses (KW) 1.45 3.00 4.50 6.50 Load losses (KW) 7.5 15.0 23.0 34.0

No weightage in prices for offers with lower losses would be given for these sizes of transformers.

10. TERMINAL ARRANGEMENT 10.1 Transformers shall preferably be provided with bushing insulators on both 33 KV and 11 KV sides, 33 KV and 11 KV bushings shall be located on opposite sides. However, cable box may be provided on the 11KV side if specially desired by the purchaser. 10.2 The electrical characteristics of bushing insulators shall be in accordance with IS:2099 as amended from time to time. All type and routine tests shall be carried out in accordance with IS:2099. The test voltages for various tests as stipulated in IS:2099-1986 are reproduced below:Nominal System Voltage KV 11 33 Rated Voltage of the bushing KV 12 36 One minute wet and dry power frequency voltage withstand test KV 28 70 Lightning impulse withstand test 1.2/50

s KV peak
KV 75 170

Dimensions of the 12 KV bushings (11 KV side) shall conform to IS:3347 (Part-III) and those of 36 KV 10.3 bushings (33 KV side) shall conform to IS:3347 (Part V). 11. GUARANTEE The manufacturer shall among other things guarantee the following : i) ii) iii) Quality & strength of materials used. Satisfactory operation during the guarantee period of one year from the date of commissioning or 24 months from date of receipt at site, whichever earlier Performance figures and all other details as required in IS:2026 are to be supplied by tenderer in the schedule of Guaranteed Particulars

12. TOLERANCES The tolerances of guaranteed performance figures shall be as specified in the latest version of IS:2026. 13. AXLES AND WHEELS The transformers of 5000 KVA rating shall be provided with flanged wheels suitable for use on a 1435 mm gauge track. These wheels shall be suitable for being turned through an angle of 90and locked in that position when the tank is jacked up. Other transformers shall be provided with bidirectional flat rollers suitable for use on a 1000mm gauge track.

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14. FITTINGS 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 specified in IS:2026 : a) b) c) d) e) f) g) h) i) j) k) Inspection Cover (1600 KVA and above) Rating Plate Diagram Plate Two Earthing Terminals Lifting Lugs Jacking Pads (3150 KVA and 5000 KVA) Conservator Dehydrating Breather Thermometer (dial type) with one Contact for Alarm Thermometer Pocket Oil level gauge indicating three positions of oil marked as follows : Minimum (-5oC) 30oC Maximum (98oC) Oil filling Hole and Cap Air Release Device Pressure Relief Device Gas and Oil actuated Relay (1600 KVA and above) Filter Valves (lower valves to be also used as drain valve)

l) m) n) o) p)

15. TESTS AND INSPECTION The following tests shall be carried out in accordance with the details specified in IS:2026 or as agreed upon between the purchaser and manufacturer. 15.1 Type Tests a) b) c) d) e) f) g) h) i) Measurement of winding resistance Measurement of voltage ratio and check of voltage vector relationship Measurement of impedance voltage Measurement of no-load loss and current Measurement of insulation resistance Lightning impulse test Temperature rise test Tests on on-load tap changers, where appropriate Vacuum test : Whereas the tank of the power transformer of 630 and 1600 KVA capacity (excluding tap changing compartment, radiators and coolers) shall be able to withstand 34.7 KN/m2 vacuum gauge pressure (250 mm of Hg), the transformer tank body of 3150 and 5000 KVA capacity shall be able to withstand a vacuum gauge pressure of 68.0 KN/m2 (500 mm of Hg). The permanent deflection of the flat plate after subjecting the transformer tank of each size to the above vaccuum for one hour shall not exceed the following values, and shall not affect the performance of the transformer : Horizontal length of flat plate (mm) Upto and including 750 751 to 1250 1251 to 1750 1751 to 2000 2001 to 2250 2251 to 2500 2501 to 3000 Above 3000 j) Short-circuit Test Permanent deflection (mm) 5 6.5 8 9.5 11 12.5 16 19

Note : In view of the high cost and delay involved in carrying out short circuit test and the cost of transportation etc., the purchaser may insist upon this test only if such a test has not been made earlier by the

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transformer manufacturer on a transformer of identical design. 15.2 Routine Tests The following shall constitute the routine tests : a) b) c) d) e) f) g) Measurement of winding resistance Measurement of voltage ratio and check of voltage vector relationship Measurement of impedance voltage/short-circuit impedance (Principal tapping) and load loss Measurement of no-load loss and current Measurement of insulation resistance Dielectric tests Tests on on-load tap changers, wherever appropriate

15.3 INSPECTION 15.3.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 15.3.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply .

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REC Specification 8/1975 (Withdrawn)

11KV OIL CIRCUIT BREAKERS FOREWORD

A meeting was convened at New Delhi on the 9th September,1974 with the representatives of the circuit breaker manufacturers to discuss the various aspects of standardisation of 11KV circuit breakers for use in rural electrification systems. The meeting was attended by the representatives of M/s BHEL, Crompton Greaves, GEC, Jyoti, MEI,NGEF, Siemens and Voltas. Subsequently, the subject was discussed in detail at the Helping Committee meeting held in November, 1974. Besides the officers of the Rural Electrification Corporation, the meeting was attended by the representatives of the State Electricity Boards of Bihar, Gujarat, Maharashtra, Orissa, Uttar Pradesh and West Bengal, Central Water and Power Commission, Indian Standards Institution and Indian Electrical Manufacturers Association. The specification has been prepared on the basis of the discussions held in the above meetings and the decisions taken in the subsequent meeting of the Technical Committee on Standardisation of Specifications and Construction Practices in Rural Electrification held in New Delhi in January, 1975. This specification has been further revised to bring it in line with the latest versions of the Indian Standard Specifications on Circuit Breakers IS:2516 (Part I to V/Sec.2)--1980, Voltage Transformers IS:3156-1978 and Current Transformers IS:2705-1981. 1. SCOPE This Specification covers 3-pole, 50Hz, 11KV Oil Circuit Breakers both for indoor and outdoor installation in rural electrification systems. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the circuit breakers shall comply with the following Indian Standards as amended from time to time: IS:2516 (Circuit Breakers) IS:3156 (Voltage Transformers) IS:2705 (Current Transformers) 3. RATED VOLTAGE The rated voltage for these circuit breakers shall be 12KV. This represents the highest system voltage corresponding to the nominal system voltage of 11KV. 4. RATED NORMAL CURRENT 4.1 4.2 5. The standard rated current shall be 400 A. The bus-bar rating of the circuit breakers (indoor type) shall be 800A

RATED SHORT CIRCUIT BREAKING CURRENT The rated short circuit breaking current is characterised by (a) rms value of its A.C.component circuit current and (b) the percentage D.C. component. 5.1 5.2

termed rated short-

5.3

The rms value of the a.c. component of the rated short circuit breaking current shall be 8KA (150MVA approximately) and 12.5KA(250 MVA approximately) It is recommended that breakers with 12.5 KA breaking current may be used only when the proposed/anticipated transformer capacity is 2 x 5 MVA (capacities above 2 x 5 MVA are not generally met within the rural system). For lower transformer capacities, breakers of only 8 KA breaking current may be used. The value of percentage D.C. component shall be calculated in accordance with the recommendations contained in IS:2516 (Pt.II/Section 2)- 1980.

6. RATED SHORT CIRCUIT MAKING CURRENT The rated short circuit making current of a circuit breaker shall be 2.5 times rms value of a.c. component of its rated short circuit breaking current. 7. RATED VOLTAGE OF OPERATING DEVICES The standard D.C. Voltage for the operating devices at 33/11KV sub-stations shall be 24 V.

METERING The meters/instruments on the incoming and outgoing circuit breaker panels shall be provided in accordance with the REC Construction Standard L-3. This Construction Standard stipulates the provision of energy meters on each of the incoming and outgoing panels to facilitate the assessment of losses. However, as a measure of economy, energy

8.

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meters may be provided in the initial stages only on one or more of the outgoing panels (in addition to the incoming panels) as considered necessary by the Electricity Boards. Suitable space and the necessary wiring should, however, be provided on all the panels so that energy meters can be provided whenever considered necessary. 9. VOLTAGE TRANSFORMER FOR METERING 9.1 9.2 Voltage Ratio: The rated voltage ratio shall be 11000/110V. The transformer shall be star-star connected and one of the secondary terminals shall be earthed Rated Output: The standard rated output (burden) of the voltage transformer shall be 100 VA per phase. Normally only one 3-phase voltage transformer of this rated out-put will be required at a 33/11KV sub-station. Accuracy Class : The standard accuracy class shall be 1.0.

9.3 10.

CURRENT TRANSFORMER FOR METERING & PROTECTION 10.1 Transformation Ratio : The standard transformation ratios shall be: (i) (ii) (iii) 50 - 25/5A 200 -100/5A 300 -150/5A

The above double ratio current transformers will generally be adequate to cover the load demands of all the outgoing feeders as well as the requirements of incoming panels to be used for transformer capacities upto 5 MVA used in rural distribution systems. 10.2 Accuracy Class: The current transformer shall have one secondary winding to serve a dual purpose, that is, for metering as well as protection. Accuracy class for the purpose of metering shall be 1.0 and for the purpose of protection shall be 5P with an Accuracy Limit Factor of 10. 10.3 Rated Output : The rated output (burden) of the current transformers which depends upon the type and make of relays and meters used, will have to be decided in each case. 11. TESTS The circuit breakers, voltage transformers and current transformers shall be subjected to the following 11.0 routine and type tests in accordance with the details specified in the relevant Indian Standards as amended from time to time. 11.1 Circuit Breakers-IS:2516(Part IV/Sec.2)-1980. 11.1.1 Routine Tests a) b) c) d) Power frequency voltage dry tests on the main circuit Voltage test on control and auxiliary circuit Measurement of resistance of the main circuit Mechanical Operating test

11.1.2 Type Tests : The type test comprise : a) b) c) d) e) f) g) h) i) j) 11.2 Tests to prove mechanical performance Tests to prove mechanical operation Tests to prove that temperature rise of any part does not exceed specified limits Test to prove that insulation complies with specified limits Test to prove short circuit making and breaking performance Test to prove short circuit current performance Test to prove performance when breaking line charging current Test to prove performance when breaking cable charging current Test to prove the performance when breaking single capacitor bank currents Test to prove the performance when breaking small inductive current

Voltage Transformer-IS:3156 (Part I)-1978 11.2.1 Routine Tests a) b) c) d) Verification of terminal marking and polarity Power-frequency dry withstand tests on primary windings Power-frequency dry withstand tests on secondary windings Determination of errors according to the requirements of the appropriate accuracy class

11.2.2 Type Tests a) Verification of terminal marking and polarity

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b) c) d) e) f) 11.3 Power frequency dry withstand tests on primary windings Power frequency dry withstand tests on secondary windings Determination of errors according to the requirements of the appropriate accuracy class Temperature-rise test Impulse voltage tests on voltage transformers for service in electrically exposed installations

Current Transformers -IS:2705 (Part I)-1981 11.3.1 Routine Tests a) b) c) d) e) Verification of terminal markings and polarity High voltage power-frequency test on primary windings High voltage power frequency test on secondary windings Over voltage inter-turn test Determination of error according to the requirements of appropriate accuracy class

11.3.2 Type Tests a) b) c) d) e) f) g) h) Verification of terminal markings and polarity High Voltage power frequency test on primary windings High voltage power frequency test on secondary windings Over voltage inter-turn test Determination of error according to the requirements of appropriate accuracy class Short-time current tests Temperature rise test Impulse voltage test for current transformers for service in electrically exposed installations

12.

INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially 12.1 agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with the specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency 12.2 whenever there is dispute regarding the quality of supply.

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REC Specification 9/1975 (Revised-1993)

RUBBER HAND GLOVES FOREWORD

Rural Electrification Corporation had issued a Specification on Rubber Hand Gloves based on the discussions in the meeting of Technical Committee on Standardisation on Specifications and Construction Practices in Rural Electrification held in New Delhi in January, 1975. The Indian Standard Specification IS:4770 which was first issued in 1968 was revised in 1991. In the revision, the requirements of type 3 gloves have been modified to make them suitable for working potential up to 7500 volts. The revision also incorporates close fitting thinner gloves for working potential up to 650V to have high degree of flexibility. The retesting prescribed before use covers additional safety factors and takes into account the effect of storage in humid conditions. The length of the gloves has also been given in the revised IS. As so many modifications have been incorporated in the revised IS, it was considered necessary to adopt the same in REC Specification. Accordingly the revised REC Specification had been prepared and was placed before 13th Conference on Standardisation, Technical Development and Training in Rural Electrification held on 4th - 6th May 1993. Based on the recommendations of the 13th Conference, this revised specification is issued. 1. SCOPE

This specification covers rubber insulated hand gloves used for protection of electrical workers from electric shock. These gloves are intended for working on live low and medium voltage lines and equipment. These are also used for the operation of 11KV and 33KV AB Switch operating handles etc. as a precaution. 2. APPLICABLE STANDARDS

Unless otherwise modified in this specification, the rubber hand gloves shall comply with the Indian Standards Specification IS:4770-1991 or the latest version thereof. 3. MANUFACTURING PROCESS

Only the gloves made from liquid rubber by dipping process shall be acceptable. The gloves should be seamless, soft and flexible to allow easy movement of hands. 4. ELECTRICAL PROPERTIES 4.1 The gloves shall be of Type 1 and Type 3 (IS:4770) conforming to the following characteristics:

Type

Max. working Potential (rms) 650V 7500V

Test potential (rms) 5000V 17000V

Leakage current (rms) at working voltage A (max.) 400 4000

Max. leakage current (rms) at Test potential 4 mA 14 mA

1 3 4.2 5.

The minimum breakdown voltage of the gloves shall be 6000V for Type 1 and 20,000 V for Type 3 gloves.

DIMENSIONS The gloves shall be of gauntlet type and the minimum internal length from the tip of the second finger to 5.1 the edge of the cuff shall be 400mm. The maximum and minimum thickness of the gloves shall be in accordance with the provisions of 5.2 Indian Standards. The gloves shall be supplied in three sizes viz. 8,9 and 11 as per requirement of the purchaser. The standard dimensions of each size shall conform to the Indian Standards.

6.

PHYSICAL PROPERTIES

The allowable values of Tensile strength, Elongation at Break, Tension set and Ageing properties shall be as stipulated in the Indian Standards. 7. PACKING AND MARKING 7.1 The gloves shall be marked with the following information :

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a) b) c) d) 8. TESTS 8.1 Routine Tests : Each and every glove shall be subjected to the following routine tests in accordance with the details indicated in IS:4770. a) Visual examination for workmanship the gloves shall have smooth surface and shall be free on both inner and outer surface from visual defects like patches, blisters, porosity, embedded foreign matter or any other physical defects Thickness Proof of voltage and leakage current Size and type of gloves Maximum working potential followed by the word working in brackets Manufacturer's name for recognised trade mark Month and year of manufacture

b) c)

8.2

Acceptance Tests: The following shall constitute acceptance tests: a) b) c) d) e) f) Thickness Tensile strength and ultimate elongation Puncture resistance Moisture absorption Test potential and leakage current Breakdown voltage

8.3 Type Tests: In addition to the routine and acceptance tests, the following type tests shall be made (for this purpose sampling procedure laid down in the IS may be followed):a) b) c) d) e) f) g) h) i) k) l) m) n) 9. PACKING Thickness Tensile strength Elongation at break Tension set Tensile stress at 200 percent elongation Tear strength Tensile strength and elongation at break after heat ageing Puncture resistance Moisture absorption Nitrogen content (for natural rubber only) Ash content (for natural rubber only) Test potential and leakage current Breakdown voltage

The gloves may be packed in polyethylene bags and sealed or as agreed to between purchaser and supplier. 10. INSPECTION 10.1 All tests and inspection shall be made at the place of manufacture unless otherwise specially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency 10.2 whenever there is dispute regarding the quality of supply.

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REC Specification 10/1976

11KV LIGHTNING ARRESTERS FOREWORD

A meeting of the Helping Committee on Standardisation of Specifications and Construction Practices in Rural Electrification was held in New Delhi in February,1976. Besides the officers of the Rural Electrification Corporation, the meeting was attended by the representatives of the State Electricity Boards of Bihar, Gujarat, Maharashtra, Uttar Pradesh, West Bengal, Central Electricity Authority, Indian Standards Institution and Indian Electrical Manufacturers Association. A representative of M/s W.S Insulators also attended the meeting by special invitation. This specification has been prepared on the basis of the decisions taken at the above meeting and subsequent discussions in the meeting of the Technical Committee & 7th Conference on Standardisation of Specifications and Construction Practices in Rural Electrification held in New Delhi in April, 1976 & October, 1976 respectively. 1. SCOPE This Specification covers non-linear resistor type lightning arresters for use in effectively earthed rural distribution system with a nominal voltage of 11KV. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the lightning arresters shall comply with the Indian Standards Specification IS:3070 (Pt-I)-1985 or the latest version thereof. 3. VOLTAGE RATING

The rated voltage of lightning arresters shall be 9KV (rms). This will be applicable to the effectively earthed 11KV system (co-efficient of earth not exceeding 80 per cent as per IS:4004) with all the transformer neutrals directly earthed. 4. NOMINAL DISCHARGE CURRENT RATING The nominal discharge current rating of the lighting arresters shall be 5 KA. 5. GUARANTEE The manufacturer shall guarantee satisfactory performance of the lightning arresters for a period of 12 months from the date of installation or 18 months from date of receipt by the purchaser, whichever is earlier. 6. TESTS The following routine and type tests as laid down in IS:3070 (Part-I)-1985 shall be carried out. 6.1 ROUTINE TEST Dry Power-frequency spark over test. TYPE TESTS Voltage withstand tests of arrester insulation. Power-frequency spark over test. Hundred per cent 1.2/50 microsecond impulse spark over test. Front-of-wave impulse spark over test. Residual voltage test. Impulse current withstand test. Operating duty test. Temperature cycle test on porcelain housing. Porosity test on porcelain components. Galvanizing test on metal parts.

6.2 a) b) c) d) e) f) g) h) i) j)

7. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed 7.1 upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency 7.2 whenever there is dispute regarding the quality of supply.

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REC Specification 11/1976 (Revised - 1993)

OUTDOOR TYPE THREE PHASE 11 KV/433-250V SEALED DISTRIBUTION TRANSFORMERS UPTO AND INCLUDING 100KVA FOREWORD This specification was originally issued in 1976 on the basis of the decisions taken in the Seventh Standardisation Conference. The specification was subsequently revised in 1979, 1981 and 1983 on the basis of the decisions taken in various Conferences. The modifications mainly related to design and testing of tank, provision of special doublebushing arrangement, short-circuit test etc. The specification had been revised in 1988 to incorporate use of improved quality transformer oil, provision for DPC and other improved insulating materials etc. as approved by the 11th Standardisation Conference. The revised specification alsoincorporated certain modifications in the design of the HV and LV bushings to make these more reliable and to remove the deficiencies noticed during field experience. These changes were approved in the 12th Standardisation Conference held in July, 1987. Based on the recommendations of 13th Conference on Standardisation, Technical Development and Training in Rural Electrification, held on 4th-6th May, 1993, the specification has been further revised to stipulate the use of clamp type terminals as integral part of the bushings to directly receive aluminium conductors/cables without requiring use of lugs and to eliminate the possibility of ingress of moisture through the exposed threads of the bushing stems. Another important provision made in this specification is the use of built-in LT circuit breaker for proper protection of transformer against overloads and system faults. This measure is expected to substantially increase the service life of transformers and reduce failures. The characteristic of transformer oil after 3 days of filling has also been incorporated. Due to all these measures, the warranty period has been increased to 2 years from the date of supply or 18 months from the date of commissioning, whichever is earlier.

1.

SCOPE This specification covers oil-immersed, naturally cooled, 3-phase, 50 Hz, double-wound, out-door type sealed distribution transformers of 16, 25, 63 and 100 KVA ratings for use in system with a nominal voltage of 11 KV.

APPLICABLE STANDARDS Unless otherwise stipulated in this specification, the Sealed Distribution Transformers shall comply with the latest version of IS:1180 (Part-II) and IS:2026.

2.

3.

STANDARD RATINGS The standard ratings shall be 16, 25, 63 and 100 KVA.

4.

NO-LOAD VOLTAGE RATIO The no-load voltage ratio shall be as follows: a) 11000/433-250V for 16,25,63 and 100 KVA b) 10450/433-250V for 100 KVA only, whenever specified. TAPS No taps are to be provided in these transformers. WINDINGS For 16 and 25 KVA transformer ratings, thermo-mechanically treated NML-PM2 designation aluminium 6.1 alloy wires should be used for HV windings for better short-circuit capability and longer life. The technical properties of these wires shall be as follows: i) ii) iii) Electrical Conductivity (Percentage IACS at 20 o C) Ultimate Tensile Strength Percentage elongation at 250mm gauge length (Kg/mm 2) 61-62 10-13 27-35

5.

6.

Note : The supplier shall furnish requisite data in support of the above properties as guaranteed technical particulars and shall also satisfy the inspecting officer in this regard. 6.2 Unless otherwise specified, DPC insulation shall be used for HV and LV winding wires and Electrical Grade Epoxy Dotted insulation paper shall be used for inter-layer insulation of the HV and LV coils. Use of single

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coil design for HV winding shall be preferred due to its better short-circuit behaviour. Use of aluminium foil for LV winding shall be preferred. 6.3 Corrugated cylinder made from pre-compressed insulation board should be used between HV and LV windings. 6.4 Angle shaped End Rings made from pre-compressed board should preferably be used between the end coils and core (with this provision, the purchaser should not specify and minimum clearance between end coil and core). 6.5 The primary winding shall be connected in delta and the secondary winding in star (Vector Symbol Dy 11), so as to produce a positive displacement of 30o from the primary to the secondary vector of the same phase. The neutral of the secondary winding shall be connected to a separate insulated terminal. 7. FITTINGS The following standard fittings shall be provided : a) b) c) d) Two earthing terminals Two lifting lugs Nitrogen/air filling device/pipe with welded cover capable of reuse An extended pipe for filling of oil at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing the welded cover

No conservator shall be provided on these transformers. 8. RATING AND TERMINAL MARKING PLATE(S) Each transformer shall be provided with non-detachable rating and terminal marking plate(s) of weather proof material, fitted in a visible position, showing the complete information as given in IS:1180 (Part-II). LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limit of 55o C (measured by resistance) for the transformer winding and 45o C (measured by thermometer) in top oil when tested in accordance with IS:2026. 10. LOSSES AND IMPEDENCE VALUES 10.1 The no-load and load losses shall not exceed the values given in the following table: KVA Rating 16 25 63 100 No-load loss (Watts) 80 100 180 260 Load loss at 75 o C (Watts) 475 685 1235 1760 9.

The above losses are to be measured exclusive of LT circuit breaker and are maximum allowable and there will not be any plus tolerance. No weightage in prices for offers with lower losses shall be given. 10.2 The percentage impedance at 75 o C shall be 4.5 percent subject to tolerance as per IS:2026 (To be measured exclusive of LT circuit breaker). 11. PERMISSIBLE FLUX DENSITY AND OVERFLUXING The flux density at rated voltage and frequency shall not exceed 1.69 tesla. The no-load current at Rated Voltage and at 112.5% Rated Voltage shall not exceed values given below: KVA Rating 16 25 63 100 Percentage of Rated Full Load Current At 100.% Rated Voltage 4 3.5 3 2.5 At 112.5% Rated Voltage 8 7 6 5

12. TRANSFORMER OIL The transformer oil shall comply with REC Specification No. 39/1985 (R-1993).

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13. HV BUSHINGS 13.1 To enable replacement of the outer porcelain bushing without opening the cover and without affecting the sealing arrangement of the transformer, the HV bushing shall be made in two parts. The external porcelain bushing shall conform to the requirements of IS:3347 Part-III/Sections 1 and 2. The internal bushing shall also preferably be made of porcelain and shall have a separate aluminium alloy stem. Alternatively, the internal bushing may be made of epoxy and shall have embedded stem and each bushing shall be subjected to Partial Discharge Test as per the stipulations of IS:2099 to avoid the possibility of any air void remaining in the cast. A typical arrangement of the two-part HV bushing with internal porcelain bushing is shown in Fig.1. The alternative arrangement with internal epoxy bushing is shown in Fig.2. However, the manufacturer is free to adopt a different arrangement provided it satisfies all the requirements of this clause. 13.2 Metal parts of the internal HV bushings inside the transformer shall remain immersed in oil under all operating conditions. 13.3 The following minimum clearance shall be provided : Enclosed 127mm 76mm External 255mm 140mm

Phase-to-phase Phase-to-earth 14.

LV ENCLOSURE 14.1 The transformer shall have a built-in 415V, LT circuit breaker on the secondary side. The breaker shall be housed in an enclosure conforming to IP44 as per IS:2147 forming integral part of the transformer. Suitable louvers fitted with wire gauze shall be provided to ensure circulation of air but not to allow ingress of rain water. The enclosure shall be suitably lined with a thermally insulating material to prevent excessive temperature rise inside the enclosure. An operating handle shall be provided outside the enclosure in such a way that ON and OFF operations of the breaker can be conveniently performed from the ground level by means of an operating rod. The ON and OFF positions of the handle shall be clearly and boldly marked on the enclosure and there should be no intermediate re-set position. 14.2 The outgoing terminals of the breaker shall be connected to outdoor type LT porcelain bushings provided on the top of the enclosure and the bushings shall have terminals of the type stipulated in clause 15. Suitable epoxy bushings, with embedded aluminium alloy stem, should be used inside the enclosure for effective sealing of the tank. The bushing shall be connected to incoming terminals of the circuit breaker. It should not be necessary to open the enclosure for making connections of the suppliers LT cables to the external bushing. 14.3 The circuit breaker shall generally conform to the requirements of IS:2516 part 1 & 2 Sec-I 1985 or its latest version. The electrical characteristics of the breakers shall be as follows : Transformer rating (KVA) 1 16 25 63 100 Full load current of the transformer (AMP) 2 21.33 33.33 84.00 133.30 Rated thermal current of C.B. (AMP) 3 31.5 40 100 160 Current setting (AMP) 4 22 35 90 140 Minimum short circuit breaking current (KA) 5 2.5 2.5 3 5

The circuit breakers shall conform to P-2 duty of IS:2516 (part I & II/Sec-1) 1985 but the tests shall be carried out at a power factor not exceeding 0.4 (lagging). The circuit breakers shall have the following time/current Characteristics when tested in 14.4 accordance with IS:2516 and tests will be made with all the 3-phases loaded. The reference calibration temperature of the breakers shall be 50 o C. Multiple of Normal Current Setting 1.05 1.2 1.3 1.4 2.5 4.0 More than 2.5 hours More than 10 minutes but less than 2 hours Less than 30 minutes Less than 10 minutes Less than 1 minute Not less than 2 seconds Tripping Time

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6.0 12.0 Less than 5 seconds Instantaneous (less than 40 milli seconds)

The LT circuit breaker and the associated terminals/wiring shall bedesigned with reference to 14.5 ambient temperature of 55 o C instead of 40 o C stipulated in IS:2516 due to operation in metallic enclosure installed outdoors. The permissible temperature rise limits stipulated in IS:2516 shall be reduced accordingly and the supplier shall furnish necessary data to show that all the components are suitable for the expected temp. rise over and above the ambient temp. of 55 o C under various loading conditions. The supplier shall furnish all the type and routine test certificates of the circuit breakers in accordance with IS:2516 (Part I & II/Sec 1) 1985 or its latest version. 15. BUSHING TERMINALS 15.1 To avoid bimetallic action at the point of connection to the aluminium windings and to the external aluminium cables/conductors, both HV & LV bushing stems shall be made of aluminium alloy conforming to the requirements of IS:3347. The bushing terminals shall be of clamp type to directly receive aluminium conductors/cables without 15.2 requiring use of lugs. The terminals shall be directly screwed on to the stem to secure effective sealing of the bushing. Details of the terminals are given in Appendix-II of REC specification No.2/1971 ( R-1997). 16. SEALING GASKETS All sealing washers/gaskets shall be made of oil and heat-resistant nitrile rubber. Gaskets made of natural rubber or cork sheet are not permissible. 17. TANK CONSTRUCTION The transformer tank shall be made of good quality steel sheet of adequate thickness and shall be suitably stiffened to provide sturdy and robust construction to withstand extreme pressure conditions. The tank shall be capable of withstanding pressure upto (+)80 KPa and (-) 70 KPa (gauge pressure) without any deformation. The transformer cover shall be welded to the tank in such a way that it shall be possible to remove the weld and reweld the transformer at least twice. 18. TANK SEALING Space on the top of the oil shall be filled either with nitrogen conforming to commercial grade as per IS:1747 or dry air. The nitrogen/air plus the oil volume inside the tank shall be such that even under extreme operating conditions, the pressure generated inside the tank shall not exceed (+) or (-) 40KPa. 19. TESTS 19.1 Routine Tests :All transformers shall be subjected to routine tests at the manufacturers works. The following routine tests shall be carried out in accordance with the details specified in IS:1180 (Part-2) & IS:2026 or as agreed upon between the purchaser and the manufacturer : a) b) c) d) e) f) g) h) Measurement of winding resistance Measurement of voltage ratio and check of voltage vector relationship Measurement of impedance voltage, short-circuit impedance and load loss Measurement of no-load loss and no-load current Measurement of insulation resistance Induced over-voltage withstand test Separate source voltage withstand test Air pressure test (IS:1180 Part-2, 1989)

19.2 Type Tests :The following type tests shall be made on the transformers : (a) to (g) as indicated under routine tests h) Unbalance current test : The value of unbalance current indicated by the ammeter as shown in the test arrangement in Fig.3 shall not be more than 2 % of the full load current i) Impulse voltage withstand test j) k) l) Temperature rise test Short circuit test (To be done without LT circuit breaker) Air pressure test (IS:1180 Part-2, 1989)

If records of a type test on a transformer which, in essential details, is representative of the one being purchased, are furnished, the purchaser may accept this as evidence of the type test instead of actual test. 19.3 The supplier shall furnish calculations in accordance with IS:2026 to demonstrate the thermal ability of the transformers to withstand short circuit.

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20. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply. 21. WARRANTY 21.1 The supplier shall guarantee satisfactory performance of transformers and all the associated components for a period of 2 years from the date of receipt by the purchaser or 18 months from date of commissioning, whichever is earlier. During the warranty period, all repairs/replacements shall be carried out free of cost. 21.2 The warranty shall cover all failures except those caused by deliberate interference such as pilferage of oil, tampering with the circuit breaker. The LT enclosure shall be suitably sealed by the manufacturer and no attempt shall be made by the field staff to tamper with this during the warranty period. 22. MOUNTING ARRANGEMENT The under-base of all transformers shall be provided with two 75x40mm channels 460mm long with holes as shown in figure 4 (at a centre-to-centre distance of 415mm) to make them suitable for fixing on a platform or plinth.

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REC Specification 12/1979 (Revised 1993) 33 KV VACUUM /SF-6 CIRCUIT BREAKERS FOREWORD REC had already issued Specification No. 12/1979 for 33 KV Outdor Circuit Breakers for use at 33/11 KV substations. This specification covered requirements of outdoor circuit breakers which were hitherto being used. As in the case of 11 KV circuit breakers, the oil type circuit breakers are now being fast replaced by the far superior technology of vacuum/SF6 breakers even for 33 KV system. The advantages include long service life with practically no maintenance, no fire risk. Accordingly, to replace the original specification for 33 KV oil circuit breakers and to incorporate use of only vacuum/SF6 technology, this specification was placed before the 13th Standardisation Conference held on 4th-6th May, 1993. Based on the decisions taken at the Conference, the revised specification covering 33 KV vacuum/SF6 circuit breakers is issued. 1. SCOPE

This specification covers 3-pole, 50 Hz, 33 KV Vacuum/SF6 Circuit Breakers for outdoor installation in 33/11 KV sub-stations in rural electrification systems. 2. APPLICABLE STANDARDS

Unless otherwise modified in this specification, the circuit breakers shall comply with the following Indian Standards as amended from time to time : IS:13118 (Circuit Breaker) IS:2705 (Current Transformers) 3. RATED VOLTAGE

The rated voltage for the circuit breakers shall be 36 KV. This represents the highest system voltage corresponding to the nominal system voltage of 33 KV. 4. RATED NORMAL CURRENT

The standard rated normal current shall be 630 A. 5. RATED SHORT CIRCUIT BREAKING CURRENT 5.1 5.2 The rms value of the a.c. component of the rated short circuit breaking current shall be 12.5 KA (750 MVA approximately) The value of percentage d.c. component shall be calculated in accordance with the recommendations contained in IS:13118-1991

6.

RATED SHORT CIRCUIT MAKING CURRENT

The rated short circuit making current shall be taken as 2.5 times the rms value of the a.c. component of the rated short circuit breaking current. 7. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE (KV PEAK)

The rated lightning impulse withstand voltage of the circuit breaker shall be 170 KV (peak). 8. RATED SINGLE CAPACITOR BANK BREAKING CURRENT

The rated single capacitor bank breaking current of the circuit breaker shall be 100 Amps. 9. METERING & PROTECTION The control panel for circuit breaker shall be provided with an ammeter (with selector switch) and an 9.1 energy meter. The voltage for the potential coils of the energy meter shall be taken from the phase and neutral terminals of the 11 KV/110V potential transformer provided at the sub-station (it shall not form part of the 33 KV Circuit Breaker supply) for metering equipment on 11 KV feeders and the energy meter shall be calibrated for 110/3V instead of 110V. For this purpose, the star point of the PT shall be brought out in the terminal box.

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9.2 The 33 KV breaker panel shall be provided with the relays having the following characteristics : a) Triple pole IDMTL type over current relay with high set elements. Plug setting range of the over current relays shall be 50% to 200% and that of the high set elements as 200% to 800% Further, the setting of the high set elements shall be so chosen as not to cause their operation for a fault on the secondary side of the transformer. Single pole Restricted Earth Fault (REF Relay) : The current setting range of the REF relay shall be 10% to 40%.

b)

10. CURRENT TRANSFORMERS FOR METERING AND PROTECTION The current transformers shall be supplied along with the circuit breaker and shall have the following characteristics/constructional features : 10.1 The current transformers shall be enclosed in a sealed housing and shall be suitable for outdoor installation. The CTs shall be supported on a suitable post insulator to be mounted on a pedestal/steel structure. Mounting flanges, bolts etc., shall be hot dipped galvanised and shall be supplied alongwith the CTs. Suitable mounting holes shall be provided at the base for clamping to the structure. 10.2 The CTs shall be provided with bolted type terminals to receive ACSR conductor sizes ranging from 80mm2 to 100mm2 (without requiring use of lugs) both in vertical and horizontal directions. The terminals shall be such as to avoid bimetallic action. 10.3 Transformation ratio : The standard transformation ratio shall be 200/100/5A.

10.4 The current transformers shall have separate cores for protection and metering and shall be of torroidal type. 10.5 Accuracy class for the purpose of metering shall be 1.0 and for the purpose of protection shall be 5P with an accuracy limit factor of 10. 10.6 Rated Output (burden) of the current transformers shall be adequate for the type and make of the relays and meters used. 11. CONSTRUCTIONAL FEATURES The circuit breakers shall have fixed type of construction and the vacuum/SF6 interrupter units 11.1 together with the HV connections shall be totally enclosed in a hermetically sealed housing(s) having inert atmosphere inside. The relays, meters, indicators and operating handle etc. shall be provided in a cabinet with a hinged door and locking device. The door shall open upwards (with hinge at the top) for protection against rain (when in open position). Alternatively, the door opening sideways shall be acceptable if a suitable hood is provided on the top for protection against rain. 11.2 No isolator shall be provided in the breaker.

12. CLOSING/TRIPPING MECHANISM The circuit breakers shall be provided with motor-operated spring-closing or solenoid mechanism. 12.1 The motor/solenoid shall operate at 230 V single-phase supply with a voltage variation of (+) 10% to (-) 20%. The closing mechanism shall have provision for manual closing. 12.2 The trip mechanism shall be suitable for operation by 24V DC battery. 13. TESTS 13.1 The circuit breakers shall be subjected to the following tests in accordance with IS:13118-1991.

13.1.1 Routine Tests a) b) c) d) Power frequency voltage dry tests on the main circuit Voltage tests on control and auxiliary circuits Measurement of resistance of the main circuit Mechanical operating test

13.1.2 Type Tests a) Tests to prove mechanical performance

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b) c) d) e) f) g) h) 13.2 Tests to prove mechanical operation Tests to prove that the temperature rise of any part does not exceed specified limit Tests to prove that the insulation complies with specified limits Tests to prove the short circuit making and breaking performance Tests to prove the short circuit current performance Tests to prove the performance when breaking line cable-charging currents Tests to prove the performance when breaking single capacitor bank current.

The Current Transformers shall be subjected to the following tests in accordance with IS:2705 :

13.2.1 Routine Tests a) b) c) d) e) Verification of terminal markings and polarity High voltage power-frequency tests on primary windings High voltage power frequency tests on secondary windings Over-voltage inter-turn test and Determination of error according to the requirements of appropriate accuracy class

13.2.2 Type Tests a) b) c) d) e) f) g) h) Verification of terminal markings and polarity High voltage power frequency test on primary windings High voltage power frequency test on secondary windings Over-voltage inter-turn test Determination of error according to the requirements of appropriate accuracy class Short time current test Temperature rise test and Impulse voltage test for current transformers for service in electrically exposed installations

14. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially 14.1 agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 14.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.

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REC Specification 13/1979 PORCELAIN INSULATORS AND INSULATOR FITTINGS FOR 33 KV OVERHEAD POWER LINES FOREWORD A meeting of the Helping Committee on Standardisation of Specification and Construction Practices in Rural Electrification was held at New Delhi in October, 1977. Besides the officers of the REC, the meeting was attended by the representatives of the State Electricity Boards and the Indian Standards Institution. This Specification has been prepared on the basis of the decisions taken at the meeting and the subsequent discussions in the meeting of the Technical Committee on Standardisation of Specification and Construction Practices in Rural Electrification held at New Delhi in April, 1978. The Specification was ratified by the Eighth Conference on Standardisation, Research & Training in Rural Electrification held on 23rd-24th February, 1979. 1. SCOPE This specification covers the details of the porcelain insulators and insulator fittings for use on 33 KV lines in rural electric sub-transmission systems. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this Specification, the insulators shall comply with the Indian Standard Specification IS:731-1971 and the insulator fittings with IS:2486 (Pt.I)-1971 and IS:2486 (Pt.II)-1974 or the latest version thereof. 3. INSULATORS 3.1 General Requirements 3.1.1 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. 3.1.2 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain parts of the insulator except those areas which serve as supports during firing or are left unglazed for the purpose of assembly. 3.1.3 The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal. 3.1.4 Cement used in the construction of the insulator shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings, and its thickness shall be as uniform as possible. 3.2 Classification 3.2.1 Only Type B insulators as defined in Indian Standards shall be used. 3.2.2 The string insulators shall only be of ball and socket type. 3.3 Basic Insulation Levels The test voltages of the insulators shall be as under : 3.3.1

Table (Clause 3.3.1)

Highest System Voltage KV (rms) 36 Visible Discharge Test KV (rms) 27 Wet Power Frequency Withstand Test KV (rms) 75 Power Frequency Puncture Withstand Test Pin KV (rms) 180 String Insulator Units KV(rms) Impulse Voltage Withstand Test KV (Peak)

1.3 times the actual dry flash over voltage of the 170 Unit.

3.3.2

impulse voltages are expressed as peak values.

In this specification, power frequency voltages are expressed as peak values divided by

2 and

3.3.3 The withstand and flashover voltages are referred to the Reference Atmospheric Conditions as per Indian Standard. 3.4 Mechanical Load The insulators shall be suitable for the minimum failing loads specified as under :

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Pin Insulator Failing Loads 10KN String Insulator Units Failing Load 45KN Recommended Pin Ball Shank Diameter 16mm

3.5 Creepage Distance The minimum creepage distance shall be as under : Highest System Voltage 1 36KV Normal and Moderately Polluted Atmosphere (Total) 2 580mm Heavily polluted Atmosphere (Total) 3 840mm

Note : For insulator used in an approximately vertical position the values given in Col.(2) or (3) shall apply. For insulators used in an approximately horizontal position, the value given in Col.(2) shall apply but the value in Col.(3) may be reduced by as much as 20%. 3.6 Tests : The insulators shall comply with the following tests as per IS:731-1971 and latest version thereof. 3.6.1 Type Tests

a) Visual examination, b) Verification of dimensions, c) Visible discharge test, d) Impulse voltage withstand test, e) Wet power-frequency voltage withstand test, f) Temperature cycle test, g) Electro-mechanical failing load test h) Mechanical failing load test (for those of Type B string insulator units to which electro mechanical failing load test (g) is not applicable). i) Twenty four hours mechanical strength test (for string insulators only when specified by the purchaser. j) Puncture Test k) Porosity test and l) Galvanising test 3.6.2 Acceptance Tests The test samples after having withstood the routine tests shall be subjected to the following acceptance test in the order indicated below : a) Verification of dimensions. b) Temperature cycle test c) Twenty four hours mechanical strength test (for string insulator units only when specified by the purchaser) d) Electro-mechanical failing load test. e) Puncture test. f) Porosity test and g) Galvanising test 3.6.3 Routine Test a) b) c)

Visual examination.
Mechanical routine test (for string insulator units only) and Electrical routine test (for string insulator units only)

3.7 Marking 3.7.1 Each insulator shall be legibly and indelibly marked to show the following :

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a) b) c) d) e) Name or trade mark of the manufacturer Month and year of manufacture Minimum failing load in Newtons Country of the manufacture and ISI Certification mark, if any.

3.7.2 Marking on porcelain shall be printed and shall be applied before firing. 3.8 Packing All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail transport. Where more than one insulator are packed in a crate, wooden separators shall be fixed between the insulators to keep individual insulators in position without movement within the crate. Disc insulators, however, may be assembled instring and packed inside a crate to prevent movement. 4. INSULATOR FITTINGS 4.1 Pins for Pin Insulators 4.1.1 General Requirements 4.1.1.1 The pin shall be a single piece obtained preferably by the process of forging. It shall not be made by joining, welding, shrink-fitting or any other process from more than one piece of material. It shall be of good finish, free from flaws and other defects. The finish of the collar shall be such that a sharp angle between the collar and the shank is avoided. 4.1.1.2 All ferrous pins, nuts and washer except those made of stainless steel shall be galvanised. The threads of nuts shall be cut after galvanising and shall be well oiled and greased. 4.1.2 Type & Dimensions 4.1.2.1 Pins with large steel head Type L300N as per IS:2486 (Pt.II) having stalk length of 300 mm and shank length of 150 mm with minimum failing load of 10 KN shall be used. 4.1.2.2 The complete details of the pin are given in Fig.1.

4.1.3 Tests Insulator pins shall comply with the following tests as per IS:2486 (pt.I). 4.1.3.1 Type Tests a) b) c) d) Visual examination test Checking of threads on heads Galvanising test and Mechanical test

4.1.3.2 Acceptance Tests a) b) c) Checking of threads on heads Galvanising test and Mechanical test

4.1.3.3 Routine Test Visual examination 4.2 String Insulator Fittings 4.2.1 General Requirements 4.2.1.1 All forgings and castings shall be of good finish and free of flaws and other defects. The edges on the outside of fittings, such as at the ball socket and holes,shall be rounded. 4.2.1.2 All parts of different fittings which provide for interconnection shall be made such that sufficient clearance is provided at the connection point to ensure free movement and suspension of the insulator string assembly. All ball and socket connections shall be free in this manner but care shall be taken that too much clearance between ball and socket is avoided.

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4.2.1.3 All ferrous fittings and the parts other than those of stainless steel, shall be galvanised. Small fittings like spring washers, nuts, etc. may be electro-galvanised. 4.2.2. Type and Dimensions 4.2.2.1 Only ball and socket type insulator sets shall be used. The nominal dimensions of the ball and sockets, ball eye and cross-arm straps are given in Fig. 2. An assembly drawing of the complete insulator string is given in Fig. 3. 4.2.2.2 Strain clamps shall be suitable for ACSR conductors 7/3.35 mm2 (50 mm2 Al. area), 7/4.09mm (80mm2 Al. area) and 6/4.72mm + 7/1.57 mm (100 mm2 Al. area). The ultimate strength of clamps shall not be less than 41 KN. 4.2.3 Tests String insulator fittings shall comply with the following tests as per IS:2486 (Pt.I). 4.2.3.1 Type Tests a) b) c) d) e) f) g) Slip strength test Mechanical test Electrical resistance test Heating cycle test Verification of dimensions Galvanising/Electroplating test, and Visual examination test

4.2.3.2 Acceptance Tests a) b) c) Verification of dimensions Galvanising/Electroplating test, and Mechanical tests

4.2.3.3 Routine Tests a) b) Visual examination test and Routine mechanical test

4.2.4 Marking 4.2.4.1 The caps and clamps shall have marked on them the following : a) b) 4.3 Packing 4.3.1 For packing of GI pins, strain clamps and related hardware, double gunny bags (or wooden cases, if deemed necessary) shall be employed. The heads and threaded portions of pins and the fittings shall be properly protected against damage. The gross weight of each packing shall not normally exceed 50 Kg. Different fittings shall be packed in different bags or cases and shall be complete with their minor accessories fitted in place. All nuts shall be hand-tightened over the bolts and screwed upto the farthest point. 4.3.2 The packages containing fittings may also be marked with the ISI certification mark. Name or trade mark of the manufacturer and Year of manufacture

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REC Specification 14/1979 ( for gaining experience )

SINGLE WIRE EARTH RETURN (SWER) DISTRIBUTION TRANSFORMERS FOREWORD

This subject was first discussed at a meeting of the Helping Committee on Standardisation held in New Delhi in February, 1976. Besides the officers of the Rural Electrification Corporation, the meeting was attended by the representatives of the State Electricity Boards, Central Electricity Authority, Indian Standards Institution and Indian Electrical Manufacturers Association. A representative of M/s NGEF Ltd., also attended the meeting by special invitation. The recommendations of the Helping Committee were subsequently discussed in the meeting of the Technical Committee held in April, 1976, and the 7th Conference on Standardisation held in October, 1976. In the Seventh Conference it was decided that the no-load voltage ratio to be adopted for these transformers should be reexamined. Accordingly, this aspect was again discussed in the meeting of the Helping Committee in October, 1977. This Specification has been prepared on the basis of the decisions taken by the Helping Committee and the subsequent discus sions in the meeting of the Technical Committee on Standardisation held in April, 1978 and the eighth Conference on Standardisation, Research and Training in Rural Electrification held in February, 1979. 1. SCOPE This Specification covers oil-immersed, naturally cooled, single-phase, 50 Hz, double-wound, outdoor type distribution transformers of 10,16 and 25 KVA ratings for use in SWER systems. This Specification is issued only to serve as a guideline for the purchase of SWER distribution transformers till more practical experience on use of such transformers is available in the country. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the SWER distribution transformer shall comply with the Indian Standards Specifications IS:1180 and IS:2026 as amended from time to time. 3. STANDARD RATINGS The standard ratings shall be 10, 16 and 25 KVA. 4. TYPE OF TRANSFORMERS The transformers shall be of either sealed or conventional breathing type, as required by the purchaser. The sealed transformers may be either air or nitrogen filled. 5. NO-LOAD VOLTAGE RATIO The no-load voltage ratio shall be 6300/460-230 V. 6. TAPS No taps are to be provided on these transformers. 7. WINDING CONNECTIONS AND TERMINAL ARRANGEMENT The winding connections shall be as shown in Fig.1. 7.1 One end of the primary (HV) winding shall be brought out through an appropriate HV bushing to be 7.2 located diametrically opposite to the pole mounting brackets. At the option of the manufacturer, the HV bushing may be located either on the side or on the top of the transformer. However, if the bushing is located on the top, it should be located towards one end of the tank (diametrically opposite to the pole mounting brackets) and it should be suitably inclined so as to provide a minimum clearance of 600 mm from the terminal of the bushing to the pole on which the transformer is mounted (See Fig.2).The other end of HV winding shall be brought out through a suitable bushing (LV bushing may be used for this purpose) which shall be externally earthed. A solid inter connection shall be provided by the manufacturer between the HV earth bushing and the transformer tank. The secondary (LV) winding shall be connected to three LV bushings (two connected to the ends of the winding and the third to the middle point of the winding which will serve as the neutral). A typical terminal arrangement is shown in Fig.2) 8. TRANSFORMER TANK

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8.1 8.2 The transformer tank may be round, oval or rectangular. In the case of sealed transformers, the tank construction and tank sealing shall be as follows: Tank Construction: The main tank of the transformer shall be made of good quality steel sheet of adequate thickness suitably stiffened to provide sturdy and robust construction to withstand extreme pressure conditions. The tank shall be capable of withstanding a pressure upto (+) 0.8 Kg/cm2 g and (-) 0.7 Kg/cm2 g (gauge pressure) without any deformation. The transformer cover shall be welded to the tank in such a manner that itshall be possible to remove the weld and re-weld the transformer at least twice. Tank Sealing : The space on the top of the oil shall be filled either with nitrogen or dry air as specified by the purchaser. The nitrogen/dry air plus the oil volume inside the tank shall be such that even under the extreme operating conditions, the pressure generated in side the tank does not exceed 0.4 Kg/cm2 g positive or negative. 9. MOUNTING ARRANGEMENT The transformers shall be provided with two mounting lugs as shown in Fig.2, suitable for fixing the transformer to a single pole by means of 2 bolts of 20mm dia. 10 FITTINGS 10.1 The following standard fittings shall be provided on breathing type transformers : a) Two earthing terminals - one of these shall have a solid inter-connection with the HV earth bushing as shown in Fig.2 b) Oil gauge c) Two lifting lugs d) Rating and terminal marking plates e) Silicagel breather or a plain breathing pipe with an inverted U band and fitted with wire gauze at the open end as required by the purchaser. f) Drain-cum-sampling valve (steel) with plug (P3/4 thread) g) A plug or blank flange as the top for connecting a valve for filtration proposes and h) Filling hole with cover. 10.2 The following standard fittings shall be provided on sealed transformers : a) Two earthing terminals-one of these shall have a solid interconnection with the HV earth bushing as shown in Fig.2. b) Two lifting lugs, c) Rating and terminal marking plates. d) Nitrogen/air filling device/pipe with welded cover capable of re-use and e) An extended pipe connection at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a re-filling connection after removing the welded cover.

11. LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limits of 550 C (measured by resistance) for transformer windings and 450 C (measured by thermometer) in top oil when tested in accordance with IS:2026. In the case of sealed transformers, the limit of temperature rise in top oil shall be 50oC instead 450C. 12. LOSSES AND IMPEDANCE VALUE 12.1 The no-load and load losses shall not exceed the following values: Rated KVA 10 16 25 No-load loss Watts 70 95 120 Load loss at 750C Watts 265 365 430

These losses are maximum allowable and there would not be any tolerance. No weightage in prices for offers with lower losses shall be given for these transformers. 12.2 Impedance The recommended percentage impedance at 750 C is 4 % with a tolerance of ( )10%.

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13. TESTS 13.0 The transformers shall be subjected to the following routine and type tests as laid down in IS:2026. 13.1 Routine Tests a) Measurement of winding resistance b) Measurement of voltage ratio and check of voltage vector relationship c) Measurement of impedance voltage/short circuit impedance and load loss d) Measurement of no-load loss and current e) Measurement of insulation resistance f) Separate source voltage withstand test g) Induced over voltage withstand test and h) Air pressure test: (Applicable for sealed transformers only). The transformer tank with welded lid and all the fittings including bushings in position shall be tested for leakage at a pressure of 0.8 Kg/cm2g above atmospheric pressure maintained inside the tank for 10 minutes. There should be no leakage at any joint. NOTE: As the above test is required to be carried out before final sealing of the transformer, to witness this test the inspecting authority would ensure to be present at the time of final sealing. The test cannot be demonstrated on a completed transformer. 13.2

Type Tests
a) to e) as indicated above, f) Lightning impulse test, g) Temperature rise test, h) Air pressure test: (Applicable for sealed transformers only)- The tank shall be fixed with a dummy cover with all fittings including bushings in position and shall be subjected to the following pressure created inside the tank : i) (+) 0.8Kg/cm2g above atmospheric pressure for 30 minutes

(ii) A vacuum corresponding to (-) 0.7 Kg/cm2 g for 30 minutes Permanent deflection of flat plate after pressure has been released shall not exceed the values given below:

Length of plate
Up to 750mm 751 to 1250mm

Deflection
5mm 6mm

(i) Short circuit test (subject to mutual agreement between the purchaser and the supplier).

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REC Specification - 15/1979
PRESTRESSED CEMENT CONCRETE POLES ( F.O.S. 2.5 ) FOR 11 KV AND LT LINES FOREWORD A research project for evolving economical designs of cement concrete poles for use on 11 KV and LT Lines was entrusted to the Cement Research Institute (CRI) of India. The basic design parameters for these poles as given in Clause 6 of this Specification were approved by the Fifth Conference on standardisation of Specifications and Construction Practices in Rural Electrification held in May, 1974. Some of these design parameters which were based on certain foreign codes/practices and certain other provisions of this Specification, although at variance with the stipulations of IS:1678 - 1960, had been adopted to achieve economy in the designs. However, these modifications have since been incorporated in the revised IS:1678 - 1978. This specification, drawn up in consultation with the CRI and ISI had been issued after approval by the Technical Committee on Standardisation in its meeting held in April,1978 and subse quently by the Eighth Conference on Standardisation, Research and Training in Rural Electrification held in February, 1979.Based on certain practical difficulties experienced by the SEBs, some amendments to this specification were approved by the 9th & 10thConference on Standardisation, Technical Development and Training in Rural Electrification held in April, 1981 and April 1983 respectively. These amendments relate to provision of full length untensioned wires in lieu of part length wires, grouping of pre-stressing wires and the position of earth wire in the pole. The revised specification incorporates all these amendments. 1. SCOPE This Specification covers PCC poles with an overall length of 7.5 M, 8.0 M and 9.0 M suitable for use in overhead 11 KV and L.T. power lines and double pole structures for 11/0.4 KV substations. 2. APPLICABLE STANDARDS Except when they conflict with specific requirements in this Specification, the poles shall comply with the relevant provisions made in the following Indian Standard Specifications: a) IS: 1678-1978, Specification for prestressed concrete poles for overhead power, traction and telecommunication lines. b) IS: 2905-1966. Methods of test for concrete poles for over-head power and telecommunication lines. c) IS: 7321-1974. Code of practice for selection, handling and erection of concrete poles for over-head power and telecommunication lines. 3. TERMINOLOGY For the purpose of this standard, the following definitions shall apply: 3.0 3.1 Average Permanent Load That fraction of the working load which may be considered of long duration over a period of one year. 3.2 Load Factor The ratio of ultimate transverse load to the transverse load at first crack. 3.3 Transverse The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a straight run, this will be normal to the run of the line. 3.4 Transverse Load at First Crack For design, the transverse load at first crack shall be taken as not less than the value of the working load. 3.5 Working load The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on the pole. This load is assumed to act at a point 600 mm below the top with the butt end of the pole planted to the required depth as intended in the design. 3.6 Ultimate Failure The conditions existing when the pole ceases to sustain a load increment owing to either crushing of concrete, or snapping of the prestressing tend on or permanent stretching of the steel in any part of the pole. 3.7 Ultimate Transverse Load The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the axis of the pole along the transverse direction with the butt end of the pole planted to the required depth as intended in the design. APPLICATION 4.1 7.5 M and 8.0 M Poles These poles shall be used at tangent locations for 11KV and L.T. lines in wind pressure zones of 50 kg/M2, 75 Kg/M2 and 100 Kg/M2 in accordance with REC Construction Standards referred to in the following table:

4.

Pole

Line description

Reference to

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length 7.5M 8.0M 11KV lines without earthwire L.T. lines, horizontal formation 11KV lines with earthwire L.T. lines, vertical formation REC Constn. Stds. A-4, B-5 A-5, B-6

The adoptable spans shall be as per REC Construction Standards A-8 (for 11 KV Lines) and B-8 (for L.T. Lines) 4.2 9.0 M Poles These poles shall be used for double pole structures of distribution transformer centres as per REC Construction Standards F-1 to F-4 and for special locations in 11 KV and L.T. Lines, such as road crossings etc. 5. MATERIALS 5.1 Cement The cement used in the manufacture of prestressed concrete poles shall be ordinary or rapid hardening portland cement conforming to IS: 269 - 1976 (Specification for ordinary and low heat portland cement) or IS : 8041 E1978 (Specification for rapid hardening portland cement). 5.2 Aggregates Aggregates used for the manufacture of pre-stressed concrete poles shall conform to IS : 383 - 1970 (Specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregates shall in no case exceed 12 mm. 5.3 Water Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable. 5.4 Admixtures Admixtures should not contain Calcium Chloride or other chlorides and salts which are likely to promote corrosion of pre-stressing steel. 5.5 Pre-stressing Steel The pre-stressing steel wires, including those used as untensioned wires (See Annex.I), should conform to IS : 1785 (Part-I) - 1966 (Specification for plain hard-drawn steel wire for prestressed concrete. Part-I cold drawn stress relieved wire), IS: 1785 (Part-II) - 1967 (Specification for plain hard-drawn steel wire)., or IS : 6003 - 1970 (Specification for indented wire for pre-stressed concrete). The type designs given in Annexure-I are for plain wires of 4 mm diameter with a guaranteed ultimate strength of 175 Kg/mm2. 5.6 The concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS : 1343 - 1980 (Code of practice for prestressed concrete) and IS : 456 - 1978 (Code of practice for plain and reinforced concrete), subject to the following special conditions; a) Minimum works cube strength at 28 days should be at least 420 Kg/cm2. b) The concrete strength at transfer should be at least 210Kg/cm2. c) The mix should contain at least 380 Kg. of cement per cubic meter of concrete. d) The mix should contain as low a water content as is consistent with adequate workability. If it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ratio is maintained.

6. DESIGN REQUIREMENTS The poles shall be designed for the following requirements: a) The poles shall be planted directly in the ground with a planting depth of 1.5 meters. b) The working load on the poles should correspond to those that are likely to come on the pole during their service life. Designs given in Annexure-I are for 140 Kg. and 200 Kg. Applied at 0.6 M from top. c) The factor of safety for all these poles shall not be less than 2.5. d) The average permanent load should be 40% of the working load. e) The F.O.S. against first crack load shall be 1.0. f) At average permanent load, permissible tensile stress in concrete shall be 30 Kg/cm2. g) At the design value of first crack load, the modulus of rupture shall not exceed 55.2 kg/cm2 for M-420 concrete. h) The ultimate moment capacity in the longitudinal direction should be at least one fourth of that in the transverse direction. i) The maximum compressive stress in concrete at the time of transfer of prestress should not exceed 0.8 times the cube strength. j) The concrete strength at transfer shall not be less than half the 28 days strength ensured in the design, i.e. 420 x 0.5= 210 Kg/cm 2. For model check calculations on the design of poles, referred to in Annexure-I, a reference may be made to the REC Manual on Manufacturing of solid PCC poles, Part-I - Design Aspects 6.1 Dimensions and Reinforcements The cross-sectional dimensions and the details of prestressing wire should conform to the particulars given in Annexure-I. The provisions of holes for fixing cross-arms and other fixtures should conform to the REC standards referred to in clause 4 of this specification and in accordance with the construction practices adopted by the State

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Electricity Boards. 7. MANUFACTURE 7.1 All prestressing wires and reinforcements shall be accurately fixed as shown in the drawings and maintained in position during manufacture. The untensioned reinforcement, as indicated in the drawings, should be held in position by the use of stirrups which should go round all the wires. 7.2 All wires shall be accurately stretched with uniform prestress in each wire. Each wire or group of wires shall be anchored positively during casting. Care shall be taken to see that the anchorages do not yield before the concrete attains the necessary strength. 7.3 Cover The cover of concrete measured from the outside of the prestressing tendon shall be normally 20 mm.

7.4 Welding and Lapping of Steel

The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire. 7.5 Compacting Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand compaction shall not be permitted. 7.6 Curing The concrete shall be covered with a layer of sacking, canvas, hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of prestress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit, the interval should depend on the atmospheric humidity and temperature. 7.7 The prestressing wires shall be detensioned only after the concrete has attained the specified strength at transfer (i.e. 210 Kg/cm2). The cubes cast for the purpose of determining the strength at transfer should be cured, as far as possible, under conditions similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS : 1343 - 1960 (Code of practice for prestressed concrete). The manufacturer shall supply when required by the purchaser or his representative, result of compressive test conducted in accordance with IS : 456 - 1964 (Code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. If the purchaser so desires, the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS : 456 1964 (Code of practice for plain and reinforced concrete). The detensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the poles. The rate of detensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. The poles shall not be detensioned or released by cutting the prestressing wires using flames or bar croppers while the wires are still under tension. 7.8 Separate eye-hooks or holes shall be provided for handling and transport, one each at a distance of 0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided for lifting purposes, should be perpendicular to the broad face of the pole. Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported on timber sleepers located at 0.15 times the overall length, measured from the end. The timber supports in the stack should be aligned in a vertical line. Poles should be transported with their broad faces placed vertically and in such a manner that shocks are avoided. Supports should be so arranged that they are located approx. at a distance equal to 0.15 times the overall length from the ends. The erection of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis. i.e. the rope used for hoisting the pole should be parallel to the broader face of the pole. 7.9 Earthing 7.9.1 Earthing shall be provided by having a length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 50 mm. At 250 mm from top and 150 mm below ground level. 7.9.2 The earth wire shall not be allowed to come in contact with the prestressing wires.

7.10 General For further details on the process of manufacture, a reference may be made to REC Manual on Manufacturing of Solid PCC Poles Part II Manufacturing Aspects. 8. TESTS 8.1 Transverse Strength Test 8.1.1 Poles made from ordinary Portland cement shall be tested only on the completion of 28 days and poles made from rapid-hardening cement only on the completion of 14 days, after the day of manufacture. 8.1.2 The pole may be tested in either horizontal or vertical position. If tested in horizontal position, provisions shall be made to compensate for the overhanging weight of the pole, for this purpose the over-

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hanging portion of the pole may be supported on a movable trolly or similar device. 8.1.3 The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting i.e. 1.5 M. 8.1.4 Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to design value of the transverse load at first crack. The deflection at this load shall be measured. A prestressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. The load shall then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80 per cent of the minimum ultimate transverse load and thereafter increased by 5 per cent of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes. The load applied to prestressed concrete pole at the point of failure shall be measured to the nearest five Kilograms. The pole shall be deemed not to have passed the test if the observed ultimate transverse load is less than the design ultimate transverse load. 8.2 Measurement of Cover After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The cover of the pole shall be measured at 3 points, one within 1.8 meters from the butt end of the pole, the second within 0.6 metre from the top and the third at an intermediate point and the mean value compared with the specified value. The mean value of the measured cover should not differ by more than()1 mm from the specified cover. The individual values should not differ by more than () 3 mm from specified value. If these requirements are not met, the workmanship with reference to aligning of the end plates and prestressing wires and assembly of moulds should be improved and inspection at pre-production stage tightened suitably. 9. SAMPLING AND INSPECTION 9.1 Scale of Sampling 9.1.1 Lot: In any batch, all poles of the same class and same dimensions shall be grouped together to constitute a lot. 9.1.1.1 Sub-lot: If the number of poles in a lot exceed 500, the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of a sub-lot shall be determined on the basis of the performance of samples selected from it. 9.1.2 The number of poles to be selected from a lot or a sub-lot shall depend upon its size and shall be in accordance with Col. 1 and 2 of the following table: SAMPLE SIZE AND CRITERION FOR CONFORMITY (Clauses 9.1.2, 9.2.2 & 9.3.2) Size of lot or sub-lot Dimentional Requirement Sample size 10 15 20 30 Permissible No. of defective samples 1 1 2 3 No. of poles for transverse strength test * 3 4 5

Upto 100 101 to 200 201 to 300 301 to 500

*The number of poles to be tested shall be subject to the agreement between the purchaser and supplier
9.1.3 These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any random pole, every rth pole may be included in the sample, being the integral part of N/n where N is the size of the lot or the sub-lot and n is the sample size. Number of Tests 9.2.1 All the poles as selected in 9.1.2 shall be tested for overall length, cross-section and uprightness. The tolerance shall be () 15 mm on overall length()3 mm on cross sectional dimensions and 0.5 per cent on uprightness. 9.2.2 The number of poles to be tested for transverse strength test shall be accordance with Col. 4 of the above table. These poles may be selected from those already tested in 9.2.1. 9.3 Criteria for Conformity 9.3.1 A lot or sub-lot shall be considered as conforming to this specification if the conditions under 9.3.2 and 9.3.3 are satisfied. 9.2

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9.3.2 The number of poles which does not satisfy the requirements of overall length, cross-section and uprightness shall not exceed the corresponding number given in Col. 3 of Table in 9.1.2. If the number of such poles exceeds the corresponding number, all poles in the lot or sub-lot shall be tested for these requirements and those not satisfying the requirements shall be rejected. 9.3.3 All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more poles fail, twice the number of poles originally tested shall be selected from those already selected and subjected to the test. If there is no failure among these poles, the lot or the sub-lot shall be considered to have satisfied the requirements of this test. 10. MARKING The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in position. a) Month and year of manufacture b) Transverse strength of pole in Kg. c) Makers serial No. and mark

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REC Specification 16/1981

33 KV LIGHTNING FOREWORD

ARRESTERS

The specification for 33 KV lightning arresters was first discussed in the meeting of the Helping Committee on Standardisation held at New Delhi in October, 1980. The meeting was attended by the representatives of Haryana, Jammu & Kashmir, Karnataka, Maharashtra, Orissa, Punjab, Rajasthan, Tamil Nadu and Uttar Pradesh State Electricity Boards, the Central Electricity Authority, the Indian Standards Institution, the Indian Electrical Manufacturers Association and officers of the Rural Electrification Corporation. The recommendations of the Helping Committee were subsequently discussed in the 9th Standardisation Conference held at New Delhi in April, 1981. Representatives of State Electricity Boards, Indian Standards Institution, Central Electricity Authority etc. participated in the Conference. This specification has been prepared on the basis of the recommendations of the Helping Committee on Standardisation and subsequent decisions taken at the 9th Conference on Standardisation. 1. SCOPE This specification covers non-linear resister type lightning arresters for use in effectively earthed system with a nominal voltage of 33 KV. 2. APPLICABLE STANDARD Unless otherwise modified in this specification, the lightning arresters shall comply with IS:3070 (Pt.I)-1985 or the latest version thereof. 3. VOLTAGE RATING The rated voltage of lightning arresters shall be 30 KV (rms). This will be applicable to the effectively earthed 33 KV system (co-efficient of earth not exceeding 80% as per IS:4004) with all the transformer neutrals directly earthed. 4. NOMINAL DISCHARGE CURRENT RATING The nominal discharge current rating of the lightning arresters shall be 10 KA (Station Class), which shall be applicable both for protection of transformers and lines. 5. MOUNTING ARRANGEMENT The lightning arresters shall be of pedestal mounting type suitable for outdoor installation on steel/cement concrete structures. All the clamps, bolts, nuts and washers etc. required for mounting the lightning arresters on the structure (to be specified by the purchaser) shall be supplied along with the arresters and shall be galvanised. 6. TERMINAL ARRANGEMENT The top metal cap and the base of the lightning arrester shall be galvanised. The top cap shall be provided with a terminal arrangement suitable for both horizontal and vertical take-off. The base of the lightning arresters shall be provided with two separate terminals distinctly marked for connection to earth. 7. SEALING AND PRESSURE RELEASE The lightning arresters shall be hermetically sealed to avoid ingress of moisture. A suitable pressure relieving device shall be provided to avoid damage to the external insulator in case of a severe discharge. 8 TESTS The following type, acceptance and routine tests, as laid down in IS:3070 (Part-I)-1985, shall be carried out : 8.1 Type Test The following shall constitute the type tests : a) b) c) d) e) f) g) h) i) j) k) l) m) Voltage withstand tests of arrester insulation Power-frequency voltage spark over test Standard lightning voltage impulse spark over test Lightning-voltage impulse spark over voltage test Switching-voltage impulse spark over voltage/time curve test Residual voltage test Current impulse withstand tests Operating-duty test Pressure-relief tests Tests of arrester disconnectors when fitted Temperature cycle test on porcelain housing Porosity test on porcelain components Galvanizing test on metal parts

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n) Visual examination of porcelain housing o) Sealing test (not specified in IS:3070 (Part-I) - 1985) To prove the effectiveness of sealing of the lightning arresters, either of the following two tests shall be carried out :i) Bubble Test A positive pressure shall be created inside the arrester and it shall be immersed in water to check if there are any bubbles. ii) Pressure/Vacuum Test Leakage shall be checked by measuring leak rate either by monitoring drop in pressure or rise in vacuum level with time or by making use of special detectors. 8.2 Acceptance Tests When the purchaser specifies acceptance tests in the purchase agreement, the following tests shall be made on the higher whole number to the cube-root of the number of arresters to be supplied : a) b) c) d) e) f) g) h) Dry power-frequency voltage spark over test on the complete arrester Standard lightning - voltage impulse spark over test on the complete arrester Residual voltage test at the nominal discharge current on the complete arrester or sections Temperature cycle test on porcelain components Porosity test on porcelain components Galvanising test on metal parts Visual examination of porcelain housing Sealing test (see clause 8.1 (o) above)

8.3 Routine Test The following shall constitute the routine tests : a) b) c) 9. Dry power-frequency voltage spark over test Visual examination of porcelain housing Sealing test (See clause 8.1 (o) above)

INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser. The manufacturer shall afford the inspector (representing the purchaser) all reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance with this specification.

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REC Specification 17/1981 ON LOAD TAP CHANGERS FOR 33/11 KV TRANSFORMERS FOREWORD The specification for on-load tap changers for 33/11 KV transformers was first discussed in the meeting of Helping Committee on Standardisation held at New Delhi in October, 1980. The meeting was attended by the representatives of Haryana, J&K, Karnataka, Maharashtra, Orissa, Punjab, Rajasthan , Tamil Nadu and Uttar Pradesh State Electricity Boards, Central Electricity Authority, Indian Standards Institution, Indian Electrical Manufacturers Association and Officers of the Rural Electrification Corporation. The recommendations of the Helping Committee were subsequently discussed in the 9th Standardisation Conference held at New Delhi in April, 1981. Besides the State Electricity Boards, the Indian Standards Institutions, Central Electricity Authority etc., the representatives of on-load tap changer manufacturers also participated in the Conference. This specification has been prepared on the basis of the recommendations of the Helping Committee on Standardisation and subsequent decisions taken at the 9th Conference on Standardisation. 1. SCOPE This specification covers on-load tap changers for 33/11 KV transformers of ratings 3150 KVA and 5000 KVA for use in rural distribution system. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the on-load tap changers shall comply with IS:8468-1977 or the latest version thereof. 3. TEMPERATURE OF TAP CHANGER ENVIRONMENT When the cooling medium is oil, on-load tap changers shall be regarded as suitable for operation over a temperature range of (-) 5oC to 100oC (the value of 100oC is based on a maximum ambient temperature of 50o C). 4. TEMPERATURE OF MOTOR-DRIVE MECHANISM ENVIRONMENT The motor-drive mechanism shall be regarded as suitable for operation in any ambient temperature between (-) 5oC and 50oC. 5. MAXIMUM RATED THROUGH CURRENT The maximum rated through current shall be 100A. 6. NUMBER OF TAPS AND TAP RANGE The tap range shall be (+) 5% to (-) 15% with a step of 2.5% on HV winding for HV variation. 7. OLTC CHAMBER The positioning of the OLTC chamber shall be such as to ensure that the oil in OLTC chamber does not get mixed up with oil in the main tank. Contacts of the OLTC should be easily accessible for repair/replacement. 8. OIL SURGE RELAY Suitable oil surge relay shall be provided on the OLTC chamber. The relay shall have only an oil surge float and shall not have an alarm float. 9. OIL LEVEL GAUGE An oil level gauge shall be provided in the OLTC chamber. 10. OPERATION OF OLTC 10.1 The OLTC shall be provided with suitable mechanism for both electrical and manual operation to be made locally. 10.2 During manual operation, the electrical motor drive shall be completely blocked. Necessary inter-lock arrangement for this purpose shall be incorporated. 11. OPERATING VOLTAGE OF MOTOR DRIVE MECHANISM The standarad voltage of motor drive mechanism shall be 415 V, 3-phase AC or 240 V, single-phase AC. 12. MARKING Tap changer and its motor drive mechanism shall have separate name plates fitted in clearly visible position. The name plates shall be marked in accordance with IS:8468. The entries shall be indelibly marked. 13. TAP POSITION INDICATOR

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Suitable indicating device shall be provided to denote the position of the tap. The position of the indicator shall be such that the tap position is easily visible through a window even when the motor drive cubical is closed. 14. ELECTRICAL/MECHANICAL CONTROLS The following electrical/mechanical controls shall be incorporated in the OLTC : a) The motor drive mechanism shall have both mechanical and electrical limiting devices to prevent overrunning of the mechanism. b) Necessary provision shall be made to check against more than one tap changing operation being performed at a time. c) All relays and operating devices shall operate correctly at any voltage between the limits specified in the relevant Indian Standards. The devices for which an auxiliary D.C supply is required, shall be made suitable for 24 V, D.C. d) Thermal or other suitable devices shall be provided to protect the motor and control circuits. All relays, switches, fuses, etc. shall be mounted in the driving gear housing and shall be clearly marked for purpose of identification. Cubicle lighting with necessary control switch shall be provided in the driving gear housing. Heater to prevent condensation of moisture shall also be provided. 15. TESTS 15.1 The following type and routine tests shall be carried out on the on-load tap changer in accordance with IS:8468-1977 or its latest version : 15.1.1 Type Tests Type tests shall be performed on the samples of the relevant tap changers or components after their final development. The following shall constitute the type tests : a) b) c) d) e) f) g) h) Mechanical test Auxiliary circuits insulation tests Test for temperature-rise of contacts Switching tests Short circuit current test Transition impedance test Mechanical life test Dielectric test

15.1.2 Routine Tests The following shall constitute the routine tests : a) b) c) The 15.2 changers. Mechanical test Auxiliary circuits insulation tests Dielectric tests following type and routine tests shall be carried out on the motor drive mechanism of on-load tap

15.2.1 Type Tests The following shall constitute the type tests : a) b) c) d) e) Mechanical test Auxiliary circuits insulation test Mechanical load test Overrun test Protection of motor-drive cubicle

15.2.2 Routine Tests The following shall constitute the routine tests : a) b) Mechanical tests Auxiliary circuits insulation tests

16. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser. The manufacturer shall afford the inspector (representing the purchaser) all reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance with this Specification.

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REC Specification 18/1981 (Revised 1983) LT CIRCUIT BREAKERS FOREWORD The Specification for LT Circuit Breakers was first discussed in the meeting of the helping Committee on standardisation held at New Delhi in October, 1980. The meeting was attended by the representatives of Haryana, Jammu & Kashmir, Karnataka, Maharashtra, Orissa, Punjab, Rajasthan, Tamil Nadu and Uttar Pradesh State Electricity Boards, the Central Electricity Authority, the Indian Standards Institution, the Indian Electrical Manufacturers Association and officers of the Rural Electrification Corporation. The recommendations of the Helping Committee were subsequently discussed in the 9th Standardisation Conference held at New Delhi in April, 1981. Besides SEBs, Indian Standards Institution, Central Electricity Authority etc., the representatives of the LT circuit breaker manufacturers also participated in the Conference. This specification has been prepared on the basis of the recommendations of the Helping Committee on standardisation and the subsequent decisions taken at the 9th Conference on Standardisation. 1. SCOPE This specification covers 3-pole, 50 Hz, a.c. LT moulded case circuit breakers (MCCB) suitable for protection of distribution transformers in rural electrification system. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, the moulded case circuit breakers shall comply with the latest version of IS:2516 (Part I & II/Section 1)-1985. 3. NUMBER OF POLES Unless otherwise specially required by the purchaser to suit specific needs, such as lighting loads, the circuit breakers for transformers protection shall have triple-pole construction so that all the three poles close or trip simultaneously. 4. RATED VOLTAGE The rated voltage of the circuit breakers shall be 415V. 5. CURRENT SETTING 5.1 The standard current settings of the circuit breakers for use with the transformers of different ratings standardised by REC shall be as follows : Transformer rating (KVA) 16 25 63 100 Current Setting 22 35 90 140 (Amps.)

5.2 The above standard current settings shall also apply if the circuit breakers are used for controlling individual LT feeders. An additional setting of 50 Amps. can also be adopted for the feeder breakers, where required. Note : In case circuit breakers are used only on individual feeders emanating from a transformer and there is no separate breaker on the secondary side of the transformer, the combined capacity of the feeder breakers should not normally exceed the full load current of the transformer. It should also be ensured that short circuit breaking capacity of the feeder breakers is not less than that required for the transformer with which these are used (see clause 7). 6. TIME/CURRENT CHARACTERISTIC 6.1 The circuit breakers shall have the following time/current characteristic : Multiple of normal current setting 1.05 1.2 1.3 Tripping time

More than 2.5 hours More than 10 minutes but less than 2 hours Less than 30 minutes

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1.4 2.5 4.0 6.0 12.0 Less than 10 minutes Less than 1 minute Not less than 2 seconds Less than 5 seconds Instantaneous (less than 40 milli seconds)

6.2 Time current characteristic of the circuit breaker shall be tested in accordance with Clause 7.7.2.3(b)(2) of IS:2516 (Part I & II/Sec.1)-1985 and the test shall be made with all the three phases loaded. 6.3 For the time/current characteristic, the reference calibration temperature of the breakers shall be 40oC. 7. RATED SHORT-CIRCUIT BREAKING CURRENT 7.1 The rated short-circuit breaking current of the circuit breakers shall be as follows: Transformer Rating (KVA) 16 25 63 100 Min. rated short circuit Breaking Current of the Circuit Breaker (KA) 2.5 2.5 3.0 5.0

7.2 The short circuit breaking capacity, as specified in clause 7.1 above, shall be based on the short circuit test carried out at power factor not exceeding 0.4 (lagging). For the purpose of this test, the following operating sequence shall be followed :Break-3 minutes interval-make break-3 minutes interval-make break 7.3 While the above stipulations regarding the test power factor and the sequence of operation shall be binding, the other procedure for making the short circuit test and the test circuit etc., shall be in accordance with IS:2516 (Part I & II/Section 1)-1985 or the latest version thereof. 8. GENERAL 8.1 The metallic portions of the mechanism shall be either inherently resistant to or so treated as to make them resistant to the atmospheric corrosion. 8.2 The circuit breakers shall have trip-free mechanism. 8.3 The breakers should clearly indicate on and off positions. 9. ENCLOSURE 9.1 The circuit breaker shall be housed in a separate enclosure. With the lid closed, the enclosure shall comply with the requirements of IP44 type as per IS:2147-1962 or the latest version thereof. Access to the circuit breaker including operating handle shall be available only after the enclosure is opened. 9.2 Suitable vent(s) fitted with wire gauze shall be provided to ensure that the temperature inside the enclosure is not substantially different from that of the atmosphere. 9.3 Fixing of circuit breaker inside the enclosure shall be such as to allow free circulation of air at its back and sides. 9.4 Cover of the enclosure shall be so provided that it can not be left in open position and it gets latched when closed manually. In addition to the latch, an arrangement for providing pad-lock shall be made. 9.5 The enclosure shall be made of sheet steel of not less than 0.9 mm thickness. 9.6 The enclosure shall be painted both inside and outside with suitable weather proof and corrosion-resistant enamel paint. The colour of the inside paint shall be white, while that of the outer paint shall be dark admiralty grey. 9.7 Necessary fixing arrangement (to be specified by the purchaser) shall be provided at the back of the enclosure to ensure proper fixing on RCC/PCC pole by means of suitable clamp(s). 10. TERMINALS AND WIRING 10.1 A suitable terminal block in the enclosure shall be provided (below the circuit breaker) for termination of incoming and outgoing cables in order to prevent direct pressure on the circuit breaker terminals. The enclosure shall be fully wired up with insulated copper wires suitable for ratings mentioned in clause 5 to connect the outgoing and incoming terminals of the circuit breaker to the terminal block by means of tinned copper lugs. The wires should have adequate clearance from each other and from the enclosure body. Necessary spacers, cleats etc. may be provided for this purpose. 10.2 Aluminium terminal ends (lugs) of adequate size shall also be provided by the supplier to connect the incoming and outgoing cables to the terminal block to facilitate proper connections of Aluminium cables at the site. The lugs shall conform to IS:8309. The sizes of lugs for various current settings of the circuit breakers are

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indicated below : Circuit Breakers Current Setting 22A 35A 50A 90A 140A Size of PVC Aluminium Cable 10mm2 16mm2 25mm2 70mm2 150mm2 Terminal and Designation as per IS : 8309 CAA-10 CAA-16 CAA-25 CAA-70 CAA-150

10.3 Necessary provision shall be made in the enclosure for a separate neutral link on the same terminal block, to which incoming and outgoing neutral conductors can be connected. Aluminium terminal ends (lugs) of adequate size shall be provided for this purpose. The design of terminal block shall be such that all the incoming and outgoing terminals (including neutral) are in a line. 10.4 The terminals and the terminal screws/nuts in the terminal block shall be of electroplated brass. Roll-bonded aluminium-copper bimetallic washers 1 mm thick (of appropriate size and shape) shall be provided by the supplier on both sides of the aluminium lugs to avoid bimetallic action in the terminations of incoming and outgoing cables in the terminal block. 10.5 A suitable insulating shield shall be provided in the enclosure to guard against accidental touching of the live parts while operating the breaker. 10.6 The bottom plate of the enclosure shall be made detachable to facilitate easy crimping of lugs to the cable ends and for convenience in making connections. The plate shall be provided with two holes suitable for the cable sizes indicated in clause 10.2 above and glands made of tough elastic material shall be provided to ensure proper grip and support to the cables. 11. EARTHING The assembly comprising of the enclosure, framework and the circuit breaker shall be provided with an earthing terminal readily accessible and of adequate size. The earthing terminal shall be clearly marked (+). One of the two fixing bolts of the enclosure shall be used for providing second earthing connection. 12. TESTS The following type and routine tests shall be carried out on the circuit breaker in accordance with the IS:2516 (Part I & II/Section 1)-1985. 12.1 a) b) c) d) e) f) g) 12.2 Type Tests: Type tests shall include the following : Verification of temperature rise limits Verification of dielectric properties Verification of rated short-circuit making and breaking capacities (see clause 7.2 above) Verification of the ability to carry rated short-time with stand current (if required) Verification of mechanical operation and of mechanical and electrical endurances Verification of overload performance Verification of operating limits and characteristics of over current opening releases

Routine Tests: Routine tests shall include the following : a) Mechanical Operation test b) Calibration of releases and c) Dielectric tests

13. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser. The manufacturer shall afford the inspector (representing the purchaser) all reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance with this specification.

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REC Specification 19/1981 (Revised 1993) 11 KV CAPACITOR BANKS AT 33/11 KV SUB-STATIONS FOREWORD With rapid expansion of the rural electrification network and growing demand for agricultural pumps, need for proper application of capacitors in the system is now being increasingly felt especially when agricultural motors usually operate at low power factor of the order of 0.7. Adequate reactive compensation in the system at suitable locations is not only necessary from the point of view of reducing power losses and improving voltage conditions but is also required for increasing the effective capability of the network to take up future load growth in the system. 2. REC had already issued Specifications for : (i) 11 kV Capacitor Banks for Sub-stations (19/1981), (ii) 11 kV Circuit Breakers for Controlling Capacitors (20/1981) and (iii) 11 kV Pole-Mounted Switched Capacitors (35/1987). It was felt that the first two Specifications which were drawn up in 1981 required a review. The important modifications proposed to be incorporated in these Specifications are briefly indicated in the following paragraphs. 11KV Capacitor Banks for Sub-Stations 3. The REC Specification stipulates 3 standard capacitor bank ratings; 1200 KVAR, 2400 KVAR and 3600 KVAR for use at 33/11KV sub-stations. However, in all cases, preference should be given to the use of 11 KV Automatically Switched Capacitors directly on 11 KV lines. Studies have shown that these capacitors are almost twice as costeffective as the capacitor banks at the sub-stations. This is due to the fact that these capacitors provide reactive compensation on the 11 KV lines, which are the main source of high power losses, in addition to the compensation on the 33 KV upstream system. Accordingly, the following scheme of compensation for 33/11 KV sub-stations of various capacities is suggested :(i) Sub-stations capacity upto 5 or 6.3 MVA (a) The first preference should be to provide on-line compensation of 600 KVAR on each feeder with more than 1.2 MVA peak load. (b) In cases where full compensation as above is not possible, capacitor bank of 1200 or 2400 KVAR may be provided at the Sub-station as may be required depending upon the Sub-station capacity/load demand. (ii) Sub-station capacity of the order of 10 MVA (a) On-line compensation of 600 KVAR should be provided on each feeder having peak demand more than 1.2 MVA. (b) In addition to above, a capacitor bank of 2400 KVAR or 3600 KVAR may be provided at sub-station depending upon the total load demand on the sub-station and the aggregate KVAR compensation provided on the 11KV lines. 4. It is also proposed to standardise capacitor units of 200 KVAR each for making capacitor banks of 1200, 2400 and 3600 KVAR at the sub-stations. This will not only prove much more economical compared to use of 100 KVAR units standardised earlier but will also be in line with the 200 KVAR units standardised for 600 KVAR pole-mounted switched capacitor banks. This will ensure interchangeability and will minimise inventory costs. In a tender floated by APSEB for both 100 KVAR and 200 KVAR units, it was found that the overall cost of capacitor banks gets reduced by as much as 40% with the use of 200 KVAR units instead of 100 KVAR units. 5. Taking into account the advances in technology, the power loss in the capacitor bank units is proposed to be reduced to 0.2 Watt/KVAR as against 1 Watt/KVAR stipulated earlier. It may be added that the modified loss figure was agreed to in the 12thStandardisation Conference held in July, 1987 with regard to 11 KV Switched Capacitors. Further it is proposed to permit use of both internal or external fuses for the individual capacitor units, as per standard practice of the manufacturer, to take advantage of the competitive prices. This is also in line with the decision taken by the 12th Standardisation Conference. 6. As there have been complaints of unsatisfactory performance of capacitor units in the past, it is proposed to increase the warranty period for satisfactory performance of complete capacitor banks to two years from the date of receipt of equipment by the purchaser. This will ensure better quality of equipment and greater involvement of the suppliers in monitoring the causes of failures thereby protecting the interest of the purchaser. However, since proper protection of capacitors plays an important part in ensuring adequate service life, it may be desirable to

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procure capacitors and the protective equipment, including the circuit breaker from the same supplier so as to make him fully responsible for satisfactory performance of the equipment at least for a period of two years. 11 KV Circuit Breakers for Controlling Capacitors 7. Considering the merits of vacuum/SF6 technology, only this type of circuit breakers are proposed to be standardised for controlling capacitor banks. However, those of the SEBs, who have still not decided to use vacuum/SF 6 circuit breakers for feeder protection at 33/11 KV sub-stations may, at their option, use bulk oil circuit breakers for controlling capacitor banks till such time they decide to adopt use of vacuum/SF6 circuit breakers in their system. In case it is decided to procure bulk oil breakers, suitable modifications may be made in clauses relating to Constructional Features and Closing/Tripping Mechanism in the enclosed Specification. It may, however, be added that even though vacuum/SF6 circuit breakers are costlier in the first instance, this will prove much cheaper in the long run due to extremely low maintenance cost and much longer service life. 8. In the protection scheme for capacitor banks, it is proposed to stipulate unbalanced current protection via split neutral CT as an alternative to RVT protection. This will reduce costs without affecting the level of protection. As indicated in para 6 above, what is really important is that full responsibility of proper protection and adequate service life of the capacitor banks is taken by the supplier of the equipment. Taking into account the above modifications, the revised Specification was placed before the 13th Conference on Standardisation, Technical Development and Training held on 4th-6th May, 1993 at New Delhi. Based on the decisions of the Conference, the revised specification is issued. 1. SCOPE This Specification covers 3-phase, 50 Hz, naturally cooled 11 KV Shunt Capacitor Banks for installation at 33/11KV Sub-stations. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this Specification, the 11 KV capacitors shall comply with the latest version of IS:2834 (ShuntCapacitors for Power Systems). 3. TEMPERATURE CATEGORY Unless otherwise specified, the capacitors shall be suitable for temperature Category 50oC as per IS:2834. 4. RATED VOLTAGE The rated voltage of 3-phase capacitor banks shall be 12 KV (Phase-to-Phase) and the individual capacitor units shall be rated for 12/ 3 KV. 5. RATED OUTPUT The standard rated output of capacitor banks shall be 1200 KVAR, 2400 KVAR and 3600 KVAR at 12 KV rated voltage. The Banks shall comprise single-phase units of 200 KVAR each connected in single or double star (with floating neutral) depending upon the type of Unbalanced Protection used. 6. PERMISSIBLE OVERLOADS The maximum permissible overloads with regard to voltage, current and reactive output shall conform to IS:2834. 7. POWER LOSS The power loss in capacitor units shall not exceed 0.2 Watt/kVAR (subject to a tolerance of plus 10%). 8. DISCHARGE DEVICE Suitable discharge device shall be provided in the capacitor units in accordance with the provision of IS:2834. The discharge device shall reduce the residual voltage from the crest value of the rated voltage to 50 V or less within 5 minutes after the capacitor is disconnected from the source of supply. 9. EARTH CONNECTION The container of each capacitor unit shall be provided with suitable earthing terminal clearly marked as (). 10. PROTECTIVE FUSES The capacitor units shall be provided with either internal or external fuses, as per standard practice of the manufacturer. In the later case, the manufacturer shall supply the external fuses together with fixing accessories; a set of six spare fuse links shall also be supplied along with each capacitor bank. 11. GENERAL REQUIREMENTS 11.1 11.2 The capacitors shall be of non-PCB type, using polypropylene film as the dielectric. The containers shall be made from sheet steel of thickness not less than 1.6 mm.

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11.3 Complete mounting brackets supporting insulators and all other components for formation of capacitor bank racks shall be supplied along with the capacitor units. Necessary foundation bolts/nuts shall also be supplied. 11.4 The outside of the capacitor containers and other structures should have smooth and tidy look and should be coated with weather proof, corrosion-resistant paint of white or light grey shade. 12. MARKING The capacitor units shall be provided with a rating plate and terminal markings as stipulated in IS:2834. 13. TESTS The capacitor shall be subjected to all type, routine and acceptance tests in accordance with IS:2834. 14. WARRANTY The supplier shall guarantee satisfactory performance of the capacitor banks for a period of two years from the date of receipt of equipment by the purchaser. During the warranty period, all repairs/ replacements of the defective capacitor units and associated components shall be carried out free of cost. 15. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance with the specification. The purchaser has the right to get the tests carried out at his own cost by an independent agency, whenever there is a dispute regarding the quality of supply.

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REC Specification 20/1981 (Revised 1993) 11 KV CIRCUIT BREAKERS FOR CONTROLLING CAPACITORS 1. SCOPE This Specification covers three-pole 50 Hz 11 KV Vacuum/SF 6 circuit breakers for controlling capacitor banks of 1200 KVAR, 2400 KVAR and 3600 KVAR at 33/11 KV sub-stations. The circuit breakers shall be of indoor or outdoor type, as required by the purchaser. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the circuit breakers shall comply with the following Indian Standards as amended from time to time. IS-13118 : Circuit Breakers IS-3156 : Voltage Transformers IS-2705 : Current Transformers 3. RATED VOLTAGE The rated voltage for the circuit breaker shall be 12 KV. This represents the highest system voltage corresponding to the nominal system voltage of 11 KV. 4. RATED CURRENT 4.1 The standard rated normal current shall be 400 A. 4.2 The bus-bar rating of the indoor type circuit breaker shall be 800 A. 4.3 The standard rating for capacitive breaking current shall not be less than 300 A. RATED SHORT-CIRCUIT BREAKING CURRENT 5.1 The rms value of the AC component of the rated short circuit breaking current shall be 12.5 KA. 5.2 The value of dc component shall be calculated in accordance with the recommendations contained in IS:13118-1991. 5.3 The circuit breakers shall be restriking-free.

5.

6. RATED SHORT-CIRCUIT MAKING CURRENT The rated short-circuit making current of the circuit breakers shall be taken as 2.5 times the rms value of the ac component of the rated short-circuit breaking current. 7. RATED VOLTAGE OF OPERATING DEVICES The standard DC Voltage for the operating devices shall be 24 V. 8. METERING The control panel shall be provided with an ammeter of suitable rating with a selector switch. 9. PROTECTION SCHEME The following relays shall be provided for protection of the capacitor banks : i) Triple-pole over-current relay with a setting range of 50% to 200%. ii) Instantaneous single pole earth fault relay with a setting range of 10% to 40%. iii) Over-voltage relay with a setting range of 100% to 170% in conjunction with an auxiliary transformer having a ratio of 121:121 with taps on the secondary side from 115 to 127 volts for finer adjustment. iv) Instantaneous under-voltage relay with cut off at 30% voltage. v) 5-minutes time delay relay vi) Neutral voltage displacement relay in conjunction with RVT OR Unbalance current relay in conjunction with split neutral CT of double-star arrangement. (The supplier may adopt the alternative arrangement as per his standard practice).

10. RESIDUAL VOLTAGE TRANSFORMER The residual voltage transformer (RVT) for the neutral voltage displacement relay shall be of out-door type naturally cooled, with a ratio of 11000/190 V with VA burden of 50 per phase and accuracy class 5.0 as per IS:3156 (Part-III). It shall have primary connected in star and secondary in open delta with ungrounded neutral to energise neutral voltage displacement relay and to discharge capacitor bank to voltage not exceeding 50 V in less than 5 minutes. 11. CURRENT TRANSFORMER 11.1 The current transformer for metering and protection shall have transformation ratio of 300-150/5A (for 2400 KVAR & 3600KVAR capacitor banks).

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11.2 The rated output (burden) of the current transformer shall be in conformity with the relays and meters provided. 11.3 Accuracy class for the purpose of metering shall be 1.0 and for the purpose of protection shall be 5 P with an accuracy limit factor of 10. 12. CONSTRUCTIONAL FEATURES 12.1 Indoor Application 12.1.1 The circuit breakers shall have fixed or draw out type of construction and shall be of extendible type. 12.1.2 In the case of fixed type of construction, an isolator shall be provided between the breaker and busbar. The isolator shall have an integral facility for earthing of the feeder. An inter-locking arrangement shall be provided to ensure that the isolator cannot be operated with breaker in closed position. 12.2 Outdoor Application 12.2.1 The circuit breakers for outdoor application shall have fixed type of construction and vacuum/SF6 interrupters with HV connections shall be totally enclosed in hermetically sealed housing having inert atmosphere inside. In the case of vacuum circuit breakers, porcelain housing shall be preferred. The operating mechanism, links etc. shall be housed in a separate cubicle and should be accessible for maintenance. The relays, meters , indicators, operating handle etc. shall be provided on the front side with a hinged door and locking device. The door shall open upwards, with hinge at the top, for protection against rain (when in open position). Alternatively, the door opening sideways shall be acceptable, if provided with automatic closing springs and a hood on the top for protection against rain. 12.2.2 No isolator shall be provided in outdoor breakers. 13. CLOSING/TRIPPING MECHANISM 13.1 The circuit breakers shall be provided with hand-operated spring-closing mechanism. Note: The hand-operated spring mechanism is quite light in the case of vacuum /SF6 circuit breakers as compared to the conventional oil circuit breakers and is ideal for rural sub-stations due to its simplicity and economy. If power-operated mechanism is desired, 230 V single-phase motor-operated spring closing 13.2 mechanism shall be used both for vacuum and SF6 circuit breakers. For vacuum circuit breakers, an additional option for solenoid mechanism suitable for operation with 24 DC battery is also available; this arrangement is particularly suitable and reliable for indoor type circuit breakers, where 24 V station. battery is provided. Note: In the case of outdoor circuit breakers, it would be preferable to house the station battery in an outdoor kiosk instead of the control room to avoid excessive voltage drop in the long leads. Alternatively, use of selfcontained, sealed-for-life, 1.8 AH, NICAD Battery in each breaker complete with automatic charging arrangement suitable for 230 V AC supply may be stipulated. 14. TESTS The circuit breakers, residual voltage transformers and current transformers shall be subjected to all the type and routine tests in accordance with the details specified in the relevant Indian Standards (See Clause 2), as amended from time to time. 15. INSPECTION 15.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 15.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding quality of supply.

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REC Specification No. 21/1981

GUY STRAIN INSULATORS FOREWORD The Specification for Guy Strain Insulators was first discussed in the meeting of the Helping Committee on Standardisation held at New Delhi in October, 1980. The meeting was attended by the representatives of Haryana, Jammu & Kashmir, Karnataka, Maharashtra, Orissa, Punjab, Rajasthan, Tamil Nadu and Uttar Pradesh State Electricity Boards, Central Electricity Authority, the Indian Standards Institution, the Indian Electrical Manufacturers Association and officers of the Rural Electrification Corporation. The recommendations of the Helping Committee were subsequently discussed in the 9th Standardisation Conference held at New Delhi in April, 1981. This specification has been prepared on the basis of the recommendations of Helping Committee on Standardisation and subsequent decisions taken at the 9th Conference on Standardisation. 1. SCOPE This Specification covers porcelain guy strain insulators for use in rural electrification system.

2.

APPLICABLE STANDARDS Unless otherwise modified in this specification, the insulators shall comply with IS:5300-1969 or the latest version thereof. 3. GENERAL REQUIREMENTS 3.1 The porcelain insulator shall be sound, free from defects, thoroughly vitrified and smoothly glazed.

The design of the insulator shall be such that the stresses due to expansion and contraction in any part of 3.2 the insulator shall not lead to its deterioration. The glaze, unless otherwise specified, shall be brown in colour. The glaze shall cover the entire porcelain 3.3 surface parts except those areas that serve as supports during firing. 4. TYPE OF INSULATORS The standard guy strain insulators shall be of designations A and C as per IS:5300. 4.1 4.2 The recommended type of guy strain insulators for use on guy wires of overhead lines of different voltage levels are as follows : Power Line Voltage 415/240V 11000V 33000V 5. Designation of Insulators A C C (2 Insulators to be used in series)

DIMENSIONS The dimensions of guy strain insulators shall be in accordance with Figs. 1 and 2. BASIC INSULATION LEVELS The test voltage of the insulators shall be as under : Designation of Insulator Dry one minute power Frequency withstand voltage KV (rms) Wet one minute power Frequency withstand voltage KV (rms)

6.

A C

18 27

8 13

7.

MECHANICAL STRENGTH The insulators shall be suitable for the minimum failing loads specified as under : Designation of Minimum failing load

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Insulator A C (KN) 44 88

8. TESTS The insulators shall comply with the following routine, type and acceptance tests as per IS:5300. 8.1 Routine Test

Visual examination
8.2 a) b) c) d) e) f) g) 8.3 a) b) c) d) 9. Type Tests Visual examination Verification of dimensions Temperature cycle test Dry one-minute power-frequency voltage withstand test Wet one-minute power frequency voltage withstand test Mechanical strength test Porosity test Acceptance Tests: (to be conducted in the following order) Verification of dimensions Temperature cycle test Mechanical strength test Porosity test

MARKING 9.1 Each insulator shall be legibly and indelibly marked to show the following : a) Name or trade mark of the manufacturer b) Year of manufacture c) ISI certification mark, if any. 9.2 Marking on porcelain shall be applied before firing.

10. PACKING All insulators shall be packed in wooden crates suitable for easy but rough handling and aeptable for rail transport. Wooden separators shall be fixed between the insulators to keep individual insulators in position without movement within the crate.

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REC Specification No. 22/1983 11KV VACUUM CIRCUIT BREAKERS FOREWORD The question of using 11 KV Vacuum Circuit Breakers in rural distribution system was discussed by the Standardisation Committee in its seventh meeting held in April, 1982. The Committee felt that vacuum circuit breakers would be especially suitable for RE system because of their long life and maintenance-free design. It was decided that, in view of the apparent advantages of these circuit breakers and satisfactory experience of other countries, a separate REC Specification be issued to enable the SEBs to use these breakers. The specification for 11 KV Vacuum Circuit Breakers has been prepared on the basis of the recommendations made by the Standardisation Committee and subsequent decisions taken by the Tenth Conference on Standardisation, Technical Development and Training in Rural Electrification held at New Delhi in April, 1983. 1. SCOPE This specification covers three-pole, 50 Hz, 11 KV vacuum circuit breakers both for indoor and outdoor installations in rural electrification system. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the vacuum circuit breakers shall comply with the following Indian Standards as amended from time to time : IS-13118 : Circuit Breakers IS-3156 : Voltage Transformers IS-2705 : Current Transformers 3. RATED VOLTAGE The rated voltage for the circuit breaker shall be 12 KV. This represents the highest system voltage corresponding to the nominal system voltage of 11 KV. 4. RATED CURRENT The standard rated normal current shall be 400A. 4.1 4.2 5. The bus-bar rating of the indoor type vacuum circuit breaker shall be 800 A.

RATED SHORT-CIRCUIT BREAKING CURRENT The rms value of the A.C. component of the rated short-circuit breaking current shall be 8 KA and 12.5 5.1 KA. Note : It is recommended that 12.5 KA circuit breaker may be used only when the proposed/anticipated transformer capacity is 2x5 MVA (capacities above 2x5 MVA are not generally met with in the rural system). For lower transformer capacities, 8 KA breakers will be adequate. The value of D.C. component shall be calculated in accordance with the recommendations contained in 5.2 IS:13118.

6. RATED SHORT-CIRCUIT MAKING CURRENT The rated short-circuit making current of the circuit breakers shall be taken as 2.5 times the rms value of the A.C. component of the rated short-circuit breaking current. 7. RATED VOLTAGE OF OPERATING DEVICES The standard DC voltage for the operating devices shall be 24 V. 8. VOLTAGE TRANSFORMER FOR METERING 8.1 Voltage Ratio : The rated voltage ratio shall be 11000/110 V. connected and one of the secondary terminals shall be earthed. The transformer shall be star-star

8.2 Rated Output: The standard rated output (burden) of the voltage transformer shall be 100 VA per phase. Normally, only one 3-phase voltage transformer of this rated output will be required at a 33/11 KV substation. 8.3 Accuracy Class : The standard accuracy class shall be 1.0.

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9. CURRENT TRANSFORMER FOR METERING & PROTECTION 9.1 Transformer Ratio: The standard transformation ratio shall be : i) ii) iii) 50-25/5A 200-100/5A 300-150/5A

Note : The above double ratio current transformers will be adequate to cover the load demands of the outgoing feeders as well as the requirements of incoming panels for sub-station capacities upto 2x5 MVA. The SEBs may select the required ratings out of the above, depending upon the sub-station capacity and feeder loadings. 9.2 Accuracy Class : Accuracy class for the purpose of metering shall be 1.0 and for the purpose of protection shall be 5P with an Accuracy Limit Factor of 10. 9.3 Rated Output : The rated output (burden) of the current transformers which depends upon the type and make of relays and meters used, will have to be decided in each case. 10. METERING AND PROTECTION Meters/instruments on the incoming and outgoing circuit breaker panels shall be provided in 10.1 accordance with the REC Construction Standard L-3. 10.2 A triple-pole IDMTL type protection relay having two elements for over-current protection and one element for earth fault protection shall be provided on 11 KV incoming as well as outgoing circuit breakers. The current setting range of the over-current elements shall be from 50% to 200% in steps of 25% and that of the earth fault element from 20% to 80% in steps of 10%. 11. CONSTRUCTIONAL FEATURES 11.1 Indoor Application : 11.1.1 The circuit breakers shall have fixed type of construction and shall be of extendible type. 11.1.2 An isolator shall be provided between the vacuum interrupter and bus-bar. The isolator shall have an integral facility for earthing of the feeder. An inter-locking arrangement shall be provided to ensure that the isolator cannot be operated with the breaker in closed position. 11.2 Outdoor Application: 11.2.1 Vacuum circuit breakers for outdoor application shall have fixed type of construction and the vacuum interrupter units together with the HV connections shall be enclosed in a sealed housing (preferably of porcelain) conforming to IP-65 protection (IS:2147). The operating mechanism, links, etc. shall be housed in a suitable cubicle and should be accessible for maintenance. The relays, meters, indicators and operating handle etc. shall be provided on the front side with a hinged door and locking device. The door shall open upwards (with hinge at the top) for protection against rain (when in open position). 11.2.2 No isolator shall be provided in outdoor breakers. 12. CLOSING/TRIPPING MECHANISM 12.1(a) The circuit breakers shall be provided with hand operated spring-closing mechanism. If specially required by the purchaser, 230 V single-phase AC motor shall be provided for spring-closing mechanism with provision for manual closing. Note : The hand-operated spring mechanism is very light in the case of vacuum circuit breakers as compared to the conventional oil circuit breakers and is ideal for rural sub-stations due to its simplicity and economy. 12.1(b) Alternatively, the SEBs have the option to order circuit breakers with solenoid closing mechanism suitable for operation with 24 V DC battery. In the case of outdoor circuit breakers, it would be preferable to house the station battery in an outdoor Note : kiosk instead of the control room to avoid excessive voltage drop in the long leads. Alternatively, use of selfcontained long life NICAD battery in each breaker may be considered. 12.2(a) The trip mechanism shall be suitable for direct operation from the current Transformers in conjunction with the Series trip relays of the type indicated in clause 10.2. Note: This tripping arrangement along-with the closing mechanism as per 12.1(a) is recommended for rural substations as the need for battery is eliminated.

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12.2(b) Alternatively, if closing arrangement as per 12.1 (b) above is adopted, the SEBs have the option toorder circuit breakers with the trip coil operated by 24 V DC battery, using Shunt trip relays. 13. TESTS The circuit breakers, voltage transformers and current transformers shall be subjected to the following 13.0 routine and type tests in accordance with the details specified in the relevant Indian standards, as amended from time to time. 13.1 Circuit Breakers - IS:13118-1991 13.1.1 Routine Tests a) Power frequency voltage dry test on the main circuit b) Voltage test on control and auxiliary circuits c) Measurement of resistance of the main circuit d) Mechanical Operating test 13.1.2 Type Tests a) Tests to prove mechanical performance b) Tests to prove mechanical operation c) Tests to prove that temperature rise of any part does not exceed specified limits d) Tests to prove that insulation complies with specified limits e) Tests to prove short-circuit making and breaking performance f) Tests to prove short-time current performance g) Tests to prove performance when breaking line-charging current h) Tests to prove performance when breaking cable-charging current i) Tests to prove the performance when breaking single capacitor bank currents j) Tests to prove the performance when breaking small inductive currents 13.2 Voltage Transformers : - IS:3156 (Part-I)-1992 13.2.1 Routine Tests: a) b) c) d) Verification of terminal markings and polarity Power-frequency dry withstand tests on primary windings Power-frequency dry withstand tests on secondary windings Determination of errors according to the requirements of the appropriate accuracy class

13.2.2 Type Tests: a) Verification of terminal markings and polarity b) Power-frequency dry withstand tests on primary windings c) Power-frequency dry withstand tests on secondary windings d) Determination of errors according to the requirements of the appropriate accuracy class e) Temperature-rise test f) Impulse voltage tests on voltage transformers for service in electrically exposed installations 13.3 Current Transformers - IS:2705 (Part-I)-1992 13.3.1 Routine Tests: a) Verification of terminal markings and polarity b) High voltage power-frequency test on primary windings c) High voltage power-frequency test on secondary windings d) Over-voltage inter-turn test e) Determination of error according to the requirements of appropriate accuracy class 13.3.2 Type Tests: a) Verification of terminal markings and polarity b) High voltage power frequency test on primary windings c) High voltage power frequency test on secondary windings d) Over-voltage inter-turn test e) Determination of error according to the requirements of appropriate accuracy class f) Short-time current test g) Temperature-rise test h) Impulse voltage test for current transformers for service in electrically exposed installations

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14. INSPECTION 14.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with the specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency 14.2 whenever there is dispute regarding the quality of supply.

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REC Specification-23/1983 (Revised 1997) OUT-DOOR TYPE THREE PHASE 11 KV/433-250 V COMPLETELY SELF- PROTECTED DISTRIBUTION TRANSFORMERS UPTO AND INCLUDING 100 KVA FOREWARD In the 7th meeting of the Committee on Standardisation held at New Delhi in April, 1982, it was decided to issue a separate specification for Completely Self-Protected type of distribution transformers commonly known as CSP transformers. These transformers have built in LT Circuit breakers, 11 KV fuses and 11 KV lightning arresters. Because of the well-coordinated and tested protection arrangement, these transformers are expected to have much lower failure rate as compared to the conventional transformers. The specification for CSP transformers was prepared on the basis of the decisions taken at the above meeting and subsequent decisions held in the Tenth Conference on Standardisation, Technical Development and Training in Rural Electrification held at New Delhi in April, 1983. This subject was further discussed in 14th Conference on Standardisation and Technical Development held on 25th April, 1997 and it was decided that the provision of an externally mounted MCCB as an integral part of the transformer needed fresh examination as it was generally felt that the MCCBs presently available in the country were not suitable for transformer protection. There is a need for either locating internationally available suitable LT circuit breakers or develop them indigeneously for external application on the distribution transformers. It was, therefore, decided that till such time an externally mounted circuit breaker of suitable characteristic is available, we may specify only internally mounted oil immersed LT circuit breakers. The Conference also recommended the use of only internally mounted 11 KV fuse links and metal oxide type lightning arresters. Based on the above recommendations, this specification is being revised and issued. 1. SCOPE This specification covers oil-immersed, naturally cooled, 11KV/433-250 V, three phase, 50 Hz, double-wound, outdoor type completely self-protected (CSP) transformers for use on systems with nominal voltage of 11 KV . The transformers shall be equipped with circuit breakers on LT side, 11 KV fuses and 11 KV lightning arresters on HV side as integral parts of the equipment. 2. STANDARD RATING The standard ratings of CSP transformers shall be 16, 25, 63 and 100 KVA.

3.

APPLICABLE STANDARDS Unless otherwise modified in the specification, the CSP transformers shall comply with the Indian Standards IS:1180(Part I and Part II) and IS: 2026 as amended from time to time. 4. NO-LOAD VOLTAGE RATIO The no-load voltage ratio shall be as follows: a) 11000/433-250 V for 16,25,63 and 100 KVA b) 10450/433-250 V for 100 KVA only, wherever specified. TAPS No taps are to be provided in these transformers.

5.

6.

WINDING CONNECTIONS AND VECTORS. The primary winding shall be connected in delta and the secondary winding in star (vector symbol DY 11) so as to produce a positive displacement of 300 from the primary to the secondary vectors of the same phase(vector rotation assumed counter clockwise). The netural of the secondary winding shall be brought out to a separate insulated terminal. 7. FITTINGS The following standard fittings shall be provided. a) Two earthing terminals. b) Two lifting lugs c) Rating and terminal marking plate(s) d) Bimetallic Terminal connector for HV/LV bushings as per Fig.1. Fittings for Conventional Distribution Transformers only: e) Oil level gauge indicating three positions of oil marked as follows: Minimum(-5 0 C) 30 0 C)

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f) g) h) i) Maximum 98 0 C)) Silica gel breather, if specially required by the purchaser. Drain-cum-sampling valve(steel) of the type shown in fig.1 of the REC Specification 2/1971 (Revised -1997). Thermometer pocket for 63 and 100 KVA units. Filling hole having P 1 thread on the transformer body/conservator.

Fittings for Sealed Transformers only: j) Nitrogen/air filling device/pipe with welded cover capable of reuse. k) An extended pipe connection at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing welded cover. 8. CONSERVATOR In the case of sealed type distribution transformers, no conservator shall be provided. 8.1 In case of conventional distribution transformers of 63 and 100 KVA rating, provision of 8.2 conservator is obligatory. For 16 and 25 KVA transformers, the manufacturers may adopt their standard practices. Other features of the conservator, if provided, shall be in accordance with Clause 8.2 and 8.3 of REC 8.3 Specification 2/1971 (R-1997). 9. RATING AND TERMINAL MARKING PLATE(S) Each transformer shall be provided with a non-detachable Rating and Terminal Marking Plate(s) of whether proof material, fitted in a visible position and showing the complete information as given in clause 20 of IS:1180(Part I)1989. 10. LIMITS OF TEMPERATURE RISE. When tested in accordance with IS : 2026, the temperature rise in winding (measured by resistance) and in top oil (measured by thermometer) shall not exceed the limits of 55 0 C and 45 0 C respectively. 11. LOSSES AND IMPEDANCE VALUE 11.1 The no-load and load-losses shall not exceed the values given in the following table: KVA Rating No-Load Loss (Watts) Load Loss at 750C (Watts)

16 25 63 100

80 100 180 260

475 685 1235 1760

The above losses are maximum allowable and there shall not be any plus tolerance. The capitalisation of losses will be allowed for lower losses offered. 11.2 The percentage impedance at 75 0 C shall be 4.5 percent subject to tolerance as per IS:2026.

Overflux in the transformer core shall be limited to 12.5% to ensure that, in the event of over 11.3 voltage to the extent of 12.5%, the core does not get saturated. The supplier will furnish necessary design data in support of this stipulation. In this regard the transformer shall comply with clause No. 22.6 of IS:1180 Part-I1989. 12. CONSTRUCTIONAL FEATURES OF SEALED TYPE TRANSFORMERS. The terminal (double-bushing or alternate) arrangement and the transformer tank design/sealing in respect of sealed type distribution transformers shall be in accordance with Clause 11 of REC Specification 11/1976 (R1997). 13. LT CIRCUIT BREAKER. The transformer shall be fitted with a trip-free LT circuit breaker which shall be provided inside the 13.1 transformer tank immersed in oil. The circuit breaker shall be capable of being operated from the ground level by means of a suitable 13.2 operating rod. For this purpose, an operating hook shall be provided on the transformer tank in a suitable

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position for easy and safe operation of the circuit breaker from the ground level. The design of the operating mechanism of the circuit breaker shall be such that it shall have only two positions i.e. ON & OFF, it shall not be require resetting before being switched to ON position. The circuit breaker shall be coordinated thermally with the transformer rating to follow closely the 13.3 variation in winding temperature due to fluctuating loads and ambient temperature. The outgoing terminals of the circuit breaker shall be connected to the LT bushings of the transformer through internal connections as in ordinary transformers. The rated short circuit breaking capacity of the circuit breaker shall not be less than 2.5 KVA. The 13.4 circuit breaker shall be tested in accordance with IS:13947(Part-2)-1993, but at a p.f. of 0.4(lagging). 14 11 KV LIGHTING ARRESTERS. A set of lightning arresters of metal oxide type with suitable failure detecting device shall be 14.1 mounted on the transformer, clamping it securely to the tank. The line terminal of the lightning arresters shall be connected to the HV Bushing and the earth terminal of the lightning arrester shall be solidly connected to the tank which in turn will be connected to a separate earth. The characteristics of the lightning arresters and all test requirements shall be conform to the REC 14.2 Specification No. 55/1987. 11 KV FUSE ARRANGEMENT. The 11 KV fuse links shall be provided internally (Mounted inside the bushings). In this case, it will be absolutely necessary to ensure that the fuses will blow off only in the case of an internal fault in the transformer and all external faults in the LT System will be cleared by the LT circuit breaker only. This will call for the use of the circuit breakers of proven design and use of proper rating fuses. 16. COORDINATION OF 11 KV FUSES AND LT CIRCUIT BREAKER. Coordination of 11 KV fuses with the LT circuit breaker is the most important feature of a CSP transformer and shall be properly tested and proved. The supplier shall furnish the time current characteristics of LT circuit breaker and 11 KV fuse for various current multiples at top oil temperature of 85 degrees C. The two characteristics shall be drawn on the same sheet to indicate coordination between circuit breaker and the fuse. This shall be based on the tuype tests carried out on one of the transformers. In addition, the supplier shall carry out coordinat5ion test, on minimum one transformer out of every 50 transformers and this will form an Acceptance Test by the purchaser. The coordination test has been proposed at 85 degrees C top oil temperature because of this top oil Note: temperature the transformer is on full load. The manufacturers and SEBs may give their suggestions based on their field experience if this test needs to be carried out at any other temperature also. 17. TESTS 17.1 Routine tests: All transformers shall be subjected to routine tests at the manufacturers work in accordance with IS:2026 and IS: 1180(Part I & II). a) Measurement of winding resistance b) Measurement of voltag3e ratio and check of voltage vector relationship c) Measurement of impedance voltage, short-circuit impedance and load loss d) Measurement of no-load loss and no-load current e) Measurement of insulation resistance f) Induced over-voltage withstand test g) Separate source voltage withstand test h) Air Pressure Test (For Sealed Transformers only). The transformer tank with welded lid and with all the fitting bushings in position shall be tested for leakage at a pressure of 0.8 Kg/cm sq.g above atmospheric pressure maintained inside the tank for 20 minutes. There should be no leakage at any point. As above test is required to be carried out before final sealing of the transformer, the NOTE: inspecting authority would ensure to be present at the time of final sealing to witness this test. The test cannot be demonstrated on a completed transformer. 17.2 Type Test ( a to g ) as indicated under routine tests h) Coordination test as per clause 16 above. i) Lightning impulse test j) Temperature rise test k) Short-circuit test l) Unbalance Current Test: The value of unbalanced current indicated by the ammeter as shown in the test arrangement in REC Specification 2/1997 shall not be more than 2% 15

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m) of the full load current. Air Pressure Test: The air pressure test shall be carried out as per IS:1180-1989 (Part-I) Clause 21.5.1 for sealed type

If records of a type test on a transformer which in essential details, is representative of the one being purchased, are furnished, the purchaser may accept this as evidence of the type test instead of actual test. 17.3 The supplier shall furnish calculations in accordance with IS:2026 to demonstrate the thermal ability of the transformers to withstand short-circuit. 17.4 Inspection 17.4.1 All tests and inspection shall be made at the place of manufacture of transformer unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 17.4.2 The purchaser has a right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply. 18. MOUNTING ARRANGEMENT The under base of all transformers shall be provided with two 75X40 mm M.S. channels 460 mm long , with holes 9 at a centre-to-cenrtre distance of 415 mm ) as shown in the REC Specification 2/1971 (R-1997) to make them suitable for fixing on a platform or plinth.

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REC Specification 24/1983 (Revised - 1987) PRESTRESSED CONCRETE POLES FOR 33 KV LINES FOREWORD Of the various types of poles being used for overhead distribution lines, PCC poles have been found to be the most economical. REC has already issued a Specification No.15/1979 for PCC poles for use on 11 KV & LT lines, which is based on the economical designs evolved by the Cement Research Institute of India now known as the National Council for Cement and Building Materials(NCBM) at the instance of REC. These designs have been widely adopted by the SEBs, which has led to substantial economy. On the demand of the SEBs, another research project was entrusted by REC to the NCBM some time back for developing suitable design of PCC poles for use on 33 KV lines. The basic design parameters for these poles, as given in Clause 6, were finalised in a meeting convened by the REC with the representatives of the SEBs and NCBM. Based on these design parameters and the relevant provisions of the Indian Standards cited in Clause 2, designs were evolved by NCBM for both Solid and Virendeel types of poles for two values of Factor of Safety, i.e. 2.5 and 2.0. Based on these designs, prototype poles were made by the NCBM and these poles were found to withstand the load tests satisfactorily. The designs evolved by the NCBM were discussed in Seventh meeting of the Standardisation Committee held in April, 1982 and the Committee approved the standardisation of only virendeel type of poles with FOS 2.0 in the interest of economy and light weight. This specification was drawn up on the basis of the economical designs developed by the NCBM which were approved by the Tenth Standardisation Conference held in April 1983. This Specification was further reviewed in the 12th Standardisation Conference held in July, 1987. Some of the SEBs expressed difficulty in casting virendeel type poles as also in transportation and erection due to higher risk of breakage. It was decided to incorporate designs of solid rectangular poles also in this Specification. This Specification has accordingly been modified and the SEBs will have the discretion to use either virendeel or solid rectangular designs depending upon their preference. 1. SCOPE This specification covers solid rectangular and Virendeel type PCC poles with FOS 2.0 with an overall length of 9.0 and 9.5M suitable for use in overhead 33 KV power lines. 2. APPLICABLE STANDARDS Except when they conflict with specific requirements in this Specification, the poles shall comply with the relevant provisions made in the following Indian Standards or the latest versions thereof. a) IS: 1678-1978, Specification for prestressed concrete poles for overhead power, traction and telecommunication lines. b) IS : 2905-1966. Methods of test for concrete poles for overhead power and telecommunication lines. c) IS : 7321-1974. Code of Practice for selection, handling and erection of concrete poles for overhead power and telecommunication lines. 3. TERMINOLOGY For the purpose of this standard, the following definitions shall apply:3.1 Average Permanent Load That fraction of the working load which may be considered of long duration over a period of one year. 3.2 Load Factor The ratio of ultimate transverse load to the transverse load at first crack. 3.3 Transverse The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a straight run, this will be normal to the run of the line. 3.4 Transverse Load at First Crack For design, the transverse load at first crack shall be taken as not less than the value of the working load. 3.5 Working Load The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on the pole. This load is assumed to act at a point 600mm below the top with the butt end of the pole planted to the

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required depth as intended in the design. 3.6 Ultimate Failure The condition existing when the pole ceases to sustain a load increment owing to either crushing of concrete, or snapping of the prestressing tendon or permanent stretching of the steel in any part of the pole. 3.7 Ultimate Transverse Load The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the axis of the pole along the transverse direction with the butt end of the pole planted to the required depth as intended in the design. 4. APPLICATION 4.1 9.0 M Poles These poles shall be used at tangent locations of 33 KV lines using conductor formation and clearances as per REC Construction Standard M-3. The requirement of working loads of the poles in different wind pressure zones would be as per REC Construction Standard M-2, which is reproduced below: Working load of Pole a) 200kg b) c) 300 kg 400 kg Zone 50 kg/M2 75 kg/M2 100 kg/M2

The maximum permissible spans shall be as per REC Construction Standard M-2. 4.2 9.5 M Poles These poles shall be used for special locations of 33 KV lines such as road crossings etc. in the same wind pressure zones, as in Clause 4.1. The poles are not suitable for use in cyclone affected Coastal areas, or in areas with higher wind 4.3 pressures than indicated in Clause 4.1. Special designs of poles would have to be evolved for such areas. 5. MATERIAL 5.1 Cement The cement used in the manufacture of prestressed concrete poles shall be ordinary or rapid hardening portland cement conforming to IS : 269-1976 (Specification for ordinary and low heat portland cement) or IS : 8041 E-1978 (Specification for rapid hardening portland cement), or high strength ordinary portland cement conforming to IS : 8112-1976 (Specification for high strength ordinary portland cement). 5.2 Aggregates Aggregates used for the manufacture of prestressed concrete poles shall confirm to IS : 383-1970 (Specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregates shall in no case exceed 10 mm. 5.3 Water Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable. 5.4 Admixture Admixtures should not contain Calcium Chloride or other chlorides and salts which are likely to promote corrosion of prestressing steel. 5.5 Pre-stressing steel The pre-stressing steel wires, including those used asuntensioned wires (See Annex.I and II), should conform to IS : 1785(Part-I)-1983 (Specification for plain hard-drawn steel wire for prestressed concrete, Part-I cold drawn stress relieved wire)

or
IS:6003-1983 (Specification for indented wire for prestressed concrete) or the latest versions thereof. The type designs given in Annexure-I and II are for plain wires of 4 mm diameter with a guaranteed ultimate strength of 175 kg/mm2 and for plain wires of 5 mm diameter with a guaranteed ultimate strength of 160 kg/mm 2. The concrete mix shall be designed to the requirements laid down for controlled concrete (also called 5.6 design mix concrete) in IS : 1343-1980 (Code of practice for prestressed concrete) and IS : 456-1978 (Code of practice for plain and reinforced concrete), subject to the following special conditions:

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a) b) c) d) Maximum works cube strength at 28 days should be at least 400 kg/cm2. The concrete strength at transfer should be atleast 200 kg/cm2. The mix should contain at least 380 kg of cement per cubic meter of concrete. The mix should contain as low a water content as is consistent with adequate workability. If it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ratio is maintained.

6.

Design requirements The poles shall be designed for the following requirements: a) The poles shall be planted directly in the ground with a planting depth as per IS : 1678-1978. b) The working load on the poles should correspond to those that are likely to come on the pole during their service life. Designs given in Annex. I and II are for 200 kg., 300 kg. and 400 kg. applied at 0.6 M from top. c) The factor of safety for all these poles shall not be less than 2.0. d) The average permanent load shall be 40% of the working load. e) The F.O.S. against first crack load shall be 1.0. f) At average permanent load, permissible tensile stress in concrete shall be 30 kg/cm2. g) At the design value of first crack load, the modulus of rupture shall not exceed 53.0 kg/cm2 for M-400 concrete. h) The ultimate moment capacity in the logitudinal direction should be at least one fourth of that in the transverse direction. i) The maximum compressive stress in concrete at the time of transfer of prestress should not exceed 0.8 times the cube strength. j) The concrete strength at transfer shall not be less than half the 28 days strength ensured in the design, i.e. 400 x 0.5 = 200kg/cm2. 6.1 Dimensions and Reinforcements The cross-sectional dimensions and the details of prestressing wires should conform to the particulars given in Annexure-I and II. The provisions of holes for fixing cross-arms and other fixtures should conform to the REC standards referred to in clause 4. of this specification and in accordance with the construction practices adopted by the State Electricity Boards.

7.

MANUFACTURE 7.1 All prestressing wires and reinforcements shall be accurately fixed as shown in drawings and maintained in position during manufacture. The untensioned reinforcement, as indicated in the drawings, should be held in position by the use of stirrups which should go round all the wires. 7.2 All wires shall be accurately stretched with uniform prestress in each wire. Each wire or a group of wires shall be anchored positively during casing. Care should be taken to see that the anchorages do not yield before the concrete attains the necessary strength. 7.3 Cover The cover of concrete measured from the outside of pre-stressing tendon shall be normally 20 mm. 7.4 Welding and Lapping of Steel The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire. Compacting Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand compaction shall not be permitted. Curing The concrete shall be covered with a layer of sacking, canvass, hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of prestress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit, the interval should depend on the atmospheric humidity and temperature. The prestressing wires shall be detensioned only after the concrete has attained the specified strength at 7.7 transfer (i.e. 200 kg/cm2). The cubes cast for the purpose of determining the strength at transfer should be cured, as far as possible, under conditions similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated

7.5

7.6

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above is reached. Thereafter the test on concrete shall be carried out as detailed in IS : 1343-1980 (Code of practice for prestressed concrete). The manufacturer shall supply, when required by the purchaser or his representative, result of compressive test conducted in accordance with IS : 456-1978 (Code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. If the purchaser so desires, the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS : 456-1978 (Code of practice for plain and reinforced concrete). The detensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the poles. The rate of detensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. The poles shall not be detensioned or released by cutting the prestressing wires using flames or bar croppers while the wires are still under tension. Separate eye-hooks or holes shall be provided for handling the transport, one each at a distance of 0.15 7.8 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided for lifting purposes, should be perpendicular to the broad face of the pole. Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported on timber sleepers located as 0.15 times the overall length, measured from the end. The timber supported in the stack should be aligned in a vertical line. Poles should be transported with their broad faces placed vertically and in such a manner that shocks are avoided. Supports should be so arranged that they are located approximately at a distance equal to 0.15 times the overall length from the ends. The erection of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis, i.e. the rope used for hoisting the pole should be parallel to the broader face of the pole. 7.9 Earthing 7.9.1 Earthing shall be provided by having length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 100mm at 250 mm from top and 150 mm below ground level. 7.9.2 7.9.3 to 8. 8. 8.1 Earth wire shall not be allowed to come in contact with the prestressing wires. The possible location of earth wire for different varieties of poles has been shown in Drawing Nos. 1

TESTS Transverse Strength Test 8.1.1 Poles made from ordinary portland cement shall be tested only on the completion of 28 days and poles made from rapid hardening cement only on the completion of 14 days, after the day of manufacture. The poles may be tested in either horizontal or vertical position. If tested in horizontal position, 8.1.2 provisions shall be made to compensate for the overhanging weight of the pole, for this purpose, the overhanging portion of the pole may be supported on a movable trolley or similar device. 8.1.3 The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting.

8.1.4 Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to the design value of the transverse load at first crack. The deflection at this load shall be measured. A prestressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. The load shall then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80 per cent of the minimum ultimate transverse load and thereafter increased by 5 per cent of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes. The load applied to prestressed concrete pole at the point of failure shall be measured to the nearest five Kilograms. The pole shall be deemed not to have passed the test if the observed ultimate transverse load is less than the design ultimate transverse load. 8.2 Measurement of Cover After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The cover of the pole shall be measured at 3 points, one within 1.8 meter from the butt end of the pole, the second within 0.6 meters

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from the top and the third at an intermediate point and the mean value compared with the specified value. The mean value of the measured cover should not differ by more than () 1mm from the specified cover. The individual values should not differ by more than () 3mm from the specified value. If these requirements are not met, the workmanship with reference to aligning of the end plates and prestressing wires and assembly of moulds should be improved and inspection at pre-production stage tightened suitably. 9. SAMPLING AND INSPECTION 9.1 Scale of Sampling 9.1.1 Lot: In any batch, all poles of the same class and same dimensions shall be grouped together to constitute a lot. 9.1.1.1 Sub-lot: If the number of poles in a lot exceeds 500, the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of sub-lot shall be determined on the basis of performance of samples selected from it. 9.1.2 The number of poles to be selected from a lot or a sublot shall depend upon its size and shall be in accordance with Col. 1 and 2 of the following table:

SAMPLE SIZE AND CRITERION FOR CONFORMITY Clause 9.1.2, 9.2.2 & 9.3.2 Size of lot or subDimensional Requirement No. of poles for lot transverse Sample size Permissible No. of strength test defective samples 1 Upto 100 101 to 200 201 to 300 301 to 500 2 10 15 20 30 3 1 1 2 3 4 * 3 4 5

* The no. of poles to be tested shall be subject to the agreement between purchaser & supplier. 9.1.3 These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any random pole, every rth pole may be included in the sample, r being the integral part of N/n where N is size of the lot or the sub-lot and n is the sample size. 9.2 Number of Tests 9.2.1 All the poles as selected in 9.1.2 shall be tested for overall length, cross-section and uprightness. The tolerance shall ()3 mm on cross sectional dimensions and 0.5 percent on uprightness. 9.2.2 The number of poles to be tested for transverse strength test shall be in accordance with Col. 4 of the above table. These poles may be selected from those already tested in 9.2.1. 9.3 Criteria for Conformity 9.3.1 A lot or sub-lot shall be considered as conforming to this specification if the conditions under 9.3.2 and 9.3.3 are satisfied. 9.3.2 The number of poles which does not satisfy the requirements of overall length, cross-section and uprightness shall not exceed the corresponding number given in Col. 3 of Table in 9.1.2. If the number of such poles exceeds the corresponding number, all poles in the lot or sub-lot shall be tested for these requirements and those not satisfying the requirements shall be rejected. 9.3.3 All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more poles fail, twice the number of poles originally tested shall be selected from those already selected and subjected to the test. If there is no failure among these poles, the lot or the sub-lot shall be considered to have satisfied the requirements of this test. 10. MARKING The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in position: a) Month and year of manufacture b) Transverse strength of pole in Kg. c) Makers serial No. and mark.

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REC Specification 25/1983

HELICALLY FORMED FITTINGS FOR 11 KV AND LT LINES FOREWORD Helically formed fittings comprise of factory-formed set of wires of definite size and requirement and is made of suitable material compatible with the material and size of the conductor on which it is applied. These fittings are now being extensively used in many countries. The main advantage is the simplicity of application. The fitting can be applied without aid of any tool and very little skill is needed for its application. Another major advantage is uniform distribution of clamping pressure all along the length of the fitting thereby eliminating concentration of pressure at any single point on the conductor as is the case with other types of clamps conventionally used. The question of standardising these fittings for application in rural distribution system was discussed in the 10th Standardisation Conference held in April 1983. This specification is based on the decisions taken by the Conference and subsequent discussions held with the manufacturers of these fittings, SEBs, ISI etc. 1. SCOPE This Standard specifies the requirements and tests for helically formed fittings for use on 11 KV and LT overhead lines. The following types of fittings are covered:a) Conductor dead end fittings b) Distribution ties, side ties and double ties c) Conductor splices d) Guy grip dead-ends e) Tap connectors f) Service grip dead-ends g) Lashing rods 2. GENERAL REQUIREMENTS Aluminium alloy, aluminium-clad steel and galvanised steel wires having required mechanical strength, 2.1 corrosion resistance and formability, depending on the type of application shall be employed in the manufacture of the fittings. The material of the formed fittings shall be compatible with the conductors with which it is used. In case of formed wires, no joints shall be permitted except those in the base rod or wire before final 2.2 drawing. 2.3 Each formed set shall be marked with indelible and distinct colour to indicate starting/cross-over point of application to facilitate its application on the conductor. 2.4 The ends of the individual wires of the formed fittings shall be suitably deburred to provide a smooth finish so as to avoid any damage to the conductor due to sharp edges. 2.5 Suitable grit shall be applied to the gripping section of the formed fitting (except lashing rods) in order to enhance its gripping strength. 3. PROPERTIES OF WIRES 3.1 Materials of the wires used in the manufacture of the fittings covered by this specification shall have the mechanical and electrical properties as specified in Tables 1,2 and 3. Materials used for chloroprene pad shall have the properties specified in Table 4.

Table 1 Aluminium Alloy Wires

Test Requirements a) b) 1. Visual c) d) No scratches No pealing off No speed crack No cut mark

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a) 2. Dimensions after forming b) Diameter Tolerance (+) .000 mm (-) .025 mm Flattening (+) .000 mm (-) .076 mm

3. Tensile strength of formed wires 4. Elongation of finished wire 5. Conductivity of finished wire 6. Wrap test Wire diameter (mm) Upto 3.07 From 3.08 to 3.45 From 3.46 to 3.71 From 3.72 to 4.24 From 4.25 and above

35 Kg/mm2 Min. 2% in a gauge length of 50 mm Min. 39% as per IACS Min. number of twists on a mandrel of its own dia without fracture at a rate of 15 turn per minute 18 16 14 12 10

Table 2 Aluminium Clad Steel Wires

Test 1. Visual Requirements Free from splints, scale, inequalities, flaws and other irregularities : Roundness to () 0.013mm As per table 2a below As per table 2b below After close helix, the sample should not fracture

2. 3. 4. 5.

Dimentional Tensile strength Weight of coating Wrap test (on a mandrel 2 times the dia of the sample and at the rate of 15 turns/minute) Adherence of coating (in a close helix not exceeding 15 turns/minute) around a cylindrical mandrel having a diameter prescribed in table 2c.

6.

No cracking or flacking to such an extent that the aluminium coating can be removed by rabbing with the bare fingers

Table 2a
Wire diameter (mm) Ultimate tensile strength (minimum) MPa 1280 1240 1210 1170 1140 Ultimate elongation (Min.) percent in 254 mm 3.0 3.5 4.0 4.0 4.0

1.270 to 2.286 to 3.048 to 3.518 to 3.785 to

2.283 including 3.045 including 3.515 including 3.782 including 4.826 including

Table 2b
Min. weight of aluminium coating on uncoated wire surface (gms/m2)

Wire diameter (mm)

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1.270 to 1.524 to 1.905 to 2.286 to 2.642 to 3.048 to 3.556 to 4.572 to 1.521 including 1.902 including 2.283 including 2.639 including 3.045 including 3.553 including 4.569 including 4.826 including 70 76 79 85 92 98 104 116

Table 2c
Wire diameter Min. ratio of mandrel diameter to wire diameter 3 4 5

1.270 to 2.283 including 2.286 to 3.553 including 3.556 to 4.826 including

Table 3 Zinc coated steel wire

Test 1. Visual Requirements Free from splints, scale, inequalities and other irregularities :

2.

Dimentional

Roundness to () 0.013mm

3.

Tensile strength of finished wire

As per table 3a below

4.

Weight of zinc coating

As per table 3b below

5.

Wrap test (on a mandrel 2 times the dia of the sample and at the rate of 15 turns/minute)

After close helix of minimum 8 turns, the sample should not fracture.

6.

Adherence of coating (in a close helix not exceeding 15 turns/minute) around a cylindrical mandrel having a diameter prescribed in table 3c.

No cracking or flacking to such an extent that zinc coating can be removed by rabbing with the bare fingers

Table 3 a
Wire diameter mm 1.270 to 2.286 to 3.048 to 3.556 to 2.283 including 3.045 including 3.053 including 4.022 including Ulitimate tensile strength (Minimum) MPa 1450 1410 1410 1380 Elongation in 200 mm gauge length minimum (%) mm 3.0 3.5 4.0 4.0

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Table 3b
Wire diameter (mm) 1.270 to 1.524 to 1.905 to 2.286 to 1.521 including 1.902 including 2.283 including 2.639 including Minimum weight of zinc coating on uncoated wire surface (gms/m2) 183 198 214 229 244 259 274 305

2.642 to 3.045 including 3.048 to 3.553 including 3.556 to 4.69 including 4.572 to 4.822 including

Table 3c
Wire diameter (mm) 1.270 to 2.283 including 2.286 to 3.553 including 3.556 to 4.822 including Ratio of mandrel diameter to wire diameter 3 4 5

Table 4 Properties for Chloroprene pad

Chloroprene cushion shall have following properties : 1a) b) 2a) b) 3a) b) Tensile Strength Tensile strenght (after ageing) Elongation Elongation (after ageing) Shore hardness A Shore hardness (after ageing) Minimum 100Kg/cm2 Loss of maximum 25% of the test value obtained in 1(a) 250% minimum Loss of maximum 25% of the test value obtained in 2(a) 65 ()5 ()15% of test values obtained in 3(a)

Note : Ageing should be carried out for 70 hours at 100oC.

4. 4.1

REQUIREMENTS OF FORMED FITTINGS FOR VARIOUS APPLICATIONS Conductor Dead-end fittings

4.1.1 Formed conductor dead-end fitting for 11 KV lines consists of the following parts for use with disc insulators of clevis and tongue type: a) Cross arms strap for attaching the fittings to the pole on one side and the disc insulator on the other. These fittings shall conform to the REC Specifications 3/1993. b) Aluminium alloy die cast thimble clevis for attaching the fitting to the tongue of disc insulator on one end and for accomodating loop of the helically formed fitting at the other end in its smooth internal contour. The thimble clevis is attached to the insulator through a steel cotter pin used with a non-ferrous split pin of brass or stainless steel. The thimble clevis shall have clevis dimensions as per IS : 2486 (Part II) - 1989 and shall have the minimum failing load strength of 3000 kg. c) Helically formed fitting acting as the dead-end grip. The die-cast aluminium alloy thimble clevis shall be manufactured with alloy A6 Designation of IS : 617 -

4.1.2 1975.

4.1.3 Nuts and bolts used shall be of galvanised steel conforming to IS : 1364 - 1967 and cotter pins conforming to

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IS : 2004 -1978. Spring washers used shall be electro-galvanised. 4.1.4 The fitting for LT lines shall comprise of the helically formed fitting to suit the LT shackle insulator as per REC Specification 4/1972. 4.1.5 The fittings shall be made to suit the following conductor sizes for 11 KV/LT Lines conforming to REC Specification 1/1971(R-1993) and each fitting shall have a clear identification mark on PVC/metallic/plastic tag, indicating size of the conductor and voltage. The following colour code shall be used for the tag as also for the starting/cross-over marks for quick identification: 20 mm2 ACSR(Squirrel) 30 mm2 ACSR(Weasel) 50 mm2 ACSR (Rabbit) 50 mm2 ACSR (Rabbit) AAC (Ant) mm2 Blue Red Yellow Brown Grey

50 4.2 4.2.1

Distribution ties side ties and double ties Helically formed ties are used to hold the conductor to pin insulators or shackle insulators.

Chloroprene pad shall be provided with the formed ties for use on 11 KV lines to avoid abrasion of the 4.2.2 conductor The conductor sizes and voltage class shall be clearly marked on each fitting and the fittings shall also be 4.2.3 identified by color code as per clause 4.1.5. 4.2.4 To ensure proper fitting of 11 KV pin insulator ties, the purchaser shall furnish full-dimensions of the insulator top particularly the crown diameter, neck diameter etc. See page 4 of REC specification 3/1971 (R-1993). 4.3 Conductor Splices

4.3.1 Conductor splices for ACSR conductors shall consist of (i) galvanised steel formed splice for steel core (ii) aluminium alloy formed filler rod (iii) aluminium alloy formed splice for the aluminium strands of the conductor. For AAC conductor, splice is formed with aluminium alloy only. 4.3.2 Repair Splice: Repair splices are non-tension splices and are used where some of the outer strands of the conductor are damaged. 4.4 Guy Grip Dead-End

4.4.1 Guy grip dead ends have one leg shorter than the other and are suitable for gripping the guy wire. These grips are applied on one side into the thimble eye of the stay rod and on the other side to the guy wire. These can also be used directly with guy insulators. 4.4.2 The fittings shall be made of two sizes to suit stay wires of 7/3.15mm(7/10SWG) and 7/2.5 mm(7/12SWG) having UTS values 3625 kg and 2300 kg respectively. 4.4.3 The fittings shall be clearly identified on a PVC/mettalic/plastic tag for the size of stay wire with which these are to be used and, in addition, the following colour codes for the tag as well as the corss-over marks shall be adopted for proper identification: Guy grip for 7/3.15 mm stay wire Guy grip for 7/2.5 mm stay wire - Green - Black

4.4.4 The guy grip shall be supplied complete with thimble to suit the fitting. Thimble shall be made of hot-dipped galvanized steel. Note: The guy grips to be used with guy insulators shall take into account the standard sizes of insulators as per REC specification No.21/1981 and the type and size of the guy insulator shall be clearly specified by the purchaser. Tap Connectors: Tap connectors consist of helically formed aluminium alloy wires for non-tension tapping of 4.5 conductors and cables from the main line. The sizes of conductors/cables for which these tap connectors are to be used have to be clearly specified by the purchaser. 4.6 Service Grip Dead End: Service grip dead-ends are used with metallic knob to hold one or more service bearer wires.

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Lashing Rods: Lashing rods are helically formed wires to secure the bearer wire to the service cable. The 4.7 number of lashing rods will depend on the length of service. 5. 5.1 DIMENSIONAL REQUIREMENTS OF THE FINISHED FORMED FITTINGS The lay of the helix shall be right hand.

5.2 The diameter and number of formed rods used per set of fittings to be used on various sizes of conductors shall be as per the approved drawings. 5.3 Tolerances of formed fittings: The various requirements of the helically formed fitting shall be within the following toleranaces: Item a) b) c) d) Pitch length Internal diameter Length of individual rod Difference in length + 0.6 mm (-)0.12 mm + 1% (-) 3% () 1% () 1% between the longest and the shortest rod in an individual set Tolerances

6. 6.1

TESTS Type Tests: The following tests shall constitute the type tests on the finished fittings: S.No. Test Applicable to All fittings All fittings All fittings All aluminium alloy fittings All fittings Conductor dead-end, guy grip and splices Conductor dead-end, guy grip and conductor splices Ties only Conductor dead-end, ties and splices Hardwares and fittings using GI wire Ties only Tap Connectors

1 Visual examination 2. Verification of dimension 3. Tensile strength test 4. Electrical resistance test 5. Wrapping test 6. Slip strength test 7. Resilence test 8. Unbalanced holding Strength Test 9. Fatigue test 10 Galvanising test 11.Pull-off strength test 12.Electrical & Mechanical Test

13.Tests for other requirements as per Tables 1,2, 3 & 4.

Acceptance Test: The following shall constitute the acceptance test: 1. Visual examination 2. Verification of dimension 3. Tensile Strength test 4. Electrical resistance test 5. Wrapping test 6. Slip Strength test 7. Resilence test 8. Unbalanced load 9. Galvanisation test 10. Pull-off strength 11. Electrical & Mechanical tests on tap connectors 12. The tests for other requirements as per Tables 1,2,3 & 4 on the individual wires used in making the helically formed fittings and chloroprene pad (where used).

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6.3 Routine Tests: The following shall constitute the routine tests: a) b) 7. Visual examination Verification of dimensions

TEST PROCEDURE

7.1 Visual Examination: All fittings and individual wires shall be checked visualy for good workmanship, smooth finish and other requirements indicated in Table 1, 2 and 3. 7.2 Verification of dimensions: The dimensins shall be checked as specified in the tables 1, 2, 3 and clause 5. 7.3 Tensile Strength Test:

7.3.1 Individual wire of the helically formed wires shall be straightened by light hammering and tested for tensile strength and elongation in accordance within the IS:398(Part II)-1976. The tensile strength and the elongation of the formed wires shall not be less than the values specified in tables 1, 2 and 3. 7.3.2 For thimbles and hardwares other than formed fittings: The dead-end clevis thimble and straps shall be tested for tensile strength in accordance with the requirements of mechanical failing load as per IS:2486(Part I)-1993. Electrical Resistance Test: This test shall be done on straightened aluminium alloy formed wires only. The 7.4 conductivity of the wires should not be less than 39% IACS. 7.5 Wrapping Test: The individual wires of the formed fittings shall be tested as specified in tables 1, 2 and 3. The wires should not break or show fracture when tested as above. Slip Strength Test: For the conductor dead-end and guy grip dead-end, the test shall be made in accordance 7.6 with IS:2486(Part I)-1993 and the value of slip/breaking strength shall not be less than 85% of the breaking strength of the conductor for conductor dead-end fitting and 100% for guy wires dead end fittings. In case of tension splices, the test shall be carried out as per IS:2121. No slippage or damage to the fitting shall occur at a value less than 100% of breaking load of the conductor. This test should be repeated after the resilence test. Reslience Test: A set of helically formed fitting is wrapped and un-wrapped on a piece of conductor 3 times 7.7 successively. The helical fitting should not lose its resilence even after three applications and should be able to pass the slip strength test requirements mentioned in 7.6 thereafter. 7.8 Unbalanced Holding test: Unbalanced holding strength is the ability of the formed ties to maintain a constant and uniform grip on the conductor when intermittent and repeated unbalanced loads impose a tension imbalance in the span. These imbalances occur due to wind induced motion, impacts, ice conditions and more so when the conductor is broken. The test is intended to simulate the broken wire condition. A span of minimum 20 meters tensioned for 40% of UTS of the conductor shall be erected in the laboratory and a pin insulator alongwith the insulator tie under test shall be applied in the middle of span. The conductor used for this purpose shall be of the specific size with which the insulator tie is to be used. The test set up shall be such that it should be possible to apply a pull on one of the two dead ends of the conductor. For the purpose of this test, a steel replica of the insulator will be used. During the test, tension on one side of the pin insulator shall be suddenly released and effect observed. No slippage or damage to the fitting shall occur. After releasing tension from the other end, the fitting should retain the original form. This test will not only check the holding strength of the fitting but will also prove the resilence of the fitting in the event of broken wire. The test shall be repeated. After releasing the conductor tension on one side, pulling force shall be slowly applied on the other dead-end to pull the conductor till slippage/damage occurs. This force shall not be less than 320 kg. 7.9 Fatigue Test: The fittings should be subjected to fatigue test alongwith the conductor by imparting 10 million cycles of peak to peak amplitude at a frequency above 30 cycles for minimum span length of 20 meters, at 40% of UTS of conductor. The amplitude of the vibrations at the antinodal points should be atleast 50% of the diameter of the conductor. The test should be carried out for 10 million cycles as continuously as possible after which the conductor fitting and insulator should be examined. There should be no damage to the conductor or the insulator where the fitting is attached. The fitting should also be able to withstand the test without any damage. 7.10 Galvanising Test: Galvanising test should be carried out in accordance with IS:4826-1979 for uniformity and IS:6745-1972 for weight of zinc coating and the fittings will meet the requirements of Table 3. 7.11 Pull-Off Strength Test: This test is intended to simulate the conductor pull-off conditions created by various factors including elevation difference of the supporting structures on the two sides of the tie. A span of minimum 20 metres tensioned for 40% of UTS of the conductor shall be erected in the laboratory with a conductor of the specified size with which the fitting is intended to be used. A steel replica of pin insulator alongwith the insulator tie under test shall be applied in the middle of span so that a suitable pull-off force can be applied on the pin by means of a

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machine. The pull-off strength of the tie shall not be less than 200 Kg. for all the three sizes of ACSR. 7.12 Electrical & Mechanical Test on Tap Connectors: The tap Connectors shall conform to all the electrical and mechanical properties as per IS:5561. 8. PACKING AND MARKING

8.1 All helically formed items covered under this specification shall be carefully handled to prevent distortion and damage. These items shall be packed and stored in suitable cartons. 8.2 Different colour codes shall be adopted for different conductor sizes and catalogue number and range of outside diameter of the conductor shall be indicated on the packing. Clevis thimbles and other hardwares for conductor dead-ends shall be packed in wooden crates with all 8.3 necessary markings. The packings of the fittings should carry the following informations. 8.4 a) b) c) d) e) Purchasers name Manufacturers name and trade mark Size of conductor, line voltage (when required) and numbers Batch number, date, month and year of manufacture Any other marking agreed to between manufacturer and user.

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REC Specification 26/1983 (Revised 1987) PVC INSULATED LT CABLES

FOREWORD The proposal for formulating a standard REC Specification incorporating the important characteristics of PVC insulated LT cables for use in rural electrification system was discussed in the 7th meeting of the Standaradisation Committee held in April, 1982. This Specification is based on the recommendations made by the Standardisation Committee and subsequent decisions taken by the 10th Conference on Standardisation held in April, 1983. The question of using single-core cables for transformers as an alternative to multi-core cables was discussed in the 12th Standardisation Conference held in July, 1987. Based on the decision taken by the Conference this Specification has been modified to incorporate sizes of single-core cables to be used for distribution sub-stations. 1. SCOPE This specification covers details of PVC Insulated LT cables for use on Service Connections and Distribution Transformers in rural electrification system. 2. APPLICABLE STANDARDS Except when it conflicts with the specific requirements of this specification, PVC insulated LT cables shall comply with the latest versions of the following Indian Standards. a Service cables IS:694 (Part-II)(PVC Insulated Cables for working voltages upto and including 1100 V with aluminium conductors) IS:4288 (PVC Insulated and PVC sheathed solid aluminium conductor cables of voltage rating not exceeding 1100 Volts). OR ii) Single-core and four-core unarmoured aluminium cables 3. IS:1554 (Part-I) (PVC Insulated Heavy Duty Electric Cables for working voltages upto and including 1100 V).

Transformer Cables i) Three-core, solid sector-shaped, aluminium armoured cables

SIZE AND TYPE The size and type of PVC insulated LT cables for different applications shall be as in Table-I below :

Table-I
Sl. No. Size Type Use

A I

Service Cables

2.5mm2

Twin-core (unarmoured) as per IS: 694-Pt-II

i) Single-phase service connections upto 2KW connected load ii) Three phase Agrl./ Indl. Service connections upto 2.2KW (3HP) connected load (2 runs to be used)

II

4.0mm2

Twin-core (unarmoured) as per IS: 694-Pt-II

i) Single-phase service connections above 2KW & upto 4KW connected load. ii) Three phase Agrl./Indl. Service connections above 2.2KW (3HP) and upto 3.7KW (5-HP) connected load (2 runs to be used) i) Three phase Agrl./Indl. Service connections above 3.7 KW (5HP) and upto 7.5 KW (10-HP) connected load. i) Three phase Agrl./Indl. Service connections above 7.5KW (10HP) and upto 11KW (15-HP) connected load.

III

6.0mm2

Four-core (unarmoured) as per IS: 694-Pt-II Four-core (unarmoured) as per IS: 694-Pt-II

IV

10.0mm2

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B
1(a) (b) Transformers cables 16.0mm 10.0mm

2 2

Four-core (unarmoured) as per IS: 1554-Pt-I

Single-core (unarmoured) as per IS: 1554-Pt-I Three - core solid sectorshaped aluminium (armoured) cable as per IS:4288 OR Four- core (unarmoured) with reduced neutral of 35mm 2 as per IS: 1554 Pt.-I.

25 KVA distribution transformers

2(a)

70.0mm

63 KVA distribution transformers

2(b)

50.0mm

Single-core( unarmoured) as per IS:1554-PT-I

(a)

120.0mm

Three - core solid sectorshaped aluminium (armoured) cable as per IS: 4288 OR Four core (unarmoured) with reduced neutral of 70mm 2 as per IS: 1554 Pt.-I.

100 KVA distribution transformers

3(b)

95.0mm2

Single-core (unarmoured) as per IS: 1554-Pt-I

4.

SHAPE OF CABLE All twin-core cables shall be of flat shape and single 3 or 4-core cables of circular shape. CONDUCTORS Aluminium conductor complying with IS:8130-1976 shall be used. 5.1 The conductors of service cables (2.5mm2 to 10mm2) shall be either solid or stranded, as required by the 5.2 purchaser.

5.

6.

TESTS All the type tests, acceptance tests and routine tests shall be carried out as per the relevant I.S. indicated in clause 2 above. PACKING Service cables of 2.5, 4, 6 and 10mm2 size shall be packed in coils of 100 metres length each. Each coil 7.1 shall be protected against damage by polythene wrapping. Transformer cables shall be supplied in wooden drums with 100 or 250 metres length, as required by the 7.2 purchaser. The cable reels/drums shall comply with IS:10418-1982 (Specification on 'Drums for Electric Cables'). 7.3

7.

8.

MARKING The following information shall be marked on the reel/drum carrying transformer cables or contained in a label attached to the coils in case of service cables : a) Manufacturer's name, brand name or trade mark b) Type of cable and voltage grade c) Number of cores d) Nominal cross-sectional area of conductor e) Length of cable on reel/drum or coil f) Direction of rotation of drums (by means of an arrow) g) Approximate gross weight h) Country of manufacture i) Year of manufacture and j) Name of the purchaser

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9. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise agreed to especially by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector, representing the purchaser, all necessary facilities (without charge) to satisfy him that the material is being supplied in accordance with the Specification.

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REC Specification No.27/1983 PVC INSULATED LT SERVICE CABLES WITH EMBEDDED BEARER WIRE FOREWORD REC Specification No. 26/1983 stipulates important characteristics of PVC insulated LT Cables for service connections and other applications. For service connections, a separate GI bearer wire has to be used to support the PVC Cable. The GI bearer wire gets corroded in the coastal areas and has to be replaced after few years. To overcome this difficulty, special type of cables with embedded bearer wire were developed and have been found successful in coastal areas. The proposal to standardise the use of special PVC cables in coastal areas was discussed by the Standardisation Committee in its meeting held in April, 1982. This specification is based on the recommendations made by the Standardisation Committee, which were subsequently approved by the Tenth Standardisation Conference held in April, 1983. 1. SCOPE This specification covers details of PVC Insulated Cables with Embedded Bearer Wire for use on LT service connections in rural electrification system. These cables are especially intended for use in coastal areas, but at the discretion of the SEBs, can also be used in other areas due to the advantages of neat appearance and less maintenance problems. This is a "Provisional" specification and is being issued to enable the SEBs to gain experience on the use of such cables. APPLICABLE STANDARDS Except when it conflicts with the specific provisions of this specification, these cables shall comply with the latest version of IS:694, Part-II (PVC Insulated Cables for working voltage upto and including 1100V, with aluminium conductors.) 3. SPECIAL FEATURES & APPLICATION The special features for various sizes/types of cables and the application shall be as in Table-I below. 2.

Table-I
Thickness of outer PVC sheath (mm) 3 Size of neck (mm) Diameter of GI wire, soft quality (IS:280) (mm) 5

Size of cables 1

Type

Application 6 i) Single-Phase service Connections upto 2 KW connected load

2.5mm2

Twin-core (unarmoured as per IS:694 Pt-II )

1.50

2X2

3.15

ii) Three-phase Agri./Indl. Service connections upto 2.2KW (3-HP) connected load (2 runs to be used) i) Single-phase service connections above 2KW and upto 4 KW connected load

4.0mm2

Twin-core (unarmoured as per IS:694 Pt-II)

1.50

2X2

3.15

ii) Three-phase Agri./Indl. Service connections above 2.2KW (3-HP) and upto3.7 KW (5-HP) connected load (2 runs to be used) Three phase Agrl./Indl. Service connections above 3.7KW (5HP) and upto 7.5KW (10-HP) connected load Three phase Agrl./Indl. Service connections above 7.5KW (10-HP) and upto 11KW (15-HP) connected load

6.0mm2

Four- core (unarmoured as per IS:694 Pt-II) Four- core (unarmoured as per IS:694 Pt-II)

1.50

2x2

10.0mm2

1.50

2x2

4.

SHAPE OF CABLE The arrangement of conductors and location of the bearer wire for 2-core and 4-core cables shall be as shown in the Figure. 5. CONDUCTORS Aluminium conductors complying with IS:8130-1976 shall be used. 5.1

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5.2 6. The conductors shall be either solid or stranded, as required by the purchaser.

TESTS All the type tests, acceptance tests and routine tests shall be carried out as per IS:694 (Part-II).

7.

PACKING Cables shall be packed in coils of 100 meters length each. Each coil shall be protected against damage by polythene wrapping. 8. MARKING The following information shall be contained in a label attached to the coils : a) b) c) d) e) f) g) h) i) 9. Manufacturer's name, brand name or trade-mark Type of cable and voltage grade Number of cores Nominal cross-sectional area of conductor Length of cable on coil Approximate gross weight Country of manufacture Year of manufacture and Name of the purchaser

INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise agreed to especially by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector, representing the purchaser, all necessary facilities (without charge) to satisfy him that the material is being supplied in accordance with the Specification.

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REC Specification 28/1983 LT REWIRABLE FUSES FOREWORD The specification for LT Rewirable Fuses for use on service connections, LT sub-mains, feeders etc., in rural distribution system was discussed in the 7th meeting of the Standardisation Committee held in April, 1982. This Specification has been prepared on the basis of the recommendations made by the Standardisation Committee and subsequent decisions taken by the Tenth Conference on Standardisation, Technical Development and Training in Rural Electrification held at New Delhi in April,1983. 1. SCOPE This specification covers LT rewirable fuses intended for use on service connections, LT sub-mains/feeders and distribution transformers in rural distribution system. 2. APPLICABLE STANDARD Unless otherwise modified in this specification, the rewirable fuses shall comply with IS:2086 as amended from time to time. 3. RATED VOLTAGE The rated voltage of fuse carrier and fuse bases constituting the rewirable fuses shall be 415 volts AC. CURRENT RATING The standard current ratings of rewirable fuses for different applications shall be as follows:Application a) Single-phase Service Connections with load i) ii) b) Three-phase SERVICE CONNECTIONS OR SUB-MAINS/ FEEDERS WITH LOAD i) ii) (iii) (iv) Upto 2 KW Above 5.5 KW (7.5HP) upto 11 KW (15HP) Above 11 KW (15HP) upto 22KW (30 HP) Above 22 KW (30HP) upto 37 KW (50HP) 16 A 32 A 63 A 100 A Upto 5.5 KW (7.5HP) Above 2KW to 4KW 16 A 32 A Current Rating

4.

c) Distribution Transformers i) (ii) (iiv) 16 KVA 25 KVA 63 KVA 32 A 63 A 100 A

NOTE:- Normally all distribution transformers shall be protected by LT circuit breakers (REC Specification No.18/1981). However, till such time use of LT circuit breakers is introduced on wide scale, rewirable fuses (alone or in combination with a switch) may be used for transformers upto 63 KVA. Transformers of 100 KVA rating shall be protected by LT Circuit Breakers. 5. RATED BREAKING CAPACITY The rated breaking capacity of rewirable fuses shall be 4 KA at 0.4 power factor (lag). DESIGN AND CONSTRUCTION 6.1 The fuses shall conform to all the design and constructional requirements as stipulated in IS:2086. In addition, the following provisions shall be made. 6.2 An asbestos sheet of 2,2,3 and 3mm size shall be provided on the fuse bases of 16 A, 32 A, 63 A and 100 A respectively. 6.3 The fuses carrier contacts and the extension strips shall be made of electro-plated electrolytic copper. All other current carrying parts of the fuse units shall be made of electroplated brass/copper. 6.4 100 Amps. fuse carriers shall have handle type of grips for easy operation.

6.

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7. TERMINALS 7.1 Terminal screws shall have smooth and clean threads free of burrs and the ends of screws shall have flat shape with round edges to prevent undue damage to the conductor and to provide adequate contact area. 7.2 Dimensions and designation of the screws in the carrier for holding the fuse element and the terminal screws of the base shall be as given in the Fig.1 and Fig.2 respectively. 7.3 Size of the terminal holes in the fuse base shall be of 4.5 mm, 5.5 mm, 9.0 mm and 12.5 mm dia in respect of fuses of 16 A, 32 A, 63 A and 100 A rating respectively. 7.4 Extended type of terminals shall be provided with the fuse bases for 63 A and 100 A rating with a facility of fixing of the cable lugs by means of bolts and nuts. The dimensions shall be as shown in Fig.3.

8.

DIMENSIONS OF CARRIERS AND BASES The dimensions of the carriers and the bases of the fuse units of different ratings shall be as per the latest version of IS:2086. 9. TESTS All type, routine and acceptance tests as laid-down in the latest version of IS:2086 shall be carried out. MARKING Every fuse carrier shall be clearly and indelibly marked with the following: a) Rated current b) Rated voltage c) Size of Fuse wire d) Maker's name and trade mark e) Purchaser's name

10.

11.

PACKING All fuse carriers and bases shall be packed in wooden crates easy to carry and suitable for rough handling and acceptable for rail/road transport. The fuse carriers shall be fitted in the fuse bases and if, necessary, wooden separators shall be provided to prevent movement of the fuse units within the crates. All screws, bolts, nuts shall be fitted in position and shall be screwed upto the farthest point.

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REC Specification 29/1983 (Revised 1987) LT LINE SPACERS FOREWORD Mid-span clashing of conductors of LT lines is a common phenomenon occurring due to various causes like excessive wind, uneven or excessive sag, use of longer spans than required, etc. To overcome this problem, LT line spacers are used in many countries, which helps in eliminating faults arising due to clashing of conductors thereby minimising interruptions of supply to the consumers, reducing maintenance problems and prolonging useful life of distribution transformers. This specification for spiral type LT spacers made of rigid PVC was originally issued in 1987 on the basis of the decision taken in the 10th Standardisation conference. The Specification was subsequently reviewed in the 12th Conference held in July, 1987 and it was decided to standardise composite Spacers made of poly-propylene as an alternative to the spiral type PVC Spacers. The Composite Spacers have the advantage that only one spacer is required for all the conductors of the LT line whereas a number of spacers are needed in the case of spiral type depending upon the number of conductors in the line. 1. SCOPE This specification covers details of LT line Spacers to overcome the problem of mid-span clashing of conductors. The specification covers two types of spacers : i) Spiral type spacers (Fig.1) ii) Composite spacers (Fig.2) 2. WORKING CONDITIONS LT Line Spacers shall be suitable for tropical climate with a maximum ambient air temp. of 50o C, humidity of 100% and wind pressure upto 150 Kg/M2. 3 MATERIAL 3.1 Spiral type spacers shall be made of high quality PVC. 3.2 The composite spacers shall be made poly-propylene and shall be made of single mould except the clamping pieces. The fly nuts and studs shall be made of Engineering Grade Nylon. The studs shall be properly fixed in position at the moulding stage. SHAPE AND DIMENSIONS 4.1 The shape and dimensions of spiral type and composite spacers are shown in Figures 1 & 2 respectively. 4.2 Unless otherwise specified by the purchaser, the spacer shall be suitable for holding conductors having diameters ranging from 6mm to 11mm. APPLICATION 5.1 Normally only one set of spiral type spacers (number of spacers will depend upon the number of conductors) or one single composite spacer in the middle of span should be adequate. However, where necessary, additional spacer(s) may be used in each span. 5.2 The spiral type spacer shall be fixed between two adjacent conductors by twisting the spiral ends around the conductors manually. The spacers shall automatically grip the conductors and remain in position. 5.3 One spiral type spacer shall hold two line conductors and two spacers shall hold three conductors and so on (Fig.1). 5.4 The composite spacer is fixed by sliding the line conductors in the grooves and tightening the flynuts manually. Only one composite spacer is required to hold a number of conductors depending upon its design. In the enclosed Figure-2, a typical spacer suitable for holding 4 conductors (3-phase, 4-wire - vertical formation) is shown. 5.5 Both spiral type and composite spacers are suitable for vertical and horizontal configuration of conductors. However, the purchaser should clearly indicate the spacing between the adjacent conductors to enable the manufacturer to supply right type of spacers. TESTS LT spacers shall comply with the following test requirement: 6.1 Type Tests (a) Dry power frequency withstand voltage test: Spacer shall withstand dry power frequency test voltage of 23KV when tested in accordance with IS : 1445-1977 with suitable modifications to simulate the actual method of application in the field. (b) Wet Power frequency withstand voltage test : The spacers shall withstand a wet power frequency test voltage of 10 KV when tested in accordance with IS : 1445-1977 with suitable modifications to simulate actual method of application in field. (c) Ageing/Tensile test : Three specimens of LT Spacers shall be maintained at a temp 70o () 2o C for a period of 24 hours. After this treatment, the specimens shall not show any deformity and after cooling,

4.

5.

6.

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shall have a minimum tensile strength of 500 Kg. (d) Dimensional verification : i) The dimensions given in Figure 1 shall have the following tolerances/range of variation : i) Length : 3mm of specified conductor spacing ii) Spacer rod dia : 3 to 14 mm iii) Spiral hole dia : 5 to 6 mm iv) Length of each spiral : Indicated dimensions () 5mm and overall spiral length Indicated dimensions : () 5 mm ii) The dimensions given in Fig.2 shall have the following tolerance : i) Overall length : () 5mm ii) Each conductor spacing : () 3mm iii) Other dimensions : (+) 1mm Note : The purchaser has the option to either accept type test certificate for the tests done earlier on spacers or get fresh tests done particularly when the ordered quantity is large, say, over 10000 Nos. for spiral type and 3000 Nos. for composite spacers. 6.2 Acceptance tests : a) Visual examination : The spacer shall have fine and uniform finish. b) Ageing/Tensile test : As per 6.1 (c) above c) Dimensional verification : As per 6.1 (d) above

Note : The manufacturer shall make necessary arrangement for carrying out the above tests in his works and the purchaser will have the option to carry out these tests at the time of inspection by selecting at random 3 specimens out of a lot of every 5000 spiral type spacers or 1000 composite spacers or part thereof depending upon the total quantity ordered. The visual and dimensional examination can be made on as many numbers as desired. 7. INSPECTION All tests and inspection shall be made at the place of manufacturer unless otherwise especially agreed upon by manufacturer and the purchaser. The manufacturer shall afford the inspector all reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance with this specification. 8. PACKING The spacers shall be suitably packed in wooden boxes suitable for easy but rough handling and acceptable by rail/ road transport. Each box shall contain not more than 500 pieces. MARKING Each spacer shall be embossed with the following information : a) Manufacturer`s name or trade mark and b) Year of manufacture.

9.

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REC Specification 30/1983 OUTDOOR TYPE THREE PHASE 11KV/433-250 V RESIN CAST DRY TYPE DISTRIBUTION TRANSFORMERS UPTO AND INCLUDING 100 KVA FOREWORD High failure rate of conventional oil-filled distribution transformers has been a matter of great concern for State Electricity Boards and other Power Utilities. Resin Cast dry type distribution transformers have the advantage of being practically maintenance free. The transformers have better short-circuit withstand capability and longer life as compared to the conventional transformers. In the Tenth Conference on Standardisation held in April,1983, it was decided to formulate a REC Standard for dry type transformers. Accordingly, this specification is being issued on provisional basis to enable the State Electricity Boards to gain experience on these transformers. Regular specification will be issued in due course after getting feed back from the State Electricity Boards and detailed consideration by Standardisation Committee/Conference. 1. SCOPE This specification covers resin-cast, dry type, naturally cooled three-phase, 50Hz, double-wound, outdoor type distribution transformers for use on system with nominal voltage of 11KV. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, the dry type of distribution transformers shall comply with the latest version of IS:1180 (Part-I), IS:2026 and I.E.C.726. 3. STANDARD RATINGS The standard ratings shall be 25, 63 and 100 KVA only. TAPS No taps are to be provided on these transformers.

4.

5.

WINDING CONNECTIONS AND VECTORS The primary winding shall be connected in delta and the secondary winding in Star (vector symbol Dy 11) so as to produce a positive displacement of 30o from the primary to the secondary vector of the same phase. The neutral of the secondary winding shall be brought out to a separate insulating terminal. 6. FITTINGS The following standard fittings shall be provided:a) Two earthing terminals b) Two lifting lugs c) Rating and Terminal Marking plate(s) d) Bimetallic Terminal Connectors for HV bushings as per Fig.1 of REC Specification No. 23/1983

RATING AND TERMINAL MARKING PLATE(S) Each transformer shall be provided with a non-detachable rating and terminal marking plate(s) of weather-proof material, fitted in a visible position and showing the complete information as given in Clause 20 of IS:1180 (Part I)-1989. 8. LIMITS OF TEMPERATURE RISE When tested in accordance with IS:2026, the temperature rise (measured by resistance method) in windings shall not exceed the following limits above the ambient air temperature of 40o C: Temperature class of Insulation E B Temperature-Rise 65o C 70o C

7.

Note : Subject to agreement between the purchaser and supplier, class F insulation can be used, in which case the permissible temperature rise shall be 90o C. The purchaser shall, however, satisfy himself about the type of insulation employed and its conformity to class F. 9. LOSSES AND IMPEDANCE VALUES The no load and load losses shall not exceed the values given in the following table: 9.1 KVA Rating 25 No Load Loss (Fixed loss) 150 W Load Loss at 750C 720 W

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63 100 220 W 280 W 1300 W 1850 W

The above losses are maximum allowable and there shall not be any plus tolerance. No weightage in prices for offers with lower losses would be given for these transformers. 9.2 The percentage impedance at 75oC shall be in the range of 4 to 4.5 per cent.

9.3 Over flux in the transformer core shall be limited to 12.5% to ensure that, in the event of over voltage to the extent of 12.5%, the core does not get saturated. The supplier will furnish necessary design data in support of the stipulation. 10. CONSTRUCTIONAL FEATURES 10.1 Core : The iron core shall be made of high grade alloy, low-loss grain oriented cold rolled steel sheets. The whole core shall be coated with resin for protection against corrosion. All iron parts except the core shall be hot-dip galvanised. 10.2 Windings : Both high and low voltage windings are impregnated and cast under vacuum into moulds of fibreglass reinforced epoxy forming rigid tubular coils. The hollow winding cylinders are centred by a suitable support system absorbing coil expansion and contraction. The moulded coils shall be such as not to absorb any moisture and shall be suitable for tropical climate and 100% humidity. The cooling ducts shall be provided between HV & LV windings and core to ensure effective heat removal. 10.3 11. Enclosure : The transformer shall be housed in steel enclosure designed for IP 34 Class of protection.

LT CIRCUIT BREAKERS The transformer shall be fitted with a Moulded Case LT Circuit Breaker, forming its integral part. The circuit breaker shall be mounted externally in an enclosure conforming to IP34 Class of protection. A suitable insulating shield shall be provided at the back of the enclosure to minimise the transfer of heat from transformer tank to the circuit-breaker enclosure. Interconnections shall be provided in the enclosure from the LT bushings to the incoming terminals of the LT circuit breaker. A separate terminal block shall be provided in the enclosure for terminating the outgoing cables in order to prevent direct pressure on the circuit breaker terminals. The terminal block and other wiring in the enclosure shall be in accordance with clause 10 of REC Specification 18/1981. The circuit breaker shall be capable of being operated from ground level by means of an operating rod. For this purpose, an operating hook shall be provided on the transformer tank in a suitable position for easy and safe operation of the circuit breaker from the ground level. The circuit breaker shall have the following time/current characteristic : Multiple of full load current of transformer 1.05 1.2 1.3 1.4 2.5 4.0 6.0 12.0 More than 2.5 Hrs. More than 10 minutes and less than 2 hrs Less than 30 minutes Less than 10 minutes Less than 1 minutes Not less than 2 seconds Less than 5 seconds Instantaneous (less than 40 mili seconds)

Tripping time

Time/current characteristic of the circuit breaker shall be tested in accordance with clause 7.7.2.3(b)(2) of IS:2516 (Part I & II/Sec I)-1985 and the test shall be made with all the three phases loaded. For the time/current characteristic, the reference calibration temperature of the circuit breaker shall be 50o C. The rated short circuit breaking capacity of the circuit breaker shall not be less than 2.5 KA for 25KVA transformers, 3KA for 63 KVA transformers and 5KA for 100 KVA transformers based on the short circuit test carried out as per P-2 duty in accordance with IS:2516 but at a power factor of 0.4 (lagging) or less. All other electrical/mechanical characteristics as also the test requirements of LT circuit breakers shall conform to REC Specification 18/1981.(R-1983).

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12. TESTS The transformers shall be subjected to the following tests : 12.1 Routine Tests : All the transformers shall be subjected to the routine tests at the manufacturers works. The following routine tests shall be carried out in accordance with IS:2026 or as agreed upon between the purchaser and the manufacturers : a) Measurement of winding resistance b) Measurement of voltage ratio and check of voltage vector relationship c) Measurement of impedance voltage, short-circuit impedance and load loss d) Measurement of no-load loss and no-load current e) Separate source voltage withstand test f) Induced over voltage withstand test g) Partial Discharge test (IS:6209)-25 PC (Max.) 12.2 (a h) i) j) Type Tests : The following shall constitute the type tests: to g) - as per clause 12.1 above Lightning impulse voltage withstand test Temperature-rise test Short-circuit test

12.3 The supplier shall furnish calculations in accordance with IS:2026 to demonstrate the thermal ability of the transformers to withstand short-circuits. 13. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 14. MOUNTING ARRANGEMENT The under-base of all transformers shall be provided with two 75x40 mm channels 460 mm long with holes as per REC Specification No. 2 (at a centre-to-centre distance of 415 mm) to make them suitable for fixing on a platform or plinth.

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REC Specification 31/1983 EARTH KNOBS FOR LT LINES FOREWORD The technical requirements of Earth Knobs for L.T. lines were discussed in the Standardisation Committee meeting held in April, 1982 and were subsequently approved by the Standardisation Conference held in April, 1983. This specification has been formulated on the basis of the decision taken in the above meeting/conference. 1. SCOPE This standard covers the requirements of knobs for supporting the neutral-cum-earth wire used for earthing of metal parts of supporting structures of overhead power lines with a nominal voltage upto 1000V (refer Construction Standard B-3 & B-4). 2. APPLICABLE STANDARDS Except when they conflict with the specific requirements of this specification, the earth knobs shall conform to the latest version of IS:9511-1980. 3. MATERIALS Earth knobs shall be made of cast iron.

4.

GENERAL REQUIREMENTS Earth knobs shall not have blow holes, shrinkage and other casting defects. The top and bottom flat portion of earth knob shall be smooth and plain. 5. SHAPE AND DIMENSIONS The shape and dimensions of earth knob shall conform to Fig. 1. ACCEPTANCE TESTS The following acceptance tests shall be carried out atleast on one knob for every 1000 nos. 6.1 Electrical Resistance 6.1.1 The electrical resistance of the earth knob shall be measured using a Kelvin bridge. Adequate electrical contact shall be ensured against the two surfaces of the knob preferably by using brass washers, soldered to the leads going to the bridge circuit. The washers shall be of adequate size to ensure sufficient area of contact. 6.1.2 The electrical resistance of the earth knob, measured as given in 6.1.1 between the two flat portions, shall not exceed 200 m ohms. 6.2 Mechanical Strength The breaking strength at the neck of the earth knob shall not be less than 11,500 kg. when force is applied in the direction shown in Fig. 2.

6.

7. MARKING
Each earth knob shall be marked with the name of the manufacturer or his trade mark.

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REC Specification 32/1984 AERIAL BUNCHED CABLES FOR LT LINES FOREWORD Many countries are now increasingly using insulated conductors for LT overhead lines. This system is commonly called ABC system (Aerial Bunched Cables). In the ABC system, the insulated aluminium conductors (3 or 4 numbers, as required) are twisted around a high strength aluminium alloy bearer wire, which carries the main weight and also serves as the earth-cum-neutral wire. The phase conductors are not under tension. The system is very safe and LT line faults are practically eliminated. Consequently, interruptions of supply are minimised and the life of transformers is considerably increased as these are not subjected to frequent faults as happens with the bare conductors. The problem of tree-clearance is also minimised. Due to reduction in the height of poles, elimination of insulators and associated hardware and the possibility of using small sizes of phase conductor like 16mm2 in certain locations (it is not normally possible to use such sizes in bare-conductor lines due to poor mechanical strength of the conductors), the overall cost of the ABC lines is practically the same as in the conventional overhead lines. During discussion in the Tenth Standardisation Conference held in April, 1983, it was decided that REC may issue a specification on this system. This view has also been expressed by the Technical Advisory Committee of the REC, constituted as a result of the recommendation made by the Chairmen, SEB's Conference held in February 1983. Accordingly, this specification is being issued on a provisional basis to enable the SEBs to gain experience on this system. A regular specification will be issued in due course after getting feed back from the SEBs and detailed consideration by the Standaradisation Committee / Conference. 1. SCOPE This specification covers the requirement of polyethylene insulated aluminium cables twisted over a central bare aluminium alloy messenger wire for use on LT overhead lines in rural electrification system. 2. RATED VOLTAGE The rated voltage of the cables shall be 1100 volts. 3. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, the following Standards as amended from time to time shall be applicable : i) IS:10810-1984 : Methods of Test for Cables ii) IS:8130-1984 : Conductors for Insulated Cables iii) IS:6474-1984 : Polyethylene Insulation of Cables iv) IS:398 (Part-IV)-1979 : Aluminium Alloy Conductors 4. GENERAL The insulated phase conductors (with additional street lighting conductor, if provided) shall be twisted 4.1 around the bare aluminium alloy messenger wire, which shall take all the mechanical stress. The messenger wire shall also serve as the earth-cum-neutral wire. 4.2 cable. Figure-1 shows a typical arrangement of the phase conductors and messenger wire in the finished

Figure 2, 3 and 4 show the typical arrangements of cables at 'Straight Run', 'Angle' and 'Dead-End' locations 4.3 respectively. 5. PHASE CONDUCTORS The phase conductors and street lighting conductors shall be insulated with black weather-resistant, 5.1 polyethylene suitable for 1100 V insulation. The insulated conductors shall generally conform to the Standards (i), (ii) & (iii) quoted in clause 3 above. The phase conductors shall be suitably compacted as shown in Fig. 5 and the outer diameter shall be within 5.2 the limits specified in 5.5 below. The phase conductors shall be provided with one, two and three 'ridges' (see Fig. 5) for quick 5.3 identification. 5.4 The tensile strength of the aluminium wires used in the conductors shall not be less than 90 N/mm2.

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The standard sizes and technical characteristics of the phase and street lighting conductors shall be as 5.5 shown in the following table : Nominal No. of Diameter of Sectional strands Compacted Area Conductor (mm2 ) 16 25 35 50 1 7 7 7 (mm) 4.4 5.5 6.8 7.9 Approximate Max. D.C. Insulation Mass resistance at 200 thickness C (Kg/Km) 42 65 95 127 (Ohm/Km) 1.91 1.20 0.868 0.641 (mm) 1.0 1.0 1.0 1.2

Note : The resistance values given in col.5 are the maximum permissible. Tolerance of +5% is allowable on diameters shown in Col. 3. 6. MESSENGER (NEUTRAL CONDUCTOR) The bare messenger wire shall be made of aluminium alloy generally conforming to IS:398 (Part-IV)-1979 6.1 composed of 7 strands and shall be suitably compacted to have smooth round surface to avoid damage to the polyethylene insulation of the phase conductors twisted around the messenger. The shape of the compacted conductors shall be as per Fig.1. There shall be no joints in any wire of the stranded messenger conductor except those made in the base rod 6.2 or wires before final drawing. 6.3 The sizes and other technical characteristics of the messenger wire shall be as given in the following table : Nominal Sectional Area (mm2 ) No. of strands Diameter of Compacted Conductor (mm) Approximate Max. D.C. Minimum resistance at Tensile Mass Strength 200 C (Kg/Km) (Ohm/Km) (KN)

25 35

7 7

5.5 6.8

65 95

1.380 0.986

7.4 10.3

Note : While the limiting values in Cols. 5 & 6 are to be guaranteed, a plus tolerance of 5% will be permissible on values in Col. 3. 7. POLYETHYLENE INSULATION The polyethylene insulation shall generally conform to IS:6474-1971. The following properties shall be guaranteed by the supplier : Melt flow index Yield stress Percentage elongation Carbon black content Vicat Softening Point Insulation Resistivity at 27oC at 70oC 1 x 1015 Ohm Cm (Min.) 1 x 1013 Ohm Cm (Min.) 0.5 or less Not less than 8 N/mm2 Not less than 350 Between 2 and 3 Not less than 85oC

8. COMPOSITION AND DESIGNATION OF FINISHED CABLES The composition and designation of finished cables are given in the following table : S.No Designation Complete Bunched Cables Overall dia approx. (mm) Total mass approx. (mm)

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1 2 3 4 5 6 7 8 3 x 16 + 25 3 x 16 + 16 + 25 3 x 25 + 25 3 x 25 + 16 + 25 3 x 35 + 25 3 x 35 + 16 + 25 3 x 50 + 35 3 x 50 + 16 + 35 19 19 22 22 24 24 32 32 250 310 330 390 430 490 580 640

Note : The first part of the designation refers to the number and size of the phase conductor, the middle to the street lighting conductor (where provided) and the last to the bare messenger wire. The sizes shown are the nominal sectional areas. 9. TESTS FOR PHASE/STREET LIGHT CONDUCTORS 9.1 Type Tests a) Tensile Test (IS:8130) b) Wrapping Test (IS:8130) c) Conductor Resistance Test (IS:8130) d) Test for thickness of insulation (IS:6474) e) Physical tests for polyethylene insulation (IS:6474) f) Test for bleeding and blooming of pigment (IS:6474) g) Insulation resistance test (IS:6474) h) High voltage test including water immersion test (IS:10810 Part 45 - 1984) 9.2 Acceptance Tests All tests as per 9.1 except (e) and (f) In addition, check of diameter values as per Clause 5.5 10. TEST FOR MESSENGER 10.1 Type Tests a) Breaking Load test (to be made on the finished conductors) (IS:398-Part-IV) b) Elongation test (IS:398-Part-IV) c) Resistance Test (IS:398-Part-IV) 10.2 Acceptance Tests All the tests indicated in Clause 10.1 above,In addition, check of diameter values as per clause 6.3

11. BENDING TEST ON THE COMPLETE CABLE The test shall be performed on a sample of complete cable. The sample shall be bent around a test mandrel at room temperature for atleast one complete turn. It shall then be unwound and the process shall be repeated after turning the sample around it axis 180o. The cycle of these operation shall then be repeated twice more. The diameter of the mandrel shall be 10 (D + d) Where D = actual diameter of the cable (i.e. the minimum circumscribing circle diameter), mm d = actual diameter of the conductor No cracks visible to the naked eye are allowed. 12. PACKING AND MARKING 12.1 The cable shall be wound in non-returnabale drums conforming to IS:1778-1961 'Specification for Reels and Drums for bare Wire' or the latest version thereof. The drum shall be marked with the following : a) Manufacturer's name b) Trade mark, if any c) Drum number or identification number d) Size of conductors e) Size of messenger f) Voltage grade g) Number and lengths of pieces of cable in each drum h) Gross mass of the packing i) Net mass of cable j) ISI mark, if any

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The drums shall be of such construction as to assure delivery of conductor in the field free from 12.2 displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that cable surface is not dented, scratched or damaged in any way during transport and erection. The cable shall be properly lagged on the drums. 12.3 The cable drum should be suitable for wheel mounting.

The mass of finished cable in a drum (without mass of drum) of various designations shall not exceed by 12.4 more than 10% of the following values : Designation No. (Clause 8) 1 to 3 4 to 8 Gross Mass 700 Kg. 1000 Kg.

The normal length of each cable shall be 1 Km. While longer lengths shall be acceptable, shorter lengths 12.5 not less than 50% of the standard lengths shall be acceptable to the extent of 10% of the ordered quantity. 13. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this specification.

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REC Specification 33/1984 (Revised 1993) ALUMINIUM ALLOY CONDUCTORS FOR OVERHEAD POWER LINES FOREWORD REC had issued a specification 33/1984 for Aluminium Alloy Conductors for overhead power lines. The advantages of All Aluminium Alloy Conductors (AAAC) include lighter weight, longer life due to higher surface hardness, higher resistance to corrosion particularly in saline atmosphere and reduced possibility of theft of wires. A number of SEBs have now started using these conductors due to their superior properties. One of the factors coming in the way of large scale use of AAAC is the higher price as compared to ACSR even though the difference has been narrowing down as more and more manufacturers are taking up production of AAAC. This aspect was considered by a working group constituted by the Department of Mines in which REC, primary producers of Aluminium Alloy and Conductor Manufacturers were represented. Based on the decision of the working group the rationalisation of AAAC was done without sacrificing the electrical performance by marginally reducing the aluminium area. It is also to be kept in view that while the AC resistance in AAAC is the same as the DC resistance, the AC resistance for ACSR is more than the DC resistance due to magnetisation of steel core. The ratio of AC to DC resistance in ACSR also varies with the current loading. All these factors have been taken into account in rationalising the AAAC sizes to get practically the same electrical performance. In the revised specification the minimum breaking load has been taken as 30 Kg/mm2 after stranding, instead of 28.5 Kg/mm2. This has been done considering the possibility of achieving the higher mechanical properties with Indian Aluminium Alloy. In fact the minimum breaking load obtaining in France & USA are of the order of 31.5 Kg. per mm square after stranding. Accordingly the specification was revised and placed before the 13th Conference on Standardisation and Technical Development and Training held on 4th-6th May, 1993 at New Delhi. The revised specification is issued based on the decisions taken at the Conference. SCOPE This specification covers details of all aluminium alloy stranded conductors for use on 33 KV, 11 KV and LT overhead lines in rural electric distribution system. 2. CONDUCTOR SIZES FOR DIFFERENT APPLICATIONS 11 KV & LT LINES i) 3/2.50 mm (14 mm2 Alloy Area) for street light only ii) 7/2.00 mm (20 mm2 Alloy Area) iii) 7/2.50 mm (30 mm2 Allloy Area) iv) 7/3.15 mm (50 mm2 Alloy Area) 33 KV LINES i) 7/3.15 mm (50 mm2 Alloy Area) ii) 7/3.81 mm (80 mm2 Alloy Area) iii) 7/4.26 mm (100 mm2 Alloy Area) 3. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, the conductor shall comply with IS:398 (Part-IV)-1979 or the latest version thereof. 4. PROPERTIES OF WIRES 1.

The properties of aluminium alloy wires to be used in the construction of the stranded conductors shall be as in Table-I :

Table-I :

ALUMINIUM ALLOY WIRES USED IN THE CONSTRUCTION OF STRANDED ALUMINIUM ALLOY CONDUCTORS Diameter Cross sectional area of nominal Dia wire Max. mm mm2 Mass Minimum breaking load after stranding Resistance at 20o C

Nominal mm

Min. mm

Kg/Km

KN

Max. Ohm/km

Standard Ohm/km

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2.00 2.50 3.15 3.81 4.26 5. 1.98 2.47 3.12 3.77 4.22 2.02 2.53 3.18 3.85 4.30 3.142 4.909 7.793 11.401 14.253 8.48 13.25 21.04 30.78 38.48 0.92 1.44 2.29 3.35 4.19 10.653 6.845 4.290 2.938 2.354 10.345 6.621 4.170 2.851 2.280

PROPERTIES OF CONDUCTORS The properties of stranded all aluminium alloy conductors of various sizes shall be as in Table-II.

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Table-II : Nominal Alloy Area 1. mm2 14 20 30 50 80 100 6. ALUMINIUM ALLOY STRANDED CONDUCTORS Sectional area Approx. overall Dia Approx. Mass Calculated resistance at 20oC (Max.) Approx. calculated breaking load

Stranding & wire dia

2.
mm 3/2.5 7/2.00 7/2.50 7/3.15 7/3.81 7/4.26

3.
mm2 14.73 21.99 34.36 54.55 79.81 99.77

4.
mm 5.38 6.00 7.50 9.45 11.43 12.78

5.
Kg/Km 40.15 60.13 94.00 149.20 218.26 272.86

6.
Ohm/Km 2.304 1.541 0.990 0.621 0.425 0.339

7.
KN 4.331 6.467 10.106 16.044 23.473 29.344

FREEDOM FROM DEFECTS The wire shall be smooth and free from all imperfection such as spills, splits etc. JOINTS IN WIRES Conductors containing three/seven wires: There shall be no joint in any wire of a stranded conductor containing three/seven wires, except those made in the base rod or wire before final drawing. STRANDING The wires used in the construction of a stranded conductor shall before stranding satisfy all the relevant 8.1 requirements of this standard. 8.2 The lay ratio shall be within the limits given in Table-III. Table-III : LAY RATIOS FOR ALUMINIUM ALLOY STRANDED CONDUCTORS No. of wires in conductors Lay ratio Min. Max.

7.

8.

3 7
8.3 9.

10 10

14 14

The outer layer shall be right handed. The wires in each layer shall be evenly and closely stranded.

TESTS The samples of individual wires for the test shall normally be taken before stranding. The manufacturer shall carry out test on samples taken out at least from 10% of aluminium wire spools. However, when desired by the purchaser, the test sample may be taken from the stranded wires. However, the minimum breaking load test shall be done on a sample taken from stranded wires and the minimum breaking load shall not be less than 30 Kg/mm2. The wires used for alloy conductors shall comply with the following tests as per IS:398 (Part-IV)-1979 : i) Breaking load test ii) Elongation test iii) Resistance test PACKING AND MARKING The conductors shall be wound in reels or drums conforming to the latest version of IS:1778-1961 Specification for Reels and drums for bare wire. 10.1 Packing: 10.1.1 The gross mass of packing for various conductors shall not exceed by more than 10% of the values given in the following table : Conductor Size 14mm2 20mm2 Alloy area (3/2.50 mm) Alloy area (7/2.00 mm) Gross Mass 1100 Kg. 1100 Kg. 1100 Kg 1500 Kg. 10.

30mm2 Alloy area (7/2.50 mm) 50mm2 Alloy area (7/3.15 mm)

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80mm2 Alloy area (7/3.81 mm) 100mm2 10.1.2 Alloy area (7/4.26 mm 1600 Kg 2000 Kg

The normal length of various conductors shall be as given in the following table : Conductor Size 14mm2 Alloy area (3/2.50 mm) 20mm2 Alloy area (7/2.00 mm) 30mm2 Alloy area (7/2.50 mm) 50mm2 Alloy area (7/3.15 mm) 80mm2 Alloy area (7/3.81 mm) Alloy area (7/4.26 mm Normal length 2.0 Km 2.0 Km 2.0 Km 1.7 Km 1.3 Km 1.1 Km

100mm2 10.1.2.1

Longer lengths shall be acceptable.

Short lengths, not less than 50% of the normal length shall be acceptable to the maximum 10.1.2.2. extent of 10% of the quantity ordered. 10.2 MARKING The following information be marked on each package: a) Manufacturers name b) Trade mark, if any c) Drum or identification number d) Size of conductor e) Number and lengths of conductors f) Gross mass of the package g) Net mass of conductor h) ISI certification mark, if any

11.

INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this specification.

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REC Specification 34/1984 (Revised 1987) NICAD BATTERIES WITH CHARGERS FOR 33/11 KV AND 66/11 KV SUB-STATIONS FOREWORD Imported Nickel Cadmium (NICAD) batteries were earlier being used at sub-stations due to their superior performance. However, their use had to be discontinued due to import restrictions and the batteries were replaced by indigenously available lead acid batteries. NICAD batteries are now being manufactured in India. This subject was discussed in the 11th Standardisation Conference held in September, 1984 at New Delhi. The Conference recommended standardisation of 24 V NICAD Batteries for 33/11 KV sub-stations keeping in view their suitability for sub-station duty. These batteries have much longer life and less maintenance requirements compared to lead acid batteries besides having other advantages including better stability of voltage under severe cyclic loads, fast recovery on trickle charge, more compact size etc. Due to small size and elimination of harmful fumes, need for a separate battery room is eliminated. This Specification was originally issued in 1984 on the basis of the recommendations made by the 11th Standardisation Conference and was subsequently revised in 1987 to incorporate the requirements of 110V, NICAD batteries for 66/11 KV sub-stations as decided in the 12th Standardisation Conference. 1. SCOPE This specification covers the requirements and tests for vented type 24 V and 110 V Nickel-Cadmium alkaline batteries with chargers, for use in 33/11 KV and 66/11 KV sub-stations in rural electrification system. The batteries covered in this specification are for indoor use; in the case of out-door use, suitable enclosure preferably made of an insulating material like FRP or lined with FRP, having rain-proof ventilating louvers shall be provided to ensure that the temperature inside the enclosure does not exceed 50oC. A. 2. BATTERY

APPLICABLE STANDARDS Unless otherwise modified in this specification, the NICAD batteries shall comply with IS:10918-1984 or its latest version. 3. STANDARD RATING The standard voltage ratings of batteries for use at 33/11 KV sub-stations and for 66/11 KV sub-stations shall be 24 volts and 110 volts respectively. Both the type of batteries shall have a rating of 15 AH. For batteries intended for use of individual or groups of breakers, lower AH ratings can be used depending upon the requirements. 4. CELL VOLTAGE The nominal voltage of a single cell shall be 1.2 V and the battery shall consist of 20 cells in case of 24 volts rating and 90 cells in case of 108 volts rating. 5. CAPACITY AT ROOM TEMPERATURE (NOT EXCEEDING 32oC) a) 3 Amps. for 5 hours to end voltage of not less than 1.0 V per cell b) 100 Amps. for 0.5 second to end voltage of not less than 1.0 V per cell

6.

CONSTRUCTION The cells shall have prismatic (rectangular), spill-proof and vented type of construction and shall be made of nonporous plastic or alkali-proof mild steel. Battery shall be equipped with nickel plated inter-cell connectors and terminals. The cells shall be housed in high-strength alkali-resistant containers. 7. TERMINALS Separate terminals shall be provided for connecting load and charger leads to the battery terminals. All terminals shall be of M12 size nickle-plated steel. Suitable nickle-plated copper lugs shall be provided by the supplier for use of the purchaser for connecting up the load wiring. A typical arrangement of terminals is shown in the sketch.

TEMPERATURE RANGE Battery must be capable of operation at temperatures upto 55oC for prolonged periods. Minimum capacity at this temperature should not be less than 2 Amps. for 5 hours. 9. ACCESSORIES The following accessories shall be supplied with each set of battery : i) Cell testing voltmeter, 3-0-3 volts scale conforming to IS:1248 (Part-I)-1983

8.

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ii) Pair of gloves iii) Insulated spanner for opening terminal nuts iv) Plastic/glass syringe 10. CHARGE RATE Full discharged batteries should get recharged at 3 Amps. for 7 hours at room temperature. At high temperature, the recharging time will be more. The trickle charge rate shall be 50-100 mA. 11. CELL DESIGNATION The practice indicated in IS:10918-1984 or latest version thereof shall be followed.

12.

MANUAL OF INSTRUCTIONS A copy of the instruction manual for commissioning and initial treatment of the battery and maintenance during service shall be supplied by the manufacturer with every battery ordered. 13. POLARITY MARKING The polarity of the terminals shall be marked for identification. The positive terminal may be identified by 'P' or a (+) sign or red colour mark and the negative terminal may be identified by 'N' or (-) sign or blue colour mark. Marking shall be permanent and non-deteriorating. WARNING MARKING The battery shall be furnished with a warning plate located at conspicuous place specifying the use of 'ALKALINE ELECTROLYTE ONLY' (in block letters) and specifying the proper filling level of the electrolyte. Marking shall be permanent and non-deteriorating. 15. PACKING The batteries shall be suitably packed securely in wooden crates suitable for handling during transit by rail/road and secured to avoid any loss or damage during transit. 16. TESTS The following tests shall be carried out in accordance with IS:10918-1984 or the latest version thereof :Type Tests a) Physical examination b) Dimensions, weight and layout c) Marking d) Polarity and absence of short circuit e) Air Pressure test f) Ampere-hour capacity g) Retention of charge h) Discharge performance at 55oC i) Life cycle test (for at least 350 cycles) i) Insulation resistance Note : As the life cycle test takes long time (2-3 years) this may not be insisted upon for the NICAD battery of the specific ratings to be ordered, if satisfactory evidence is furnished for having made this test on battery of any other AH capacity/voltage rating manufactured by the same supplier. Acceptance Tests The following shall constitute acceptance test : a) Physical examination b) Dimension, weight and layout c) Marking d) Polarity and absence of short circuit e) Ampere-hour capacity f) Insulation resistance Routine Tests a) Physical examination b) Dimensions, weight and layout c) Marking d) Polarity and absence of short circuit B. BATTERY CHARGER 14.

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17. RATINGS OF THE CHARGER 24 Volts a) Trickle charge voltage across the battery terminals 26-28 V 30-33 V 1.2V per cell 50-100 mA 2-5 A 110 Volts 117-126 V 126-148.5 V 1.2V per cell 50-100 mA 2-5 A

b) Quick charge voltage across battery terminals c) Voltage per cell at the end of charge at normal rate d) Range of Trickle charging e) Range of quick charging 18.

GENERAL REQUIREMENTS 18.1 The charger shall be of fully automatic type. It should automatically switch over to trickle charge when the voltage reaches 33 volts in case of 24 V battery and 148.5 V in case of 110 V battery and it should switch over to the quick charge if the voltage falls below 26 V and 117 volts for 24 volt and 110 volt batteries respectively. 18.2 The charger shall be enclosed in a cabinet made of sheet steel not less than 1.5mm thickness. The cabinet which will house battery as well as the charger shall be suitable for floor mounting with ventilating louvers on two sides and finish painted with synthetic enamel paint both inside and outside. Two coats of zinc primer shall be applied before the finishing synthetic enamel paint. The cabinet shall have vermin-proof construction. 18.3 a) b) c) d) The following provisions conforming to relevant ISS shall be made on the front panel : Voltmeter to indicate battery/charging voltage Ammeter to indicate charging current (0-10 Amps. range) Indicating LEDs to indicate (i) supply of power (ii) quick charge and (iii) trickle charge Alarm to indicate power or charger failure

18.4 Electrical indicating instruments shall be mounted flush-on panel with only flange projecting. The dial shall be white with black numbers and lettering. 18.5 Control and instruments switches shall be of toggle type. 18.6 Charger cabinet shall be supplied completely wired ready for purchaser's external connections at the terminal blocks . All the wiring shall be carried out with 1100 V grade PVC insulated standard conductors. 18.7 All door-mounted equipment as well as equipment mounted inside the cabinet shall be provided with individual labels with equipment designation engraved. 18.8 The battery charger cabinet shall be provided with two separate suitable earthing terminals. 18.9 Detailed dimensional drawings, commissioning and operating instructions and Test Certificates of the manufacturer shall be supplied with the equipment. 19. SYSTEM DESCRIPTION The charger shall be naturally air-cooled type and shall be suitable for charging the battery and also supplying the steady load (not exceeding 2 amps.) simultaneously. The charger shall be suitable for operation with 240V () 20% single-phase AC supply. The charger shall be automatic type for both trickel and quick charge mode of operation. AC main switch of 15A shall be provided. 20. TESTING The following tests shall be carried out by the manufacturer on each battery charger : i) Checking of wiring and continuity of circuits ii) Checking of charging current and load currents iii) Checking of automatic operation iv) Checking of relays operation, alarm circuit operation and lamp indication

21.

PACKING AND MARKING The equipment shall be despatched securely packed in wooden crates suitable for handling during transit by rail/road so as to avoid any loss or damage during transit.

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REC Specification 35/1984 (Revised - 1993) 11KV POLE MOUNTED SWITCHED CAPACITORS FOREWORD

At present, 11 KV shunt capacitor banks are normally installed at 33/11KV sub-stations etc. and these are controlled by costly circuit breakers. In spite of the heavy cost involved, this arrangement provides reactive compensation only in the power transformers and the 33KV lines and does not reduce the reactive power flow in the 11KV lines, which are the main cause of power losses in the system as also the voltage drop. In many countries, such as USA and Canada, the capacitors are installed directly on the 11KV lines at suitable locations. The polemounted capacitors are controlled by automatic capacitor switches so that the capacitors are switched on only when the load current exceeds the pre-set value. The capacitors are automatically cut off under light load conditions. The experience of other countries has shown that, with the use of such capacitor installations in the 11KV network, the power losses in the system can be considerably reduced and the voltage conditions are also improved. The cost of a single installation is recovered in a short period of about 2 years due to saving of electric energy. This subject was discussed in the 11th Standardisation Conference held at New Delhi in September, 1984. The Conference recommended the wide scale use of such installations with a view to conserving energy and improving the system efficiency. It was felt that the practice of providing capacitors directly on the 11KV lines will be far more advantageous as compared to their installation at the grid sub-station. The conference also approved the characteristics of Automatic Capacitor switches and the 11KV Pole Mounted Capacitors suitable for such installations on the basis of which this specification was originally issued in 1984. The 12th Standardisation Conference held at New Delhi in July, 1987 reviewed this Specification and decided to modify the rating of Capacitor Bank from 6 units of 100 KVAR each to 3 units of 200 KVAR each. Subsequently, further suggestions were received from SEBs and manufacturers to (i) provide in-built arrangement for control supply for the Capacitor Switch instead of making the supply available from the nearby distribution transformer, (ii) modify the specified limit of power loss and (iii) give option to SEBs to specify either internal or external fuses. In addition, certain other modifications were also agreed to. This Specification incorporates the amendments approved by the 12th Standardisation Conference and the subsequent modifications in the light of the suggestions made by the SEBs/ manufacturers, which were approved by the 13th Standardisation Conference held on 4th-6th May, 1993, at New Delhi. 1. SCOPE This Specification covers 11KV, 50Hz, pole-mounted automatically switched capacitor installations comprising of (i) 11 KV Automatic Capacitor Switches and (ii)11KV Capacitor Banks of 600 KVAR rating.

A. 11KV AUTOMATIC CAPACITOR SWITCHES 2. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, the capacitor switch shall comply with the latest version of IS:9920 (AC switches for voltages above 1000V). 3. RATED VOLTAGE The rated voltage for the capacitor switch shall be 12 KV. This represents the highest system voltage corresponding to the nominal system voltage of 11 KV. 4. RATED CURRENT The standard rated normal current shall be 200 A. 5. RATED CAPACITIVE SWITCHING CURRENT The rated capacitive switching current shall not be less than 50 A. 6. RATED SHORT-TIME CURRENT The rated a short-time symmetrical current for 1 second shall be 4.5 KA. 7. RATED MAKING CURRENT The rated making current shall be 9 KA. Note: Even though the specification covers both capacitor switches and capacitor banks, these may preferably be procured separately to take advantage of the competitive prices as these equipments are normally manufactured by different companies. Technically, no coordination is required between the two equipment.

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8. BASIC IMPULSE LEVEL (BIL) The rated basic impulse level of switch to earth as also across the open terminals shall be 75 KV. 9. CONTROL SUPPLY The capacitor switch shall be self-powered from the 11KV line, i.e., no AC or DC control supply shall be required to be provided by the Utility for its operation. The source of control supply (auxiliary transformer, etc.) should work satisfactorily with voltage fluctuations on the 11KV line from (+)10% to (-)20%. 10. TYPE The switches shall be of either vacuum or SF6 type. 11. DESIGN AND CONSTRUCTION REQUIREMENTS 11.1 The capacitor switches may be of either single-phase or three-phase construction as per standard design of the manufacturer. 11.2 The capacitor switch shall be suitable for outdoor installation and shall have sealed weather-proof type construction. 11.3 The capacitor switch shall be provided with a mechanical indicator to show the contact position in open/closed position. Provision shall also be made for manual closing and opening . 11.4 The metallic enclosure of the capacitor switch shall be provided with two earthing terminals (marked with the earth symbol). 11.5 The bushings provided on the switch shall be of high quality porcelain and shall have clamp type of terminal to directly receive aluminium conductors up to 10mm dia in both horizontal and vertical directions. The terminal arrangement shall be such as to avoid bimetallic corrosion. 12. CONTROL PARAMETER 12.1 The control parameter for switching operation shall be the line current at the point of installation of the switch. The maximum value of the line current shall be 150A and accordingly a current transformer of 150/5A ratio shall be supplied along with the switch to monitor the line current in one of the phases for the purpose of control. The switch shall have adjustable values of current at which the capacitor bank shall be switched on or switched off. this adjustment shall be available in continuous variation or in steps not exceeding 5A each over a minimum range of 10-40 Amps. (line current). 12.2 There shall be an inherent delay of at least 5 minutes in each switching operation to avoid any damage to the capacitors. 13. OPERATING MECHANISM The operating mechanism shall be either solenoid or motor-charged spring for which the control supply shall be as per clause 9. 14. MECHANICAL AND ELECTRICAL ENDURANCE The switch shall be capable of performing not less than 10,000 mechanical operations and 10,000 electrical operations at 50A capacitive current without getting damaged. 15. MARKING The capacitor switch shall be provided with a name plate legibly and indelibly marked with the following : a) Name of the manufacturer b) Type, designation and serial number c) Rated voltage and current d) Rated frequency e) Number of poles f) Rated short time current (symmetrical) g) Rated making current h) Rated capacitive switching current 16. TESTS The switch shall be subjected to the following tests in accordance with the IS:9920 (part-IV) : 16.1 Type Tests a) Tests to verify the insulation level, including withstand tests at power-frequency voltages on auxiliary equipment. b) Tests to prove that the temperature rise of any part does not exceed the specified values.

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c) d) e) f) Making and breaking tests Tests to prove the capability of the switch to carry the rated short-time current . Tests to prove satisfactory operation and mechanical/electrical endurance. Tests to prove satisfactory operation under ice conditions.

16.2 Routine Tests a) Power-frequency voltage dry test b) Voltage tests for auxiliary circuits c) Measurement of the resistance of the main circuits d) Tests to prove satisfactory operation B. 17. 11KV CAPACITORS BANKS

APPLICABLE STANDARDS Unless otherwise stipulated in the specification, the 11KV pole-mounted switched capacitors shall comply with the latest version of IS:2834 (Shunt capacitors for power systems). TEMPERATURE CATEGORY Unless otherwise specified, the capacitors shall be suitable for upper limit of temperature category 500C as per IS:2834. 19. RATED VOLTAGE The rated voltage of the capacitors shall be 12KV (phase-to-phase). 20. RATED OUTPUT The standard rated output of a switched capacitor bank shall be 600 KVAR at 12 KV rated voltage. The bank shall comprise of 3 single-phase units of 200 KVAR each connected in star with floating neutral. 21. PERMISSIBLE OVERLOADS The maximum permissible overloads with regard to voltage, current and reactive output shall conform to IS:2834. 22. POWER LOSS The power loss in capacitor shall not exceed 0.2 Watt/KVAR (subject to a tolerance of plus 10%). 23. DISCHARGE DEVICE Suitable discharge device shall be connected across the capacitor units in accordance with provision of IS:2834. The discharge device shall reduce the residual voltage from crest value of the rated voltage to 50V or less within 5 minutes after the capacitor is disconnected from the source of supply. 24. EARTH CONNECTION The container of each capacitor unit shall be provided with suitable earthing terminal clearly marked as (). 25. PROTECTIVE FUSES The capacitors shall be provided with either internal or external fuses, as per standard practice of the manufacturer. In the later case, the manufacturer shall supply a set of external fuses together with fixing accessories and a set of three spare fuse links along with the capacitor bank. 26. GENERAL REQUIREMENTS 26.1 The capacitors shall be of non-PCB type, using polypropylene film as the dielectric . 26.2 The containers shall be made from sheet steel of thickness not less than 1.6mm. 26.3 The container shall be hermetically sealed by controlled arc welding process. The metal flanges of the bushing should be soldered/welded to the container and covered with epoxy compound providing a strong hermetical seal to the container. 26.4 Suitable mounting brackets, as required by the purchaser, shall be welded to the container. 26.5 The outside of the container should have smooth and tidy look and should be coated with weather-proof and corrosion-resistant paint of white or light grey shade. 27. MARKING The capacitor shall be provided with a rating plate and terminal markings as stipulated in IS:2834. 18.

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28. TESTS The switched capacitor shall be subjected to all type, routine and acceptance tests in accordance with IS:2834. 29. INSPECTION 29.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance with the Specification. 29.2 The purchaser has the right to get the tests carried out at his own cost by an independent agency, whenever there is a dispute regarding the quality of supply.

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REC Specification No.36/1984

AUTOMATIC TRANSFORMER DISCONNECTION SWITCHES

FOREWORD Due to low load factor of agricultural loads and the consequent poor utilisation of distribution transformers, no-load losses of transformers constitute a very high proportion of the power losses in the distribution system. It is estimated that as much as 5% of the total energy consumed in the rural sector is wasted in the form of no-load losses in distribution transformers. To reduce these losses, a special automatic transformer disconnection switch has been developed at the instance of REC. Due to shortage of power, most of the SEBs are now resorting to 2-phase supply on the 11KV feeders for certain number of hours in a day to stop tubewells from running and to make supply available only for lighting and other purposes in the villages. Under these conditions, the switches will automatically cut off the transformers on which these are installed. This will not only save substantial energy in the form of no-load losses of transformers but will also help in overcoming the problem of the tubewell consumers trying to run 3-phase motors on 2-phase supply. The later practice not only defeats the purpose of load rostering but also results in damage to the motors. Studies have shown that the cost of this switch will be recovered in a short period of about 2 years due to the resultant saving in energy. This subject was discussed in the 11th Standardisation conference held at New Delhi in September, 1984. The Conference recommended the wide scale use of these switches on transformers exclusively feeding tubewell loads with a view to conserving energy and ensuring effective load rostering. This specification is based on the decision taken by the Conference. As this is a new equipment, the specification is being issued on a provisional basis to gain experience on these special switches. 1. SCOPE This specification covers 11KV, single-pole, 50Hz, pole-mounted Automatic Transformer Disconnection Switches for 11/0.4 KV, 3-phase distribution transformers upto and including 100KVA capacity.

2.

APPLICABLE STANDARDS Unless otherwise modified in this specification, the transformer disconnection switches shall comply with the latest version of IS:9920 (Alternating Current Switches for Voltage above 1000V). 3. RATED VOLTAGE Rated voltage for the transformer switch shall be 12KV. This represents the highest system voltage corresponding to the nominal system voltage of 11KV. 4. RATED NORMAL CURRENT The rated normal current of the switch shall be 31.5A. RATED LOAD BREAKING CAPACITY The switches shall be capable of breaking a load of 20A at 0.7p.f. RATED SHORT-TIME CURRENT The rated short-time current of the switch shall be 125A (min.), for 3 secs. RATED MAKING CAPACITY The rated making capacity of the switch shall not be less than 312.5A. RATED BASIC IMPULSE LEVEL (BIL) The rated BIL of the switch to earth as also across the open terminals shall be 75 KV. POWER FREQUENCY WITHSTAND VOLTAGE The rated power frequency withstand voltage for 1 minute shall be 28 KV. CONTROL SUPPLY 10.1 The rated control voltage for the operation of the switch shall be 220V AC and fluctuations upto (+) 10% and (-) 20% in the supply voltage shall not affect the normal working of the switch. 10.2 The switch shall not open out unless the control voltage falls below 40% of the rated voltage (220V). Note : The LT Control supply should be made available directly from the LT bushings of distribution transformer on which the switch is installed and this transformer should be provided with a MCCB on the

5.

6.

7.

8.

9.

10.

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secondary side to avoid unnecessary operations of the disconnection switch due to failure of LT supply.

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MECHANICAL AND ELECTRICAL ENDURANCE The switch is expected to have a life of not less than 50,000 mechanical operations and 50,000 electrical operations at magnetising current of 100 KVA, 3-phase transformers without getting damaged. However, periodical maintenance, such as replacement of oil, will be necessary after every 10,000 operations. Accordingly, the endurance tests as per clause 15.1 (e) shall be made for 10,000 electrical/mechanical operations without requiring maintenance. 12. DESIGN AND CONSTRUCTIONAL REQUIREMENTS 12.1 The switch shall be outdoor type and suitable for mounting on a cross member of 2-pole structure or on one of the poles itself. 12.2. The switch shall be oil-immersed and housed in sealed high grade porcelain enclosure. 11.

The switch shall have clamp type of terminals suitable for directly receiving aluminium conductors upto 12.3 10mm dia both in horizontal and vertical directions. The terminal arrangement shall be such as to avoid bimetallic corrosion. All iron parts such as frame of the control equipment, bolts, nuts, washers etc. shall be hot-dip 12.4 galvanized. 13. APPLICATION The disconnection switches covered in the specification are intended to automatically disconnect distribution transformers by sensing 2-phase supply conditions being imposed for load rostering on 11 KV feeders. Use of these switches will not only reduce no-load losses in distribution transformers during load-shedding periods but will also prevent the consumers from running 3-phase motor on 2-phase supply. The schematic diagram showing the application of the switch is shown in the enclosed diagram. 14. MARKING The switch shall be provided with a name-plate legibly and indelibly marked with the following : a) Name of the manufacturer b) Type, designation and serial number c) Rated voltage and current d) Rated frequency e) Rated breaking capacity f) Rated making capacity g) Rated short-time current for one second h) Rated control voltage i) Date of manufacturing j) Connection diagram 15. TESTS The switch shall be subjected to the following tests in accordance with IS:9920 (part-IV) : 15.1 Type Tests: a) Tests to verify the insulation level, including withstand tests at power-frequency voltages on auxiliary equipment. b) Tests to prove that the temperature rise of any part does not exceed the specified values. c) Making and breaking tests d) Tests to prove the capability of the switch to carry the rated short-time current. e) Tests to prove satisfactory operation and mechanical/electrical endurance. f) Tests to prove satisfactory operation under ice conditions. 15.2 Routine Tests a) Power frequency voltage dry tests b) Voltage tests for auxiliary circuits c) Measurement of the resistance of the main circuits d) Tests to prove satisfactory operation 16. INSPECTION 16.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance with the specification. 16.2 The purchaser has the right to get the tests carried out at his own cost by an independent agency, whenever there is a dispute regarding the quality of equipment.

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REC Specification No.37/1984 (Revised 1993) 11 KV AUTOMATIC VOLTAGE BOOSTERS/REGULATORS FOREWORD Automatic Voltage Boosters/regulators are now being used in many countries as a tool to improve the power carrying capability of 11 KV Lines. Selective use of these boosters/regulators not only ensure availability of proper voltage to the consumers but also helps in reducing the cost of electrification by increasing the length of 11 KV lines fed from a single 33/11 KV sub-station and thus reducing the number of sub-stations required in the system. Apart from resulting in substantial economy in investment on the infrastructure, the voltage boosters/ regulators help in reducing frequent motor burn-outs due to improved voltage conditions. The standard specification for the voltage booster was first discussed in the 11th Standardisation Conference held at New Delhi in September, 84. The Conference recommended the use of auto voltage boosters in the rural electrification system to reduce the cost of electrification and to eliminate damage to the consumers' motors due to low voltage. The voltage boosters, as standardised by REC in its 11th Conference on Standardisation had a provision of only increasing the voltage upto 10% and there was no provision for reducing the voltage. During discussions with some of the SEBs, it was brought out that there is need for increasing the range of stepping up the voltage as in many long feeders, voltage drop of the order of 20-25% is often encountered. This would call for a step up range of at least 15%. It is also seen that during light load period the voltage tends to go up resulting in damage to bulbs etc. To cope with this situation, a small provision of 5% on the 'buck' side is desirable. Keeping these requirements in view, the specification has been revised to provide a choice to the SEBs to select the desired range out of the standard ranges stipulated in the Specification. Apart from this, the rated voltage on load side has been kept as 11250 V instead of 11000 V to ensure better voltages to the consumers. Considering the possibility of load development and to obviate the need for upgrading the equipment at a later date, a standard rating of 100 Amps. only has been specified as against the earlier rating of 50 Amps. and 100 Amps. This will also avoid possibility of overloading and will increase life of the equipment. The revised Specification is issued based on the decisions taken by the 13th Standardisation Conference held on 4th - 6th May, 1993 at New Delhi.

SCOPE This specification covers oil-immersed, naturally air cooled (type ON), outdoor type, pole-mounted, 50 Hz, 11 KV voltage boosters/regulators intended for improving voltage regulation in 11 KV lines having excessive voltage variations. These are normally installed mid-way on long/heavily loaded rural 11 KV lines. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, IS:2026 - Power Transformers as amended from time to time shall be applicable. 3. CURRENT RATING The standard continuous current rating shall be 100 A.

1.

Note: The equipment is normally installed on 11 KV line at a point where voltage drop is approximately half of the maximum voltage drops on the feeder. The current rating refers to the load current at the point of installation and not at the sub-station. 4. VOLTAGE REGULATION The standard automatic voltage regulation will be as follows: 4.1 i) (-) 10%, (+) 0% (Boost only) ii) (-) 15%, (+) 0% (Boost only) iii) (-) 15%, (+) 5% (Boost & Buck) Note: The purchaser should carefully select the range to suit his requirements depending upon the field conditions and specify only the required range in the tender document.

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The equipment shall provide voltage boost or buck in steps of 2.5% each. The supplier has, however, the 4.2 option to offer equipment with smaller steps. The supplier has the option to supply equipments in single-phase units as per his standard design. The 4.3 standard voltage regulation as per 4.1 above will apply to both. 5. VOLTAGE LEVEL SETTING The equipment shall be designed to give a normal output voltage of 11250 volts on load side terminals. 5.1 Percentage sensitivity for automatic tap change operation shall be 80% of step voltage on either side of the 5.2 normal voltage of 11250 volts.

6.

CONTINUOUS MAXIMUM RATING AND TEMPERATURE RISE The equipment shall comply with appropriate requirements of IS:2026. BASIC IMPULSE INSULATION LEVEL (B.I.L) The equipment shall have BIL of 75 KV. FITTINGS Unless otherwise specified, the following standard fittings shall be provided: a) Rating plate (as per IS:2026) b) Diagram plate c) Two earthing terminals d) Lifting lugs e) Oil level indicator with minimum level marking f) Oil filling hole with cap g) Pressure release device h) Drain-cum-filter valve POWER LOSSES IN 3-PHASE SYSTEM The maximum permissible power losses at highest boost tap are as follows: Sr. No. Voltage Range 3-phase Unit No load loss in Watts i) ii) iii) (-10%) (-15%) (-15%) (+0%) (+0%) (+5%) 640 960 960 No. of 1phase Units Full load reqd. loss in Watts Single phase Units Loss per Unit No load loss in Watts 320 320 320 Load loss in Watts 2750 2750 2750 Total losses No load loss in Watts 640 960 960 Full load loss in Watts 5500 8250 8250

7.

8.

9.

5500 8250 8250

2 3 3

SHORT CIRCUIT CAPABILITY The voltage regulator shall be capable of withstanding rms symmetrical short circuit current of 25 times the rated current for 2 secs. without injury (ANSI C.57.15). TERMINALS The bushing terminals shall be designed to directly receive aluminium/ACSR conductors upto 7/3.55 mm (both vertically and horizontally) through a bolted arrangement (4 bolts) without requiring use of lugs. The terminal arrangement shall be such as to avoid bimetallic corrosion. SURGE ARRESTERS To avoid abnormal voltage stresses due to lightning and switching transients, suitable surge arresters of metal oxide type shall be mounted on the equipment. Use of oil-immersed arresters provided inside the tank is also permissible. 12. 11.

10.

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13. TAP CHANGER REQUIREMENT The equipment shall have a motor operated tap changer rated for 100A. The operation of the tap changer 13.1 shall be controlled by voltage sensing device. The tap changer mechanism shall be operated by a single phase motor operating under oil. 13.2 To avoid switching transient conditions an inherent time delay of 30-50 secs. shall be provided for each tap change. The equipment shall be self-contained and self-powered. The power for motor and other control mechanism 13.3 shall be supplied from built-in source. 14. CONTROL UNIT The control unit shall be capable of operating the voltage booster/regulator automatically as well as 14.1 manually. 14.2 14.3 The control unit shall be housed in a fully weather-proof cabinet, mounted on the equipment. The control unit shall be provided with the following:i) Auto-Manual selection ii) Testing terminals

15.

APPLICATION The boosters/regulators are intended for installation on the 11 KV lines at a suitable distance from the sub-station to correct tail-end voltage thereby increasing the KW-KM capability of the lines and allowing longer distance to be fed from the sub-station. In the case of single-phase equipment two or three units shall be used to get the desired voltage range (see clause 9). Only one unit will be required in case of 3-phase equipment. 16. The following tests shall be made in accordance with IS:2026: 16.1 Type Tests a) Measurement of winding resistance b) Measurement of voltage ratio on all taps c) Measurement of no load loss and no load current and load loss d) Measurement of Insulation resistance e) Induced over voltage withstand test f) Separate source voltage withstand test g) Tests on tap changer to the extent applicable h) Lightning impulse test i) Temperature rise j) Short circuit test to prove the requirement of clause 10 16.2 Routine Tests a) Measurement of winding resistance b) Measurement of voltage ratio on all taps c) Measurement of no load loss, no load current and load loss d) Measurement of insulation resistance e) Induced over voltage withstand test f) Separate source voltage withstand test g) Test on tap changer to the extent applicable If records of a type test on a voltage booster/regulator which in essential details is representative of the one being purchased, are furnished, the purchaser may accept this as evidence of the type test instead of the actual test. 17. INSPECTION 17.1 All tests and inspection shall be made at the place of manufacture unless otherwise specially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge to satisfy him that the material is being furnished in accordance with this specification.

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The purchaser has the right to have the tests carried out at his own cost by an independent agency 17.2 whenever there is dispute regarding the quality of supply.

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REC Specification No.38/1984 (Revised - 1997) 11 KV AUTO RECLOSERS FOREWORD 11 KV Auto Reclosers are being extensively used in many countries for fast and automatic restoration of supply following temporary faults in the system. Their experience has shown that over 80% faults are of temporary nature and are cleared by these Auto Reclosers. In the event of permanent faults, which are comparatively few in occurrence, the recloser is automatically locked after which it requires manual closing. The modern auto reclosers either use vacuum or SF6 interrupters and are practically maintenance-free. The equipment is generally self-powered from the 11 KV line and hence no auxiliary DC or AC control supply is needed. Use of 11 KV Auto Reclosers was discussed in the 11th Standardisation Conference held at New Delhi in September, 1984. The Conference recommended that this equipment could find useful application in the rural distribution system for two important applications : (i) to control major T-off lines thereby providing discrimination of the faulty section and ensuring un-interrupted supply to the healthy network and (ii) to set up low cost unattended type 33/11 KV sub-stations particularly for the electrification of remote and backward areas thereby reducing the cost of electrification. These applications are shown in the annexure. This Specification was originally issued in 1984 on the basis of decisions taken in the 11th Standardisation Conference. The Specification was subsequently revised in the 12th Standardisation Conference held in July, 1987 when certain amendments were agreed to and the decisions taken by the 12th Conference were incorporated in it. Subsequently some of the SEBs had expressed that the breaking capacity of 6 KA may not be adequate in situations where the fault level may be high. Hence, this specification was revised incorporating an additional value of 12.5 KA for the breaking current and the capacity of 6 KA was also modified to 6.3 KA to align it with the IS: 7567-1993 for Automatic Circuit Reclosers. These changes were approved in the 14th Conference on Standardisation and Technical Development, held in New Delhi in April, 1997. Based on the recommendations of this Conference, the specification is being revised and issued. 1. SCOPE This Specification covers 3pole, 50 HZ, 11 KV Auto Reclosers for outdoor installation in rural electrification system with solidly earthed neutral. 2. APPLICABLE STANDARDS Unless otherwise stipulated in the Specification, the Auto Reclosers shall comply with the following Standards as amended from time to time : IS : 13118: 1991 ANSI C37.60 IS : 2705 IS : 7567 1993 3. Circuit Breakers Automatic Circuit Reclosers Current Transformers Automatic Circuit Reclosers

RATED VOLTAGE The rated voltage for the auto-reclosers shall be 12 KV. This represents the highest system voltage corresponding to the nominal system voltage of 11 KV. RATED CURRENT The rated normal current shall be 400A. RATED SHORT CIRCUIT MAKING AND BREAKING CURRENTS The rated symmetrical short-circuit breaking capacity at 12 KV shall be 6.3 KA and 12.5 KA. Note : The rating 6.3 KA is considered adequate for all applications of auto-reclosers to control the T-off lines as the auto-reclosers will be installed at some distance from the sub-station resulting in reduced fault level. It is also adequate for use at substations with transformer capacities up to 6 MVA. This would cover most of the situations in rural electrification system. For higher fault levels 12.5 KA rating shall be used. 5.2 The value of symmetrical fault breaking current and symmetrical making currents shall be calculated in accordance with the provisions of clause 4.6, 4.7, 5.3.3 and 5.4 of the ANSI standard indicated in Clause 2 of this Specification.

4.

5.

6.

RATED SHORTTIME CURRENT The rated short-time current of the recloser shall be equal to and not less than the rated short-circuit breaking

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current for a period of 3 seconds. 7. OPERATING DUTY The minimum tested operating duty of the recloser shall be as specified in ANSI standard C37.60, which is reproduced below :

Sl. No.

Rated short circuit Breaking Current

Per cent of Rated Short Circuit Breaking Current 15-20 Min. No. of Unit Min. X/R operations X/R 45-55 No. of Unit Min. operations X/R 60 56 14 15 90-100 No. of Unit operations 16 16

Total No. of unit operations

1 2

6 KV* 12.5 KA

3 4

48 44

7 8

124 116

* The minimum tested operating duty for 6.3 KA shall be the same as that of 6 KA.
8. MECHANICAL ENDURANCE The Recloser shall be tested for minimum 2000 unit operations without maintenance as stipulated in IS : 7567 1993 (clause 8.1.2). 9. BASIC IMPULSE LEVEL (BIL) The rated BIL shall be 75 KV.

10. CONTROL SUPPLY / OPERATING MECHANISM 10.1 The auto-reclosers shall be completely self-powered and no external AC or DC control supply shall be required to be provided by the utility for their operation. 10.2 If an auxiliary transformer is used by the manufacturer for providing control supply, it shall be of resin cast type and shall be supplied as an integral part of the equipment. 10.3 If a battery is provided to power the electronic circuitry etc.,it shall be of maintenance free type with a life of not less than 10 years or minimum of 10,000 operations ( satisfactory evidence shall be provided by the supplier in support of this stipulation). 10.4 Suitable indication shall be provided to show that control supply(AC or DC) is in healthy condition.

The reclosers shall have solenoid closing mechanism either directly powered from 11 KV line or 10.5 through an auxiliary transformer indicated in 10.2 above. The closing operation shall also charge the tripping spring. 11. DESIGN AND CONSTRUCTIONAL REQUIREMENT 11.1 11.2 The auto - reclosers shall have either vacuum or SF6 interruption. The auto - reclosers shall be suitable both for mounting on a pole or sub-station structure. All the three poles shall be mechanically

The auto - reclosers shall have triple-pole construction. 11.3 coupled so as to operate simultaneously and housed in a single tank.

Provision shall be made for the control cabinet to be fixed separately through a control cable. The 11.4 length of the control cable to be supplied along with the equipment shall not be less than 3 meters. 11.5 The control cabinet shall provide for the following adjustments/operations : i) Operating sequence for phase trip (Ref. Clause 15) ii) Operating sequence for ground trip (Ref. Clause 15) iii) Phase current trip setting (Ref. Clause 16) iv) Ground current trip setting (Ref. Clause 16) v) Reclosing Interval (Dead-time) : Adjustable from I sec to 60 sec. (independent adjustment shall be available for each reclosing interval) vi) Resetting Time : Adjustable from 30 secs. to 180 secs. vii) Electrical controls for : a) Trip & Lock-out

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b) Close & reset c) Auto/Manual viii) Operation counter (digital display) 11.6 The auto - reclosers shall be provided with a mechanically operated contact position indicator. Provision shall also be made on the reclosers for manual tripping and closing. 11.7 The bushing terminals/leads shall be designed so as to directly receive aluminum / ACSR conductor upto 7/3.35 mm (both vertically and horizontally) without requiring the use of lugs. The terminal arrangement shall be such as to avoid bimetallic corrosion. 12. INDICATION / ALARM ON LOCK OUT Suitable contacts shall be provided in the control cabinet to enable the utility to connect a lamp/alarm for providing an indication in the event of a lockout. The contacts shall be suitable for operation by external 230 volts AC supply to be provided by the Utility. Note : The above provision is intended for auto reclosers to be used at the sub-stations.

13. AUTOMATIC OPERATION THROUGH TIME SWITCH It shall be possible to switch on and switch off the auto-recloser at pre-determined hours by a programmable electronic time switch. While the supplier shall make the auto-recloser suitable for this facility, the time switch shall not form part of the equipment. The auxiliary power supply for operation of time switch shall be made available by the Utility. Note : This provision is intended for automatic load-rostering during certain hours of the day if required. 14. TELECONTROL The autoreclosers shall be suitable for operation through tele-control. A suitable port may be provided for this purpose. 15. OPERATING SEQUENCE The recloser, shall be capable of 1, 2, 3 or 4 tripping operations, as required, before getting locked out. The control shall enable adjustment of different combinations of fast and delayed tripping operations upto a total of 4 operations. Separate adjustments shall be available for phase and ground trips. 16. PROTECTION The auto-recloser shall provide protection against over-current as well as earth-leakage current and shall have built in current transformers capable of providing variable trip current settings from 20A to 200A and 40A to 400A for the phase current. The current settings shall be 20A, 40A, 100A, 150A, and 200A for 200A rating and 40A, 80A, 200A, 300A, and 400A for 400A rating. The variable trip current settings for earth fault current shall be 5A to 50A. 17. MARKING The Auto-Recloser shall be provided with a name plate legibly and indelibly marked with the following : a) b) c) d) e) f) g) h) i) j) 18. TESTS The auto-reclosers and the current transformers shall be subjected to the following routine and type tests in accordance with the details specified in the standard indicated against each : Name of the manufacturer Type, designation and serial number Rated voltage and current Rated frequency Number of poles Rated short circuit breaking current Rated Making current Rated short time current and its duration Maximum number of closing operations before locking out Range of the over-current and earth fault relays

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18.1 Auto Recloser 18.1.1 Routine Tests & Acceptance Tests (As per IS : 7567 1993) a) b) c) d) e) Power frequency voltage dry tests on the main circuit Voltage tests on control and auxiliary circuits Measurement of the resistance of the main circuit Mechanical Operating tests Calibration tests

18.1.2 Type Tests a) b) c) d) e) f) g) 18.2 Mechanical Operation Tests Tests to prove that the temperature rise of any part does not exceed specified limits Tests to prove that the insulation complies with specified limits Tests to prove the short-circuit making and breaking performance Tests to prove rated duration of short-circuit current Performance characteristic test/Operating Duty Test Time-current characteristic tests

Current Transformers IS : 2705 (Part I) 18.2.1 Routine Tests : a) b) c) d) e) Verification of terminal marking and polarity High voltage power frequency test on primary winding High voltage power frequency test on secondary winding Over - voltage inter-turn test Determination of error according to the requirements of appropriate accuracy Clause.

18.2.2 Type Tests a) b) c) d) e) f) g) h) Verifications of terminal marking and polarity High voltage power frequency test on primary winding High voltage power frequency test on secondary winding Over- voltage inter-turn test Determination of error according to the requirements of appropriate accuracy clause Short-time current test Temperature rise test Impulse voltage test for current transformers for service in electrically exposed installations

19. INSPECTION 19.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge to satisfy him that the material is being furnished in accordance with this specification. 19.2 The purchaser has a right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.

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REC Specification 39/1985 Revised -1993) TRANSFORMER OIL FOR POWER/DISTRIBUTION TRANSFORMERS F0REWORD There is a general complaint by the SEBs and the transformer manufacturers that the quality of transformer oil being produced in the country is not upto the mark and the insulating properties of oil deteriorate very fast. The quality of oil often deteriorates even after a short period of storage or over a short-span of service of transformer, indicating unstable characteristics of the oil. This has an adverse effect on the service life of transformers and also poses serious maintenance problems for the SEBs. To improve the quality and stability of transformer oil, it appears necessary to specify certain ageing characteristic. IS:335-1983 which covers the specification for transformer oil does not specify the ageing characteristics. This aspect was discussed during the 11th Standardisation Conference held on 28th & 29th September, 1984 at New Delhi and it was decided to issue a standard specification for improved quality of transformer oil taking into account the useful experimental work done by the CPRI . This specification is based on the decision taken by the Conference. During 13th Standardisation Conference held on 4th-6th May 1993, this REC Specification was further discussed as a part of revision of REC Specification for conventional transformers (2/1971) and it was decided that the oil characteristics after filling in the transformer shall be tested after 3 days instead of 3 months as the oil characteristic gets stabilised after 3days of filling. This will save time for the transformer manufacturers and will also ensure good quality oil to the purchaser. Accordingly the specification has been revised. These characteristics will be further aliened to IS:1866 which is under revision and where characteristics of oil in the transformer are under consideration. 1. SCOPE

This specification covers the requirements of insulating oil for use in distribution and power transformers used in the rural electrification system. The requirements have been given in two parts : A) B) For new transformer oil in drums/tankers. For oil after it is filled in the transformer ( the values shall be applicable after 3 days from the date of filling).

Note: The difference between the characteristics stipulated for 'A' & 'B' above is in recognition of the fact that the oil characteristics may undergo some change after it is filled in the transformer. 2. APPLICABLE STANDARD Except as modified in this specification, the transformer oil will comply with latest version of IS:335-1983.

A.
3. Sl.

New Oil
The important characteristics of new oil shall be as follows: Characteristics Flash point Pensky Marten(closed), Min. Neutralization value a) Total acidity, Max. b) Inorganic acidity/alkalinity Corrosive Sulphur Electric Strength (breakdown voltage) Min. a) New unfiltered oil b) New oil after filtration Dielectric dissipation factor (tan delta) at 90oC (Max.) Specific resistance ( resistivity) a) At 900C (Min.) b) At 270C (Min.) Oxidation stability a) Neutralization value after oxidation (Max.) 140oC 0.03mg KOH/g Nil Non-Corrosive 30KV(rms) 50KV(rms) 0.005 30x1012 ohm-cm 500x1012 ohm-cm 0.40mg KOH/g Requirement

1 2
3 4 5 6

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b) Total sludge after oxidation (Max.) 4. 0.10% by weight

AGEING CHARACTERISTICS Ageing characteristics after accelerated ageing (open beaker method with copper catalyst). Specific resistance (resistivity) a)

i) ii)

at 27oC at 90oC

2.5x1012 ohm-cm (Min.) 0.2x1012 ohm-cm (Min.) 0.20 Max. 0.05 Max. 0.05 Max.

b)
c) d)

Dielectric dissipation factor (tan delta) at 900C Total acidity in mg KOH/g Total sludge value (%) by weight

B.

Characteristics of oil in the transformer

The important characteristics of the transformer oil after it is filled in the transformer (after 3 days of filling) shall 5. be as follows: S.No. Characteristics Electric strength (Breakdown voltage) Dielectric dissipation factor (tan delta) at 90oC Specific delta resistance (resistivity) at Flash point, P.M (Closed) Interfacial tension at 27o C Neutralization value (total acidity) Water content, PPM 27oC (Ohm-cm) Specification 30 KV Min. 0.01 Max 10x1012 140oC (Min.) 0.03 N/m (Min.) 0.05 mg KOH/g (Max.) 35 (Max.)

1 2 3 4 5 6
7 6.

TESTS All tests to verify the characteristics as incorporated in this specification shall be carried out in accordance with IS:335-1983 or its latest version.

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REC Specification No. 40/1985 (Revised 1997) FIBRE GLASS CROSS ARMS FOR 11 KV LINES FOREWORD Many countries are now extensively using line cross arms and other hardwares made of Fibre Glass Reinforced Plastic (FRP) as substitute for steel. FRP cross arms have the following advantages over steel cross arms:i) FRP cross arms being light in weight (about one-fifth of steel), transportation costs are reduced and the cross arms are very easy to erect on poles. ii) Due to good insulating property of FRP, the birdage problem is eliminated and flashing of insulators (particularly in coastal areas) is minimised. iii) iv) v) No painting is required, saving periodical costs and labour. The cross arms are especially suitable for coastal areas due to their corrosion-resistance properties. Earthing of pins can be dispensed with, resulting in saving of time and money.

Adoption of FRP cross arms for 11 KV lines was discussed in the 11th Standardisation Conference held in September, 1984 and it was decided to issue an REC Specification for these cross-arms. A specification No.40/1985 was issued based on the decision taken in that Conference. The Specification was subsequently reviewed in the 12th Standardisation Conference held in July, 1987 and it was decided to reduce the test loads taking into account the actual forces likely to act on the cross arms with suitable factor of safety. Hence a revised specification incorporating the amendments as decided in the Conference, was issued in 1987. The present revised draft includes the various tests to be conducted on the cross arms and on the raw materials as per the relevant Indian Standards. It has been reported by TNEB & GEB that the FRP cross arms develop cracks at the places where the bolts are tightened. This is due to the excessive pressure applied by the line staff who are not used to FRP cross arms. To overcome this problem, provision of polymeric ferrules as packing material for improving the mechanical strength of the cross arms at the places of tightening of the bolts have been incorporated in this revised specification. The revisions incorporated in this specification have been approved in the 14th Conference on Standardisation and Technical Development. 1. SCOPE

This specification covers details of Fibre Glass Reinforced Plastic cross arms to be used on 11 KV overhead lines in rural distribution system. 2. APPLICABLE STANDARDS

Unless otherwise mentioned in this specification, the raw materials used shall comply with IS : 101921982 and IS : 67461972 or their latest version. 3. SHAPE & SIZE 3.1 The cross arms shall be of either channel or rectangular hollow section with an overall length of 1150 mm and a minimum top width of 45 mm. 3.2 The cross arms shall have two holes of 22 mm dia for fixing of pin insulators. The centre-to-centre distance between the holes shall be 1070 mm and holes shall be in the middle of the top width of cross arm. 3.3 If required by the purchaser, holes of specified size and spacing shall also be provided for fixing of pole back clamp to suit the pole. 3.4 The enclosed fig. 1 gives the general details of a typical rectangular cross arm showing various dimensions, size of holes, mounting arrangement etc. These details shall also apply to channel cross arms. 4. GENERAL REQUIREMENTS 4.1 The cross arms shall be made from good quality fibreglass and plastic 0ingredients conforming to standards laid down in this specification in Clause 2 suitable for outdoor application and shall be manufactured by automatic pultrusion process. 4.2 The cross arms shall have smooth surface finish and the cut cross-section shall give a homogeneous appearance.

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4.3 The cross arms shall be of light colour so as not to attract birds. It shall not corrode while in contact with steel fittings/fixtures, P.C.C. poles and aluminium conductor. 4.4 Supply of cross arms with Ultra Violet resistant Poly Urethene coating is optional for which the SEBs may have to specifically mention in their tender specifications. 5. MECHANICAL PROPERTIES 5.1 The cross arms shall be able to withstand a vertical load of 300 kg applied at each of the two points coinciding with the centre of the pin insulators on both sides as shown in the enclosed drawing. For the purpose of this test, the cross arm shall be mounted on a support with 200 mm centre-to-centre distance between clamp bolts (16 mm dia). With the application of this load, no damage should occur to the cross arm and it should remain serviceable. 5.2 In the other direction, the cross arm should be able to withstand a load of not less than 100 Kg. applied on both sides as shown in the drawing. 5.3 Accessories for Improving the Mechanical Strength For improving the mechanical strength, Rectangular Solid Polymeric ferrules may be provided as packing material at both ends of the cross arm (F-2) where the 11 KV Pin insulators are bolted to the cross arm and also at the center where the cross arm is fixed to the PCC pole (F-1), to prevent development of cracks in the cross arm at the place of tightening of bolts. Note : The polymeric ferrules will be made out of formulation of fire retardant thermoset resins. The ferrules will be resin cast of the shape and sizes of solid rectangular bars as per the drawings. The polymeric ferrules shall be fixed inside the hollow portion of the cross arms to provide mechanical support while fastening the nuts and bolts at the pole back clamp and the 11 KV pin. 6. TESTS The cross arms shall be subjected to the following tests as per IS : 10192-1982 and IS : 6746-1972. 6.1 Type Tests The following tests shall constitute the type tests :

a) b) c) d)
e) f) g) h) i) j) k) l) 6.2

Visual Inspection Dimensional check Load test Impact Strength Tensile Strength Comparative Tracking Specific Gravity Water absorption Cross Breaking strength Compressive Strength Insulation Resistance Flammability ( As per IS : 67461972 ) ( As per IS : 101921982 )

Acceptance & Routine tests

The following tests shall constitute the Acceptance & Routine tests :-

a) b) c) d)
e) f)

Visual Inspection Dimensional check Load test Specific Gravity test Water absorption test Cross Breaking strength ( As per IS : 101921982 )

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g) h) i) Compressive Strength Insulation Resistance Flammability ( As per IS : 67461972 )

The routine and acceptance tests should be performed on one sample chosen at random out of every 20 samples subject to a maximum of 2% of the supply batch. 7. MARKING The following information shall be marked on each cross arm : a) Manufacturers name or trade mark b) Year of manufacture 8. PACKING The FRP cross arms will be packed in quantities of 10 to 20. Each cross arm will be covered with stretch wrapping film on the winding machine. The items so wound will be grouped as per numbers per packet. The information like product quantity should be mentioned on the packets.

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REC Specification 41/1985 RECTANGULAR HOLLOW STEEL POLES FOREWORD Development of suitable designs of light steel poles for use in hilly areas and other difficult terrains was discussed in the Standardisation Conference held in New Delhi in September, 1984. It was brought out during discussions that, at the instance of REC, suitable designs of jointed type steel poles using hollow rectangular sections had been developed. These poles are in two parts, which can be conveniently jointed at site by means of nuts and bolts. The conference felt that these poles would be particularly useful for hilly areas due to their light weight and convenience of transportation. Based on the discussions held in the Conference, this specification has been prepared to cover important design and testing requirements for such poles and is being issued on provisional basis to gain experience on this new design of steel poles. 1. SCOPE This Specification covers sizes, application, design and testing requirements of steel poles comprising of two unequal rectangular hollow sections to be jointed at site. 2. SIZES AND APPLICATION The following varieties (length/working loads) of poles shall be used at tangent locations of 11 KV and LT lines in wind pressure zones upto 100 Kg/M2 : i) ii) iii) iv) 7.5 M/140 Kg. 7.5 M/200 Kg. 8.0 M/140 Kg. 8.0 M/200 Kg.

The permissible spans in different wind pressure zones shall be as per Construction Standards A-8, B-8 & B-11. MATERIAL The material to be used for making rectangular hollow steel poles shall be preferably LT-42 grade steel with a minimum yield stress of 2600 Kg/Cm2 conforming to IS:1079-1973 or the latest version thereof. Other grades of steel may also be used, provided all the other requirements of this Specification are satisfied. 4. DESIGN REQUIREMENTS 4.1 The poles shall be designed for the following requirements : a) The poles shall be planted directly in the ground with a planting depth of 1.5 metres. b) The working load on the poles should correspond to those that are likely to come on the poles during their service life. c) The factor of safety for design of poles shall not be less than 1.5 as per provisions of I.E. Rules, 1956. d) The ultimate moment capacity in the longitudnal direction shall be not less than 1/4th of that in the transverse direction. A sectional view of typical pole showing various features including the jointing details, is shown in the 4.2 enclosed drawing. Even though the design details are left to the supplier, the following table gives the acceptable values of 4.3 weights of different varieties of poles : Length of Pole 7.5M 7.5M 8M 8M 5. Working Load 140 Kg. 200Kg. 140Kg 200Kg. Combined weight of the two sections (excluding nut, bolts etc.) 55-65 70-85 60-70 90-100 Maximum weight of the individual section 45 50 50 60 3.

GENERAL Cold formed rectangular hollow sections of steel shall be used for the manufacture of poles. 5.1 The poles shall be well finished, clean and free from harmful surface defects. Ends of the poles shall be cut 5.2 smoothly (free from burs). Poles shall be straight smooth and rectangular. 5.3 Red oxide primer coating shall be applied to the poles to prevent rusting.

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5.4 5.5 All nut-bolts shall be electro-galvanised. Holes shall be provided in the poles for fittings and fixtures, as per requirement of the purchaser.

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6. TESTS The following Type Tests shall be carried out on the poles : 6.1 Tensile Test

he test shall be made on the steel used for manufacture of poles and shall be done in accordance with IS:18941981 or the latest version thereof. 6.2 Deflection Test and Permanent Set Test

The jointed poles shall conform to the following test requirements when tested in accordance with IS:2713-1980 or the latest version thereof : Length of Pole 7.5M 7.5M 8.0M 8.0M Working Load 140Kg. 200Kg. 140Kg. 200Kg. Load for Permanent set not exceeding 13mm 170Kg 250Kg. 170Kg. 250Kg. Load for temporary deflection not exceeding 150mm 75Kg. 115Kg. 65Kg. 100Kg.

In addition to the above, the poles shall be tested for their performance at maximum permissible loads, i.e., 6.3 1.5 times the values given in Col. (2) above. On application of these loads, the poles shall withstand the loads and shall remain serviceable. This test should be repeated on the weaker direction of the pole by applying load equal to 1/4th of the earlier value and the pole should withstand the load. 6.4 Drop Test The test shall be carried out as per IS:2713.

Note : The deflection, permanent set and drop test shall be conducted in succession on each of the poles selected for testing. 7. SAMPLING PLAN FOR TESTING The sampling plan for testing of poles is left to the purchaser. It shall, however not be less than 1 in a lot of 500. MARKING The following information shall be marked on each pole: a) b) c) Manufacturer's name or trade mark Year of manufacture Batch No.

8.

The above information should be marked at a position so as to be easily read after erection of the pole in position.

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REC Specification No. 42/1987 (Revised 1997) FIBRE GLASS CROSS ARMS FOR 33 KV LINES FOREWORD Many countries are now extensively using line cross arms and other hardwares made of Fibre glass Reinforced Plastic (FRP) as substitute for steel. FRP cross arms have the following advantages over steel cross arms :i) FRP cross arms being light in weight (about one-fifth of steel ), transportation costs are reduced and the cross arms are very easy to erect on poles. ii) Due to good insulating property of FRP, the birdage problem is eliminated and flashing of insulators (particularly in coastal areas) is minimised. iii) No painting is required, saving periodical costs and labour. iv) The cross arms are especially suitable for coastal areas due to their corrosion-resistance properties. v) Earthing of pins can be dispensed with, resulting in saving of time and money. Adoption of FRP cross arms for 11 KV lines was discussed in the 11th Standardisation Conference held in September, 1984 and accordingly REC Specification No.40/1985 was issued earlier. Subsequently, on the request of some of the SEBs, a Specification was prepared for 33 KV Cross Arms, which was considered in the 12th Standardisation Conference held in July, 1987. A Specification was issued in 1987 on the basis of the decision taken by that Conference. The present revised specification includes the various tests to be conducted on the cross arms and on the raw materials as per the relevant Indian Standards. It has been reported by TNEB & GEB that the FRP cross arms develop cracks at the places where the bolts are tightened. This is due to the excessive pressure applied by the line staff who are not used to FRP cross arms. To overcome this problem, provision of polymeric ferrules as packing material for improving the mechanical strength of the cross arms at the places of tightening of the bolts have been incorporated in this revised specification. The revisions in this specification have been approved in the 14th Conference on Standardisation and Technical Development. 1. SCOPE This specification covers details of Fibre Glass Reinforced Plastic cross arms to be used on 33 KV overhead lines in rural distribution system. 2. APPLICABLE STANDARDS Unless otherwise mentioned in this specification, the raw materials used shall comply with IS : 101921982 and IS : 67461972 or their latest version. 3. SHAPE & SIZE 3.1 The cross arms shall be of either channel or rectangular hollow section with an overall length of 1605 mm and a minimum top width of 50 mm. 3.2 The cross arms shall have two holes of 26 mm dia for fixing of pin insulators. The centre-to-centre distance between the holes shall be 1525 mm and holes shall be in the middle of the top width of cross arm. 3.3 If required by the purchaser, holes of specified size and spacing shall also be provided for fixing of pole back clamp to suit the pole. 3.4 The enclosed drawing gives the general details of a typical rectangular cross arm showing various dimensions, size of holes, mounting arrangement etc. These details shall also apply to channel cross arms. 4. GENERAL REQUIREMENTS 4.1 The cross arms shall be made from good quality fibre glass and plastic ingredients conforming to standards laid down in this specification in Clause 2 suitable for outdoor application and shall be manufactured by automatic pultrusion process. 4.2 The cross arms shall have smooth surface finish and the cut cross-section shall give a homogeneous appearance.

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4.3 The cross arms shall be of light colour so as not to attract birds. It shall not corrode while in contact with steel fittings/fixtures, P.C.C. poles and aluminium conductor. 4.4 Supply of cross arms with Ultra Violet resistant Poly Urethene coating is optional for which the SEBs may have to specifically mention in their tender specifications.

5.

MECHANICAL PROPERTIES 5.1 The cross arms shall be able to withstand a vertical load of 400 kg applied at each of the two points coinciding with the centre of the pin insulators on both sides as shown in the enclosed drawing. For the purpose of this test, the cross arm shall be mounted on a support with 230 mm centre-to-centre distance between clamp bolts (16 mm dia). With the application of this load, no damage should occur to the cross arm and it should remain serviceable. In the other direction, the cross arm should be able to withstand a load of not less than 135 Kg. applied on 5.2 both sides as shown in the drawing. For improving the mechanical strength, rectangular solid polymeric ferrules may be provided as packing 5.3 material at both ends of the cross arms (F-2) where 33 KV pin insulators are bolted to the cross arm and also in the middle where the cross arm is fixed to the PCC pole (F-1), to prevent development of cracks in the cross arm at the place of tightening of bolts. Note :The polymeric ferrules will be made out of formulation of fire retardant thermoset resins. The ferrules will be resin cast of the shape and sizes of solid rectangular bars as per the drawings. The polymeric ferrules shall be fixed inside the hollow portion of the cross arm to provide mechanical support while fastening the nuts and bolts at the pole back clamps and the 33 KV pin.

6.

TESTS The cross arms shall be subjected to the following tests as per IS : 10192-1982 and IS : 6746-1972. 6.1 Type Tests The following tests shall constitute the type tests :

a) b) c) d)
e) f) g) h) i) j) k) l)

Visual Inspection Dimensional check Load test Impact Strength Tensile Strength Comparative Tracking Specific Gravity Water absorption Cross Breaking strength Compressive Strength Insulation Resistance Flammability ( As per IS : 67461972 ) ( As per IS : 101921982 )

6.2 Acceptance & Routine tests The following tests shall constitute the Acceptance & Routine tests :-

a) b) c) d)
e) f) g)

Visual Inspection Dimensional check Load test Specific Gravity test Water absorption test Cross Breaking strength Compressive Strength ( As per IS : 101921982 )

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h) i) Insulation Resistance Flammability ( As per IS : 67461972 )

The routine and acceptance tests should be performed on one sample chosen at random out of every 20 samples subject to a maximum of 2% of the supply batch. 7. MARKING The following information shall be marked on each cross arm : a) b) 8. Manufacturers name or trade mark Year of manufacture

PACKING The FRP cross arms will be packed in quantities of 10 to 20. Each cross arm will be covered with stretch wrapping film on the winding machine. The items so wound will be grouped as per numbers per packet. The information like product quantity should be mentioned on the packets.

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REC Specification No.43/1987 11KV AIR BREAK SWITCHES FOREWORD 11 KV Air Break Switches are extensively used in the 11 KV network on locations such as distribution transformer sub-station, sectionalising / tapping points of 11 KV lines etc. However, the quality of this equipment is invariably not up to the mark. In many cases, the requisite electrical and mechanical requirements are not met with and the switches develop mechanical defects and sparking due to loose contacts after only a few months of operation. Continuous sparking not only causes unnecessary power losses but also sends surges through the transformers which can be one of the causes of pre-mature failure of transformers. Poor contacts also lead to single phasing conditions resulting in damage to consumers' motors. This specification for 11 KV Air Break Switches takes into account the latest advances in technology as also certain stringent requirements laid down in the new IS:9920 (Pts. I to IV). In formulating this I.S., it was recognised that the AB switches, even though meant for off-load operation, are required to be assigned certain minimum making and breaking current ratings in addition to short-circuit current carrying capability. This specification is being issued on the basis of the recommendations of the 12th Standardisation Conference held in July,1987. The specification not only stipulates important electrical and mechanical characteristics but also describes essential constructional features to ensure proper quality of the equipment. 1. SCOPE This specification covers 11KV, 50Hz Air Break Switches for outdoor installation. The switches are suitable for operation under off-load conditions only and are intended for use on Distribution sub- stations and tapping/sectionalising points of 11KV lines. 2. APPLICABLE STANDARD Unless otherwise stipulated in this specification , the AB switches shall conform to IS:9920 (Pt.I to IV). 3. RATED VOLTAGE The rated voltage shall be 12 KV. 4. RATED NORMAL CURRENT The rated normal current shall be 400 Amps. 5. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE KV (PEAK) i) To earth and between poles 75 KV ii) Across the terminals of open switch 85 KV 6. RATED ONE-MINUTE POWER FREQUENCY WITHSTAND VOLTAGE KV (rms) i) To earth and between poles 28 KV ii) Across the terminals of open switch 32 KV Note : The withstand values in Clauses 5 & 6 shall apply at the standard reference atmosphere (temperature, pressure and humidity) specified in IS:2071 (part-I)-1974. 7. TEMPERATURE RISE The temperature rise shall not exceed the maximum limits specified below : Temperature rise limit at Ambient temperature not exceeding 40oC Copper contacts (Silverfaced) in air Terminals of the switch intended to be connect to external conductors by bolts 8. RATED SHORT TIME CURRENT The rated short time current shall be 16 KA. 9. RATED PEAK WITHSTAND CURRENT The value of peak current that the switch can withstand in the closed position shall be 40 KA. = 65oC = 50oC

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10. RATED MAINLY ACTIVE LOAD BREAKING CAPACITY The rated mainly active load breaking capacity shall be 10A. 11. RATED TRANSFORMER OFF-LOAD BREAKING CAPACITY The rated transformer off-load breaking capacity shall be 6.3A (rms). 12. RATED LINE CHARGING BREAKING CAPACITY The rated line-charging breaking capacity shall be 2.5 A (rms) 13. RATED CABLE-CHARGING BREAKING CAPACITY The rated cable charging breaking capacity shall be 10 A(rms). 14. CONSTRUCTIONAL FEATURES 14.1 The AB switch shall have triple-pole construction and shall be suitable for horizontal or vertical mounting as required by the purchaser. The switch shall have two 11 KV post insulators per phase suitably mounted on angle irons to enable easy movement of insulators. The angle supports shall be mounted on a 70mm 2 hollow beam suitable for fixing on the double pole structure. Alternatively, the angles shall be mounted on a steel frame made of two angle/channel supports. The switch shall be manually operated with a rocking type arrangement through a 30mm2 G.I coupling rod. 14.2 All current carrying parts shall be made of silver or nickle-plated 90% elecrtrolytic copper. The arcing horns shall be made of phosphor bronze and shall have spring-assisted operation. The switch shall have a spring mechanism so as to ensure that the speed of opening of contacts is independent of the speed of manual operation. 14.3 The spacing between the phases shall be adjustable between 600mm to 760mm. Total length of the square beam/base frame shall be kept as 2650mm. The switch assembly shall be suitable for mounting on a H-pole structure with centre-to-centre distance between poles upto 2440mm. 14.4 The vertical operating rod shall comprise of 25mm (nominal bore) Galvanised steel tube (medium class) as per IS:1161-1979. Length of the operating tube shall vary from 4800mm to 6000mm depending upon the mounting position of the switch on the structure (exact length to be specified by the purchaser). 14.5 Suitable arrangement shall be provided to pad-lock the operating handle in 'ON' and 'OFF' positions.

The switch shall be provided with bimetallic connectors on the incoming side to accommodate ACSR of 14.6 sizes 20, 30 and 50mm2. On the outgoing side, about 1 metre long flexible coil type cable jumper of not less than 50mm2 aluminium section shall be provided. 14.7 14.8 All iron parts shall be hot dip galvanised. The tubes shall be galvanised in accordance with IS:4736-1968. Typical constructional details of the AB Switch are shown in the enclosed drawing.

15. TYPE TESTS The AB Switch shall be subjected to the following type tests in accordance with IS:9920. i) Dielectric test (impulse and one minute wet power frequency withstand voltage tests) ii) Temperature rise test (for contacts and terminals) iii) Short time current and peak withstand current tests iv) Mainly active load breaking capacity test v) Transformer off-load breaking capacity test vi) Line charging breaking capacity test vii) Cable charging breaking capacity test viii) Operation and Mechanical Endurance test 16. ROUTINE TESTS The AB Switches shall be subjected to the following routine tests: i) Power frequency voltage dry test ii) Measurement of the resistance of main circuit iii) Operating test 17. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed 17.1 upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this specification.

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The purchaser has the right to have the tests carried out at his own cost by an independent agency 17.2 whenever there is dispute regarding the quality of supply.

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REC Specification No.44/1987 (Revised - 1993) 11KV LINE SECTIONALISERS FOREWORD Many countries are using line sectionalisers to improve the reliability of power supply in rural areas. Sectionalisers are intended for installation on the tapping points of long branch lines emanating from the main 11KV line thereby enabling automatic isolation of the faulty branch line in the event of a permanent fault. Thus supply is maintained on the healthy sections of the feeder. Sectionalisers work in coordination with the 11KV circuit breaker/auto recloser controlling the main line. Modern sectionalisers make use of vacuum or SF6 technology and are designed to give long maintenance-free service. Apart from their use for automatic isolation of the faulty sections, the sectionalisers serve the purpose of loadbreak and fault-make switches to enable the field staff to carry out maintenance work on the branch lines without the need for taking a shut down from the controlling sub-station (33/11KV, 66/11KV etc.). This Specification was originally issued in 1987 on the basis of the decisions taken in the 12th Standardisation Conference held in New Delhi in July, 1987 and covered Sectionalisers based on the Voltage Sensing principle only. The Specification was subsequently revised to include Sectionalisers based on the current sensing principle so as to gain experience on both type of sectionalisers. The revised specification incorporating the above change was discussed during 13th Standardisation Conference held on 4th-6th May, 1993 at New Delhi and based on the decisions taken at this Conference, the revised specification is issued. 1. SCOPE This specification covers 3-pole, 11KV, 50Hz, pole-mounted Automatic Line Sectionalisers for outdoor 1.1 installation in rural electrification system with solidly earthed neutral. Unless specially stipulated by the purchaser, the sectionalisers may be of either voltage sensing or current 1.2 sensing type as per normal design of the supplier. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this specification automatic line sectionalisers shall comply with the latest version of IS:9920. 3. RATED VOLTAGE

The rated voltage for the line sectionalisers shall be 12KV. This represents the highest system voltage corresponding to the nominal system voltage of 11KV. 4. RATED CURRENT The standard rated normal current shall be 200 A. RATED BREAKING CAPACITY i) Mainly active load breaking capacity ii) Transformer off-load breaking capacity iii) Line-charging breaking capacity iv) Cable-charging breaking capacity

5.

200A 6.3A 2.5A 10 A

6.

RATED SHORT TIME CURRENT The rated short-time symmetrical current for one second shall be 10 KA. RATED MAKING CURRENT The rated making current shall be 25 KA. RATED BASIC IMPULSE LEVEL

7.

8.

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i) To earth and between poles ii) Across the terminals of open switch 9. 75 KV 85 KV

RATED ONE MINUTE POWER FREQUENCY WITHSTAND VOLTAGE i) To earth and between poles 28 KV ii) Across the terminals of open switch 32 KV iii) Control circuit to earth 2 KV CONTROL SUPPLY The line sectionalisers shall be self-powered from the 11 KV line, i.e. no external AC or DC control supply shall be required to be provided by the utility. FAULT BREAKING CAPACITY The sectionalisers shall have no rated fault breaking capacity and will sectionalise the faulty section (which it is con- trolling) only when the power supply to the line is interrupted by the controlling circuit breaker/auto recloser at the main sub station. OPERATION A. VOLTAGE SENSING TYPE The sectionaliser shall automatically open on sensing loss of supply on the incoming side and close 12.1 when the supply is restored. 12.2. In the event of a fault in the line section controlled by the sectionaliser, the main sub-station breaker will trip. Sensing loss of power supply, the sectionaliser will automatically open. On closing the sub-station breaker, the sectionaliser will automatically reclose after a pre-set time interval (a variable setting of 10 to 60 seconds shall be provided in the multiples of 10 seconds). In case of temporary fault, the supply to the total area will be restored. However, in the case of a permanent fault, the sub-station breaker will again trip and the sectionaliser relay will open and lock-out the sectionaliser following the second tripping of the main breaker. The faulty section thus gets isolated and the next reclosing trial of the main sub-station breaker shall restore supply to the healthy sections. 12.3 If more than one sectionalisers are provided on 11 KV feeder, time discrimination in the sequence of their operation shall be obtained by setting closing time periods of the consecutive sectionalisers at intervals of 10 secs. each. The lock-out time for sectionaliser shall be 5 seconds. This represents the maximum time from the 12.4 closing of the sectionaliser to the tripping of the sub station breaker on permanent fault. The sectionaliser relay shall re-set after 5 seconds. Inherent time delay of 2 seconds shall be provided in the operation of the sectionaliser to avoid its 12.5 opening under fault condition before clearance of the fault by the main sub-station breaker. It shall also be ensured that the sectionaliser does not open on transient faults and momentary voltage dip due to system disturbances. B. CURRENT SENSING TYPE 12.6 If the line current in the protected section increases above a certain pre-set value (i.e. the pick-up level), the sectionaliser registers the faulty condition. The upstream auto-recloser also registers the fault current and trips out. The upstream breaker will successfully reclose the first time if the fault is of a transient nature and has disappeared. However, if the fault is permanent, the sectionaliser will register the second fault passage and the upstream recloser will again trip. The sectionaliser having registered the fault current twice followed by loss of voltage, opens out the faulty section. The upstream breaker will now successfully reclose as the faulty line section has been disconnected; thus the rest of the system reverts to normal operation. The Sectionaliser shall have adjustable over-current trip setting from 20 A to 200 A and earth fault trip 12.7 setting from 5 A to 50 A.

10.

11.

12.

13.

ELECTRICAL AND MECHANICAL ENDURANCE The voltage sensing sectionalisers shall be capable of performing not less than 20,000 mechanical operations and 20,000 electrical operations at rated current without getting damaged. For current sensing sectionalisers, the corresponding figures shall be a minimum of 10,000 and 5,000 operations respectively. FAULTY SECTION INDICATOR

14.

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(FOR VOLTAGE SENSING SECTIONALISERS ONLY) An indicator to indicate the faulty section shall be provided on the controlling breaker in the main substation. The indicator shall indicate the particular sectionaliser which has locked out on permanent fault. The indicator will work on the basis of discrimination of time lapsed between the first reclosing of the circuit breaker and its next tripping due to permanent fault in a particular section. Note : One indicator will be required at the sub-station for each feeder and hence the total number of indicators required to be supplied along with sectionalisers will depend upon the number of sectionalisers per feeder and it shall be clearly specified by the purchaser while ordering sectionalisers. 15. DESIGN AND CONSTRUCTIONAL REQUIREMENTS 15.1 The sectionalisers shall be of either vacuum of SF6 type. 15.2 The equipment shall be of outdoor type and suitable for mounting on single or double-pole structure.

The sectionalisers shall be provided with a mechanically operated contact position indicator. The 15.3 provision shall also be made for manual opening and closing of the sectionaliser from ground level; this provision is in addition to the on and off operation from the control cabinet. Sectionaliser bushing terminals shall be designed so as to directly receive ACSR conductor upto 7/3.35 15.4 mm size by using bolted clamps so as not to require the use of lugs. The terminal arrangement shall be such as to avoid bimetallic corrosion. 16. COORDINATION WITH THE SUB-STATION BREAKER As the sectionalisers installed on a feeder work in coordination with the circuit breaker or an auto-recloser at the main sub-station controlling the feeder, this aspect requires proper attention. In the case of manually operated circuit breaker, the normal interval between the first and subsequent trials is two minutes or so. In such cases only voltage sensing sectionalisers can be used. However, in the case of an auto-recloser, it is possible to use both Voltage and Current Sensing Sectionalisers. MARKING The sectionalisers shall be provided with a name plate legibly and indelibly marked with the following:Name of the manufacturer Type, designation and serial number Rated voltage and current Rated frequency Number of poles Rated normal current Rated breaking capacity Rated short-time current Rated making current TESTS The sectionalisers shall be subjected to the following tests in accordance with the IS:9920 (Part-IV): 18.1 Type Tests a) Tests to verify the insulation level, including withstand tests at power-frequency voltage on auxiliary equipment. b) Tests to prove that the temperature rise of any part does not exceed the specified values c) Making and breaking tests d) Tests to prove the capability of the switch to carry the rated short-time current e) Tests to prove satisfactory operation and mechanical/electrical endurance f) Tests to provide satisfactory operation under ice conditions. Routine Tests Power-frequency voltage dry tests Voltage tests for auxiliary circuits Measurement of the resistance of the main circuits Tests to prove satisfactory operations

17. a) b) c) d) e) f) g) h) i) 18.

18.2 a) b) c) d)

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19. INSPECTION 19.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge,to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency 19.2 whenever there is dispute regarding the quality of supply.

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REC Specification 45/1986 G I WIRES FOREWORD G.I. wires of different sizes are used in rural distribution system for various applications such as earthing of metallic fittings, bearer wire for service cables, guarding of power lines etc. This specification for G.I. Wires for use in rural electrification system was approved by the 12th Standardisation Conference held at New Delhi on July 30, 1987. 1. SCOPE This specification covers details of solid G.I. Wires for use in rural distribution system.

2.

APPLICABLE STANDARDS Except when they conflict with the specific requirements of this specification, the G.I. wires shall comply with the provisions of IS:280-1978 and IS:7887-1975 or the latest version thereof. 3. APPLICATION & SIZES G.I. wires covered in this Specification are intended for the following applications :

Application Bearer wire for service Earthing of Transformers, poles & Fittings. Continuous Earthwire for. 11 KV lines Protective guarding at the crossing of over-head power lines with roads, railway tracts and telecommunication lines

Sizes (nominal dia) 3.15mm (for single phase cables services) ( for three phase services) 4 mm 4 mm 4 mm

3.15, 4 and 5 mm

4. 4.1 4.2

MATERIAL The wires shall be drawn from the wire rods conforming to IS:7887-1975 or the latest version thereof. The requirements for chemical composition for the wires shall conform to IS:7887.

The wires shall be sound, free from split surface flaws, rough jagged and imperfect edges and other 4.3 detrimental defects on the surface of the wires. 5. GALVANISING The wires shall be galvanised with Heavy Coating as per IS:4826-1979 or the latest version thereof. GRADES GI wires shall be classified into two grades based on their tensile strength : Grade Annealed Hard 7. Tensile Strength (MPa) 300-550 550-900

6.

TOLERANCE IN DIAMETER The tolerance on nominal diameter at any section of wire shall not exceed ()2.5%. Further, the maximum difference between the diameters at any two cross-sections of wires shall not exceed 2.5%. 8. TESTS The following tests shall be carried out in accordance with IS:280-1978 or the latest version thereof as per

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sampling criteria stipulated therein : i) ii) iii) iv) v) vi) vii) 9. Dimensional check (dia) - refer clause 7 above. Visual inspection regarding freedom from defects refer clause 4.3 above. Tensile test Wrapping test (for wire diameters smaller than 5mm) Bend test (for wire diameters 5mm only) Coating test - refer clause 5 above Chemical composition

PACKING The wires shall be supplied in 50-70 kg. coils, each coil having single continuous length. Each coil of wire shall be suitably bound and fastened compactly and shall be protected by suitable wrapping. MARKING Each coil shall be provided with a label fixed firmly on the inner part of the coil bearing the following information : a) Manufacturers name or trade mark b) c) d) e) f) g) Lot number and coil number Size Grade (Annealed or Hard) Mass Length ISI Certification mark, if any

10.

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REC Specification 46/1986 G I STAY WIRES FOREWORD G.I. Stay Wires are used for anchoring of power lines poles at special locations such as angles, dead-ends etc. This Specification for G.I. Stay Wires for use in rural electrification system was approved by the 12th Standardisation Conference held at New Delhi on July 30, 1987. 1. SCOPE This Specification covers details of G.I. stranded stay wires for use in rural distribution system. 2. APPLICABLE STANDARDS Except when they conflict with the specific requirements of this specification, the G.I. Stranded Wires shall comply with the specific requirements of IS:2141-1979. IS:4826-1979 & IS:6594-1974 or the latest versions thereof. 3. APPLICATION AND SIZES The G.I. stranded wires covered in this Specification are intended for use on the overhead power line 3.1 poles, distribution transformer structures etc. 3.2 The G.I. stranded wires shall be of 7/2.5mm, 7/3.15mm and 7/4.0mm standard sizes.

4. MATERIAL The wires shall be drawn from steel made by the open hearth basic oxygen or electric furnace process and of such quality that when drawn to the size of wire specified and coated with zinc, the finished strand and the individual wires shall be of uniform quality and have the properties and characteristics as specified in this specification. The wires shall not contain sulphur and phosphorus exceeding 0.060% each. 5. TENSILE GRADE The wires shall be of tensile grade 4, having minimum tensile strength of 700 N/mm2 conforming to IS:2141. 6. GENERAL REQUIREMENTS The outer wire of strands shall have a right-hand lay. 6.1 6.2 The lay length of wire strands shall be 12 to 18 times the strand diameter.

7. MINIMUM BREAKING LOAD The minimum breaking load of the wires before and after stranding shall be as follows :

No. of wires & const. 7(6/1) 7(6/1) 7(6/1)

Wire dia (mm) 2.5 3.15 4.0

Min. breaking load of Single wire Min. breaking load of the before stranding (KN) standard wire (KN) 3.44 5.45 8.79 22.86 36.26 58.45

8. CONSTRUCTION The galvanised stay wire shall be of 7-wire construction. The wires shall be so stranded together that 8.1 when an evenly distributed pull is applied at the ends of completed strand, each wire shall take an equal share of the pull. Joints are permitted in the individual wires during stranding but such joints shall not be less than 15 metres 8.2 apart in the finished strands. 8.3 The wire shall be circular and free from scale, irregularities, imperfection, flaws, splits and other defects.

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9. TOLERANCES A tolerance of ()2.5% on the diameter of wires before stranding shall be permitted. 10. SAMPLING CRITERIA The sampling criteria shall be in accordance with IS:2141. 11. TESTS ON WIRES BEFORE MANUFACTURE The wires shall be subjected to the following tests in accordance with IS:2141. i) Ductility Test ii) Tolerance on Wire Diameter

12. TESTS ON COMPLETED STRAND 12.1 The completed strand shall be tested for the following tests in accordance with IS:2141. a) Tensile and Elongation Test : The percentage elongation of the stranded wire shall not be less than 6%. b) Chemical analysis c) Galvanising Test : The Zinc Coating shall conform to Heavy Coating as laid down in IS:4826 13. MARKING Each coil shall carry a metallic tag, securely attached to the inner part of the coil, bearing the following information: a) Manufacturers name or trade mark b) Lot number and coil number c) Size d) Construction e) Tensile Designation f) Lay g) Coating h) Length i) Mass j) ISI certification mark, if any 14. PACKING The wires shall be supplied in 75-100 Kg. coils. The packing should be done in accordance with the provisions of IS:6594.

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REC Specification 47/1987 SPUN CONCRETE POLES FOREWORD At present, solid and virendeel type PCC poles are used for overhead power lines up to 33 KV. Many countries are now using Pre-Stressed Spun Concrete Poles (hollow circular type) not only for distribution and sub-transmission lines but also for EHV Lines like 66 KV and 132 KV. Spun concrete poles are produced in bulk in large mechanised plants and have a number of advantages over the conventional PCC poles. Some of the superior features of these poles are: i) The poles have equal strength in all directions and therefore, do not need special care in handling and transportation. The number of stay anchors is also considerably reduced. ii) The centrifugal process involved in spinning gives better and uniform strength to concrete and the outside surface of pole is stronger and more resistant to cracks. iii) Due to circular form and absence of edges/angles, the magnitude of wind forces acting on the poles is less than on rectangular pole for the same projected area. iv) The poles give better aesthetic look. The hollow portion of the pole can be used as a duct for carrying earth wire(s) or cables, where used. While these poles are likely to be costlier for LT and 11 KV lines as compared to the solid rectangular poles, the cost may be comparable in the case of 33 KV poles (assuming bulk production). In any case, the cost would be much lower as compared to steel poles being used by some of the SEBs for 33 KV lines. The specification covers the general and technical requirements of such poles for various lengths/working loads standardised by REC for power lines upto 33 KV. For the present, the detailed designes have been left to the manufacturers but general, technical and test requirements as stipulated in this specification shall be fully met with. In preparation of this specification, help has been taken from the draft specification for pre-stressed Concrete Spun Poles for overhead power traction and tele-communication lines circulated by BIS. This specification was approved in the 12th Standardisation Conference of REC held in July, 1987 and is being issued on a provisional basis to enable the SEBs to gain experience on new type of poles for which the technology is now indigenously available. 1. SCOPE The Specification covers prestressed concrete circular spun poles for use on LT, 11 KV and 33 KV overhead power lines.

2.

APPLICABLE STANDARDS Except when they conflict with specific requirements in this specification, the poles shall comply with the relevant provisions made in the following Indian Standard Specifications or the latest version thereof: a) b) c) IS: 1678 - 1978 IS: 2905 - 1966 IS: 7321 - 1974 Specification for pre-stressed concrete poles for overhead power, traction and communication lines. Methods of test for concrete poles for overhead power and telecommunication lines. Code of practice for selection, handling and erection of concrete poles for overhead power and telecommunication lines.

3.

TERMINOLOGY For the purpose of this specification, the definitions of Average Permanent Load, Load Factor, Transverse Load at first crack, Ultimate Failure, Ultimate Transverse Load and Working Load shall be as per IS: 1678.

4.

CLASSIFICATION AND APPLICATION Various lengths and working loads of poles to be used for different applications are indicated in the following table:

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Sl. No Length 7.5M Working Load 140 Kg 200 Kg. 140 Kg. 200 Kg 200Kg. i) Special Location of 11 KV and LT Lines (Road Crossing, etc.) ii) 33 KV lines in a wind pressure zone of 50 Kg/m2 33 KV lines in a wind pressure zone of 75 Kg/m2 33 KV lines in a wind pressure zone of 100 Kg/m2 (refer REC construction Standard M-2 for application of 33 KV poles) For Special locations of 33 KV lines ( road crossing, etc.) 11 KV LT lines (refer REC construction Standards A-8, B-8 and B-11 Application

1 2

8.0M

9.0M

300 Kg 400 Kg. 200 Kg. 300 Kg. 400 Kg.

9.5M

5.

CEMENT High strength ordinary portland cement conforming to IS: 8112 or ordinary Portland cement 5.1 conforming to IS: 269 - 1976 or Rapid hardening cement conforming to IS: 8041E - 1978, shall be used, which shall have the following additional requirements: a) Initial Setting Time b) Final setting Time Not less than 90 minutes Not more than 600 minutes.

5.2 The minimum compressive strength of standard mortar cube with standard sand as per IS: 650 at 7 days shall be 375 Kg/cm2. 5.3 As far as possible, the cement shall be obtained from one source to minimize variations in the quality. Each consignment shall be covered by a test certificate, which shall be submitted to the purchaser or inspecting officer for check. Each consignment of cement shall be stocked separately and shall be clearly identified. 5.4 If required by the purchaser, before using a particular batch of cement, a minimum of 3 trial cubes shall be made with aggregate grading to be used for the approved design mix and the average compressive strength results at 7 days, shall be determined to assess the suitability of the cement. Suitable quick tesing method may be adopted with the approval of the purchaser. AGGREGATES Coarse and fine aggregates used for the casting of poles shall conform to IS: 383. A sample of aggregates shall be submitted by the manufacturer to the purchaser for approval, if so desired by the purchaser. The nominal maximum size of aggregates shall in no case exceed 20mm or 1/4th the minimum thickness of the pole, whichever is less, provided further that the size of aggregates shall be at least 5 mm less than the spacing between the prestressing wires. Each size of graded aggregate shall be stocked in different storage bins or stock piles and shall be mixed only after the quantity required for each size has been separately weighed. The storage bins or stock piles shall be under cover to protect from weather. 7. WATER Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable. 8. ADMIXTURES Admixtures should not contain Calcium Chloride or other Chlorides and salts which are likely to promote corrosion of pre-stressing steel. 9. REINFORCEMENT 6.

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9.1 Reinforcing bars and wires used for the manufacture of prestressed concrete poles shall conform to the following Indian Standards. a) IS: 432 (part-I) - 1982 : Specification for mild steel and medium tensile steel and hard-drawn steel wire for concrete reinforcement : Part-I Mild Steel and medium tensile steel bars (third revision). b) IS : 432 (Part-II) - 1982 Specification for mild steel and medium tensile steel bars and hard-drawn steel wire for concrete reinforcement : Part-II Hard drawn steel wire (third revision). c) IS : 1785 (part-I) - 1983 Specification for plain and hard-drawn steel wire for prestressed concrete : partI Cold- drawn stress relieved wire (second revision). d) IS: 1785 (part-II) - 1983 Specification for plain and hard drawn steel wire for prestressed concrete Part-II As drawn wire. (first revision). e) IS:2090 - 1983 Specification for high tensile steel bars used in prestressed concrete. (first revision). f) IS: 6003 - 1983 Specification for indented wire for pre- stressed concrete. (first revision)

g) IS: 6006 - 1983 Specification for uncoated stress relieved strand for prestressed concrete. (first revision) 9.2 The surface of all reinforcement shall be free from loose scale, oil, grease, clay or other material that may have deteriorating effect on the band between the reinforcement and the concrete, slight rust may, however, be permissible. 10. CONCRETE The concrete mix shall be designed to the requirement laid down for controlled concrete (also called design mix concrete) in IS: 1343 (code of practice for prestressed concrete) and IS: 456 (code of practice for plain and reinforced concrete), subject to the following special conditions: a) Minimum works cube strength at 28 days should be atleast 40N/ mm2. b) The concrete strength at transfer should be atleast half the 28 days strength ensured in the design. c) The mix should contain as low a water content as is consistent with adequate workability. If it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ratio is maintained. 11. DESIGN REQUIREMENTS The pole shall be designed for the following requirements. a) The poles shall be so designed that they do not fail owing to failure initiated by compression of concrete. b) The poles shall be planted directly in the ground with a planting depth of 1.5 M for poles upto a length of 9.0 M and 1.8 M for poles of 9.5 M length. c) Factor of safety for the poles shall not be less than 2.0. d) The average permanent load shall be taken as 40% of the working load. e) The F.O.S. against first crack load shall be 1.0. f) At average permanent load, permissible tensile stress in concrete shall be 3.0N mm2 g) At the design value of first crack load, the hypothetical flexural tensile stress shall not exceed the following values:

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Concrete Grade M-40 M-45 M-50 & above Maximum value of Modulus of rupture N/per mm2 5.3 5.8 6.3

h) The maximum compressive stress in concrete at the time of transfer of prestress shall not exceed 0.8 times the cube strength. i) The permissible tolerances shall be as follows: (i) ()15 mm (ii) () 4mm - 2mm (iii) 0.5% 12. MOULDS Moulds shall be of steel and of rigid construction to prevent distortion and so arranged as to provide smooth surfaces. The moulds shall not allow any leakage of cement grout during casting. The holes in the end plates for the H.T. wires shall be accurately drilled by jigs to ensure interchangeability. The end plates shall be designed to withstand the forces arising out of the change in direction of prestressing wires during tensioning. 13. STRETCHING OF WIRES 13.1 The prestressing wires shall be stretched by an approved method. The anchoring of the stretched wires shall be such that during manufacture and until the wires are release, no slipping occurs. The forces at the time of initial stretching shall in addition to imparting of designed prestress also be sufficient to overcome the friction on account of any change in the inclination of wires and slippage that might occur during the anchoring process which will have to be suitably compensated. 13.2 The tensioning of prestressing steel shall be carried out in a manner that will induce a smooth and even rate of increase of stress in the wires. The force induced in the prestressing wires shall be determined by means of guages attached to the 13.3 tensioning appratus and cross checked by extension of the wires observed. The extension to be achieved shall be determined in advance, based on trials conducted on representative samples of the wires as used in the poles. The accuracy of the devices for measuring of the tensioning force shall be within ()5%. 14. MIXING AND CONSOLIDATION OF CONCRETE Provision shall be made to measure the quantities of cement and of fine and coarse aggregates by weight 14.1 only. The accuracy of the measuring equipment shall be ()3%. All the measuring equipments shall be maintained in clean, serviceable condition and its accuracy checked regularly. Modern high speed mixers, preferably pan or turbine type shall be used for mixing the concrete. 14.2 Mixing and placing of concrete shall, as far as possible, be avoided during the extreme temperatures in summer and winter. The concreting shall commence within 2 hours of stressing of the wires, failing which the tensioned wires shall be checked and retensioned, if necessary. 14.3 14.4 The manufacture of poles shall be done under suitable cover and not in the open. The concrete shall be thoroughly mixed and consolidated. in the overall length of pole in the cross sectional dimension of pole in the uprightness of the pole.

The freshly cast poles shall be protected during the first stage of hardening from the 14.5 harmful effects of sunshine, dry winds, cold and rains.

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15. DE-TENSIONING OF WIRES 15.1 The anchoring system shall provide a device for gradual detensioning of the wires. No back pulling of the wires shall be permitted in the gradual detensioning device for the purpose of release of any wedge or other parts of the detensioning device. Flame cutting of the wires before release of the full tension shall be strictly prohibited. 15.2 The transfer of prestress shall not be effected until the concrete in the poles has attained the specified strength as established by cube-tests. 16. CURING 16.1 The concrete shall be covered with a layer of sacking, canvas, hessain or similar absorbent material and kept constantly wet upto the time of transfer of prestress. However, preferably steam curing at atmospheric pressure may be done till transfer of prestress. Prior approval of purchaser shall be obtained for the process and details such as temperature, duration etc. for the steam curing cycle. After de-tensioning, the poles shall be cured for a further period of not less than 14 days by submerging in water tanks for a period of 7 days followed by curing for a further 7 days with mechanical water spraying arrangements which shall be invariably carried out under cover and shall ensure full humidity conditions. 16.2 During manufacture, periodical tests on concrete cubes shall be carried out till the concrete achieves the required strength at transfer. Thereafter, the test on concrete shall be carried out as detailed in IS: 1343. The manufacturer shall supply, when required by the purchaser, results of compressive test conducted in accordance with IS: 456 on concrete cubes made from the concrete used for the poles. If the purchaser so desires, the manufacturer shall supply, cubes for test purposes and such cubes shall be tested in accordance with IS: 456. 17. EARTHING Under finalisation. 18. FINISH 18.1 Poles shall be free from surface defects including hair cracks. The surface of the poles in contact with the steel mould shall be smooth and regular in shape and shall, as far as possible, be free from pores. Water retaining pockets or honey-combing formation shall not be admissible. 25 mm thick 1:2 cement mortar cover shall be provided on the full area of the top of pole. 18.2 The ends of the prestressing wires shall be out as close to the surface of the pole as possible and in any case shall not project more than 3 mm. 18.3 The ends of the prestressing wires shall be given two coats of suitable anti-corrosive paints approved by the purchaser. 18.4 No touching up or finishing by cement grout etc. shall be done on the poles after it is removed from the moulds. 19. WELDING AND LAPPING OF STEEL The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire. 20. PROVISION OF HOLES & HOOKS Under finalisation 21. TESTS During manufacture, tests on concrete shall be carried out as detailed in clauses 16.2 21.1 of this Specification.

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21.2 Transverse Strength Test 21.2.1 Poles made of ordinary portland cement shall be tested on the completion of 28 days and poles made from rapid hardening cement only on the completion of 14 days after the day of manufacture. 21.2.2 The pole may be tested in either horizontal or vertical position. If tested in horizontal position provisions shall be made to compensate for the overhanging weight of the pole for this purpose the over hanging portion of the pole may be supported on a movable trolley or similar device. 21.2.3 The pole shall be rigidly supported at the butt and for distance equal to the agreed depth of planting. 21.2.4 Load shall be applied at a point 600mm from the top of the pole and shall be steadily and gradually increased to the design value of the transverse load at first crack. The deflection at this load shall be measured. A prestressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. The load shall then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80% of the minimum ultimate transverse load and thereafter increased by 5% of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes. The load applied to prestressed concrete pole at the point of failure and shall be measured to the nearest five kilograms. The pole shall be deemed not to have passed the test if the observed ultimate transverse load is less than the designed ultimate transverse load. 22. SAMPLING AND INSPECTION 22.1 Scale of Sampling 22.1.1 Lot - In a consignment, 500 poles or part thereof of the same mounting height same dimensions and belonging to the same batch of manufacture, shall be grouped together to constitute a lot. 22.1.1.1 Sub-lot: If the number of poles in a lot exceed 500, the lot shall be divided into a suitable number of sub-lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of a sub-lot shall be determined on the basis of the performance of samples selected from it. 22.1.2 The number of poles to be selected from a lot or a sub-lot shall depend upon its size and shall be in accordance with Col. 1 and 2 of the following table: Sample size and criterion for conformity Size of Lot or Sub-lot Dimentional Recruitment Sample Upto 100 101 - 200 201 - 300 301 - 400 Permissible No. Defective sample No. of Poles for transverse strength test

10 15 20 30

1 1 2 3

* 3 4 5

* The number of poles to be tested shall be subject to the agreement between the purchaser and the supplier. 22.1.3 These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any random pole, every rth pole may be included in the sample, r being the integral part or N/n where N is the size of the lot or the sub-lot and n is the sample

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size. 22.2 NUMBER OF TESTS 22.2.1 All the poles as selected in 22.1.2 shall be tested for overall length, cross-section and uprightness. The permissible tolerances shall be within the limits specified in Clause 11(i) of this Specification. 22.2.2 The number of poles to be tested for transverse strength test shall be in accordance with Col. 4 of the table in 21.1.2. These poles may be selected from those already tested in 22.2.1. 22.3 CRITERIA FOR CONFORMITY 22.3.1 A lot or sub-lot shall be considered as conforming to this Specification if the conditions under 22.3.2 and 22.3.3 are satisfied. 22.3.2 The number of poles which do not satisfy the requirements of overall length, cross-section and uprightness shall not exceed the corresponding number given in col. 3 of the Table under clause 22.1.2. If the number of such poles exceeds the corresponding number, all poles in the lot or sub-lot shall be tested for these requirements, and those not satisfying the requirements shall be rejected. 22.3.3 All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more poles fail,twice the number of poles originally tested shall be selected from those already selected and subjected to the test. If there is no failure among those poles, the lot or the sub-lot shall be considered to have satisfied requirements of this test. 23. MARKING The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to easily read after erection in position: a) b) c) d) Month and year of manufacture Transverse Strength of pole in kg. Serial number of the pole Position of centre of gravity of the pole with the word c.g.

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REC Specification 48/1987

12 V BATTERIES FOR SOLAR STREET LIGHTS

FOREWORD REC is promoting a major programme of providing solar street lights in remote villages. The success of this programme depends upon the maintenance-free nature of the installations. The batteries hitherto used for solar street lights require periodical maintenance in the form of topping up of water, which poses a serious problem in remote areas. If proper maintenance is not carried out, the battery life is drastically reduced. Battery technology has made rapid advances over the years and maintenance-free batteries are now available which are especially suitable for solar application. This specification covers technical requirements of this type of batteries. The Specification was approved by the 12th Standardisation Conference of REC held in July, 1987. 1. SCOPE This specification covers the requirements and tests for 12V Pocket-plate Nickel Cadmium (NICAD) and Lead Acid Batteries for use with Street Lights (Floursecent Tubes) operated with Solar Photovoltaic energy. Note : Both types of batteries shall be considered at par provided the requirements of this Specification are met. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the NICAD batteries shall comply with IS:10918-1984 and Lead Acid batteries with IS:1651-1979 or the latest version thereof. Note : Even though IS:1651 relates to Tubular Plate batteries, supplier may offer batteries of a different plate construction provided all the other requirements laid down in this Specification and IS:1651 are complied with. 3. STANDARD RATING The rated Ampere-Hour capacity of NICAD batteries shall be 25AH and that of Lead Acid batteries shall be 60AH. The nominal rated voltage of the battery shall be 12 V. 4. CELL VOLTAGE The nominal voltage of a single cell shall be 1.2 V and 2 V for NICAD and Lead Acid batteries respectively. The NICAD batteries shall consist of 10 cells and the lead acid battery of 6 cells. 5. CAPACITY AT ROOM TEMPERATURE (not exceeding 32o C) 5Amps. for 5 hours for NICAD and 6 Amps. for 10 hours for Lead Acid to an end voltage of not less than 10 volts for NICAD and 11.1V for Lead Acid batteries. 6. CAPACITY AT HIGH TEMPERATURE Battery must be capable of operation at temperatures upto 55o C for prolonged periods. Minimum capacity at this temperature should not be less than 4 Amps. for 5 hours for NICAD and 4.8 Amps. for 10 hrs. for Lead Acid batteries. 7. CHARGING CAPABILITY Due to variation in insulation on the photo voltaic panel, the battery should be designed to maintain full state of charge even at the float voltage level of 14.5 volts. 8. MAINTENANCE AND BATTERY LIFE The battery shall not have a service life of less than 5 years and should not require any maintenance (topping up of water) during this period. The supplier has the option to either offer Sealed batteries or alternatively the battery may have the provision for topping of distilled water but no addition of water shall be necessary for a period of 5 years and subsequent addition of water should result in further increase in life of battery.

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9. VOLTAGE REGULATOR No control device to protect the battery against overcharge or deep-discharge shall be provided by the purchaser. However, if such a device is considered necessary by the supplier of the battery, the same will be supplied alongwith the battery and the price quoted for battery shall be inclusive of such a device. 10. POLARITY MARKING The polarity of the terminal shall be marked for identification. The positive terminal may be identified by 'P' or a (+) sign or red colour mark and the negative terminal be identified by 'N' or (-) sign or blue colour mark. Marking shall be permanent and non-detoriorating. 11. CELL DESIGNATION The practice indicated in IS:10918-1984 for NICAD and IS:1651-1979 for Lead Acid batteries shall be followed. 12. SELF DISCHARGE Self-discharge shall not exceed 0.25% at 25o C per day. 13. NUMBER OF BLOCK The battery shall be preferably supplied as a single 12V block. However, the supplier has the option to offer batteries in multi-blocks in which case the interconnecting links shall be supplied alongwith the blocks. 14. GUARANTEE Batteries covered in this specification shall be purchased under a warranty for free replacement during a period of 3 years from the date of delivery in the event of battery not functioning properly. 15. TECHNICAL DATA OF SPV PANELS Technical data of Solar photovaltaic panels presently in use are given in the Annexure. The type, make and details of SPV panels to be actually used shall be furnished by the user to supplier of the batteries.

LOAD DATA

The street lights shall comprise of 20W flouroscent tubes and are intended to work six hours each day with the help of automatic time switches. 16. MANUAL OF INSTRUCTION A copy of the instruction manual for commissioning and maintenance during service shall be supplied by the manufacturer with every battery ordered. 17. STANDARD ACCESSORIES The following accessories shall be supplied with each set of battery : i) ii) iii) iv) 18. Cell testing voltmeter, 3-0-3 volts scale conforming to IS:1248 part-I-1983 Pair of gloves Insulated spanner for opening terminal nuts Glass funnel (not required for sealed batteries)

PACKING The batteries shall be suitably packed securely in wooden crates suitable for handling during transit by rail/road and secured to avoid any loss or damage during transit.

19.

TESTS The following tests shall be carried out in accordance with IS:10918-1984 for NICAD batteries and IS:1651-1979

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for Lead Acid batteries : Type Test (IS:10918 for NICAD Batteries) a) b) c) d) e) f) g) h) i) j) Physical examination Dimensions, Weight and layout Marking Polarity and absence of short circuit Air pressure test Ampere hour capacity Retention of charge Discharge performance at 55 o C Life cycle test (for atleast 500 cycles at 80% DOD) Insulation resistance

Type Tests (IS:1651 for Lead Acid Batteries) a) b) c) d) f) g) h) Verification of constructional requirement Verification of marking and packing Verification of dimensions Test for loss of capacity on storage Life cycle test (for atleast 500 cycles at 80% DOD as per IS:10918) Ampere hour and watt hour efficiency test Test for voltages during discharge

Note : As the life cycle test takes long time (about 2 years), the purchaser has the discretion to waive this test in the initial stage of manufacture of these batteries in the country provided the supplier furnishes a suitable performance Guarantee in support of Clause 14 of the specification.

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REC Specification 49/1987

SINGLE PHASE RESIN ENCAPSULATED DRY TYPE DISTRIBUTION TRANSFORMERS

FOREWORD During the discussion in the 12th Standardisation Conference of REC, the use of small rating distribution transformers with shorter LT lines was recommended. However, due to inherent design problems, the reliable and sturdy transformers with less than 25 KVA capacity cannot be manufactured and hence small single phase transformers of 6.3,10 and 16 KVA were recommended for use with phase- to-earth system and phase-to-phase system. The use of smaller distribution transformers will reduce the length of LT lines which is a major cause of LT line losses and LT faults which mostly reflect directly on the distribution transformer causing failures. This specification is issued based on the discussions/decisions of the 12th Standardisation Conference. 1. SCOPE The specification covers outdoor type, single-phase 50 Hz, Resin Encapsulated Dry Type Distribution Transformers suitable for use in rural electrification system. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, these transformers shall comply with the latest versions of IS:2026, IS:1180 and IS:11171-1985. 3. STANDARD RATINGS

The standard ratings shall be 6.3, 10 and 16 KVA for KVA for 11 KV (Phase-to-Phase) transformers. 4.

11/3 KV

(phase-to-Neutral) transformers and 10 & 16

NO LOAD VOLTAGE RATIO The no load voltage ratio shall be one of the following as required : i) ii)

11/3 KV/440-220V (Phase-to-Neutral single phase system)

11KV/440-220V (Phase-to-Phase single phase system)

5.

WINDING CONNECTIONS Winding connections for the transformers referred to in clause 4 above shall be as shown in figures 1 & 2. The transformers for phase-to-neutral system shall have only one HV bushing and those intended for use in phase-tophase system shall have two HV bushings. In the former case, the other end of HV winding shall be brought out through a suitable bushing (LV bushing may be used for this purpose) which shall be externally earthed. A solid inter-connection (external) shall be provided by the manufacturer between HV earth bushing and the transformer tank. 6. CORE AND WINDING The transformer core shall have wound type construction using high quality CRGO Steel. The core 6.1 shall be coated with resin for protection against corrosion. All iron parts except the core shall be hot-dip galvanised. Both high and low voltage windings shall be either cast under vacuum into moulds of fibre-glass 6.2 reinforced epoxy to form rigid tubular coils or alternatively, the windings are fully encapsulated in thick layer of epoxy resin by vapour pressure impregnation process. The windings shall be such as not to absorb any moisture and shall be suitable for tropical climate and 100% humidity. 6.3 7. The core and winding assembly shall be fully weather proof and moisture-proof.

TAPS No taps are to be provided in these transformers. COOLING MEDIUM The cooling shall be of AN type. TANK

8.

9.

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The tank shall be made of mild steel and shall have adequate ventilation for cooling the transformers. The enclosure shall conform to IP 34 class of protection. The tank cover shall have plasticised surface at the top to guard against birdage faults. Alternatively, suitable insulating shrouds shall be provided on the bushing terminals. 10. BUSHING TERMINALS The bushing stems/terminals for both HV and LV shall be made of suitable aluminium alloy and shall be so designed as to directly receive aluminium stranded conductors (upto 7mm dia) with bolted type clamping arrangement both in horizontal and vertical directions. Details of this arrangement are shown in the appendix. 11. FITTINGS The following standard fittings shall be provided : a) Two earthing terminals b) Two lifting lugs c) Rating and terminal marking plate(s) as per clause 13 below d) Hot line connectors for making connection(s) to the HV line (one each for phase-to neutral transformers and two each for phase-to-phase transformers) 12. MOUNTING ARRANGEMENT 12.1 The transformers of 6.3 and 10 KVA ratings shall be provided with two mounting lugs (as shown in figure 3) suitable for fixing the transformers to a single pole by means of two bolts of 20mm dia. 12.2 In the case of 16 KVA transformers, the under-base shall be provided with two 75x40 mm channels, 460 mm long, with 14mm dia holes to make them suitable for fixing on a platform or plinth. The arrangement and dimensional details are shown in Fig. 4 for fixing on a platform or plinth. 13. RATING AND TERMINAL MARKING PLATE The transformers shall be provided with non-detachable rating and terminal marking plate(s) of weatherproof material fitted in a visible position and showing the complete information as given in clause 8.1 of IS:111711985.

14.

LIMITS OF TEMPERATURE RISE When tested in accordance with IS:2026, the temperature rise (measured by resistance method) in windings shall not exceed the following limits above ambient air temperature of 40oC. Temperature class of Insulation B F H Temp. Rise 700C 900C 1150C

The purchaser shall however, satisfy himself about the type of insulation used and its conformity to the particular class of insulation. 15. LOSSES AND IMPEDANCE VALUES 15.1 No-load and load losses shall not exceed the following values :

11/3 KV/440-220V Transformers

Capacity No-load loss (watts) 45 55 70 Load loss at 750C (watts) 170 225 285

11 KV/440-220V Transformers Capacity No-load loss (watts) 70 85 Load loss at 750C (watts) 210 250

6.3KVA 10 KVA 16KVA

10KVA 16KVA

Note : The above loss values are provisional and will be reiewed on the basis of actual experience. These losses are the maximum allowable and there would not be any plus tolerance. No weightage in prices for offers with lower losses shall be given for these transformers.

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15.2 16. The recommended percentage impedence at 75oC is 4% with a tolerance of ( + ) 10%.

OVER FLUX In the transformer core, over flux shall be limited to 12.5% to ensure that, in the event of over-voltage to the extent of 12.5%, the core does not get saturated. The supplier shall furnish necessary design data in support of this stipulation. LT CIRCUIT BREAKER 17.1 The transformer shall be fitted with a LT Moulded Case Circuit Breaker (MCCB) of suitable capacity to protect it from over-loads and short circuits on the secondary side. The circuit breakers shall have 2-pole construction with a provision to close or trip both the poles (phases) simultaneously. MCCB shall be mounted externally in the LT enclosure (conforming to IP 34 class of protection as per IS:2147) forming an integral part of the transformer. A suitable insulating shield shall be provided at the back of the enclosure to minimise transfer of heat from the transformer tank to the circuit breaker enclosure. 17.2 Suitable insulated connecting leads shall be provided in the enclosure from the LT bushings to the incoming terminals of the LT Circuit Breaker in such a way as to avoid bimetallic corrosion. A separate set of outdoor type LT Bushings shall be provided on the LT enclosure for connection to the outgoing cables of the Utility. Suitable insulated leads shall be provided within the LT enclosure to connect the outgoing terminals of the MCCB to the external LT bushings. The design of bushings stems shall be such as to directly receive the outgoing aluminium cables upto 7mm dia without requiring the use of lugs (refer appendix). The LT circuit breaker shall be capable of being operated from the ground level by means of an 17.3 operating rod. For this purpose, a suitable hook shall be provided on the transformer in a suitable position for easy and safe operation of the circuit breaker from the ground level. The design of the operating mechanism of the circuit breaker shall be such that it shall have only two positions, i.e. ON and OFF; it shall not require resetting before being switched to ON position. 17.4 The circuit breaker shall have the following time/current characteristics : Multiple of full load current of transformer 1.05 1.2 1.3 1.4 2.5 4.0 6.0 12.0 Tripping time More than 2.5 hours More than 10 minutes but less than 2 hours Less than 30 minutes Less than 10 minutes Less than 1 minute Not less than 2 seconds Less than 5 seconds Instantaneous (less than 40 mill seconds)

17

Time/current characteristic of the circuit breaker shall be tested in accordance with clause 7.7.2.3 (b)(2) of IS:2516 (Part I & II/Sec. I)/1985 or its latest version. For the time/current characteristic, the reference calibration temperature of the circuit breaker shall be 50oC. 17.5 The rated short circuit breaking capacity of the circuit breaker shall not be less than 2.5 KA based on the short-circuit test carried out as per P-2 duty in accordance with IS:2516 but at a power factor of 0.4 (lagging) or less. All other electrical/mechanical characteristics as also the test requirements of LT Circuit Breakers shall 17.6 conform to IS:2516 (Part-I & II)/Section I/1985 or its latest version. 18. APPLICATION Single-phase transformers are normally intended for making available single phase supply to the 18.1 consumers at 220V. For meeting isolated demand for motive loads, either single phase motors will have to be used or 3-phase motors can be operated by making use of Phase-Converters.

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In areas having predominant demand for motive loads, it is more appropriate to use two single phase 18.2 transformers in open delta connections as shown in figure 5 & 6. In the case of phase-to-neutral system, the 11 KV spur lines will comprise of two phase conductors and one neutral conductor whereas in phase-to-phase system, the spur lines shall be normal 3-phase lines. In the former case, load in the main 11 KV line should be suitably balanced by tapping spur lines from different phases. 19. TESTS 19.1 Routine Tests : All the transformers shall be subjected to the routine tests at the manufacturers works. The following routine tests shall be carried out in accordance with IS:2026 (or as agreed upon between the purchaser and the manufacturer) except the partial discharge test, which shall be carried out as per IS:6209 : a) Measurement of winding resistance b) Measurement of voltage ratio and check of voltage vector relationship c) d) e) f) g) h) 19.2 a) i) j) k) Measurement of impedance voltage, short circuit impedance and load loss Measurement of no-load loss and no-load current Measurement of insulation resistance Separate source voltage withstand test Induced over-voltage withstand test Partial discharge test (25 PC max.) Type Tests : The following shall constitute the type tests : to (h) as per clause 19.1 above Lightning impulse voltage withstand test Temperature rise test Short-circuit test

19.3 The supplier shall furnish calculations in accordance with IS:2026 to demonstrate the thermal ability of the transformers to withstand short circuit. INSPECTION All tests and inspection shall be made at the place of manufacturer unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply. 20.

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REC Specification 50/1987 (Revised- 1997) SINGLE PHASE DISTRIBUTION TRANSFORMERS (OIL FILLED) FOREWORD In the 12th Standardisation Conference of REC, the use of small rating distribution transformers with shorter LT lines was recommended. However, due to inherent design problems, reliable and sturdy transformers with less than 25KVA capacity cannot be manufactured in 3-phase configuration and hence small single phase transformers of 6.3, 10 and 16 KVA were recommended for use with phase to earth system and phase-to-phase system. The use of smaller distribution transformers will reduce the length of LT lines which is a major cause of LT line losses and LT faults which mostly reflect directly on the distribution transformers causing their failure . Accordingly, a specification was issued for single phase transformers based on the discussions/decisions of the 12th Standardisation Conference. Subsequently during the 14th Conference on Standardisation and Technical Development held on 25th April, 1997, in New Delhi, it was decided that the specification for single phase transformers should cover transformers of all types of cores ( CRGO, Amorphous, Hi-B). The Conference also recommended that the secondary voltage of the transformer be revised to 250 volts and for simplicity of design, single voltage secondary (250 V) should be used instead of double voltage(440 V- 220 V). The rated voltage of the transformers in the earlier issued REC Specification was 11/ 3KV/440V220V (for phase-to-neutral system) and 11 KV/440V220V (for phase-to-phase system), but the national declared voltage is 415V for three phase and 240V for single phase. Due to the non-standard voltages of single phase transformers some of the Boards especially APSEB, which is the largest user of the single phase system, were facing problems when it came to the standard voltage rating of single phase motors to be used along with agricultural pumpsets. To overcome this problem, the specification for single phase transformers has been revised to make the voltage ratio of distribution transformers as 11/ 3 KV/250V and 11 KV/250V for phase-to-neutral and phase-to-phase systems respectively. The single phase motors can now be designed for rated voltage of 240V which is in line with the national declared voltage. The secondary voltage of 250 V is also in line with REC Specification No.2/1971 (R1993) for three phase distribution transformers. It may also be noted that with the revised voltage ratio, it will not be possible to feed 3-phase loads by connecting 2 single phase transformers in open delta, as was possible with the previous rating specified (before revision). The Conference also decided that the rating of 6.3 KVA, being uneconomical, may be deleted. Based on the above recommendations, the specification for single phase transformers has been revised and issued. 1. SCOPE This specification covers oil-immersed, naturally cooled, single phase, 50HZ, outdoor type sealed/non-sealed distribution transformers for use in rural electrification system. 2. APPLICABLE STANDARDS Unless otherwise modified in the specification, the single-phase distribution transformers shall comply with the Indian Standard Specification IS : 1180 and IS : 2026 as amended from time to time. 3. STANDARD RATINGS The standard ratings shall be 10 and 16 KVA for both (Phase-to-Phase) transformers.

11/3

KV (phase-to-neutral) transformers and 11 KV

4. NO-LOAD VOLTAGE RATIO The no-load voltage ratio shall be one of the following as required. i) 11/ 3 KV/250 V (Phase-to-neutral single phase system) ii) 11KV/250 V (Phase-to-phase single phase system) 5. WINDING CONNECTIONS Winding connections for the transformers referred to in clause 4 above shall be as shown in figures 1 and 2. The transformers for phase-to-neutral system shall have only one HV bushing and those intended for use in phase-to-phase system shall have two HV bushings. In the former case, the other end of HV winding shall be brought out through a suitable bushing (LV bushing may be used for this purpose) which shall be externally earthed. A solid inter-connection (external) shall be provided by the manufacturer between HV earth bushing and the transformer tank. All bushings shall conform to IS : 1347 and 2099. The bushings shall not have arcing horns. 6. CORE AND WINDINGS 6.1 Transformer core shall have wound type construction. The core shall be properly annealed to relieve stresses.

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6.2 Since the Govt. of India, Ministry of Industry, New Delhi vide its letter No.19/(53)/93-EL Ind. dated 13-4-94 has allowed the use of copper winding also, the SEB may specify use of either aluminium or copper winding for these transformers depending on their economic advantage. 6.3 Unless otherwise specified, DPC insulation shall be used for HV and LV winding wires and electrical grade plain insulation Kraft paper for interleaving. In case PVA enamelled conductor is used for HV/LV winding, electrical grade epoxy dotted thermally upgraded Kraft paper shall be used for interlayer insulation. 6.4 The core and coil assembly shall be securely held in position to avoid any movement under short-circuit conditions. 7. TAPS No taps are to be provided on these transformers. 8. TRANSFORMER TANK 8.1 The Transformer tank should be round and made of good quality steel sheet of adequate thickness suitably stiffed to provide sturdy and robust construction to withstand extreme pressure conditions. The tank should be capable of withstanding pressure as per values specified in IS : 1180 (Part - I) for non-sealed type and IS : 1180 (Part - II) for sealed type transformers. 8.2 The tank cover shall have plasticised surface at the top to guard against birdage faults. Alternatively, suitable insulating shrouds shall be provided on the bushing terminals. 8.3 For Sealed Transformers 8.3.1 Sealing of the transformer cover shall be achieved by providing a continuous ( without break) oil resistant high quality nitrile rubber gasket on the top of the tank rim and the cover should be suitably clamped to provide a uniform pressure on the rubber seal. 8.3.2 The space on the top of the oil shall be filled with dry air. The dry air plus the oil volume inside the tank shall be such that even under the extreme operating conditions, the pressure generated inside the tank does not exceed 40 Kpa positive or negative. 8.3.3 Pressure Relief Device: The transformer shall be provided with suitable pressure relief device to release pressure under fault conditions. Alternatively, self-venting type of cover assembly shall be used to serve the purpose. 9. BUSHING TERMINALS The bushing stems/terminals for both HV & LV made of suitable aluminium/copper alloy shall be so designed as to directly receive aluminium stranded conductors upto 7mm dia, with bolted type clamping arrangement both in horizontal and vertical directions. In case of copper/copper alloy stems, suitable bimetallic clamps with bolted type arrangement described above shall be used. Details of these arrangements are shown in the Appendix. (Fig. 4, 5, 6, 7 for Aluminium Alloy Stem and Fig. 8 for copper/copper alloy stem). 10. FITTINGS The following standard fittings shall be provided for both sealed and non sealed type transformers : a) Two earthing terminals b) Two lifting lugs c) Rating and terminal marking plate(s) as per clause 12 of this specification. d) Hot line connectors for making connection(s) to the HV line (one each for phase-to-neutral transformer and two each for phase-to-phase transformer) as per REC Construction Standard E-37. 10.1 Fittings for Non-sealed Type Transformers only : a) Plain breathing device comprising an inverted Upipe with wire gauze at the open end (to prevent entry of insects) or silica gel breather as required by the purchaser. b) Drain-cum-sampling valve (steel) welded to the tank. Special tool for operating this valve shall be supplied with the transformer. c) Oil filling hole, with cover having 1 nominal size threads on the transformers body. d) Oil level gauge indicating three positions of oil at minimum (5o C), 30o C, maximum (98o C). 10.2 Fittings for sealed type transformers only a) Nitrogen/air filling device/pipe with welded cover capable of reuse. b) An extended pipe for filling of oil at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing the welded cover.

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11. MOUNTING ARRANGEMENT The transformer shall be provided with two mounting lugs (as shown in figure 3) suitable for fixing the transformer to a single pole by means of two bolts of 20 mm dia. 12. RATING AND TERMINAL MARKING PLATE The transformer shall be provided with non-detachable rating marking plate(s) of weather proof material, fitted in a visible position and showing the complete information as given under clause 20 of IS : 1180 (Part I) 1989. 13. LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limits of 55o C (measured by resistance) for transformer windings and 45o C (measured by thermometer) in top oil above the ambient temperature of 40o C, when tested in accordance with IS : 2026. 14. LOSSES AND IMPEDENCE VALUES 14.1 The suppliers shall furnish the maximum guaranteed values of no load and load losses with no plus tolerance. The offers shall be evaluated on the basis of capitalisation of losses as per the REC standard on the same.

14.2 The percentage impedance at 75o C shall not exceed 4%

15. OVERFLUX In the transformer core, over flux shall be limited to 12.5% to ensure that in the event of over-voltage to the extent of 12.5%, the core does not get saturated. The supplier shall furnish necessary design data in support of this stipulation. 16. APPLICATION Single phase transformers are normally intended for making available single phase supply to the consumer at 240 V. For meeting isolated demand for motive loads, either single phase motors will have to be used or 3phase motors can be operated by making use of phaseconverters. 17. TESTS 17.1 Routine tests : All transformers shall be subjected to the following routine tests at the manufacturers works and in accordance with IS : 2026 and IS : 1180 (Part - I & II) (or as agreed upon between purchaser and the manufacturer). a) Measurement of winding resistance b) Measurement of voltage ratio and check of voltage vector relationship c) Measurement of impedance voltage/short-circuit impedance and load loss d) Measurement of no-load loss and no load current. e) Measurement of insulation resistance f) Induced over voltage withstand test g) Separate source voltage withstand test h) Air Pressure Test (IS : 1180 (Pt II), Cl : 21.5.1) for sealed transformers only. 17.2 Type Tests : The following type tests shall be made on the transformers as per details given in IS : 2026: a) to (g) as indicated under routine tests h) Lightning impulse test i) Temperature rise test j) Shortcircuit test k) Air Pressure test : As per IS : 1180 (Pt I) Clause : 22.5 for Non-sealed type As per IS : 1180 (Pt II) Clause : 21.5.1 for sealed type. 17.3 The supplier shall furnish calculations in accordance with IS : 2026 to demonstrate the thermal ability of the transformers to withstand short circuit. 18. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that material is being furnished in accordance with the specification. The purchaser has the right to have tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.

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REC Specification 51/1987 EPOXY BASED PROTECTIVE PAINT FOREWORD The SEBs are commonly using Aluminium paint on the steel structures for protection against rust as also for better appearance. Aluminium paint is, however, not a good protective coating and the structures are, therefore, required to be repainted periodically and even so adequate protection against rust or other forms of corrosion is not obtained, thereby reducing useful life of the structures. After carefully examining the practices followed abroad and the indigenous availability, REC has brought out this Specification for a special protective coating which can be used even in highly corrosive atmosphere. The paint covered in this Specification is suitable for both new and old structures such as poles, cross arms, sub-station structures etc. One of the advantages of this paint is that it is not necessary to thoroughly clean the steel surface before use and normal cleaning by wire brush will be adequate. This specification was sent for wide circulation to all the SEBs in Jan., 1987 and has been approved by the 12th Conference on Standardisation, Technical Development & Training held at New Delhi on 30.7.1987. 1. SCOPE This specification covers the requirement of self-priming epoxy-based protective paint both for new and old steel structures such as poles, sub-station structures etc. COMPOSITION The paint shall be epoxy-based with metallic zinc as an essential component. The paint shall be supplied in two components and shall be suitable for a single coat application. It shall have such composition as to satisfy the requirements of this standard. The mixing ratio (base-to-accelerator) shall be specified by the manufacturer. REQUIREMENTS 3.1 3.2 3.3 3.4 Volume Solids Theoretical covering Capacity Weight per 10 litres of mixed paint Drying time (at 30 OC) dry 85% ()3% 6.5 sq. mtrs. per litre at 125 microns dry film thickness 14 to 15 Kg. () 0.3 kg Surface : Not more than 4 hours Hard Dry 16-18 hours Recoating Time: 16-18 hours Curing time : 7 days :

2.

3.

3.5 3.6 3.7 3.8

Scratch hardness (with 1.5 kg.load) Finish Colour Dry Film Thickness

No such scratch as to show the base metal Smooth and semi-glossy Ash Grey or Aluminium (as required) The paint shall develop a dry film of minimum 100-125 microns in a single coat (measured by Elcometer)

3.9 3.10 3.11 3.12

Flash point Flexibility and adhesion Resistance to humidity Resistance to lubricating oil petroleum, hydrocarbon solvent, petrol and heat

Not below 40 OC The paint shall not show damage, detachment or cracking. Shall pass 1000 hours (minimum) at 125 microns D.F.T Shall show no sign of permanent injury

4.

STORAGE LIFE & POT LIFE 4.1 Storage life Minimum 6 months from the date of manufacture in original sealed container under normal covered storage

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conditions 4.2 Pot life (at 30OC) Not less than 4 hours

5.

DURABILITY Under severe surface conditions, paint shall protect the substrate at least for 5 years, if it is wire-brushed/power tool cleaned and 7 years for commercially grit-blasted steel sub-strate. SURFACE PREPARATION If possible, the surface on which the paint has to be applied shall be cleaned by grit blasting, otherwise manual wire brushing or power tool cleaning process may be used as convenient. METHOD OF APPLICATION Brushing, rollers or spraying. TESTS The following tests shall be carried out in accordance with the procedure given in the Indian Standard quoted against each, except requirements stipulated in clauses 3.1 and 3.2 which shall be tested in accordance with the procedure indicated in Annexure-II; preparation of painted panels for conducting different tests shall be done as given in Annexure-I. 8.1 Requirement stipulated in clauses 3.3 to 3.12 8.2 Resistance to Salt Spray Shall pass 1000 hours (minimum with 200 microns D.F.T.) 8.3 Chemical Resistance Shall be resistant to acid/alkaline chemicals or solvents IS:101 IS:2074 IS:8662

6.

7.

8.

9.

PACKAGE Unless otherwise specified by the purchaser, the paint shall be normally supplied in 2 litre packs.

Annexure I DETAILS OF PREPARATION OF PAINTED PANELS FOR TESTING EPOXY BASED PROTECTIVE PAINT ( TWO PACKS) S. N. Test Type of Metal 3 Mild Steel Size in mm Painting Details Dry Film Thickness Method of Application Duration of air drying before commencement of test 8 Special Instructions

1 1

2 Drying Time

4 150x100x1.25

5 One coat of Epoxy based protective paint -do -do -do-

6 100

7 Brush /Spray

9 -

-do 2 3 4 Finish Colour Dry Film Thickness Flexibility and adhesion Scratch Hardness -do 7 days -do -do -do -do -do -do -do -do -do-do -do -do5 Tinned 150x150x0.315 -do -do-do 6 -do -do -do-do -do Apply a load of 1.5 Kgs. Instead of 1 kg. As specified in Col.15.1 of IS: 101 64 7 days 24 hours 24 hours 48 hours -

7 Resistance to Salt Spray

Mild Steel

150x150x1.25

-do

200

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8 Protection against corrosion under conditions of condensation ANNEXURE-II - do - do -do125 - do - do -

Procedure for determining volume solids

1. Scope : This method is applicable to the determination of the volume non-volatile matter of paint coatings.

2. Significance : This method is intended to provide a measure of the volume of dry coating obtainable from a given volume of liquid coating. This volume is considered to be the most equitable means of comparing the coverage (square metre of surface covered at a specific film thickness per unit volume) and also for calculating the wet film thickness of the given paint. 3. Apparatus i) Analytical Balance ii) Steel disc : Preferably stainless steel, 60mm dia, and 0.70mm thickness with a small hole 2 to 3mm from the edge. A fine wire such as chromel is attached through the hole and madeof the appropriate length for suspending the disc in a liquid. iii) Weight Box iv) Beaker : 1 litre for weighing the disc in liquid. v) Weight per litre cup for determining the specific gravity of the paint material and of the suspending liquid if not known. vi) Oven Procedure Dry the disk in an oven at 1050C for 10 minutes and cool. Weigh the disk in air, let it be W1 grams. Suspend the disk in water and weigh again. Let it be W2 grams. Calculate the volume of disk V as follows:

4. i) ii) iii) iv)

V = W1-W2/d where d is the density of the water at room temperature v) Determine the weight of non-volatile content per gram of the liquid coating material by drying a known amount of paint at 1050C for 3 hours. Let it be W grams. vi) Determine the specific gravity of the paint to the nearest 0.001 g/ml. by using weight per liter cup. Let it be p. vii) Dip the disk in the paint sample for 10 minutes, and take out the disc and allow the excess coating material to drain off. Blot the coating material off the bottom edge of the disc so that beads or drops do not dry on the bottom edge of the disc. viii) Dry the disc in oven for 3 hours at 1050 C and cool. ix) Weigh the coated disc in air. Let it be W3 grams. x) Suspend the coated disc in water and weigh it. Let it be W4 grams. xi) Calculate the volume of the coated disc as follows: V1 = W3-W4/d, where d is the density of the water at room temperature. xii) Calculate the volume of the dried coating as follows: Volume of dried coating (Vd) = V1-V xiii) Calculate the volume of the wet coating as follows: Vw = W3-W1/WxP , where W = grams of non volatile matter in one gram of wet coating

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P= Specific gravity of the paint. xiv) Calculate the percentage volume solids of the paints as follows: = V1 Vx100 Vw or Vdx100 Vw

The volume of non volatile matter or the percentage volume solids of a paint is related to the covering capacity and film thickness in the following manner: a) Theoretical Coverage (m2/1) % volume solids x 10 Dry film thickness (in microns) b) Wet film thickness (in microns) = Dry Film thickness x 100 (in microns) % volume solids. =

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REC Specification 52/1987 33KV SWITCH ISOLATORS FOREWORD At present, the quality of 33 KV Switch Isolators used at the sub-stations is invariably not up to the mark. In many cases, the isolators are still being procured according to old IS:4710-1968, which has since been revised and superceded by IS:9920 (Alternating Current Switches for Voltages above 1000 V). The new standard takes into account the technological improvements which have taken place over the years and it also recognises the fact that, even though these isolators are intended for off load duty, these are sometimes required to break the no load current of power transformers. IS:9920, therefore, stipulates certain minimum breaking current rating considered necessary for long life and better performance of the isolators. Based on the above consideration, a new specification for 33KV Switch Isolators was formulated, which was approved by the12th Standardisation Conference held in July, 1987. 1. SCOPE This specification covers 33 KV, 50 Hz, alternating current switch-isolators for outdoor installation for use at 33/11 KV sub-stations. 2. APPLICABLE STANDARD Unless otherwise stipulated in this specification, the switch-isolator shall conform to IS:9920 (Parts I to IV). RATED VOLTAGE The rated voltage shall be 36 KV. RATED NORMAL CURRENT The rated normal current shall be 630 A. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE i) ii) To earth and between poles Across the isolating distance = 170 KV (Peak) = 195 KV (Peak)

3.

4.

5.

6. i) ii) 7.

RATED ONE-MINUTE POWER FREQUENCY WITHSTAND VOLTAGE (KV) To earth and between poles Across the isolating distance = 70 KV (rms) = 80 KV (rms)

TEMPERATURE RISE The temperature rise shall not exceed the maximum limits specified below : Temperature rise limit at Ambient Air Temperature not exceeding 400C

Copper contacts (Silver - faced) in air Terminals of switches to be connected to external conductors by bolts 8.

650C 500C

RATED SHORT-TIME CURRENT The rated short-time current shall be 16 KA (rms) for 1 second. RATED PEAK WITHSTAND CURRENT The rated peak withstand current shall be 40 KA (Peak). TRANSFORMER OFF-LOAD BREAKING CAPACITY The transformer off-load breaking capacity shall be 6.3A(rms). LINE CHARGING BREAKING CAPACITY The line charging breaking capacity shall be 6.3A (rms). CONSTRUCTIONAL FEATURES

9.

10.

11.

12.

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The switch-isolator shall be manually-operated, triple-pole, centre-post-rotating type with double-break 12.1 operation. It shall be suitable for horizontal mounting arrangement. 12.2 All current carrying parts shall be made of silver faced 90%electrolytic copper. The arcing contacts shall be made of phosphor bronze and shall have spring assisted operation. The switch isolator shall have a spring mechanism so as to ensure that speed of opening of contacts is independent of speed of manual operation. The switch-isolator shall be provided with six 24 KV post insulators per pole (total 18 insulators) 12.3 conforming to IS:2544-1973 and IS:5350 (Pt .III)-1971 as amended from time to time. Six bimetallic connectors shall be provided on the incoming and outgoing sides to directly receive ACSR 12.4 sizes 10-15 mm diameter without the use of lugs. The connectors shall be suitable for current ratings as stipulated in clauses 4 and 8 of this specification and shall conform to all the test requirements of IS:5561. 12.5 The frame of each switch-isolator shall be provided with a separate earthing terminal for each phase for connection to an earthing conductor having a clamping bolt of not less than 12 mm dia. The terminal shall be marked with Earth symbol. 12.6 The switch-isolator shall have a pad-lock arrangement both for ON and OFF positions.

The vertical operating rod shall comprise of 40 mm (nominal bore) Galvanised Steel Tube (medium class) 12.7 as per IS:1161-1979. Length of the operating rod shall depend upon the mounting position of the isolator (exact length of the rod to be specified by the purchaser). Operating handle shall be fixed to the concrete structures approx. 1 metre above the ground level. Provision shall be made for the earthing of operating handle only through the flexible copper strap 12.8 connected to the supporting metallic structure. 12.9 The switch-isolator shall open when operating handle is pulled downwards and the switch-isolator shall close when the operating handle is moved upwards. 12.10 The rotating parts, i.e. bell crank lever and fork etc. shall be either forged or made of mild steel (castcomponents shall not be used).. 12.11 Tubes shall be galvanised in accordance with IS:4736-1968 and other metal parts shall be hot dip galvanised. 12.12 Phase clearance i.e. centre-to-centre distance between the insulators of adjacent phases in the assembled position of the isolator shall be 1200 mm. 12.13 The centre-to-centre distance between insulators of the adjacent poles of the same phase in the assembled position of the switch shall be 400 mm. 12.14 All the post insulator stacks, except the central rotating stacks, shall be provided with arcing horns made of 10mm GI rod. 12.15 All similar materials and removable parts of similar equipment shall be interchangeable with each other. 13. INTERLOCKING ARRANGEMENT When required by the purchaser, the isolator shall be provided with a suitable mechanical interlocking arrangement with the associated circuit breaker and other equipments in the sub-station. 14. TYPE TESTS The switch isolators shall be subjected to the following type tests in accordance with IS:9920 : i) Dielectric test (Impulse and one-minute wet power frequency with stand voltages) ii) Temperature rise test (for contacts & terminals) iii) Rated short-time current and Rated Peak Withstand Current tests iv) Operation and mechanical endurance test v) Transformer off-load breaking capacity test vi) Line charging breaking capacity test ROUTINE TESTS The equipment shall be subjected to the following routine tests : i) Power-frequency voltage dry test ii) Measurement of resistance of the main circuit iii) Operating test

15.

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16. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed 16.1 upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency 16.2 whenever there is dispute regarding the quality of supply.

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REC Specification 53/1987 11 KV DROP OUT FUSE CUT OUTS FOREWORD Even though 11 KV Drop-Out Fuse Cut-Outs are widely used for protection/isolation of distribution transformers, their quality is invariably not up to the mark. This Specification not only stipulates the electrical and mechanical requirements of good quality drop-out fuse cutouts but also specifies important constructional features to ensure uniformity and proper quality. This Specification was approved by the 12th Standardisation Conference held on July 30,1987. 1. SCOPE This specification covers outdoor, open, drop-out expulsion type Fuse Cutouts suitable for installation in 50 Hz, 11 KV distribution system. 2. APPLICATION The distribution fuse cutouts are intended for use in distribution transformers and have no inherent load break capacity. 3. APPLICABLE STANDARD Unless otherwise modified in this specification, the cutout shall conform to IS:9385 (Part-I to III) as amended from time to time. 4. RATED VOLTAGE The rated voltage shall be 12 KV. RATED CURRENT

5.

The rated current shall be 100 A. 6. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE VALUES FOR THE FUSE BASE The rated lightning impulse withstand voltages both for positive and negative polarities shall be as given below: a) To earth and between poles 75 KV (Peak) b) Across the isolating distance of fuse base 85 KV (Peak) 7. RATED ONE MINUTE POWER FREQUENCY WITHSTAND VOLTAGE (DRY & WET) VALUES a) To earth and between poles b) Across the isolating distance 8. TEMPERATURE RISE LIMIT (In Air) a) Copper contacts silver faced b) Terminals c) Metal parts acting as springs. 65oC 50oC The temp. shall not reach such a value that elasticity of the metal is changed. 28 KV (rms) 32 KV (rms) FOR THE FUSE BASE

9.

RATED BREAKING CAPACITY

The rated breaking capacity shall be 8 KA (Asymmetrical). 10. GENERAL REQUIREMENTS/CONSTRUCTIONAL DETAILS 10.1 The cutouts shall be of single vent type (downward) having a front connected fuse carrier suitable for angle mounting. 10.2 All ferrous parts shall be hot dip galvanised in accordance with the latest version of IS:2633. Nuts and bolts shall conform to IS:1364. Spring washers shall be electro-galvanised. 10.3 11. Typical constructional details of the fuse cutout are shown in Fig. 1.

FUSE BASE TOP ASSEMBLY

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11.1 The top current carrying parts shall be made of a highly conductive copper alloy and the contact portion shall be silver plated for corrosion resistance and efficient current flow. The contact shall have a socket cavity for latching and holding firmly the fuse carrier until the fault interruption is completed within the fuse. The top contact shall be actuated by a strong steel spring which keeps it under sufficient pressure to 11.2 maintain a firm contact with the fuse carrier during all operating conditions. The spring shall also provide flexibility and absorbs most of the stresses when the fuse carrier is pushed into the closing position. 11.3 The current carrying parts of the assembly shall be protected from water and dust formation by a stainless steel top cover. The top contact assembly shall have a robust galvanised steel hook to align and guide the fuse carrier 11.4 into the socket latch even when the fuse carrier is closed at an off-centre angle. 11.5 The top assembly shall have an aluminum alloy terminal connector (refer clause 19).

11.6 The top assembly shall be robust enough to absorb bulk of the forces during the fuse carrier closing and opening operations and shall not over-stress the spring contact. It shall also prohibit accidental opening of the fuse carrier due to vibrations or impact. 12. FUSE BASE BOTTOM ASSEMBLY 12.1 The conducting parts shall be made of high strength highly conductive copper alloy and the contact portion shall be silver plated for corrosion resistance and shall provide a low resistance current path from the bottom fuse carrier contacts to the bottom terminal connector. 12.2 The bottom assembly shall have hinge contacts made from highly conductive, anti-corrosive copper alloy and shall accommodate and make a firm contact with the fuse carrier bottom assembly. The fuse carrier shall be placed easily in or lifted from The hinges without any maneuvering. In addition, the bottom assembly shall perform the following functions :i) When opened manually or after fault interruption the fuse carrier shall swing through 180o to the vertical and its further travel shall be prevented by the fuse base bottom assembly. ii) The fuse carrier shall be prevented from slipping out of the self locking hinges during all operating conditions and only when the fuse carrier has reached its fully open position can it be removed from the hinge support. 12.3 13. The assembly shall have an aluminium alloy terminal connector (refer clause 19).

FUSE CARRIER TOP ASSEMBLY 13.1 The fuse carrier top contact shall have a solid replaceable cap made from highly conductive, anti-corrosive copper alloy and the contact portion shall be silver plated to provide a low resistance current path from the Fuse Base Top Contact to the Fuse Link. It shall make a firm contact with the button head of the fuse link and shall provide a protective enclosure to the fuse link to check spreading of arc during fault interruptions. 13.2 The fuse carrier shall be provided with a cast bronze opening eye (pull ring) suitable for operation with a hook stick from the ground level to pull-out or close-in the fuse carrier by manual operation.

14.

FUSE CARRIER BOTTOM ASSEMBLY The fuse carrier bottom assembly shall be made of bronze castings with silver plating at the contact 14.1 points to efficiently transfer current to fuse base. It shall make smooth contact with the fuse base bottom assembly during closing operation. 14.2 14.3 i) The bottom assembly shall have a lifting eye for the hook stick for removing or replacing the fuse carrier. The bottom assembly shall have a suitable ejector which shall perform the following functions : It shall keep the fuse link in the centre of fuse tube and keep it tensioned under all operatingconditions.

ii) It shall be capable of absorbing the shock when the fuse carrier is pushed into the closed position and shall not allow the fuse link to be damaged. This is specially important when the fuse link is of low-ampere rating. iii) The ejector at the instant of interruption shall retain the fuse carrier in the closed position long enough to ensure that the arc is extinguished within the fuse tube thereby excluding the possibility of arcing and subsequent damage at the contact surfaces. iv) The ejector shall help the fuse link separation after fault interruption, allowing the fuse carrier to drop out and clearing the pigtail of the blown fuse link through the bore of fuse tube.

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FUSE BASE (PORCELAIN) The fuse base shall be a bird-proof, single unit porcelain insulator with a creepage distance (to earth) not less than 320mm. The top and bottom assemblies as also the middle clamping hardwares shall be either embedded in the porcelain insulator with sulphur cement or suitably clamped in position. For embedded components, the pull out strength should be such as to result in breaking of the porcelain before pull out occurs in a test. For porcelain insulators, the beam strength shall not be less than 1000 Kg. 16. FUSE TUBE The fuse tube shall be made of fibre glass coated with ultraviolet inhibitor on the outer surface and having arc quenching bone fibre liner inside. The tube shall have high bursting strength to sustain high pressure of the gases during fault interruption. The inside diameter of the fuse tube shall be 17.5mm. The solid cap of the fuse carrier shall clamp the button head of the fuse link, closing the top end of the fuse tube and allowing only the downward venting during fault interruption. 17. TYPE TESTS The cutout shall be subjected to the following type tests : i) ii) Dielectric tests (rated impulse withstand and rated one minute power frequency with stand test voltages) Temperature rise test The above tests shall be carried out in accordance with IS:9385 Part I & II. For Porcelain Fuse Base only. iii) iv) 18. Pull out test for embedded components of the fuse base Beam strength of porcelain base 15.

MOUNTING ARRANGEMENT 18.1 The cutouts shall be provided with a suitable arrangement for mounting these on 75x40mm or 100x50mm channel cross arm in such a way that the centre line of the fuse base is at an angleof 15o to 20o from the vertical and shall provide the necessary clearances from the support. Mounting arrangement shall be made of high strength galvanised steel flat and shall be robust enough to sustain the various stresses encountered during all operating conditions of the cutout. For more details see enclosed figure 2. 18.2 Strength of the component marked 1 (see figure) shall be determined by clamping the member with the shorter leg at the top to a rigid support by M-10 carriage bolts. A downward force shall be applied along the axis of M-14 carriage bolt parallel to the longer leg and in the direction of longer leg of the member under test. A load of 50 Kg. shall be applied and then removed to take up any slack in the mounting arrangement before the measurement of position is taken, the permanent set measured at the axis of the M-14 carriage bolt shall not exceed 1.6mm when a load of 425 Kg. is applied and removed. 18.3 The strength of the M-14 bolt shall in no case be less than1900 Kg. and the strength of M-10 bolts not less than 3500 Kg.

19.

TERMINAL CONNECTIONS The cutout shall be provided with two aluminium alloy (alloy designation 2280 (A-11) as per IS:617-1975) terminal connectors at top and bottom of fuse base assemblies to receive aluminium conductors of diameters between 6.3mm to 10.05mm. These terminals shall be easily accessible irrespective of the cutout location with respect to the pole. The terminals shall meet the test requirements of REC Construction Standard E-30. 20. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time to purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.

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REC Specification No.54/1987 (Revised - 1993) 33KV LOAD BREAK SWITCHES FOREWORD At present, off load type 33 KV Air Break Switches are invariably used at the sectionalising/ tapping points of 33 KV lines. However, these switches are not suitable for this application as it poses a serious problem if a shut down is required for urgent maintenance work on the 33KV line section controlled by the switch. It becomes necessary to establish contact with the upstream controlling sub-station (110 KV, 132 KV etc. ) to switch off the line through the circuit breaker, which often results in considerable delay in carrying out the maintenance work and restoration of supply. Further, supply to a large area gets effected. The above difficulties can be overcome by use of 33KV Load Break Switches in the 33KV network at selected points (see enclosed sketch) thereby providing the required facility to field staff for carrying out maintenance work by operating the load break switch as and when required. This specification for 33KV Load Break Switches is being issued on the basis of the recommendations of the 12th Standardisation Conference held in July, 1987. The specification has been subsequently modified to incorporate single-break type switches and a few other amendments in the performance characteristics to make the equipment more economical and versatile. The revised/modified specification was approved by the 13th Conference on Standardisation, Technical Development and Training held on 4th-6th May, 1993 at New Delhi. Based on the decisions of this conference the revised specification is issued. 1. SCOPE This specification covers 33KV, 50Hz alternating current Load-Break Switches for outdoor installation for use at sectionalising/tapping points of 33KV lines. 2 APPLICABLE STANDARD Unless otherwise stipulated in this specification, the Load-Break Switch shall conform to IS:9920 (Pt-I to IV). RATED VOLTAGE The rated voltage shall be 36 KV. RATED NORMAL CURRENT The rated normal current shall be 400 A. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE (KV) i) To earth and between poles ii) Across the isolating distance 6. 170 KV (Peak) 195 KV (Peak)

3.

4.

5.

RATED ONE MINUTE POWER FREQUENCY WITHSTAND VOLTAGE (KV) i) To earth and between poles ii) Across the isolating distance 70 KV (rms) 80 KV (rms)

7.

TEMPERATURE RISE The temperature rise shall not exceed the maximum limits specified below : Temperature rise limit at Ambient Air Temp. not exceeding 40o C Copper contacts (Silver faced in air) 65o C oC Terminals of switches to be connected to external conductors by bolts 50

8.

RATED MAINLY ACTIVE LOAD BREAKING CAPACITY The rated mainly active load breaking capacity shall be 400A. TRANSFORMER OFF-LOAD CURRENT BREAKING CAPACITY The rated transformer off-load current breaking capacity shall be 10 A. RATED LINE CHARGING BREAKING CAPACITY The rated line charging breaking capacity shall be 6.3 A(rms).

9.

10.

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11. RATED CABLE CHARGING BREAKING CAPACITY The rated cable charging breaking capacity shall be 40 A. RATED SHORT-TIME CURRENT The rated short-time current shall be 10 KA for 1 sec. RATED PEAK WITHSTAND CURRENT The rated peak withstand current shall be 25 KA (peak). MECHANICAL & ELECTRICAL ENDURANCE 1000 Operations 20 operations at 400 A at 33 KV 200 operations at 200 A at 33 KV

12.

13.

14.

Mechanical Endurance Electrical Endurance

15.

CONSTRUCTIONAL FEATURES 15.1 The load break switch shall be manually-operated triple-pole type with either single-break or doublebreak operation. The operation of the switch shall be through rotating motion of the post insulators. The switch shall be fitted with a special interrupter unit to absorb the arc energy in an insulated 15.2 chamber. The interrupter unit shall be easily replaceable. 15.3 15.4 The contacts shall be made of silver-faced bronze/copper. The speed of breaking of load shall be independent of the speed of operation.

The incoming and outgoing terminals shall be such as to directly receive ACSR sizes 10-15 mm 15.5 diameter without the use of lugs. The terminals shall be suitable for current ratings stipulated in clauses 4 and 12 of this specification and shall conform to all the test requirements of IS:5561. The terminals shall be so designed as to avoid bimetallic corrosion. 15.6 The frame of each of switch shall be provided with a separate earthing terminal/for each phase for connection to an earthing conductor having a clamping bolt of not less than 12mm dia. The terminal shall be marked with Earth symbol. 15.7 The switch shall have pad lock arrangement both for ON and OFF positions.

15.8 The vertical operating rod shall comprise of not less than 40mm (nominal bore) Galvanised Steel tube (medium class) as per IS:1161-1979. The length of the operating rod shall depend upon the mounting position of the switch (exact length of the rod to be specified by purchaser). 15.9 Provision shall be made for earthing of the operating handle.

15.10 Tubes shall be galvanised in accordance with IS:4736-1968 and other metal parts shall be hot dip galvanised. 15.11 Phase clearance i.e. centre-to-centre distance between the insulators of adjacent phase in the assembled position of the switch shall not be less than 1200mm. 15.12 The centre-to-centre distance between insulators of the adjacent poles of the same phase in the assembled position of the switch shall not be less than 400mm. 15.13 other. 16. All similar materials and removable parts of similar equipment shall be interchangeable with each

TYPE TESTS The switches shall be subjected to the following type tests in accordance with IS:9920 : i) Dielectric test (Impulse and one minute wet power frequency withstand voltages) ii) Temperature rise test (for contacts and terminals) iii) Rated mainly Active Load Breaking Capacity iv) Rated transformer off-load current breaking capacity v) Rated line charging breaking capacity vi) Rated cable-charging breaking capacity vii) Rated short-time current viii) Rated peak withstand current

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xi) Mechanical and Electrical Endurance 17. ROUTINE TESTS The equipment shall be subjected to the following routine tests : i) Power-frequency voltage dry test ii) Measurement of resistance of the main circuit iii) Operating test 18. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially 18.1 agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has right to have the test carried out at his own cost by an independent agency 18.2 whenever there is dispute regarding the quality of supply.

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REC Specification No.55/1987 11KV AND 33KV METAL OXIDE LIGHTNING ARRESTERS FOREWORD REC has already issued Specification No. 10/1976 and 16/1981 for 11KV & 33KV non-linear resistor type lightning arresters. During the last decade, a new type of arresters based on metal oxide have been introduced by many countries and the new technology is fast replacing the conventional non-linear resister type arresters. The metal oxide lightning arresters has gapless construction and there is practically no time delay in responding to over voltages. Unlike conventional arresters, there is no abrupt transient in the voltage characteristic at the time of spark over and there is practically negligible power follow current after the surge operation. Metal Oxide arresters have higher life expectancy and higher energy handling capacity. The only disadvantage is the higher cost compared to conventional arresters. Considering the superiority of the new technology, it was decided in the 12th Standardisation Conference to issue a new REC Specification for Metal Oxide Lightning Arresters for use at 33/11KV Sub-stations to assure better protection of power transformers and other equipment. In due course, their use can be extended to distribution transformers when bulk production is undertaken in the country and the cost gets reduced. 1. SCOPE This specification covers Metal Oxide Lightning Arresters for use in effectively earthed systems with nominal voltage of 11KV & 33KV. 2. APPLICABLE STANDARDS As the Indian Standard on Metal Oxide Lightning Arresters is under finalisation, the lightning arresters shall generally conform to stipulations made in IEC document TC-37. 3. RATED VOLTAGE The rated voltage of arresters shall be 9 & 30 KV (rms) for 11 & 33 KV systems respectively. These ratings are applicable for effectively earthed systems with the transformer neutral effectively earthed. 4. NOMINAL DISCHARGE CURRENT RATING The nominal discharge current rating of arresters shall be 5 KA for 11 KV system and 10 KA for 33KV system.

5.

CURRENT IMPULSE WITHSTAND LEVELS The 9 KV arresters shall withstand 18 impulses of long duration current with a peak level of 75 Amps. and duration 1000 micro-secs. 30 KV arresters shall meet the duty prescribed in line discharge class-1 of IEC TC-37. 6. PROTECTIVE LEVELS These arresters shall meet the following maximum protective levels : 9 KV 30KV

Maximum residual voltage at nominal discharge current 11KV (Peak) Maximum steep current impulse residual voltage at nominal discharge current KV (Peak) Maximum switching impulse residual voltage at 500 Amps. Peak

32 38

85 93 70

Not applicable

7.

TERMINAL ARRANGEMENT The top metal cap and the base of the lightning arresters shall be galvanised. The line terminal shall have a builtin-clamping device which can be adjusted for both horizontal and vertical take off to suit ACSR (conductor size to be specified by the purchaser). The base of the lightning arresters shall be provided with two separate terminals distinctly marked for connection to earth. 8. SEALING The arresters shall be hermetically sealed to avoid ingress of moisture. Suitable rubber gaskets with effective sealing system should be used. Manufacturers should devise a suitable routine production testing to verify the efficiency of sealing. 9. DISCONNECTING DEVICE

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The arrester for 11KV system may be provided with a suitable disconnecting device. This shall be connected in series with the ground lead and should not affect the sealing system of the arresters. The disconnecting device shall conform to the requirements specified in IS:3070 (part-2)-1985. 10. PRESSURE RELIEF DEVICE The arresters for 33KV system should have a suitable pressure relief system in order to avoid damage to its porcelain housing. 11. TESTS 11.1 Type Tests a) Insulation withstand test b) Residual voltage test c) Current impulse test d) Operating duty test e) Pressure relief test (for 30KV Arresters only) f) Test for arrester disconnectors (for 9 KV Arresters only) g) Temperature cycle test on porcelain housing h) Porosity test for porcelain components i) Galvanising test on exposed steel metal parts j) Visual examination 11.2 Acceptance Tests The following tests shall be done on the lower whole number of the cube root of the number of arresters to be supplied : a) b) c) d) Power frequency reference voltage test at reference current on complete arresters Lightning impulse residual voltage test at nominal discharge current on complete arresters Galvanising test on exposed steel parts Visual examination

11.3 Routine Tests a) Measurement of the reference voltage on the complete arresters b) Residual voltage test at nominal discharge current on the complete arresters or sections. c) Test to verify the efficiency of sealing 12. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise specially agreed upon 12.1 by the manufacturer and the purchaser. The manufacture shall afford the inspector (representing the purchaser) all reasonable facilities without charge to satisfy him that the material is supplied in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency, 12.2 whenever there is dispute regarding the quality of supply.

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REC Specification No.56/1988 (Revised 1993) OUTDOOR TYPE THREE PHASE FAIL SAFE DISTRIBUTION TRANSFORMERS FOREWORD Frequent failure of distribution transformers has been posing a serious problem as it not only causes financial loss to the State Electricity Boards but also results in interruption of supply to the consumers for long durations. To overcome this problem, REC has developed Fail Safe Distribution Transformers. These transformers have built-in LT circuit breaker which is controlled by a special electronic device to provide fool-proof protection against excessive over loads, system faults and low oil level. A signal light will indicate that transformer is being over-loaded so that necessary action can be taken to either relieve load or to augment the transformer capacity. However, pending this action, the transformer will not get damaged. Another special feature of these transformers is the provision for automatic reclosing of the circuit breaker. This will result in automatic restoration of supply following temporary faults, which constitute fairly high proportion (about 80%) of the total line faults. Even in the case of tripping due to excessive over-loading, supply will be automatically restored after a short interval to allow for cooling of oil by 5C. Thus, apart from adequate protection, use of these transformers will reduce work load on the maintenance staff and will ensure more reliable power supply to the consumers. This development was discussed in the 12th Standardisation Conference held in July, 1987. The Conference welcomed the new development and it was decided that these transformers should be extensively tried in the field to gain experience on their use. It was also decided that the transformers should be procured under a 3 year guarantee to start with, and, in due course this can be extended even to 5 years in the light of field experience. This specification is being issued on the basis of the decision taken at the conference. Based on further technical development the specification has been revised. The revised specification includes increased short circuit breaking capability of LT circuit breakers, Endurance test for LT circuit breakers, Reclosing after 3 minutes instead of 10 seconds provided earlier, to enhance the reliability of the equipment. The Cooling of oil in case of overloads has been reduced from 10C to 5C so that the transformer is available for more service time without adversely affecting the life of the transformer. Mention has also been made for provision of pad lock arrangement of LT circuit breakers to facilitate maintenance of LT lines. 1. SCOPE This specification covers three-phase, 50 Hz, double-wound oil immersed, naturally air-cooled, outdoor type sealed/conventional fail safe distribution transformer for use on systems with nominal voltage of 11 KV. 2. STANDARD RATINGS The standard ratings of transformers shall be 16, 25, 63 and 100 KVA. 3. APPLICABLE STANDARDS Unless otherwise stipulated in this specification the transformers shall comply with IS:1180 (Pt I or II) and IS:2026, as amended from time to time. 4. NO-LOAD VOLTAGE RATIO The no-load voltage ratio of transformers shall be 11KV/433-250V except for 100 KVA transformers for which an alternative ratio of 10.45 KV/433-250V is also permissible, if specified. 5. TAPS No taps are to be provided in these transformers. 6. WINDINGS AND INSULATION 6.1 For 16 and 25 KVA transformer ratings, thermo-mechanically treated NML-PM2 designation aluminium alloy wires should preferably be used for HV windings. 6.2 Unless otherwise specified, DPC insulation shall be used for HV and LV winding wires and Electrical Grade Epoxy Dotted Insulation paper shall be used for inter layer insulation of the HV and LV coils. Use of single coils for HV and LV windings shall be preferred due to their better short-circuit behavior. Use of aluminium foil for LV winding would be preferred. 6.3 Corrugated cylinder made from pre-compressed insulation board should preferably be used between HV and LV windings. 6.4 Angle shaped End Rings made from pre-compressed board should preferably be used between the end coils and core (with this provision, the purchaser should not specify any minimum clearance between end coil and core). 6.5 The primary winding shall be connected in delta and the secondary winding in star (Vector Symbol Dy 11),

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so as to produce a positive displacement of 300 from the primary to the secondary vector of the same phase. The neutral of the secondary winding shall be connected to a separate insulated terminal. 7. FITTINGS 7.1 The following standard fittings shall be provided : A. FOR CONVENTIONAL AND SEALED TRANSFORMERS i) ii) iii) Two earthing terminals Two lifting lugs Rating and terminal marking plate(s)

B. FOR CONVENTIONAL TRANSFORMERS i) Oil level gauge indicating three positions of oil marked as follows : - Minimum (-5oC) - 30oC - Maximum (98oC)

ii) Plain breathing device comprising an inverted U-Pipe with wire gauze at the open end or silica gel breather as required by the purchaser. iii) Drain-cum-Sampling valve (steel) of the type shown in figure 6 welded to the tank. The special tool for operating this valve shall be supplied with the transformer. iv) Filling hole having P 1/ thread (with cover) on the transformer body/conservator.

C. FOR SEALED TRANSFORMERS

i) Nitrogen/air filling device/pipe with welded cover capable of re-use

ii) An extended pipe connection at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide an oil refilling connection after removing the welded cover. iii) No conservators shall be provided on these transformers.

7.2 Conservator (For Conventional Transformers only) On transformers of 63 and 100 KVA, provision of conservator is obligatory. For 25 KVA transformers the manufacturers may adopt their standard practice. The conservator shall be provided with the drain plug and a filling hole with cover. In addition, the cover of main tank shall be provided with an air release plug to enable trapped air to be released unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank. The inside diameter of the pipe connecting the conservator to the main tank shall be within 20 to 50mm and it should project into the conservator in such a way that its end is approximately 20mm above the bottom of the conservator so as to create a sump of collection of impurities. The minimum oil level corresponding to (-) 5oC should be above the sump level. RATING AND TERMINAL MARKING PLATE(S) Each transformer shall be provided with a non-detachable Rating and Terminal Marking Plate(s) of weather proof material fitted in a visible position and showing complete information as specified in IS:1180 (Pt I or II)-1989. 9. LIMITS OF TEMPERATURE RISE When tested in accordance with IS:2026 (Pt.II), the temperature rise in winding (measured by resistance) and in top oil (measured by thermometer) shall not exceed 550C and 450C respectively. 10. LOSSES AND IMPEDANCE VALUES 10.1 The no-load and load losses shall not exceed the values given in the following table : 8.

KVA Rating

No Load Loss (Watts) 80

Load Loss at 75oC (Watts) 475

16

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25 63 100 100 180 260 685 1235 1760

The above values of losses are the maximum allowable and there shall be no plus tolerance. 10.2 The percentage impedance at 75oC shall be 4.5% subject to tolerance as per IS:2026.

10.3 Overflux in the transformer core shall be limited to 12.5% to ensure that in the event of over-voltage to the extent of 12.5% the core does not get saturated. The supplier will furnish necessary data in support of this stipulation. 11. TRANSFORMER OIL The transformer oil shall comply with REC Specification No. 39/1985 (R-1993). HV BUSHINGS For Sealed Transformers only 12.1 To enable replacement of the outer porcelain bushing without opening the cover and without affecting the sealing arrangement of the transformer, the HV bushing shall be made in two parts. The external bushing shall conform to the requirements of IS:3347 part-III/section 1 and 2. The internal bushing shall also preferably be made of porcelain and shall have separate aluminium stem. In case, the internal bushing is made of epoxy, it shall have an embedded stem and each bushing shall be subjected to 'Partial Discharge Test' as per the stipulations in the latest version of IS:2099-1986 to avoid the possibility of any air voids remaining in the cast. A typical arrangement of two-part HV bushing with internal porcelain bushing is shown in Fig. 1. The alternative arrangement with internal epoxy bushing is shown in fig. 2. However, the manufacturer is free to adopt a different arrangement provided it satisfies all the requirements of this clause. 12.2 Metal parts of the internal HV bushings inside the transformers shall remain immersed in oil under all operating conditions. 12.3 The following minimum clearances shall be provided : Enclosed Phase-to-phase Phase-to-Earth 13. 127 76 External 255mm 140mm

12.

LV BUSHINGS 13.1 Two sets of LV bushings shall be provided : i) Internal LV bushings inside the LT Enclosure ii) External LV bushings mounted on the LT Enclosure 13.2 The internal LV bushings shall preferably be made of epoxy (with embedded stem) for effective sealing. The minimum phase-to-phase and phase-to-earth clearances for these bushings shall be 45mm and 20mm respectively. 13.3 The LV bushings mounted externally on the LT enclosure shall be outdoor porcelain type, conforming to the requirements of IS:7421-1988 and IS:3347 (Part-I)/(Sec.1&2). The minimum phase-to-phase and phase-toearth clearances of these bushing shall be 75mm and 40mm respectively.

14.

BUSHING TERMINALS To avoid bimetallic action at the point of connection to the aluminium windings and to the external 14.1 aluminium cables/conductors, both HV & LV bushing stems shall be made of aluminium alloy only conforming to the requirements of IS:3347. The bushing terminals shall be of clamp type to receive the conductors/cables. The terminals shall be 14.2 directly screwed on to the stems to secure effective sealing of the bushings. Details of the terminals are given in appendix 'A'.

15. TANK CONSTRUCTION For Sealed Transformers only The transformer tank shall be made of good quality steel sheet of adequate thickness and shall be suitably stiffened to provide sturdy and robust construction to withstand extreme pressure conditions. The tank shall be capable of withstanding pressure upto (+) 0.8Kg/cm2g (80 KPa) and (-) 0.7Kg/cm2g(-70 KPa) (gauge pressure) without any deformation. The transformer cover shall be welded to the tank in such a way that it shall be possible to remove the weld and reweld the transformer at least twice. 16. TANK SEALING For Sealed Transformers only

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Space on the top of the oil shall be filled either with nitrogen conforming to commercial grade as per IS:1747 or dry air. The nitrogen/air plus the oil volume inside the tank shall be such that even under extreme operating conditions, the pressure generated inside the tank shall not exceed (+) or (-) 0.4 Kg./cm2g()(40 KPa). 17. 11KV LIGHTNING ARRESTERS The transformers shall be provided with a set of 11KV lightning arresters. The lightning arresters shall be securely clamped to the transformer body and earthed to the tank through a solid connection. A solid inter-connection shall also be provided between the 11KV bushing terminals and the 11KV L.A. terminals. The characteristics of the lightning arresters and all the test requirements shall conform to REC Specification 10/1976. 18. LT CIRCUIT BREAKER The transformer shall have built-in 3-pole, LT circuit breaker conforming to the test requirements of 18.1 IS:2516 (Pt. I & II/Sec.1)-1985, as amended from time to time. Use of miniature circuit breakers as per IS:8828 is not acceptable. 18.2 The rated voltage of the circuit breaker shall be 415V.

The standard rated thermal current and normal current settings of the circuit breaker for use with 18.3 transformers of different ratings shall be as follows : Transformer rating (KVA) Rated thermal current of C.B. (Min.) Amps. Normal current setting in Amps (In)

16 25 63 100

31.5 50 125 200

22 35 90 140

18.4 Rated short circuit breaking capacity : 5KA or more Rated short-time withstand current : 5KA or more for 1 sec. The circuit breaker shall be tested for the short circuit rating as per P-2 Duty in accordance with IS:2516 (Pt.I & II/Sec.1)-1985 but at a power factor of 0.4 (lagging) or less. Endurance Test (No. of C/O cycles) The circuit breaker shall be type tested for endurance as indicated below : i) Mechanical ii) Electrical 18.5 15000 cycles 10000 cycles (at rated thermal current and 0.8 pf)

The circuit breaker shall have trip-free mechanism.

18.6 Operating Characteristics of LT Circuit Breaker The operation of the LT circuit breaker shall be controlled by an Electronic Control Unit (ECU), which will automatically trip or close the breaker to achieve the following operating characteristics: 18.6.1 Overloading - upto 1.4 times In i) To trip when temperature of top oil reaches 85C ii) Indicating light to show that maximum oil temperature has been reached, light to remain 'ON' till manually reset. iii) To reclose automatically when top oil temperature drops to 80C. 18.6.2 Excessive overloading or Low-faults - Above 1.4 In upto 6 In i) To trip after 5 seconds, if current is between 1.4 In and 4 In, and after 2.5 secs., if it is between 4 In and 6 In. (Time delay of 2.5 seconds is provided to guard against nuisance trippings due to inrush current on account of motor-starting, etc.) ii) To reclose once after 3 minutes and to lock-out if circuit breaker re-trips within 5 seconds. iii) Indicating light to show 'Line Fault', which will get automatically re-set when circuit breaker is success fully closed manually otherwise it will again show 'Line Fault'. 18.6.3 High Faults - Above 6 In i) To trip instantaneously (not more than 40 milliseconds) ii) To re-close once after 3 minutes and to lock-out if re-trip occurs within 5 seconds.

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iii) Indicating light to show 'Line Fault' which will automatically re-set when circuit breaker is successfully closed manually otherwise it will again show 'Line Fault'. Note : In reference to full load transformer current which is 33.3A, 84.0A, and 133.3A for 25KVA, 63KVA and 100 KVA transformers respectively. 18.6.4 i) ii) 18.6.5 i) Low Oil Level To trip and lock-out if oil level drops to the minimum permissible limit Indicating light to show 'Low Oil' which will automatically re-set after oil is topped up. Electronic Control Unit Faulty To trip circuit breaker in the event of any fault in ECU such as: a) Open circuit or short circuit of temperature/oil level sensor leads b) Equipment faulty light shall also glow in the event of mal-function in the circuit breaker is not being able to switch on or switch off as commanded by ECU. Indicating light to show 'Control Faulty'

ii) 18.7

Tolerances Accuracy of current and time values for the operation of LT circuit breaker (clause 18.6) shall be within 5% and the temperature values shall have a tolerance of 1oC. Control Supply 18.8.1 The ECU will draw control supply from the secondary side of the transformer and no separate auxiliary power supply will be required. 18.8.2 The Electronic control unit shall be so designed as to automatically switch over to the healthy phase to neutral supply in the event of voltage in the other phases going below the operating limit of the controller due to faults such as blowing off of transformer fuse on the 11 KV side. The design will also take into account voltage variations in the range of (+) 20% to (-) 40% of the rated phase to neutral voltage i.e. 240 Volts.

18.8

18.9

Temperature Rise The LT Circuit Breakers and the associated terminals/wiring shall be designed with reference to ambient temperature of 55oC (instead of 40oC stipulated in IS:2516) due to operation in sealed enclosure in outdoor environment. The supplier shall furnish necessary data to show that all the components are suitable for the expected temperature rise, over and above the ambient temperature of 55oC, under various loading/operating conditions.

19.

LT ENCLOSURE 19.1 The circuit breaker along with ECU shall be housed in a suitable enclosure of sheet steel mounted on the LV side of the transformer in such a way that the entire enclosure can be easily replaced under field conditions. The general arrangement of the enclosure is shown in Fig. 3. 19.2 The LT enclosure shall be suitably sealed to avoid ingress of moisture and to make the enclosure weather-proof. This will also avoid possibility of tampering with the protection equipment in the enclosure. 19.3 For control purposes, the top oil temperature and the oil level inside the tank shall be monitored externally without any wires entering the transformer tank. The temperature of oil shall be monitored through a sensing element dipped in oil in the thermometer pocket of transformer tank. Design of ECU will take into account the difference between the top oil temperature and the temperature of oil in the pocket. The oil level shall also be sensed externally through a magnetic gauge. This will facilitate easy removal of the LT enclosure for replacement etc. Indicating lamps shall be provided at the bottom of the enclosure as shown in Fig. 3. The bottom shall be 19.4 suitably recessed to avoid access of rain water and for easy visibility of lamps from the ground level. The lamps shall be easily replaced from outside without opening the enclosure and without affecting its sealing arrangement. Lamps shall be of Neon/LED type, having long life of several years. In the event of power failure, all the indications and the position of the LT circuit breaker shall be automatically 19.5 restored to the original position after the power supply is resumed. A suitable operating handle shall be provided at a convenient location (preferably at the bottom) for easy 19.6 operation of the circuit breaker from ground level by means of an operating rod. The 'ON' and 'OFF' positions shall have suitable mechanical stops to avoid damage to the circuit breaker mechanism. The circuit breaker operating handle should have only two positions i.e. 'ON' and 'OFF' and no 'Reset' position. Suitable pad lock arrangement for the circuit breaker's operating handle shall be provided as a safety measure to facilitate LT line maintenance. The LT enclosure shall be mounted about 200mm away from the tank as shown in Fig. 3 to ensure that the 19.7 temperature inside the enclosure is not seriously affected by the temperature rise of transformer oil inside the tank. The LT

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enclosure shall be protected against direct exposure to sun by a suitable shield made of a thermally insulating material like FRP. The design of the shield shall be such as to provide air gap to allow circulation of air between the shield and the LT enclosure. The temperature inside the enclosure shall not exceed 70oC under most adverse operating conditions. The ECU including the associated wiring shall be suitable for operation in temperature range of (-) 10oC to (+) 75oC. The connecting wires shall have taflon / fibre-glass insulation to withstand effects of high temperature. 19.8 Test Switch The LT enclosure shall have a test switch to check whether indicating lamps shall start glowing/ flashing except the fused one, which can thus be identified and replaced. The function of the control mechanism shall not be affected by pressing of test switch. 20. WARRANTY The supplier shall guarantee satisfactory performance of transformers and all the associated components for a 20.1 period of 3 years from the date of receipt by the purchaser. During the warranty period all repairs/replacements shall be carried out free of cost. The warranty shall cover all failures except those caused by deliberate interference, for example, pilferage of oil, 20.2 tempering with the control mechanism/circuit breaker. The LT enclosure shall be suitably sealed by the manufacturer and no attempt shall be made by the field staff to tamper with this during warranty period. 21. TESTS 21.1 Routine Tests : All transformers shall be subjected to routine tests at the manufacturer's works. The following routine tests shall be carried out in accordance with the details specified in IS:1180 (Pt.I&II) & IS:2026 or as agreed upon between the purchaser and the manufacturer : a) Measurement of winding resistance b) Measurement of voltage ratio and check of voltage vector relationship c) Measurement of impedance voltage, short-circuit impedance and load loss d) Measurement of no-load loss and no-load current e) Measurement of insulation resistance f) Induced over-voltage withstand test g) Separate source voltage withstand test h) Air Pressure Test i) Air Pressure Test (For Sealed Transformers only): The transformer tank with welded lid and with all the fittings including bushings in position shall be tested as per IS:1180 Part-II-1989. Note : As the above test is required to be carried out before final sealing of the transformer, the inspecting authority would ensure to be present at the time of final sealing to witness this test. The test cannot be demonstrated on a completed transformer. ii) Air Pressure Test (For Conventional Transformers only): This test will be carried out as per IS:1180 part-I1989. 21.2 Type Tests : The following type tests shall be made on the transformers : (a) to (g) as indicated under routine tests (h) Unbalanced Current Test : The value of unbalanced current indicated by the ammeter as shown in the test arrangement in Fig. 4 shall not be more than 2% of the full load current. (i) Impulse Voltage withstand test (j) Temperature-rise test (k) Short-circuit test (without ECU being in the circuit) (l) Air Pressure Test as per IS:1180 Part-I for Conventional transformers and as per IS:1180 Part-II for Sealed transformers.

If records of a type test on a transformer which in essential details, is representative of the one being purchased, are furnished, the purchaser may accept this as evidence of the type test instead of actual test. The supplier shall furnish calculations in accordance with IS:2026 to demonstrate the thermal ability of the 21.3 transformers to withstand short-circuit. 21.4 Acceptance Tests 21.4.1 The following shall constitute the Acceptance tests : i) Verification of operating characteristics of LT Circuit Breaker as per clauses 18.6 and 18.8.2. ii) Verification of the provisions of clauses 19.7 21.4.2 The acceptance tests shall be carried out by selecting at random one transformer out of each lot of 100 transformers or part thereof for each rating.

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NOTE: The manufacturer shall make necessary arrangements for carrying out the acceptance tests, as indicated above in his works. 22. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by 22.1 the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this Specification. 22.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply. 23. MOUNTING ARRANGEMENT The under-base of all transformers shall be provided with two 75x40mm channels 460mm long, with holes as shown in the Fig.5 (at a centre-to-centre distance of 415mm) to make them suitable for fixing on a platform or plinth.

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REC Specification 57/1993 DANGER NOTICE PLATES FOREWORD As per provisions of IE Rules 1956, Danger Notice Plates in Hindi or English and, in addition, in the local language with the sign of skull and bones are required to be provided on power line supports and other installations. It is further stipulated in the I.E. Rules that such Notice Plates are not required to be provided on supports like PCC, tubular, wood, steel rails, etc. which cannot be climbed easily without the aid of ladder or special appliances. To adopt a uniform pattern and for helping easy procurement, a specification on Danger Notice Plates has been drawn up. This Specification was approved by the 13th Conference on Standardisation, Technical Development and Training in Rural Electrification held on 4th-6th May, 1993. 1. SCOPE This Specification covers Danger Notice Plates to be displayed in accordance with rule No. 35 of Indian Electricity Rules, 1956. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the Danger Notice Plates shall comply with IS:2551-1982 or the latest version thereof. 3. 3.1 a) b) DIMENSIONS Two sizes of Danger Notice Plates as follows are recommended: For display at 415 V installations - 200x150mm For display at 11 KV (or higher voltages) installations - 250x200mm

3.2 The corners of the plate shall be rounded off. 3.3 The location of fixing holes as shown in Figs. 1 to 4 is provisional and can be modified to suit the requirements of the purchaser. 4. LETTERINGS All letterings shall be centrally spaced. The dimensions of the letters, figures and their respective position shall be as shown in figs. 1 to 4. The size of letters in the words in each language and spacing between them shall be so chosen that these are uniformly written in the space earmarked for them. 5. LANGUAGES 5.1 Under Rule No. 35 of Indian Electricity Rules, 1956, the owner of every medium, high and extra high voltage installation is required to affix permanently in a conspicuous position a danger notice in Hindi or English and, in addition, in the local language, with the sign of skull and bones. 5.2 The type and size of lettering to be done in Hindi is indicated in the specimen danger notice plates shown in Fig. 2 and 4 and those in English are shown in Figs. 1 and 3. 5.3 Adequate space has been provided in the specimen danger notice plates for having the letterings in local language for the equivalent of' Danger',' 415' '11000' and 'Volts'. MATERIAL AND FINISH The plate shall be made from mild steel sheet of at least 1.6mm thick and vitreous enameled white, with letters, figures and the conventional skull and cross-bones in signal red colour (refer IS:5-1978) on the front side. The rear side of the plate shall also be enamelled. 7. TESTS The following tests shall be carried out : i) Visual examination as per IS:2551-1982 ii) Dimensional check as per IS:2551-1982 iii) Test for weather proofness as per IS:8709-1977 (or its latest version) 8. MARKING Maker's name and trade mark and the purchaser's name shall be marked in such a manner and position on the plates that it does not interfere with the other information. 9. PACKING The plates shall be packed in wooden crates suitable for rough handling and acceptable for rail/road transport. 6.

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REC Specification 58/1993 TRANSFORMER OIL TESTING KIT FOREWORD Proper maintenance of insulating oil is an important factor for ensuring normal service life of transformers, circuit breakers etc. Transformer oil testing kit is the basic equipment to monitor the condition of oil. In order to bring about uniformity in the specification of this equipment, a REC Specification was placed before the 13th Conference on Standardisation, Technical Development and Training in Rural Electrification held on 4th-6th May 1993. Based on the recommendations of the conference, the specification for Transformer oil Testing kit is issued. 1. SCOPE This specification covers the requirements of the portable transformer oil testing kit for determination of electric strength of insulating oils. 2. APPLICABLE STANDARDS Unless otherwise modified, the portable oil testing kit shall comply with the requirements of IS:6792-1992 or its latest version. 3. CLIMATIC CONDITIONS This apparatus is basically an indoor type apparatus. The maximum temperature of air in shade may be 45C and the minimum temp. as 0C. The apparatus may be used in 100% humidity conditions. 4. TEST CELL The test cell made of glass or plastic shall be transparent and non-absorbant. It shall have an effective volume between 300 and 500 ml. It shall be perfectly closed with interlocking arrangement to avoid danger to the operator while high voltage is induced at the HT terminals. 5. ELECTRODES The copper , brass, bronze or stainless steel polished electrodes shall be either spherical (12.5mm to 13mm diameter) or spherical surfaced. The electrodes shall be mounted on a horizontal axis and shall be 2.5mm apart. The gap between the electrodes shall be set to an accuracy of ( ) 0.1mm by means of thickness gauges. The electrodes shall be of replaceable type so that these can be easily replaced as soon as pitting caused by discharge is observed. The thickness gauge mentioned above shall be supplied with the testing kit. 6. ELECTRICAL APPARATUS 6.1 Transformer : The test voltage may be obtained by using a step up transformer supplied from a AC low voltage source of 230V ( ) 10%. The secondary output of the transformer should be up to 70KV. The primary voltage is gradually increased preferably by an automatic control device. The frequency of source supply shall be within the range 40-62Hz. The transformer associated with the equipment shall be designed to produce a minimum short circuit current of 20mA for voltage higher than 15KV. To avoid damage to the electrodes, the short circuit current shall be limited to a maximum of 1.04A if necessary by addition of external impedance. The voltage applied to the electrodes of the oil filled cell shall be of approximately sinusoidal wave form, such that the peak factor is within 1.34 and 1.48 (i.e. 2( ) 5%). 6.2 Protective Gear : The test is carried out as to prevent high frequency oscillations as far as possible.

To protect the equipment and to avoid excessive decomposition of the oil at the instant of break down, a resistance limiting the breakdown current may be inserted in series with the test cell. The primary circuit of high voltage transformer shall be fitted with a circuit breaker operated by the current flowing following the breakdown of the sample and with a delay not more than 0.02 second. The circuit breaker shall be fitted with a no voltage release coil to protect the equipment. 7. TYPE TEST Measurement of test voltage as per IS:6792. 8. DRAWING AND OPERATION MANUALS Three copies of the drawings indicating the circuit diagram and various components along with operation manual for operating and maintaining the equipment shall be provided along with each test kit.

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REC Specification 59/1993 11 KV CURRENT TRANSFORMERS FOREWORD The need for a REC specification on 11 kv Current Transformers for Rural Electrification work was felt by many SEBs. Accordingly the specification was put up for approval to the 13th Conference on Standardisation, Technical Development and Training in Rural Electrification held on 4th-6th May, 1993. Based on the recommendation of the Thirteenth Conference the specification for 11KV Current Transformers is issued. 1. SCOPE This specification covers 11 KV outdoor and indoor type single phase Current Transformers (CTs) suitable for 11 KV, 3phase, 50 Hz solidly grounded system. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the CTs shall conform to the requirements of IS:2705 (Pts.I, II & III)1992 or the latest version thereof. 3. STANDARD RATINGS The standard ratings of CTs for use at 33/11 KV sub-stations shall be as under : 300-150/5-5A 200-100/5-5A 100-50/5-5A 50-25/5-5A 4. CONSTRUCTIONAL FEATURES 4.1 Outdoor Type : The outdoor CTs shall be either oil filled type or of resin cast type which shall be enclosed in a sealed housing to avoid direct exposure to sun and other atmospheric effects. The CT shall be supported on a suitable post insulator to be mounted on a pedestal/steel structure. Mounting flanges, bolts etc. shall be hot dip galvanised and shall be supplied along with the CT. Suitable mounting holes shall be provided at the base for clamping to the structure. The CTs shall be provided with bolted type terminals to receive ACSR conductors upto 15mm dia (without requiring use of lugs) both in vertical and horizontal directions. The terminals shall be such as to avoid bimetallic action. 4.2 Indoor Type : The CTs shall be of resin-cast type suitable for indoor installation.

5. TECHNICAL REQUIREMENTS The 11 KV single-phase CTs shall comply with the following technical requirements :

i) ii) iii) iv) v) vi) vii) viii) ix)

Nominal system voltage Highest system voltage Frequency System earthing One-Minute power frequency withstand voltage Basic Insulation level (BIL) 3-second short time current rating (rms) Dynamic rating (Peak) No. of cores

11 KV 12 KV 50 Hz Solidly grounded system 28 KV 75 KV 12.5 KA 2.5 times of (vii) above Double-core

6. WINDINGS Change in the CT ratio shall be obtained by providing tappings in the secondary winding. The primary bar and secondary windings shall be of copper. 7. CORE The core of the CT shall invariably be of torroidal type. The magnetic circuit shall be of high grade, non-ageing electrical silicon laminated steel of low hysteresis loss and high permeability to ensure high accuracy at both normal and over currents.

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8. CLASS OF ACCURACY AND BURDEN Core-II Core-I (Metering) (Protection) Accuracy class : Rated Output (VA): 5 P 10 15 1 15

9. TEMPERATURE RISE The maximum temperature rise of windings shall not exceed the following : Indoor type Maximum ambient temp Permissible temp. rise for 45oC 70oC 80oC 105oC Outdoor type 65oC 50oC 60oC 85oC

a b c

Class E Insulation Class B Insulation Class F Insulation

Note : The supplier shall furnish evidence to the satisfaction of the purchaser about the class of insulation used. 10. TESTS The CTs shall be subjected to the following tests as per IS:2705-1992 or the latest version: 10.1 Type Tests : a) Verification of terminal marking and polarity b) Power frequency dry withstand tests on primary winding c) Power frequency dry withstand tests on secondary winding. d) Determination of errors according to the requirements of the appropriate accuracy class e) Over-voltage inter-turn test f) Short-time current tests g) Temperature rise test h) Impulse voltage test i) Power frequency wet withstand test (for outdoor CTs only) j) Partial Discharge test IS (6209)-1991 - 25 PC (Max.) 10.2 a) b) c) d) e) f) Routine Tests Verification of terminal markings and polarity High voltage power frequency test on primary windings High voltage power frequency test on secondary windings Over-voltage inter-turn test Determination of error according to the requirements of the appropriate accuracy class Partial Discharge Test - IS:6209 - 1982 - 25 PC (Max.)

11. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.

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REC Specification 60/1993 11 KV VOLTAGE TRANSFORMERS FOREWORD The need for a REC Specification on 11KV Voltage Transformers for Rural Electrification work was felt by many SEBs. Accordingly the specification was put up for approval of the 13th Conference on Standardisation, Technical Development and Training in Rural Electrification held on 4th-6th May 1993. Based on the recommendation of the thirteenth conference, the specification for 11KV Voltage Transformer is issued. 1. SCOPE This specification covers 11KV 3-phase 50Hz, outdoor and indoor type voltage transformers for metering etc.

2.

APPLICABLE STANDARDS Unless otherwise modified in this specification, the voltage transformers shall conform to IS:3156-1992 (part-I & II) or the latest version thereof. 3. TECHNICAL REQUIREMENTS The voltage transformers shall have the following ratings : Nominal system voltage Highest system voltage Frequency System earthing Transformer ratio Rated burden per phase Class of accuracy Basic Insulation Level Rated voltages factor 1.2 1.5 11KV 12KV 50Hz solidly grounded 11KV/110V 100 VA 1 75 KV Continuous 30 Seconds

4.

TEMPERATURE RISE When tested in accordance with IS:3156, the temperature rise of the windings shall not exceed the following limits : Class E Insulation 50oC Class B Insulation 60oC Class F Insulation 85oC Note : Maximum ambient temperature shall be taken as 65oC.

CONNECTIONS The transformer shall be star-star connected. The secondary terminals of the transformer shall be brought out on one side of the tank to a separate terminal box for making connection to the supplier's cables. LT fuses shall also be housed in this terminal box. 6. CONSTRUCTIONAL FEATURES 6.1 Outdoor Type 6.1.1 The voltage transformers shall be of outdoor, 3-phase either oil filled type or resin cast type, which shall be enclosed in a weather-proof housing to avoid direct exposure to Sun and other atmospheric influences. The incoming and outgoing terminals shall be brought out through suitable porcelain bushings. The voltage transformer shall be suitable for operation in a solidly grounded system. The tank shall be given three coats of rust preventing paint. The other iron parts shall be hot dip 6.1.2 galvanised. The tank shall be provided with lifting lugs either welded on the sides or top cover plate of the tank. 6.1.3 The dimensions and electrical characteristics of the 11KV bushings shall be in accordance with IS:2099-1986 or its latest version. 6.1.4 The tank shall be provided with two separate earthing terminals.

5.

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6.1.5 The unit shall have rating and diagram plate and will have suitable base channels to facilitate mounting of the equipment on the structure. 6.1.6 Terminals: The voltage transformers shall be provided with bolted type terminals on the 11KV side to receive ACSR conductors upto 8mm dia (without requiring use of lugs) both in vertical and horizontal directions. The terminals shall be such as to avoid bimetallic action. 6.2 Indoor Type The voltage transformer shall be of resin-cast type suitable for indoor installation and shall be normally mounted on one of the 11KV incoming circuit breakers. 7. TESTS The voltage transformers shall be subjected to the following tests as per IS:3156-1992 or its latest version : 7.1 Type Tests a) Verification of terminal marking and polarity b) Power frequency dry withstand tests on primary winding c) Power frequency dry withstand tests on secondary winding d) Determination of errors according to requirements of the appropriate accuracy class e) Temperature rise test f) Impulse voltage test g) High voltage power frequency wet withstand voltage test h) Partial Discharge test (IS:6209-1982)-25PC (Max.) 7.2 Routine Tests a) Verification of terminal marking and polarity b) Power frequency dry withstand tests on primary winding c) Power frequency dry withstand tests on secondary winding d) Determination of errors according to requirements of the appropriate accuracy class e) Partial discharge test (IS:6209-1982) 25-PC(Max.) 8. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.

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REC Specification No.61/1993 MINIATURE CIRCUIT BREAKERS FOR SERVICE CONNECTIONS FOREWORD Miniature Circuit Breakers (MCBs) are now extensively used all over the world and have practically replaced the use of rewireable fuses. The MCB is designed to clear over-loads and system faults quickly and efficiently and unlike fuses, it can be easily operated even by a lay-man with utmost safety and ease. We understand that some of the SEBs including Andhra Pradesh, Karnataka, Gujarat, Madhya Pradesh and Rajasthan have already enforced the use of MCBs for LT service Connections. The specification was discussed in the 13th Standardisation Conference held in May 1993. The question of replacing the conventional IC cutouts with MCBs was also discussed during the Conference. For safe working on the consumers installation, the IE Rules stipulate a visible disconnection of supply which can be achieved by removing the fuse from the IC cutout. The convention al MCBs will not be able to meet this requirement. Therefore, it was decided to retain provision of IC cutout to meet the requirement of IE Rules while providing MCBs for LT Service Connections. However, it was informed by some of the SEBs that plug-in type of MCBs are now commercially available and those could be used to replace IC cutouts. It was decided to issue REC Construction Standards for LT service connections with conventional IC cutout and MCBs and another standard with plug-in type MCBs where the provision of IC cutout may not be required. The specification on the MCBs for service connection is issued based on the decisions taken in the 13th Conference on Standardisation, Technical Development and Training held on 4th-6th May, 1993 at New Delhi. 1. SCOPE This specification covers single-pole and 3-pole 50Hz, AC,LT Miniature Circuit Breakers (MCBs) suitable for single-phase and 3-phase service connections. These circuit breakers are intended to be provided by the SEBs at the consumers premises in place of conventional rewireable fuses/switch-fuse units. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the MCBs shall comply with the requirements of IS:8828/1978 or the latest version thereof. 3. TYPE OF MCBs MCBs meant for single-phase service connections shall be of single-pole type and those for 3-phase 3.1 connections for motive loads shall be of 3-pole type with mechanically linked common operating bar for simultaneous closing or tripping of the three poles. 3.2 The MCBs shall have trip-free operating mechanism. 4. RATED VOLTAGE The rated voltage of single-phase and 3-phase MCBs shall be 240V and 415V respectively. 5. RATED CURRENT 5.1 Single-phase MCBs The rated current of single-pole MCBs suitable for service connections of various connected loads shall be as follows : Connected Load Rated Current Upto 0.5 KW 4 Amps 0.6 to 1 KW 8 Amps 1.1 to 2 KW 16 Amps 2.1 to 3 KW 25 Amps 3.1 to 4 KW 32 Amps 5.2 3-phase MCBs The rated current of 3-pole MCBs 2.2 KW (3 HP) 3.7 KW (5 HP) 5.5 KW (7.5 HP) 7.5 KW (10 HP) 11KW (15 HP) 6. RATED SHORT CIRCUIT CAPACITY

for 3-phase motive loads shall be as follows : 6 Amps 10 Amps 16 Amps 20 Amps 32 Amps

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The rated short circuit breaking capacity for single-phase MCBs shall be 6 kA (M-6 duty) and, for 3-phase MCBs, it shall be 9kA (M-9 duty). the test duty shall be B-2-MB-2-MB. Separate tests are required to be made for single pole and triple pole MCBs in accordance with the requirements of IS:8828. 7. TIME/CURRENT CHARACTERISTICS 7.1 The time/current characteristics of MCBs shall be as follows : Rated Current (In) Single Phase/3-Phase All Ratings Upto 10 A Above 10A All Ratings Single Phase All Ratings All Ratings Three Phase All Ratings All Ratings All Ratings Multiple of Rated Current In 1.5 In 1.35 In 2.5 In 4 In 7 In 5 In 7 In 10 In Tripping time

No Trip Less than 1 hr Less than 1 hr Within 1 minute Not less than 0.1 Sec Instantaneous (not more than 40 milli-sec) Not less than 2 seconds* Not less than 0.1 sec. Instantaneous ( not more than 40 milli-secs)

*This is necessary to prevent tripping due to in rush current on starting of the motor. 7.2 8. The reference calibration temperature shall be 400 C.

MECHANICAL & ELECTRICAL ENDURANCE 8.1 The MCBs shall be capable of 6000 operations on load and additional 4000 operations without load (total 10,000 operations) when tested in accordance with IS:8828. 8.2 The number of operating cycles for overload performance test as per IS:8828 shall be 50. The value of overload current shall be equal to 600% of the rated current or 150A whichever is higher at a p.f. 0.7 to 0.8 lagging and test voltage 5% or ratedvoltage.

9.

TEMPERATURE RISE The temperature rise of various components shall not exceed the limiting values specified in the IS:8828.

10. TERMINALS The MCB terminals should be suitable for directly receiving aluminium cables from 1mm2 to 25 mm2 size without requiring use of lugs etc. 11. ENCLOSURE 11.1 The MCB shall be housed in a metallic enclosure which shall be capable of being sealed at two points in closed position. The operating knob/bar of the MCB and the markings (Clause 13) shall remain outside the enclosure. The enclosure shall be such as to have sufficient space for accommodating the incoming and outgoing 11.2 cables for enabling easy connections to the MCB. The MCB shall be mounted on a DIN rail provided inside the enclosure and shall be capable of being fixed action without the need for removing the DIN rail. The entry of the cables shall be from the back side of the enclosure and the design should be such as to make the cable inaccessible once the enclosure is fixed in position. The fixing screws shall be inside the sealed enclosure. 12. EARTHING Suitable earthing terminal(s) (one in the case of single-phase and two in the case of 3-phase MCB) shall be provided on the enclosure for making earthing connection(s). The earthing terminal(s) shall be marked with Earth symbol. 13. MARKING Each MCB shall be indelibly marked with the following particulars so as to be clearly visible on the front : i) Make ii) Rated Voltage iii) Rated current

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iv) v) Rated short circuit capacity Name of the purchaser (Electricity Board etc.)

14. TESTS The following tests shall be made in accordance with the IS:8828. 14.1 Type Tests a) Test Duty-1 i) High voltage Test ii) Over Current Device Calibration Tests iii) Temperature-rise Test iv) Overload Performance Test v) Endurance Test b) Test Duty-II Short-circuit Capacity Tests Test Duty-III i) Time/Current Characteristic Test ii) Flexible Cord Test iii) Shock Test Routine Tests i) High Voltage Test ii) Over Current Device Calibration Test

c)

14.2

15. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser. The manufacturer shall afford the inspector, representing the purchaser, all reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is any dispute regarding the quality of supply.

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REC Specification 62/1993 HIGH TENSILE STEEL WIRES FOR PCC POLES FOREWORD REC Specifications 15/1979 and 24/1983 stipulate the requirements of pre-stressed cement concrete poles for 11KV/LT lines and for 33KV lines respectively. Therefore it is proposed to issue a Specification for High Tensile Steel Wires used for manufacturing PCC poles. Two types of wires are generally used for making PCC Poles, which are covered in IS:6003 (Indented) and IS:1785 (Pt-I)(Cold Drawn Stress Relieved). Considering the advantage of better grip of indented wires, the proposed Specification stipulates only these wires. This Specification is based on the discussions/decision of 13th Standardisation Conference held on 4th-6th May 1993. 1. SCOPE This specification covers the requirements of indented type High Tensile Steel Wires for manufacturer of PCC Poles. 2. APPLICABLE STANDARDS Except when it conflicts with the specific requirements of this Specification, the wires shall comply with the provisions made in IS:6003/1983 (Specification for Indented Wires for pre-stressed Concrete). 3. NOMINAL SIZES The nominal diameter of the finished wires shall be 4mm and 5mm, as required. TOLERANCE The tolerance on the nominal diameter shall be (+) 2% to (-) 1%. 4.1 The diameter shall be determined with a micro-meter by taking two measurements at right angles to 4.2 each other at three places along a length of not less than 250mm and the average of these six measurements shall be taken as the diameter of the wire. As indenting is done after drawing, there are chances of the material being compressed at the points of 4.3 indenting. In taking the measurement of diameter, such points shall be avoided to enable correct measurement. 5. MANUFACTURE AND CHEMICAL COMPOSITION 5.1 The wires shall be cold drawn from steel made by the open hearth, electric duplex, acid Bessemer, basic oxygen or a combination of these processes. 5.2 6. The chemical composition and manufacturing details shall conform to IS:6003.

4.

MECHANICAL PROPERTIES 6.1 Tensile Strength Unless otherwise agreed to between the purchaser and the supplier, the minimum specified tensile strength of wires shall be as given below :

Nominal Dia Tensile strength (Min) (mm) (N/mm 2)

4 5
6.2

1715 1570

Proof Stress The proof stress of the wires shall be not less than 85% of its minimum specified tensile strength. Ductility The wires shall withstand the reverse bend test specified in IS:6003. Elongation after fracture Elongation after fracture over a gauge length of 200mm shall be as follows :

6.3

6.4

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Nominal Dia (mm) Elongation % (Min.) (Gauge length 200mm)

4 5
6.5

3 4

Relaxation Stress The relaxation stress in the wires shall not exceed the provision of IS:6003-1983. Alternatively, the manufacturer shall provide proof that the quality of wires supplied is such as to comply with this requirement. Stress Corrosion The manufacturer shall provide proof that the quality of wires supplied is such that it is not susceptible to stress corrosion.

6.6

7.

SELECTION OF TEST PIECES 7.1 All test pieces of wires of sufficient length for specified tests shall be selected either from. a) the cuttings of length of wires or ends of coils of wires; or b) from the coil or a length of wire, after it has been cut to the required or specified length and the test pieces taken from any part of it. 7.2 A test piece shall be detached from the coil or length or wires only in the presence of the purchaser or his authorised representative. 7.3 Before the test pieces are selected, the manufacturer shall furnish the purchaser with copies of the mill record giving the number of coils or bundles in each cast with sizes as well as identification marks whereby each coil or bundle of wire can be identified. 7.4 Test samples shall not be subjected to any form of heat treatment. sample may require shall be done cold. Any straightening which the test

8.

TESTS The following tests shall be carried out in accordance with IS:6003. i) Tensile test ii) Test for proof stress iii) Reverse bend test iv) Test for elongation after fracture v) Test for relaxation stress SAMPLING AND CRITERIA FOR CONFORMITY The details for sampling and criteria for conformity shall be as per IS:6003.

9.

10. MARKING The following information shall be tagged to each coil : i) ii) iii) iv) v) vi) vii) Manufacturers name Purchasers name Trade Mark, if any Year of manufacturing Coil identification number Sizes of wire Length of wire

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REC Specification 63/1993 (Revised 1997) 11 KV XLPE CABLES FOREWORD Cross linked polyethylene (XLPE) cables have practically replaced the use of PILC (paper insulated lead covered) cables all over the world due to their superior physical and electrical properties compared to PILC cables. For a comparable size, XLPE cables have higher current rating, better short circuit and over load withstand capability and are more rugged and flexible in use. These cables have lower power losses and are lighter in weight. On the whole, it is seen that XLPE cables are more economical for comparable current carrying capacities. The existing REC Construction Standards L4 and L5 cover recommended sizes of PILC and XLPE cables respectively. The intention was to permit use of both type of cables till availability and use of XLPE cables is fully established. However, a stage is now reached, when a number of cable manufacturers have taken up manufacture of XLPE cables and majority of the SEBs have gained experience in their use. It is, therefore, felt that use of only XLPE cables be standardised, in view of the advantages indicated above. Based on the decisions taken by the 13th conference on Standardisation, Technical Development and Training held on 4th - 6th May 1993, at New Delhi, REC specification No.63/1993 was issued. Based on the recommendations of the 14th Standardisation Conference held on 25th April, 1997, this specification is being revised. The revised specification includes many more standard sizes of cables apart from those recommended sizes as indicated in REC Standard L5. Type test for armouring wires/strips has been added. Useful information on indicative values of continuous current ratings at 90o C and the Short Circuit ratings which were not included earlier have now been included. This makes the specification more comprehensive for utilities. 1. SCOPE This Specification covers requirements of 11 KV Cross Linked Polyethylene (XLPE) insulated and PVC sheathed aluminum cables for use in Rural Distribution. APPLICABLE STANDARD Except when it conflicts with the specific requirements of this specification, the cables shall comply with the latest version of IS : 7098 (Pt. II) - 1985 - Specification for Cross Linked Polyethylene Insulated PVC Sheathed Cables. 3. RATED VOLTAGE AND TEMPERATURE The rated voltage of the cables shall be 6.35KV/11KV and the maximum operating voltage shall be 12 KV. Maximum continuous operating temperature (combination of ambient temperature and temperature rise due to load) shall be 90o C under normal operation and 250 degree C under short circuit conditions. 4. TYPE OF CABLES The type of cables covered in this specification shall be (i) single-core armoured (non-magnetic) screened and (ii) three-core armoured screened. 5. STANDARD SIZES OF CABLES The standard sizes of cables which can be used for various applications are as mentioned below : 5.1 Single core Cables : 25 sq.mm., 35 sq.mm., 50 sq.mm., 70 sq.mm., 95 sq.mm., 120 sq.mm., 150 sq.mm., 185 sq.mm., 240 sq.mm., 300 sq.mm., 400 sq.mm., 500 sq.mm., 630 sq.mm. 5.2 Three Core Cables : All the above sizes upto and including 500 sq.mm., may be treated as preferred sizes. 2.

For standard recommended sizes of XLPE cables in 33/11 KV Sub-stations (for 33/11KV transformers and 5.3 for 11 KV outgoing feeders) please refer REC Standard L5. 6. CONTINUOUS CURRENT AND SHORT CIRCUIT RATINGS The indicative values of the continuous current carrying capacities (for design purposes by field engineers) of the various sizes of the cables are given in the tables in clause 6.1 and 6.2. 6.1 Single Core cables : S. No. Size of cable sq.mm. Indicative values of continuous current carrying capacity in Amps at maximum conductor temperature of 90o C. In Ground 1 25 93 In Air 105

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2 3 4 5 6 7 8 9 10 11 12 13 6.2 Three Core Cables : S. No. Size of cable sq.mm. Indicative values of continuous current carrying capacity in Amps at maximum conductor temperature of 90o C. In Ground 1 2 3 4 5 6 7 8 9 10 11 12 25 35 50 70 95 120 150 185 240 300 400 500 93 110 130 160 185 205 235 270 305 340 395 455 In Air 95 115 140 175 200 230 265 310 345 396 460 590 35 50 70 95 120 150 185 240 300 400 500 630 111 138 170 200 230 255 290 335 380 429 481 541 130 159 198 240 280 325 365 430 495 528 680 780

6.3 The short circuit rating for the various sizes of the cables (single core and three core) calculated for a duration of 1 second at maximum temperature of 250o C is given below :Sl. No. Size (sq. mm.) (3 phase/and Single phase) 25 35 50 70 95 120 150 185 240 300 400 500 630 Conductor Short Circuit rating (KA) (rms value)*

1 2 3 4 5 6 7 8 9 10 11 12 13

2.35 3.29 4.70 6.58 8.93 11.3 14.1 17.4 22.6 28.2 37.6 47.0 59.2

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* For guidance only 7. DETAILS OF CABLES 7.1 Conductor: The cable conductors shall be of round, stranded and compacted aluminum of nominal size as stipulated in Table under Clause 5. Corresponding wire diameter and number of wires in the conductor shall be as given in IS : 8130. 7.2 Conductor Screen: Conductor screening shall be provided over the conductor by applying non-metallic semi-conducting tape or by extrusion of semi-conducting compound or a combination of the two. 7.3 Insulation: The insulation shall be of extruded cross linked polyethylene (XLPE) of nominal insulation thickness 3.6 mm and its properties shall conform to IS : 7098 (Pt. II). 7.4.1 Insulation screen: The insulation screen shall consist of two parts; namely, metallic and non-metallic. Non-metallic part shall be applied directly over the insulation of each core and shall consist of either a semiconducting tape or extruded semi-conducting compound or a combination of the two or either material with semi-conducting coating. 7.4.2 The metallic part shall consist of either tape, or braid or concentric serving of wires or a sheath; shall be non-magnetic and shall be applied over the non-metallic part. For single-core armoured cables, the armouring may constitute the metallic part of the screening. 7.5 Core-identification & laying up of cores: The core identification and laying up of cores shall be as per IS : 7098 (Pt. II). For identification of different cores in three-core cable, use of coloured stripes, red, yellow and blue, or use of numbered strips shall be employed. 7.6 Inner Sheath: The laid up cores shall be covered with inner sheath made of thermoplastic material applied either by extrusion or wrapping. It shall be ensured that the shape is as circular as possible. Thickness of inner sheath shall conform to IS : 7098 (Pt. II). Single Core cables shall have no inner sheath, but in case of cables having both metallic part of screen and armour, there shall be an extruded inner sheath between them. 7.7 Armouring: Armouring shall be applied over non-metallic part of insulation screening or the inner sheath as the case may be for single-core cables and over the inner sheath for 3core cables. The method, type, dimensions, joints, conductance etc. of armour shall conform to IS : 7098 (Pt. II). 7.8 Outer Sheath: The outer sheath shall be applied over the armouring. The minimum thickness and properties of outer sheath shall conform to the requirement of IS : 7098 (Pt. II). 8. TESTS 8.1 The following tests shall be carried out on the cables as per IS : 7098 (Pt. II). 8.1.1 Type Tests a) Tests on conductor : i) Tensile test ii) Wrapping test iii) Resistance test b) Tests for armouring wires/strips c) Tests for thickness of insulation and sheath d) Physical tests for insulation i) Tensile strength and elongation at break ii) Ageing in air oven iii) Hot test iv) Shrinkage test v) Water absorption e) Physical Tests for outer sheath i) Tensile strength and elongation at break ii) Ageing in air oven iii) Shrinkage test iv) Hot deformation v) Bleeding and blooming test f) Partial discharge test g) Bending Test h) Dielectric power factor test : i) As a function of voltage ii) As a function of temperature i) Insulation resistance test (volume resistivity)

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j) k) l) m) 8.1.2 a) b) c) d) e) f) g) h) i) 8.1.3 a) b) c) 9. Heating cycle test Impulse withstand test High voltage test Flammability test Acceptance Tests Tensile test Wrapping test Conductor resistance test Test for thickness of insulation and sheath Hot set test for insulation Tensile strength and elongation at break test for insulation and sheath Partial discharge test High voltage test insulation resistance (volume resistivity) test Routine Tests Conductor resistance test Partial discharge test High voltage test

PACKING AND MARKING 9.1 Packing: The cables shall be supplied in wooden drums conforming to IS : 10418. The standard length of cable in each drum shall be 0.5 KM ( ) 5%. 9.2 Marking: The cable drum shall carry the information as per requirement of IS : 7098 (Pt. II).

The manufacturers name or trade-mark, the voltage grade, year of manufacture etc. may be printed or 9.3 embossed on the cable as stipulated in IS : 7098 (Pt. II). 10. INSPECTION All the tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturers shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that material is being furnished in accordance with the Specification. The purchaser has the right to have tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.

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REC Specification 64/1993

AERIAL BUNCHED CABLES FOR 11KV LINES FOREWORD REC has already issued a Specification for Aerial Bunched Cables for LT lines and some of the SEBs have already initiated action to use these cables for LT distribution. APSEB had procured a fairly large quantity of these cables. Power distribution through aerial bunched cables (ABC) has many advantages including total safety, minimal system faults, significant reduction in theft of energy (unlike bare conductors, it is difficult to tap power from insulated cables, twisted together, by hooking etc.), eliminating the problem of tree clearance etc. At the instance of some of the SEBs notably Maharashtra, Andhra Pradesh and Kerala, it is now proposed to issue an REC Specification for Aerial Bunched Cables for 11 KV lines. These cables are especially intended for use in forest areas where tree clearance poses a serious problem and narrow streets in towns where it is difficult to get clearance for bare conductor lines. Distribution through aerial bunched cables, even though, much costlier than bare conductor overhead lines, is considerably cheaper as compared to underground distribution. This type of cables have been used in many countries for the type of locations indicated above. The composite cable comprises of 3 XLPE insulated single phase cables twisted around a bare messenger wire made from aluminium alloy. As both XLPE insulated cables and aluminium alloy conductors are now indigenously available, there should not be any difficulty in manufacturing these cables. Based on the decisions taken in the 13th Conference on Standardisation, Technical Development and Training held on 4th-6th May, 1993 at New Delhi, this specification is issued. 1. SCOPE This Specification covers requirements of XLPE insulated, 11 KV Aerial Bunched Cables for overhead lines.

COMPOSITION OF THE CABLE The composite cable shall comprise three single-core cables twisted around a bare aluminium alloy messenger wire, which will carry the weight of the cable. 3. RATED VOLTAGE The rated voltage of the cables shall be 6.35KV/11KV and the maximum operating voltage shall be 12 KV. APPLICABLE STANDARDS Unless otherwise stipulated in this Specification, the following Standards shall be applicable : i) ii) iii) 5. IS:7098 (Part-II) - 1985 Cross linked Polyethylene Insulated PVC Sheathed Cables IS:8130-1984 - Conductors for Insulated Cables IS:398 (Part-IV) - 1979 - Aluminium Alloy Conductors

2.

4.

DETAILS OF SINGLE-CORE CABLE The cable conductors shall be of round, stranded and compacted aluminium of nominal cross sectional 5.1 areas 35mm2 and 70 mm2. Corresponding nominal conductor diameter and number of wires in the conductor shall be as given in clause 5.7. 5.2 Conductor Screen The conductor screen shall be of extruded semi-conducting cross linked polyethylene compound of thickness not less than 0.5mm. 5.3 Insulation The insulation shall be of extruded cross linked polyethylene (XLPE) of nominal insulation thickness 3.6mm and its properties shall conform to IS:7098 (Part-II). 5.4 Insulation Screen The insulation screen shall comprise extruded semi-conducting compound and/or semi-conducting tape. Thickness of the screen shall be not less than 0.6 mm. 5.5 Metallic Screen The metallic screen shall consist of aluminium tape/sheath of thickness not less than 0.2mm. 5.6 Outer Sheath The outer sheath shall be black polyethylene. The nominal thickness of sheath shall be 1.8mm and it shall

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conform to the technical requirements of ST-3 of IEC-502. 5.7 Dimensional and Electrical Data The dimensional and electrical data for single-core cable is given below:

S.No.

Nominal Area of Conductors 35mm2 70mm2 10/12

i) ii)

Nominal conductor diameter (mm)/No. of wires in conductor Approx. over dia of cable (mm)

6.8/6

22 0.868 3.4 106

25 0.443 6.7 156

iii) Max. D.C resistance at 20oC Ohm/Km iv) Max. SC current for 1 sec. kA v)
Max. continuous load (Amps.)

Note : Due to limitations of the short circuit current rating, it is recommended that 70mm2 cable is used on the base line for the first 4-5 Kms. from the 33/11 KV sub-station and thereafter the lower size of cable, i.e. 35mm2 can be used depending upon the line loading. Normally the current loading of 70mm 2 cable should not exceed 145 Amps. and that of 35mm 2 cable as 95 Amps. For a maximum ambient temperature of 50oC. 6. MESSENGER (NEUTRAL CONDUCTOR) The bare messenger wire shall be of 70mm2 (nominal area) aluminium alloy, generally conforming to 6.1 IS:398 (Part-IV) - 1979, comprising of 7 strands and shall be suitably compacted to have smooth round surface to avoid damage to the outer insulating sheath of single-core phase cables twisted around the messenger. There shall be no joints in any wire of the stranded messenger conductor except those made in the base rod 6.2 or wires before finally drawing. 6.3 The technical characteristics of the messenger wire shall be as follows :

i) ii) iii) iv) v) vi)

Nominal sectional area (mm2) No. of wires Nominal dia of wires/compacted conductor (Approx.) mm Approx. mass Kg/Km DC resistance at 20o C Ohm/Km

70 7 3.5/10 184 0.493 20 59 23x10-6 oC

Breaking load (KN)

vii) Modulus of elasticity (Approx.) KN/mm2 viii) Coefficient of linear expansion (Approx.)

Note : The value in item v above is to be guaranteed. A tolerance of (-) 5% is permissible on the value in item vi above. 7. DESIGNATION AND PARAMETERS OF FINISHED CABLES The designation and parameters of finished cables are given in the following table :

Sl. Designation No.

Complete Bunched Cable Overall dia Approx. mm Total mass (approx.) Kg/Km 1450 1900

i) ii)

3x35+70 3x70+70

53 59

Note : The first part of the designation refers to the number and size of phase conctor and the second

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to the size of messenger wire. The sizes shown represent the nominal cross sectional areas in mm. 8. TESTS The following tests shall be carried out on the single-core cables as per IS:7098 (Part-II). 8.1 8.1.1 Type Tests a) Tests on conductor : i) Tensile test ii) Wrapping test iii) Resistance test b) Tests for thickness of insulation and sheath c) Physical tests for insulation : i) Tensile strength and elongation at break ii) Ageing in air oven iii) Hot test iii) Shrinkage test iv) Water absorption d) Tests for outer sheath : i) Tensile strength and elongation at break ii) Ageing in air oven iii) Shrinkage test iv) Hot deformation v) Bleeding and blooming test e) Partial discharge test f) Bending test g) Dielectric power factor test:

i) As a function of voltage
h) i) j) k) l) ii) As a function of temperature Insulation resistance test Heating cycle test Impulse withstand test High voltage test Flammability test

8.1.2 Acceptance Test a) Tensile test b) Wrapping test c) Conductor resistance test d) Test for thickness of insulation and sheath e) Hot set test for insulation f) Tensile strength and elongation at break test for insulation and sheath g) Partial discharge test h) High Voltage test i) Insulation resistance (volume resistivity) test 8.1.3 Routine Tests a) Conductor resistance test b) Partial Discharge test c) High voltage test 8.2 The following tests shall be carried out on the bare messenger wire in accordance with IS:398 (Part-IV). Type Tests/Acceptance Tests a) Breaking Load Test (on finished wire) b) Elongation Test c) Resistance Test

9.

PACKING AND MARKING 9.1 Packing Cables shall be supplied in wooden drums conforming to IS:10418. The standard length of the bunched cable in each drum shall be 1 Km () 10%. 9.2 Marking The cable drum shall carry the information as per the requirements of IS:7098 (Part-II).

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Suitable identification marks shall be given on the outer sheath to clearly distinguish three phases of the 9.3 bunched cable. 10. INSPECTION All the tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturers shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that material is being furnished in accordance with the Specification. The purchaser has the right to have tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.

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REC Specification 65/1993 OIL FILTRATION SET

FOREWORD Considering the important role of insulating oil in satisfactory performance of Transformers and switchgears and keeping in view the need to conserve oil, it is proposed to issue REC Specification for Oil Filtration Set suitable for use in the field as well as for transformer repair workshop. The old type of filtration sets were based on the concept of processing of oil at High Temperature (80oC) and Low Vacuum in line with IS:6034-1971. The latest trend is to carry out the purification process under High Vacuum of the order of 1-5 Torr with a working temperature not exceeding 60oC. This process ensures more effective degassification and dehumidification and at the same time the oil does not undergo unnecessary ageing which is likely to occur at high temperatures. Further, the conventional filtration sets are not normally designed to treat the oil for deacidification and only the BDV value is raised due to removal of moisture etc. The modern plants make provision for deacidification treatment in addition to filtration, degassification and dehumidification. The enclosed Specification is based on state-of-art technology. To ensure high level of purification, stringent performance criteria have been stipulated in terms of the critical test parameters of the treated oil. Based on the recommendations of the 13th Conference on Standardisation, Technical Development and Training in Rural Electrification, held on 4th-6th May, 1993, this specification is issued. SCOPE This specification covers requirements of mobile, outdoor type oil filtration sets for purification of insulating oil used in transformers/switchgear. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, the oil filtration sets shall conform to the latest version of IS:6034. STANDARD RATINGS The standard ratings of oil filtration sets shall be 500, 1000 and 2000 litres per hour. 1.

3.

Note : 500 Lph sets are intended for field use especially to meet the requirements of distribution transformers. Filtration sets of 1000 and 2000 Lph ratings are suitable for on-line filtration of oil in power transformers at 33/11 KV and 66/11 KV sub-stations and for use in transformer repair workshops. 4. PERFORMANCE REQUIREMENTS 4.1 The filtration sets shall be designed for High Vacuum/Low Temperature processing of oil. These shall be capable of producing a working vacuum of less than 5 torr in the first pass and less than 10 torr in maximum 5 passes. Working temperature shall remain between 40o to 60oC. The filtration sets shall have the following essential components : i) Heating System ii) De-acidification System iii) Filtration System iv) Degassing System 4.2 The equipment shall be capable of achieving the following results in maximum of five passes :i) Improvement in break-down voltage from 20 kv to 50 kv. ii) Reduction in moisture content from 80 ppm to 5 ppm. iii) Reduction in gas content from 10% to 0.1% by volume. iv) Removal of all suspended impurities above 1 Micron. v) Upgradation of tan-delta at 90oC and resistivity at 27oC to 0.01 (max.) and 10x1012 (min.) respectively. vi) Reduction in acidity from 0.5 to 0.1 mg KOH/gm.

5. CLIMATIC CONDITIONS The filtration sets shall be capable of satisfactory operation in atmosphere having 100% humidity and ambient temperature varying from 0oC to 50oC. The effect of direct sun radiation on the equipment shall also be taken into account. 6. HEATING SYSTEM 6.1 Method of heating shall be so designed as to avoid general or localised over-heating of oil to an extent which will result in deterioration of the insulating properties of the filtrate.

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6.2 The heater elements shall be operated from 50 Hz, 415 V, 3-phase, AC supply and shall be so connected as to cause equal load on all the phases. The heater elements shall preferably of re-wireable type. The size of wire and its electrical properties shall be indicated by supplier. The surface loading of the heater pipes should not exceed 2.5 watts/sq. cm at rated voltage and the supplier shall furnish calculations in support of this. 6.3 The temperature of oil shall be thermostatically controlled so that the temperature of oil during treatment process shall not rise above 60oC. Additional safety thermostat shall be provided to avoid over-rise of temperature in the heating chamber. 6.4 A dial type thermometer having marked in red the optimum temperature for filtration shall be provided to indicate temperature of oil. 6.5 A suitable relief valve set to a pressure of 2 to 5 lb/sq. in (O.14 - 0.35 Kg/cm2) shall be provided in the heater chamber to prevent any pressure rise in the chamber. 6.6 The heater capacity should be based on a minimum ambient temperature of 0oC so that the filtration plant shall have the same efficiency even when operating under ambient condition of 0oC. 7. DE-ACIDIFICATION SYSTEM The de-acidification chamber shall be suitably charged with activated alumina so as to achieve the results stipulated in Clause 4.2 (vi). The supplier shall give necessary information on the replacement/recharging of activated alumina to maintain adequate efficiency of the de-acidification system. 8. FILTRATION SYSTEM 8.1 Main Filtration Chamber : 8.1.1 The filter elements shall consist of suitable number of discs of specially prepared, chemically treated paper, mounted on a central perforated tube and maintained in compression by spring loading. The dirty oil shall be passed through the face of filter discs from outward towards the centre and all solid matter such as soot, sludge, insulating material, fibre etc. shall accumulate on outer periphery of filter elements. To enable constant flow a large filtering surface shall be provided. The paper shall be of high quality and shall not get damaged by the passage of hot oil through the filter elements. 8.1.2 The filter stack shall be easily removable for replacement and maintenance and detailed instructions shall be provided in this regard. 8.1.3 Suitable provision shall be made for quick and thorough cleaning of clogged matter on the paper edges by means of compressed air or oil pressure. A separate compressor and a air reserve tank shall be provided for this purpose. The filter tank shall be such that all impurities accumulate at the bottom of tank and can be conveniently withdrawn by means of a drain valve/discharge cock. 8.1.4 The quantity of oil which can be filtered without replacing the filter elements and normal life of the filter packs shall be indicated. Note : As an alternative to the above filtration process, the purchaser has the option to specify use of filter cartridges of throw-away type. However, considering the replacement costs, this alternative is not preferable. A coarse filter with magnetic strainer shall be provided for preliminary filtering and serving as protection for 8.2 feed pump. A filter press shall be provided for removal of sludge and shall be designed for easy and quick replacement 8.3 of filter paper. 9. DEGASSING SYSTEM The degassing chamber shall be built from best quality steel suitable to withstand the designed vacuum. 9.1 Moisture and gases in dissolved form shall be removed from oil in this chamber. Special type of shallow trays with rasching rings shall be provided in the chamber to increase the surface area for oil to get spread in thin film for effective removal of moisture/dissolved gases. The chamber shall be connected to vacuum pump on top side and clean oil pump on lower side. A float switch shall be provided to switch off the oil feed pump if the oil level in the chamber rises above a 9.2 predetermined limit. A suitable inspection window or gauze glass shall be provided to give clear indication of oil in the chamber. Another low-level switch shall be provided and interlocked with the centrifugal pump on discharge side. The vacuum pump shall be of suitable design and capacity so as to achieve a working vacuum of not less 9.3 than 5 Torr in the first pass and less than 1 Torr in maximum of five passes. The vacuum pump shall be connected to the degassing chamber by means of suitable pipes and valves. A vacuum gauge of high vacuum range shall be provided for indicating the working vacuum of the system. A vacuum breaking valve shall also be provided. The pipe line shall be of adequate capacity and shall be provided with smooth bends for ensuring smooth working of

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vacuum pump. The vacuum pump shall be of enclosed type and shall be able to run continuously without attaining harmful temperature. The bearings of vacuum pump shall be of such a design and quality as to ensure noiseless operation; suitable means for lubrication shall be provided. Automatic non-return valve should be provided to avoid back flow of oil in the event of power failure. The vacuum pump shall conform to a recognised international standard which shall be clearly indicated by 9.4 the supplier and supported by Type Test Certificates of the manufacturer of pump. 10. DIRTY AND CLEAN OIL PUMPS 10.1 Dirty and clean oil pumps shall be of such type as to avoid churning and foaming of oil and also to maintain constant output irrespective of variation in the suction head. The inlet pump shall be protected by a pressure valve against over pressure. The pump shall be driven by a separate motor and its contactor relay shall be interlocked with the high-level float switch in the degassing chamber. The pump shall be suitable for a suction lift of not less than 4.5 metres. The clean oil pump shall have a high suction and discharge lift so as to draw purified oil from the 10.2 degassing chamber held under high vacuum and pump it back to the transformer up to a height of 6 metres. The pump shall have an independent drive. 10.3 Suitable solenoid valves shall be provided at inlet and outlet to shut-off flow of oil to avoid mixing of dirty and clean oil in case of power failure. The valves should also be interlocked with the respective pumps. 10.4 The filtration set shall be supplied with 10 metres of suction and 10 metres of delivery hose pipes of flexible type for dirty and clean oil. The hose pipes must be weather-proof and oil-proof and shall be capable of withstanding high vacuum and maximum oil temperature of 80oC. The pipes should be made of good quality synthetic rubber and shall not be of natural rubber. The pipes shall be provided with suitable flanges for connecting them to filtration set on the one side and transformer/switchgear on the other. 11. ELECTRIC SUPPLY SYSTEM The driving motors for various pumps/compressor shall be of 3-phase, 415V, 50 Hz, conforming to IS:325 except that the motors shall work satisfactorily with a voltage variation from (+)6% to (-)15%. The motors shall be of totally enclosed type capable of working continuously without attaining dangerous temperature rise in the ambient temperature up to 50 o C. Allowance shall also be made for the equipment being directly exposed to sun. The motors shall be suitable for direct on-line starting and shall be provided with suitable starters for proper protection. In addition, an earth leakage circuit breaker shall be provided on the incoming supply to comply with the safety requirements of IE Rules. A suitable MCCB conforming to IS:2516 shall be provided for overload and short-circuit protection and also to act as the main switch for the incoming power supply. A mimic diagram with indicating lamps shall be provided on the control panel. 12. OUTER CASING 12.1 The entire equipment shall be enclosed in weather-proof casing made from sheet steel of best quality. The casing shall be provided with suitable door(s) for access to electrical controls, gauges, inspection cover etc. All joints shall be lined with rubber lining and suitable type of latches/handles shall be provided for easy handling and keeping the doors/openings closed when not required to remain open. The complete filtration set shall be mounted on a trailer bearing pneumatic tyres. The trailer shall be 12.2 complete with tow bar and automatic mechanical over-run brakes conforming to road regulations. Suitable type of leaf springs/shock absorbers shall be provided so as to save the equipment from jerks during transit from one place to another. Lighting system plate bracket to comply with traffic regulations shall be provided. The towing arrangement shall be of folding type so that it is possible to transport the entire equipment in a truck, if required. 12.3 Four screw jacks shall be provided for proper leveling of the equipment and to take the load off the tyres.

13. PAINTING Before painting, all ungalvanised parts shall be thoroughly cleaned and given phosphate treatment. The surface shall then be applied two coats of primer before being finally spray-painted. 14. TOOLS Necessary tools for maintenance of oil filtration set shall be supplied along with the set, free of cost. 15. MARKING The marking shall conform to the requirements of IS:6034-1971 or its latest version. 16. WARRANTY The filtration set shall be guaranteed against all defects in materials, workmanship and performance under normal use and service for a period of one year from the date of receipt of equipment by the purchaser. 17. TESTS The supplier must furnish details of all type and routine tests performed to ensure proper performance of the

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equipment in accordance with this Specification. 18. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.

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REC Specification No.66/1993

RESIDUAL CURRENT OPERATED CIRCUIT BREAKERS

FOREWORD The use of earth leakage protective device has been made mandatory under Indian Electricity Rules 1956 (Amendment to Rule 61) for all low voltage (240 V) installations of 5KW and above and all medium voltage (415V) installations. The intention of this provision is to provide safety against electric shock. The device shall instantaneously disconnect supply by sensing earth leakage current caused by direct or indirect contact of a person with any part of the installation having electric potential . A number of States have already enforced this provision and new connections are released only after the requirements of the amended IE Rules are met with. A need was felt by many SEBs for a proper standard for earth leakage devices. In order to provide guidance to the SEBs and to the consumers, it is proposed to issue a REC Specification for RCCBs specially for use in rural electrification system. The RCCBs have been in use in many countries for a long time to ensure safety for users of electricity. But their use is relatively new in this country. It is, therefore, necessary to have a proper understanding of these devices and standardise the important features so as to ensure use of only right type of devices. Apart from provisions for use in the consumer installations these RCCBs should also be used in all offices, control rooms, residential quarters of SEBs as a safeguard against electric shock and prevention of fire due to high leakage currents. The RCCBs, with integral over current and short circuit protection are also available and the cost is only marginally higher than the RCCBs. Use of composite devices of proper rating will not only satisfy the requirements of IE Rules to provide both over current and earth leakage protection, but will also enable the SEBs to keep better control on the consumers load demand which is not possible with the use of fuses. This will be of special relevance to the states having flat tariff for agricultural consumers as it will inhibit the tendency of the consumer to use higher rating motors to avail of lower monthly charges. Use of integrated circuit breakers will thus help in (i) providing safety against shock and fire (ii) Boosting the revenue (iii) Reducing transformer burn outs due to over-loading on account of unauthorised extensions by consumers. Based on the decisions taken in the 13th Conference on Standardisation, Technical Development and Training, this Specification is issued. 1. SCOPE This specification covers requirements of single-phase and 3-phase, 50Hz, Residual Current-operated 1.1 Circuit Breakers (RCCBs), also called Earth Leakage Circuit Breakers. 1.2 RCCBs are intended for protection against electric shock and their use is mandatory for all low voltage (240V) installations of 5KW and above and all medium voltage (415V) installations as per amendment to Rule 61 of Indian Electricity Rules 1956. Use of RCCB also afford protection against possibility of fire due to high earth leakage currents, which are not taken care of over-current protective devices. Note : Even though low voltage installations below 5 KW are exempted from the application of RCCBs as per provisions of the law, their use is desirable on the installations from the point of view of human safety. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, RCCBs will conform to the requirements of IS:12640-1988. 3. NUMBER OF POLES RCCBs shall be of two-pole and four-pole type for use on single-phase and 3-phase installations/service connections respectively. 4. RATED VOLTAGE The rated voltage of RCCBs shall be 240V for single phase and 415V for 3-phase type. 5. RATED CURRENT 5.1 The rated current for RCCBs covered in this specification shall be 25 Amps. NOTE: The above rating will be adequate for most of the applications in rural distribution system and is suitable for single-phase connections up to 5KW and 3-phase up to 15 KW. 5.2 The next higher standard ratings for special applications shall be 40 Amps. and 63 Amps.

6. RATED TRIPPING CURRENT

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The rated tripping current shall be 30 milli Amps. 7. BREAK TIME Maximum break time at rated tripping current shall be 0.2 secs. and at 5 times the rated tripping current, shall be 0.04 secs. 8. RATED FAULT THROUGH CAPACITY The rated fault through capacity for the purpose of Circuit Fault Current Test shall be 1500 Amps. 9. RATED BREAKING CAPACITY The rated breaking capacity under high-current earth fault shall be 500A. 10. TERMINAL Screw type terminals shall be provided to receive copper/aluminium cables of sizes ranging from 2.5 to 16mm2. 11. TEST DEVICE A push button or any other suitable device shall be provided to periodically test healthy tripping operation of the RCCB by simulating earth leakage current. 12. GENERAL REQUIREMENTS 12.1 The terminals shall be so arranged that the exposed current carrying parts are not accessible and prone to accidental contact by the person operating the RCCB. 12.2 If the RCCB is housed in a metallic enclosure, it shall be provided with one earthing terminal in the case of low-voltage and two terminals in the case of medium voltage RCCBs. 12.3 12.4 The operating mechanism shall be trip-free. There shall be a clear indication for 'ON' and 'OFF' positions of RCCB.

12.5 The operating mechanism of RCCB shall be such that the neutral pole shall open after and close before the phase pole(s). 13. FUNCTION DEPENDENCE ON LINE VOLTAGE The RCCB design should preferably be such as not to be functionally dependent on line voltage; the 13.1 tripping mechanism should be directly actuated by the residual current resulting from earth leakage fault in the installation irrespective of the line voltage. 13.2 If the mechanism depends for its operation on the line voltage, the RCCB shall function satisfactorily in the voltage range 50V to 1.2 times the rated voltage. In the event of loss of voltage due to break in neutral conductor in the case of single-phase RCCB and 13.3 break in neutral and/or any one or two of phase conductors for 3-phase RCCB, the RCCB shall either remain functional or shall automatically trip within 0.5 sec. Note : RCCBs requiring use of earth connection to satisfy the above requirements are not suitable for installations not having an independent and effective earthing system to provide an alternative current path for tripping of RCCB in the event of break in the neutral conductor. 14. MARKING 14.1 RCCB shall be marked legibly and in durable manner with the following particulars : a) Manufacturer's name or trade mark b) Type designation c) Reference to the Standard d) Number of poles e) Rated voltage f) Rated current g) Rated tripping current 14.2 When mounted in the normal service position, the following markings shall also be readily visible on the front of the RCCB : i) 'e' 'f' and 'g' of clause 14.1 ii) Test device shall be marked 'T' iii) Closed and open positions shall be marked ON/OFF or I/O or both iv) The terminal for the connection of the neutral conductor shall be distinguished by the symbol 'N'; where it

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is necessary to distinguish between supply side and the load side terminals, it shall be clearly indicated. 14.3 The diagram of connections shall appear on the RCCB.

15. TESTS The following tests shall be carried out in accordance with IS:12640-1988 or its latest version : 15.1 Type Tests Test sequence 1 a) High voltage b) Temperature rise c) Transformer (current) balance d) Making and breaking e) Speed of operation f) Durability of marking g) Determination of test device ampere-turns h) Effective earthing Test sequence 2 a) Endurance b) Sensitivity Test Sequence 3 a) Circuit fault current test Test a) b) c) d) e) Sequence 4 Resistance to humidity High voltage flash Sensitivity Rated earth fault breaking current Shock test

15.2 Routine Tests a) Sensitivity b) Verification of performance of test Device c) High-voltage flash test In addition to above tests, tests to establish requirement of Clause 13 shall be made on RCCBs 15.3 functionally dependent on line voltage. These shall constitute Type as well as Routine tests. 16. COORDINATION WITH OVER-CURRENT PROTECTION DEVICE 16.1 RCCBs conforming to this specification are capable of breaking earth fault current as specified in Clause 9 and can withstand fault through current as stipulated in Clause 8. Whereas RCCB may open under high earth fault current, it will not operate under short circuit conditions when there is no earth fault current. The device is, therefore, required to be protected by a suitable back-up over-current protection device like fuse, miniature circuit breaker, etc., which should be selected on the basis of the prospective fault current. Use of a suitable over-current protection device is also mandatory under the provisions of IE Rules. Alternatively, RCCBs with integral over-current/short-circuit protection can be used. In selecting this 16.2 composite device, it should be ensured that the short-circuit withstand capacity is not less than the prospective fault current in the installation. The standard short-circuit braking capacity of this integrated device of rural applications shall be 6 KA and standard current ratings shall be 6, 10,16 and 25Amps. Note: Use of proper current rating for RCCBs with integrated over-current/short-circuit protection will help in restricting the consumer's power demand within the sanctioned load. 16.3 The integrated circuit breakers shall conform to the requirements of IS:8828 in addition to the requirements of this specification. 17. DISCRIMINATION RCCB covered in this specification are normally intended for controlling individual installations. Where it is considered necessary to use RCCBs for individual circuits of the installation or for individual installations (e.g. multistory building) fed from a common power supply connection, it is possible to achieve discrimination by using selective tripping currents. For example,30 milli Amps. device can be used for individual circuit/installations and 300 milli Amp. rating can be used at the common point of commencement of supply. Alternatively, graded break times can be adopted such as 0.2 sec. for the main incomer device and 0.040 sec. for the individual circuits/installations.

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18. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.

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REC Specification 67/1993

CONTROLLER CUM INVERTER FOR SOLAR STREET LIGHTS

1. SCOPE This specification covers the requirements and tests for 12 Volt DC to 110V AC controller cum Inverter, for use in Rural Street Lighting stand alone applications using solar photovoltaic panels. 2. ELECTRICAL CHARACTERISTICS The Controller Cum Inverter for Solar Street Lights shall have the following Electrical Characteristics : a) b) c) d) e) Input voltage Output voltage Output frequency Current drawn on input side at 12V on No load Current drawn on output side at full rated load Output wave form Efficiency 12V () 2V DC 110 () 20V AC Above 10 KHz 0.8 to 1.0 A 1.7 to 2.0 A Approximately square or sinusoidel 80% or more

f) g)

3. PROTECTIONS INDICATIONS & CONTROLS PROTECTION a) Short circuit protection on AC output side shall be provided b) The reverse current flow protection shall be provided by means of a blocking diode or any other means so as to prevent reverse current flow from battery to panel. c) Reverse polarity protection shall be provided. Note : No provision has been made for protection against voltage variations as a suitable control device is being incorporated in the Specification of the Battery, if it is considered necessary by the supplier of the battery. It is understood that in case of NICAD batteries this type of protection is not needed as advised by the battery manufacturers. However, it may be necessary for Lead Acid Batteries and in that case the manufacturer of the battery will provide this protection along with the battery. INDICATIONS a) Red LED indication shall be provided when the battery voltage falls below 10.5 V. b) Green LED indication shall come when the unit is ON. CONTROLS "A push button switch" shall be provided to test the functioning of the equipment. CASING The enclosure shall be made of mild steel (spray painted) lined with an insulating material or, alternatively the enclosure shall be made of strong FRP material. 4. GUARANTEE The controller-cum-inverter for solar street light shall be supplied under 3 year guarantee for free replacement/repair in the event of the improper performance. 5. TEMPERATURE, MAINTENANCE & LIFE The controller cum inverter shall be suitable for outdoor use along with solar photovoltaic system and therefore should be capable of operation upto temp. of 60oC for prolonged periods without developing any fault. 6. TESTS As no Standards are available at present for the tests required to be carried out, the tests will be specified after gaining sufficient field experience. 7. PACKING The controller cum inverter shall be suitably packed securely in wooden crate/cardboard boxes suitable for handling during transit by road/rail and shall be secured to avoid any loss or damage during transit. 8. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge to satisfy him that the material is being furnished in accordance with

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this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.

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REC Specification 68/1993 SWITCHED LT CAPACITORS FOREWORD With rapid increase in power demand for agricultural pumpsets, most of which operate at low power factor, the need for providing adequate reactive compensation in the system has assumed considerable importance. REC has been advocating the use of 11KV automatically switched capacitors directly on the long and heavily loaded 11KV lines as one of the effective and economical methods for controlling the line losses. However, it is always better to provide the reactive compensation as near to the load as possible and therefore as an alternative to the provision of capacitors on 11KV lines, some of the SEBs suggested provision of LT Switched capacitors on the secondary side of the distribution transformers mainly feeding agricultural load. To enable the SEBs to try the new concept a draft REC Specification was formulated and circulated a few years back. Based on the experience gained on the equipment tried in the field and certain useful suggestions/comments received from the SEBs, IEEMA and manufacturers, the specification was modified and placed before the 13th Conference on Standardisation, Technical Development and Training held on May 4th - 6th, 1993 at New Delhi. This specification is being issued taking into consideration the concensus reached on this subject during the conference. 1. SCOPE This specification covers outdoor type automatically switched LT capacitor Banks for use on the secondary side of distribution transformers mainly feeding agricultural pumping loads. The equipment covered in this specification comprises (i) Capacitor Bank and (ii) Automatic Control panel. 2. APPLICABLE STANDARDS Unless otherwise modified in this Specification, the Capacitor Units shall comply with IS:13340 and 13341 and other components such as Contactors, MCCBs etc. shall comply with the latest versions of relevant Indian Standards.

A. CAPACITOR BANKS 3. STANDARD CAPACITOR RATINGS The standard capacitor bank ratings for use with transformers of different capacities shall be as follows : 3.1 Transformer Rating (KVA) 3-phase Capacitor Bank Rating (KVAR)

25 63 100

9 27 36

3KVAR Single phase capacitor units shall be used for marking the capacitor banks. The units shall be 3.2 connected in delta formation. 3.3 Only ISI marked capacitor units shall be accepted.

4. TEMPERATURE CATEGORY The capacitor units shall be suitable for Temperature category 500 C as per IS:13340-1993. 5. RATED VOLTAGE The rated voltage of the capacitor units shall be 415 V. 6. REACTIVE OUTPUT The maximum continuous reactive output of a capacitor unit (including any due to the flow of harmonic current) shall not exceed 30% over the rated reactive output of the capacitor. 7. RATING PLATE A rating plate shall be provided on each capacitor unit containing the information specified in IS:13340-1993. 8. CONSTRUCTIONAL AND DESIGN FEATURES The capacitors shall use metallised polypropylene film impregnated with non-PCB oil or coated with epoxy 8.1

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resin. Note : SF-6 gas filled hermitically sealed capacitors with metallised polypropylene film shall also be acceptable under this specification to gain experience on the new technology. 8.2 The capacitor shall be of self-healing type.

A suitable device shall be provided to automatically disconnect the capacitor unit from supply if excessive 8.3 pressure is generated inside the unit. Note : Provision of the above device can be dispensed with if a special design is adopted which does not result in development of excessive pressure inside the container resulting in its bulging/ bursting. The power loss in capacitor shall not exceed 1 watt per KVAR measured at the bushing terminals of the 8.4 finished capacitor units. If required, suitable induction coil shall be provided to control the inrush current due to switching of the 8.5 capacitors. The supplier shall furnish data to prove suitability of the contactors to handle inrush current with or without induction coil. Reference is also invited to provision of Clause D-7.1 on page 20 of IS:13340-1993. Suitable discharge device shall be connected across the capacitor terminals to reduce the residual voltage 8.6 from the crest value of the rated voltage to 50V or less within one minute after the capacitor is disconnected from the source of supply. Suitable HRC switch-fuse unit of 16 KA rupturing capacity shall be provided for protection/switching off of 8.7 the total capacitor bank panel. Alternatively, MCCB of not less than 10 KA capacity or MCB of not less than 9 KA capacity can be used if their capability to handle capacitor duty is proved by suitable tests, since such a duty is not prescribed in IS:2516 or IS:8828. Suitable HRC fuses of 16 KA rupturing capacity or MCBs of 9 KA capacity or MCCBs of 10 KA capacity 8.8 shall be provided for protection of each capacitor bank step, provided capability of MCBs/MCCBs for capacitor switching duty is proved by suitable tests. Alternatively suitable electronic overload protection circuitry can be used to automatically disconnect the faulty capacitor step and another attempt will be made to switch on the particular capacitor step after an interval of 30 minutes and if the fault still persists the electronic circuitry will not switch on again till the fault is attended to . 9. TESTS The capacitor units shall be subjected to routine, type and acceptance tests as specified in IS:13340 and 9.1 13341 as amended from time to time. B. AUTOMATIC CONTROL UNIT (ACU)

10. SWITCHING ARRANGEMENT 10.1 The capacitors shall be switched on through contactors in steps of 9 KVAR as under:

Transformer Rating (KVA) 25 63 100

Capacitor Bank Rating (KVAR ) 9 27 36

No. of steps 1 3 4

Use of thyristors for switching ON or OFF of Capacitors is also acceptable as an alternative to contactors. The automatic control unit shall continuously monitor total load KVAR on the secondary side of the 10.2 transformer and shall automatically switch ON or switch OFF the capacitor banks in accordance with the parameters given in the following table : Transformer Rating Load KVAR for switching ON capacitor bank Load KVAR for switching OFF capacitor bank

25KVA

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One step* (9 KVAR) 63 KVA 1st step (9KVAR) 2nd step (9KVAR) 3rd step (9KVAR) 100 KVA 1st step (9KVAR) 2nd step (9KVAR) 3rd step (9KVAR) 4th step (9KVAR) 13KVAR 13KVAR 22KVAR 31KVAR

10KVAR
10KVAR 19KVAR 28KVAR

13KVAR 22KVAR 31KVAR 40KVAR

10KVAR 19KVAR 28KVAR 37KVAR

*Note: SEBs have the option to specify the 3-stepped arrangement even in the case of 25 KVA transformers. However, as this will add to the cost, it may be specified only if the load pattern is such that the transformers are likely to operate in under-loaded conditions (say 5-10 KVAR) for long durations. In such cases, use of two contactors (controlling 3 and 6 KVAR capacitors) is suggested to get steps of 3,6 and 9 KVAR with suitable switching 'ON' and 'OFF' instructions. 10.3 A schematic diagram of Switched LT Capacitor system for a 63 KVA transformer is given in the annexure.

10.4 A suitable protective circuit should be used to avoid damage to capacitor units when one step of capacitor is switched on to another step of capacitor already in circuit. Necessary details in this regard will be furnished by the supplier. 11. TIME DELAY The switching 'on' operation will take place only if the KVAR value indicated in column (2) of the Table in Clause 10.2 persists (or is exceeded) for a period of 2 minutes. However, switching 'off' operation will take place instantaneously if the KVAR value indicated in column (3) of the table is reached. In no case, switching 'on' operation will take place within a period of less than 2 minutes after the capacitor is switched 'off' due to any reason. 12. CONTROLS The automatic control unit shall instantaneously switch off the contactor in the following contingencies occurring in any of the phases : i) Voltage 10% above 415 V ii) Voltage 35% below 415 V iii) Load current imbalance (due to single phasing and/or any other reasons) between any of the two phases exceeding 50% of the lowest current of the 3 phases. iv) Capacitor current 30% above the rated current (only the relevant contactor will open); for capacitor current 20% - 30% above the rated current, the relevant contactor shall open if the condition persists for 30 minutes. v) Capacitor current between any of the two phases for any step differs more than 15% of the lowest current of the three phases (only the relevant contactor will open). Note: In the case of (i), (ii) & (iii) above, normal automatic functioning of the capacitor bank will resume after the excessive voltage has dropped to 5% above 415 V in the case of (i), the low voltage has risen to 25% below 415 V in the case of (ii) and the imbalance in load currents reaches to below 25% in the case of (iii) and the specified values in all these cases are maintained for two minutes. In case of (iv) & (v) above, the particular contactor will resume normal function after an interval of 30 minutes; if the fault persists it will not switch on again till the faulty condition is attended to. A suitable indication of the type of fault i.e. whether (iv) or (v) above, will also be provided. The healthy capacitor units (steps) will continue to function as the initial step(s) as per table under clause 10.2. 13. MONITORING FACILITY Suitable plug-in terminal conforming to RS 232-C (serial output) shall be provided in the panel to read out the following parameters at any point of time by using a hand-held instrument with dot-matrix printer. (The instrument and printer will not form part of the equipment to be supplied as per this specification): i) Serial number of the equipment ii) Current, voltage and power factor on the load side in each phase. iii) Current in each phase of each capacitor step. iv) Current and power factor on the transformer side in each phase (as computed by the ACU) taking into account the effect of capacitors. v) Voltage of each phase with capacitors switched off. 14. CONTROL POWER 14.1 The control unit shall get power supply from the secondary side of the transformer and no separate auxilliary

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power supply will be required for its operation. The control unit shall operate satisfactorily within voltage variation ranging from (+) 20% to (-) 40% of the 14.2 rated voltage of 415V. 15. TEMPERATURE VARIATION The control equipment and the associated circuitry shall be suitable for operation in a temperature range of (-) 100C to (+) 750C. 16. PROTECTION OF ACU 16.1 Besides in-built protection against line surges and transient over voltages, suitable fuses shall be provided for protection against over currents. NOTE : Over-voltages will include any possible voltage rise (which under extreme conditions may go up to twice the normal voltage) in the event of partial or total loss of supply and the capacitors forming a close loop with the motor(s) still revolving. Duration of the over-voltage will depend upon the time taken by the equipment to automatically disconnect the capacitors, sensing imbalance current (due to single phasing etc. or over-voltage in any phase or de-energisation of contactors due to loss of power supply). The ACU shall remain fully functional during and after these contingencies. 17. CONTROL UNIT CASING Except for the terminals, the Automatic control Unit shall be enclosed in a suitable casing so as to avoid ingress of dust.

C. CONTACTORS

18. UTILISATION CATEGORY The contactors shall be of 3-pole type suitable for switching 'on' and switching 'off' operations of capacitor banks. The supplier shall choose a contactor of a suitable operational current rating taking into consideration the inrush current and the special considerations of capacitor switching duty. Incidence of higher inrush current in the case of successive switching of capacitor banks should also be taken into account. The supplier shall furnish data in support of proper selection of the contactor rating including the making and breaking current ratings. 19. RATED CONTINUOUS CURRENT 19.1 The rated continuous current of the contactors shall not be less than 20Amps. for 9KVAR bank for operation in enclosed cabinet having a maximum ambient temperature of 550 C. The rated current indicated above i.e. 20 Amps. should correspond to 550C and necessary correction for 19.2 temperature over and above 40 0C shall be applied for this purpose. 20. RATED VOLTAGE The rated operational voltage (Ue) shall be 415 V; the insulation voltage (U) for the purpose of carrying out dielectric tests shall not be less than 500 V. 21. TEMPERATURE RISE Limits of temperature rise of various parts of the contactors as stipulated in IS:2959 shall be suitably reduced keeping in view the higher ambient temperature of 550C instead of 400C specified in IS:2959. 22. CONTROL SUPPLY 22.1 The rated voltage of control coil shall be 415V (phase-to-phase). This voltage is subject to a variation of (+) 20% and (-) 40%. The contactors shall work satisfactorily within this voltage range. 22.2 The pick up voltage of coil shall be 60% and drop out voltage shall not be more than 50%.

23. MECHANICAL/ELECTRICAL ENDURANCE The mechanical endurance of the contactors shall not be less than 3 million operating cycles at no load. The electrical endurance at normal utilisation duty for capacitor (clause 18) shall not be less than 2,00,000 operations. 24. TESTS The contactors shall be subjected to routine and type tests as described in IS:2959 but keeping in view specific requirements as indicated in this specification. In addition, type tests for verification of electrical endurance as per clause 23 above will be carried out. D. CONSTRUCTIONAL DETAILS OF THE CAPACITOR CONTROL CABINET

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25. The entire equipment comprising Capacitor Banks, Automatic Control Unit and Contactors/ Thyristors shall be housed in a suitable metallic cabinet having a front door with a provision for locking arrangement. To avoid excessive temperature rise inside the cabinet, a suitable metallic/FRP (or any other insulating material suitable for outdoor use) shield shall be provided to avoid direct exposure of the metallic cabinet to Sun. There shall be provision for free circulation of air between the shield and metallic surface of the cabinet. The cabinet shall have suitable louvers with fine wire gauze so as not to allow ingress of rain water and insects in the cabinet. Alternatively non-metallic material can be used for cabinet subject to approval of purchaser regarding strength and suitability for outdoor use and with this, use of outer shield can be dispensed with. The ambient temperature inside the cabinet shall not exceed 500 C under the most adverse operating conditions. Provision for proper earthing of the metallic cabinet will be made. 26. LED indications shall be provided on the cabinet for (i) 'on' & 'off' position of power supply to the cabinet and (ii) 'on' & 'off' position for each step of the capacitor bank (iii)fault condition due to excessive capacitor current for each step (iv) fault condition due to unbalanced capacitive current for each step. 27. The control cabinet shall be provided with a suitable fixing arrangement for proper mounting on a 2-pole structure. 28. The cabinet should be connected directly to the LT terminals of the transformer and connections should not be taken from the Distribution Box of the utility. 29. CONTROL CTs Three control CTs for sensing the load current (for computation of KVARs) along with suitable housing for outdoor use shall be provided. Unless otherwise required by the purchaser CTs shall be mounted on the power cable between the transformer and utility's distribution box. The control CTs shall be of epoxy cast type suitable for operation in ambient temperature up to 550C. The primary current rating shall be suitable for the transformer full load current and secondary rating shall match the automatic control unit requirements. 30. TESTS The specific requirements of Clauses 10 to 14 shall be proved by a Type Test carried out at a reputed laboratory. A tolerance of () 5% shall be permissible on the specified parameters like voltage, current, power factor, KVAR, temperature and time delay. 31. GUARANTEE CLAUSE The supplier shall guarantee satisfactory operation of the entire equipment for a period of 18 months from the date of supply or 12 months from the date of commissioning, whichever is earlier.

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REC Specification 69/1993 (For Gaining Experience) 11KV AUTOMATICALLY SWITCHED CAPACITOR BANKS AT SUB-STATIONS FOREWORD At present the operation of 11 KV capacitor banks is controlled by manually operated 11 KV circuit breakers. This practice suffers from the following disadvantages : i) The entire operation of switching ON or switching OFF the capacitor banks is left to the Operator and it is, therefore, difficult to ensure proper utilisation of the capacitors according to the changing load requirement of the system, often resulting in sub-optimal utilisation of the heavy investment made. ii) The capacitor bank is either fully in circuit or is out of circuit and the compensation cannot be closely matched with the transformer loading. This results in under utilisation or over utilisation of the capacitor bank. iii) A modern circuit breaker specially of SF6/vacuum type is a costly equipment and is mainly designed for handling the faults rather than for respective switching duty. The breaker is there-fore, not an ideal equipment for control of capacitor bank which may have to be operated a number of times in a day. The above shortcomings can be overcome by use of 11 KV capacitor switches (instead of circuit breakers) to control the operation of capacitor bank which can be divided into suitable steps for optimum utilisation of the total installed capacity. The reactive compensation can be closely controlled through automatic switching of the capacitor bank steps depending upon the loading pattern. In addition, it is possible to keep a close watch on various parameters such as current in each phase of the capacitor bank, system voltage, unbalanced operating conditions etc., so as to provide adequate protection to the capacitor bank against abnormal operating conditions thereby minimising the chances of capacitor failures. The scheme eliminates conventional components like RVT, Electro-Magnetic Relays etc. The Circuit Breaker is replaced by two Capacitor Switches with which it is possible to have the advantage of utilising the capacitor bank in two or three steps as required. With all these advantages, the overall cost is likely to be marginally higher, if at all, than the present system. On the other hand the benefit in terms of more effective and closer reactive compensation will make the overall investment on the capacitor bank installation far more cost effective and trouble free compared to the present practice. With these advantages kept in view, this specification for 11 KV Automatically Switched Capacitor Banks at SubStations was placed before the 13th Conference on Standardisation, Technical Development and Training on 4th-6th May, 1993 at New Delhi. As approved by the Conference, the Specification is issued for gaining experience by the SEBs. 1. SCOPE This specification covers 3-phase, 50 Hz, out-door type Automatically Switched Shunt Capacitor Banks intended for installation at 33/11 KV and 66/11KV sub-stations. The equipment covered in this specification comprises (i) Capacitor Bank, (ii) Automatic Control Unit, (iii) Capacitor Switches and (iv) Auxiliary Equipment. 2. APPLICABLE STANDARDS Unless otherwise modified in this specification, the capacitors shall comply with latest version of IS:2834. The other components such as Capacitor Switches, Auxiliary Equipment shall comply with the latest version of relevant Indian Standards.

A. CAPACITOR BANKS 3. TEMPERATURE CATEGORY The capacitor shall be suitable for upper limit of temperature category 500C as per IS:2834.

4. RATED VOLTAGE 4.1 The rated voltage of the 3-phase capacitor banks shall be12KV(phase-to-phase) and the individual capacitor units shall be rated for 12/3 KV. 4.2 Supplier shall make extra allowance for voltage rise due to use of 6% reactors wherever provided, for which necessary details will be provided by the purchaser. 5. RATED OUTPUT The rated out put of 3-phase capacitor banks shall be 600 KVAR and 1200 KVAR at the rated voltage of 5.1 12 KV intended for use on power transformers of 3.15 MVA and 5 MVA (see Clause 14.3). The standard basic unit rating of capacitors (single phase) shall be 200 KVAR. The units shall be 5.2 connected in star formation with floating neutral.

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6. PERMISSIBLE OVER LOADS For capacitors covered in this specification, the maximum permissible overloads with regard to voltage, current and reactive output shall not exceed the limits specified in IS:2834. 7. POWER LOSS The power loss in capacitors shall not exceed 0.2 watt/KVAR (subject to a tolerance of +10%). 8. DISCHARGE DEVICE Suitable discharge device shall be connected across the capacitor unit in accordance with the provision of IS:2834. The discharge device shall reduce the residual voltage from the crest value of the rated voltage to 50V or less within 5 minutes after the capacitor is disconnected from the source of supply. 9. EARTHING CONNECTIONS The container of each capacitor unit shall be provided with suitable earthing terminal clearly marked with "Earth" Symbol. 10. PROTECTIVE FUSES The capacitor units shall be provided with either internal or external fuses, as per standard practice of the manufacturer. In the later case, the manufacturer shall supply the external HRC fuses together with fixing accessories; a set of six spare fuse links shall be supplied along with each capacitor bank. 11. GENERAL REQUIREMENTS 11.1 The capacitors shall be of non-PCB type, using polypropylene film as the dielectric. 11.2 Complete mounting brackets supporting insulators and all other components for formation of capacitor bank racks shall be supplied along with the capacitor units. Necessary foundation bolts/nuts shall also be supplied. 11.3 The outside of the capacitor container and other structures should have smooth and tidy look and should be coated with the weather-proof, corrosion-resistant paint of white or light grey shade. 12. MARKING The capacitor units shall be provided with a rating plate and terminal markings as stipulated in IS:2834. 13. TESTS The switched capacitors shall be subjected to all the type, routine and acceptance tests in accordance with IS:2834. In addition, Endurance Test as per IEC 871-2, 1981 shall be carried out as a type test. (This test is under consideration for adoption by BIS).

B. AUTOMATIC CONTROL UNIT (ACU)

14. SWITCHING ARRANGEMENT The Automatic Control Unit shall be provided inside the control room to continuously monitor total load 14.1 KVAR on secondary side of the transformer and shall automatically switch ON or switch OFF the capacitor banks through the operation of 11KV Capacitor Switch in accordance with the parameters given in clause 14.3. Overriding provision shall also be made for electrical switching ON or OFF of the capacitor switch by the operator from the ACU panel. In the case of 3.15 MVA transformer, the capacitor banks will be controlled by two 11KV automatic 14.2 capacitor switches each controlling a 600 KVAR bank. For 5 MVA transformer, the capacitor banks will be controlled by two 11KV automatic switches; the 1st switch controlling 600 KVAR bank and the 2nd switch controlling 1200 KVAR bank. The following scheme shall be adopted for automatic operation of 11KV capacitor switches/capacitor 14.3 banks:

S.No

Transformer Capacity 2 1x3.15MVA

Capacitor Bank Size 3 1200 KVAR

Capacity to be Switched on 4 600 KVAR

1 1

Status of capacitor switches when load KVAR on transformer reaches 5 700 KVAR (Switch-I ON,

Status of Capacitor Switches when load KVAR drops to 6 600 KVAR (Switches I &

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split into 600 KVAR + 600 KVAR 2 1x5 MVA 1800 KVAR split into 600 KVAR + 1200 KVAR Switch-II OFF) 1200 KVAR 600 KVAR 1300KVAR (SwitchesI&II ON) 700 KVAR(Switch-I ON, Switch-II OFF) 1300 KVAR(Switch-I OFF, Switch-II ON) 1900 KVAR (Switches-I & II ON) II OFF) 1200 KVAR (Switch-II OFF, Switch-I ON). 600 KVAR (Switches- I & II OFF) 1200 KVAR (Switch-II OFF, Switch-I ON) 1800 KVAR (Switch-I OFF, Switch-II ON)

1200 KVAR

1800 KVAR

NOTE : 1. For more than one transformer, a separate capacitor bank for each transformer shall be provided.

The required 11KV CTs and PTs for measurement of Load KVAR are normally available at the Sub2. station and will not form part of the equipment to be supplied against this Specification. 15. TIME DELAY The switching ON operation will take place only if the KVAR value indicated in column 5 of the table in clause No.14.3 persists (or is more) for a period of 5 minutes. The switching OFF operation will take place if the KVAR value indicated in column 6 of the table persists (or is less) for a period of 5 minutes. However, if the load drops to less than 80% of value specified in column 6, the switching off operation of the relevant step will be instantaneous. In no case switching ON operation will take place within a period of less than 5 minutes after the capacitor is switched OFF due to any reason. 16. CONTROLS The automatic control unit shall instantly switch OFF the capacitor switch in the following contingencies occurring in any of the phases : i) Voltage increases by 7% above the rated voltage of 12KV. ii) Power Transformer current imbalance (due to single phasing and for any other reasons) between any of the two phases exceeding 20% of the lowest current of the 3-phases. iii) Current increases in any Capacitor unit by 30% above the rated current (only the relevant capacitor switch will open). iv) Current between any of the two phases of the capacitor bank differs more than 15% of the lowest current of the 3-phases (only the relevant capacitor switch will open). NOTE: Normal automatic functioning of the Capacitor Bank will resume :

In the case of (i) above, after the excessive voltage has dropped to 3.5% above the rated 12 KV. and In the case of (ii) above, the power transformer current imbalance between any two phases reduces to 15%. In case of (iii) & (iv) above, a suitable indication for the type of fault i.e. whether (iii) or (iv) above will be provided on ACU Panel and the capacitor bank will not get automatically switched ON again till the faulty condition is attended to and ACU is reset for its normal operation. 17. MONITORING FACILITY A suitable ammeter with a selector switch to indicate the capacitor current in each phases of the capacitor bank shall be provided on the ACU panel inside the control room. Indicating lamps will also be provided to indicate ON & OFF status of each capacitor switch. 18. CONTROL POWER The D.C. control voltage for operation of the ACU shall be taken from sub-station battery. The standard D.C. control voltages at the 33/11KV Sub-station and 66/11KV Sub-stations are 24 Volts and 110V respectively.

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Note : The purchaser will clearly specify the battery voltage if voltage other than that specified above is to be adopted. 19. TEMPERATURE VARIATION The control equipment and associated circuitry shall be suitable for operation in a temperature range of 00 C to (+) 550C. 20. PROTECTION OF ACU Besides in-built protection against line surges and transient over voltages, suitable fuses shall be provided for protection against over current. The ACU shall remain fully functional during and after line surges and transient over voltage. 21. CONTROL UNIT CASING Except for the terminals, the Automatic Control Unit shall be enclosed in a suitable casing so as to avoid ingress of dust.

C. 11 KV AUTOMATIC CAPACITOR SWITCH

22. SCOPE This specification covers 11KV, 50Hz, out-door type automatic capacitor switches suitable for switching capacitor banks of 600 KVAR and 1200 KVAR ratings or any other higher rating specified. 23. APPLICABLE STANDARDS Unless otherwise stipulated in this specification the capacitor switch shall comply with the latest version of IS:9920 (AC Switches for voltages above 1000V). RATED VOLTAGE The rated voltage for the capacitor switch shall be corresponding to the nominal system voltage of 11KV. 25. RATED CURRENT The standard rated normal current shall be 200A. 26. RATED CAPACITIVE SWITCHING CURRENT The rated capacitive switching current shall not be less than 100 A. Note : The capability of the switch shall also take into account the parallel switching of capacitor bank steps. 27. RATED SHORT TIME CURRENT The rated short time symmetrical current for 1 second shall be 10KA (rms A.C. component). 28. RATED MAKING CURRENT The rated making current shall be 2.5 times the rms value of the a.c. component of rated short time capacity. 29. BASIC IMPULSE LEVEL (BIL) The rated basic impulse level of switch to earth as also across the open terminals shall be 75 KV. 30. CONTROL SUPPLY The control power for closing the switch shall be 230V single phase AC supply. The closing mechanism shall be suitable for a voltage variation of (+) 10% to (-) 20%. 31. DESIGN & CONSTRUCTION REQUIREMENTS 31.1 Type The switches shall be of either vacuum or SF6 type. 31.2 The capacitor switches shall be of three phase construction and shall be suitable for remote operation. The capacitor switch shall be suitable for outdoor installation and shall have sealed weather proof type 31.3 construction. 31.4 The capacitor switch shall be provided with a mechanical indicator to show whether the contact is in open/closed position, locally, as also through indication on the ACU panel. Provision shall also be made for manual closing and opening. 24.

12KV. This represents the highest system voltage

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31.5 The metallic enclosure of the capacitor switch shall be provided with two earthing terminals marked with the earth symbol. The bushings provided on the switch shall have clamp type of terminals to directly receive aluminium 31.6 conductors up to 10mm dia in both horizontal and vertical directions. The terminal arrangement shall be such as to avoid bimetallic corrosion. 32. OPERATING MECHANISM The operating mechanism shall be either solenoid or motor charged spring for which the control supply shall be as per clause 30. 33. MECHANICAL AND ELECTRICAL ENDURANCE The switch shall be capable of performing not less than 10,000 mechanical operations and 10,000 electrical operations at 100A capacitive current without getting damaged. 34. MARKING The capacitor switch shall be provided with a legible and indelibly marked name plate with the following : a) Name of the manufacturer, b) Type, designation and serial number. c) Rated voltage and current. d) Rated frequency. e) Number of poles. f) Rated short time current (symmetrical). g) Rated making current. h) Rated capacitive switching current. 35. TESTS The switch shall be subjected to the following tests in accordance with the IS:9920 (Part-IV). 35.1 Type Tests a) Tests to verify the insulation level, including withstand tests at power frequency voltages on auxiliary equipment. b) Tests to prove that the temperature rise of any part does not exceed the specified values. c) Making and breaking tests including tests for the rated capacitive current d) Tests to prove the capability of the switch to carry the rated short time current. e) Tests to prove satisfactory operation and mechanical/electrical endurance. f) Tests to provide satisfactory operation under ice conditions. 35.2 Routine Tests a) Power frequency voltage dry tests. b) Voltage tests for auxiliary circuits. c) Measurement of the resistance of the main circuits. d) Tests to prove satisfactory operation. D. AUXILIARY EQUIPMENT 36. CURRENT TRANSFORMER The current transformers of suitable current ratio and burden for measuring the capacitor current shall form part of the equipment to be supplied. These CTs shall form either an integral part of capacitor switches or may be of separate outdoor type. The accuracy class for the purpose of measuring the current shall be 1.0. 37. HRC FUSES Suitable outdoor type 11KV HRC fuses along with the mounting insulators etc. to provide proper protection for the entire installation (and also HRC fuses for protection of individual capacitor bank step where internal fuses for capacitors are not provided) shall form part of the equipment to be supplied. The rupturing capacity of the fuses shall be 12.5 KA. 38. SURGE ARRESTERS 5 KA, 9 KV metal oxide surge arrestor, conforming to REC Specification No.55/1987 shall be used for the entire capacitor bank for each transformer and will form part of the equipment to be supplied. 39. INRUSH SUPRESSION SERIES REACTOR (I SSR)

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Suitable Inrush Suppression Series Reactors shall be provided on each capacitor Bank steps to limit the inrush current due to parallel switching within a safe limits. 40. SCHEMATIC DIAGRAM A Schematic diagram showing typical arrangement of 11KV automatically switched capacitor bank for a 5 MVA transformer at 33/11 KV sub-station is given in the Annexure. 41. INSTALLATION OPERATION & MAINTENANCE The supplier shall provide : i) Necessary manual on installation, operation and maintenance as also the schedule for routine testing or check ups of all the equipment covered by the installation. ii) List of recommended spares indicating prices and specialised test equipments required for routine testing of the system. 42. GUIDANCE FOR PROCUREMENT The entire equipment covered in this specification shall be covered as a single package to avoid the problem of mismatching and responsibility for maintenance etc. 43. WARRANTY The supplier shall guarantee satisfactory performance of the complete capacitor bank installation for a period of 18 months from the date of supply or 12 months from the date of commissioning, whichever is earlier. During the warranty period, all repairs/replacements shall be carried out free of cost. 44. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser, all reasonable facilities, without charge, to satisfy him that the material being supplied is in accordance with the specification. The purchaser has the right to get the tests carried out at his own cost by an independent agency, whenever there is a dispute regarding the quality of supply.

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REC Specification 70/1993 (Revised - 1997)

OUTDOOR TYPE THREE PHASE 11KV/433-250V CONVENTIONAL AND SEALED DISTRIBUTION TRANSFORMERS WITH AMORPHOUS METAL CORE UPTO AND INCLUDING 100 KVA FOREWORD Development of new core material, Amorphous Metal Alloy, has enabled the transformer industry to offer transformers having substantially lower no-load losses (about one-third of the losses in conventional transformer using CRGO core). The component of load losses remains practically unchanged. These transformers are finding increasing application in advanced countries. Considering the substantial savings in energy, the additional cost involved is recovered in few years. Extensive use of such transformers can be one of the major initiatives for conservation of scarce electrical energy. Based on the recommendations of the 13th Standardisation Conference held in May 1993, REC Specification 70/1993 on Amorphous Metal Core Distribution Transformer was issued to gain experience. Subsequently, during the 14th Conference on Standardisation and Technical Development, held in New Delhi on 25th April,1997, it was brought out that the manufacturers of Amorphous metal transformers were finding it difficult to achieve the values of no load losses specified in the original specification issued in 1993. The Conference had recommended that the maximum permissible values of no load losses may be raised by 10% to facilitate large scale production of amorphous transformers and to allow the manufacturers more time for absorption of the new technology, after which the stipulated losses can be reviewed. The Conference had further recommended changes in the values of no load current and flux density, keeping in view the manufacturing experience and latest design practices in the technology of manufacture of amorphous metal cores. Based on the above recommendations, the specification is being revised and issued. 1. SCOPE This specification covers oil-immersed, naturally cooled, 3phase, 50 Hz, double wound, outdoor type conventional/sealed distribution transformers with amorphous metal core of 25, 63 and 100 KVA ratings for use on systems with a nominal voltage of 11 KV. 2. APPLICABLE STANDARDS Unless otherwise stipulated in this specification, the Conventional/sealed Amorphous Metal Core Distribution Transformers shall comply with the latest version of IS : 1180 (Part-I)/(Part-II) and IS: 2026. 3. STANDARD RATINGS The standard ratings shall be 25, 63 and 100 KVA. NO LOAD VOLTAGE RATIOS The no-load voltage ratio shall be as follows : a) 11000/433-250 V for 25, 63 and 100 KVA b) 10450/433-250 V for 100 KVA only, whenever specified TAPS No taps are to be provided in these transformers WINDINGS 6.1 Unless otherwise specified, DPC insulation shall be used for HV and LV winding wires and Electrical Grade plain insulation Kraft paper shall be used for inter-layer insulation of the HV and LV coils. In case of PVA enamelled conductor being used for HV/LV winding, electrical grade epoxy dotted thermally upgraded Kraft paper shall be used for inter layer insulation. Use of single coil design for HV winding shall be preferred due to its better shortcircuit behaviour. 6.2 The primary winding shall be connected in delta and the secondary winding in star (Vector Symbol Dy 11), so as to produce a positive displacement of 30o from the primary to the secondary vector of the same phase. The neutral of the secondary winding shall be connected to a separate insulated terminal. 6.3 Since the Govt.of India, Ministry of Industry, N.Delhi, vide its letter No.,19/(53)/93-El. Ind. dated 13-4-94 has allowed the use of copper winding also, the SEB may specify use of either aluminium or copper winding for these transformers depending upon their economic advantage. 7. FITTINGS The following standard fittings shall be provided :

4.

5.

6.

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A. a) b) B. For Conventional and Sealed Transformers Two earthing terminals Two lifting lugs For Conventional Transformers a) Oil level gauge indicating three positions of oil, marked as follows : - Minimum (5o C) - 30o C - Maximum (98o C) b) Plain breathing device comprising an inverted U-pipe with wire gauze at the open end or silica gel breather as required by the purchaser. c) Drain-cum-sampling valve (steel) of the type shown in Fig. 1 welded to the tank. The special tool for operating this valve shall be supplied with the transformer. d) Thermometer pocket for 63 and 100 KVA units e) Filling hole having P 1 thread (with cover) on the transformer body/conservator. For Sealed Transformers a) Nitrogen/air filling device/pipe with welded cover capable of reuse. b) An extended pipe for filling of oil at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing the welded cover. No conservator shall be provided on these transformers. 8. CONSERVATOR (For Conventional Transformers only) 8.1 On transformer of 63 and 100 KVA, provision of conservator is obligatory. For 25 KVA transformer the manufacturers may adopt their standard practices. 8.2 The conservator shall be provided with a drain plug and a filling hole with cover. In addition, the cover of main tank shall be provided with an air release plug to enable trapped air to be released unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank. 8.3 The inside diameter of the pipe connecting the conservator to the main tank shall be within 20 to 50 mm and it should project into the conservator in such a way that its end is approximately 20 mm above the bottom of the conservator so as to create a sump for collection of impurities. The minimum oil level (corresponding to () 5o C should be above the sump level. 9. RATING AND TERMINAL MARKING PLATE(S) Each transformer shall be provided with non-detachable rating and terminal marking plate(s) of weather-proof material fitted in a visible position showing the complete information as given in IS : 1180 (Part - I). 10. LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limit of 55o C (measured by resistance) for the transformer winding and 45o C (measured by thermometer) in top oil when tested in accordance with IS : 2026. 11. LOSSES AND IMPEDANCE VALUES 11.1 The no-load and load losses shall not exceed the values given in the following table :

C.

No Load Loss KVA Rating (Fixed loss) (Watt)

Load loss at 75o C (Watt)

25 63 100

28 50 66

685 1235 1760

The above losses are maximum allowable and there will not be any plus tolerance. The above losses are for wound core design. 11.2 The percentage impedance at 75o C shall be 4.5% subject to tolerance as per IS : 2026. 12. PERMISSIBLE FLUX DENSITY AND OVERFLUXING

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The flux density at rated voltage and frequency shall not exceed 1.38 tesla. The no load current at rated voltage and at 112.5 per cent rated voltage shall not exceed values given below KVA Rating Percentage of Rated Full Load Current 100% Rated Voltage At 112.5% Rated Voltage

25 63 100

1.50 1.25 1.10

4.0 3.5 30

13. TRANSFORMER OIL The transformer oil shall comply with REC Specification No.39/1985 (R-1993). 14. BUSHING TERMINALS 14.1 To avoid bimetallic action at the point of connection to the aluminium windings and to the external aluminium cables/conductors, both HV & LV bushing stems shall be made of aluminium alloy conforming to the requirements of IS : 3347. 14.2 The bushing terminals shall be of clamp type to directly receive aluminium conductors/cables without requiring use of lugs. The terminal shall be directly screwed on to the stems to secure effective sealing of the bushing. Details of the terminals are given in Appendix - I. 14.3 The following minimum clearances shall be provided :

Enclosed Phase-to-phase Phase-to-earth 127 mm 76 mm

External 255 mm 140 mm

14.4 HV Bushings (For Sealed Transformers only) 14.4.1 To enable replacement of the outer porcelain bushing without opening the cover and without affecting the sealing arrangement of the transformer, the HV bushing shall be made in two parts. The external porcelain bushing shall conform to the requirements of IS : 3347 Part - III/Sections 1 and 2. The internal bushing shall also preferably be made of porcelain and shall have a separate aluminium alloy stem. Alternatively, the internal bushing may be made of epoxy and shall have embedded stem and each bushing shall be subjected to Partial Discharge Test as per the stipulations of IS : 2099 to avoid the possibility of any air void remaining in the cast. A typical arrangement of the two part HV bushing with internal porcelain bushing is shown in Fig. 2. The alternative arrangement with internal epoxy bushing is shown in Fig. 3. However, the manufacturer is free to adopt a different arrangement provided it satisfies all the requirements of this clause. 14.4.2 Metal parts of the internal HV bushings inside the transformer shall remain immersed in oil under all operating conditions. 14.4.3 As an alternative to the two parts bushing of porcelain type mentioned at 14.4.1 and 14.4.2, the manufacturer may provide unbreakable polymer bushings which can electrically be equivalent to the porcelain bushings in performance. 15. SEALING GASKETS All sealing washers/gaskets shall be made of oil and heat resistant nitrile rubber. Gaskets made of natural rubber or cork sheet are not permissible. 16. TANK CONSTRUCTION (For Sealed Transformer only) The transformer tank shall be made of good quality steel sheet of adequate thickness and shall be suitably stiffened to provide sturdy and robust construction to withstand extreme pressure conditions. The tank shall be capable of withstanding pressure upto (+) 80 Kpa and () 70 Kpa (gauge pressure) without any deformation. The transformer cover shall be welded to the tank in such a way that it shall be possible to remove the weld and reweld the transformer at least twice. Apart from welding, any other suitable option for sealing of the cover ( Bolted type with welded U shape clamps on each side of the tank etc.,) as agreed to by the purchaser shall also be provided. 17. TANK SEALING (For Sealed Transformers only) Space on the top of the oil shall be filled either with nitrogen conforming to commercial grade as per IS : 1747 or dry air. The nitrogen/air plus the oil volume inside the tank shall be such that even under extreme operating conditions, the pressure generated inside the tank shall not exceed (+) or (-) 40 KPa.

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18. TESTS 18.1 Routine Tests All transformers shall be subjected to routine tests at the manufacturers works. The following routine tests shall be carried out in accordance with the details specified in IS : 1180 (Part - I) & IS :2026. a) Measurement of winding resistance b) Measurement of voltage ratio and check of voltage vector relationship c) Measurement of Impedance voltage, short-circuit impedance and load loss d) Measurement of no-load loss and no-load current e) Measurement of insulation resistance f) Induced over-voltage withstand test g) Separate source voltage withstand test h) Air Pressure Test (IS : 1180 Part - II) For Sealed Transformer only. 18.2 Type Tests The following type tests shall be made on the transformers as per details given in IS : 2026: a) to (g) as indicated under routine test h) Unbalanced Current Test : The value of unbalanced current indicated by the ammeter as shown in the test arrangement in Fig.4 shall not be more than 2% of the full load current. i) Impulse voltage withstand test j) Temperature rise test k) Short circuit test l) Air Pressure Test As per IS - 1180 (Pt - I) clause 22.5 for Non-sealed type As per IS 1180 (Pt II) clause 21.5.1 for sealed type If records of a type test on a transformer which, in essential details, is representative of the one being purchased, are furnished, the purchaser may accept this as evidence of the type test instead of actual test. 18.3 The supplier shall furnish calculations in accordance with IS : 2026 to demonstrate the thermal ability of the transformers to withstand short circuit. 19. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply. 20. WARRANTY The supplier shall guarantee satisfactory performance of transformers and all the associated components for a period of 2 years from the date of receipt by the purchaser or 18 months from date of commissioning, whichever is earlier. During the warranty period, all repairs/replacements shall be carried out free of cost. 21. MOUNTING ARRANGEMENT The under-base of all transformers shall be provided with two 75 x 40 mm channels 460 mm long with holes as shown in figure 5 (at a center to center distance of 415 mm) to make them suitable for fixing on a platform or plinth.

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REC SPECIFICATION 71/1993 (For Gaining Experience)

REMOTE CONTROLLED LOAD MANAGEMENT SCHEME

FOREWORD Steep rise in the number of electrically operated irrigation pumpsets in the country during the last two decades has thrown up a serious load management problem. The pumping load causes a high peak demand on generation even though its annual load factor is only of the order of 20-25%. This also results in high power losses in the distribution network. Present methods used by the power utilities (State Electricity Boards) to control the peak demand such as periodically switching off power supply to 11 KV feeders by rotation, single-phasing of feeders etc., have not proved effective and also disrupt supply for domestic, commercial and industrial use in the village. The Remote Controlled Load Management Scheme covered by this specification will ensure round-the-clock supply to the villages for domestic, commercial and industrial loads whereas the pumping loads can be subjected to a definite load rostering plan. This will not only effectively reduce peak demand on the system but will also reduce power losses and improve power capability of the distribution network on a permanent basis by flattening the load curve thereby saving investments on system augmentation. This specification is issued for gaining experience based on the recommendations of the 13th Conference on Standardisation, Technical Development and Training held on 4th-6th May, 1993, at New Delhi. 1. SCOPE 1.1 This specification covers design, survey, manufacture, inspection at factory, installation, commissioning, operation and maintenance for one year of the following components of the Remote Controlled Load Management Scheme for rural areas on aturn-key basis: (i) Remote Controlled Circuit Breakers (ii) Master Control Unit at 33/11 KV or 66/11 KV Sub-station (iii) Communication System including interfacing equipments for the operation of Remote Controlled Circuit Breakers 1.2 The Specification also covers additional features for proper protection of distribution transformers against over-loads, system faults and low oil level. In addition, to improve reliability of supply, an in built provision for auto-reclosing has also been made which will ensure automatic restoration of power supply in the event of temporary faults. Note:-Retrofitting of existing/new distribution transformers with the remote controlled Circuit Breaker and or associated control equipment forming integral part of the transformer shall also be covered within the scope of the turnkey work. 2. REMOTE CONTROLLED CIRCUIT BREAKER 2.1 Applicable Standards Unless otherwise stipulated in this Specification, the L.T. Circuit Breaker shall comply with latest version of IS:2516(Parts 1 and 2/Sec 1)-1985. 2.2 L.T. Circuit Breaker Rating The 3-pole remote controlled LT circuit-breaker will have the following ratings a) Rated voltage and frequency 415 V A.C. 50 Hz 40 A for 25 KVA Transformer b) Rated Thermal Current at 400 C 100 A for 63 KVA Transformer 160 A for 100 KVA Transformer Should work satisfactorily within the range 180 V to 255 V Mechanical Endurance (No. of C/O cycles) e) f) Electrical 15000 cycles 10000 cycles(at rated thermal current and 0.8 pf) 5 KA or more 5 KA or more for 1 sec

c) d)

Control Supply Voltage*

Rated Short-circuit breaking capacity Rated short-time withstand current

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*Note: Considering that enforcement of the load management scheme will considerably improve the voltage conditions due to reduction in the maximum demand of the feeder, the above voltage range is expected to meet the requirements of even areas having serious low voltage problem. However, the voltage range can be reviewed based on the experience gained on the pilot scheme. 2.3 Tripping Mechanism and Operation The circuit breaker shall have trip-free mechanism. To facilitate local maintenance or checking on the site, the manual mode will take priority over the automatic control system. Suitable pad-lock arrangement for the circuit breaker operating rod shall be provided as a safety measure. 2.4 Enclosure The Remote Controlled Circuit Breaker and the communication equipment shall be housed in an outdoor enclosure forming integral part of the distribution transformer. The metallic enclosure shall be lined with FRP or other suitable insulating material to avoid direct contact of sun rays on the metallic body and shall be mounted in such a manner as to provide a connecting duct of about 200 mm length between the transformer tank and the enclosure.

Suitable louvers fitted with wire gauze shall be provided to ensure circulation of air but not to allow ingress of rain water. It should be ensured that the temperature inside the enclosure does not exceed 700C under extreme operating conditions. However, for additional safety the entire equipment in the enclosure should be able to withstand temperature of 750C for at least for 8 hours continuously. Relative humidity up to 95%shall be taken into account for design purpose. An operating handle shall be provided outside the enclosure in such a way that ON and OFF operations of the breaker can be conveniently performed from the ground level by means of an operating rod. The operating handle arrangement shall be such as to indicate the mechanical status of moving contacts of the Circuit Breaker. The ON and OFF positions of the handle shall be clearly and boldly marked on the enclosure so as to be distinctly visible from the ground. 3. COMPREHENSIVE TRANSFORMER PROTECTION SCHEME 3.1 Whereas general purpose LT Circuit Breakers conforming to IS:2516, as specified above, forming an essential component of the load management scheme will improve the level of transformer protection compared to the use of fuses, to obtain comprehensive transformer protection, use of an Electronic Control Unit (ECU) will be necessary to regulate the tripping characteristics of the circuit breaker. This will not only ensure optimum protection against overloads and system faults but will also provide protection against pilferage/leakage of oil. An auto reclosing feature is also envisaged to ensure automatic restoration of power supply in the event of temporary faults. The comprehensive protection scheme shall have the following important features:i) Protection Against Faults In case of line faults, the breaker will trip as indicated below : 1.4 In to 4.0 In : 5.0 Seconds 4.0 In to 6.0 In : 2.5 Seconds >6 In : Instantaneous (not more than 40 milli seconds) The circuit breaker will automatically reclose once after three minutes and shall get locked out if it trips again within 5seconds after reclosing. An indicator lamp will show Line Fault which shall automatically get reset on successful closing of the breaker after clearance of fault. Note :(a) Tolerances for current and timing values are 5% (b) In reference to full load transformer current which is 33.3 A, 84.0 A and 133.3 A for 25 KVA, 63 KVA and 100 KVA transformer respectively.

Protection Against Overloading Up to 1.4 In, the circuit-breaker will trip only by sensing the temperature of top oil in the transformer. It will trip when the temperature reaches 850C and will get automatically reclosed when oil temperature drops to 800C. An indication light will show that maximum oil temperature has been reached and will remain ON(till manually reset). Note :iii). Temperature tolerance 10C

ii)

Protection Against Low Oil Content The breaker will trip and lock-out if oil level in the transformer drops to a limit indicative of definite leakage or pilferage of oil. The level for tripping should be such as not to effect critical clearances thereby endangering life of the trans-former. Indication light will show Low Oil and will reset (either manually or automatically) only when oil is topped up to the required level. iv). Test Switch The ECU shall have a test switch to check whether LED lamp are healthy. By pressing the test switch, all indicating lamps shall start glowing/flashing except the fused one, requiring replacement.

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Note: The Circuit Breaker to be supplied for the control and protection of transformer will include all the control circuitry/equipment including temperature and oil level sensors. v). Electronic Control Unit (ECU) Faulty The circuit breaker shall trip in the event of any fault in ECU such as : a) Open circuit or short circuit of temperature/oil level sensor leads b) Equipment faulty light shall also glow in the event of mal-function in the circuit breaker in not being able to switch on or switch off as commanded by ECU. Control Supply to ECU The electrical control unit shall be so designed as to automatically switch over to the healthy phase to neutral supply in the event of voltage in the other phases going below the operating limit of the controller due to faults such as blowing off of transformer fuse on the 11 kV side. The design will also take into account voltage variations in the range of 180-255 V as indicated in Clause 2.2. vii) Current rating of circuit breakers Considering the no-trip provision up to 1.4 In as per Clause 3.1(ii) above, the thermal rating of circuit breakers used for comprehensive transformer protection shall be increased to 50A, 125A, 200A for 25, 63 and 100 KVA transformers respectively. Other characteristics as per clause 2 will however, remain un-changed. vi)

4.

MASTER CONTROL UNIT 4.1 The Master Control Unit at the feeding Sub-station (33 KV or 66 KV) will have the following components:i) Computerised Control System built around IBM PC compatible hardware with colour monitor and dot matrix printer. ii) Communication System. 4.2 The master control unit must be of rugged design for 24-hour working and shall have the following facilities:a) Capability to communicate, control and interrogate the Remote Controlled Circuit Breakers through appropriate communication system. b) Master Control Unit operations shall be on a 100 % Hot-Standby basis.

c) Capability to display simple graphics on colour monitor and also to obtain hard copy for status and other measured parameters of all equipment under control and operational on the system. d) Facilities to programme operation of distribution transformers in two or three groups on automatic rostering basis and also to rotate or change the schedule as and when desired. e) Equipment should be modular in design to permit easy and cost-effective expansion/upgrading.

f) Power supplies available at the Sub-station will be 240 V AC with variation of (+) 10 % and (-)20 %.Suitable power stabilisation and conditioning equipment comprising converter- inverter circuit along with 24 V batteries for proper working of the Master Control Unit shall form part of the equipment to be supplied. The ampere-hour capacity of the batteries shall be such that in the event of power failure it shall be adequate to operate the Master Control Unit at least for 5 hours with out getting discharged below 50 % of its full capacity. g) The premises where the Master Control Equipment is to be installed would not be air conditioned. The surrounding room temperature could go up to 450C. All equipment must work satisfactorily up to this temperature limit. h) The Master Control Unit (MCU) will have access to any Remote Control Unit to know its status at any point of time. i) The status of all of the remote controlled circuit breaker shall be recorded at the Sub-station immediately after switching ON or switching OFF operations of the remote Circuit Breakers for the purpose of load rostering. 5. COMMUNICATION SYSTEM The communication between the Master Control Unit (MCU) and the Remote Control Unit (RCU) could be 5.1 either through radio (VHF/UHF) or through distribution line carrier communications or through Ripple control. The choice will depend upon cost effectiveness and trouble-free service .In the case of radio transmission, allocation of the requisite frequency band by the competent authority will be an important consideration. Getting requisite frequency allocated by the competent authority shall be the responsibility of the SEB. The supplier however, will extend all necessary assistance to the SEB in obtaining such frequency allocation. Tentatively the frequency ranges would be 136-174 MHz for VHF Bands and 314-367 M Hz or 585-622 M Hz for UHF Bands.

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5.2 Suitable communication error detection and correction techniques would be adopted so that chances of false operation or data errors are almost nil. 6. REMOTE CONTROL UNIT 6.1 The Remote Control Unit interfaced with the L.T .Circuit Breaker should be suitable for carrying out switching ON/OFF operations of the circuit-breaker as per the command received from the Central Station through communication system. The Remote Control Unit will also have the facility to send back signal to the Master Control Station to confirm the status of the Circuit Breaker. 6.2 Apart from carrying out switching ON/OFF operations of the Circuit Breaker and carrying out functions as indicated above, the Remote Control Unit will also have the facility that in the event of failure of communications with the Master Control Station, the unit should be capable of maintaining load rostering locally as per pre-set schedule till such time communications are restored. 7. GENERAL REQUIREMENTS 7.1 There may be about 200 transformers located within the jurisdiction of a Sub Station. The furthest transformer may be at a distance of about 30 Kms from the Sub Station; necessary provision to the extent required shall be made for repeated/relay/ rebroadcast so as to ensure acceptable communication. 7.2 In all data transmissions between the Master Station and the Remote Terminal, suitable Alpha Numeric code shall be adopted as EQUIPMENT-ID or LOCATION-ID for various Distribution Sub Stations, 11 KV Feeders etc. 8. RESPONSIBILITY FOR MAINTENANCE Apart from supply and commissioning of the system, the supplier shall be fully responsible for satisfactory operation and maintenance of the complete system for a period of 12 months from the date of successful commissioning. During this period all repairs/ replacements shall be carried out free of cost. A typical load management scheme is given in the Appendix-A. APPENDIX-A LOAD MANAGEMENT SCHEME A typical load management scheme will have the following features: Minor modifications will be made in the system configuration wherever required, so as to segregate distribution 1. transformers feeding pump loads in the farms and those feeding domestic/ commercial/industrial loads in the main inhabited areas of the villages. The distribution transformers feeding pumping loads will be equipped with remote controlled L.T. circuit breakers 2. which will be housed in a chamber forming integral part of the transformers The chambers will also house the communication unit interfaced with the circuit breaker. In a typical case, transformers feeding pumping loads will be divided into two groups, each being given supply 3. during fixed hours in a day, say, between 6 am to 12 noon and between 12 noon to 6 pm; the supply hours can be rotated on weekly or fortnightly basis to avoid inconvenience to any particular group. While all the transformers could remain energised during off peak period(say between 10 pm to 6 am), during peak hours (6 pm to 10 pm)no distribution transformer feeding pumping loads, shallremain energised. The remote controlled units fitted with the transformers shall receive and act on the instructions as received 4. from the Master Control Unit at the Sub-station and will give feed back to the Master Controller regarding status of the circuit breaker i.e whether in ON or OFF position at any point of time. 5. The software for Master Control Unit will provide for any variation in the hours of supply to each group.

The proposed load management scheme will have the following advantages over the existing practices of 6. controlling supply of 11 kV feeders, etc.:a) Domestic/Commercial and Industrial consumers in the inhabited areas of the villages will have uninterrupted power supply round the clock irrespective of the rostering schedule adopted for the agricultural pumping consumers. b) Pumping loads will have assured power supply for, say,14 hours in a day with advance knowledge of the supply hours -removing the uncertainties prevailing with the ad hoc load management techniques presently in vogue. c) Maximum demand on individual 11 KV feeders as also on the Power Transformers at the sub-station would be significantly reduced (to almost half) on a permanent basis. This would substantially reduce power losses and improve voltage conditions and thereby deferring investments in routine augmentation for a number of years.

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REC Specification 72 /1997 SINGLE PHASE COMPLETELY SELF PROTECTED (CSP) DISTRIBUTION TRANSFORMERS (OIL FILLED) FOREWORD In the 12th Standardisation conference of REC, the use of small rating distribution transformers with shorter LT lines was recommended. However, due to inherent design problems, reliable and sturdy transformers with less than 25KVA capacity cannot be manufactured in 3-phase configuration and hence small single phase transformers of 6.3, 10 and 16 KVA were recommended for use with phase to earth system and phase-to-phase system. The use of smaller distribution transformers will reduce the length of LT lines which is a major cause of LT line losses and LT faults which mostly reflect directly on the distribution transformers causing their failure. Accordingly, a specification was issued for single phase transformers based on the discussions/decisions of the 12th Standardisation Conference. Subsequently, during the 14th Conference on Standardisation and Technical Development held on 25th April, 1997 at New Delhi, it was decided that the specification for Single Phase Transformers should cover transformers with all types of cores( CRGO, Amorphous, Hi-B etc.,) and also it was decided to make provision for special protective features like 11 KV lightning arresters mounted on the transformer tank, 11 KV fuse links inside the bushings and internally mounted LT Circuit Breaker, making it a Completely Self Protected (CSP) transformer , in line with REC Specification No. 23/1983. This specification should be issued as an alternative to conventional single phase transformers (REC specification No.50/1987 Revised 1997) without in built protection. The Conference also recommended that the secondary voltage of the transformer be revised to 250 Volts and for simplicity of design, only single voltage secondary (250 V) should be used instead of double voltage (440 V-220 V). The rated voltage of the transformers in the earlier issued REC Specification was 11/3KV/440V220V (for phase-to-neutral system) and 11 KV/440V220V (for phase-to-phase system), but the national declared voltage is 415V for three phase and 240V for single phase. Due to the non-standard voltages of single phase transformers some of the Boards especially APSEB, which is the largest user of the single phase system, were facing problems when it came to the standard voltage rating of single phase motors to be used along with agricultural pumpsets. To overcome this problem, the specification for single phase transformers has been revised to make the voltage ratio of distribution transformers as 11/3 KV/250V and 11 KV/250V for phase-to-neutral and phase-to-phase systems respectively. The single phase motors can now be designed for rated voltage of 240V which is in line with the national declared voltage. The secondary voltage of 250V is also in line with REC Specification No.2/1971 (R1993) for three phase distribution transformers. The Conference also decided that the transformer rating of 6.3 KVA, being uneconomical, may be deleted. Based on the above recommendations of the 14th Standardisation Conference, this new specification for Single Phase Completely Self Protected transformers is being issued. 1. SCOPE This specification covers oil-immersed, naturally cooled, single phase, 50HZ, CSP outdoor type sealed/non-sealed distribution transformers for use in rural electrification system. 2. APPLICABLE STANDARDS Unless otherwise modified in the specification, the single-phase distribution transformers shall comply with the Indian Standard Specification IS : 1180 and IS : 2026 as amended from time to time. 3. STANDARD RATINGS The standard ratings shall be 10 and 16 KVA for both 11/ 3KV (phase-to-neutral) transformers and 11 KV (Phase-to-Phase) transformers. 4. NO-LOAD VOLTAGE RATIO The no-load voltage ratio shall be one of the following as required i ) 11/3 KV/250 V (Phase-to-neutral single phase system) ii) 11KV/250 V (Phase-to-phase single phase system) 5. WINDING CONNECTIONS Winding connections for the transformers referred to in clause 4 above shall be as shown in figures 1 and 2. The transformers for phase-to-neutral system shall have only one HV busing and those intended for use in phase-to-phase system shall have two HV bushings. In the former case, the other end of HV winding shall be brought out through a suitable bushing (LV bushing may be used for this purpose) which shall be externally earthed. A solid inter-connection (external) shall be provided by the manufacturer between HV earth bushing and the transformer tank. All bushings shall conform to IS : 1347 and 2099. The bushings shall not have arcing horns.

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5.1 HV protection : The HV protection shall be provided by an internally mounted fuse link inside the busing which will operate only in case of internal faults as the faults on LT side are cleared by the LT circuit breaker. 5.2 Surge Arrestor : 11 KV surge arrestor of metal oxide type and with suitable failure detecting device can be mounted on the transformer tank itself. The line terminal of the surge arrestor shall be connected to the HV bushing and the earth terminal of the surge arrestor shall be solidly connected to the tank, which in turn will be connected to a separate earth. 6. CORE AND WINDINGS 6.1 Transformer core shall have wound type construction. The core shall be properly annealed to relieve stresses. 6.2 Since the Govt. of India, Ministry of Industry, New Delhi vide its letter No.19/(53)/93-EL Ind. dated 13-4-94 has allowed the use of copper winding also, the SEB may specify use of either aluminium or copper winding for these transformers depending on their economic advantage. 6.3 Unless otherwise specified, DPC insulation shall be used for HV and LV winding wires and electrical grade plain insulation Kraft paper for interleaving. In case PVA enamelled conductor is used for HV/LV winding , electrical grade epoxy dotted thermally upgraded Kraft paper shall be used for interlayer insulation. 6.4 The core and coil assembly shall be securely held in position to avoid any movement under short-circuit conditions. 7. TAPS No taps are to be provided on these transformers. 8. TRANSFORMER TANK 8.1 The Transformer tank should be round and made of good quality steel sheet of adequate thickness suitably stiffed to provide sturdy and robust construction to withstand extreme pressure conditions. The tank should be capable of withstanding pressure as per values specified in IS : 1180 (Part - I) for non-sealed type and IS : 1180 (Part - II) for sealed type transformers. 8.2 The tank cover shall have plasticised surface at the top to guard against birdage faults. Alternatively, suitable insulating shrouds shall be provided on the bushing terminals. 8.3 For Sealed Transformers 8.3.1 Sealing of the transformer cover shall be achieved by providing a continuous (without break) oil resistant high quality nitrile rubber gasket on the top of the tank rim and the cover should be suitably clamped to provide a uniform pressure on the rubber seal. 8.3.2 The space on the top of the oil shall be filled with dry air. The dry air plus the oil volume inside the tank shall be such that even under the extreme operating conditions, the pressure generated inside the tank does not exceed 40 Kpa positive or negative. 8.3.3 Pressure Relief Device: The transformer shall be provided with suitable pressure relief device to release pressure under fault conditions. Alternatively, self-venting type of cover assembly shall be used to serve the purpose. 9. BUSHING TERMINALS The bushing stems/terminals for both HV & LV made of suitable aluminium/copper alloy shall be so designed as to directly receive aluminium stranded conductors up to 7mm dia, with bolted type clamping arrangement both in horizontal and vertical directions. In case of copper/copper alloy stems, suitable bimetallic clamps with bolted type arrangement described above shall be used. Details of these arrangements are shown in the Appendix. (Fig.4, 5, 6, 7for Aluminium Alloy Stem and Fig. 8 for copper/copper alloy stem).

10. FITTINGS The following standard fittings shall be provided for both sealed and non sealed type transformers : a) Two earthing terminals b) Two lifting lugs c) Rating and terminal marking plate(s) as per clause 12 of this specification. d) Hot line connectors for making connection(s) to the HV line (one each for phase-to-neutral transformer and two each for phase-to-phase transformer) as per REC Construction Standard E-37. 10.1 Fittings for Non-sealed Type Transformers only :

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a) Plain breathing device comprising an inverted Upipe with wire gauze at the open end (to prevent entry of insects) or silica gel breather as required by the purchaser. b) Drain-cum-sampling valve (steel) welded to the tank. Special tool for operating this valve shall be supplied with the transformer. c) Oil filling hole, with cover having 1 nominal size threads on the transformers body. d) Oil level gauge indicating three positions of oil at minimum (5o C), 30o C, maximum (98o C). 10.2 Fittings for sealed type transformers only a) Nitrogen/air filling device/pipe with welded cover capable of reuse. b) An extended pipe for filling of oil at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing the welded cover. 11. MOUNTING ARRANGEMENT The transformer shall be provided with two mounting lugs (as shown in figure 3) suitable for fixing the transformer to a single pole by means of two bolts of 20 mm dia. 12. RATING AND TERMINAL MARKING PLATE The transformer shall be provided with non-detachable rating marking plate(s) of weather proof material, fitted in a visible position and showing the complete information as given under clause 20 of IS : 1180 (Part I) 1989. 13. LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limits of 55o C (measured by resistance) for transformer windings and 45o C (measured by thermometer) in top oil above the ambient temperature of 40o C, when tested in accordance with IS : 2026. 14. LOSSES AND IMPEDENCE VALUES The supplier shall furnish the maximum guaranteed values of no load and load losses (with no plus 14.1 tolerance). The offers shall be evaluated on the basis of capitalisation of losses as per the REC standard on the same. 14.2 The percentage impedance at 75o C shall not exceed 4%. 15. OVERFLUX In the transformer core, overflux shall be limited to 12.5% to ensure that in the event of over-voltage to the extent of 12.5%, the core does not get saturated. The supplier shall furnish necessary design data in support of this stipulation. 16. LT CIRCUIT BREAKER 16.1 The transformer shall be fitted with a trip-free LT Circuit Breaker of suitable capacity to protect it from overloads and short-circuits on the secondary side. Unless otherwise specified by the purchaser, the circuit breaker shall be two-pole construction with a provision to close or trip both the poles simultaneously. 16.2 The circuit breaker shall be provided inside the transformer tank immersed in oil. The breaker shall be coordinated thermally with the transformer rating to follow closely the variation of winding temperature due to fluctuating loads and ambient temperature. The outgoing terminals of the circuit breaker shall be connected to the LT bushing of the transformer through internal connections. 16.3 The rated short circuit breaking capacity of the circuit breaker shall not be less than 2.5 KA. The circuit breakers shall be tested in accordance with IS : 13947 (Part 2) : 1993 but at a power factor of 0.4 (lagging) or less. 16.4 The circuit breaker shall be capable of being operated from the ground level by means of an operating rod. For this purpose a suitable hook shall be provided on the transformer tank in a suitable position for easy and safe operation of the circuit breaker from the ground level. The design of the operating mechanism of the circuit breaker shall be such that it shall have only two positions i.e. ON and OFF, it shall not require resetting before being switched to ON position. 17. COORDINATION OF 11 KV FUSE AND LT CIRCUIT BREAKER Coordination of 11 KV fuse with LT Circuit Breaker is the most important feature of the CSP transformer and shall be properly tested and proved. 18. APPLICATION Single phase transformers are normally intended for making available single phase supply to the consumer at 240 V. For meeting isolated demand for motive loads, either single phase motors will have to be used or 3phase motors can be operated by making use of phaseconverters. 19. TESTS 19.1 Routine tests : All transformers shall be subjected to the following routine tests at the manufacturers works and in accordance

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with IS : 2026 and IS : 1180 (Part - I & II) (or as agreed upon between purchaser and the manufacturer). a) Measurement of winding resistance b) Measurement of voltage ratio and check of voltage vector relationship c) Measurement of impedance voltage/short-circuit impedance and load loss d) Measurement of no-load loss and no load current. e) Measurement of insulation resistance f) Induced over voltage withstand test g) Separate source voltage withstand test h) Coordination test as per clause 17 i) Air Pressure Test (IS : 1180 (Pt II), CL : 21.5.1) for sealed transformers only 19.2 Type Tests The following type tests shall be made on the transformers as per details given in IS : 2026: (a) to (h) as indicated under routine tests i) Lightning impulse test j) Temperature rise test k) Shortcircuit test l) Air Pressure test : (As per IS : 1180 (Pt I) CL : 22.5 for Non-sealed type As per IS : 1180 (Pt II) CL : 21.5.1 for sealed type) 19.3 The supplier shall furnish calculations in accordance with IS : 2026 to demonstrate the thermal ability of the transformers to withstand short circuit. 20. INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that material is being furnished in accordance with the specification. The purchaser has the right to have tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.

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REC Specification 73 /1997 (For Gaining Experience) OUTDOOR TYPE THREE PHASE 11KV/433-250V COMPLETELY SELF PROTECTED DISTRIBUTION TRANSFORMERS WITH AMORPHOUS METAL CORE UPTO AND INCLUDING 100 KVA FOREWORD Development of new core material, Amorphous Metal Alloy, has enabled the transformer industry to offer transformers having substantially lower no-load losses (about one-third of the losses in conventional transformer using CRGO core). The component of load losses remains practically unchanged. These transformers are finding increasing application in advanced countries. Considering the substantial savings in energy, the additional cost involved is recovered in few years. Extensive use of such transformers can be one of the major initiatives for conservation of scarce electrical energy. Based on the recommendations of the 13th Standardisation Conference held in May 1993, REC Specification 70/1993 on Amorphous Metal Core Distribution Transformer was issued to gain experience. The Corporation has been studying the reasons for the large scale failure of distribution transformers in the field and one of the major factors seems to be the inadequate protection provided on the low voltage side of the transformers. This issue was discussed at length at the 14th Conference on Standardisation and Technical Development held in New Delhi on the 25th April, 1997 and it was decided to issue a separate specification for Amorphous core transformers on the lines of Completely Self Protected transformers(REC Specification No. 23/1983) as an alternative to REC Specification No. 70/1993 Revised-1997 for Amorphous Core transformers without in built protection. These transformers have internally mounted oil immersed LT Circuit breakers, 11 KV fuses and 11 KV lightning arresters. Because of the well coordinated and tested protection arrangements, these transformers are expected to have a much lower failure rate as compared to the conventional transformers. Based on the above decision taken during the Conference, this specification for Amorphous Metal Core Completely Self Protected Transformers is issued. 1.

SCOPE

This specification covers oil-immersed, naturally cooled, 3phase, 50 Hz, double wound, outdoor type completely self protected (CSP) conventional/sealed distribution transformers with amorphous metal core of 25, 63 and 100 KVA ratings for use on systems with a nominal voltage of 11 KV. 2.

APPLICABLE STANDARDS

Unless otherwise stipulated in this specification, the Completely Self Protected Conventional/sealed Amorphous Metal Core Distribution Transformers shall comply with the latest version of IS : 1180 (Part-I)/(Part-II) and IS: 2026. For LT Circuit Breaker, IS: 13947(pt- II)-1993 or its latest version shall be applicable. 3.

STANDARD RATINGS

The standard ratings shall be 25, 63 and 100 KVA. 4.

NO LOAD VOLTAGE RATIOS

The no-load voltage ratio shall be as follows : a) 11000/433-250 V for 25, 63 and 100 KVA b) 10450/433-250 V for 100 KVA only, whenever specified 5.

TAPS

No taps are to be provided in these transformers 6.

WINDINGS

6.1 Unless otherwise specified, DPC insulation shall be used for HV and LV winding wires and Electrical Grade plain insulation Kraft paper shall be used for inter-layer insulation of the HV and LV coils. In case of PVA enamelled conductor being used for HV/LV coils, Electrical Grade Epoxy Dotted thermally upgraded Kraft paper shall be used for inter layer insulation. Use of single coil design for HV winding shall be preferred due to its better short-circuit behaviour. 6.2 The primary winding shall be connected in delta and the secondary winding in star (Vector Symbol Dy 11), so as to produce a positive displacement of 30o from the primary to the secondary vector of the same phase. The neutral of the secondary winding shall be connected to a separate insulated terminal.

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6.3 Since the Govt.of India, Ministry of Industry, N.Delhi, vide its letter No.,19/(53)/93-El.India dated 13-4-94 has allowed the use of copper winding also, the SEB may specify use of either aluminium or copper winding for these transformers depending upon their economic advantage. 7.

FITTINGS

The following standard fittings shall be provided : A. For Conventional and Sealed Transformers a) Two earthing terminals b) Two lifting lugs B. For Conventional Transformers a) Oil level gauge indicating three positions of oil, marked as follows : Minimum (5o C) 30o C Maximum (98o C)

b) Plain breathing device comprising an inverted U-pipe with wire gauze at the open end or silica gel breather as required by the purchaser. c) Drain-cum-sampling valve (steel) of the type shown in Fig. 1 welded to the tank. The special tool for operating this valve shall be supplied with the transformer. d) Thermometer pocket for 63 and 100 KVA units e) Filling hole having P 1 thread (with cover) on the transformer body/conservator. C. For Sealed Transformers a) Nitrogen/air filling device/pipe with welded cover capable of reuse. b) An extended pipe for filling of oil at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing the welded cover. No conservator shall be provided on these transformers. 8.

CONSERVATOR (For Conventional Transformers only)

8.1 On transformer of 63 and 100 KVA, provision of conservator is obligatory. For 25 KVA transformer the manufacturers may adopt their standard practices. 8.2 The conservator shall be provided with a drain plug and a filling hole with cover. In addition, the cover of main tank shall be provided with an air release plug to enable trapped air to be released unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank. 8.3 The inside diameter of the pipe connecting the conservator to the main tank shall be within 20 to 50 mm and it should project into the conservator in such a way that its end is approximately 20 mm above the bottom of the conservator so as to create a sump for collection of impurities. The minimum oil level (corresponding to () 5o C) should be above the sump level.

9.

RATING AND TERMINAL MARKING PLATE(S)

Each transformer shall be provided with non-detachable rating and terminal marking plate(s) of weather-proof material fitted in a visible position showing the complete information as given in IS : 1180 (Part - I). 10. LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limit of 55o C (measured by resistance) for the transformer winding and 45o C (measured by thermometer) in top oil when tested in accordance with IS : 2026. 11. LOSSES AND IMPEDANCE VALUES 11.1 The no-load and load losses shall not exceed the values given in the following table : KVA Rating 25 No Load Loss (Fixed loss) (Watt) 28 Load loss at 75o C (Watt) 685

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63 100 50 66 1235 1760

The above losses are maximum allowable and there will not be any plus tolerance. The above losses are for wound core design. 11.2 The percentage impedance at 75o C shall be 4.5% subject to tolerance as per IS : 2026. 12. PERMISSIBLE FLUX DENSITY AND OVERFLUXING The flux density at rated voltage and frequency shall not exceed 1.38 tesla. The no load current at rated voltage and at 112.5 per cent rated voltage shall not exceed values given below : KVA Rating 25 63 100 13. TRANSFORMER OIL The transformer oil shall comply with REC Specification No.39/1985 (R-1993). 14. BUSHING TERMINALS 14.1 To avoid bimetallic action at the point of connection to the aluminium windings and to the external aluminium cables/conductors, both HV & LV bushing stems shall be made of aluminium alloy conforming to the requirements of IS : 3347. 14.2 The bushing terminals shall be of clamp type to directly receive aluminium conductors/cables without requiring use of lugs. The terminal shall be directly screwed on to the stems to secure effective sealing of the bushing. Details of the terminals are given in Appendix - I. 14.3 The following minimum clearances shall be provided : Enclosed Phase-to-phase Phase-to-earth 127 mm 76 mm External 255 mm 140 mm Percentage of Rated Full Load Current At 100% At 112.5% Rated Voltage Rated Voltage 1.50 4.0 1.25 3.5 1.10 3.0

14.4 HV Bushings (For Sealed Transformers only) To enable replacement of the outer porcelain bushing without opening the cover and without affecting the 14.4.1 sealing arrangement of the transformer, the HV bushing shall be made in two parts. The external porcelain bushing shall conform to the requirements of IS : 3347 Part III/Sections 1 and 2. The internal bushing shall also preferably be made of porcelain and shall have a separate aluminium alloy stem. Alternatively, the internal bushing may be made of epoxy and shall have embedded stem and each bushing shall be subjected toPartial Discharge Test as per the stipulations of IS : 2099 to avoid the possibility of any air void remaining in the cast. A typical arrangement of the two part HV bushing with internal porcelain bushing is shown in Fig. 2. The alternative arrangement with internal epoxy bushing is shown in Fig. 3. However, the manufacturer is free to adopt a different arrangement provided it satisfies all the requirements of this clause. 14.4.2 Metal parts of the internal HV bushings inside the transformer shall remain immersed in oil under all operating conditions. 14.4.3 As an alternative to the two parts bushing of porcelain type mentioned at 14.4.1 and 14.4.2, the manufacturer may provide unbreakable polymer bushings which can electrically be equivalent to the porcelain bushings in performance. 15. SEALING GASKETS All sealing washers/gaskets shall be made of oil and heat resistant nitrile rubber. Gaskets made of natural rubber or cork sheet are not permissible. 16. TANK CONSTRUCTION (For Sealed Transformer only) The transformer tank shall be made of good quality steel sheet of adequate thickness and shall be suitably stiffened to provide sturdy and robust construction to withstand extreme pressure conditions. The tank shall be capable of withstanding pressure upto (+) 80 Kpa and () 70 Kpa (gauge pressure) without any deformation. The transformer cover shall be welded to the tank in such a way that it shall be possible to remove the weld and reweld the transformer at least twice. Apart from welding, any other suitable option for sealing of the cover ( Bolted type with welded U shape

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clamps on each side of the tank etc.,) as agreed to by the purchaser can also be used. 17. TANK SEALING (For Sealed Transformers only) Space on the top of the oil shall be filled either with nitrogen conforming to commercial grade as per IS : 1747 or dry air. The nitrogen/air plus the oil volume inside the tank shall be such that even under extreme operating conditions, the pressure generated inside the tank shall not exceed (+) or () 40 Kpa. 18. LT CIRCUIT BREAKER 18.1 The transformer shall be fitted with an oil immersed trip-free LT circuit breaker, provided inside the transformer tank. The out going terminals of the circuit breaker shall be connected to the LT bushings of the transformer through internal connection as in ordinary transformers. 18.2 The circuit breaker shall be capable of being operated from the ground level by means of a suitable operating rod. For this purpose, an operating hook shall be provided on the transformer tank in a suitable position for easy and safe operation of the circuit breaker from ground level. The ON and OFF positions of the handle shall be clearly and boldly marked on the enclosure and there should be no intermediate re-set position. 19. 11 KV LIGHTNING ARRESTERS 19.1 A set of lightning arresters of metal oxide type with suitable failure detecting device, shall be mounted on the transformer, clamping it securely to the tank. The line terminal of the lightning arrester shall be connected to the HV Bushing and the earth terminal of the lightning arrester shall be solidly connected to the tank, which in turn will be connected to a separate earth. 19.2 The characteristics of the lightning arresters and all test requirements shall conform to REC specification No. 55/1987. 20. 11 KV FUSE ARRANGEMENT The 11 KV fuse links shall be provided as only internal fuses (mounted inside the bushings). In this case, it will be absolutely necessary to ensure that the fuses will blow off only in the case of an internal fault in the transformer and all external faults in the LT system will be cleared by the LT circuit breaker only. This will call for the use of circuit breakers of proven design and use of proper rating fuses.

21. COORDINATION OF 11 KV FUSES AND LT CIRCUIT BREAKER Coordination of 11 KV fuses with the LT circuit breaker is the most important feature of a CSP transformer and shall be properly tested and proved. 22. TESTS (for transformers only excluding LT Circuit Breaker by detaching ) 22.1 Routine Tests All transformers shall be subjected to routine tests at the manufacturers works. The following routine tests shall be carried out in accordance with the details specified in IS : 1180 (Part - I) & IS : 2026. a) Measurement of winding resistance b) Measurement of voltage ratio and check of voltage vector relationship c) Measurement of Impedance voltage, short-circuit impedance and load loss d) Measurement of no-load loss and no-load current e) Measurement of insulation resistance f) Induced over-voltage withstand test g) Separate source voltage withstand test h) Coordination test as per clause 21 above i) Air Pressure Test (IS : 1180 Part - II) For Sealed Transformer only 22.2 Type Tests The following type tests shall be made on the transformers as per details given in IS : 2026 : a) to (h) as indicated under routine test i) Unbalanced Current Test : The value of unbalanced current indicated by the ammeter as shown in the test arrangement in Fig.4 shall not be more than 2% of the full load current. j) Impulse voltage withstand test k) Temperature rise test l) Short circuit test m) Air Pressure Test As per IS - 1180 (Pt - I) clause 22.5 for Non-sealed type As per IS - 1180 (Pt - II) clause 21.5.1 for sealed type If records of a type test on a transformer which, in essential details, is representative of the one being purchased, are furnished, the purchaser may accept this as evidence of the type test instead of actual test. 22.3 The supplier shall furnish calculations in accordance with IS : 2026 to demonstrate the thermal ability of the transformers to withstand short circuit.

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23. INSPECTION All tests and inspection shall be made at the place of manufacture of transformer unless otherwise especially agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply. 24. WARRANTY The supplier shall guarantee satisfactory performance of transformers and all the associated components for a period of 2 years from the date of receipt by the purchaser or 18 months from date of commissioning, whichever is earlier. During the warranty period, all repairs/replacements shall be carried out free of cost. 25. MOUNTING ARRANGEMENT The under-base of all transformers shall be provided with two 75 x 40 mm channels 460 mm long with holes as shown in figure 5 (at a center to center distance of 415 mm) to make them suitable for fixing on a platform or plinth.

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REC Specification No. 74/1997

22 KV AND 33 KV XLPE CABLES

FOREWORD XLPE cables have practically replaced the use of PILC (Paper Insulated Lead Covered) cables all over the world due to their superior physical and electrical properties compared to PILC cables. For a comparable size, XLPE cables have higher current rating, better short circuit and over load withstand capability and are more rugged and flexible in use. These cables have lower power losses and are lighter in weight. On the whole, it is seen that XLPE cables are more economical for comparable current carrying capacities. A stage is now reached, when a number of cable manufacturers have taken up manufacture of XLPE cables and majority of the SEBs have gained experience in their use. It is, therefore, felt that use of only XLPE cables be standardised, in view of the advantages indicated above. 1. SCOPE This specification covers requirements of 22 KV and 33 KV cross linked polyethylene (XLPE) insulated, PVC sheathed aluminium cables for use in various sub-stations for transformer and 22 KV and 33 KV feeder cables. 2. APPLICABLE STANDARD Except when it conflicts with the specific requirements of this specification, the cables shall comply with the latest version of IS : 7098 (Pt-II)/1985 Specification for Cross Linked Polyethylene Insulated PVC Sheathed Cables. 3. RATED VOLTAGE AND TEMPERATURE The rated voltage of the cables shall be 12.7 KV/22 KV and 19 KV/33 KV and the maximum operating voltage shall be 10% higher than the rated voltage. Maximum continuous operating temperature (combination of ambient temperature and temperature rise due to load) shall be 90o C under normal operation and 250o C under short circuit conditions. 4. TYPE OF CABLES The type of cables covered in this specification shall be (i) single-core armoured (non-magnetic) screened and (ii) threecore armoured screened. 5. STANDARD SIZES OF CABLES The standard sizes of cables which can be used for various applications mentioned under clause (1) of this specification are as mentioned below:5.1 Single Core Cables : 50 Sq.mm, 70 sq. mm, 95 sq. mm, 120 sq. mm, 150 sq. mm, 185 sq. mm, 240 sq. mm, 300 sq. mm, 400 sq. mm, 500 sq. mm, and 630 sq. mm. 5.2 Three core Cables : Generally SEBs are found to be using three core cables only upto 500 sq. mm. Hence all the above sizes upto and including 500 sq.mm may be treated as preferred sizes. 6. CONTINUOUS CURRENT AND SHORT CIRCUIT RATINGS The indicative values of the continuous current carrying capacities of the various sizes of the cables are given in the tables in Clause 6.1 and 6.2. 6.1 S.No. Single Core Cables Indicative values of continuous current carrying capacity in Amps. at maximum conductor temp. of 90o C. (3) In Ground 1. 2. 3. 4. 5. 6. 35 50 70 95 120 150 111 135 165 200 225 255 (4) In Air 130 159 198 240 280 325

Size of cable Sq. mm. (2)

(1)

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7. 8. 9. 10. 11. 12. 6.2 185 240 300 400 500 630 Three Core Cables 285 330 375 425 480 541 365 430 495 590 680 780

(1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

(2) 35 50 70 95 120 150 185 240 300 400 500

(3) 110 130 155 175 195 225 255 290 325 385 450

(4) 115 135 165 200 230 265 310 345 396 460 590

The short circuit ratings for the various sizes of the 3-core and single core cables calculated for a duration of 1 6.3 second at maximum temperature of 250o C are given below:

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S.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. * For guidance only 7. DETAILS OF CABLES 7.1 Conductor :The cable conductors shall be of round, stranded and compacted aluminium of nominal size as stipulated under Clause 5. Corresponding maximum wire diameter and number of wires in the conductor shall be as given in IS : 8130. 7.2 Conductor Screen: Conductor screening shall be provided over the conductor by applying non-metallic semi-conducting tape or by extrusion of semi-conducting compound or a combination of the two. 7.3 Insulation: The insulation shall be of extruded cross linked polyethylene (XLPE) of nominal insulation thickness 6.0 mm. for 22 KV and 8.8 mm. for 33 KV and its properties shall conform to IS : 7098 (Pt. II). 7.4 Insulation Screen: 7.4.1 The insulation screen shall consist of two parts, namely metallic and non-metallic. Non-metallic part shall be applied directly over the insulation of each core and shall consist of either a semi-conducting tape or extruded semi-conducting compound or a combination of the two or either material with semi-conducting coating. The metallic part shall consist of either tape, or braid or concentric serving or wires or a sheath and 7.4.2 shall be non-magnetic and shall be applied over the non-metallic part. For single-core armoured cables, the armouring may constitute the metallic part of the screening. 7.5 CoreIdentification and Laying Up of Cores: The core identification and laying up of cores shall be as per IS : 7098 (Part - II). For identification of different cores in three-core cable, use of coloured stripes, red, yellow and blue or use of numbered strips shall be employed. 7.6 Inner sheath: The laid up cores shall be covered with inner sheath made of thermoplastic material, applied either by extrusion or wrapping. It shall be ensured that the shape is as circular as possible. Thickness of inner sheath shall conform to IS : 7098 (Pt. II). Single core cables shall have no inner sheath, but in case of cables having both metallic part of screen and armour, there shall be an extruded inner sheath between them. 7.7 Armouring: Armouring shall be applied over the nonmetallic part of insulation screening or over the inner sheath as the case may be for single core cables. For three core cables, it is to be applied over the inner sheath. The method, type, dimensions, joints, conductance etc., of armour shall conform to IS : 7098. 7.8 Outer Sheath: The outer sheath shall be applied over the armouring. The minimum thickness and properties of outer sheath shall conform to the requirement of IS : 7098 (Pt. II) 8. TESTS 8.1 The following tests shall be carried out on the cables as per IS : 7098 (Part II). 8.1.1 Type Tests a) Tests on conductor : i) Tensile Test ii) Wrapping Test iii) Resistance Test b) Tests for armouring wires/strips Sizes of 3-phase & single phase cables (Sq. mm) 35 50 70 95 120 150 185 240 300 400 500 630 Conductor Short Circuit rating in KA (rms value)* 3.29 4.70 6.58 8.93 11.3 14.1 17.4 22.6 28.2 37.6 47.0 59.2

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c) Tests for thickness of insulation and sheath d) Physical tests for insulation i) Tensile strength and elongation at break ii) Ageing in air oven iii) Hot test iv) Shrinkage test v) Water absorption e) Physical tests for outer sheath : i) Tensile Strength and elongation at break ii) Ageing in air oven iii) Shrinkage test iv) Hot deformation v) Bleeding and Blooming test f) Partial Discharge Test g) Bending Test h) Dielectric Power Factor Test i) As a function of voltage ii) As a function of temperature i) Insulation resistance test (Volume Resistivity) j) Heating Cycle Test k) Impulse Withstand Test l) High Voltage Test m) Flammability Test 8.1.2 Acceptance tests a) Tensile Test b) Wrapping Test c) Conductor Resistance Test d) Test for thickness of insulation and sheath e) Hot set test for insulation f) Tensile strength and elongation at break test for insulation and sheath g) Partial Discharge Test h) High Voltage test i) Insulation Resistance (Volume resistivity) test 8.1.3 Routine Tests a) Conductor resistance test b) Partial Discharge Test c) High Voltage Test 9. PACKING AND MARKING 9.1 Packing The cables shall be supplied in wooden drums conforming to IS : 10418. The standard length of the cable in each drum shall be 0.2 KM 5%. 9.2 Marking The cable drum shall carry the information as per requirement of IS : 7098 (Part II). 9.3 The manufacturers name or trademark, the voltage, grade, year of manufacture, etc. may be printed or embossed on the cable as stipulated in IS : 7098 (Part II). 10. INSPECTION All the tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that material is being furnished in accordance with the specification. The purchaser has the right to have tests carried out at his own cost by an independent agency whenever there is a dispute regarding the quality of supply.