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TAMIL NADU TRANSMISSION CORPORATION LTD

CHENNAI
TAMIL NADU, INDIA



Specification for Establishment of 230/110 KV SF6 Gas Insulated
Switch Gear Sub-Station under EPC contract at Guindy, Chennai





SPECIFICATION NO. T-1687




OFFICE OF THE CHIEF ENGINEER/TRANSMISSION
6
TH
FLOOR, NPKRR MAALIGAI,
144, ANNA SALAI, CHENNAI - 600 002.
Tamil Nadu, INDIA




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I N D E X

Description TITLE PAGE NOs.
Section I INVITATION FOR BID 3-5
Section II GUIDE LINES AND INSTRUCTIONS TO TENDERERS 8-21
Section III COMMERCIAL 25-74
Section IV BID QUALIFICATION REQUIREMENTS 75-78
Section- V TECHNICAL SPECIFICATIONS 80-519
Section- VI PRICE SCHEDULES 520-545
Section-VII DRAWINGS 546
























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SECTION-I

INVITATION FOR GLOBAL BID

INTERNATIONAL COMPETITIVE BIDDING INVITATION FOR BID.
Global Sealed Tenders in Duplicate Two Part Tender system are invited for
and on behalf of TAMIL NADU TRANSMISSION CORPORATION, hereinafter
referred to as PURCHASER, so as to reach on or before the due date prescribed.
1. SCOPE:
1.1 Establishment of 230/110 KV GIS Substation under EPC Contract with the
following Equipments/Materials at Guindy., Chennai
a) 5 Nos 230 KV GIS Feeder Bays and 6 Nos 230 KV GIS Transformer Bays
b) 7 Nos 110 KV GIS Feeder bays and 3 Nos 110 KV GIS Transformer Bays
c) 3 Nos 230/110 KV 100 MVA Auto Transformers.
d) Other Substation equipments as per price schedule
1.2 Construction of GIS room & control room , the foundation shall be for G + 6
Floors, compound wall, road, cable duct etc.,

2. COST OF BID DOCUMENTS (NON-REFUNDABLE)


With in
India
OUTSIDE INDIA
OBTAINED
IN PERSON
Rs. 10,000/- Rs. 10,000/-
(or) U.S.$ 225
BY POST Rs. 10,300/- Rs.11,350/-
(or) U.S $ 280


3. Earnest Money Deposit :

The EMD for local bidders is Rs. 100 Lakhs . For foreign bidders US $ 2,22,000/-
or equivalent in convertible currency by Bankers cheque / Demand Draft.

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4. SCHEDULE FOR RECEIPT AND OPENING OF BID
i) Date of commencement of sale : 18.1.2012
ii) Date and time of closing of sale : 17.00 hrs on 20.3.2012
iii) Date and time of pre bid meeting : 11.00 hrs on 8.2. 2012
iv) Due date and time of receipt of bids :upto 14.00 hrs on 21.3.2012
v) Time of Opening of bids : 15.00 hrs on 21.3.2012
N.B.:- If any of the above happen to be a holiday, the next working day will be
due date.
5. SALE OF BID DOCUMENTS :
Bid documents can be obtained by remitting the cost either by cash or by
money order or crossed Demand Draft payable to the Collection account-
TANTRANSCO, VII Floor, N.P.K.R.R. Maaligai, Electricity Avenue, Anna Salai,
Chennai 600 002, India noting the Specification number and sending the
receipt to the Superintending Engineer, 400KV, Tamil Nadu Transmission
Corporation, VI Floor, Western Wing, N.P.K.R.R Maaligai, 144, Anna Salai,
Chennai 600 002. INDIA, with a requisition furnishing the complete postal
address. who shall authorize sale of document on all working days from 10.30
a.m to 5.00 pm during the period of sale mentioned above, Demand draft should
be drawn in favour of TANTRANSCO Collection Account. Chennai.
Bid documents can also be downloaded from WEBSITE of Tantransco
www.tneb.in. or from the WEBSITE of the Tamil Nadu Government
www.tenders.tn.gov.in at free of cost.
address for Communication. Chief Engineer/Transmission.
Tamil Nadu Transmission Corporation Ltd
6
th
Floor, Western Wing
144, Anna Salai, Chennai- 600 002.
INDIA- Fax No. 91 44 28555539.

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6. Telex / Fax / Telegraphic bid will not be accepted and the Board is not
responsible for any postal delay in submission of bids.
7. GENERAL
The Purchaser will not be responsible for any costs or expenses incurred
by bidders in connection with the preparation or delivery of bids including the
costs and expenses related to site visits.






















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SECTION II
GUIDE LINES AND INSTRUCTIONS TO TENDERERS























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I N D E X
Sl.No TITLE PAGE NOs.
1 Invitation for Bid 8
2 Transparency in Tenders Act 8
3 Submission of Tender Offer 8
4 Two parts Tender 8-12
5 Tender opening 12
6 Information Required and clarifications. 13
7 Evaluation and comparison of Tender Offers 14
8 Validity 14
9 Rights of the Board 15
10 Deviations 15
11 Appeal 16
12 Clarifications 16
13 Earnest Money Deposit 17-19
14 Reimbursement of Duties and Taxes. 19
15 Local Conditions 20














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GUIDE LINES AND INSTRUCTIONS TO TENDERERS
1.0. Invitation for Bid
Sealed tenders in Two Part System (a) Technical Bid with Commercial
terms but without Price Bid and (b) Price Bid (both bids in duplicate) will
be received for and on behalf of TAMILNADU TRANSMISSION
CORPORATION LTD herein after referred as Board so as to reach on or
before the due date prescribed. All the tenders shall be prepared and
submitted strictly in accordance with the Instructions set forth herein.
THE TENDERERS WHO DO NOT FULFILL THE BID QUALIFICATION
REQUIREMENTS NEED NOT PARTICIPATE IN THE TENDER. OFFERS
NOT SATISFYING THE "BID QUALIFICATION REQUIREMENTS WILL NOT
BE CONSIDERED AND WILL BE SUMMARILY REJECTED.
2.0 Tender Transparency Act
The Transparency in Tenders Act 1998 and the Transparency in Tender
Rules 2000 are applicable to this tender.
3.0 SUBMISSION OF TENDER OFFER :
3.1 The Tenderer is expected to examine all instructions and Schedules
detailed in the Specification and submit the Schedule of prices and other
required particulars in the schedules and drawings called for in this
specification only as per the formats prescribed herein.
4.0 TWO PARTS TENDER:
4.1 The Tenders shall be in Two Parts as detailed below each in a separate
sealed Envelope marked, " ENVELOPE - A " AND " ENVELOPE - B "
1. The first envelope, called Envelope - A shall contain:
(a) Un priced bid (i.e. Technical Bid with commercial terms except price.)

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(b) Any other information called for in the specification other than price.
THIS ENVELOPE - A SHOULD NOT CONTAIN ANY PRICE BID.
4.2 The second envelope, called Envelope-B, shall contain the PRICE BIDS
only as per Price Schedule.
4.3 The Tender in two parts shall be prepared in duplicate and put in a
separate sealed super scribed envelope (Envelope-A and Envelope-B) as
instructed above.
4.4 Envelope- A and Envelope-B and the Earnest Money Deposit in approved
form or proof of exemption from payment of EMD along with undertaking
in lieu of EMD shall be enclosed in an overall envelope i.e., Inside the
outer sealed cover or in A cover, Earnest Money Deposit/ Permanent
Earnest Money Deposit/ Proof of Exemption from payment of Earnest
Money Deposit and undertaking in lieu of EMD should be placed.
1) EMD IN APPROVED FORM
2) ENVELOPE - A
3) ENVELOPE - B
4.5 Envelope-A and Envelope-B and the overall envelope should be
individually sealed, super scribed with the Specification number, materials
offered and due date of submission and addressed to the Chief
Engineer/Transmission, 6
th
Floor, NPKRR Maaligai, 144, Anna Salai,
Chennai 2
4.6 The Tender offers in complete shape in one overall envelope
containing Envelope A and Envelope-B, as required in Clause 4.3 shall
be sent so as to reach the Chief Engineer/ Transmission on or before
2.00 P.M. on the due date for submission of offers.

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4.7 The Tender documents shall be addressed to the Chief Engineer /
Transmission, 6
th
Floor, Western Wing, NPKRR Maaligai, 144, Anna
Salai, Chennai 600 002.
4.8 At the time of opening the Tenders, any offer which does not satisfy the
Earnest Money Deposit Conditions shall not be readout. If any of the
Bidders indicate price in Envelope A, the Bid will not be read out and
will be rejected.
4.9. Envelope B will not be opened at the time of opening Envelope A
but will be authenticated in the covers by officers authorized to open the
bids. Envelope B so authenticated will be kept under the safe
custody of the empowered officer to open the tender. Envelope B
Price Bid will be opened later, the date of which will be intimated to the
tenderer at a later date, after technical evaluation of the tender is
completed.
4.10 If the tenderer finds any ambiguity in any of the terms and
conditions stipulated in this specification, he shall get it clarified from the
Chief Engineer/ Transmission, 6
th
floor, Western Wing, NPKRR Maaligai,
Electricity Avenue, 144, Anna Salai, Chennai 600 002. The clarification
to the tender documents if any asked for by any tenderer 30 days before
the date of Bid closing will be replied to and copies of such clarification
will be communicated to all the tenderers. If this is not done and
subsequent to the opening of the tenders, it is found that the doubt,
about the meaning or, ambiguity in the interpretation, if any of the terms
and conditions stipulated in the specification are raised by the tenderer,
the interpretation or clarification issued by the Chief Engineer /
Transmission, Tamil Nadu Transmission Corporation, shall be final and
binding on the tenderer.

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4.11 All tender offers shall be prepared by typing or printing in the formats
enclosed with the specifications. One original and one duplicate of the
original proposal which are identical shall be submitted by each tenderer.
4.12 All information in the tender offer shall be in ENGLISH only. It shall not
contain interlineations, erasures or over writings except as necessary to
correct errors made by the tenderer. Such erasures or other changes in
the tender document shall be attested by the person signing the tender
offer.
4.13 The tender offer shall contain full information asked for in the
accompanying schedules and elsewhere in the specification.
4.14 The tenderer has the option of sending the offer by Registered Post/
Courier or submitting the same in person so as to reach by the date and
time indicated.
4.15 In case of postal delivery, tenderers are advised to send them well in
advance so that they are delivered at the office of the Chief
Engineer / Transmission, Chennai-2 before the prescribed date and time.
4.16 The tenders delivered in person / courier shall be handed over to the
Executive Assistant to The Superintending Engineer / 400 KV, Chennai
600 002 before 14.00 hrs. on the due date.
4.17 The Board will not be responsible for any postal or other transit loss
or delay in receipt of the tender offer.
4.18 Telex/Fax/E-Mail or telegraphic offers will not be entertained and will be
rejected.

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4.19 Any offer received by the Purchaser after the due date and time specified
for submission of tender will be declared late, rejected and returned
unopened to the tenderer.
4.20 No tender offer shall be allowed to be modified Subsequent to the
deadline for submission of tender offers.
4.21 Tenderer shall bear all costs associated with the preparation and delivery
of the offers, and the PURCHASER will in no case be responsible or liable
for these costs.
4.22 No offer shall be withdrawn by the tenderer in the interval between the
deadline for submission and the expiry of the period of validity
specified/extended validity of the tender offer.
4.23 The Tenderers are requested to furnish the exact location of their
factories with detailed postal address, Pin Code, Telephone and Fax Nos.
etc., in their tender so as to arrange inspection by the Board if considered
necessary.
5. TENDER OPENING:
5.1 The Tender offers except price Bid will be opened at 15.00 Hrs. on the
date notified, at the Office of the Chief Engineer / Transmission, 6
th
Floor,
NPKRR Maaligai, Electricity Avenue, 144, Anna Salai, Chennai 600 002
in the presence of tenderers authorised representatives who may wish to
be present on the date of opening.
5.2 If the last date set for submission of tender offers and opening date
happens to be a holiday, the tenders will be received and opened on the
succeeding working day, without any changes in the timings indicated.

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5.3 The duly authorized representatives of the tenderers who are present
shall sign the tender opening register.
5.4 The Tenderers Name, prices, all discounts offered, and such other details
as the Board, at its discretion, may consider appropriate will be
announced and recorded at the time of tender opening.
6.0 INFORMATION REQUIRED AND CLARIFICATIONS:
6.1 To assist in the examination, evaluation and comparison if tender
offers, the Board may, at its discretion, ask the tenderer for a
clarification of his offers. All responses to requests for clarification shall
be in writing and to the point only. No change in the price or substance
of the offer shall be permitted.
6.2 The Board will examine the tender offers to determine whether they are
complete, whether any computational errors have been made, whether
required sureties have been furnished, whether the documents have
been properly signed and whether the offers are generally in order.
6.3 Prior to the detailed evaluation, the Board will determine the Substantial
responsiveness of each offer to the Bidding Documents.
6.4 A substantially responsive offer is one which conforms to all the terms
and conditions of the specification without any deviation.
6.5 The Tender offers shall be deemed to be under consideration immediately
after they are opened and until such time official intimation of
award/rejection is made by the Board to the tenderers. While the offers
are under consideration, tenderers, and / or their representatives or other
interested parties are advised to refrain from contacting by any means,
the Board and/or Boards employees/representatives on matters related to
the offers under consideration.

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6.6 Mere submission of any Tender offer connected with these documents
and Specification shall not constitute any agreement. The tenderer shall
have no cause of action or claim, against the Board for rejection of his
offer. The Board shall always be at liberty to reject or accept any offer or
offers at its sole discretion and any such action will not be called into
question and the tenderer shall have no claim in that regard against the
Board.
6.7 An attempt by any tenderer to bring to bear extraneous pressures on the
tender accepting authority shall be sufficient reason to disqualify the
tenderer.
7.0 EVALUATION AND COMPARISON OF TENDER OFFERS :
7.1 The tender offers received and accepted will be examined to determine
whether they are in complete shape, all data required have been
furnished, the tender offer is properly signed and the offers are
generally in order and the tender offer conforms to all the terms and
conditions of the Tender document without any deviation.
7.2.0 For the purpose of evaluation of the tender offers, the following factors
will be taken into account for arriving at the evaluated price.
7.2.1 The amount of Sales Tax and percentage of Sales Tax shall be indicated
in the offer.
7.2.2 The amount of Sales Tax under the Tamil Nadu General Sales Tax Act
1959 ( Tamil Nadu Act 1 of 1959) and Percentage shall be Indicated in the
offer.
7.2.3 The quoted price should be corrected for arithmetical errors.
7.2.4 In case of discrepancy between the price quoted in words and figures, the
lowest of the two shall be considered.

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7.2.5 Adjustments to the price quoted shall be made for deviations in
commercial deviations such as the delivery schedules and minor variations
in the payment terms which are quantifiable.
7.2.6 Evaluation will be done for the entire package.
8.0 VALIDITY :
8.1 The tender offer shall be kept valid for acceptance for period of 180 days
from the date of opening of offers. The offers with lower validity
period are liable for rejection.
8.2 Further, the tenderer shall agree to extend the validity of the Bids
without altering the substance, and prices of their Bid for further periods,
if any, required by the Board.
9. 0 RIGHTS OF THE TANTRANSCO :
Not withstanding anything contained in this specification, the
TANTRANSCO reserves the right to :
(a) Accept the lowest tender.
(b) Revise the quantities at the time of placing orders.
(c) Reject any or all the tenders or cancel without assigning any reasons
therefore.
(d) To split the Tender Quantity and place orders on one or more than one
Firm to meet the delivery requirements.
(e) Relax or waive or amend any of the conditions stipulated in the tender
specification wherever deemed necessary in the best interest of the
Board.

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(f) Recover losses if any sustained by Board, from the supplier who pleads
inability to supply, and backs out of his obligation after award of
contract. The Security Deposit paid shall be forfeited.
(g) To cancel the orders for not keeping up the delivery schedule.
10.0 DEVIATIONS :
10.1 The tenderer shall furnish, if there are any deviations in the commercial/
technical terms in the Schedule annexed. Deviations mentioned elsewhere
will not be considered. If no deviations are furnished, it will be construed
that the tenderer is accepting all terms specified in the specification.
Similarly if any deviations are furnished in the said schedules it will be
construed that these are the only deviations and the tenderer is accepting
all other terms of the specification and the offer will be taken for
evaluation accordingly.
10.2 THE OFFERS OF THE TENDERERS WITH DEVIATIONS IN COMMERCIAL
TERMS OF THE TENDER DOCUMENT WHICH COULD NOT BE ACCEPTED
WILL BE REJECTED.
10.3 NO ALTERNATE OFFER WILL BE ACCEPTED.
11.0 APPEAL:
Any tenderer aggrieved by the order Passed by the Tender accepting
Authority under section 10 of the Tamil Nadu Transparency in Tender Act 1998
may prefer an appeal to Government within 10 (Ten) days from the date of
receipt of order.
12.0 CLARIFICATIONS :
The tenderer is required to carefully examine the specifications and
documents and fully inform himself as to all the conditions and matters which

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may in any way affects the supply or the cost thereof. If any tenderer finds
discrepancies or omissions in the specification and documents or is in doubt as to
the true meaning of any part, he shall at once request in writing for an
interpretation / clarification to the Superintending Engineer / 400KV. Such a
request for clarifications shall reach the PURCHASER 30 days (Thirty) before the
date of Bid closing. The Superintending Engineer, then will issue interpretations /
clarifications as he may think fit in writing to all prospective tenderers. After
receipt of such interpretations / clarifications form the Board, the tenderer may
submit his offer but within the time and date as specified. All such interpretations
/ clarifications shall form a part of the specification and documents and
accompany the tenderers proposal. Verbal clarification and informations
obtained by the tenderer shall not in any way be binding on the Board. It will be
the responsibility of each tenderer to fully inform himself of all local conditions
and factors which may have any effect on the equipments / materials / execution
of works covered under these specification and documents.
It must be understood and agreed that such factors are properly
investigated and considered while submitting the proposals. No claim for
financial adjustment to any contract awarded under these specification and
document will be permitted by the PURCHASER.
Neither any change in the time schedule of the Contract; nor any financial
adjustments arising thereof shall be permitted by the PURCHASER which are
based on the lack of such clear information or its effect on the cost of the Supply
to the tenderer.
13.0 EARNEST MONEY DEPOSIT :
Intending Tenderers should pay towards Earnest Money Deposit a sum of
US$ 222000 or equivalent amount in convertible currency. In the case of Foreign
Bidders the EMD in the form of Bankers cheque/ Demand Draft shall be
furnished.

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In case of bidders from outside India the instruments of payment towards
EMD shall be payable at Chennai. Any collection charges if any incurred at the
time of crediting to the TRANSCO account by Bank the same will be adjusted
while refunding EMD or in adjusting against Security Deposit in the event of
successful bidder.
In respect of foreign bidders the other option of payment of EMD through
Telegraphic Transfer from overseas account is acceptable.
The bidder shall enclose the copy of Telegraphic Transfer format along
with the copy of FIRC certificate to be issued by the beneficiary banker.
The details of beneficiary bank and account details are as below for filling
up the Telegraphic Transfer format.
The amount may be remitted by SWIFT
Through JP MORGAN CHASE BANK
NEW YORK N.A
SWIFT CODE: CHASUS 33
ABA ROUTING NO. 021000021

FOR

CREDIT TO A/C No. 011-1395969 OF
CANARA BANK, INTERNATIONAL DIVISION MUMBAI
SWIFT No. CNRBINBBBID

FOR

FINAL CREDIT To A/C No. 0911201022266 of
M/S TANTRANSCO WITH
CANARA BANK, MOUNT ROAD BRANCH
CHENNAI- 600 002 INDIA.
The EMD for Local Domestic Bidders is Rs.100 Lakhs.
The Earnest Money specified above should be deposited first either by
CASH and the receipt for the same may be obtained from the CHIEF FINANCIAL
CONTROLLER, Board Office, ACCOUNTS Branch, 7
th
Floor, N.P.K.R. Ramasamy
Maaligai, Electricity Avenue, 144 Anna Salai, Chennai 600 002.

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A DEMAND DRAFT/PAY QRDER From any of the Nationalised / scheduled /
Foreign banks with branches in India for the above amount drawn in favour of
the TANTRANSCO Collection Account., NAKRR Maaligai, 7
th
Floor, Electricity
Avenue, 144, Anna Salai, Chennai 600 002 and payable at Chennai.
The earnest money deposit made by the Tenderer will be forfeited if:-
(a) he withdraws his tender or backs out after acceptance of the
tender or fails to remit the Security Deposit.
(b) he withdraws his tender before the expiry of validity / rejection by
the Board / competent Authority.
(c) he revises any of the terms quoted during the validity period.
(d) he violates any of the provisions of these regulations contained
herein.
13.1 Cheques, Bank Guarantees, etc, other than Cash/Demand Drafts / Banker
cheque will not be accepted towards earnest money deposit and the
tenders will be rejected. (For local Bidders).
13.2 In the case of cash, it should be deposited with the Chief Financial
Controller, Tamil Nadu Transmission Corporation Ltd, NPKRR Maaligai, 7
th

Floor, 144, Anna Salai, Chennai 600 002. and the receipt obtained
thereon.
13.3 In the case of Demand Draft it should be either deposited with the
Director/Finance, Tamil Nadu Transmission Corporation Ltd , Chennai
600 002 and the receipt obtained thereon should be enclosed or the
Demand Draft/Pay Order itself Should be enclosed with the tender cover
as specified.
13.4.1 If on opening the outer cover it is found that the Cash Receipt/ Demand
Draft/Pay Order has not been attached to the inner Tender cover then the
Tender will be summarily rejected.

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13.4.2 Telegraphic quotation and Tenders accompanied by Part Earnest Money
Deposit will not be considered. This Earnest Money Deposit will be refunded to
the successful tenderer, only after receipt of materials at site in good condition
as per the order. The successful tenderer in whose favour the order is issued,
should on demand pay, in addition, the Security Deposit, if any called for by
the Board. If the successful tenderer either fails to execute the contract the
Earnest Money Deposit remitted by him will be forfeited.
13.4.3 In the case of unsuccessful tenderers except Permanent Earnest Money
Deposit the Earnest Money Deposit will be refunded by means of cheque to them
on application to the Superintending Engineer / Transmission after intimation is
sent to them conveying the rejection / non-acceptance of their tender.
13.4 The Earnest Money Deposit / Security Deposit paid by the Tenderers will
not carry any interest.
13.5 In respect of the successful tenderer, the EMD remitted by him will be
carried over as part of the Security Deposit payable by the tenderer. In
respect of permanent EMD holders, the Permanent EMD will not form part
of the Security Deposit payable by the tenderer and he will have to remit
the Security Deposit in full.
13.6 The Tenders will be opened at the office of the Superintending Engineer /
400 KV . 6
th
Floor, Western Wing, N.P.K.R. Ramasamy Maaligai, Electricity
Avenue, 144, Anna Salai, Chennai 600 002. at 2.00 P.M on the due date
in the presence of such of those tenderers who may desire to be present.
If the due date for tender opening happens to be a holiday , the tenders
will be opened on the succeeding working day.
13.7 The individuals attending the opening of tenders should be duly
authorized by the participated firms in the tender. Only tenderers who
had previous experience in manufacture and supply of equipments /

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materials of the nature and description detailed in the specification shall
quote and such tenderer shall detail their experience and particulars of
their previous supplies.
14.0 Reimbursement of Duties and taxes.
In case where the Board has to reimburse the actual duties and taxes, it is
obligatory on the part of the supplier/concerned authorities in case the
assessment is found to be excessive in the opinion of the Board. The refund if
any obtained should be passed on to the Board. In case the supplier/contractor
himself has paid the taxes and duties under protest or has made only provisional
payment, it shall be clearly understood that payment made by the Board to the
supplier / contractor is subject to the condition that any refund received shall be
passed on to the Board.
15.0 LOCAL CONDITIONS
It will be imperative on each BIDDER to fully inform himself of all local
conditions and factors which may have any effect on the equipments / materials
/the execution of the Works covered under these specifications and documents.
In their own interest, the income Tax Act, 1961the Companies Act 1956 :
Customs Act, 1962 and other related acts and laws prevalent in India. It must be
understood and agreed that such factors have properly been investigated and
considered while submitting the proposals. No claim for financial adjustment to
any contract awarded under these specifications and documents will be
permitted by the PURCHASER. Neither any change in the time schedule of the
Contract nor any financial PURCHASER which are based on the lack of such
clear information or its effect on the cost of the Supply/Works to the BIDDER.



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SECTION III - COMMERCIAL





















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I N D E X
Sl.No TITLE PAGE NOs.
1 Definition of Terms 24-25
2 Completeness of Tender 26
3 Royalties and patents 26-27
4 Price 27-28
5 Split up details of quoted price 28
6 Sales tax 29
7 Excise Duty 29-30
8 Customs Duty 30-31
9 Packing and Forwarding 31
10 Payment 33-34
11 Security Deposit 34-36
12 Delivery 36-37
13 Loss or Damage 37-38
14 Liquidated Damages 38-40
15 Force Majerue 40
16 Guarantee 41
17 Replacement of Defective/damaged materials 41-42
18 Vendors/contractors Default 42-43
19 Delays by purchaser or his authorised agents 43
20 Termination of the contract by the purchaser 44
21 Termination for convenience 44-45
22 Non-assignment 45
23 Effecting of recoveries 45
24 Income tax 45
25 Works contract tax 45
26 Service tax 46
27 Labour welfare Fund 46
28 Patent Rights 46
29 Jurisdiction for Legal Proceedings 46
30 Arbitration 47
31 Deviations from specification 47
32 Test certificates 47
33 Responsibility 48
34 Maximum weights and dimensions of packing. 48
35 Inspection. 48
36 Completeness of Tender 49
37 Interchangeability 49
38 Quantities 49
39 Climatic Conditions 49
40 Electricity Rules 49

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41 Materials and Workmanship 50
42 Recoveries of Dues 51
43 Dispatch of Equipments 51
44 Past Performance 51
45 Defective Supplies 52
46 Special 52-53
47 General Conditions 53-54























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COMMERCIAL AND GENERAL CONDITIONS OF CONTRACT
1.0. DEFINITION OF TERMS:
1.1. In construing these general conditions and the annexed specification, the
following words shall have the meanings herein assigned to them unless there is
some thing in the subject or context inconsistent with such construction.

1.2. The Board / Owner / Purchaser / Employer shall mean the Tamil Nadu
Transmission Corporation Ltd, Chennai and shall include their legal
representatives, successors and permitted assignees.

1.3. The Contractor / Supplier shall mean the Tenderer whose tender has
been accepted by the Board and shall include the Tenderers legal/personal
representatives, successors and assignees.

1.4. The Sub-Contractor shall mean the person named in the Contract for
any part of the work or any person to whom any part of the Contract has been
sublet with the consent in writing of the Owner/Engineer shall include legal
representatives, successors and permitted assigns of such person.

1.5. Engineer shall mean the Chief Engineer / Transmission, Tamil Nadu
Transmission Corporation Ltd, Chennai-2. In case, where no such Engineer has
been so appointed, the word Engineer shall mean the Board or its duly
authorized Representative. Engineers Representative means any resident
Engineer or Assistant of the engineer or any clerk appointed for works from time
to time by the Employer or the Engineer whose duties and authority will be
noticed to the Contractor in writing by the Engineer.

1.6. The Goods means all the equipment, machinery and/or other materials,
which the Contractor is required to supply to the Board under the contract.

1.7. Plant, Work or Works shall mean and include plant materials to be
provided and work and / or services to be done by the Contractor under the
Contract. This also includes all temporary works of every kind required in or
about the execution of the works.

1.8. Services means services auxiliary to the detailed engineering,
fabrication, supply, erection, testing and commissioning of 230/110 KV GIS
Substation and such as transportation and Insurance, and any other incidental
services, such as testing and commissioning, providing of technical assistance,
training and other such obligations of the supplier/Contractor under the Contract,
whether specified or not but necessary for completion of the work.

1.9. The Contract shall mean the Agreement and include the general
conditions, specifications, schedules, sections, drawings, form of tender, covering

26

letter, schedule of prices or the final general conditions, any specific conditions
applying to the particular contract, specification and drawings, Contractors
quotation and subsequent correspondence lists under reference and the
agreement to be entered as per the conditions of supply or work with these
general conditions.

1.10. The Specification shall mean all technical and other stipulations annexed
to these general conditions.

1.11. The Site shall mean the place where equipments are to be installed/
erected and serviced for commercial operation and also include all the area in
which operation in respect of the works are carried out. This term shall also
include material stocking yard and the area where temporary structures are put
up for installing any part of the work etc.

1.12. Tests and Commissioning shall mean such tests as prescribed by the
Engineer before the substation is taken over by the Board.

1.13. Commercial Use shall mean that use of the work, which the Contract
contemplates or usage when it is to be commercially available.

1.14. Guarantee Period shall mean 36 months for all equipments / materials
and accessories and works from the date of commissioning of the whole work.

1.15. Month shall mean calendar month.

1.16. Writing shall include any manuscript, typewritten, print out or seal as
the case may be.

1.17. Persons shall include firm, Company, Corporation and other body of
persons whether incorporated or not.

1.18. Words imparting the singular meaning shall also include the plural and
vice versa where the context so requires.

2.0 CONTRACTOR TO INFORM HIMSELF FULLY:
The Contractor shall be deemed to have carefully examined the general
conditions and specifications. If he shall have any doubt as to the meaning of
any portion of these general conditions of the Contract, he shall set forth the

27

particulars thereof, and send them to the Engineers in writing, in order that such
doubt may be clarified.
3. 0 ENHANCEMENT OF RATES:
No representation for enhancement of rates will be considered during the
currency of the Contract.

4.0 SUB LETTING OF CONTRACT:
4.1 The Contractor shall not, without the consent in writing of the Board,
assign or sublet his contract including supply of material or any substantial part
thereof, provided that any such consent shall not relieve him from any obligation,
duty or responsibility, liability under the Contract. If the Contractor sublets or
changes the sub-contractor without notification to the Board, then Board shall
not make payments for such works/materials. If any defects/damages in works
or materials are noticed in such unauthorized sublet portion within the expiry of
guarantee period/Board reserves the right to rectify/redo the defective goods/
works at its own cost; and such cost/damages will be recovered from Contractor.
4.2. The tenderer should furnish an Undertaking that he is responsible for any
portion of works if carried out by the sub-contractor and he is jointly and
severally accountable to the Tamil Nadu Transmission Corporation Ltd, in the
event of defective design or defaults in the performance.
5.0 COMPLETENESS OF TENDER :
The tender should be complete with all details of illustrative and descriptive
literature and drawing of the materials offered. Information regarding the
country of manufacture and origin of materials used in the manufacture of the
equipments should be furnished. The tenderers shall furnish the complete
technical details of the materials offered. In order that the tenders may receive
full consideration, the whole information asked for in the accompanying schedule
and elsewhere together with relative leaflets, literature, drawings etc., must be
supplied by the tender. The language of Bidding and documents shall be in
ENGLISH only. The tenders not containing the complete details as above are
liable for rejection.

28

6.0 ROYALTIES AND PATENTS :
All royalties and patents or the charges for the use or infringement thereof that
may be involved in the construction or use of any equipment or appliance to be
supplied against this specification shall be included in the tender prices. The
contractor shall
protect the purchaser against any claims, actions, suits and proceedings for the
infringement or alleged either in the country of origin or in India by the use of
any equipment supplied by the contractor other than for the purpose indicated
by or reasonable to be inferred from the specification.
A quality plan will have to be furnished by the successful tenderer.
7.0 PRICE :
7.1 The Tenderers shall quote FIRM price and Fixed for the entire duration of
the contract. However the taxes , duties, other statutory levies, exchange rate
variation etc shall be payable by Board at actuals.
7.2 The prices should be for delivery F.O.R. (Destination) Stores in CHENNAI
inclusive of freight and insurance. In addition, the Ex-works/FOB price should
also be indicated separately. The ocean freight, FOB price, ocean insurance,
inland freight and insurance shall be separately shown in the currency of
payment. The prices should include all State and Central Taxes, Octroi and
Excise Duty and these elements should be indicated separately. The rates ruling
on the date of tender shall be specified. A format for price schedule is given in
the Specification.
7.3 It is the responsibility of the tenderer to inform himself of the correct rates of
duty leviable on the materials at the time of tendering. If the rates assumed by
the Tenderer are less than the current rates prevailing at the time of tendering,
the Board will not be responsible for the mistake and only the lower rate quoted

29

by the tenderer will be admitted, in cases where such tenderer is successful in
getting an order from the Board. If the rates assumed are higher than current
rates prevailing at the time of tendering, the difference will be to the credit of
the Board.
7.4 The tenderer should quote their rates taking into account the E.D. relief
available to them on account of duty paid for procurement of raw materials
under MODVAT scheme and this has to be confirmed by each tenderer. The
tenderer shall furnish a certificate to that effect that the Cenvat Credit to be
availed has been taken into account in the quoted price and passed on to the
Board.
7.5 Prices and rates quoted shall include cost of all materials, labour,
supervision/ payment to Corporation authorities for obtaining permission for
laying cables, all incidental charges thereon, crafts, tools, equipments, and plant
mobilizing and demobilising, fuels, lubricants, fixtures, setting and transport,
duty and taxes on raw materials / bought out items if any, royalties, octroi,
temporary and permanent works, local taxes, levies if any etc., and other costs
those are not specifically mentioned herein but will be incurred by the tenderers
for the satisfactory and timely completion of the works.
8.0 Split up details of the quoted prices.
The following splitup details shall be given
I) Ex-works price / FOB price
II) Packing and forwarding charges
III) Freight charges for delivery at site / stores.
IV) Transit insurance covering storage at site / store for 90 days from
the date of receipt of materials / equipment at site / stores.
V) Excise duty as applicable payable on the ex-works price. Customs
duty payable on FOB & CVD

30

VI) Value Added TAX if any as applicable payable on the ex-works plus
excise duty.
VII) Other statutory levies such as work contract tax , service tax etc
VIII) Ocean Freight
IX) Marine insurance
Total of (i) to (ix)
Tenders with break up rates not furnished as above are liable for
rejection.
Note : The break up for ED/CD/VAT etc., adopted in the Tender will form the
basis for regulating the variation in statutory levies after opening the tender.
9.0 SALES TAX
The Board has been registered as a dealer, under Central sales tax
Act 1956 under Registration No.32929/81-82 dated.18-1-1982. Appropriate
Central Sales Tax in accordance with the provisions of the Act in force shall be
included by the Tenderer in the price quoted.
The Commissioner of Commercial Taxes in their Lr. No. VAT Cell /
2952/2007 (VCC No.995) dt.6-8-2007 has clarified that exemption already
granted for registration of TNEB will continue as per Section 88 (3) (i) of the VAT
Act 2006. Hence TIN shall not be applicable to TNEB.
As per Sl.No.305 of Annexure to TN VAT Act, 2006 Sale of any
goods except Petrol, Diesel and Cement to TNEB for use in Generation,
Transmission and Distribution of Electrical energy will attract TNVAT @ 4% as
per G.O. Ms. No.31, Commercial Taxes, B.2, dt.27-3-2002.
The Commissioner of Commercial Taxes has confirmed in their Lr.No. VAT
Cell/2952/2007 (VCC No.995) dt.6-8-2007 that exemption is continued as per
Sec.88 (3) (i) of the TN VAT Act 2006.
Hence the tenderers are requested to quote appropriately TN VAT
@ 4% even if the items attract VAT @ 12.5% for the goods to be supplied to

31

TNEB used in Generation, Transmission and Distribution of Electrical energy
except Petrol, Diesel and cement. The necessary certificate as per G.O. shall be
furnished.

10.0 EXCISE DUTY
10.1. It is the responsibility of the tenderer to make sure about the correct
rates of duty leviable on the material at the time of tendering. If the rate
assumed by the Tenderer are less than the current rates prevailing at the time
of tendering, the Board will not be responsible for the mistake. If the rates
assumed by the tenderer are higher than the current rates prevailing at the
time of tendering, the Excise duty prevailing at the time of tendering will only
be paid.
10.2 Any Increase in Excise duty consequent to the supplier coming into
different duty slab during the execution of the contract shall be to the suppliers
account No claim for increase in the above respect will be admitted. Any
variation in Excise Duty due to statutory variation within the contract delivery
date shall be considered.
10.3 In case of delayed delivery, the Excise duty prevailed on the date of actual
delivery or the Excise duty applicable on the contractual delivery period
whichever is less shall be admitted.
10.4 Authenticated Invoice containing the details viz. Central Excise, Registration
No., PLA No. etc. date and time of removal of goods, debit entry in PLA/RG 23
duly authenticated by authorised signatory shall be preferred by the supplier for
claim of ED.
10.5 The Tenderer who have quoted ED as NIL and in the event of placement of
order on such tenderer against this specification where the value of order is
above Rs.150 Lakhs, such tenderer shall furnish an undertaking to the effect that
the ED commitment on account of crossing the turnover slab will be discharged

32

to the ED authorities and that the TANTRANSCO shall not be responsible for any
ED evasion by the tenderer in respect of this transaction.
10.6 In the case of tenderer who has quoted ED as Nil and in the event of
placement of order against this specification and the proposed order value is less
than Rs.150 lakhs, the tenderer shall furnish an undertaking to the effect that he
has not obtained any other order in the same financial year and that the Board
shall not be responsible for ED evasion if any by the tenderer in respect of this
transaction.

11.0 CUSTOMS DUTY :
For equipments/materials of foreign origin and within the delivery
period the Customs duty to be paid on the port of entry shall be paid by the
supplier, which will be reimbursed at actuals on production of necessary
documentary evidences. (Bill of Entry).
For goods delivered beyond the delivery period, the customs duty
prevailing during the actual date of delivery or on the schedule date of
delivery whichever is less will be paid.
If the bidder is not the manufacturer of the imported materials /
equipments High sea sales shall be permitted. The necessary documentary
work shall be done by the bidder.
The concessional customs duty where ever applicable shall be availed
by the bidder. The bidder shall quote only concessional customs duty.
The purchaser will render all necessary assistance in availing the
concessional customs duty.



33

12.0 INSURANCE :
Contracting firms shall arrange insurance for the equipments and all its
accessories, being supplied by them, through any of the scheduled / Nationalised
Insurance Companies at their cost. The equipment shall be insured to cover
transport (from ware house) and 90 days storage risk at site. Marine Transport
and marine Insurance in case of import. It will be the responsibility of the
supplier to replace the defective / damaged materials and make good the
shortages and other losses in transit, free of cost and lodge and recover claim
from Insurance, Under-writers / Carriers.
12.1 In addition to the conditions covered under the Clause, the following
provisions will also apply to the portion of works to be done beyond the
Contractor's own or its Sub-Contractor's manufacturing Works.
12.2. Workmens Compensation Insurance
This insurance shall protect the Contractor against all claims applicable
under the Workmen's Compensation Act, 1948(Government of India). This
policy shall also cover the Contactor against claims for injury, disability disease
or death of its or its Sub-Contractors employees, which for any reason are not
covered under the Workmens Compensation Act, 1948. The liabilities shall not
be less that
Workmen's Compensation : As per statutory Provisions
Employee's liability : As per statutory Provisions
12.3. Comprehensive Automobile Insurance
This insurance shall be in such form to protect the Contractor against all
claims for injuries, disability, disease and death to members of public including
the Owner's men and damage to the property of other arising from the use of
motor vehicles during on or off the Site operations, irrespective of the owner-
ship of such vehicles. The minimum liability covered shall be as herein indicated
Fatal Injury : Rs. 100,000 each person
: Rs. 200,000 each occurrence

34

Property Damage : Rs. 100,000 each occurrence
12.4. Comprehensive General Liability Insurance
12.4.1. The insurance shall protect the Contractor against all claims arising from
injuries, disabilities, disease or death of members of public or damage to
property of others, due to any act or omission on the part of the
Contractor, its agents, its employees, its representatives and Sub
Contractors or from riots, strikes and civil commotion. This insurance shall
also cover all the liabilities of the Contractor arising out of the Clause titled
Defense of Suits under General Conditions of Contract of this Volume-1A.
12.4.2. The hazards to be covered will pertain to all the works and areas
where the Contractor, its Sub-Contractors, its agents and employees have to
perform work pursuant to the Contract.
12.5. The above are only illustrative list of insurance covers normally
required and it will be the responsibility of the Contractor to maintain all
necessary insurance coverage to the extent both in time and amount to
take care of all its liabilities either direct or indirect, in pursuance of the
Contract.

13.0 PACKING AND FORWARDING :
The equipment and all its accessories shall be securely packed and
dispatched, freight paid, duly insured, at suppliers risk and cost. The
packing may be in accordance with the manufacturers standard practice.
The contractor is responsible for ascertaining the facilities that exist for
Road Transport to site. Each package shall be clearly marked and contain
detailed packing list, such as gross weight, the nett weight etc., The
contractor is solely responsible for any loss or damage during transport and
safe delivery of the equipments at site in good conditions. The dispatch of
materials shall be only after the approval of test certification by the Board.

35

The scope of supply includes unloading the equipment at site / stores. Only
packages constructed out of sound materials and of dimensions
proportional to the site and weight of contents shall be used. Loose
materials eg. Bolts, nuts etc., shall be packed in gunny bags and sealed in
polythene bags with proper tagging. Components containing glass fragile
materials shall be carefully covered with shock absorbing protective
materials such as expanded polysterene (Thermocole).
All opening of the equipments shall be tightly covered, plugged or capped
to prevent foreign material from entering.
In the case of large and bulk equipment, the vendor shall be responsible for
ascertaining transport limitations and supply the equipments in the
minimum number of components or sub-assemblies with the frame work of
transport limitation.
Where necessary proper arrangements for attaching hinges for lifting shall
be provided. The contents of the packages shall be sealed in thick
polythene sheets and all the inside walls of the packages shall be lined with
waterproof paper to protect the equipment from damages due to dust or
moisture.
All equipment shall be protected for the entire period of dispatch, storage
and erection against corrosion, incidental damage due to vermin, sunlight,
rain, high temperature, humid atmosphere, rough handling in transit and
storage in the open including possible delays in transit. Silica gel or
approved equivalent moisture absorbing materials in small cotton bags shall
be placed and tied at various points on the equipment, wherever necessary.
Adequate provision of skids or pellets shall be made to keep the
packages above the collecting drainage. Crates and other large containers
shall have drain holes in the bottom to prevent collection of water within
the packing. Each crate or package shall contain a packing list, in a water

36

proof envelope. Copies of the packing list, in triplicate shall be clearly
marked for easy identification against the packing list.
All spare parts shall be packed and treated for long storage conditions
at stores/site. Any materials found short inside the intact pack up cases
shall be supplied by the vendor at no extra cost to the purchaser,including
transportation up to the stores/site.
All packing cover and packing material shall become the property of the
PURCHASER.
All packages shall be clearly, legibly and durably marked with uniform block
letters (preferably with water proof paint) on atleast three sides with:-
a) Destination address as communicated
b) Purchase order reference
c) Dimensions
d) Nett and Gross weights
e) Sign showing Side-up
f) Sign showing fragile marks in case of delicate equipments
g) Sign showing slinging and slinging position.
h) Any handling and unpacking instructions, If considered necessary.
14.0 PAYMENT :
14.1 The foreign currency portion of the contract price will be made in the
currency of the bid. Where-ever the payment could not be made in the currency
of bid as per Banker instructions, the payment will be made in U.S. Dollars as per
exchange rate prevailing then. This will be as per exchange rate prevailing as on
the date of payment so far as supplies are received as per delivery schedule. In
case the supply is delayed the payment will be restricted to the exchange rate
prevailing on the scheduled date of delivery or on the actual date of delivery
whichever is less.

37

14.2 Payments will not be made for materials damaged during transit. All
defective materials shall be replaced by the contractor free of charge. Payments
will not be made unless Test Certificates are approved by the Purchaser.
14.3 Payments for the suppliers will be made by cheque on any one of the
Nationalized / Scheduled Banks as may be decided by the Board from time to
time. Exchange commission for issue of Bank Drafts will be to the account of the
Tenderer. Subject to any deductions which the purchaser may be authorized to
make under the contract, the contractor shall on the certificates of the Engineer,
be entitled to payment as follows :
14.4 Letter of credit payment will be made for foreign currency payment and
also for the initial payment only. All balance payments will be through direct
payment procedure only. All charges for opening and operation of L.C are to the
account of the beneficiary. The Letter of credit is to be opened 60 days prior to
delivery.
The usuance letter of credit for a period of 45 days shall be opened. The
payment will be made on 45
th
date of receipt of documents at L/C openers Bank
or the date of issue of materials receipt certificate at site in good condition/work
executed certificate issued by the engineer whichever is earlier.
14.5 TERMS OF PAYMENT:
A. FOR SUPPLY PORTION
70% payment will be made for the materials/equipments received in
good condition at site and on physical verification by the purchaser.
20% after satisfactory completion of erection of the supplied
materials/ equipments.
Balance 10% after completion of successful testing and
commissioning.

38

In case of delay in supply portion of any equipment/material the
appropriate amount of Liquidated damages will be deducted from the
initial payment itself.
B. FOR ERECTION PORTION
80% progressive payment against the certification by the Boards
Engineer/Boards representative.
10% after satisfactory completion of erection.
Balance 10% after successful testing and commissioning and hand
over the project in complete shape to the satisfaction of the Board.
In the case of delay in the execution of any works, the appropriate
amount of Liquidated damages will be deducted from the initial
payment itself.

C. Civil Works:
For the contract completion within delivery period
95% payment will be made for the receipt of Materials/equipments in
good condition at site and used on works only.
balance 5% after completion of works.

For the contract completion beyond delivery period
90% payment for the completed work. Balance 10% after completion of
works. Apart from 10% withheld amount, Liquidated damages will be
recovered from each bill.
14.5.1 For the delayed payments, if any, the purchaser will not pay any interest
on any account.
14.6 The bills for payment will be passed only after receipt and approval of the
following:
a) Security Deposit Bank Guarantee for 5% value of the Order
b) Sales Tax Clearance Certificate

39

c) Performance Bank Guarantee.
d) Test Certificate for the respective materials/equipments.
14.7 The supplier should give a schedule of dispatches to suit the programme
of completion of the project and get the same approved by the purchaser
one month prior to the actual date of dispatch. The supplier should
dispatch each material/ equipment only after getting approval from the
consignee for such dispatches. The dispatch instruction will be issued by
the Superintending Engineer/400KV.
If the supplier dispatches the materials without the prior approval, the
purchaser shall not be responsible of any damage or warfage or both and
only the supplier should bear any expenditure arising out of such
unapproved dispatches.
14.8 L.C. Payment will not be accepted in respect of indigenous
supply.
14.9 The supplier shall bear any expenditure arising out of unapproved
dispatches.
14.10 Offers agreeing to the above terms of payment will be preferred. Board
may reject the offer with other terms of payment.
14.11 For the supplies/works carried out beyond delivery schedule the exchange
rate prevailed on the scheduled date or actual date which ever is less shall
be admitted.
14.0 SECURITY DEPOSIT :
15.1 The successful tenderer will have to furnish Security Deposit for 5% of the
total accepted value of the contract inclusive of Earnest Money deposit paid if
any and balance by Bank Guarantee from any Nationalized / Scheduled Bank or
Foreign Banks with Branches in India valid upto the date of completion of supply.

40

15.2 The Security Deposit will be released to the Contractor only if the contract
is completed to the satisfaction of the purchaser. If the Purchaser incurs any loss
or damages on account of breach of any of the clauses mentioned above or any
other amount arising out of the contract becomes payable by the contractor to
the purchaser, then the purchaser will in addition to such other dues that they
shall be under the law, appropriate the whole or part of the security deposit and
such amount that is appropriated will not be refunded to the contractor.
16.0 DELIVERY :
The period of delivery for the supply , erection , testing and
commissioning and handing over of the Substation is 12 Months from the date
of receipt of LOI.
The Board is at liberty to alter the delivery dates on the lesser side to suit its
needs as and when necessity arises, during the pendency of the contract. The
acceptance of this clause should be specifically confirmed in the tender. The
successful bidder shall furnish a PERT Chart showing the plan of completion of all
the activities connected to the work and got approved by the TANTRANSCO. The
chart shall also indicate the date by which various materials & equipments for
the work will be required. The materials shall be dispatched as per the schedule
and if any of the materials/ equipments are supplied in advance than when it is
required the payment for the same will be made as per the schedule already
agreed and approved unless the purchaser himself seeks to advance the
schedule.
17.0 LOSS OR DAMAGE :
17.1 External damages and / or shortages that are prime facie, the results of
rough handling in transit or due to defective packing, Internal defects, damages
or shortages of integral parts which cannot ordinarily be detected on a superficial
visual examination, though due to bad handling in transit or defective packing,

41

the defective materials shall be replaced by the supplier, free of cost to the
TANTRANSCO.
17.2 If during the period of erection, found that goods already supplied are
defective in material or workmanship or do not conform to specification or
unsuitable for the purpose for which they are purchased, then it will be open to
the purchaser either to reject the good or repudiate the entire contract and claim
such loss that the purchaser may suffer on that account or require the contractor
to replace the defective goods, free of cost.
17.3 Similarly, if during the thirty six months subsequent to the date of receipt of
the goods, any of the goods found to be defective in materials or workmanship or
do not conform to specification or unsuitable for the purpose for which they are
purchased, it will be open to the purchaser either to repudiate the entire contract
and claim damages or accept such parts of the goods that are satisfactory and
require the contractor to replace the balance or to claim compensation for the
entire loss sustained by the purchaser on that account.
17.4 In the event of supplies being received damaged or short, the cost of
materials with CD, ED, Sales Tax (if payable) and other charges payable thereof
will be paid only proportionate to the value of materials received in good
condition, unless the damaged goods or short supplies are made good free of
cost by the suppliers.
17.5 For all legal purposes, the materials shall be deemed to pass into the
Boards ownership at the destination stores/site, where they are delivered ,
commissioned and taken over.
18.0 LIQUIDATED DAMAGES :
18.1 The delivery period given in the clause DELIVERY should be guaranteed
by the contractor under the liquidated damage clause given below :

42

If the contractor fails to deliver the equipment / materials within the time
specified in the contract or any extension thereof, the purchaser shall recover
from the contractor as liquidated damages a sum of HALF PERCENT (0.5%) of
the contract price of the undelivered equipment / materials / unfinished portion
of works for each completed week of delay. The total liquidated damages shall
not exceed TEN PERCENT of the contract price of the units / materials / works so
delayed. In respect of contracts where supply affected in part or works executed
in part, could not be beneficially used by the TANTRANSCO due to such
incomplete supply / execution / liquidated damages should be worked out on the
basis of entire contract price only and not on the value of delayed portion.
The purchaser will not produce any definite proven commercial loss
incurred solely on account of the delayed delivery. L.D. will also be recovered
for the short supplies as is done for the belated supply. It is the responsibility of
the supplier to arrange for inspection, dispatch etc., in time to keep up the
delivery schedule. It should be noted that if a contract is placed on a higher
tenderer in preference to the lowest acceptable tender in consideration of the
offer of earlier delivery, the said contractor will be liable to pay the Board the
difference between the contract rate and that of the lowest acceptable tender in
case of failure to complete the delivery terms of such contract within the delivery
period specified in the tender and incorporated in the contract. This is without
prejudice to other rights under the terms of contract.
18.2 Equipment will be deemed to have been delivered only when all its
components parts are also delivered. If certain components are not delivered in
time the equipment will be considered as delayed unless the missing parts are
delivered.
18.3 If supplies are made by the contractor beyond the period of delivery and
they are accepted by the Board, such acceptance is without prejudice to Boards
right to levy liquidated damages for the delay in supply, If there is delay in

43

delivery, then claims for increase in statutory levies arising after the delivery
period specified in the contract will not be admitted even if the materials are
accepted.
18.4 If the ordered materials are not delivered, the purchaser shall recover
from the contractor, liquidated damages of a sum of 10% of the contract price of
the units/equipments undelivered in addition to forfeiture of EMD / SD and
recoveries as per 18.6 of this specification.
18.5 Tenderer not giving clear and specific acceptance to the above clauses are
liable to be rejected.
18.6 The contractor is liable to pay the amount of loss sustained by the
TANTRANSCO in the event of non-execution of order, if any placed on them
either in full or part to the satisfaction of the TANTRANSCO under the terms of
conditions of contract and order will be placed for such quantities of
works/supplies on some others at a higher price. This is without prejudice to
other rights under the terms of the contract.
18.7 The actual date of delivery at destination stores shall be reckoned for the
purpose of deciding Liquidated Damages for delay in supply. It should be the
suppliers responsibility to arrange for inspection, dispatch etc.,, in time to keep
up the delivery schedule.
18.8 The Foreign Exchange rate variation forms part of contract value for
Liquidated Damages calculation.
19.0 FORCE MAJEURE :
19.1 If at any time, during the continuance of the contract, the performance in
whole or in part, in any obligation under this contract, shall be prevented or
delayed by reasons of any war, hostility, acts of public enemy, act of civil
commotion, strikes, lockouts, sabotages, fires floods, explosions epidemics

44

quarantine restrictions or other acts of God (therein after referred to as
eventualities) then, provided notice of the happening of any such eventually is
given by the tenderer to the Board within 15days from the date of occurrence
thereof neither party shall, by reasons of such eventuality, be entitled to
terminate this contract nor shall have any claim for damages against the other in
respect of such non-performance or delay in performance, and deliveries under
this contract, shall be resumed as soon as practicable after such eventually has
come to an end or ceased to exist.
19.2 Provided that if the performance in whole or part by the supplier on any
obligation under this contract is prevented or delayed by reasons of any
eventuality for a period exceeding 60 days, the Board may at its option terminate
this contract by a notice in writing. Power cut will not be considered under force
majeure condition. The period of extension shall be decided only by the authority
who placed the order, after verifying the evidence for the cause of delay.
19.3 It is hereby specifically agreed that time is the essence of the contract.
The termination of the contract as aforesaid shall not absolve the supplier /
contractor of his liability to pay damages to the Board for the breach of contract
to delivery the goods or complete the contract within the time fixed by the
P.O./Contract or extension thereof.
20.0 GUARANTEE :
20.1 The entire equipments should be guaranteed for satisfactory operation
atleast for a period of 36 months from the date of commissioning.
20.2 Any defects noticed during this period shall be rectified free of cost to the
Board within two months from the date of failure. Irrespective of number of
failures and repairs the Contractor is responsible for free replacement of the
defective materials till the same serves a continuous period of 36 months from
the date of last rectification.

45

20.3 The incidental expenses, transport and freight charges for the replacement
of defective materials including the visit of some experts, skilled workers etc.,
within guarantee period may also be borne by the Contractor till such time it
serves continuous period of 36 months as said above.
20.4 The tenderer shall guarantee among other things, the following
i) Quality and strength of materials used.
ii) Safe electrical and mechanical stresses on all parts of the
equipments under all specified conditions.
iii) Performance figures given by the tenderer in the Schedule of
Guaranteed particulars.
20.5 The successful tenderer should furnish a performance guarantee in the
form of a bank guarantee for a value of 5% contract value and shall be valid for
a period of 36 months from the date of commissioning of the substation.
21.0 REPLACEMENT OF DEFECTIVE / DAMAGED MATERIALS :
21.1 Not withstanding anything contained in the above liquidated damage
clause when the whole or part of the materials supplied by the supplier are found
to be defective / damaged are not in conformity with the specification or sample
such defects or damages in materials supplied shall be rectified within two
months either at the point of destination or at the suppliers works, at the cost of
supplier, against proper security and acknowledgement. In the alternative, the
defective or damaged materials shall be replaced free of cost within three
months on receipt of the intimation from the purchaser of such defects or
damages. If the defects or damages are not rectified or replaced within this
period, the supplier shall pay a sum towards liquidated damages as per
liquidated damages clause given above, for the delay from the date of receipt of
intimation of the defects or damages.

46

21.2 If even after such rectification or replacement of the damaged or defective
part, if the equipment ordered is not giving the satisfactory performance as per
the contract, then it will be open to the purchaser either to reject the goods or
repudiate the entire contract and claim such loss sustained by the Board.
22.0 VENDOR'S/CONTRACTOR'S DEFAULT
22.1 If the VENDOR/CONTRACTOR shall neglect to execute the supply/works
with due diligence and expedition or shall refuse or neglect to comply with any
reasonable orders given to him, in writing, by the PURCHASER in connection
with the supply/works or shall contravene the provisions of the 'Contract', the
PURCHASER may give notice in writing to the VENDOR to make good the
failure, neglect or contravention complained of. Should the VENDOR fail to
comply with the notice within thirty (30) days from the date of service thereof,
then and in such case, the PURCHASER shall be at liberty to place fresh orders
on other firms and get the equipments/materials required for the project,
without prejudice to any other right the PURCHASER may have under the
contract to delete "Works" wholly or in part out of the VENDOR's hands. If the
cost of completing the supply or executing a part thereof as aforesaid shall
exceed the balance due to the VENDOR, the VENDOR shall pay such excess.
Such payment of excess amount shall be independent of the liquidated damages
for delay which the VENDOR/CONTRACTOR shall have to pay if the completion
of supply/works is delayed.
In addition, such action by the OWNER/PURCHASER as aforesaid shall not
relieve the VENDOR/CONTRTACTOR of his liability to pay liquidated damages for
delay in completion of 'Supply/Works.
22.2 The termination of the 'Contract' under this clause shall not entitle the
VENDOR to reduce the value of the performance Guarantee nor the time

47

thereof. The performance Guarantee shall be valid for the full value and the full
period as originally stipulated in the 'Contract'.
23.0 DELAYS BY PURCHASER OR HIS AUTHORISED AGENTS
23.1 In case the Contractor's performance is delayed due to any act of omission
on the part of the Purchaser or his authorised agents, then the Contractor shall
be given due extension of time for the completion of the works, to the extent
such omission on the part of the Purchaser has caused delay in the Contractor's
performance of his work, for which no compensation will be payable for idle
labour, shift and machineries.
24.0 TERMINATI0N OF CONTRACT BY THE PURCHASER
24.1 The Purchaser reserves the right to terminate the Contract due to reasons
other than those mentioned under clause entitled "Contractors Default". The
Purchaser shall in such an event give fifteen (15) days notice in writing to the
Contractor of his decision to do so. The Contractor shall be paid by the
Purchaser for all work executed prior to the date of termination at the rates &
prices provided in the contract.
24.2 The Contractor upon receipt of such notice shall discontinue the work on
the date and to the extent specified in the notice, make all reasonable efforts to
obtain cancellation of all orders and contracts to the Purchaser, stop all further
sub-contracting or purchasing activity related to the work terminated, and assist
the Purchaser in maintenance, protection, and disposition of the works acquired
under the Contract by the Purchaser.
24.3 If the contract is terminated under the provisions of the above clause, the
Contractor shall with all reasonable diligence remove from the site all the
Contractor's equipment and shall give similar facilities to his sub-contractors to
do so.

48

24.4 If the contract is terminated as aforesaid, the Contractor shall be paid by
the Purchaser (in so far as such amounts or items shall not have already been
covered by on account payment made to the Contractor) for all work executed
and accepted by the Engineer prior to the date of termination at the rates and
prices provided in the Contract and in addition.
(a) The amount payable in respect of any preliminary items, so far as the work
or service comprised therein has been carried out or performed and an
appropriate portion as certified by the Engineer of any such items of the work or
service comprised therein which has been partially carried out or performed
(b) Any other expenses which the contractor has expended for performing the
works under the Contract subject to being duly certified by the Engineer, based
on documentary evidence for having incurred such expenses.
24.5 The contractor shall be further required to transfer the title and provide
the Purchaser with the following, in the manner and as directed by the
Purchaser.
(a) Any completed works
(b) Such partially completed works including drawings, information and contract
rights as the Contractor has specially performed, produced or acquired for the
performance of the Contract.
26.0 TERMINATION FOR CONVENIENCE
26.1 The Purchaser may, by written notice sent to the supplier, terminate the
Contract, in whole or in part, at any time for its convenience. The notice of
termination shall specify that termination is for the Purchaser's convenience, the
extent to which performance of work under the Contract is terminated and the
date upon which such termination becomes effective.

49

26.2 The Goods that are complete and ready for shipment within thirty (30)
days after the Supplier's receipt of notice of termination shall be purchased by
the Purchaser at the Contract prices and on the other Contract terms. For the
remaining Goods, the Purchaser may elect:
(a) to have any portion thereof completed and delivered at the Contract prices
and on the other Contract terms; and/or
(b) to cancel the remainder and pay to the Supplier an agreed amount for
partially completed Goods and for materials and parts previously procured by the
Supplier for the purpose of the Contract, together with a reasonable allowance
for overhead and profit.
27.0 NON-ASSIGNMENT:
The contractor shall not assign or transfer the contract or any part the
contract or any part there-of without the prior approval of the purchaser.
28.0 EFFECTING OF RECOVERIES :
Any loss, arising incident to non-fulfillment of this contract or any other
contract, will be recovered from the Security Deposit held and or any other
amount due to the contractor from the Board.
29. INCOME TAX :
The Tenderers shall furnish their Permanent Account Number in their Offer.
30.0 SALES TAX CLEARANCE CERTIFICATE :
The tendered should enclose with the tender, a current Certificate of sales
tax clearance from the appropriate sales Tax Authorities.
31.0 WORKS CONTRACT TAX:
The works contract tax of 2% for civil works and 4% in case of other than
Civil works will be deducted from the contractors bill as per the conditions
stipulated in TNVAT Act 2006.
32.0 SERVICE TAX:
The tenderers shall quote the appropriate percentage and amount of Service
Tax.

50

The Service Tax quoted will be included for the purpose of evaluation.
The Service tax claim in the offer shall be reimbursed on production of
documentary evidence.
The tenderer who have not quoted service tax shall provide an
undertaking to that effect that any service tax liability at a later date shall be
discharged from their account and Board shall not be responsible for any lapses
on this account.
33.0 LABOUR WELFARE FUND:
An amount of 0.3% towards manual labour welfare fund will be
recovered.
34.0 PATENT RIGHTS ETC :
The contractor shall indemnify the purchaser against all claims, actions,
suits and proceedings for the infringement or alleged infringement or alleged
infringement of an patent, design or copy right protected either in the country of
origin or in India by the use of any equipment supplied by the contractor other
than for the purpose indicated by or reasonably to be inferred from the
specification.
35.0 JURISDICTION FOR LEGAL PROCEEDINGS :
No suit or any proceedings in regards to any matter arising in any respect
under this contract shall be instituted in any court, save in the appropriate Civil
Court of Chennai or the court of small cause at Chennai. It is agreed that no
other court shall have jurisdiction to entertain any suit or proceedings, even
thought, part of the cause, any part of cause of action arises within the
jurisdiction of any of the courts in Tamil Nadu and not in the courts in Chennai
city, then it is agreed to between parties that such suits or proceedings shall be
instituted in court within Tamil Nadu and no other court outside Tamil Nadu shall

51

have jurisdiction, even though any part of the cause of action might arise within
the jurisdiction of such courts.
The successful tenderer shall furnish an undertaking in a non judicial stamp
paper of Rs.80/- agreeing to the above condition.
36.0 ARBITRATION :
The Board will not accept any arbitration in case of dispute arising in any respect
under this contract. Any dispute arising out of this contract shall not be subject
to arbitration under the provisions of Arbitration Act 1940 in the event of any
dispute between the parties.
37.0 DEVIATIONS FROM SPECIFICATION :
Should the tenderer wish to deviate from the provisions of this specification, he
shall list out such deviations only in the format enclosed and submit full
particulars and reasons there for, unless this is done, the equipment offered shall
be considered to comply, in every respect with the terms and conditions of this
specification.
38.0 TEST CERTIFICATES :
The test certificates in triplicate for the materials furnishing the results of the
tests as per latest issue of ISS/or relevant international standards shall be
forwarded and got approved before the materials are dispatched. In addition to
the tests called for in the specification, the purchaser reserves the right of having
such tests as he desires carried out at his own expenses to satisfy himself that
the materials conform to the requirements of this specification. The materials
may be rejected if the test results are not satisfactory. The type tests certificates
(Photostat copies) as per latest ISS/International Standard such as IEC shall be
furnished with the tender for inference.


52

39.0 RESPONSIBILITY:
The tenderer is responsible for safe delivery of the materials at the
destination stores, The tenderer should include and provide for packing and
secure protection of the materials so as to avoid damages or loss in transit.
40.0 MAXIMUM WEIGHTS AND DIMENSIONS OF PACKINGS:
The Contractor is responsible for informing himself of the facilities that
exist for Road and Sea transport to site the maximum packages which can be
conveyed by the railways and crane life available at the destination station. The
contractor is also responsible for any loss or damage during transport and
erection.
Each case or package should be clearly marked and should contain
detailed packing list.
41.0 Inspection:
41.1 The representatives of the purchaser shall have free access to the contractor
a or sub contractor s works at any time during working hours for the purpose
of inspecting the manufacture of the materials and for testing the select samples
form the materials covered by this specification. The contractor or the sub-
contractor shall provide facilities for the above. A notice calling for inspection
shall be given at least 15 days in advance for arranging inspection. The
arrangement for inspection shall be made by the supplier in such a way that the
delivery schedule is kept up. The materials should not be dispatched without
instruction from the Board. If the inspection is offered other than the purchasers
country then at least 30 days notice shall be given for arranging inspection.
41.2 Tenderers are requested to furnish in their tenders the exact location of
their factory with address to enable inspection by Board if considered necessary.

53

42.0. COMPLETENESS OF TENDER:
The tender should be complete with all details of illustrative and
descriptive literature and drawings. The tenderers shall furnish the complete
technical details of the equipment information regarding the country of
manufacture or origin of materials used in the manufacture of the articles. The
tenders should include all minor accessories even though not specifically
mentioned in this specification but which are essential for the completeness of
the materials ordered. The tendered shall not be eligible for any extra charges in
respect of such minor accessories though not included in the tender.
43.0 INTERCHANGEABILITY:
All similar parts and removable parts of similar items shall be
interchangeable with each other.
44.0 QUANTITIES:
The purchaser reserves the right to revise the quantities at the time of
placing the order and ordering more materials. During the pendency of the order
at the accepted rates.
45.0 CLIMATIC CONDITIONS:
The materials are for use in Tamil Nadu and the materials should be
satisfactory for operation under tropical conditions in Tamil Nadu .
All electrical devices shall be given tropical and fungicidal treatment, Fog,
smoke and milked acids are also present in the atmosphere.
46.0. ELECTRICITY RULES:
All works shall be carried out in accordance with the latest provisions of
the Indian Electricity Act 2003 unless modified by this specification.

54

47.0. MATERIALS AND WORKMANSHIP:
47.1 All materials, equipments and spare parts there of shall be new, unused
and originally coming from manufacturers plant to the destination stores. Those
including used, rebuilt or overhauled materials / equipments will not be
accepted.
47.2 All the materials shall be of best class and capable of satisfactory operation
in the tropics with humid atmospheric condition, Unless otherwise specified, they
shall conform to the requirements of appropriate Indian Standards. Where these
are not available, IEC and American / British Standards shall be followed.
47.3 The equipments should be designed to facilitate inspection and repairs and
to ensure satisfactory operation under atmospheric conditions prevailing at site
and under sudden variations of load and voltages as may be met with under
working conditions in the system including those due to faulty synchronizing and
short circuits within the rating of the apparatus.
47.4 The design shall incorporate every reasonable precautions and provisions
for the safety of all those concerned in the operation and maintenance of
equipment.
47.5 All the equipments should operate without undue vibration and with the
least practicable amount of noise.
47.6 The workmanship shall be of the highest grade and the entire construction
in accordance with the best modern practice.
47.7 The whole of the work shall be of the highest class throughout well
finished and approved make. The entire design and construction shall be capable
of withstanding the severest stresses likely to occur in actual service and
resisting rough handling during the transport.

55

48.0. RECOVERIES OF DUES ETC.:
The Board is empowered:
a. To recover any dues against this contract in any bills/Security Deposit/
Earnest Money Deposit due to the suppliers either in this contract or any other
contracts with Board.
b. To recover any dues against this contract of the suppliers with Board,
with the available amount due to the suppliers against this contract.
49.0. Raw materials
It is the responsibility of the tendered to make his own arrangement to procure
the necessary raw materials required for the manufacture.
50.0. DESPATCH OF EQUIPMENTS
It is the responsibility of the contractor to dispatch the materials /
equipments to the site. Materials can be brought to site by Road. The dispatch
intimation may however be given to Chief Engineer / Transmission VI th floor.
NPKRR Maaligai TNEB 144, Anna Salai, Chennai 600 002.
All Materials should be dispatched only after getting dispatch clearance
from Superintending Engineer/400 KV /Chennai 600 002.
51.0. PAST PERFORMANCE:
The intending Tenderers shall furnish the details of various supply
order/works contracts executed by them for the past Five years as on the date of
tenders in the performa enclosed to the Tender Specification. The details
furnished by the tenderer shall be complete in shape and if it is found that any
information is found omitted suppressed incomplete or incorrect the same will be
taken note of dealing with the Tender in future. Tender furnished by the

56

Tenderer without these accompanying details of their past performance are liable
for rejection.
52.0 Tender Form
The tenderers should furnish the Tender Form duly signed along with
their Tender Document.
53.0 DEFECTIVE SUPPLIES:
If during the period of supply it is found that goods already supplied are
defective in materials or workmanship or do not conform the speciation or are
unsuitable for the purpose for which they are purchased then it will be open to
the purchaser either to reject the goods and repudiate the entire contract and
claim such loss that the purchaser may suffer on that account or require the
contractor to replace the defective goods free of cost.
Similarly if during the guarantee period stipulated under guarantee clause
subsequent to the date of receipt of goods any of the goods found to be
defective in materials or workmanship or do not conform to the specification or
unsuitable for the purpose for which they are purchased then it will be open to
the purchaser either to repudiate the entire contract and claim damages or
accept such part of the goods that are satisfactory and require the contractor to
replace the balance or pay compensation to the extent of the loss sustained by
the purchaser on that account The tenderer should with his tender shall submit
dimensioned general drawings for the equipments offered. Illustrated and
descriptive literature also should be enclosed. Any approval given to the detailed
drawings by the purchaser shall not relieve the Contractor of the responsibility
for drawings and in the execution of the work in accordance with the clauses of
the specification.


57

54.0. SPECIAL:
54.1 The Tenderer shall list out his experience, with documentary evidence
along with the tender.
54.2 The tenderers should clearly indicate their acceptance or otherwise to the
following terms and conditions.
1. Payment of security deposit bank guarantee for 5% of order
Value.
2. Specific acceptance of Boards terms of Payment.
3. Boards terms of liquidated damages for delay in delivery.
4. Furnishing of performance guarantee backed by Bank Guarantee
for a value of 5% of the contract value and valid for 36 months.
54.3 In case of any contradiction between General conditions and Technical
condition, the Technical condition shall prevail.
55.0. Exchange rate
For bid evaluation the exchange rate on the date of Technical bid opening
will be taken into account.
56.0 General conditions
56.1 The Tenderers are requested to procure the equipments/materials only
from reputed suppliers to SEBs/Power Utilities for the equipments/materials
purchased within India. Further the Suppliers equipments/Materials should have
been in satisfactory service for a minimum period of two years. Necessary
documentary proof shall be furnished.
56. The Type Test for all the equipments/materials used for this project should
have been conducted only in the approved Government/Govt. recognized
laboratories and such of those laboratories mentioned in clause 5 of the BQR
for GIS equipments conforming to latest IS/IEC as the case may be. The
above type test certificates should accompany the drawings of the

58

materials/equipments, duly signed under seal by the Institution, who have
issued the type test certificate.
The above type test should have been conducted not earlier than five
(Five) years as on the date of Tender Opening.
The original type test certificates shall be furnished for verification on
request.
The purchaser reserves the right to demand repetition of some or all the
type tests in the presence of purchasers representative at no extra cost and
without affecting the completion period of the contract.
56.3 All the intending Tenderers are informed that in the event of documents
furnished with the offer being found to be bogus or the documents containing
false particulars, the EMD paid by such tenderers will be forfeited in addition to
blacklisting them for future orders / contracts in Tamil Nadu Transmission
Corporation Ltd.
56.4 The Tenderers should submit the drawings obtained from approved
suppliers of Tantransco and should get approval for each equipment / materials.
56.5 Any other items not specifically mentioned in the specification but which
are required for erection, testing and commissioning and satisfactory operation
of the substation are deemed to be included in the scope of the specification
unless specifically excluded.
56.6 The spares required towards maintenance of the equipments ordered
shall be made available for replacement for a minimum period of ten years
from the date of last despatch at a reasonable price.



59

SCHEDULE C1
DEVIATION FROM TECHNICAL SPECIFICATION

All technical deviations from the specification shall be filled in by the Tenderer,
clauses by clause, in the Schedule.
---------------------------------------------------------------------------------------------------
SECTION CLAUSE NO. DEVIATION
---------------------------------------------------------------------------------------------------








--------------------------------------------------------------------------------------------------
Note : Deviation if not listed in this list will not be considered and it will be
assumed that there are no deviation.

The Tenderer hereby certifies that the above mentioned are the only deviations
from the Technical Specification and the tender conforms to the specification in
all other respects without any reservations.

COMPANY SEAL SIGANTURE :
DESIGNATION :
COMPANY :
DATE :


60

SCHEDULE C2
DEVIATION FROM COMMERCIAL CONDITIONS

All commercial deviations from the specification shall be filled in by the Tenderer,
clause by clause, in the Schedule.
---------------------------------------------------------------------------------------------------
SECTION CLAUSE NO. DEVIATION
---------------------------------------------------------------------------------------------------








--------------------------------------------------------------------------------------------------
Note : Deviation if not listed in this list will not be considered and it will be
assumed that there are no deviation.
The Tenderer hereby certifies that the above mentioned are the only deviations
from the commercial Specification and the tender conforms to the specification in
all other respects without any reservations.


COMPANY SEAL SIGANTURE :
DESIGNATION :
COMPANY :
DATE :


61

BANK GUARANTEE IN LIEU OF SECURITY DEPOSIT PAYABLE BY THE
CONTRACTOR FOR THE PERFORMANCE OF CONTRACT
(To be furnished in non-judicial stamp paper of value not less than
Rs.80/-)
THIS DEED OF GUARANTEE made AT..ON THIS THE
DAY OF---------------------------------------TWO THOUSAND . BY
the------------------------------------------------------------------Bank of -------------------
(Branch name and address) (herein after called the Bank) to and in favour of
the Tamil Nadu Transmission Corporation a Body corporate constituted under the
electricity (supply) Act 1948 (C A 54 of 1948) having its office at Anna salai,
Channai-2, represented by the Chief Engineer/ Transmission (herein after called
for the PURCHASER).

WHEREAS M/S. (hereinafter
called the CONTRACTOR) have by virtue of the contract entered into with the
purchaser as per PO. No. dt. Acceptance Letter
No.
TO AND IN FAVOUR OF ---------------------------------------------------------------------
-THE TAMIL NADU TRANSMISSION CORPORATION, a Body Corporate
constituted under the Electricity (Supply) Act, 1948 (Central Act LIV of 1948)
having its office at 6
th
Floor, NPKRR Maaligai, 144, Anna Salai, Chennai 600
002, herein called the TANTRANSCO (which expression shall where the context
so admits mean and include its successors in office and Assigns).

WHEREAS THE Supplier is required to pay Security Deposit of Rs-----
---------------------for participation in the purchase order for supply of---------------
--------------------------------------in terms of P.O. No-----------------------------

AND WHEREAS the Supplier is exempted by the TANTRANSCO from payment of
Security Deposit in the form of cash, subject to the Supplier executing an

62

undertaking to the value of Rs. (Rupees..)
representing the amount equivalent to the amount of Security Deposit specified
to be paid to the Board in the event of non-fulfillment or breach of any of the
conditions of the purchase order by the Supplier as mentioned hereunder.

AND WHEREAS in consideration of the acceptance by the TANTRANSCO of the
above proposal, The Supplier has agreed to pay to the TANTRANSCO the said
amount of Rs----------------------------- in the event of:-
(1) Withdrawing his purchase order before the expiry of the validity period,
OR
(2) Withdrawing his purchase order after acceptance, OR
(3) Violating any of the conditions of the purchase order issued by the competent
authority;
OW THIS UNDERTAKING WITNESSES that in pursuance of the said agreement
the Supplier hereby doth covenant with the Board that in consideration of the
TANTRANSCO waiving the condition of payment of Security Deposit in cash in
terms of the said purchase order, the Supplier has agreed to pay to the
TANTRANSCO Rs. . only) in the event of :

(1) Withdrawing his purchase order before the expiry of the validity period,
OR
(2) Withdrawing his purchase order after acceptance, OR
(3) Violating any of the conditions of the purchase order issued by the competent
authority;

NOW THE CONDITION OF THE above written undertaking is such that if the
Supplier shall duly and faithfully observe and perform the conditions specified as
above, then the above written undertaking shall be void, otherwise it shall
remain in full force.

63

The Supplier undertakes not to revoke this guarantee till the contract is
completed under the terms of contract.
The expression, `Supplier and the `Board hereinafter before used shall include
their respective successors and assign in office.

IN WITNESS WHERE OF THIRU---------------------------------------------------------
--- acting for and on behalf of the Supplier has signed this deed on the day,
month and year herein before first mentioned.

In the presence of Witnesses:

1. Signature
Name & Address


2. Signature
Name & Address



SIGNED AND DELIVERED ON
BEHALF OF SUPPLIER








64

ANNEXURE
TENDER FORM
TAMIL NADU TRANSMISSION CORPORATION LTD

To
THE CHIEF ENGINEER / TRANSMISSION,
Tamil Nadu Transmission Corporation,
6
th
Floor, Western wing,
NPKAR Maaligai, Electricity Avenue,
144, Anna Salai, Chennai 600 002.
TAMIL NADU, INDIA.

Dear Sir,
Having examined the above specification together with the accompanying
schedule etc., and general conditions therein referred to, we hereby offer to
manufacture and supply the equipments / materials in general specification at
the rates entered in the attached contract schedule of prices.
1. We hereby guarantee the particulars entered in the schedules
attached to the specification.
2. In accordance with Security Deposit, Clause 15, Section-III, of the
Specification we agree to furnish security to the extent of 5% of the
value of the contract.
3. In accordance with performance guarantee, Clause 20, Section-
III, of the Specification we agree to furnish security to the extent
of 5% of the value of the contract.
4. Our company is not a potentially Sick Industrial Company or a Sick
Industrial Company in terms of Section-23 of Section-15 of the Sick
Industrial Companies (Special Provisional Act, 1985)

Yours faithfully,
Place :
Date :

65

FORM OF CONSORTIUM/JOINT VENTURE AGREEMENT

(ON NON-JUDICIAL STAMP PAPER OF VALUE RS.100/- TO BE PURCHASED IN
ANY ONE NAME OF CONSORTIUM/JOINT VENTURE MEMBER)


THIS Consortium/ Joint Venture agreement executed on this ----------------- day
of --------------Two Thousand and -------------------- between M/s --------------------
------------------a company incorporated under the laws of ----------------------------
-----------------
and having its registered office at ---------------------------------------------------------
( herein after called the Lead Company which expression shall include its
successors , executors and permitted assigns) , M/s ----------------------------------
a company incorporated under the laws of ------------------------------------and
having its registered office at -------------------------------(herein after called the
Constituent company which expression shall include its successors, executors
and permitted assigns) and M/s ------------------------a company incorporated
under the laws of ------------------------------------------------------- and having its
registered office at ---------------------------------------------(hereinafter called the
Member which expression shall include its successors, executors and
permitted assigns) for the purpose of making a bid and entering into a contract
(in case of award) against the Specification No. for the establishment of
230/110KV GIS SS for the Tamil Nadu Transmission Corporation Ltd, having its
registered office at NPKRR Maaligai, 144, Anna Salai, Chennai-600 002, Tamil
Nadu (hereinafter called the Owner). The leader of the consortium/joint
venture shall abide by the general terms and conditions specified by the
purchaser.
WHEREAS the Owner invited bids as per the above mentioned Specification for
the design manufacture, supply and erection, testing and commissioning of
Equipment/Materials stipulated in the bidding documents under subject Package

66

for the establishment of 230/110KV GIS SS----------------------------------------------
---------------------- under Specification No. -------------

AND WHEREAS Section-IV (Bid Qualification Requirement) , forming part of the
bidding documents, stipulates that a consortium/ joint venture of firms meeting
the requirement of Section-Iv, applicable may bid, provided the consortium/
Joint Venture fulfills all other requirements of Specification and in such a case,
the BID shall be signed by the members so as to legally bind the members and
who will be jointly and severally liable to perform the Contract and all obligations
hereunder.

The above clause further states that the consortium/ joint venture agreement
shall be attached to the bid and the contract performance guarantee will be as
per the format enclosed with the bidding document without any restriction or
liability for either party.

AND WHEREAS the bid has been submitted to the Owner vide proposal No.-------
----------------dated ----------------------------by Lead Company based on the
Constituent agreement between all the consortium/joint venture partners under
these presents and the bid in accordance with the requirements of Specification.
(Qualification Requirements).

NOW THIS INDENTURE WITNESSETH AS UNDER:
In consideration of the above premises and agreements all the Partners to this
joint venture members do hereby now agree as follows:

1) In consideration of the award of the Contract by the Owner to the joint
venture members, we, the members to the consortium/ joint venture
agreement do hereby agree that M/s-------------------------------------shall act as
Lead company and further declare and confirm that we shall jointly and severally
be bound unto the Owner for the successful performance of the Contract and

67

shall be fully responsible for the design, manufacture, supply and successful
performance of the equipments in accordance with the Contract.
2) In case of any breach of the said Contract by the Lead Company or other
Constituent of the consortium/joint venture agreement, the Lead Company do
hereby agree to be fully responsible for the successful performance of the
Contract and to carry out all the obligations and responsibilities under the
Contract in accordance with the requirements of the Contract.

3) Further, if the owner suffers any loss or damage on account of any breach
in the Contract or any shortfall in the performance of the equipment in meeting
the performance guaranteed as per the specification in terms of the Contract,
the Lead Company of these presents undertake to promptly make good such loss
or damages caused to the Owner, on its demand without any demur. It shall not
be necessary or obligatory for the Owner to proceed against Lead Partner to
these presents before proceeding against or dealing with the other Partner(s).

4) The financial liability of the members of this consortium/ joint venture
agreement to the Owner, with respect to any of the claims arising out of the
performance or non-performance of the obligations set forth in the said
consortium/ joint venture agreement, read in conjunction with the relevant
conditions of the Contract shall, however, not be limited in any way so as to
restrict or limit the liabilities of any of the members of the agreement.

5) It is expressly understood and agreed between the members to this
consortium/ joint venture agreement that the responsibilities and obligations of
each of the Partners shall be as delineated in Appendix-I (To be incorporated
suitably by the member to this agreement). It is further agreed by the member
that the above sharing of responsibilities and obligations shall not in any way be
a limitation of joint and several responsibilities of the members under this
contract.

68

6) This consortium/ joint venture agreement shall be construed and
interpreted in accordance with the laws of India and the courts of Chennai
shall have the exclusive jurisdiction in all matters arising there under.
7) In case of an award of a Contract, we the consortium/ joint venture
members do hereby agree that we shall be jointly and severally responsible for
the works respectively executed and Lead Company shall furnishing a contract
performance security from a bank in favour of the PURCHASER in the forms
acceptable to purchaser for value of 5% of the Contract Price in the
currency/currencies of the Contract.
8) It is further agreed that the consortium/ joint venture agreement shall be
irrevocable and shall form an integral part of the Contract, and shall continue to
be enforceable all the owner discharges the same. It shall be effective from the
date first mentioned above for all purposes and intents.

IN WITNESS WHEREOF the Partners to the consortium/joint venture agreement
have through their authorised representatives executed these presents and
affixed Common Seals of their companies, on the day, month and year first
mentioned above.


1. Common Seal of For Lead Company
has been affixed in my/our presence
pursuant to the Board of Directors (Signature of authorised
resolution dated. Representative)

Signature Name

Name Designation

Designation Common Seal of the company

69


2. Common seal of For other Constituents
has been affixed in my/our presence
pursuant to the Board of Directors (Signature of authorised
resolution dated. Representative)

Signature--------------------------- Name-----------------------

Name ------------------------------- Designation----------------------

Designation------------------------ Common Seal of the company

WITNESSES:
1. --------------------------------- ------------------------------
(Signature) (Signature)
Name-------------------------- Name-----------------------
----------------------------------- --------------------------------
(Official address) (Official address)


















70

FORM OF POWER OF ATTORNEY FOR CONSORTIUM/JOINT VENTURE
(On Non-judicial Stamp Paper of value Rs.100/- to be purchased in any
one Name of Consortium/Joint venture member)


KNOW ALL MEN BY THESE PRESENTS THAT WE, the Consortium/ joint venture
members whose details are given hereunder (1) (2)
3) . ... have formed a joint venture under the
laws of and having our Registered Office(s)/Head Office
(s) at ..
(hereinafter called the Consortium/ joint venture which expression shall unless
repugnant to the context or meaning thereof, include its successors,
administrators and assigns) acting through M/s
being the company in charge do hereby
constitute, nominate and appoint M/s a company
incorporated under the laws ofand having its
Registered/ Head Office at.as our duly constituted
lawful Attorney (hereinafter called Attorney or Authorised Representative or
Partner in charge ) to exercise all or any of the powers for and on behalf of the
consortium/ joint venture in regard for the establishment of 230/110KV GIS SS,
------------------------------------------------------ for the Tamil Nadu Transmission
Corporation Ltd , NPKRR Maaligai, 144, Anna Salai, Chennai 600 002
(hereinafter called the OWNER ) and the Bids for which have been invited by
the Owner, to undertake the following acts:

71

i) To submit proposal and participate in the aforesaid Bid Specification of the
Owner on behalf of the consortium/joint venture.
ii) To negotiate with the Owner in the terms and conditions for award of the
Contract pursuant to the aforesaid Bid to sign the Contract with the Owner for
and on behalf of the consortium/ joint venture.
iii) To do any other act or submit any document related to the above.
iv) To receive, accept and execute the Contract for and on behalf of the
consortium/ joint venture.
It is clearly understood that the Lead Company shall ensure performance of the
Contract (s) and if one or more Company fail to perform their respective portion
of the Contract (s), the same shall be deemed to be a default by the Lead
Company.
It is expressly understood that this Power Of Attorney shall remain valid binding
and irrevocable till completion of the Defect Liability Period in terms of the
Contract.
The consortium/joint venture hereby agrees and undertakes to ratify and confirm
all the whatsoever the said Attorney/ Authorised representative of the Lead
Company in charge quotes in the Bid, negotiates and signs the Contract with the
Owner and/or proposes to act on behalf of the joint venture by virtue of this
Power Of Attorney and the same shall bind the joint venture as if done by itself.

72

IN WITNESS THEREOF the Company constituting the joint venture as aforesaid
have executed these presents on this ----------------------------------------------------
----
Day of ----------------------------------------------------------- under Common seal(s)
of their Companies.
For and on behalf of
the Partners of consortium/ Joint Venture

--------------------------------------

--------------------------------------
--------------------------------------

The common Seal of the above Companies of the consortium/ Joint Venture:

The Common Seal has been affixed there unto in the presence of :


WITNESS

1.

Signature.

Name

Designation

Occupation

2.

Signature.

Name .

Designation

Occupation

73

PROFORMA OF TOTAL BACK UP GUARANTEE
To
The Chief Engineer/Transmission
6
th
Floor, Western Wing,
New No.144, (Old No.800) Anna Salai,
Tamil Nadu Transmission Corporation Ltd
Chennai-600 002. (India)

Sub:

Ref:

With reference to the proposal submitted by ..
we M/s
having our corporate office at.
.have associated with M/s.
for executive the contract required for the proposed 230/110 KV GIS Sub-station
at Guindy, Chennai, as per TANTRANSCO specification No.T-1687.

We confirm having studied your specification and the bid
documents submitted by M/s..

We, M/s.hereby certify and guarantee as follows
and confirm our participation throughout the execution of the Project including
the warranty period.

1) All design, engineering manufacture, inspection and testing at manufacturers
works, supply and delivery at site, assembly, erection, testing, Performance
testing and commissioning handing over as well as review shall be done by us
under a Quality Assurance Programme approved by TANTRANSCO.

2) We Guarantee the sequential and timely execution of the Contract works
required for the project as per the agreed project schedule.

3) We guarantee the performance of the Contract works as specified in the
tender specification.

4) We guarantee to provide all necessary assistance during the guarantee period
of 36 months from the date of commissioning for maintaining the system to
meet the tender specification requirement.

5) We hereby Guarantee to extend our full technical support, total back up
guarantee for design, engineering, manufacture, supply, erection, testing,
commissioning, Performance testing, handing over and after sales service

74

including spares, tools etc. as per TANTRANSCOs requirement under
specification No.T. , against this invitation of bid.


6) We do hereby authorize M/s, a company registered
under the Indian Companies Act.1956, having registered office at and Regional
office at .to bid, negotiate and conclude the Contract with
TNTransco against the above bid for the equipment and services to be supplied
by us.

7) We along with M/sare held jointly and severely bound to
TNTransco for the successful execution of the entire Contract works as per
specification for the above project.
We hereby agree,
a) To depute technical experts from time to time to M/sworks
at.for the implementation of the contract works as mutually
agreed between TNTransco and M/sto discharge
obligations as stipulated in the Contract.
b) To attend the key design definition/review meeting called for by TNTransco
during various stages of Project implementation/Commissioning / warranty
maintenance of Contract.

We along with M/shereby agree that this
undertaking shall be irrevocable and shall form an integral part of the Contract.

Yours faithfully,


i) BIDDER

Signature..
NAME COMPANY SEAL
Designation .

ii) JOINT VENTURE PARTNER
Signature
NAME .. COMPANY SEAL
Designation

Note : THE ABVOE UNDERTAKING SHOULD BE EXECUTED ON
NON-JUDICIAL STAMP PAPER OF VALUE RS NOT LESS THAN Rs.80/- AND
SHOULD BE SIGNED BY THE BIDDER AND THE AUTHORIZED EXECUTIVE
DIRECTOR OF THE JOINT VENTURE PARTNER AND SUBMITTED ALONGWITH
THE TECHNO-COMMERCIAL BID.

75

SECTION IV
BID QUALIFICATION REQUIREMENTS
I. The bidder should have supplied atleast 20 Nos of 110 KV class or above
rating GIS bays of which atleast 5 nos shall be of 220 KV class during the last
five years. The end user certificate shall be furnished in support of the claim.
2. The bidder should have erected, tested & commissioned atleast Five Nos
G.I.S Substations of 110 KV or above rating of which atleast one number shall
be with a capacity of 220 KV or above rating. The substations shall be in
satisfactory operation for atleast two years. The end user certificate shall be
furnished as proof of having completed the works satisfactorily and for the
satisfactory operation of the Substation as above.
Bidders who are subsidiaries and have recently established production line in
India can also be considered as meeting with the above criteria (1&2), provided
the parent company meets the above criteria.
3. The financial turnover of the bidder shall be more than Rs.25 Crores or USD
5.55 Million in any one of the preceding three financial years, the copy of the
Profit & Loss account or turnover certificate issued by the chartered accountant
shall be furnished.
4 The bidder shall furnish a total back up guarantee for the GIS equipments
offered by them from the GIS manufacturer for successful operation for three
years.
5. The bidder shall submit Type test reports as per the relevant IEC standards for
110 KV & 220KV or higher Voltage grade GIS obtained from any of the following
Laboratories.
a. KEMA, Holland
b. CESI, Italy
c. IPH, Germany
d. EDF, France
e. Keri, South Korea
f. CRIEPI, Japan.

76

g. CERDA, France
h. PHELA, Italy.
i. STRI, Sweden.
j. China national High Voltage apparatus Inspecting Centre, China
k. Xian High Voltage research institute, China
The type tests should have been conducted on the GIS manufactured at the
same source/unit from where the bidder is proposing to supply the tendered GIS.
Bidders who are subsidiaries and have recently established production line in
India can furnish Type test reports conducted on the GIS of the same design
offered from their parent company.
The type tests should have been conducted within 5 years prior to the date of
opening of techno commercial bid.
In case the type test reports furnished is not for the quoted GIS but for the GIS
with higher voltage class , then type test reports shall be furnished for the
quoted GIS before offer of inspection of the GIS.
6. End user certificate is to be produced for the quantity of GIS claimed to
have been supplied and the number of GIS substations , erected, tested and
commissioned along with the corresponding copy of purchase order placed by
the end user, attested by the Indian High Commissioner / Ambassador of the
respective country where the manufacturing is done. In case of local
manufacturers the same should be got attested by Notary Public or
Commissioner of Oaths. Before price bid opening, such of the original Purchase
orders and other documents will be referred to the authority who had placed the
order to get the genuineness of the claim made by the bidder verified.
7.1 The Bidding is also open to consortium/joint venture (maximum of two
members) who shall meet the clauses 1 & 2 of qualifying requirements
individually
or together subject to the following conditions.
7.2 The joint venture/consortium can be formed between bidder, supplier of GIS,
EPC Contractor in any combination.

77

7.3 No member can be a member in more than one consortium/ joint venture.
7.4 The bid and the contract agreement between PURCHASER and consortium/
joint venture shall be signed by all members of the Joint venture.
7.5 The consortium/ Joint Venture agreement duly certified by a Notary Public in
case of Domestic Bidder and the Consulate General of India in Foreign country in
case of foreign bidder, confirming the intent of all the members to form the
consortium/joint venture should be submitted along with the Bid. It should also
distinctly show the financial participation of each member of the consortium/
joint venture, scope of work and responsibilities of each member with regard to
planning, execution and performance of the work under the entire scope of
contract between Purchaser and consortium/joint venture.
7.6 The signatory of the consortium/ joint venture agreement shall be only those
holding valid power of attorney. A certified copy by the company secretary to
the respective members of the joint venture shall be attached as evidence for
authentication.
7.7 Any one member of the joint venture shall be nominated as leader of the
consortium/joint venture with proper authorization submitting a power of
attorney signed by legally authorised signatories of all the members of joint
venture.
7.8 The leader of the consortium/joint venture shall abide by the general terms
and conditions specified by the purchaser or his authorised representatives.
7.9 The leader of the consortium/joint venture shall be the only one who will be
authorised to receive the instructions for and on behalf of the consortium/ joint
venture. The leader of the consortium/ joint venture is primarily responsible for
the total execution of the contract including all contractual obligations and
receipt of the payment due in accordance with the provision of the contract.
7.10 All the members of the consortium/joint venture shall be liable jointly and
severally for the execution of the contract in accordance with the terms and
conditions of the contract and a statement to this effect shall be included in the
consortium/ joint venture agreement as well as in the contract document.

78

7.11 There shall be no conditional offer in the consortium/ joint venture
agreement with regard to this Project.
7.12 The consortium/ joint venture formed for the purpose of this Project shall
be valid till completion of the performance guarantee period.
8. The bidder shall furnish copy of purchase order and performance certificate
from the end user in support of the above bid qualification requirements along
with the bid documents.
Bids not satisfying the above requirements will be summarily rejected.




















79

SECTION V
TECHNICAL SPECIFICATIONS
I N D E X
Sl.No TITLE PAGE NOs.
1 230 KV GIS 80-126
2 123 KV GIS 127-172
3 230/110 KV Auto Transformer 173-253
4 C&R panels & SAS 254-310
5 Battery, Battery Charges, DC panel, AC panel 311-359
6 DG SET 360-369
7 Distribution Transformer 370-394
8 Illumination Climatization, Firefighting & Earthing,
Cable Terminations.RMU
395-433
9 Civil works 434-519
















80

TECHNICAL SPECIFICATION FOR 230KV GAS
INSULATED SWITCHGEAR (GIS)


. GENERAL ARRANGEMENT FOR MAIN EQUIPMENT TO BE SUPPLIED:

The Indoor type GIS bay shall be of single bus bar arrangement. The arrangement
shall be such that in future double bus bars connection is also possible.

The GIS bay arrangement comprises the following:

(i) Bus Enclosure:
1. Single phase enclosure for main bus bar
2. Single phase earthing switch in separate enclosure for each bus
bar
3. Single phase VT on each phase

(ii) Feeder bay arrangement includes in each phase
1. Connection for a XLPE insulated cable,
2. High speed group operated earth switch
3. Disconnector switch three pole group operated
4. Voltage transformer on each phase with one secondary
winding
5. Multi core (minimum 5 core) current transformer on each
phase
6. Circuit breaker
7. Maintenance earth switch.
8. Bus bar disconnector
9. Connection with bus bar.
10. Local control cubicle.

(iii)Transformer bay arrangement includes
1. Connection for a XLPE insulated cable,
2. High speed group operated earth switch.
3. Disconnector switch three pole group operated
4. Multi core (minimum 5 core) current transformer on each phase.
5. Circuit breaker.
6. Maintenance earth switch.
7. Bus bar disconnector
8. Connection with busbar.
9. Local control cubicle.



81

(iv) Bus Sectionalizer:
1. Single phase Bus Coupler breaker.
2. Local control cubicle.

III. DOCUMENT TO BE SUPPLIED BY THE BIDDER:

III.A. Along with Bid:

(i) Description of the equipment together with a document setting out
chosen methods and principles of dismantling. The aim of the dossier is to show
the user that the switchgear has successfully passed type tests.

(ii) Floor space plan of GIS bay, giving all sizes and static and dynamic
stresses and precise design of the structures needed to install equipment.

(iii) Equipotential earth mat diagram for the GIS equipments and earthmat
risers.

(iv) Procedure for installing switchgear, sub assemblies on site and
verifications, tests to be carried out prior to commissioning, format for tests
reports and verifications on site.

(v) Design principles of the 230KV GIS viz Conductor, enclosure, anti
corrosion protection, internal fault and constructional features and typical
arrangements


III.B. After the placement of purchase order and before the supply :
Five copies of the following documents shall be supplied.

(i) For each switchgear, a credibility dossier giving a summary of
investigative studies and tests already made on the switchgear proposed.

(ii) Technical document specifying quality control tests conducted on the
delivered switchgear during manufacture as per the standards.

(iii) Auxiliary electrical wiring diagram for operation and control of earthing
switches, circuit breakers, disconnectors, current and voltage transformers,
together with wiring diagrams necessary to define cable connections for the
equipment of each switchgear.

(iv) Schedule for preventive maintenance.

(v) Dismantling and reassembling of connection in the cable box.

82


(vi) Civil engineering drawings indicating dimensions and static and
dynamic stresses exerted by metal clad equipment.

(vii) General layout drawings of equipment, support frames, earthing loop
and removable earthing circuits, LV auxiliary circuits, texts inscribed on
identification / instruction plates.

(viii) Dismantling and reassembling of switchgear and sub assemblies in
case of failure so that it can be changed entirely.

(ix) Precautions to be taken prior to dismantling and in particular the
elements of the installation for which there are specific settings, etc., Size and
qualifications of the team needed to carry out the envisaged operation, and
duration of the operation.

(x) Operation manual for Tools and handling equipment required for the
above works.

(xi) Checks and tests required prior to commissioning.

(xii) Preventive maintenance procedure shall be prepared in accordance
with TNEB practice describing the methods of preventive maintenance and the
frequency of maintenance operations normally anticipated on all the switchgear.

(xiii) Drawings for control and low voltage cables.

(xiv) Drawings for earthmat connection.

(xv) Wiring diagrams of the local control cubicle.

(xvi) Description of the indoor type 230KV GIS Circuit breaker, disconnector,
earthing switch, CT, PT, cable connection, SF6, local control cubicle.


IV. Scope of supply:

Design, manufacture, assembly ,testing at works, inspection, packing,
transport, unloading and delivery at departmental stores/ site at CHENNAI,
storage of 230KV insulated switchgears (GIS) and supply of accessories, startup,
essential spares, tools, tackles and erection, testing and commissioning at site.

The provisions indicated below shall also be included in the scope as per
general arrangement.

83


1. First filling of SF6 gas.
2. Control cabling between GIS and local control cubicle.
3. Earthing circuits to the earthmat risers.
4. Equipotential earthmat.
5. Tools, accessories and testing instruments required for erection,
tests and commissioning.
6. Spares required to meet out any emergency situation during
erection at site.
7. All supports of GIS.
8. All special tools required for operation and maintenance of GIS.
9. Sf6 gas handling plant
10. Sf6 gas service cart
11. Sf6 gas leak detector.
12. Spares for auxiliary system


V .TRAINING

Training in maintenance for 2 Engineers of TANTRANSCO for 4 weeks
at manufactures works.

Training in operation for 4 Engineers of TANTRANSCO for 4 weeks at
site.




















84

COMMON SPECIFICATIONS
1.GENERAL

The specification applies to the design, manufacture supply,
testing, delivery, installation, testing at site and commissioning of 230KV indoor gas
insulated switchgear and associated equipments as per the general arrangement.

The assembled equipment shall be capable of withstanding
electrical, mechanical and thermal ratings of the specified system. All joints and
connections shall be able to withstand the forces of expansions, vibrations,
contraction and specified seismic requirements without deformation, malfunction
and leakage. Optimized arrangements are required to reduce installation time,
provide ease of operations, minimize maintenance, repair and facilitate future
additions.

1.1 STANDARDS:
Unless otherwise specified, the following standards are
applicable,

1. IEC 62271 100 - High voltage alternating current
circuit breaker.
2. IEC 62271 203 - High voltage metal enclosed
Switchgear for rated voltage 72.5KV
and above.
3. IEC 62271 102 - High voltage alternating current
disconnectors & earth switches.
4. IEC 60480 - Guide for checking of SF6
5. IEC 61634 - Use and Handling of SF6
6. IEC 61639 - Direct connections transformer GIS
7. IEC 60364, 60479, 60621, IEEE std 80 Standards for
station grounding
8. IEC 60529 - Degrees of protection
9. IEC 60815 - Pollution levels
10. IEC 61000 - Electromagnetic compatibility (EMC)
11. IEC 60044 1ed1.2 - Current transformers.
12. IEC 60044 2ed1.2 - Voltage transformers.
13. IEC 620678,62271 209,IEEE 1300 - Cable connections for
XLPE cable (33 to 150KV)
14. IEC 60137 ed 5.0 - Bushing for alternating voltage
above 1000V.
15. IP 54 - Degree of protection provided by
enclosures.
16. IEC 60376 - Specification and acceptance of new
Sf6.

85

17. IEC 60694 - Common classes for high voltage
Switchgear and control gear
standards.
18. IEC 60060 - High voltage test techniques.
19. IEC 60071 - Insulation coordination.
20. IEC 60099 - Surge arrestors.
21. IEC 60255 - Electrical relays.
22. IEC 60265 - High voltage switchgear.
23. IEC 60270 - Partial discharge measurements.

1.2 ENVIRONMENTAL AND CLIMATIC CONDITIONS:

The equipments shall be suitable for satisfactory operation in
the following environment.
1. Equipment location - Indoor.
2. Altitude - 3m from sea level
3. Min Ambient temperature - 20c
4. Max Ambient temperature - 45c
5. Relative humidity - 100%
6. Earthquake withstand ability

Zone - III
Horizontal component - 0.02
Safety factor - 1.5
7. Wind speed - 200Kg/m
2
for structures at 30m
height
8. Pollution level - Heavy
9. Avg. Annual rainfall - 1300mm
10. No. of months for which
tropical monsoon prevail - 4 months

General climate conditions is Hot, dusty, humid, salt laden
and conductive to rust. All equipment supplied against this specification shall
be given tropical and fungicidal treatment in view of the severe climatic
conditions prevailing at site.

1.3 ELECTRICAL RATINGS:

The equipments shall have the following basic electrical and
design characteristics.

1. Phase design - single phase/ three phase
2. Rated voltage - 245 KV
3. Frequency - 50Hz

86

4. Normal service voltage - 230KV
5. Rated with stand voltage

I) Impulse
To earth & between phases - 1050KV
Across the isolating distances - 1200KV
2) Power frequency
To earth & between phases - 460KV
Across the isolating distances -530kv
1. Rated current -
Busbar - 2000A
Bays 1250A
2. Rated short time current without burn through of enclosures - 40KA for
3 Sec
3. Partial discharge level of complete bay - <10pc
At 1.5Uo
4. Material
Enclosures - Aluminium/stainless steel
Conductors - Aluminium

The rated currents have to be guaranteed for maximum
ambient temperature.
The rated withstand voltage has to be guaranteed for
second low level of SF6 gas pressure.
The switchgear should withstand rated voltage for atleast
30min, when SF6 pressure falls to atmospheric pressure.


2.EQUIPMENT SPECIFICATION:

2.1 GENERAL:
The switchgear shall be completely metal clad with modular
design, all modules standardized and interchangeable. The GIS shall be designed so
that normal service, inspection and maintenance operations, earthing of connected
cables, locating of cable faults, voltage tests on connected cables or other apparatus
and the elimination of dangerous electrostatic charges can be carried out safely,
including the checking of phase sequence after installation.

The switchgear shall be made of Aluminium/Stainless steel
enclosure with SF6 for insulation. It shall be of single phase /Three phase
encapsulation arrangement. The switchgear shall be modular design so that future
extensions shall be easily accomplished for adding additional feeders without
dismantling any major parts of the equipment. All the modules shall be standardized
and interchangeable. It shall be compatible for IP54.

87


The switchgear shall be preassembled at the factory and
installed at the site using bolts and sealed flange connections. Welding of enclosures
at field is not acceptable. In order to ensure electrical continuity the metal clad
enclosures shall be bonded together by straps of adequate cross sectional area for
the rating of the equipment.

The equipment should be designed in such a way that, the
permitted movements of foundation, mechanical or thermal effects do not impair the
assigned performance of the equipment. The SF6 pressure monitoring devices,
optical indicators, emergency, mechanical operating device, locking and all other
working devices shall be easily accessible from the floor to the extent possible.

In case of an internal fault in any one of the Bus bar sections, it
shall be possible to remove and replace the faulty bus bar with out the necessity of
removing the healthy, energized Bus bar and Bus bar disconnectors from service. All
components of the same rating and construction which may need to be replaced
shall be interchangeable.

2.2. CONDUCTOR

Conductor shall be made of Aluminium suitable for the specified
voltage and current rating. The electrical connections between the neighboring gas
sections shall be made by multiple contact connectors (Plug in type) so that
electrical connection is achieved automatically when one section is bolted to the
other one. The surface of the connector fingers and conductor tubes on such
connections shall be silver plated.

2.3. SUPPORT INSULATORS AND SECTION BARRIERS

Support insulators shall be used to maintain the conductors and
enclosures in proper relation. The insulators shall be manufactured from high quality
epoxy resin, free from all voids and designed to reduce the electrical stresses on the
insulators. The insulator cones shall be embedded in full return current carrying
metal fixing rings in order to avoid mechanical stress to the cast resin part and to
impart full conductivity across the flange connections.

The mechanical strength must be sufficient to ensure the
conductors space requirements and clearances when short circuit fault occurs.
Barrier insulators are used to isolate the gas compartments and non-barrier
insulators allow gas pressure to equalize. The gas barrier insulators sealing to the
conductors and the enclosure wall shall be designed to withstand the maximum
difference that could occur across the barrier i.e maximum operating pressure at
one side and vacuum at the other side.

88


Tests shall be carried out during the manufacturing process to
ensure that all the insulators are free of partial discharge at a voltage at least 10%
higher than the rated voltage.

2.4. SF6 Gas
The GIS shall be filled with sufficient SF6 gas to pressurize the
complete system in sequential approach, one zone or compartment at a time to the
rated normal density. It shall be possible to fill and evacuate the SF6 gas easily from
the main circuit after earthing the circuit. The supplier/manufacturer shall specify
rated density for each compartment and corresponding quantity of SF6 gas to be
used. Also, necessary quantity and quality of Sf6 gas used for effective maintenance
shall be intimated.
The manufacturer shall provide information about the total amount of SF6 gas
contained in the GIS equipments supplied.

The SF6 gas supplied shall comply with the IEC 60376.

Handling of SF6 shall be in accordance with IEC 61634.

All apparatus necessary for filling and evacuating of SF6 gas to
and from the switchgear shall be supplied with all necessary accessories. It shall be
guaranteed that the pressure loss in each gas compartment will not be more than
1% per year under normal operating conditions.
The manufacturer shall provide information about the total
amount of SF6 contained in the GIS equipments supplied.
Temperature compensated gas pressure monitoring devices
shall be provided for each gas compartment. It shall provide continuous and
automatic monitoring of the gas. It shall have two alarms,


I. Advanced warning can be given when the gas pressure is approaching a low
level. It shall be indicated as
REFILLING
II. This 2
nd
level requires immediate interventions. When the pressure reaches
this level, the circuit breaker shall be tripped automatically and further closing
operation is blocked.

The manufacturer is responsible for choosing minimum functional
pressure for insulation and operation. The rated filling pressure is related to the
alarm pressure and the leakage rate in order to reach a sufficient period for refilling.


89

The time between alarm pressure and minimum functional
pressure should allow sufficient reaction time to permit actions. The tolerance of the
gas monitoring device should be considered.

All gas seals shall be designed to ensure leakage rates kept to
an absolute minimum, under normal pressure, temperature and electrical load
conditions. All gas seals in the flanges of equipment shall be of O-ring type. Sub
clause 5.15 of IEC 60694 is applicable with the following additions. Leakage losses
and handling losses shall be considered separately. The objective is to achieve a
total loss as low as possible. A value of less than 15% average in overall gas
compartments for a service period of 25 Years shall be considered.


2.5. Pressure relief:

Automatic external pressure relief devices shall be incorporated
as a precaution against bursting of enclosure. The bursting pressure or abnormal
pressure rise due to arcing shall be calculated and the pressure relief device shall be
designed accordingly.

The arc faults shall be confined to the operating compartment
and shall not spread to the other parts of the equipments so that no part of the
enclosure or any loose part may fly off the switchgear.

Limitation of pressure rise due to internal arc shall be in
accordance with clause 5.105. 2 of IEC 62271-203

The internal arcing test reports for Aluminium/stainless steel
enclosures having similar configuration and wall thickness shall be furnished. The
effect of pressure rise and time to burn through shall also be incorporated while
conducting such a testing on the relief device. The pressure relief device shall be
positioned to ensure that personnel will not be affected. The pressure relief device
shall be by means of metallic bursting disc system like Nickel alloy with a preset
opening pressure. Bursting discs made of graphite or non metallic material shall be
avoided for better gas tightness.


2.6 SWITCHGEAR ENCLOSURE:

The metal enclosure for the GIS equipment shall be of
Aluminium/stainless steel and tubular in construction. All flanges shall be directly
bolted together for good metallic contact to make enclosures equipotential.
Enclosures shall withstand normal as well as transient pressures in operation.


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Enclosures shall be designed to withstand any burn through for
a period long enough to enable the back up relay to clear the fault, i.e. the
enclosure must withstand the short circuit current of 40KA (rms) as per clause
5.102.2 of IEC 62271 -203 without burn through.

All joint surfaces shall be machined, all castings shall be spot
faced for all bolt heads, nuts and washers. All screws, bolts, studs and nuts shall
confirm to metric system.
Each gas filled compartment shall be fitted with static filters to
absorb water vapour. Design calculations or test reports to prove/demonstrate the
strength of the enclosures at design pressure and temperature shall be furnished.

2.7 EXPANSION JOINTS AND FLEXIBLE CONNECTIONS:

Thermal expansion, contraction, vibration during making and
braking operations and installation alignment shall be considered in the design of
the bus and enclosure. In order to ensure the continuity of the equipment in service
during thermal expansion, contraction and vibrations expansion joints with
compensators for the enclosures and sliding plug in contacts for the bus shall be
provided.

The total number and design of expansion joints and plug in
contacts has to be determined by the manufacturer to ensure that the complete
installation will not subject to expansion stresses which may lead to distortion or
failure of GIS equipments, support structures or foundations.

Pressure tests on the partitions shall be conducted and reports
submitted as per clause 6.103 of IEC 62271-203.

2.8 FUTURE EXTENSION:

The design and arrangement of the GIS sections shall be in
such a way so as to facilitate future extension without any drilling, cutting or
welding on the existing equipment and also without the necessity of moving or
dislocating the existing switchgear bays. Facilities to test the extension equipments
shall be provided.

3. CIRCUIT BREAKER

The circuit breaker shall be operating on self blast / puffer
principle and with spring /hydraulic operating mechanism. (Pneumatic type will be
summarily rejected).


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The breaker layout arrangements shall be horizontal/vertical for
higher mechanical stability. The operating principle shall ensure minimum dynamic
floor loading for low reaction forces on the foundations.

Technical Data:

A) Max. operating Voltage - 245 KV
B) Rated Withstand voltage between contacts -
Impulse
To earth & between phases - 1050KV
Across the isolating distances - 1200KV
Power frequency
To earth & between phases - 460KV
Across the isolating distances - 530KV
C) Rated short circuit breaking current and duration- 40KA for 3 sec
D) Rated making current - 100KA
E) Rated Break time - 60 msec
F) Rated operating time - 30 msec
G) Rated closing time - 100 msec
H) Close Open time - 60 msec
I) No. of breakes per pole - 1 No

Operating Mechanism:
A) Rated operating sequence - 0 0.3s CO 3min CO / CO - 15
sec - CO
B) Type - Spring/Hydraulic
C) No of trip coils - 2 Nos
D) No of closing coils - 1 Nos
E) No of operations permissible `
1. With minimum maintenance - 10000
2. at 40 KA - 20
F) Contact material - Copper, silver

3.1 OTHER NECESSARY FEATURES:

1. The circuit breaker shall be capable of breaking all currents from zero
up to the specified fault current and also the breaking time shall be as
short as possible.
2. The breaker shall be suitable to withstand the high stresses imposed
on them during fault clearing, load rejection, out of phase switching,
re-energization with trapped charge and to perform the operations
satisfactorily.

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3. The circuit breaker shall have anti pumping and phase discrepancy
protection. Facilities to detect the phase discrepancy and to trip all the
three phases after a minimum time delay shall be provided.
4. The circuit breaker driving mechanism shall have sufficient stored
energy for completing the O CD duty cycle even in case of failure of
auxiliary supply.
5. If the stored energy is not sufficient to perform the duty cycle, then
the tripping and closing circuits shall be locked and a circuit breaker
failure information shall be annunciated.
6. The circuit breakers shall be provided with facilities to operate them
either in local or in remote mode. But the protection trips shall remain
operable regardless of local or remote mode selection. When in
maintenance mode, all remote trip or close signals shall be blocked.
7. All electrically operated closing and tripping devices, and motors shall
be suitable for operation at any voltage from 85% to 110% of their
nominal control voltage.
8. An emergency hand tripping (Mechanical) device shall be provided.
9. Charging of operating mechanism shall be possible by means of
mechanical operation in the case of failure of the motor
10. Position indicator shall be provided to indicate whether the circuit
breaker is open or closed. A counter to count the number of operations
of the breaker shall also be provided.


4. DISCONNECTOR SWITCH:

Disconnector switches shall be single pole/three pole, group
operated (single motor), with one/three operating mechanism per pole/phase.
Facilities shall be provided for emergency manual operations. Necessary handles and
cranks shall be supplied for the same. But manual operation shall be possible only if
the interlocks are satisfied. Disconnector shall be mechanically interlocked with the
earth switch so that the earth switch is prevented from closing on an energized bus
section.

All the contacts shall be silver plated or silver inserts. Each
disconnector switch shall be capable of being opened or closed (shall open or close)
by motor driven mechanism or by manual operation.

4.1 TECHNICAL DATA DISCONNECTOR SWITCH:

i. Rated voltage - 245KV
ii. Rated withstand voltage
Impulse
o To earth & between phases - 1050KV

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o Across the isolating distances - 1200KV
Power frequency
o To earth & between phases - 460KV
o Across the isolating distances - 530KV
iii. Rated current - 2000A
iv. Rated short circuit withstand current -40KA for 3 sec
v. Capacitive current braking - 80A
vi. Bus transfer current switching - 1600A
vii. Type of operating mechanism - Motor
viii. Number of CO permissible with minimum maintenance - 10000

Signaling of the disconnector closed position shall not take place
unless it is certain that the movable contacts have reached a position, wherein the
rated normal current, peak withstand current and short time withstand current can
be carried safely.
Similarly, the disconnector open position shall not take place
unless the movable contacts have reached a position such that the clearance
between the contacts is at least 80% of the rated isolating distance.

The disconnector operation shall be interlocked electrically with
the associated circuit breaker earth switch such that the disconnector control is
inoperative if the circuit breaker is closed.

Operation of disconnector shall be possible either form local or
remote. All electrical sequence interlocks shall apply in both remote and local control
modes.

The electric motor for the driving mechanism shall be AC
operated. All the three phases of any disconnector switch shall be operated
simultaneously irrespective of electrical or mechanical operation.

Locking facilities shall be provided for the operating mechanism
irrespective of open or close position. View ports shall be provided for each pole of
the switch to permit visual inspection of contact position of pole.

5. MAINTENANCE EARTH SWITCH:

The maintenance grounding switch shall be three pole, group
operated (single motor), no load break with one operating mechanism per pole.

Provision for emergency manual operation shall be available.
Necessary cranks and handles shall be provided. The maintenance earth switch shall
be electrically interlocked so that it could not be operated when the bus is in
energized condition.

94

All the main contacts shall be silver plated or shall have silver
inserts. Regardless of electrical or mechanical operation, once initiated the motor
mechanism shall complete an open or close operation, without the necessity of
keeping the contact in the position.
The electric motor for the driving mechanism shall be AC
operated. All the three phases of any earthing switch shall be made to be operated
simultaneously.
Locking facilities shall be provided to lock the operating
mechanism either in the open or close position.

View ports shall be provided for each pole for visual inspection
of contact position of the pole. External mechanically connected position indicators
shall also be provided.

Each earth switch shall be electrically interlocked with the
associated disconnector switch and the circuit breaker so that it can be closed only if
both the circuit breaker and the disconnector switch are open.

The maintenance earth switch shall be made operable only from
local. Remote operation need not to be provided.

Interlocks shall be provided in such a way that manual
operation of the maintenance earth switch will disable the electrical control circuits.

Sufficient auxiliary NC and NO contacts shall be provided for use
by others. Padlocking shall be made possible either in open or closed position.

Flat copper conductor with minimum cross sectional area of 240
sq.mm shall be used to ground all parts of the earth switch and its operating
mechanism.

5.1 TECHNICAL DATA:

i. Rated voltage - 245KV
ii. Rated withstand voltage upon open contacts
Impulse
To earth & between phases - 1050KV
Across the isolating distances - 1200KV
Power frequency
To earth & between phases - 460KV
Across the isolating distances - 530KV
iii. Rated current - 2000A
iv. Rated short circuit withstand current -40KA for 3 sec
v. Number of CO permissible with minimum maintenance - 10000

95


6. HIGH SPEED EARTH SWITCH:

The high speed earth switches shall be provided at the bus bars
and at all external connections like EHV cable, OH line or transformer connections.
The switch shall be three pole operated with one driving mechanism per pole/phase.
An emergency manual operation shall be provided with necessary cranks and
handles. The high speed switch shall be electically interlocked to prevent from
closing on an energized bus section.

All main contacts shall be silver plated or shall have silver
inserts. Once, initiated motor mechanism shall complete an open or close operation
with out requiring the initiating contact to be held closed.

The mechanism shall be arranged in such a way that all the
three phases of any particular high speed earth switch can be operated
simultaneously.

The motor shall be suitable for operating between 85% to
110% of the rated auxiliary voltage.

Each high speed switch shall be furnished with 8 (4 NO and 4
NC) potential free contacts.

View ports shall be provided to ensure visual inspection of each
switch. Inspection of the main contacts shall be possible using an optical device
which shall also provide lighting at contact zone.

These high speed earth switches shall be capable of interrupting
the inductive, capacitive, currents and to withstand the transient voltages.

The switches shall be fitted with a stored energy closing system
to provide fault making capability.

Both local and remote operation shall be made available.

Interlocks shall be provided so that insertion of manual
operating device will disable the electrical control circuit. Pad locking facility shall be
provided for the high speed earth switch either in open position and in closed
position.

Flat copper conductor of 240 Sq.mm or 400 Sq mm flat
aluminium conductor size shall be used to ground all parts of the grounding switch
and the operating mechanism.

96


6.1. TECHNICAL DATA

i. Rated voltage - 245KV
ii. Rated withstand voltage upon open contacts
Impulse
To earth & between phases - 1050KV
Across the isolating distances- 1200KV
Power frequency
To earth & between phases - 460KV
Across the isolating distances - 530KV
iii. Rated current - 2000A
iv. Rated short circuit withstand current - 40KA for 3 sec
v. Inductive current switching capability - 80A,2KV
vi. Capacitive current switching capability - 2A, 6KV
vii. Closing time - 100 msec
viii. Number permissible with minimum maintenance - 10000
ix. No. of short circuit making at 40KA - 2


7. CABLE CHAMBER:

Choice of materials

The choice of materials (metal parts, bolts etc.) must be made to avoid
any risk of corrosion referring to the prescribed specifications on this subject for
metal-cald substations.

Mechanical characteristics

The cable termination casing must withstand different electromechanical,
thermo-mechancial and pressure constraints.

A sealed partition ensures the separation between the gas volumes
contained in the cable termination casing and the adjacent compartments.

The two functions above, mechanical support and sealing may be ensured
by one or several insulators.

Gas dielectric

The internal volume of the metal clad casing is filled with SF6 gas which
ensures insulation. The rated pressure must be specified by the switchgear
manufacturer.

97


Sealing of the cable core

Sealing must be ensured in order to avoid gas leaks through the open
strands of the core.

Pressure surveillance

Pressure surveillance is ensured by one or more pressure monitoring
devices balanced for temperature compensation and it shall have two stages:

.P1 : first level, not requiring rapid intervention.
.P2 : second level requiring rapid intervention.

These pressure monitoring are equipped with a device which allows their
control without emptying the cable termination casing.

Rate of gas leakage

. It shall be guaranteed that the pressure loss in each gas compartment will
not be more than 1% per year under normal operating conditions.

7.1 SPECIFICATION FOR SF 6 GAS INSULATED METAL CLAD
TERMINATION FOR XLPE CABLES:

The following specification applies to single core XLPE insulated cable
terminations connected to SF 6 gas insulated metal-clad substations (G.I.S.) for
rated voltage of 245 KV, where the HV power cables are terminated directly in
the metal clad switchgear using cable-sealing ends designed for use in SF6 gas
and shall comply with IEC 62271-209 & IEEE 1300.

The arrangements and dimensions of the XLPE Cable termination for Gas
Insulated Metal enclose Switchgear will be in accordance with IEC 62271-305
(i.e)Dry type A-inner cone type. The position, its entrance below or above, and
the inclination angle in relation to the horizontal plane will be specified by the
switchgear manufacturer.

The SF6 gas insulated metal clad termination for XLPE cable shall confirm to
the following specification. They are meant for use with the following cables:

The following type of cables will be used.

230KV, 1x1200sq.mm, Aluminium, XLPE cable


98

The outer diameter and other details of the cables will be supplied by
TANTRANSCO. The GIS feeder breaker shall have facility to test the connected
power cable at site. Removable bolted links or similar arrangement will be accepted.
7.2. COMPONENTS

The cable termination is made generally up of the following
elements

1. The enclosure is filled with SF 6 in which the cable termination
has to be placed. This enclosure is closed by an insulating
partitions on the high voltage side and by the flange and the
cable gland on the earth side.

2. The connecting system allowing the electrical joining between
the core of the cable and GIS should withstand the total
dynamic forces generated during short circuit conditions and the
axial forces due to temperature variations during service.

3. The mechanical connecting system shall be available between
the cable gland and the GIS cable connection enclosure.

4. The flange shall provide completely even surfaces. Sealing joints
are fixed in the flange of the metal enclosure and in the cable
gland.

5. The metallic sheath of the cable must be electrically insulated
from the GIS enclosure. In order to protect against over voltage
at high voltage levels, three non-linear resistors (C.C.P.U.) must
be connected between the metallic sheath of the cable and the
metal-clad cable termination. The connections must be as short
as possible, of the same length and be located at 120 degrees
on the same circumference.

6. The cable gland can be linked either to the cable sheath and
insulated from the GIS enclosure or linked to the GIS enclosure
and insulated from the sheath of the cable

7. A free space is reserved under the cable end for the exclusive
use of the cable supplier. This space is necessary for the
passage of the cable termination on connection and can be
used for the placing of the cable gland and the device which
ensures insulation between the metallic sheath of the cable and
the GIS enclosure.

99

7.3. LIMIT OF SUPPLIES AND SERVICES
The cable manufacturer

The cable manufacturer supplies the following elements:

1. The cable connector.
2. The terminal end.
3. The sealing joints ensuring the sealing of the core, and those
between cable gland and flange of the GIS enclosure.
4. The fixing device.
5. The earthing system of the cable sheath
6. Non-linear resistors(CCPU)

The required insulating ring, bolts, nuts, washers and insulating shield
necessary for fixing the cable gland of the cable termination shall also be
supplied. On testing, this assembly can be put through the same electrical tests
on the inner sheath of the cable.

GIS manufacturer

The GIS manufacturer supplies the following elements:

1. The metal enclosure and flange.
2. The pressure monitoring device
3. The electrical contacts ensuring the continuity of the electrical circuit
between the terminal end of the cable and the conductor of the metal-
clad substation.
4. The mechanical blocking device of the terminal end. This shall be
designed so as to withstand a strain, three times that of the maximum strain
guaranteed by the cable supplier.
5. The parts ensuring the sealing of the different compartments between
themselves and with the insulating flange up to the end of the enclosure
6. The grooves and joints are necessary to ensure sealing between the cable
gland and the flange. As this sealing is the responsibility of the cable supplier,
the dimensions of the grooves and joints, the surface condition of the grooves
and the quality of the joints shall be furnished. The filling with SF6 gas is
ensured by the manufacturer of the GIS.

8. CURRENT TRANSFORMER:

Ring core type CT is preferred.

Transformer bay
. Core 1: Transformer differential protection,

100
. Core 2: Over current and local breaker back up protection,
. Core 3: Spare
. Core 4: Bus bar differential protection,
. Core 5: Metering.

Feeder bay
. Core 1: Distance protection,
. Core 2: Spare
. Core 3: Local breakers back up protection,
. Core 4: Bus bar differential protection,
. Core 5: Metering.
The rating of the current transformers shall be as per the relevant standards in
vogue.

For metering cores VA burden is indicated. For protection cores knee point
voltage and resistance of CT secondary are indicated.


Ratio of
transformation
Knee point
voltage
Max
secondary
Resistance
at 75 C
Max
Exciting
current
I max
at VK/2
Rated
burden
Class
of
accuracy
230KV
Core
1
1600/1200/800/600/1 1600V/1600/1A
12ohms at
1600/1A at
75C
30 mA - PS
Core
2
1600/1200/800/600/1 1600V/1600/1A
12ohms at
1600/1A at
75C
30 mA - PS
Core
3
1600/1200/800/600/1 1600V/1600/1A
12ohms at
1600/1A at
75C
30 mA - PS
Core
4
1600/1200/800/600/1 1600V/1600/1A
12ohms at
1600/1A at
75C
30 mA - PS
Core
5
1600/1200/800/600/1 1600V/1600/1A
12ohms at
1600/1A at
75C
-
30 VA
at
600/1A
0.2

NOTE: PS class and class X of British standards are same. ISF shall be greater
than 5




101
9. VOLTAGE TRANSFORMERS

The rating of the voltage transformers shall be as per the relevant
standards in vogue.The voltage transformers shall be of electromagnetic type
and SF6 gas insulated.
The line side (feeder) PTs shall be of insulated Type to enable cable
testing.
The ratio of transformation, rated burden and class of accuracy shall be as
below:
230KV bus bar:
Rated primary voltage: 230/ 3 KV,
Rated secondary voltage, rated burden and accuracy class are

Winding 1- 110/ 3V , 200 VA ,0.2

Winding 2- 110/ 3V ,200 VA ,3 P

230KV bays:
Rated primary voltage: 230/ 3 KV,
Rated secondary voltage, rated burden and accuracy class are

110/ 3V, 200 VA , 0.2

The inductive voltage transformer shall be housed in a metal tank, which
complies with the internal arcing requirement of IEC 62271-203. The tank shall
have a suitable lifting facility.

The high voltage insulators (barriers) shall be suitable for withstanding the
differential pressure i.e. the normal working pressure on one side and the
vacuum on the other side. They shall be compatible with SF6 gas and its
degradation products.

The pressure of the gas at normal temperature and the pressure shall be such
that remains in its gaseous state when operating at the lowest temperatures as
stated in the schedules.

Facilities shall be provided for constant local monitoring of the SF6 gas pressure
inside the tank, while topping up or sampling the gas.

Power frequency tests for the completed GIS at site shall be possible without
removing the voltage transformers.
A bursting disc shall be fitted to the voltage transformer housing for safety
reasons.


102
10.INTERLOCKS

Electrical interlock shall be provided between :
1. Circuit breakers and disconnector.
2. Disconnectors and earthing switches.

The principles of electrical interlocks are the following:

On each bay:

- The disconnector from the bus bar may not be closed if the
associated circuit breaker is closed.
The bus bar disconnector may not be closed if the earthing
switch located between itself and the circuit breaker is closed.
- The earthing switch located between the bus bar disconnector
and circuit breaker may not be closed if the bus bar
disconnector is closed.
- The circuit breaker may not be closed if the ear thing switch of
the associated section of bus bar is closed.
- The feeder disconnector may not be closed or opened if the
associated circuit breaker is closed.
- The feeder disconnector may not be closed if the earthing
switch is closed.


On the bus bar:

- cable disconnector can be opened and earthing switch can
be closed only if the voltage transformer reads zero.
- Cable earth switch can be closed only if cable disconnector is
opened.
- Cable disconnector can be opened only if the associated circuit
breaker is opened.
- The feeder disconnector cannot be closed if the switchgear is
closed and bus bar disconnector is closed.
- The earthing switch of each bus bar may be closed only if all
the bus bar disconnections are opened.


11. LOCAL CONTROL CUBICLE:
A local control cubicle for each GIS breaker shall be supplied. It should enable
local control, indication and interlocking operation of the devices associated with
the GIS bay. The LCC shall be free standing or integrated with the GIS
switchgear.

103
Each local control cubicle will include principally:

A local / remote selector switch,
An operation counter for circuit breaker, and a start up counter for motor
pump,
A mimic of single line diagram of the gas compartments clearly shown,
Push buttons for local opening and closing operation of circuit breakers,
Disconnectors and earth switches,

The arrangement for the push button shall be as below:
- Green TO CLOSE
- Red TO OPEN

All electrical closing and opening operations of circuit-breakers ,disconnectors
and earth switches shall be connected to the terminal block in LCC.
All relays contacts for operation of circuit breakers , disconnectors and earth
switches shall be made available at the LCC.
Terminals shall be available for the two trip coils of the circuit breaker which are
to be connected to two different battery circuits.
All cabling from control boxes of each switchgear will be connected to the
relevant local control cubicle.

11.1 ARRANGEMENTS

Wiring
The wiring must be carried out with stranded copper conductors of at
least 7 strands. The size of the conductors shall be suitable enough for the
expected usage, but it must not be less than 1.5 sq.mm.

All precautions should be taken to minimize the inductive and capacity
coupling between circuits especially with the wiring of the AC and DC circuits.

The cable trays shall be designed in such a way that it has at least 20%
space for future usage.

Terminal Blocks
The design of the terminal shall be as per the relevant standards in vogue.
The terminals permitting the direct control of SF 6 surveillance from pressure
monitoring devices must be fitted with test point.
The outgoing terminal connection must be unique and comprises of 2
distinct parts:
- an arrangement for auxiliary voltage supply (alternating or direct current)
- an arrangement for control common.


104
Worker Safety
All precautions must be taken to ensure an efficient protection against
accidental contact with the live elements.

Degree of protection
The required level of protection shall be established for the enclosures of
boxes and cubicles as per the relevant standards in vogue.

Frame work
The boxes and cubicles shall have metallic enclosures to ensure effective
protection against radio interference. If these enclosures are of non-metallic
materials, the screen shall be connected to the earth to ensure efficient
protection.

Cable entrance
Cable glands or grommets shall be provided for cable entry through the
lower side. These cable glands should avoid electrolytic corrosion at the lower
side of the box.

Closing devices
A simple handle will suffice at the door of the cubicles.
The door must open at at least 120 deg.

Lighting and socket :
Lighting facility at the cubicles shall be activated by opening the door.
In each local control cubicle a single phase 3 pin socket with switch shall
also be provided. The lighting points and sockets should be connected by a
circuit separate from other circuits.

Space heaters
In each box and local control cubicle a space heater is required to prevent
condensation. It should be connected by the same separate A.C. circuit as
above. Space heaters shall be of hydrostat with PTC heaters ( Positive thermal
coefficient heaters) may be adopted everywhere.
The manufacturer shall indicate the electrical power of each heater.

Earthing of boxes and cubicles
Depending upon the location of boxes and cubicles, the earthing terminal
is either linked to the metal enclosure, or linked directly to the general earth mat
by an earthing conductor of sufficient cross section.
Equipotential connections between boxes, cubicles and doors shall be
provided to ensure that no movable part of the enclosure can, once it is in place,
be isolated from the part to which the earthing terminal is connected.


105
Voltage transformer
The cable from voltage transformers shall be terminated in the cubicles
with removable fuses and shall be padlocked.
The fuses are connected in such a way that the locking devices forbids
access to the cells corresponding to the conductors from the voltage
transformers.
The fuse units shall be of 25 amp rating with a 6amp fuse cartridge.

Boxes and cubicles.
Other than stainless steel, all the boxes and cubicles shall be painted with a
minimum one primer coat and one top coat.

Bolts, screws and nuts.
In case of stainless steel a diameter of 16mm and above shall be provided.
If the diameter is below 16mm hot galvanized will be allowed and in such case
the thickness of zinc plating shall be 375 g /sq.m.
All precautions shall be taken:
- to ensure that contacting materials do not cause electrolytic corrosion.
- to avoid water stagnation.
The manufacturer shall specify the measures adopted to ensure the above
conditions.

12. LOW VOLTAGE & CONTROL CABLES

12.1 415V/24OV A.C. AND 110V D.C. POWER CABLES :

These cables shall be 1100V Grade, single/multi-core, stranded, copper
conductor, PVC insulated, aluminium wire armoured (for single core) and steel
strip armoured (for multi-core) with extruded inner and outer sheaths made of
Fire Retardent Low Smoke (FRLS) conforming to the following performance
requirements:

i. The critical oxygen index value shall be minimum at 250C when
tested for temperature index as per ASTM-D-2863-1974.
ii. The maximum acid gas generation as determined by titration shall
be less than 15% by weight when tested as per IEC. 745-1.
iii. The smoke generation test shall pass the light transmission of
minimum of 40% when tested as per ASTM-D-2843-77.
iv. The finished cable shall pass the flammability test as per IEC.332-1
and also as per Swedish Svensk Standard SS. 404-1475 (1978).
The cable shall conform to IS.1554 (Part-I).
v. The cables shall be type tested for resistance to ultra violet rays as
per DIN 533887 and ASTMG 53-77.

106
vi. The cables shall be type tested for hydrolytic resistance as per
ASTM G 53-77.
vii. Water absorption outer sheath shall be subjected to tests for water
absorption, both electrical and gravimetric as per Parts 28 and 33
of IS. 10810, respectively. The test sample shall pass the
requirement of reference specification. Maximum value for water
absorption by gravimetric method shall not exceed 1 mg/sq.cm. of
the areas of sample tested.
viii. Test for rodent and termite repulsion :
Vendor shall conduct type tests for proving the presence of rodent
and termite repellant material in the outer sheath.


12.2 CONTROL CABLES :

12.2.1 The control cable shall be of 1100V Grade, stranded, tinned, annealed,
high conductivity copper conductor of size 2.5 sq.mm. (except for C.T.
circuits for which the size shall be 4 sq.mm.) steel strip armoured,
extended inner and outer sheath made of FRLS PVC compound
conforming to the performance requirements outlined above. Cables shall
conform to IS.1554 (Part-I). Cables having cores up to 5 shall be colour
coded. Cables with 6 cores and above shall have printed numbers.

12.2.2 In additions, the control cables shall have a copper screen over the inner
sheath for protection against electromagnetic disturbances.

12.2.3 SPECIAL CABLES AND PANEL WIRES :
Any other special cables being supplied as a part of this contract shall
conform to the performance requirements, as per standards.

12.2.4 SCREEN CHARACTERISTICS :
The screen consists of either a copper tube or a bare copper tape laid
longitudinally over the sheath. The screen is corrugated to improve the
flexional strength. The length wise tape must overlap the screen edges by
at least 5mm.The DC electric resistance of the screen must be lower than
2 ohm/km at 20C.
The measurement is made before and after the bending test.

12.2.5 TRANSFER IMPEDENCE MEASUREMENT
The transfer impedance is measured on the cable completed so as to
check the degree of protection provided by the copper core. The
transfer impedance must be measured and value must be between 1kHz
and 1 MHz.
The transfer impedance curve according to the frequency must be

107
<2ohms and constantly fall from 100kHz.

12.3 CABLING

The manufacturer shall carry out the erection of control cables between
the different phases of a same GIS module and the cubicles. Suitable
marks on each cable between the different boxes and the cubicles shall be
provided for easy identification.
The control cables should occupy only up to 80% of the space in the cable
trays initially.
All cabling between boxes of switchgear and control cubicles shall be
multicore cable and it shall be glanded with a suitable shield for protection
against electromagnetic effects. (It shall comply with the technical
specification for low voltage cable.)
This shield shall be connected to the earthing at both ends by a braided
conductor wire on a suitable copper flat within boxes and cubicles.

13. ACCESSORIES:

13.1 Sf6 gas service cart
The SF6 gas service cart shall be adequate to:
- refill each compartment between the first or second level of SF6 gas
pressure to the rated pressure.
- check the SF6 monitoring.

13.2 Sf6 handling plant
The SF6 handling plant shall contain compressors and vacuum pump
necessary for recovering vacuum and filling SF6 gas. It shall be movable
with wheels.

It shall allow the storage of SF6 in liquid state in a built in tank having
capacity sufficient to empty any three adjacent compartment of 245 KV
GIS.

The capacity of compressors and vacuum pumps shall be selected in such
a way for
-filling a compartment to the rated pressure within one hour.
-recovering SF6 gas from any compartment to the built in tank from the
rated pressure to 50mb pressure within three hours.
-evacuating a compartment from 50 mb pressure to less than 1 mb
pressure within one hour.
The cart shall have the following provisions:
-accessories for connections and operation (valves and coupling)
-dry type filters, dust and oil traps,

108
-tools and spares for operation and Maintance,
-hand-book for description, commissioning, operation, and Maintance.

13. 3 230KV SF 6 test bushings:
These bushings shall conform to IEC 60137 standard.
The design shall meet the following requirements:
- Minimum creep age distance : 31mm / KV for heavy pollution level
according to the IEC60815 standard.
-The terminal clamp shall be supplied by the GIS manufacturer

14. EARTHING

14.1 Earthing of the main circuits
All earthing arrangements shall comply with IEEE 80.
In order to ensure security during maintenance work, it should be possible
to earth all the parts of the main circuits by earthing switches. In addition, even
after opening the enclosure, it must be possible to connect earthing devices
while the work is in progress.
The earthing switches designed for busbars and feeders shall be
supplemented by the following arrangements :
i) At each point where it may be necessary to have such an earthing for
worker safety, an orifice with a cover permits the easy installation of a removable
earthing device already connected to the earth mat of the substation.
ii) In cases where it is necessary to take out the earthing switch from service,
either to carry out maintenance on it, or to take out a piece of apparatus in the
compartment in which it is installed, provision shall be given in such a way that
prior to taking the earthing switch out from service , a removable earthing
device (temporary earthing device) shall be given to the main circuit at where
intervention is required.
iii) The possible connection points of the removable earthing devices have
to be indicated on the instructions. There shall be at least one connecting point
on each compartment of the busbar and on each cable box.
In order to reenergize a part of the main circuit, provision shall be given to refill
the compartment in which the removable earthing device was installed, to its
rated pressure of SF 6.
The manufacturer shall give the description of the removable earthing device.
14.2 EARTHING OF THE ENCLOSURES:

Generally the metal clad equipment are assembled, by bolting the structures,
cover and partition which may be considered adequate as long as the electrical
continuity has been maintained.


109
Consequently the metal enclosure of metal-clad substation are used as earth
conductors and hence continuity has to be maintained. In the case of
dismantling of any enclosure, the continuity of the earthing should be maintained
by a temporary earthing arrangement.

In all cases where the enclosures do not ensure earthing continuity, the two
neighboring enclosures must be linked to a same general earthing network by a
conductor or by an equipotential link.

In order to ensure the continuity of the earthing circuit, it is essential that the
enclosures are linked as directly as possible to the general earthing circuit of the
substation by copper flat cross section sufficient to carry the rated short circuit
current.

The earthing electrodes of the different pieces of equipment are therefore
directly connected to the enclosures:

- either by copper flat of a cross section equivalent to that of the general
earthing circuit, so as to carry the short-circuit current
These connections shall be supplied by the manufacturer.

14.3 Nature and size of connecting conductors:

In order to avoid electrolytic corrosion problems, these connections must be
made by tinned copper flat because the enclosure are made of aluminum
alloy/stainlees steel.

The minimum size of these earth conductors should carry the short circuit
current shall be specified by the manufacturer and hence its size shall be
specified accordingly.

Concerning the conductors which ensure earthing only, their cross sections shall
be a minimum of 240 Sq.mm for copper

14.4 Bonding circuits

In case where the three phase of a feeder or of a bus bar are placed in
separated enclosures, it is necessary to link the enclosures by Bonding circuits,
of size suitable to carry a continuous current equal to the rated current of the
feeder or of the bus bar. It is imperative that these bonding circuits are linked to
the general earth mat of the substation by a circuit suitable to carry the rated
short-circuit current.



110
14.5 Connection to the general earth mat.
All metal parts intended which does not belong to a main or an auxiliary circuit,
shall be connected to earth.

The general copper earth circuit of the substation shall be formed by an
uninterrupted loop which originates from the buried copper conductor of a cross
section of 240sq.mm. These loops shall be fixed to the base of the chassis with
the help of an earth riser connection bolted into a hole in the chassis or frame
and situated at 0.30 m above the floor level of the switchgear.

The general earth mat design, the connection device and the bimetallic plate
shall be supplied by the GIS manufacturer. The earth connection from earth pad
of equipment to the general earth mat near shall be provided by the supplier.

The continuity of the earthing circuits shall be ensured taking into account the
thermal and electrical stress by the current they may have to carry.

14.6 Equipotential Earthmat :
When a fault current flows through the earthing connections into the soil, the
enclosures, linked to the earthing circuits, will be at the same potential as the
earthing mat conductors but this potential is generally different from that on the
soil surface.

In order to ensure the security of personnel, it is necessary to install an
equipotential mat linked to the general earthing mat in the zones where metal
enclosures and fixed accessories are accessible from the floor.

It is also necessary to provide an equipotential earthing mat in the zones where
an emergency mechanical operation or a locking system is accessible from the
floor. It is therefore possible to extend the equipotential mat to allow the
operator to carry out his maneuvers.

In order to ensure a good equipotential surface, each element of the
equipotential mat must be connected to the general earthing network by the
manufacturer.
This mat will be placed on the floor, all around the switchgears. It is not
required in front of the control cubicles.
If it is an oxidizing material, it should be hot dip galvanized.
The manufacturer must design, specify, and provide this equipotential earth
mat. The location of the equipotential mat should be defined by the supplier for
all the GIS and at places where :
- the enclosures are accessible for the floor.
- Manual operation of apparatus or locking system is located.


111
Five copies of equipotential earth mat drawings along with design calculations
may be submitted for approval by the successful Bidder along with general
arrangement drawings.

15 TESTING & COMMISSIONING:

15.1 TYPE TEST:
Type tests shall be conducted according to the IEC 62271-203 and other
relevant IEC standards, for M2 type.

15.2 ROUTINE TESTS

Routine tests shall be as per the IEC 62271-203 and other relevant
standards.

15.3 COMMISSIONING TESTS/ON SITE TESTS AFTER ERECTION

The EPC contractor shall arrange to provide all the testing equipments required
for the site tests.
After erection, and before putting into service, the gas-insulated metal
enclosed Switchgear shall be tested for the correct operation and dielectric strength
of the equipment.

These tests and verifications shall comprise:

15.3.1) Tests to be conducted on the circuit breaker at site

i) At all required operating sequences
Measurement of operating time
ii) Checking of wiring and connections and dielectric checks
iii) Indications, alarms and interlocks, auxiliary contacts
iv) Operation at minimum and maximum control supply
voltage/pressure
v) Operation of anti-pumping device.

15.3.2) Test to be conducted on the Disconnectors at site

i) Checking of wiring and connections and dielectric checks
ii) Indications, alarms and interlocks, auxiliary contacts
iii) Operation at minimum and maximum control supply
voltage.

15.3.3) Other Tests at Site


112
- Dielectric tests on auxiliary circuits
- Measurement of the resistance of the main circuit
- Measurement of gas condition
- Gas tightness tests
- General verifications

15. 3.4) POWER FREQUENCY TEST:

15.3.4 A) ON SITE TESTING OF GIS

Power frequency tests for the completed GIS at site shall be
possible without removing the voltage transformers. The power frequency test
voltage at site shall be 80% of the factory test voltage for 1 min at 100Hz.

15.3.4 B) The Supplier is responsible to furnish all the test equipment
for conducting following performance tests at site.

Voltage tests on main circuits at reduced voltage (80%) comprising:

-100 Hz A.C. voltage test for 1 min

- Partial Discharge test shall be conducted and report submitted as
per clause 6.2.9.101 of IEC 62271.203

The supplier shall provide :

-The test voltage source.

-All connections between the switchgear and the test voltage source.

The procedure to be implemented following a discharge during dielectric
tests is as follows :

- if a disruptive discharge occurs at the first test while increasing of test
voltage, a second test is performed.

- If a second disruptive discharge occurs in the same compartment before
reaching the highest level, there are two possibilities :

- If the second disruptive discharge is higher than the first voltage again the
voltage is immediately increased. If a new discharge occurs the value of
which is again higher, a new test is carried out.


113
- If the second disruptive discharge is lower than or equal to the first, the
test is stopped and the compartment dismantled.

The process is continued in order to reach the test voltage. If a disruptive
discharge occurs at this voltage, there are two possibilities:

-if it is the first disruptive discharge in the compartment since the test was
begun, voltage is again increased. If there is no other discharge, the test has
been successful. The test is stopped and the compartment dismantled.

-if some discharge have previously occurred in this compartment during
the increase in voltage, the test is stopped and the compartment dismantled.

































114
SCHEDULE OF EQUIPMENT/MATERIALS:

Item No Description of Equipment/Materials Quantity
1 Package 230 KV (Single bus)
230 KV Indoor line bays with all equipments 5 Nos.
230 KV Indoor Transformer bays with all equipments 3 Nos.
Indoor bus bar VTs and bus bar earthing Switches etc., 4 Sets
2 ACCESSORIES
SF6 Gas handling plant of adequate capacity 1 Set
SF6 gas service cart with all accessories 1 Set


Schedule for Essential Tools and Spares

S.No Description Qty
1 Single phase voltage transformer 1 Set
2 Single phase set of 5 cores current transformer including enclosure 1 Set
3 Enclosure insulators and main circuit of bus bar 1 Set
4 Tripping and closing coils 3 Sets
5 SF6 Pressure gauges 2 Sets
6 SF6 Pressure relief devices 2 Sets
7 Oil pressure switch 2 Sets
8 Auxiliary contacts for circuit breaker 1 Set
9 Auxiliary contacts for DS and ES 1 Set
10 SF6 gas in steel bottle 52 Kg / bottle 2 Nos.
11 Hydraulic Pump for circuit breakers 1 unit
12 Complete drive mechanism for disconnect
switches and grounding switches
1 unit
13 Motor for disconnect switches and
grounding switches
1 unit
14 Complete drive mechanism for
fast acting grounding switches
1 unit
15 Motor for fast acting grounding switches 1 unit

115
16 Rupture disc for circuit breakers / potential transformer 1 no
17 Set of spares for local control cabinet including m.c.b., fuses, time
relays, auxiliary relay and terminals
1 lot
18 Rupture disc for other compartments 2 no
19 O rings (assorted sizes) 5 Nos. /
Module
SPECIAL TOOLS
i) SF6 gas leak detector 1 Set
ii) Hygrometer 1 Set
iv) Milli volt drop measurement appliance 1 Set
v) Sf6 gas bottle locking, measuring and filling assembly with all hose 2 Set
vi) One set of pipe grooving tools for the hydraulic operating mechanism 1 Set
viii) Infra red camera 1 set
















116

SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS
FOR 245 KV SF6 INSULATED SWITCHGEAR
DESCRIPTION
SPECIFICATION
REQUIREMENT
To be filled up by the
Tenderer
COMMON
Type M2
Standards IEC
Rated voltage KV 245
Normal service voltage KV 230
Lighting impulse withstand voltage:
at nominal gas pressure KV peak --
at minimum gas pressure KV peak 1050
Power frequency withstand voltage
- at nominal gas pressure KV --
- at minimum gas pressure KV 460
Short time withstand current KA 40
Duration of short time current S 3
Peak withstand current KA peak 100
. Normal current at 45 C:
- busbar A 2000
- bays A 1250
. Insulation medium SF 6
. Rated pressure of SF 6 insulation.
- at 20 C ambient bar --
. Maximum pressure :
- at 45 C ambient bar --
. Setting of pressure relief device bar --
1
st
level low pressure (refilling) at 20 C
. 2
nd
level low pressure (pressure failure) at 20 C
--
Admissible power frequency voltage at
atmospheric SF6 pressure KV

. Material of conductor --
. Material of enclosures
. Material of insulators
. Pressure design of enclosure
. Max relative leakage %
. Enclosures :
.Type of enclosure 1 or 3 phase

117
. Material Aluminium
alloy or
stainless steel

. Shape of enclosure
Minimum thickness and diameter of enclosure
. Degree of protection
Burn through time due to internal arc
. Resistivity
Temperature rise over ambient of 45 C / design
temperature of enclosure.

- At rated current
short circuit current flows for 1 second.
. Each Gas Compartment :
. Design pressure
. Minimum bursting pressure
. Routine test pressure
. Leakage test pressure
. Type of pressure relief device
. Material pressure relief device
. Setting of pressure relief device
. Rated density of gas
. Minimum gas density
. Volume of gas
.Insulator :
. Material of insulator
. P.D. Level (PC)
Any special design to protect insulator from the
deteriorating effect of sf6 decomposed gases

.Circuit breakers
Maker name and country of manufacturer


. Type M2
Standards IEC
. Short circuit breaking current KA 40
Short circuit making current KV peak 100
. Power frequency withstand voltage
- across opening distance KV 530
. Lighting impulse withstand voltage :
- across opening distance KV 1050
. Normal current at 45 C A 1250
. Insulation medium SF6
. Rated pressure of SF 6 insulation :

118
- at 20 C ambient bar
. Maximum pressure :
at 45 ambient bar
. Setting of pressure relief device bar
1
st
level low pressure (refilling) at 20C
2
nd
level low pressure (pressure failure) :
. First pole to clear factor 1.3
. Rated operating duty cycle 0.3s-CO-3min-
CO

Rated transient recovery voltage KV peak
Rated out of Phase breaking current KA
Rated cable charging breaking current A


. Rated characteristics for short line faults- KA


. Rated line charging breaking current A


Rated transformer charging breaking current A


Rated cable charging breaking current A
415/230

. Operating mechanism type Spring/
Hydraulic

. Motor voltage V.a.c. 415/230
. Motor power W
Rated power of closing coil W
. Rated power of tripping coil :
normal trip W
- emergency trip W
. Closing time : ms 100
tolerence ms --
. Dead time : ms 100
tolerence ms --
.Break time ms 60
-tolerance ms --
.Make time ms 60
-tolerance ms --
.Arcing time ms --
-tolerance ms --
.Synchronism ms 3.3
Number of breaks in series (per phases)
. Number of auxiliary contacts
- N0 --
- NC --

119
. Pressure design enclosure --
. Material contacts
- main copper, silver
-arcing --
. Whether CB is restrike free Yes/No
Breaker is fixed with trip coils and closing coils
. No. of trip coils and closing coils 2 trip and 1
closing

No. of opening operations CB is capable of
performing

- at rated current
- at rated breaking capacity 20
without inspection, replacement of contacts or
other main parts without replacing/
reconditioning SF6 gas
10000
. No. of operations after which routine
inspection / maintaince of CB is necessary


Maximum temperature rise over ambient
temperature of 45 C



-Main current carrying part in SF 6 gas
- Operating coils
- Operating motor
. Thickness of Sliver plating for contacts.
. Overvoltage corresponding to (cable charging,
line charging, transformer charging, out of
phase current)


. Disconnectors
. Maker name and country of manufacturer


. Type M2
. Standards IEC
. Characteristics Live off-Load
operation

. Power frequency withstand voltage :
- across opening distance KV 530
. Lighting impulse withstand voltage :
- across opening distance KV peak
1050

. Normal current at 45 C
- busbar A 2000
- bays A 1250
. Number auxiliary contact
- close position

120
NO --
NC --
- open position
NO --
NC --
. Motor voltage V a.c. 415 / 230
. Motor power W --
. Speed of opening operation --
. Speed of closing operation --
. Earthing switches
. Maker name and country of manufacturer --
. Type M2
. Standards IEC
. Characteristics Off-load break
and fault make

. Short circuit making current KA Peak 80
. Continuous current A
Withstand of earthing connection KV
. Motor voltage V. a.c. 415/230
. Motor power W --
. Speed of opening operation --
. Speed of closing operation
. Number of auxiliary contacts
- Close position
NO --
NC --
- Open position
NO --
NC --
Current transformers
Core-1 (distance protection or transformer
differential protection

. Maker name and country of manufacturer --
. Type --
. Standards IEC/IS/BS
. Rated primary current A 1250
. Ratio of transformation 1600-1200-
800-600/1A

. Rated burden VA --
. Accuracy class PS
. Minimum knee point voltage 500 at 600/1A

121
. Exciting current at half minimum knee point
voltage mA

. Maximum secondary winding
resistance at 75 C ohm 3 at 600/1A
. insulation material
. Current transformers --
Core 2 (spare)
Maker name and country of manufacturer.
. Type --
. Standards IEC/IS/BS
. Rated primary current A 1250
. Ratio of transformation 800-600/1A
. Rated burden VA --
. Accuracy class PS
. Minimum knee point voltage 500 at 600/1A
. Exciting current at half minimum knee point
voltage mA

. Maximum secondary winding
resistance at 75C ohm 3 at 600/1A
. insulation material
. Current transformers --
Core -3 ( local breaker backup protection &OC
protection)

. Maker name and country of manufacturer
. Type --
. Standards IEC/IS/BS
. Rated primary current A 1250
. Ratio of transformation 800-600/1A
. Rated burden VA --
- accuracy class PS
. Minimum knee point voltage 500 at 600/1A
. Exciting current at half minimum
knee point voltage mA
. Maximum secondary winding
resistance at 75 C ohm 3 at 600/1A
. insulation material --
. Current transformers
Core -4 (busbar differential protection)
. Maker name and country of manufacturer --
. Type --
. Standards IEC

122
. Rated primary current A 2000
. Ratio of transformation 800-600/1A
. Rated burden VA --
-accuracy class PS
. Minimum knee point voltage 500 at 600/1A
. Exciting current at half minimum 30 mA
knee point voltage mA --
. Maximum secondary winding
resistance at 75 C ohm 3 at 600/1A
. insulation material
Core-5 (metering) --
. Maker name and country of manufacturer --
. Type
. Standards IEC/IS
. Rated primary current A 1250
. Ratio of transformation 800-600-300-
150/1A

. Rated burden VA 30 at 600/1A
. Accuracy class 0.5
. Minimum knee point voltage
. Exciting current at half minimum
knee point voltage mA.
. Secondary winding resistance at 75C ohm
. insulation material
. Voltage transformers busbars
. Maker name and country of manufacturer
. Type
. Standards IEC
. Rated primary voltage KV 230/3
. Winding 1 :
- Rated secondary voltage V 230/3
- Accuracy class 0.5
- Rated burden VA 200
. Winding 2 :
- Rated secondary voltage V 230/3
- Accuracy class 3P
- Rated burden VA 100
. insulation materials SF 6
. Rated voltage factor
- continuous
- for 30 seconds

123
. Whether VTs are capable of sustaining
capacitive discharge current of a de-energized
cable feeder.

. Ratio error
- for metering cores
- for protection cores
- phase displacement error
Power frequency withstand voltage of
secondary voltage
. Voltage transformers bays
. Maker name and country of manufacturer --
. Type --
. Standards IEC / IS
. Rated primary voltage kV 230/3
. Rated secondary voltage V 230/3
. Accuracy class 0.5
. Rated burden VA 50
. insulation material SF 6
. Local Control cubicle :
. Dimension
. Thickness of sheet used
. Cross sectional area of conductor for control
wiring (CT, PT other circuits)

. Dimension
- width
- breadth
- Height
















124
TECHNICAL SPECIFICATION FOR 123 KV GAS INSULATED SWITCHGEAR
(GIS)

SPECIAL SPECIFICATIONS

I. GENERAL:

The proposal comprises the following:

The proposed 230/110 KV Indoor type GIS SS situated in Chennai, TamilNadu, will
function with 3x100 MVA Auto transformers.

Single line diagram of the substation is enclosed

II. GENERAL ARRANGEMENT FOR MAIN EQUIPMENT TO BE SUPPLIED:

The Indoor type GIS bay shall be of single bus bar arrangement. The
arrangement shall be such that in future double bus bars connection is also possible.

The GIS bay arrangement comprises the following:

(i) Bus Enclosure:
1. Single phase enclosure bus bar
2. Single phase earthing switch for each phase
3. Single phase VT on each phase
4. High speed Single phase three pole group operated disconnector
switch for each phase
5. Local control cubicle

(ii) Feeder bay arrangement includes in each phase

1. Connection for a XLPE insulated cable,
2. High speed group operated earth switch.
3. Disconnector switch three pole group operated
4. Voltage transformer on each phase with one secondary winding
5. Multi core (minimum 5 core) current transformer on each phase
6. Circuit breaker
7. Maintenance earth switch.
8. Bus bar disconnector
9. Connection with bus bar.

125
10. Local control cubicle.
(iii)Transformer bay arrangement includes

1. Connection for a XLPE insulated cable,
2. High speed group operated earth switch.
3. Disconnector switch three pole group operated
4. Multi core (minimum 5 core) current transformer on each phase.
5. Circuit breaker.
6. Maintenance earth switch.
7. Bus bar disconnector
8. Connection with busbar.
9. Local control cubicle.

(iv) Bus section includes:

1. Single phase group operated disconnector.
2. Local control cubicle.



III. DOCUMENT TO BE SUPPLIED BY THE BIDDER:

III.A. Along with Bid:

(i) Description of the equipment together with a document setting out chosen
methods and principles of dismantling. The aim of the dossier is to show the user that
the switchgear has successfully passed type tests.

(ii) Floor space plan of GIS bay, giving all sizes and static and dynamic stresses
and precise design of the structures needed to install equipment.

(iii) Equipotential earthing mat diagram for the GIS equipments and earthmat
risers.

(iv) Procedure for installing switchgear and sub assemblies on site and
verifications and tests to be carried out prior to commissioning, formats for tests report
and verifications on site.

(v) Design principles of the GIS viz Conductor, enclosure, anti corrosion
protection, internal fault and constructional features and typical arrangements


126

III.B. After the placement of purchase order and before the supply :
Five copies of the following documents shall be supplied.

(i) For each switchgear, a credibility dossier giving a summary of investigative
studies and tests already made on the switchgear proposed.

(ii) Technical document specifying quality control tests conducted on the
delivered switchgear during manufacture as per the standards.

(iii) Auxiliary electrical wiring diagram for operation and control of earthing
switches, circuit breakers, disconnectors, current and voltage transformers, together
with wiring diagrams necessary to define cable connections for the equipment of each
switchgear.

(iv) Schedule for preventive maintenance.

(v) Dismantling and reassembling of connection in the cable box.

(vi) Civil engineering drawings indicating dimensions and static and dynamic
stresses exerted by metal clad equipment.

(vii) General layout drawings of equipment, support frames, earthing loop and
removable earthing circuits, LV auxiliary circuits, texts inscribed on identification /
instruction plates.

(viii) Dismantling and reassembling of switchgear and sub assemblies in case of
failure so that it can be changed entirely.

(ix) Precautions to be taken prior to dismantling and in particular the elements of
the installation for which there are specific settings, etc., Size and qualifications of the
team needed to carry out the envisaged operation, and duration of the operation.

(x) Operation manual for Tools and handling equipment required for the above
works.

(xi) Checks and tests required prior to commissioning.

(xii) Preventive maintenance procedure shall be prepared in accordance with
TNEB practice describing the methods of preventive maintenance and the frequency of
maintenance operations normally anticipated on all the switchgear.


127
(xiii) Drawings for control and low voltage cables.

(xiv) Drawings for earthmat connection.

(xv) Wiring diagrams of the local control cubicle.

(xvi) Description of the indoor and outdoor type 110KV GIS Circuit breaker,
disconnector, earthing switch, CT, PT, cable connection, SF6, local control cubicle.

IV. Scope of supply:

Design, manufacture, assembly ,erection , testing at works, inspection, packing,
transport, unloading and delivery at departmental stores/ site at CHENNAI, storage of
123 KV gas insulated switchgears (GIS),and supply of accessories, startup, essential
spares, tools, tackles and erection, testing and commissioning at site.

The provisions indicated below shall also be included in the scope of main
equipment supply as per general arrangement for main equipment to be supplied.

1. First filling of SF6 gas.
2. Control cabling between GIS and local control cubicle.
3. Earthing circuits to the earthmat risers.
4. Equipotential earthmat.
5. Tools, accessories and testing instruments required for erection, tests
and commissioning.
6. Spares required to meet out any emergency situation during erection at
site.
7. All supports of GIS.
8. All special tools required for operation and maintenance of GIS.
9. Sf6 gas handling plant
10. Sf6 gas service cart
11. Sf6 gas leak detector.
12. Spares for auxiliary system










128
COMMON SPECIFICATIONS
1.GENERAL

The specification applies to the design, manufacture supply, testing,
delivery, installation, testing at site and commissioning of 123KV indoor gas insulated
switchgear and associated equipments as per the general arrangement.

The assembled equipment shall be capable of withstanding electrical,
mechanical and thermal ratings of the specified system. All joints and connections shall be
able to withstand the forces of expansions, vibrations, contraction and specified seismic
requirements without deformation, malfunction and leakage. Optimized arrangements are
required to reduce installation time, provide ease of operations, minimize maintenance,
repair and facilitate future additions.

1.1 STANDARDS:
Unless otherwise specified, the following standards are applicable,

1. IEC 62271 100 - High voltage alternating current
circuit breaker.
2. IEC 62271 203 - High voltage metal enclosed
Switchgear for rated voltage 72.5KV
and above.
3. IEC 62271 102 - High voltage alternating current
disconnectors & earth switches.
4. IEC 60480 - Guide for checking of SF6
5. IEC 61634 - Use and Handling of SF6
6. IEC 61639 - Direct connections transformer GIS
7. IEC 60364, 60479, 60621, IEEE std 80 Standards for
station grounding
8. IEC 60529 - Degrees of protection
9. IEC 60815 - Pollution levels
10. IEC 61000 - Electromagnetic compatibility (EMC)
11. IEC 60044 1ed1.2 - Current transformers.
12. IEC 60044 2ed1.2 - Voltage transformers.
13. IEC 620678,62271 209,IEEE 1300 - Cable connections for XLPE
cable (33 to 150KV)
14. IEC 60137 ed 5.0 - Bushing for alternating voltage
above 1000V.
15. IP 54 - Degree of protection provided by
enclosures.
16. IEC 60376 - Specification and acceptance of new

129
Sf6.
17. IEC 60694 - Common classes for high voltage
Switchgear and control gear
standards.
18. IEC 60060 - High voltage test techniques.
19. IEC 60071 - Insulation coordination.
20. IEC 60099 - Surge arrestors.
21. IEC 60255 - Electrical relays.
22. IEC 60265 - High voltage switchgear.
23. IEC 60270 - Partial discharge measurements.

1.2 ELECTRICAL RATINGS:

The equipments shall have the following basic electrical and design
characteristics.

1. Phase design - single phase
2. Rated voltage - 123 KV L-L
3. Frequency - 50Hz
4. Normal service voltage - 110KV L-L
5. Rated with stand voltage

I) Impulse
To earth & between phases - 550
Across the isolating distances - 630KV
2) Power frequency
To earth & between phases - 230
Across the isolating distances - 265KV
1. Rated current -
Busbar - 2000A
Bays - 1250A
2. Rated short time current - 40KA for 1 sec
3. Partial discharge level of complete bay
At 1.5Uo - <10pc
4. Material
Enclosures - Aluminium/Stainless steel
Conductors - Aluminium

The rated currents has to be guaranteed for maximum ambient
temperature.
The rated withstand voltage has to be guaranteed for second low
level of SF6 gas pressure.

130
The switchgear should withstand rated voltage for atleast 30min,
when SF6 pressure falls to atmospheric pressure.


2.EQUIPMENT SPECIFICATION:

2.1 GENERAL:
The switchgear shall be completely metal clad with modular design, all
modules standardized and interchangeable.
The switchgear shall be made of Aluminium or stainless steel enclosure
with SF6 for insulation. It shall be of single phase encapsulation arrangement. The
switchgear shall be modular design so that future extensions shall be easily accomplished
for adding additional feeders without dismantling any major parts of the equipment. All the
modules shall be standardized and interchangeable.
The switchgear shall be preassembled at the factory and installed at
the site using bolts and sealed flange connections. Welding of enclosures at field is not
acceptable. In order to ensure electrical continuity the metal clad enclosures shall be
bonded together by straps of adequate cross sectional area for the rating of the
equipment.
The equipment should be pre designed in such a way that, the
permitted movements of foundation or thermal effects do not impair the assigned
performance of the equipment. The SF6 pressure monitoring devices, optical indicators,
emergency, mechanical operating devise, locking and all other working devices shall be
easily accessible from the floor to the extent possible.

In case of an internal fault in any one of the Bus bar sections, it shall
be possible to remove and replace the faulty bus bar with out the necessasity of removing
the healthy, energized Bus bar and Bus bar disconnectors from service.

2.2. CONDUCTOR
Conductor shall be made of Aluminium suitable for the specified
voltage and current rating. The electrical connections between the neighboring gas
sections shall be made by multiple contact connectors (Plug in type) so that electrical
connection is achieved automatically when one section is bolted to the other one. The
surface of the connector fingers and conductor tubes on such connections shall be silver
plated.

2.3. SUPPORT INSULATORS AND SECTION BARRIERS

Support insulators shall be used to maintain the conductors and
enclosures in proper relation. The insulators shall be manufactured from high quality epoxy
resin, free from all voids and designed to reduce the electrical stresses on the insulators.

131
The insulator cones shall be embedded in full return current carrying metal fixing rings in
order to avoid mechanical stress to the cast resin part and to impart full conductivity across
the flange connections.

The mechanical strength must be sufficient to ensure the conductors
space requirements and clearances when short circuit fault occurs. Barrier insulators are
used to isolate the gas compartments and non-barrier insulators allow gas pressure to
equalize. The gas barrier insulators sealing to the conductors and the enclosure wall shall
be designed to withstand the maximum difference that could occur across the barrier i.e
maximum operating pressure at on side and vacuum at the other side.

Tests shall be carried out during the manufacturing process to ensure
that all the insulators are free of partial discharge at a voltage at least 10% higher than
the rated voltage.


2.4. SF6 Gas
The GIS shall be filled with sufficient SF6 gas to pressurize the
complete system in sequential approach, one zone or compartment at a time to the rated
normal density. It shall be possible to fill and evacuate the SF6 gas easily from the main
circuit after earthing the circuit. The supplier/manufacturer shall specify rated density for
each compartment and corresponding quantity of SF6 to be used. Also, necessary quantity
and quality of Sf6 used for effective maintenance shall be intimated.

The SF6 gas supplied shall comply with the IEC 60376.

All apparatus necessary for filling and evacuating of SF6 gas to and
from the switchgear shall be supplied with all necessary accessories. It shall be guaranteed
that the pressure loss in each gas compartment will not be more than 1% per year under
normal operating conditions.

Temperature compensated gas pressure monitoring devices shall be
provided for each gas compartment. It shall provide continuous and automatic monitoring
of the gas. It shall have two alarms,


I. Advanced warning can be given when the gas pressure is approaching a low level. It
shall be indicated as
REFILLING
II. This 2
nd
level requires immediate interventions. When the pressure reaches this
level, the circuit breaker shall be tripped automatically and further closing operation
is blocked.

132
All gas seals shall be designed to ensure leakage rates kept to an
absolute minimum, under normal pressure, temperature and electrical load conditions. All
gas seals in the flanges of equipment shall be of O-ring type. The minimum time required
for refilling shall be once in 10 years under normal operating conditions.

2.5. Pressure relief:

Automatic external pressure relief devices shall be incorporated as a
precaution against bursting of enclosure. The bursting pressure or abnormal pressure rise
due to arcing shall be calculated and the pressure relief device shall be designed
accordingly.

The arc faults shall be confined to the operating compartment and
shall not spread to the other parts of the equipments so that no part of the enclosure or
any loose part may fly off the switchgear.


The internal arcing test reports for Aluminium / stainless steel
enclosures having similar configuration and wall thickness shall be furnished. The effect of
pressure rise and time to burn through shall also be incorporated while conducting such a
testing on the relief device. The pressure relief device shall be positioned to ensure that
personnel will not be affected. The pressure relief device shall be by means of metallic
bursting disc system like Nickel alloy with a preset opening pressure. Bursting discs made
of graphite or non metallic material shall be avoided for better gas tightness.

2.6 SWITCHGEAR ENCLOSURE:

The metal enclosure for the GIS equipment shall be of
Aluminium/Stainless steel and tubular in construction. All flanges shall be directly bolted
together for good metallic contact to make enclosures equipotential. Enclosures shall
withstand normal as well as transient pressures in operation.

Enclosures shall be designed to withstand any burn through for a
period long enough to enable the back up relay to clear the fault, i.e. the enclosure must
withstand the short circuit current of 40KA (rms) for 1 sec without any burn through.

All joint surfaces shall be machined, all castings shall be spot faced for
all bolt heads, nuts and washers. All screws, bolts, studs and nuts shall confirm to metric
system.
Each gas filled compartment shall be fitted with static filters to absorb
water vapour. Design calculations or test report to prove/demonstrate the strength of the
enclosures at design pressure and temperature shall be furnished.

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2.7 EXPANSION JOINTS AND FLEXIBLE CONNECTIONS:

Thermal expansion, contraction, vibration during making and braking
operations and installation alignment shall be considered in the design of the bus and
enclosure. In order to ensure the continuity of the equipment in service during thermal
expansion, contraction and vibrations expansion joints with compensators for the
enclosures and sliding plug in contacts for the bus shall be provided.

The total number and design of expansion joints and plug in contacts
has to be determined by the manufacturer to ensure that the complete installation will not
be subjected to expansion stresses which may lead to distortion or failure of GIS
equipments, support structures or foundations.
Pressure Tests on the portions shall be conducted and reports
submitted as perclause 6.103 of IEC 62271-203.

2.8 FUTURE EXTENSION:

The design and arrangement of the GIS sections shall be in such a way
to facilitate future extension without any drilling, cutting or welding on the existing
equipment and also without the necessity of moving or dislocating the existing switchgear
bays. Facilities to test the extension equipments shall be provided.

3. CIRCUIT BREAKER

The circuit breaker shall be operating on self blast principle and with
spring /hydraulic operating mechanism. (Pneumatic type will be summarily rejected).

The breaker layout arrangements shall be horizontal/vertical for higher
mechanical stability. The operating principle shall ensure minimum dynamic floor loading
for low reaction forces on the foundations.

Technical Data:

A) Max. operating Voltage -123 KV
B) Rated Withstand voltage between contacts -
Impulse
To earth & between phases - 550
Across the isolating distances - 630KV
Power frequency
To earth & between phases - 230
Across the isolating distances - 265KV
J) Rated short circuit breaking current and duration- 40KA & 1 sec

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K) Rated making current - 100KA
L) Rated Break time - 40 msec
M) Rated operating time - 20 msec
N) Rated closing time - 55 msec
O) Close Open time - 30 msec
P) No. of breakers per pole - 1 No

Operating Mechanism:
A) Rated operating sequence - 0 0.3s CO 3min CO / CO - 15
sec - CO
A) Type - Spring/Hydraulic
B) No of trip coils - 2 Nos
D) No of closing coils - 2 Nos
E) No of operations permissible
-With iminimum maintenance - 10000
- At rated current at 40 KA - 20

A) Contact material - Copper, silver

3.1 OTHER NECESSARY FEATURES:

1. The circuit breaker shall be capable of breaking all currents from zero up to
the specified fault current and also the breaking time shall be as short as
possible.
2. The breaker shall be suitable to withstand the high stresses imposed on them
during fault clearing, load rejection, out of phase switching, re-energisation
with trapped charge and to perform the operations satisfactorily.
3. The circuit breaker shall have antipumping and phase discrepency protection.
Facilities to detect the phase discrepancy and to trip all the three phases after
a minimum time delay shall be provided.
4. The circuit breaker driving mechanism shall have sufficient stored energy for
completing the O CD duty cycle even in case of failure of auxiliary supply.
5. If the stored energy is not sufficient to perform the duty cycle, then the
tripping and closing circuits shall be locked and a circuit breaker failure
information shall be annunciated.
6. The circuit breakers shall be provided with facilities to operate them either in
local or in remote. But the protection trips shall remain operable regardless of
local or remote mode selection. When in maintenance mode, all remote trip
or close signals shall be blocked.
7. All electrically operated closing and tripping devices and motors shall be
suitable for operation at any voltage from 85% to 110% of nominal control
voltage.

135
8. An emergency hand tripping (Mechanical) device shall be provided.
9.Charging of operating mechanism shall be possible by means of mechanical
operation in the case of failure of the motor
10.Position indicator shall be provided to indicate whether the circuit breaker is
open or closed. A counter to count the number of operations of the breaker shall
also be provided.

4. DISCONNECTOR SWITCH:

Disconnector switches shall be single pole, group operated (single
motor), with one operating mechanism per pole. Facilities shall be provided for emergency
manual operations. Necessary handles and cranks shall be supplied for the same. But
manual operation shall be possible only if the interlocks are satisfied. Disconnector shall be
interlocked with the earth switch from closing on a energized bus section.

All the contacts shall be silver plated or silver inserts. Each
disconnector switch shall open or close only by motor driven mechanism or manual
operation.

4.1 TECHNICAL DATA DISCONNECTOR SWITCH:

i. Rated voltage - 123KV
ii. Rated withstand voltage
Impulse
o To earth & between phases - 550
o Across the isolating distances - 630KV
Power frequency
o To earth & between phases - 230
o Across the isolating distances - 265KV
iii. Rated current - 2000A
iv. Rated short circuit withstand current -40KAfor 3sec
v. Capacitive brakingcurrent - 25A
vi. Bus transfer current switching - 1600A
vii. Type of operating mechanism - Motor
viii. Number of CO permissible (with mninimum maintenance)- 10000

Signaling of the disconnector closed position shall not take place
unless it is certain that the movable contacts have reached a position, where in the rated
normal current, peak withstand current and short time withstand current can be carried
safely.

136
Similarly, the disconnector open position shall not take place unless
the movable contacts have reached a position such that the clearance between the
contacts is at least 80% of the rated isolating distance.

The disconnector operation shall be interlocked electrically with the
associated circuit breaker earth switch such that the disconnector control is inoperative if
the circuit breaker is closed.
Operation of disconnector shall be possible either form local or
remote. All electrical sequence interlocks shall apply in both remote and local control
modes.
The electric motor for the driving mechanism shall be AC operated.
All the three phases of any disconnector switch shall be operated simultaneously
irrespective of electrical or mechanical operation.

Locking facilities shall be provided for the operating mechanism
irrespective of open or close position. View ports shall be provided for each pole of the
switch to permit visual inspection of contact position of pole.

5. MAINTENANCE EARTH SWITCH:

The maintenance grounding switch shall be three pole, group operated
(single motor), no load break with one operating mechanism per pole.

Provision for emergency manual operation shall be available.
Necessary cranks and handles shall be provided. The maintenance earth switch shall be
electrically interlocked so that it could not be operated when the bus is in energized
condition.
All the main contacts shall be silver plated or shall have silver inserts.
Regardless of electrical or mechanical operation, once initiated the motor mechanism shall
complete an open or close operation, without the necessity of keeping the contact in the
position.
The electric motor for the driving mechanism shall be AC operated. All
the three phases of any earthing switch shall be made to be operated simultaneously.

Locking facilities shall be provided to lock the operating mechanism
either in the open or close position.

View ports shall be provided for each pole for visual inspection of
contact position of the pole. External mechanically connected position indicators shall also
be provided.


137
Each earth switch shall be electrically interlocked with the associated
disconnector switch and the circuit breaker so that it can be closed only if both the circuit
breaker and the disconnector switch are open.

The maintenance earth switch shall be made operable only from local.
Remote operation need not to be provided.

Interlocks shall be provided in such a way that manual operation of the
maintenance earth switch will disable the electrical control circuits.

Sufficient auxiliary NC and NO contacts shall be provided for use by
others. Padlocking shall be made possible either in open or closed position.

Flat copper conductor with minimum cross sectional area of 240
sq.mm or 400 sq mm flat aluminium conductor shall be used to ground all parts of the
earth switch and its operating mechanism.

5.1 TECHNICAL DATA:

i. Rated voltage - 123KV
ii. Rated withstand voltage upon open contacts
Impulse
To earth & between phases - 550
Across the isolating distances - 630KV
Power frequency
To earth & between phases - 230
Across the isolating distances - 265KV
iii. Rated current - 2000A
iv. Rated short circuit withstand current - 40KA for 3 sec
v. Number of CO permissible with minimum maintenance - 10000

6. HIGH SPEED EARTH SWITCH:

The high speed earth switches shall be provided at the bus bars and at
all external connections like EHV cable, OH line or transformer connections. The switch
shall be three pole operated with one driving mechanism per pole. An emergency manual
operation shall be provided with necessary cranks and handles. The high speed switch shall
be eclectically interlocked to prevent from closing on an energized bus section.

All main contacts shall be silver plated or shall have silver inserts.
Once, initiated motor mechanism shall complete an open or close operation with out
requiring the initiating contact to be held closed.

138

The mechanism shall be arranged in such a way that all the three
phases of any particular high speed earth switch can be operated simultaneously.
The motor shall be suitable for operating between 85% to 110% of
the rated auxiliary voltage.

Each high speed switch shall be furnished with 8 (4 NO and 4 NC)
potential free contacts.
View ports shall be provided to ensure visual inspection of each switch.
Inspection of the main contacts shall be possible using an optical device which shall also
provide lighting at contact zone.

These high speed earth switches shall be capable of interrupting the
inductive, capacitive, currents and to withstand the transient voltages.

The switches shall be fitted with a stored energy closing system to
provide fault making capability.

Both local and remote operation shall be made available.

Interlocks shall be provided so that insertion of manual operating
device will disable the electrical control circuit. Pad locking facility shall be provided for the
high speed earth switch either in open position and in closed position.

Flat copper conductor of 240 Sq.mm or 400 Sq mm flat aluminium
conductor size shall be used to ground all parts of the grounding switch and the operating
mechanism.

6.1. TECHNICAL DATA

i. Rated voltage - 123KV
ii. Rated withstand voltage upon open contacts
Impulse
To earth & between phases - 550
Across the isolating distances - 630KV
Power frequency
To earth & between phases - 230
Across the isolating distances - 265KV
iii. Rated current - 2000A
iv. Rated short circuit withstand current -40KA for 3 sec
v. Inductive current switching capability - 160A, 15KV
vi. Capacitive current switching capability - 10A, 15KV

139
vii. Closing time - 50 msec
viii. Number of CO permissible with minimum maintenance -10000
ix. No. of short circuit making at 40KA - 2

7. CABLE CHAMBER:

Choice of materials

The choice of materials (metal parts, bolts etc.) must be made to avoid any risk
of corrosion referring to the prescribed specifications on this subject for metal-cald
substations.

Mechanical characteristics

The cable termination casing must withstand different electromechanical,
thermomechancial and pressure constraints.

A sealed partition ensures the separation between the gas volumes contained in
the cable termination casing and the adjacent compartments.

The two functions above, mechanical support and sealing may be ensured by one
or several insulators.

Gas dielectric

The internal volume of the metal clad casing is filled with SF6 gas which ensures
insulation. The rated pressure must be specified by the switchgear manufacturer.

Sealing of the cable core

Sealing must be ensured in order to avoid gas leaks through the open strands of
the core.

Pressure surveillance

Pressure surveillance is ensured by one or more pressure monitoring devices
balanced for temperature compensation and it shall have two stages:

.P1 : first level, not requiring rapid intervention.
.P2 : second level requiring rapid intervention.


140
These pressure monitoring are equipped with a device which allows their control
without emptying the cable termination casing.

Rate of gas leakage

The minimal time interval between the filling pressure and supplementary filling
up to the appearance of the first P1 level must not be less than three years.

7.1 SPECIFICATION FOR SF 6 GAS INSULATED METAL CLAD TERMINATION
FOR XLPE CABLES:

The following specification applies to single core XLPE insulated cable
terminations connected to SF 6 gas insulated metal-clad substations (G.I.S.) for rated
voltage of 123 KV, where the HV power cables are terminated directly in the metal clad
switchgear using cable-sealing ends designed for use in SF6 gas and shall comply with
IEC 62271-209 & IEEE 1300.

The arrangements and dimensions of the XLPE Cable termination for Gas
Insulated Metal enclose Switchgear will be in accordance with IEC 62271-305 (i.e)Dry
type A-inner cone type. The position, its entrance below or above, and the inclination
angle in relation to the horizontal plane will be specified by the switchgear
manufacturer.

The SF6 gas insulated metal clad termination for XLPE cable shall confirm to the
following specification. They are meant for use with the following cables:

The following type of cables will be used.
110KV, 1x630 sq.mm, Aluminium, XLPE cable.
The outer diameter and other details of the cables will be supplied by TANTRANSCo.
The GIS feeder breaker shall have facility to test the connected power cable on site.
Removable bolted links or similar arrangement will be accepted.

7.1. COMPONENTS

The cable termination is made generally up of the following elements

1. The enclosure is filled with SF 6 in which the cable termination has to be
placed. This enclosure is closed by an insulating partitions on the high
voltage side and by the flange and the cable gland on the earth side.


141
2. The connecting system allowing the electrical joining between the core of
the cable and GIS should withstand the total dynamic forces generated
during short circuit conditions and the axial forces due to temperature
variations during service.

3. The mechanical connecting system shall be available between the cable
gland and the GIS cable connection enclosure.

4. The flange shall provide completely even surfaces. Sealing joints are fixed
in the flange of the metal enclosure and in the cable gland.

5. The metallic sheath of the cable must be electrically insulated from the GIS
enclosure. In order to protect against over voltage at high voltage levels,
three non-linear resistors (C.C.P.U.) must be connected between the metallic
sheath of the cable and the metal-clad cable termination. The connections
must be as short as possible, of the same length and be located at 120
degrees on the same circumference.

6. The cable gland can be linked either to the cable sheath and insulated
from the GIS enclosure or linked to the GIS enclosure and insulated from the
sheath of the cable

7. A free space is reserved under the cable end for the exclusive use of the
cable supplier. This space is necessary for the passage of the cable
termination on connection and can be used for the placing of the cable gland
and the device which ensures insulation between the metallic sheath of the
cable and the GIS enclosure.
7.2. LIMIT OF SUPPLIES AND SERVICES
The cable manufacturer

The cable manufacturer supplies the following elements:
1. The cable connector.
2. The terminal end.
3. The sealing joints ensuring the sealing of the core, and those between
cable gland and flange of the GIS enclosure.
4. The fixing device.
5. The earthing system of the cable sheath
6. Non-linear resistors(CCPU)


142
The required insulating ring, bolts, nuts, washers and insulating shield necessary
for fixing the cable gland of the cable termination shall also be supplied. On testing, this
assembly can be put through the same electrical tests on the inner sheath of the cable.

GIS manufacturer

The GIS manufacturer supplies the following elements:

1. The metal enclosure and flange.
2. The pressure monitoring device
3. The electrical contacts ensuring the continuity of the electrical circuit between
the terminal end of the cable and the conductor of the metal-clad substation.
4. The mechanical blocking device of the terminal end. This shall be designed so as
to support a strain, three times that of the maximum strain guaranteed by the cable
supplier.
5. The parts ensuring the sealing of the different compartments between
themselves and with the insulating flange up to the end of the enclosure
6. The grooves and joints necessary to ensure sealing between the cable gland and
the flange. As this sealing is the responsibility of the cable supplier, the dimensions of
the grooves and joints, the surface condition of the grooves and the quality of the joints
shall be submitted to him for agreement. The filling with SF6 gas is ensured by the
manufacturer of the metal enclosure.

8. CURRENT TRANSFORMER:

Ring core type CT is preferred.

Transformer bay
. Core 1: Transformer differential protection,
. Core 2: Over current and local breaker back up protection,
. Core 3: Spare
. Core 4: Bus bar differential protection,
. Core 5: Metering.

Feeder bay
. Core 1: Distance protection,
. Core 2: Spare
. Core 3: Local breakers back up protection,
. Core 4: Bus bar differential protection,
. Core 5: Metering.

The rating of the current transformers shall be as per the relevant standards in vogue.

143

For metering cores VA burden is indicated. For protection cores knee point voltage and
resistance of CT secondary are indicated.


Ratio of
transformation
Knee
point
voltage
Max
secondary
Resistance
at 75 C
Max
Exciting
current
I max at
VK/2
Rated
burden
Class
of
accuracy
110KV
Core 1
800-600/1A
500V at
600/1A
3 ohms at
600/1A
At 75.C
30 mA - PS
Core 2
800-600/1A
500V at
600/1A
3 ohms at
600/1A
At 75.C
30 mA - PS
Core 3
800-600/1A
500V at
600/1A
3 ohms at
600/1A
At 75.C
30 mA - PS
Core 4
800-600/1A
500V at
600/1A
3 ohms at
600/1A
At 75.C
30 mA - PS
Core 5
800-600-300-
150/1A
- - -
30 VA
at
600/1A
0.2

NOTE: PS class and class X of British standards are same.

9. VOLTAGE TRANSFORMERS

The rating of the voltage transformers shall be as per the relevant standards in
vogue. The voltage transformers shall be of electromagnetic type and SF6 gas insulated.

The ratio of transformation, rated burden and class of accuracy shall be as
below:
110KV bus bar:

Rated primary voltage: 110/ 3 KV,
Rated secondary voltage, rated burden and accuracy class are

Winding 1- 110/ 3V , 200 VA ,0.2

144
Winding 2- 110/ 3V ,100 VA ,3 P

110KV bays:

Rated primary voltage: 110/ 3 KV,
Rated secondary voltage, rated burden and accuracy class are

110/ 3V, 50 VA , 0.2
The inductive voltage transformer shall be housed in a metal tank, which complies with
the internal arcing requirement of IEC 62271-203. The tank shall have a suitable lifting
facility.

The high voltage insulators (barriers) shall be suitable for withstanding the differential
pressure i.e. the normal working pressure on one side and the vacuum on the other
side. They shall be compatible with SF6 gas and its degradation products.

The pressure of the gas at normal temperature shall be such that it remains in its
gaseous state when operating at the lowest temperature.

Facilities shall be provided for constant local monitoring of the SF6 gas pressure inside
the tank, while topping up or sampling the gas.

. Power frequency tests for the completed GIS at site shall be possible without
removing the voltage transformers.

A bursting disc shall be fitted to the voltage transformer housing for safety reasons.

10.INTERLOCKS

Electrical interlock shall be provided between :

1. Circuit breakers and disconnector.
2. Disconnectors and earthing switches.

The principles of electrical interlocks are the following:


On each bay:

- The disconnector from the bus bar may not be closed if the associated
circuit breaker is closed.

145
The bus bar disconnector may not be closed if the earthing switch
located between itself and the circuit breaker is closed.
- The earthing switch located between the bus bar disconnector and
circuit breaker may not be closed if the bus bar disconnector is closed.
- The circuit breaker may not be closed if the ear thing switch of the
associated section of bus bar is closed.
- The feeder disconnector may not be closed or opened if the associated
circuit breaker is closed.
- The feeder disconnector may not be closed if the earthing switch is
closed.

On the bus bar:

- cable disconnector can be opened and earthing switch can
be closed only if the voltage transformer reads zero.
- Cable earth switch can be closed only if cable disconnector is opened.
- Cable disconnector can be opened only if the associated circuit breaker
is opened.
- The feeder disconnector cannot be closed if the switchgear is closed
and bus bar disconnector is closed.
- The earthing switch of each bus bar may be closed only if all the bus
bar disconnections are opened.

11. LOCAL CONTROL CUBICLE:

A local control cubicle for each GIS breaker shall be supplied. It should enable local
control, indication and interlocking operation of the devices associated with the GIS
bay. The LCC shall be free standing or integrated with the GIS switchgear.
Each local control cubicle will include principally:

A local / remote selector switch,
An operation counter for circuit breaker, and a start up counter for motor pump,
A mimic of single line diagram of the gas compartments clearly shown,
Push buttons for local opening and closing operation of circuit breakers,
Disconnectors and earth switches,

The arrangement for the push button shall be as below:
- Green TO CLOSE
- Red TO OPEN


146
All electrical closing and opening operations of circuit-breakers ,disconnectors and earth
switches shall be connected to the terminal block in LCC.
All relays contacts for operation of circuit breakers , disconnectors and earth switches
shall be made available at the LCC.
Terminals shall be available for the two trip coils of the circuit breaker which are to be
connected to two different battery circuits.
All cabling from control boxes of each switchgear will be connected to the relevant local
control cubicle.

11.1 ARRANGEMENTS

Wiring

The wiring must be carried out with stranded copper conductors of at least 7
strands. The size of the conductors shall be suitable enough for the expected usage,
but it must not be less than 1.5 sq.mm.

All precautions should be taken to minimize the inductive and capacity coupling
between circuits of especially with the wiring of the AC and DC circuits.

The cable trays shall be designed in such a way that it has at least 20% space
for future usage.

Terminal Blocks
The design of the terminal shall be as per the relevant standards in vogue. The
terminals permitting the direct control of SF 6 surveillance from pressure monitoring
devices must be fitted with test point.
The outgoing terminal connection must be unique and comprises of 2 distinct
parts:
- an arrangement for auxiliary voltage supply (alternating or direct current)
- an arrangement for control common.

Worker Safety
All precautions must be taken to ensure an efficient protection against accidental
contact with the live elements.

Degree of protection
The required level of protection shall be established for the enclosures of boxes
and cubicles as per the relevant standards in vogue.

Frame work

147
The boxes and cubicles shall have metallic enclosures to ensure effective
protection against radio interference. If these enclosures are of non-metallic materials,
the screen shall be connected to the earth to ensure efficient protection.

Cable entrance
Cable glands or grommets shall be provided for cable entry through the lower
side. These cable glands should avoid electrolytic corrosion at the lower side of the box.

Closing devices
A simple handle will be suffice at the door of the cubicles.
The door must open at at least 120 deg.

Lighting and socket :
Lighting facility at the cubicles shall be activated by opening the door.
In each local control cubicle a single phase 3 pin socket with switch shall also be
provided.The lighting points and sockets should be connected by a circuit separate from
other circuits.

Space heaters
In each box and local control cubicle a space heater is required to prevent
condensation. It should be connected by the same separate A.C. circuit as above.
The manufacturer shall indicate the electrical power of each heater.

Earthing of boxes and cubicles
Depending upon the location of boxes and cubicles, the earthing terminal is
either linked to the metal enclosure, or linked directly to the general earth mat by an
earthing conductor of sufficient cross section.
Equipotential connections between boxes, cubicles and doors shall be provided
to ensure that no movable part of the enclosure can, once it is in place, be isolated
from the part to which the earthing terminal is connected.

Voltage transformer
The cable from voltage transformers shall be terminated in the cubicles with
removable fuses and shall be padlocked.
The fuses are connected in such a way that the locking devices forbids access to
the cells corresponding to the conductors from the voltage transformers.
The fuse units shall be of 25 amp rating with a 6amp fuse cartridge.

Boxes and cubicles.
Other than stainless steel, all the boxes and cubicles shall be painted with a minimum
one primer coat and one top coat.


148
Bolts, screws and nuts.
In case of stainless steel a diameter of 16mm and above shall be provided.
If the diameter is below 16mm hot galvanized will be allowed and in such case the
thickness of zinc plating shall be 375 g /sq.m.
All precautions shall be taken:
- to ensure that contacting materials do not cause electrolytic corrosion.
- to avoid water stagnation.
The manufacturer shall specify the measures adopted to ensure the above conditions.


12. LOW VOLTAGE CABLES & CONTROL CABLES

12.1 415V/24OV A.C. AND 110V D.C. POWER CABLES :

These cables shall be 1100V Grade, single/multi-core, stranded, copper
conductor, PVC insulated, aluminium wire armoured (for single core) and steel strip
armoured (for multi-core) with extruded inner and outer sheaths made of Fire
Retardent Low Smoke (FRLS) conforming to the following performance requirements:

i. The critical oxygen index value shall be minimum at 250C when tested for
temperature index as per ASTM-D-2863-1974.
ii. The maximum acid gas generation as determined by titration shall be less
than 15% by weight when tested as per IEC. 745-1.
iii. The smoke generation test shall pass the light transmission of minimum of
40% when tested as per ASTM-D-2843-77.
iv. The finished cable shall pass the flammability test as per IEC.332-1 and
also as per Swedish Svensk Standard SS. 404-1475 (1978). The cable
shall conform to IS.1554 (Part-I).
v. The cables shall be type tested for resistance to ultra violet rays as per
DIN 533887 and ASTMG 53-77.
vi. The cables shall be type tested for hydrolytic resistance as per ASTM G
53-77.
vii. Water absorption outer sheath shall be subjected to tests for water
absorption, both electrical and gravimetric as per Parts 28 and 33 of IS.
10810, respectively. The test sample shall pass the requirement of
reference specification. Maximum value for water absorption by
gravimetric method shall not exceed 1 mg/sq.cm. of the areas of sample
tested.
viii. Test for rodent and termite repulsion :
Vendor shall conduct type tests for proving the presence of rodent and
termite repellant material in the outer sheath.


149
12.2 CONTROL CABLES :

12.2.1 The control cable shall be of 1100V Grade, stranded, tinned, annealed, high
conductivity copper conductor of size 2.5 sq.mm. (except for C.T. circuits for
which the size shall be 4 sq.mm.) steel strip armoured, extended inner and outr
sheath made of FRLS PVC compound conforming to the performance
requirements outlined in 1.0. above. Cables shall conform to IS.1554 (Part-I).
Cables having up to 5 cores shall be colour coded. Cables with 6 cores and above
shall have printed numbers.

12.2.2 In additions, the control cables shall have a copper screen over the inner sheath
for protection against electromagnetic disturbances.

12.2.3 SPECIAL CABLES AND PANEL WIRES :
Any other special cables being supplied as a part of this contract shall conform
to the performance requirements, as per standards.

12.2.4 SCREEN CHARACTERISTICS :
The screen consists of either a copper tube or a bare copper tape laid
longitudinally over the sheath. The screen is corrugated to improve the flexional
strength. The length wise tape must overlap the screen edges by at least 5mm.
The DC electric resistance of the screen must be lower than 2 ohm/km at 20C.
The measurement is made before and after the bending test.

12.2.5 TRANSFER IMPEDENCE MEASUREMENT
The transfer impedance is measured on the cable completed so as to check

The degree of protection provided by the copper core. The transfer
impedance must be measured and value must be between 1kHz and 1 MHz.
The theoretical transfer impedance value is given in Appendix. The transfer
impedance curve according to the frequency must be <2ohms and
constantly fall from 100kHz.

12.3 CABLING

The manufacturer shall carry out the erection of cables between the different
phases of a same GIS module and the cubicles. Suitable marks on each cable
between the different boxes and the cubicles shall be provided for easy
identification.
The control cables should occupy only up to 80% of the space in the cable trays
initially.

150
All cabling between boxes of switchgear and control cubicles shall be multicore
cable and it shall be glanded with a suitable shield for protection against
electromagnetic effects. It shall comply with the technical specification for low
voltage cable.
This shield shall be connected to the earthing at both ends by a braided
conductor wire on a suitable copper flat within boxes and cubicles.

13. ACCESSORIES:

13.1 Sf6 gas service cart
The SF6 gas service cart shall be adequate to:
- refill each compartment between the first or second level of SF6 gas pressure
to the rated pressure.
- check the SF6 monitoring.

13.2 Sf6 handling plant
The SF6 handling plant shall contain compressors and vacuum pump necessary
for recovering vacuum and filling SF6 gas. It shall be movable with wheels.

It shall allow the storage of SF6 in liquid state in a built in tank having capacity
sufficient to empty any three adjacent compartment of 123 KV GIS.

The capacity of compressors and vacuum pumps shall be selected in such a way
for
-filling a compartment to the rated pressure within one hour.
-recovering SF6 gas from any compartment to the built in tank from the rated
pressure to 50mb pressure within three hours.
-evacuating a compartment from 50 mb pressure to less than 1 mb pressure
within one hour.
The cart shall have the following provisions:

-accessories for connections and operation (valves and coupling)
-dry type filters, dust and oil traps,
-tools and spares for operation and Maintance,
-hand-book for description, commissioning, operation, and Maintance.

13. 3 110KV SF 6 test bushings:
These bushings shall conform to IEC 60137 standard.
The design shall meet the following requirements:
- Minimum creep age distance : 31mm / KV for heavy pollution level according to
the IEC60815 standard.
-The terminal clamp shall be supplied by the GIS manufacturer

151

14. EARTHING

14.1 Earthing of the main circuits

In order to ensure security during maintenance work, it should be possible to
earth all the parts of the main circuits by earthing switches. In addition, even after
opening the enclosure, it must be possible to connect earthing devices while the work is
in progress.

The earthing switches designed for busbars and feeders shall be supplemented
by the following arrangements :

ii) At each point where it may be necessary to have such an
earthing for worker safety, an orifice with a cover permits
the easy installation of a removable earthing device
already connected to the earth mat of the substation.

iii) In cases where it is necessary to take out the earthing
switch from service, either to carry out maintenance on it,
or to take out a piece of apparatus in the compartment in
which it is installed, provision shall be given in such a way
that prior to taking the earthing switch out from service ,
a removable earthing device (temporary earthing device)
shall be given to the main circuit at where intervention is
required.

iv) The possible connection points of the removable earthing
devices have to be indicated on the instructions. There
shall be at least one connecting point on each
compartment of the busbar and on each cable box.

In order to reenergize a part of the main circuit, provision shall be given to refill the
compartment in which the removable earthing device was installed, to its rated
pressure of SF 6.
The manufacturer shall give the description of the removable earthing device.
14.2 EARTHING OF THE ENCLOSURES:
Generally the metal clad equipment are assembled, by bolting the structures, cover and
partition which may be considered adequate as long as the electrical continuity has
been maintained.


152
Consequently the metal enclosure of metal-clad substation are used as earth
conductors and hence continuity has to be maintained. In the case of dismantling of
any enclosure, the continuity of the earthing should be maintained by a temporary
earthing arrangement.

In all cases where the enclosures do not ensure earthing continuity, the two
neighboring enclosures must be linked to a same general earthing network by a
conductor or by an equipotential link.

In order to ensure the continuity of the earthing circuit, it is essential that the
enclosures are linked as directly as possible to the general earthing circuit of the
substation by copper flat / Aluminium alloy flat of cross section sufficient to carry the
rated short circuit current.

The earthing electrodes of the different pieces of equipment are therefore directly
connected to the enclosures:

- either by copper flat / Aluminium alloy flat of a cross section equivalent to that of
the general earthing circuit, so as to carry the short-circuit current .

These connections shall be supplied by the manufacturer.

14.3 Nature and size of connecting conductors:

In order to avoid electrolytic corrosion problems, these connections must be made by
tinned copper flat or Aluminium Alloy flat because the enclosure are made of aluminum
/ stainless steel.

The minimum size of these earth conductors shall be able to carry the short circuit
current shall be specified by the manufacturer and hence its size shall be specified
accordingly.

Concerning the conductors which ensure earthing only, their cross sections shall be a
minimum of 400 sq. mm for Aluminium of Aluminium alloy and 240 Sq.mm for copper
flat.


14.4 Bonding circuits
In case where the three phase of a feeder or of a bus bar are placed in separated
enclosures, it is necessary to link the enclosures by Bonding circuits, of size suitable
to carry a continuous current equal to the rated current of the feeder or of the bus bar.

153
It is imperative that these bonding circuits are linked to the general earth mat of the
substation by a circuit suitable to carry the rated short-circuit current flow.

14.5 Connection to the general earth mat.
All metal parts intended which does not belong to a main or an auxiliary circuit, shall be
connected to earth.

The general copper earth circuit of the substation shall be formed by an uninterrupted
loop which originates form the buried copper conductor of a cross section of 240sq.mm.
These loops shall be fixed to the base of the chassis with the help of an earth riser
connection bolted into a hole in the chassis or frame by the manufacturer of the metal-
clad equipment, and situated at 0.30 m above the floor level of the switchgear. The
hole is of 14mm diameter for rated voltage of 123 KV .

The general earth mat design, the connection device and the bimetallic plate shall be
supplied by the GIS manufacturer. The earth connection from earth pad of equipment
to the general earth mat near shall be provided by the supplier.

The continuity of the earthing circuits shall be ensured taking into account the thermal
and electrical stress by the current they may have to carry.

14.6 Equipotential Earthmat :
When a fault current flows through the earthing connections into the soil, the
enclosures, linked to the earthing circuits, are carried at the same potential as the
earthing mat conductors but this potential is generally different from that on the soil
surface.

In order to ensure the security of personnel, it is necessary to install an equipotential
mat linked to the general earthing mat in the zones where metal enclosures and fixed
accessories are accessible from the floor.

It is also necessary to provide an equipotential earthing mat in the zones where an
emergency mechanical operation or a locking system is accessible from the floor. It is
therefore possible to extend the equipotential mat to allow the operator to carry out his
maneuvers.

In order to ensure a good equipotential surface, each element of the equipotential mat
must be connected to the general earthing network by the manufacturer.

This mat will be placed on the floor, all around the switchgears. It is not
required in front of the control cubicles.


154
If it is an oxidizing material, it should be hot dip galvanized.

The manufacturer must provide and specify this equipotential earthing mat. The
location of the equipotential mat should be defined by the supplier for all the GIS and
at places where :

- the enclosures are accessible for the floor.

- Manual operation of apparatus or locking system is located.


Five copies of equipotential earth mat drawings along with design calculations may
be submitted for approval by the successful Bidder.


15 TESTING & COMMISSIONING:

15.1 TYPE TEST:

Type tests shall be conducted according to the IEC 62271-203 and other relevant
IEC standards for type M2


15.2 ROUTINE TESTS

Routine tests shall be as per the IEC 62271-203 and other relevant standards.


15.3 COMMISSIONING TESTS/ON SITE TESTS AFTER ERECTION

The EPC contractor shall arrange to provide all the testing equipments required for the
site tests.

After erection, and before putting into service, the gas-insulated metal enclosed
Switchgear shall be tested for the correct operation and dielectric strength of the
equipment.

These tests and verifications shall comprise:

15.3.1) Tests to be conducted on the circuit breaker at site

i) At all required operating sequences

155
Measurement of operating time
ii) Checking of wiring and connections and dielectric checks
iii) Indications, alarms and interlocks, auxiliary contacts
iv) Operation at minimum and maximum control supply voltage/pressure
v) Operation of anti-pumping device.

15.3.2) Test to be conducted on the Disconnectors at site

i) Checking of wiring and connections and dielectric checks
ii) Indications, alarms and interlocks, auxiliary contacts
iii) Operation at minimum and maximum control supply voltage/pressure

15.3.3) Other Tests at Site

- Dielectric tests on auxiliary circuits
- Measurement of the resistance of the main circuit
- Measurement of gas condition
- Gas tightness tests
- General verifications

15. 3.4) POWER FREQUENCY TEST:

15.3.4 A) ON SITE TESTING OF GIS

Power frequency tests for the completed GIS at site shall be possible
without removing the voltage transformers. The power frequency test voltage at site shall
be 80% of the factory test voltage for 1 min at 100Hz.

Voltage tests on main circuits at reduced voltage (80% p.f.) comprising:

- 100 Hz A.C. voltage test for 1 min

- Partial Discharge test


15.3.4 B) The Supplier is responsible to furnish the test equipment for
conducting following performance tests at site.

The supplier shall provide :

-The test voltage source.


156
-All connections between the switchgear and the test voltage source.

The procedure to be implemented following a discharge during dielectric tests is
as follows :

- if a disruptive discharge occurs at the first test while increasing of test voltage, a
second test is performed.

- If a second disruptive discharge occurs in the same compartment before
reaching the highest level, there are two possibilities :

- If the second disruptive discharge is higher than the first voltage again the
voltage is immediately increased. If a new discharge occurs the value of which is
again higher, a new test is carried out.

- If the second disruptive discharge is lower than or equal to the first, the test is
stopped and the compartment dismantled.

The process is continued in order to reach the test voltage. If a disruptive discharge
occurs at this voltage, there are two possibilities:

-if it is the first disruptive discharge in the compartment since the test was
begun, voltage is again increased. If there is no other discharge, the test has been
successful. The test is stopped and the compartment dismantled.

-if some discharge have previously occurred in this compartment during the
increase in voltage, the test is stopped and the compartment dismantled.

16. NOISE: during the operation, the level of noise of noise emitted by the switchgear
shall be in accordance with the clause 5.106 of IEC 62271.203

17. General Conditions for both 230 KV & 110KV
The GIS Floor level shall be paved in such a way that the level difference shall not
exceed +/- 2 mm.
The GIS shall not be welded to the Floor beam
The cable trays shall be of Galvanized Iron.
All bolts and nuts in the GIS shall be stainless steel.
The view ports of the earth switch, disconnector switches and breakers shall be clearly
visible




157

SCHEDULE OF EQUIPMENT/MATERIALS:

Item No Description of Equipment/Materials Quantity
1 Package 123 KV

123 KV Indoor line bays with all equipments 7 Nos

123 KV Indoor Transformer bays with all equipments 3 Nos

Indoor bus bar VTs and bus bar earthing Switches etc., 5 Sets
2 ACCESSORIES

Bushing for cable testing 1 set


Schedule for Essential Tools and Spares

S.No Description Qty
1 Single phase voltage transformer 1 Set
2 Single phase set of 5 cores current transformer including enclosure 1 Set
3 Enclosure insulators and main circuit of bus bar 1 Set
4 Tripping and closing coils 3 Sets
5 SF6 Pressure gauges 2 Sets
6 SF6 Pressure relief devices 2 Sets
7 Oil pressure switch 2 Sets
8 Auxiliary contacts for circuit breaker 1 Set
9 Auxiliary contacts for DS and ES 1 Set
10 SF6 gas in steel bottle 52 Kg / bottle 2 Nos.
11 Hydraulic Pump for circuit breakers 1 unit
12 Complete drive mechanism for disconnect
switches and grounding switches
1 unit
13 Motor for disconnect switches and
grounding switches
1 unit
14 Complete drive mechanism for 1 unit

158
fast acting grounding switches

15 Motor for fast acting grounding switches 1 unit
16 Rupture disc for circuit breakers / potential transformer 1 no
17 Set of spares for local control cabinet
including m.c.b., fuses, time relays,
auxiliary relay and terminals
1 set
18 Rupture disc for other compartments 2 no
19 O rings 5 Nos. /
Module

SPECIAL TOOLS
i) SF6 gas leak detector 1 Set
ii) Hygrometer 1 Set
iv) Milli volt drop measurement appliance 1 Set
v) One set of Box Spanner 1 Set
vi) One set of adjustable Spanner 1 Set















159
SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS
FOR 123 KV SF6 INSULATED SWITCHGEAR
DESCRIPTION
SPECIFICATION
REQUIREMENT
TO BE FILLED BY
THE TENDERER
COMMON
Type M2
Standards IEC
Rated voltage KV 123
Normal service voltage KV 110
Lighting impulse withstand voltage:
at nominal gas pressure KV peak --
at minimum gas pressure KV peak 550
Power frequency withstand voltage
- at nominal gas pressure KV --
- at minimum gas pressure KV 230
. Short time withstand current KA 40
. Duration of short time current S 1
. Peak withstand current KA peak 100
. Normal current at 45 C:
- busbar A 2000
- bays A 1250
. Insulation medium SF 6
. Rated pressure of SF 6 insulation.
- at 20 C ambient bar --
. Maximum pressure :
- at 45 C ambient bar --
. Setting of pressure relief device bar --
1
st
level low pressure (refilling) at 20 C
. 2
nd
level low pressure (pressure failure) at 20
C
--
Admissible power frequency voltage at
atmospheric SF6 pressure KV
123
. Material of conductor --
. Material of enclosures
. Material of insulators
. Pressure design of enclosure
. Max relative leakage %
. Enclosures :
.Type of enclosure 1 phase

160
. Material Aluminium alloy or
stainless steel

. Shape of enclosure
Minimum thickness and diameter of
enclosure

. Degree of protection
Burn through time due to internal arc
. Resistivity
. Temperature rise over ambient of 45 C /
design temperature of enclosure

-At rated current
short circuit current flows for 1 second.
. Each Gas Compartment :
. Design pressure
. Minimum bursting pressure
. Routine test pressure
. Leakage test pressure
. Type of pressure relief device
. Material pressure relief device
. Setting of pressure relief device
. Rated density of gas
. Minimum gas density
. Volume of gas
.Insulator :
. Material of insulator
. P.D. Level (PC)
. Any special design to protect insulator
from the deteriorating effect of sf6 gas


.Circuit breakers
Maker name and country of manufacturer
. Type
M2

Standards IEC
. Short circuit breaking current KA 40
Short circuit making current KV peak 100
. Power frequency withstand voltage
- across opening distance KV 265
. Lighting impulse withstand voltage :
- across opening distance KV 550
. Normal current at 45 C A 1250

161
. Insulation medium SF6
. Rated pressure of SF 6 insulation :
- at 20 C ambient bar
. Maximum pressure :
at 45 ambient bar
. Setting of pressure relief device bar
. 1
st
level low pressure (refilling) at 20C


. 2
nd
level low pressure (pressure failure)


. First pole to clear factor 1.3
. Rated operating duty cycle 0.3s-CO-3min-CO
Rated transient recovery voltage - KV peak
Rated out of Phase breaking current KA
Rated cable charging breaking current A
Rated characteristics for short line faults-
KA


Rated line charging breaking current A


Rated transformer charging breaking
current A


Rated cable charging breaking current A
. Operating mechanism type Spring/ Hydraulic
. Motor voltage V.a.c. 415/230
. Motor power W
Rated power of closing coil W
. Rated power of tripping coil :
normal trip W
-emergency trip W
. Closing time : ms
tolerence ms --
. Dead time : ms 100
tolerence ms --
.Break time ms 60
-tolerance ms --
.Make-time ms 60
-tolerance ms --
.Arcing time ms --
-tolerance ms --
.Synchronism ms 3.3
Number of breaks in series (per phases)

162
. Number of auxiliary contacts
- N0 --
- NC --
. Pressure design enclosure --
. Material contacts
- main copper, silver
-arcing --
. Whether CB is restrike free Yes/No
Breaker is fixed trip or coils and closing
coils

. No. of trip coils and closing coils
No. of opening operations CB is capable of
performing

- at rated current
- at rated breaking capacity
without inspection, replacement of
contacts or other main parts without
replacing/reconditioning SF6 gas

. No. of operations after which routine
inspection / maintaince of CB is necessary


Maximum temperature rise over ambient
temperature of 45 C

-Main current carrying part in SF 6 gas
- Operating coils
- Operating motor
. Thickness of Sliver plating for contacts.
. Overvoltage corresponding to (cable
charging, line charging, transformer
charging, out of phase current)


. Disconnectors
.Make name and country of manufacturer


. Type M2
. Standards IEC
. Characteristics Live off-Load
operation

. Power frequency withstand voltage :
- across opening distance KV 265
. Lighting impulse withstand voltage :
- across opening distance KV peak 630

163
. Normal current at 45 C
- busbar A 2000
- bays A 1250
. Number auxiliary contact
- close position
NO --
NC --
- open position
NO --
NC --
. Motor voltage V a.c. 415 / 230
. Motor power W --
. Speed of opening operation --
. Speed of closing operation --
. Earthing switches
. Maker name and country of
manufacturer
--
. Type M2
. Standards IEC
. Characteristics Off-load break and
fault make

. Short circuit making current KA Peak 80
. Continuous current A
Withstand of earthing connection KV
. Motor voltage V. a.c. 415/230
Motor power W --
. Speed of opening operation --
. Speed of closing operation
. Number of auxiliary contacts
- Close position
NO --
NC --
- Open position
NO --
NC --
Current transformers
Core-1 (distance protection or transformer
differential protection

Maker name and country of manufacturer --

164
. Type --
. Standards IEC/IS/BS
. Rated primary current A 1250
. Ratio of transformation 800-600/1A
. Rated burden VA --
. Accuracy class PS
. Minimum knee point voltage 500V at 600/1A
. Exciting current at half minimum knee
point voltage mA

. Maximum secondary winding
resistance at 75 C ohm 3 at 600/1A
. insulation material
. Current transformers --
Core 2 (spare)
Maker name and country of manufacturer.
. Type --
. Standards IEC/IS/BS
. Rated primary current A 1250
. Ratio of transformation 800-600/1A
. Rated burden VA --
. Accuracy class PS
. Minimum knee point voltage 500V at 600/1A
. Exciting current at half minimum knee
point voltage mA

. Maximum secondary winding
resistance at 75C ohm 3 at 600/1A
. insulation material
. Current transformers --
Core -3 ( local breaker backup protection
&OC protection)

Maker name and country of manufacturer
. Type --
. Standards IEC/IS/BS
. Rated primary current A 1250
. Ratio of transformation 800-600/1A
. Rated burden VA --
- accuracy class PS
. Minimum knee point voltage 500V at 600/1A
. Exciting current at half minimum

165
knee point voltage mA
. Maximum secondary winding
resistance at 75 C ohm 3 at 600/1A
. insulation material --
. Current transformers
Core -4 (busbar differential protection)
Maker name and country of manufacturer --
. Type --
. Standards IEC
. Rated primary current A 2000
. Ratio of transformation 800-600/1A
. Rated burden VA --
-accuracy class PS
. Minimum knee point voltage 500V at 600/1A
. Exciting current at half minimum 30 mA
knee point voltage mA
. Maximum secondary winding 3 at 600/1
resistance at 75 C ohm
. insulation material
Core-5 (metering) --
Maker name and country of manufacturer --
. Type
. Standards IEC/IS
. Rated primary current A 1250
. Ratio of transformation 800-600-300-150/1A
. Rated burden VA 30 at 600/1A
. Accuracy class 0.5
. Minimum knee point voltage
. Exciting current at half minimum
knee point voltage mA.
Secondary winding resistance at 75C
ohm

. insulation material
. Voltage transformers busbars
Maker name and country of manufacturer
. Type
. Standards IEC
. Rated primary voltage KV 110/3
. Winding 1 :

166
- Rated secondary voltage V 110/3
- Accuracy class 0.5
- Rated burden VA 200
. Winding 2 :
- Rated secondary voltage V 110/3
- Accuracy class 3P
- Rated burden VA 100
. insulation materials SF 6
. Rated voltage factor
- continuous
- for 30 seconds
. Whether VTs are capable of sustaining
capacitive discharge current of a de-
energized cable feeder.

. Ratio error
- for metering cores
- for protection cores
- phase displacement error
Power frequency withstand voltage of
secondary voltage
. Voltage transformers bays
Maker name and country of manufacturer --
. Type --
. Standards IEC / IS
. Rated primary voltage kV 110/3
. Rated secondary voltage V 110/3
. Accuracy class 0.5
. Rated burden VA 50
. insulation material SF 6
. Control cubicle :
. Dimension
. Thickness of sheet used
. Cross sectional area of conductor for
control wiring (CT, PT other circuits)

. Dimension
- width
- breadth
- Height


167
100 MVA 230/110 KV AUTO TRANSFORMER.
TECHNICAL
1.0. SCOPE

1.1 The equipment shall be manufactured in the manner setout in this specification or
where not setout, to the reasonable satisfaction of the purchaser. The transformers
shall conform in all respects to high standards of engineering, design and
workmanship and latest revisions of relevant standards at the time of offer, and the
purchaser shall have the power to reject any work or material, which, in his
judgment is not in full accordance therewith.

1.2 Alll fittings and accessories or apparatus which may not have been specifically
mentioned below, but which are necessary and essential for the efficient working of
the equipment, shall be deemed to be included in the contract. All outdoor apparatus
including bushing insulators with their mountings shall be designed so as to avoid any
accumulation of water.


2.0. CODES AND STANDARDS
2.1. The design, material, construction, manufacture, inspection, testing and
performance of the power transformers shall comply with all currently applicable
statutes, regulations and safety codes.
2.2. Except otherwise stated, the transformers and associated accessories shall
conform in all respects to the latest issues of relevant Indian/International standards.
Some of them are given below:

Indian
Standard
No.
TITLE International
and
Internationally
recognised
Standards
IS-325 Three Phase Induction Motors IEC- 34
IS-335 Insulating oils for transformers and Switchgears IEC-296,
BS-148
IS-778 Gun metal gate, globe and check-valves for
general purpose.

IS-1866

Code of practice for maintenance and supervision
of insulating oil in service.

IS-1886 Code of practice for installation and maintenance
of transformers.

IS-2099 Bushings for AC voltage above 1000V IEC-137, BS
223
IS-2026 Power transformers IEC-76

168
IS-2147 Degrees of protection provided by enclosures for
low voltage switchgear and control gear

IS-2705 Current Transformers IEC-185
IS-3203 Code of practice of climatic proofing of electrical
equipments.

IS-3347 Specification for Outdoor Bushings.
IS-3401 Silica gel
IS-3637 Gas operated relays
IS-3639 Fittings & Accessories for power transformers.
IS-4253 Cork and rubber
IS-5561 Electric power connector
IS-5578 Marking and arrangements for switch gear, bus
bars, Main connections and auxiliary wiring.

IS-6272 Industrial cooling fans
IS-6600 Guide for loading of oil immersed transformers BSCP-0160
IS-8468 ON load tap changer IEC-60214
IS-8478 Application guide for OLTC IEC-60542
IS-9434
IS-10593
Guide for sampling and analysis of dissolved gas
in oil filled equipments,

IS-12676 Oil impregnated paper-insulated condenser
Bushing Dimension and requirements.

Insulation Coordination, Indian Electricity Rules
1959
IEC-71
High voltage test techniques

IEC-60
IEMA Standard publication - Transformer -1
CBIP Manual on power transformers-1999 & 2006


IS BUREAU OF INDIAN STANDARDS, Manak
Bhawan, No.9, Bahadur Shah zafar Marg, New
Delhi - 110 001, INDIA.

INTERNATIONAL ELECTRO TECHNICAL
COMMISSION, Bureau Central de ta Commission
Electro Technique International I, Rue de
Verembe, Geneva, SWITZERLAND.


2.3 Wherever the relevant ISS are not applicable, the specifications of IEC,CBIP and
BSS may be adopted.

2.4. The equipment or materials, meeting recognized National or International
Standards which ensure an equal or superior quality than Indian/IEC standards
specified, will also be accepted. When the equipment offered by the supplier conforms

169
to other standards, salient points of difference between standards adopted and the
standards specified in this specification, shall be clearly brought out in the offer.


3.0. TYPE, RATING AND OTHER TECHNICAL REQUIREMENTS

The requirement of Auto transformers shall be as per price schedule

4.0. INSULATION:

The insulation requirement of windings shall be as per IS 2026.

5.0. IMPEDANCES

5.1. The percentage Impedance Voltage at principal tapping and on the rated
primary/secondary MVA base shall be as per ANNEXURE I .

5.2. Impedance shall include positive and zero sequence and shall be expressed in
terms of branches of the star connected equivalent diagrams, all on the same
MVA base, and the range shall be given for each branch of the equivalent circuit in
turn.

5.3. The tenderer shall indicate the guaranteed impedance, tolerances and
upper and lower limit of impedance which can be offered without an increase in the
quoted price. Tender shall also indicate the percentage variation from the normal tap
to extreme taps.

5.4. To achieve the above percentage impedance values, no reactor, either inside
or outside the tank, shall be used.

5.5 Tap 1 should correspond to highest voltage/lower impedance and the last
Tap should correspond to the lowest voltage/higher impedance.

6.0. LOSSES

6.1 The No load loss at rated voltage & frequency and Load loss at the rated current,
frequency and rated output at 75C and auxiliary loss for the Power Transformer,
shall not exceed the limits as follows.

100MVA, 230KV
1) No load loss : 30 KW (max.)
2) Load loss : 190 KW (max.)
3) Auxiliary loss : 7 KW (max.)


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In addition, the conditions laid down in Clause 10.0 shall apply.

7.0. TEMPERATURE RISE :

The transformer shall be capable of operating continuously at full rating giving
rated output without exceeding the temperature limits specified below, over and above
the ambient temperature of 45
o
C.

Permissible Temperature rise of top oil, measured by thermometer : 50
o
C.

Permissible Temperature rise of winding, measured by resistance : 55
o
C.


8.0. DUTY REQUIREMENTS

8.1. The transformers would be used for Bi-directional flow of rated power.

8.2. The transformer and all its accessories like bushing CTs etc. shall be designed
to withstand, without injury, the thermal and mechanical effects of any external
short circuit to earth and of short circuits at the terminals of any winding for a period of
2 seconds. Transformer windings shall be capable of withstanding the thermal and
mechanical stresses caused by symmetrical or asymmetrical faults.

8.3. The transformer shall be capable of being loaded in accordance with IS 6600.
There shall be no limitation imposed by bushings, tap-changer etc.

8.4. The overload capacity of the transformer and their emergency short time ratings
called for in schedule shall be furnished.

8.5. The transformer shall be suitable for continuous operation with a frequency
variation of 5% without exceeding the specified temperature rise.

8.6. The transformer shall be capable of being operated without danger on any
tapping at the rated MVA with voltage increase of 10% in the system corresponding to
the voltage of that tapping and at the same time with a frequency of 5% below normal.

8.7 Transformers of similar ratio & impedance, now in service in TNEB shall operate
satisfactorily in parallel with each other.





171
8.8. Radio interference and Noise Level:

i) The transformer shall be designed with particular attention to the
suppression of harmonic voltages, especially the third and fifth to the maximum extent,
so as to minimise interference with communication circuits.

ii) The noise-level, when energised at normal voltage and frequency with
fans running, shall be less than 81 decibels for 100MVA, when measured under
standard conditions.

8.9. The maximum flux density in any part of the core and yoke at the rated MVA,
for the combined effect of voltage and frequency variation specified shall not exceed
1.6 Tesla.

8.10. The maximum current density in any winding shall not exceed 300 Amp./
sq.cm.

8.11. Transformer shall be capable of operating under the natural air cooled
condition up to the specified load. The forced air cooling equipment shall come into
operation by pre-set contact of winding temperature indicator and transformer shall
operate as a forced air cooled-unit initially up to the specified and rated load and then
as ODAF.

8.12. Transformer shall be capable of remaining in operation at full load for 10
minutes after failure of the fans without the calculated winding hot-spot temperature
exceeding 140C. Also, stopping of one or two cooling fans should not have any effect
on the cooling system. Transformers fitted with two coolers each capable of dissipating
50 % of the loss at continuous maximum rating shall be capable of remaining in
operation for 20 minutes in the event of failure of fans associated with one cooler
without the estimated winding hot-spot temperature exceeding 115C.

8.13. Transformer shall accept, without injurious heating combined with increased
voltage and reduced frequency fluctuation, which produce the following over fluxing
conditions.
i) 125% for 1 minute.
ii) 140% for 5 seconds.

9.0. CONSTRUCTIONAL FEATURES

9.1. The transformer and accessories shall be designed to facilitate operation,
inspection, maintenance and repairs.

9.2. All materials used shall be of the best quality and of the class most suitable for
working under the conditions specified and shall withstand the variations of temperature

172
arising under working conditions and atmospheric conditions without undue distortion
or deterioration or setting up of undue stresses in any part and also without affecting
the strength and suitability of the various parts for the work which they have to perform.

9.3. No patching, plugging, shimming or other such means of over-coming defects,
discrepancies or errors will be accepted.

9.4. Corresponding parts liable for replacement shall be inter- changeable.

9.5. All outdoor apparatus, including bushing insulators with their mounting shall be
designed so as to avoid pocket in which water can collect.

9.6. All mechanism shall, wherever necessary, be made out of stainless steel, brass
or gun-metal to prevent sticking due to rust or corrosion.

9.7. FASTENERS:

9.7.1 All bolts, studs, screw threads, pipe threads, bolts and nuts shall comply with
appropriate Indian Standards for metric threads or the technical equivalent.

9.7.2 Bolts or studs shall not be less than 6 mm. in diameter except when used
for small wiring terminals.

9.7.3 If bolts and nuts are placed so that they are inaccessible by means of ordinary
spanners, spectral spanners shall be provided.

9.7.4 Taper washers shall be provided where necessary.

9.7.5 Protective washers of suitable material shall be provided front and back of
the securing screws.

9.7.6 All nuts and pins shall be adequately locked. Nuts, bolts and pins used inside
the transformer and tap-changer compartment where gaskets are not used shall
be provided with spring washers or locknuts. Where galvanizing is specified, it
shall be applied by the hot dipped process or by electro-galvanizing process
and for all parts, other than steel wires, shall consist of a thickness of zinc
coating equivalent to not less than 610 gm of zinc per square metre of surface. The
zinc coating shall be smooth, of uniform thickness and free from defects.

9.7.7 All taper pins used in any mechanism shall be of the split type.

9.7.8 Surface, which are in contact with oil, shall not be galvanised or cadmium
plated.


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9.7.9 Labels or plates of non-corrosive material shall be provided for all apparatus
such as relays, switches and fuses, contained in any cubicle or marshalling kiosks.

9.7.10 Steel bolts and nuts exposed to atmosphere shall be with suitable finishes like
cadmium plated or zinc coated.

10.0. Painting

10.1. Before painting or filling with oil, all ungalvanised parts shall be completely
cleaned and freed from rust, scale and greases, and all external surface cavities on
castings shall be filled by metal deposition.

10..2. The interior of transformer tank and other oil filled chambers and internal
structural steel work shall be cleaned off all scale and rust by shot-blasting. These
surfaces shall be painted with not less than two coats of heat resistant varnish (hot oil
proof) or paint. Un-exposed welds need not be painted.

10..3. Similarly the outer surface shall also be cleaned off all scale and rust by shot
blasting, and then the primary coat shall be applied, immediately after cleaning. The
second coat shall be of Aluminium paint. Before despatch, the transformer shall be
given another final coat of Aluminium paint. Primer paint shall be, ready made zinc
chrome as per IS : 2932.

10..4. All interior surfaces of mechanism chambers and kiosks, except those which
have received anticorrosion treatment, shall receive three coats of paint, applied to
the thoroughly cleaned metal surface. The final coat shall be of a light coloured anti-
condensation mixture.

10..5. Metal parts not accessible for painting shall be made of corrosion -resistant
material.

10..6. Marshalling box and Drive mechanism box shall also be painted with
Aluminium paint. The RTCC panel shall be painted with light grey as per shade-631 of
IS-5.

10..7 DAMAGED PAINT WORK:

i) Any damage occurring to any part of a painting scheme shall be made good to the
same standard of corrosion protection and appearance as that was originally applied.

ii) Any damaged paint work shall be made good as follows:
a) The damaged area, together with an area extending 25mm. around its boundary ,
shall be cleaned down to bare metal.

174
b) A priming coat shall be immediately applied, followed by a full paint finish equal to
that originally applied and extending 50mm around the perimeter of the original
damage.
c) The repainted surface shall present a smooth surface. This shall be obtained by
carefully chamfering the paint edges before ad after priming.

10.8 DRY FILM THICKNESS

i) To the maximum extent practicable the coats shall be applied as a continuous film of
uniform thickness and free of pores. Overspray, skips, runs, sags, and drips should be
avoided. The different coats may or may not be of the same colour.

ii) Each coat of paint shall be allowed to harden before the next is applied as per
manufacturers recommendation.

iii) Particular attention must be paid to full film thickness at the edges.

10.9 TESTS FOR PAINTED SURFACE:

i) The painted surface shall be tested for paint thickness.

ii) The painted surface shall pass the cross hatch adhesion test and impact test as
acceptance tests and Salt spray test and Hardness test as type test as per the relevant
ASTM standards.

NOTE: Supplier shall guarantee the painting performance requirement for a period of
not less than 5 years.

11.0. CORE

11.1. The core shall be constructed from high grade, cold rolled, non-ageing, high
permeability, low loss, grain oriented, silicon steel laminations, known as HI-BI steel
trade name. The maximum flux density in the core shall not exceed 1.6 Tesla at
rated MVA, voltage and frequency and also it should not exceed 1.6 Tesla for the
voltage and frequency variation specified. This has to be ensured during stage
inspection; otherwise the unit will not be accepted. Core assembly shall employ
mitred-interleaved joints.

11.2. The oxide-silicate coating given on the core steel is adequate. However,
laminations can be insulated at least on one side by hot resistant insulation, other than
paper and varnish, is welcome. The insulation shall be inert to the action of hot
transformer oil.


175
11.3. The design of the magnetic circuit shall be such as to avoid static discharges,
development of short circuit paths within itself or to the earthed clamping structure
and the production of flux components at right angles to the plane of the lamination
which may cause local heating.

11.4. The insulation structure for the core to bolts and core clamp plates shall be such
as to withstand a voltage of 2000V AC for one minute. The bolts and clamps, used in
the assembly of the core, shall be suitably insulated with fibre glass tubes and the
clamping structure shall be constructed so that eddy current will be minimum.

11.5. All steel sections, used for supporting the core, shall be thoroughly sand blasted
or shot-blasted after cutting, drilling and welding.
11.6. Adequate lifting lugs shall be provided to enable the core and windings to be
lifted.

11.7. Suitable projecting guides shall be provided on core assembly to facilitate
removal of tank, in case Bell type tank construction or the core assembly from
the transformer tank

11.8. Core and winding shall be capable of withstanding the shock to which they may
be subjected during transport, installation and service. Adequate provision shall be
made to prevent movement of the core and winding, relative to the tank, during
these conditions.

11.9. The core and winding assembly shall be secured independently, with no
connections to the tank cover.

11.10. The supporting frame work of the core shall be so designed, as to avoid the
presence of pockets which would prevent complete emptying of the tank through the
drain valve, or cause trapping of air during filling.

11.11. Oil ducts shall be provided, where necessary, to ensure adequate cooling.
The winding structure and major insulation shall not obstruct the free flow of oil through
such ducts. Where the magnetic circuit is divided into segments by cooling ducts,
parallel to the planes of the laminations or by insulating material above 0.25 mm
thick, tinned copper bridging strips shall be inserted to maintain electrical continuity
between segments. The frame work and clamping arrangements shall be earthed as
specified separately, herein.

12.0.WINDINGS

12.1. The conductor shall be of electrolytic grade copper and windings shall be
made in dust proof, conditioned atmosphere. The supplier shall furnish the facilities

176
available in this regard at his works, along with the tender offer. The current density in
any part of the winding shall not exceed 300 amps per sq.cm.

12.2. Coils of the windings of identical voltage and ratings shall be interchangeable.

12.3. The star connected winding shall have graded insulation. The neutral point of
the star connected winding shall be insulated for the voltages specified in IS:2026.

12.4. The windings shall be designed to reduce the out-of-balance forces in the
transformer to a minimum, at all voltage ratios. They shall withstand the impulse
and power frequency test voltages as specified in this specification.

12.5. The insulation of transformer windings and connections shall be free from
insulating compounds which are liable to soften, ooze out, shrink or collapse and be
non-catalytic and chemically in-active in transformer oil during service.

12.6. Coil assembly and insulating spacers shall be so arranged as to ensure free
circulation of oil and to reduce the hot spot temperature of the windings.

12.7. The stacks of windings shall receive adequate shrinkage treatment before final
assembly. Adjustable devices shall be provided for taking up any possible
shrinkage of coils in service.

12.8. Coils shall be supported at frequent intervals by means of wedge type
insulation spacers permanently secured in place and arranged to ensure proper oil
circulation. To ensure permanent tightness of winding assembly, the insulation
spacers shall be dried and compressed at high pressure , before use.

12.9. The completed core and coil assembly shall be dried in vacuum , at not more
than 0.5 mm of mercury absolute pressure and shall be immediately impregnated with
oil after processing to ensure the elimination of air and moisture within the insulation.

12.10. All threaded connections shall be provided with locking facilities. All leads
from the winding to terminal board and bushings shall be rigidly supported to
prevent injury from vibration. Where applicable, guide tubes shall be used for the
leads.

12.11. Adequate insulation and clearances between high voltage windings and low
voltage windings shall be provided. All clearances of windings and other live parts
shall be adequate for the normal voltage of operation plus 10%.


177
12.12. The conductors shall be transposed at sufficient intervals in order to minimise
eddy current and equalise the distribution of currents and temperature along the
windings.

12.13. The connections of all windings and winding segments shall be crimped;
wherever crimping could not be done , they may be braced.

12.14.The strip conductor wound on edge shall not have a width exceeding six times its
thickness.

12.15. The transformer shall be capable of withstanding the stresses due to short
circuits on HV, IV and LV terminals.

The core coil assembly shall be securely held in position to avoid any movement
under short circuit conditions.

12.16. TERTIARY WINDING

12.16.1. Tertiary windings shall be brought out through weather-proof bushings of 36KV
class.

12.16.2. The tertiary winding insulation shall be adequate to withstand transferred
surge voltage appearing across them due to an impulse on HV or IV windings.
Therefore 11KV windings shall be designed to withstand impulse and power frequency
voltage corresponding to 36KV highest system voltage. The tertiary winding will be kept
idle and no lightning arrestors or capacitors are contemplated to be connected at
present. If however any additional protective device, if required for withstanding the
transferred surge shall be supplied by the bidder.

12.16.3. Tertiary windings rating is indicated for normal voltage. If required, the
supplier shall increase this value for additional reactive power absorbed at maximum
voltage and for suppression of harmonic currents.

13.0. INSULATING OIL:

13.1. The insulating oil, supplied with the transformer, shall be of EHV grade conforming
to IS:335 of latest issue. No inhibitors shall be used in the oil. All the tests, specified in
the standard, shall be carried out for confirmation of the quality on the oil samples,
drawn at the following stages.

i) Prior to filling of the transformer
ii) Before carrying out the Heat-Run test
iii) After carrying out the Heat-Run test
iv) Before energising the transformer at site

178

13.2 Oil shall be filtered and tested for breakdown voltage (BDV) and moisture content
before filling. The design and all materials and processes used in the manufacture of
the transformer shall be such as to reduce to a minimum the risk of the development of
acidity in the oil.

13.3. The insulating oil shall be subjected to testing at the manufacture's works/reputed
laboratory before supply, in the presence of Inspecting personnel.

13.4. Sufficient quantity of oil necessary for first filling of all tanks, coolers and radiators
shall be supplied in sealed non returnable containers, suitable for out door storage.

13.5. The tenderer shall furnish the following information in his offer to enable the
purchaser, to procure, if decided to go for separate procurement.

i) Recommended Technical parameters of the oil.
ii) List of manufacturers of oil, who are preferred by the tenderer for the
transformers offered by them.

13.6. Where the supplier prefers to despatch the transformer without oil , due to
limitations in the handling and transport facility, the transformer tank shall be filled with
dry Nitrogen or equivalent inert gas. A gas cylinder, with suitable reducer connection
and pressure gauge, shall be supplied to monitor the pressure of the gas in the tank
during transit and storage at site, till completion of oil filling. These accessories shall
become the property of the Purchaser.


14.0.TANK AND TANK ACCESSORIES

14.1.Tank Construction

14.1.1. The transformer tank shall be of conventional type construction, with
removable top cover. The transformer tank and cover shall be fabricated from good
quality, low carbon steel, of adequate thickness and shall be designed to withstand

a) lifting of the complete transformer with the tank completely filled with oil,
by crane or jacks and transportation, by road or rail , without
overstraining any joints and without causing subsequent leakage of oil.
b) Mechanical shocks, during transportation
c) Vacuum filling of oil
d) Continuous internal pressure of 35 kN/sq.m, over normal hydrostatic
pressure of oil.
e) Short circuit forces


179
14.1.2.The base of each tank shall be so designed that it shall be possible to move
the complete unit by skidding on metal plates or rails in any direction without injury.

14.1.3. The minimum thickness of the tank plate shall be as per ANNEXURE I
(Package I & II).

Adequate stiffeners shall be provided , wherever necessary, for general rigidity
and these shall be designed to prevent retention of rain water.

14.1.4. Wherever possible the transformer tank and its accessories shall be
designed without pockets wherein gas may collect. Where pockets can not be
avoided, pipes shall be provided to vent the gas into the main expansion pipes.

14.1.5. Adequate space shall be provided at the bottom of the tank for collection of
sediments. Suitable guides shall be provided for positioning the core & coil assembly
and other various parts during assembly or dismantling.

14.1.6. Suitable shielding arrangement with a magnetic material of low permeability
shall be provided inside the tank to shield off the leakage/stray magnetic fields, entering
the tank and causing local heating/temperature rise at the joints. If required,
impermeable shields shall be provided at the coil ends. Tank shield shall not resonate
when excited at the natural frequency of the equipment. The Tenderer may confirm
use of tank shields in the schedule of additional information.

14.1.7. All seam and joints, other than those which may have to be opened, shall be
welded and wherever possible, double welded. After completion of construction of tank
and before painting, dye penetration test shall be carried out on welded parts of
jacking bosses, lifting lugs and all load bearing members.

14.2. Lifting and Haulage Facilities

Each tank shall be provided with:

(a) Lifting lugs, suitable for lifting the transformer complete with oil.

(b) Pulling eyes shall be provided to facilitate movement of the
transformers and they shall be suitably braced in vertical direction,
so that bending does not occur when the pull has vertical component.

(c) Lashing lugs.

(d) A minimum of four jacking pads at a height of about 500 mm (from the
bottom of the tank) to enable the transformers, complete with oil, to be

180
raised or lowered using hydraulic or screw jacks.

14.3. Tank Cover

14.3.1. The detachable top portion of the cover shall be designed for adequate
strength. It shall be sloped to prevent collection of water on any part . It must be
separate from the core and coil and shall be capable of being lifted separately from
the tank for inspecting the core and winding at site. It shall not distort, when lifted.

14.3.2. Inspection openings shall be provided, as necessary to give easy access to
bushings, core and windings, OLTC, earth connection, etc. Each inspection opening
shall be of ample size for the purpose for which it is provided and at least two
openings one at each end of the tank, shall be provided.

14.3.3. The inspection covers shall be of box type to avert trapping of air during oil
filling, or gas during incipient faults inside the transformers, from entering the Bucholtz
relay. As an alternative the space under the cover shall be blanked with a solid
insulating material, fitted to the cover itself.

14.3.4. The tank cover and inspection covers shall be provided with suitable lifting
arrangements. Unless otherwise approved, inspection covers shall not weigh more
than 25 kg, each.

14.3.5. The tank cover shall be provided with pockets for the probes/bulbs for oil
temperature and winding temperature indicators. Metal sheath protection shall be
provided to the capillary tubes of the temperature indicators. It shall be possible to
remove these bulbs without lowering the oil in the tank.

14.3.6. The pockets for Temperature indicator shall be fitted with a captive screwed
top to prevent ingress of water.

14.3.7. Bushing turrets, covers of inspection openings, thermometer pockets shall not
permit ingress of water into or leakage of oil from the tank.


15.0. VALVES AND AIR RELEASE PLUGS

15.1. Each tank shall be fitted with the following valves.

i) Oil valves between each cooler and main tank.
ii) One 100 mm drain valve with padlocking arrangement, located on
the low voltage side of the transformer at the bottom most point of the
tank , enabling complete draining of oil.
iii) Two 50 mm filter valves, one on the top of the tank and at a

181
diagonally opposite end to that of drain valve and another at the
bottom.
The bottom valve shall be with padlocking arrangement. These shall
have adaptor suitable for 32 mm hose.
iv) Two sampling valves (size 25 mm) at top and bottom of the main tank,
with provision for fixing PVC pipe.
v) One 15 mm air release plug on the top cover.
vi) Two plugged pipe outlets for applying vacuum.

15.2. All valves with opening to atmosphere, shall be fitted with blank flanges.

15.3. All valves shall be of gun metal or cast steel or may have cast iron bodies with
gun metal fittings.

15.4. Valves shall be provided with flanges, having machined faces/ screw
connection for external piping.

16.0. AXLES AND WHEELS

16.1. The transformers are to be provided with bi-directional flanged wheels and
axles of suitable dimensions and so supported that under any service condition,
they shall not deflect sufficiently to interfere with the movement of the transformer,
complete with oil. Suitable locking arrangements shall be provided to prevent the
accidental movement of the transformer.

16.2. All wheels should be detachable and shall be provided with suitable bearings
which shall be rust and corrosion resistant. Fittings for lubrication shall also be
provided. The flanged wheels shall be suitable for use on gauge track and shall be
so placed that a pinch bar can be used to move the transformer. Track shall be of
1676 mm gauge between adjacent rails(inner faces), both on longer and shorter axis.
It is noted that rails along shorter axis will be provided.

16.3. The wheels shall be arranged so that they can be turned through an angle of
90 deg. (on both directions) when the tank is jacked up, clear of the rails or floor.
Necessary jacking steps shall be provided . Bi directional wheels without locking and
swivel movements shall be provided.

17.0. CONSERVATOR, TANK AND ITS ACCESSORIES

i) Main conservator shall have air cell type constant oil pressure to prevent
oxidation and contamination of oil due to contact with moisture and shall
be fitted with magnetic oil level gauge with low oil electrically insulated
alarm contacts.


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ii) OLTC conservator shall have conventional type conservator with
prismatic oil level gauge.

17.1. CONSERVATOR TANK

17.1.1 The conservator shall have adequate capacity to meet the requirement of
expansion of the total cold oil volume in the transformer and cooling equipment from
the minimum ambient temperature to 100 C or 7.5% of the total volume of oil in the
main tank whichever is higher.

17.1.2. One end of the conservator shall have bolted cover so that it can be removed
for cleaning.

17.1.3. The conservator shall be bolted into position so that it can be removed for
cleaning purpose.

17.1.4. The conservator shall be fitted in such a position, as not to obstruct the
electrical connections to the transformer & lifting of the OLTC units.

17.1.5. The conservator shall be provided with one 50 mm flanged valve for oil filling
and this should have box/canopy type cover, if fitted on the top.

17.1.6. The conservator shall be provided with one 50 mm flanged valve to completely
drain the oil from the conservator.

17.1.7. The conservator shall have provision to receive one 80mm dia. feed pipe from
the main tank, fitted with Bucholtz relay with two shut off valves on either side of the
Bucholtz relay. Of the two valves one shall be on the conservator side, beyond a length
of 240mm (3 times the internal diameter of the pipe line) and another on the main tank
side beyond a length of 400mm (5 times the internal diameter of the pipe line) from the
Bucholtz relay.
The feed pipe shall be free from sharp bends and make an inclination of 3 to 7
to the horizontal.

17.1.8. The feed pipe shall extend inside the conservator for at least 25mm so as to
form a sump inside the conservator.

17.2 Oil Preservation equipment

The requirement of air cell type oil sealing system are given below:

17.2.1. Contact of oil with atmosphere is prohibited by using a flexible air cell of nitrile
rubber reinforced with nylon cloth air cell.

183

17.2.2. The temperature of oil is likely to rise up to 100C during operation. As such air
cell used shall be suitable for operating continuously at 100C.

17.2.3. Air cell of conservator shall be able to withstand the vacuum during
installation/maintenance periods. Otherwise provision shall be kept to isolate the
conservator from the main tank when the latter is under vacuum by providing a vacuum
sealing valve or other suitable means in the pipe connecting main tank with the
conservator.

17.2.4. The connection of air cell to the top of the reservoir is by air proof seal
preventing entrance of air into the conservator.

17.2.5. A device shall be provided so that in the event of air enters into the conservator
as a result of rupture of the air cell, an alarm sound.

17.3. Magnetic oil level gauge:

17.3.1. The conservator shall be fitted with one magnetic oil level gauge having,

i) Dial with minimum, maximum and normal (at 30
o
C) oil level markings
and a pointer.
ii) Low oil level alarm contacts of 0.5 Amp. 110V/30V D. C. rating

17.4. Oil sealing system

17.4.1. The conservator shall be fitted with constant oil pressure (COP) Diaphragm
type or Air cell type oil sealing system to prevent oxidation and contamination of oil by
the atmospheric oxygen/moisture. 2 Nos. of silica gel breathers in parallel, each one
with a valve shall be provided. A single breather is sufficient for the OLTC of the
Transformer. Design shall be such that ,

(i) The passage of air is through silicagel, not less than 1 kg for every
3500 litres of oil in the tank.

(ii) The silicagel is isolated from atmosphere by an oil seal.

(iii) The moisture absorption, indicated by a change in colour of the
tinted crystals, can be easily seen from a distance.

17.4.2. The Breathers shall be mounted at an approximate height of 1,400 mm above
ground level.



184


18.0. PRESSURE RELIEF DEVICE

18.1. Adequate number of pressure relief devices of sufficient size (
atleast two numbers, one on each end ) shall be provided at suitable
locations for rapid release of any pressure that may be generated inside the tank
and which may result in damage to the equipment. They shall be mounted
directly on the tank. If mounted on the tank cover, they shall be
away from the active parts of the transformer and
the openings in the top cover shall be provided with a skirt, extending 25 mm inside the
tank and holding a deflector plate, sufficiently away from the opening, so as to avert
inadvertent trapping of gas during incipient fault inside the transformer. The device shall
operate at a static pressure less than the hydraulic test pressure of transformer tank.
Means shall be provided to prevent ingress of rain.

18.2 It is desirable to provide the PRV on the top cover. If there is any constraint in the
space on the top cover, in such cases the PRV may be fixed directly on one side of the
main tank below the top cover.

18.3. The pressure relief device shall be of safety valve type, capable of resealing
after any pressure developed inside the tank is released. It shall be provided with
switches for actuating trip contacts, when it acts. The switches shall be able to reset,
once the pressure is released, only by manually.

19.0. EARTHING ARRANGEMENTS

19.1. All metal parts of the transformer with exception of the individual core
laminations, core bolts and associated individual clamping plates shall be maintained at
some fixed potential.

19.2. Earthing of core clamping structure

Main core clamping structure at the top shall be connected to the tank body by
a copper strip. The bottom clamping structure shall be earthed by one or more of the
following methods.

a) By connecting through vertical tie-rods to the top structure.
b) By direct metal-to -metal contact with the tank base maintained by the weight of
the core and winding.
c) By connection to the top structure on the same side of the core as the main
earth connection to the tank.



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19.3. Earthing of magnetic circuit

a) The magnetic circuit shall be earthed to the clamping structure at one point only
through a link placed in an accessible position beneath an inspection opening in the
tank cover, the connection to the link shall be on the same side of the core as the main
earth connection.

b) Magnetic circuits having an insulated sectional construction shall be provided with
a separate link for each individual section. Where oil ducts insulating barriers parallel to
the plane the laminations divide the magnetic circuit in to two or more electrically
separate parts the ducts or barriers shall be bridged and the magnetic circuit shall not
be regarded as being of sectional construction.

19.4. Earthing of Coil clamping rings

Where coil clamping rings are of metal, each ring shall be connected to the
adjacent core clamping structure on the same side of transformer as the main earth
connections, so as to maintain at earth potential.

19.5 Size of earthing connection

All earthing connections with the exception of those from the individual coil
clamping rings shall have a cross sectional area of not less than 0.8 sq.cm.
Connections inserted between laminations of different sections of core and shall have a
cross sectional area of not less than 0.2 sq.cm.

19.6. Two earthing pads, at diagonally opposite external ends of the main tank, at its
bottom, capable of carrying the short circuit current for 4 seconds without injurious
heating, shall be provided with clamp type terminal for external connection.

20.0. RATING AND DIAGRAM PLATES

20.1. The following plates, suitable for outdoor use, shall be fixed to the transformer
tank, at an average height of about 1750 mm above ground level.

(a) A rating plate, of not less than 300 X 300 mm size , bearing the data
specified in the appropriate clause of IS 2026.The details of the current
transformers and normal operating pressure of PRV may also be indicated.

(b) A diagram plate, showing the internal connections and also the voltage vector
relationship of the several windings in accordance with IS 2026 and in addition
a plan view of the transformer giving the correct physical relationship of the
terminals. No-load voltage shall also be indicated for each tap.


186
(c) A plate, showing the location and function of all valves and air release cocks
or plugs. This plate shall also warn operators to refer to the maintenance
instructions before applying the vacuum treatment for drying.

(d) A plate showing the schematic wiring diagram of the respective cubicle may be
provided in the cubicle.

20.2. The rating diagram and other plates shall be of brass or stainless steel.

21.0. JOINTS AND GASKETS

21.1. All gaskets used for making oil tight joints shall be of proven material such as
granulated cork bonded with synthetic rubber or synthetic rubber gaskets conforming to
IS:4253, unless otherwise specified.
21.2 All bolted joints shall be fitted with weather proof, hot oil resistant gaskets in
between, for complete oil tightness. Special attention shall be given to the oil tight joints
between the tank and the cover and the bushing ,the turrets, covers of inspection
openings, thermometer pockets etc and the other out- lets to prevent ingress of water
into or leakage of oil even under hot condition from the tank. If gasket is
compressible, metallic stops shall be provided to prevent over compression.

21.3 One complete set of gaskets shall be supplied with the transformer
additionally, for all openings.

22.0. TERMINAL ARRANGEMENT

22.1. Bushings: Porcelain bushings only shall be used for high & low voltage.

22.1.1. HV and IV leads shall be brought out of the tank through OIP condenser
bushings. The LV and neutral leads shall be brought out of the tank through porcelain
bushings.

22.1.2. The electrical & mechanical characteristics of bushings shall be as per IS 2099
of latest issue. The requirements of condenser bushings shall be as per IS 12576-
1989. The dimensions of the bushings shall be as per IS 3347-1982 and as per the
latest amendment.

22.1.3. The bushings for 230KV and 110 KV shall be of the self contained,
hermetically sealed type, condenser bushings with a lower porcelain cap for enclosing
bushing oil, totally independent of the main tank oil for maintaining its insulation
strength and potential gradation. Re-entrant type bushings are not entertained.

22.1.4 Condenser type bushings shall be provided with


187
(i)oil level gauge
(ii)oil filling plug and drain valve if not hermetically sealed and
(iii) tap for capacitance/tan-delta measurement with appropriate marking.

22.1.5. Stress shield for the bushings shall be considered as an integral part of the
bushing- assembly.

22.1.6. All bushings shall be equipped with suitable terminals and terminal clamps of
approved type and size and all external current carrying contact surfaces shall be
adequately silver plated. Main terminals shall be solder less. Flexible connectors shall
be made from tinned copper sheets. Size of terminal/ conductor for which the clamp
is suitable and the rated current shall be embossed/ punched.

22.1.7. Clamps and flanges shall not be re-entrant shape, which may trap air.

22.1.8. Each bushing shall be co-ordinated with the insulation class of the winding.

22.1.9. All porcelain, used in bushings, shall be homogeneous and free from cavities
or other flaws. The glazing shall be uniform in colour and free from blisters, burrs and
other defects. The glaze shall be brown.

22.1.10. Bushing-turrets shall be provided with vent pipes which shall be connected
to route the gas collection if any, through the Buchholtz relay. The bushings shall be
removable without disturbing the current transformers.

22.1.11. Specific requirements of bushings and their ratings etc. are given in the
Annexure - I.

22.2.TERMINAL CONNECTORS

i) Bushing terminals on HV and IV sides, shall be out door type provided with
clamping arrangement and suitable bi-metallic sleeves to receive 3" Aluminium bus
bar.
ii) Bushing terminals on LV side shall be provided with clamping arrangement and
suitable bimetallic sleeves to receive KUNDAH conductor. The clamp shall be such
that the conductor takes off from the bushings vertically.

iii) The connectors shall be designed for minimum 120% of the maximum current
carrying capacity of the conductor and the temperature rise under any condition shall
not be more than 50% of that in the main conductor.

iv) All the terminal connectors shall conform to IS:5561 of latest issue.


188
v) All castings shall be free from blow holes, surface blisters, cracks and cavities. All
sharp edges and corners shall be blurred and rounded off.

vi) All ferrous parts shall be hot dip galvanised conforming to IS:2633.For bimetallic
clamps copper alloy liner of minimum 2 mm thickness shall be cast integral with
aluminium body.

vii) Size of the terminal/conductor for which the clamp/connector is suitable shall be
embossed/punched on each clamp/connector.

viii) Neutral bushing terminal shall be suitable to receive 2 Nos. 50 x 10 mm G.I flats
placed side by side on insulators up to ground level. Necessary outdoor type porcelain
insulators, GI flats and bi-metallic sleeves shall also be supplied.

23.0. BUSHING CURRENT TRANSFORMERS

23.1 Bushing current transformers of required ratio PS class may be provided in the
bushing turrets of HV, IV, LV and neutral ends of each phase for restricted earth fault
protection. The requirement of the bushing current transformers shall be as per
ANNEXURE I

23.2. The current transformers shall be of low resistance type, complying with I.S
2705, Part-IV of latest issue. The current transformers on HV, IV and LV sides shall
have matching characteristics to the extent feasible to have differential protection
scheme more effective. The bushing current transformers shall be housed in separate
turrets and shall not be an in-built unit of the transformer. The housing of current
transformers shall be so arranged that bushing can be removed, without disturbing
the current transformers. The magnetization characteristic curves, indicating the knee
point voltage, excitation current and secondary resistance shall be furnished.

23.3. It shall be possible to remove the current transformers from the tank without
removing the tank cover. Necessary precautions shall be taken to minimise the eddy
currents and local heat generation in the turret.

23.4. All secondary leads shall be brought into a terminal box near each bushing.
The terminals shall be wired up to marshalling box , using separate cables for each
core.

24.0.VOLTAGE CONTROL EQUIPMENT ( ON LOAD TAP CHANGER)

24.1 The transformer shall be provided with reputed make voltage control equipment
of the on-load tap changing type for varying its specified effective transformation ratio
as furnished in Annexure-I SL.NO.15, without producing phase displacement and
suitable for remote control operation from switch board in the control room, in addition to

189
being capable of local-manual as well as local-electrical operation. The design,
manufacture and performance of the OLTC shall comply with the CBIP regulations,
other statutes and safety codes and IS 8468 of latest issue. The transformer supplier
shall ensure the above.

24.2. a) On Load Tap Changer shall be sourced from reputed manufacturer and it
should be type tested as per relevant IEC 60214 and test methods shall be in full
conformance to the procedures indicated in IEC 60214.

b) The on-load tap changer shall include the following:
a) An oil immersed divertor switch of transition resistor type.
b) Motor driven mechanism for local as well as remote operation.
c) Control and protective devices.
d) Remote Tap Changer control panel.
e) Annunciation schemes.
f) Local - manual operating device.

24.3. The tap changing switches and mechanism shall be mounted in oil tanks or
compartments mounted in an accessible position on the transformer tank. It shall not
be possible for the oil in the divertor switch to mix with oil in the transformer tank. The
OLTC oil shall be of the same EHV grade oil as used for the main transformer or of
higher quality insulating oil and low viscosity is preferred. The oil in the OLTC
compartment shall be maintained under conservator head by means of a pipe
connection from the highest point of the chamber to the OLTC conservator. This
connection shall be controlled by a suitable valve, and shall be arranged so that any
gas leaving the chamber will pass into the gas and oil actuated relay. This surge
relay shall be of reputed make.

24.4. The OLTC chamber shall have oil filling valve, air release plug, pressure relief
device, tap position indicator, oil sampling valve and provision for circulation of oil in
the OLTC compartment and equalization of OLTC compartment and main tank during
application of vacuum. Necessary pipes, valves, blanking plates etc for the above
purpose shall form part of the accessories.

24.5. The tap changer shall be so mounted that top cover of the transformer can be
lifted without removing the connections between the windings and the tap changer.

24.6. It is preferable that the contact be accessible for inspection without lowering oil
level in the main tank and the contact tips shall be replaceable. Special tools and
tackles if any, required for maintenance of OLTC gear shall be supplied.

24.7. The divertor switch or arcing switch shall be designed so as to ensure that its
operation once commenced shall be completed independent of the operation of the
control relays or switches, failure of auxiliary supply etc. OLTC shall have a

190
mechanical fuse incorporated in the design to ensure the protection of diverter switch in
the event of an undue mechanical stress on the Tap changer.
24.8. Drive mechanism chamber shall be mounted on to the transformer tank, in an
accessible position. It shall be adequately ventilated and provided with anti-
condensation metal clad heater. All contactors, relay coils or other parts shall be
protected against corrosion or deterioration due to condensation, fungi, etc.

i) The Tap selector contacts shall not be of the threaded type to ensure positive, full
face and firm contact from Transformer leads to tap changer.

ii) No continuity break shall be allowed during changeover between any two taps. The
OLTC shall be tested for the same by ensuing that there is no open circuit showing
while changing two taps.

iii) OLTC design should have been seismic tested and qualified.

iv) OLTC manufacturer shall conduct the following routine tests fully in compliance with
IEC 60214 on every unit, as given below, before despatch to assure the quality of the
products.

S. No. IEC Reference Test Description
1. Cl.5.3.1 - Mechanical Test
2. Cl.5.3.2 - Sequence Test
3. Cl.5.3.3 - Auxiliary circuits Insulation Tests
4. Cl.5.3.4 - Pressure Test
5. Cl.5.3.4 - Vacuum Test

All the relevant test reports shall be submitted along with the test report of transformer
for approval.

v) The Tap Changer shall be suitably protected through Oil Surge Relay. This surge
relay shall be tested for an Oil flow velocity of 1.20+/- 0.20 m/s.

24.9. The whole of the drive mechanism shall be of robust design and capable of
giving satisfactory service and shall not require frequent maintenance under the
operating conditions met with, in service.

24.10. A permanently legible lubrication chart shall be fitted within the driving
mechanism chamber.

24.11. The OLTC driving mechanism and its associated control equipment shall
be mounted in an outdoor, weather-proof and vermin proof housing which shall
include


191
a) Driving motor, operating on 3-phase 415V, 50HZ AC supply.

b) Remote/local electrical and local manual selector switch. It shall
control in the following manner.
i) When the selector switch is in LOCAL position, it shall be possible
to operate the RAISE/LOWER control switches. Remote control
of RAISE/LOWER functions shall be prevented.
ii) When the selector switch is in REMOTE, the RAISE/LOWER
switches in the local control cubicle shall become inoperative. Remote
control of the RAISE, LOWER functions shall be possible from the
remote control panel. The local REMOTE selector switch shall have
at least two spare contacts per position which are closed in that
position.

c) Motor starting contactor with thermal overload relay, isolating switch
and MCB to protect the motor from overloading. All relays, switches,
MCBs etc shall be mounted in the drive mechanism chamber and shall
be clearly marked for the purpose of identification.

d) Limit switch, to prevent motor over-travel in either direction.

e) Counter (digital type), to indicate the number of operations
completed.

f) Electrically interlocked reversing contactors.

g) Space heaters with switches.

h) Master/follower selector switch.

i) Cable termination glands for power and control cables.

j) Interior lighting with door switch.

k) Auxiliary relays.

l) Mechanical tap- position indicator.

m) Manual operating device. This cranking device for manual operation shall
be removable and suitable for operation by man at ground level. It shall
have mechanical stops to prevent over cranking of the mechanism beyond
the extreme tap positions. The mechanism shall have interlock with the
motor to block motor-start-up during manual operation.


192
n) Necessary lamp indications and annunciation schemes of various
operations of OLTC gear from RTCC panel.

o) RAISE-LOWER CONTROL SWITCH shall be spring loaded to return to
the centre OFF position and shall require movement to the RIGHT, to
raise the voltage of the transformer. Movement to LEFT shall lower the
voltage of the transformer. This switch shall be operative only when the
LOCAL/REMOTE SELECTOR switch is in LOCAL position.

24.12. 0. Tap changer control requirements :

1) It shall not be possible for any two controls (ie. MANUAL, LOCAL
ELECTRICAL, REMOTE) to be in operation at the same time.

2) It shall be capable of permitting parallel operation with transformers of the
same ratio, say maximum four units.

3) Suitable selector switch shall be provided, so that , any one transformer
of the group can at a time be selected as 'Master' 'Follower' or independent.

4) An out-of-step device with timer contacts shall be provided , which shall be
arranged to prevent further tap-changing when transformers in a group ,
operating in 'Parallel control' ,are one tap out-of-step.

5) The equipment shall be suitable for supervisory control and indication with a
"Make before Break" multi-way switch, having one potential free contact for
each tap position. This switch shall be provided in addition to any other
switch/switches which may be required for the purpose of remote tap position
indication. All other components of the supervisory gear, if required, shall be
provided separately.

6) Operation from the local or remote control switch shall cause one tap
movement only, until the control switch is returned to the 'off' position
between successive operations.

7) All electrical control switches and the local operating gear shall be clearly
labeled in a suitable manner to indicate the direction of tap-changing.

8) Limit switches to prevent motor 'over-travel' in either direction may be
located in the control circuit of the operating motor, provided with a
mechanical declutching mechanism.

9) Necessary interlock, blocking the independent controls when the units are in
parallel, shall be provided.

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10) A time delay relay for INCOMPLETE STEP alarm, consisting of a normally
open contact, which closes, if the tap changer fails to make a complete tap
change. The alarm shall not operate momentarily for loss of auxiliary supply.

25.0.COOLING EQUIPMENTS

25.1.COOLER:

25.1.1. The cooler shall be supplied with the requisite number of radiators. The wall
thickness of radiator shall be not less than 1.2 mm.

25.1.2. Each radiator bank shall have its own cooling fans, oil pumps, oil flow
indicators, shutoff valve, lifting lugs, air release plug, a drain valve and thermometer
pockets fitted with captive screw cap on the inlet and outlet.

25.1.3. Each radiator shall be designed to withstand the pressure test. When
assembled, they shall be accessible for cleaning and painting. Each radiator unit shall
be provided with the following:

(a) An 100 mm shut-off valve at each point of connection to the
header/ transformer tank
(b) Removable blanking plates to permit blanking-off the oil connection
(c) A drain valve of size 25mm at the lowest point
(d) Air release plug of 15 mm dia. at the highest point
(e) Lifting lugs

25.1.4 The clearance between all pipe work and live parts shall be more than the
clearance for live parts to earth.

25.1.5 The radiator bank shall be designed for same pressure and vacuum conditions
as specified for main tank.

25.2.0. Oil piping and flanges

25.2.1. Necessary oil piping shall be provided for connecting each transformer to the coolers
and oil pumps. The oil piping shall be with flanged gasketed joints. Cast iron pipes shall not
be used.

25.2.2. A suitable expansion piece shall be provided, in each oil pipe connection of the oil
pump, for easy removal of the pump assembly.

25.2.3. Drain valves/plugs shall be provided in order that each sections of pipe work can be
drained independently. Drain valves shall be provided with blanking plates.

194

25.2.4. The drilling of all pipe flanges shall comply with IS:3639.

25.3.0. Oil pumps

25.3.1. Each forced oil cooler shall be provided with two 100%, motor driven, oil pumps of
the on-line type and of adequate capacity, out of which, one will be connected standby.
The oil pump shall be of impeller type to permit oil circulation when the pump is idle.

25.3.2. It shall be possible to remove the pump and motor from the oil circuit without having to
lower the level of oil in the transformers or coolers and without having to disturb the pump
foundation fixing. Oil pump shall be capable of dealing with the maximum output of
transformer and total head which may occur in service and with the varying head due to
changes in the viscosity of the oil.

25.3.3. Each pump assembly shall be provided with an oil flow indicator with alarm contacts
to indicate normal pump operation and oil flow.

25.3.4. Measures shall be taken to prevent mal-operation of Buchholz relay when all oil pumps
are simultaneously put into service. Suitable baffles shall be provided inside the tank at oil inlet
points when forced oil circulation is used.

25.3.5. The suction pipe of the cooler bank shall be suitably arranged to prevent the gas
generated inside the Transformer getting sucked into the cooler bank.

25.4.0. Air blowers/fans

25.4.1. Adequate number of air blowers/fans, for use with oil coolers shall be provided.
They shall be suitable for continuous outdoor operation; Two numbers connected -
standby air-blowers, one in each cooler bank, shall also be provided additionally.

25.4.2. Air blowers/fans shall be capable of withstanding the stresses, imposed
when brought up to speed by the direct application of full line voltage to the motor.

25.4.3. Air blowers/fans shall be complete with all necessary air-ducting and coolers
shall be designed so that they operate with a minimum of noise or drumming. They
shall not be mounted-on to the radiators and must be physically separate from the
radiators. It shall be possible to remove the blower complete with motor, without
disturbing or dismantling the cooler structure frame work.

25.4.4. If fans are mounted at a height less than 2.5m, suitably painted wire-mesh
guards with a mesh, not greater than 25 mm, shall be provided to prevent accidental
contact with the blades. Fans mounted at more than 2.5 m, height, shall be provided

195
with outside guards against birdage. Fans shall be so mounted that hot air shall not
get directed towards the transformer.


25.5.0. Motors

25.5.1. Motors shall be of the squirrel cage, totally enclosed, weather proof type and
shall comply with IS:325. The motors shall be capable of operating at all loads without
undue vibration and with a minimum noise. They shall be suitable for direct starting and
for continuous running from 415-440 volts, three phase, 4 wire, 50 Hz supply.

25.5.2. Motors shall also be capable of continuous operation at 85 percent of the
nominal voltage, at normal frequency, without injurious overheating. Motors shall be
provided with thermal overload and short circuit protection.


25.6.0. Local cooler control cubicle:

25.6.1. Each transformer shall be supplied with outdoor type, vermin and weather proof
local cooler control cubicle for accommodating the control gears of the cooling fans and
pumps, besides cable termination from remote tap changer control panel and other
transformer accessories.

25.6.2. The cooler control cubicle shall be provided with three pole, electrically
operated, contactor and with control gears of suitable design, both for starting and
stopping the individual oil pumps and groups of cooling fans, manually and also
automatically, from the contacts of the Winding Temperature Indicating device. These
shall be accommodated in the local cooler control cubicle.

25.6.3. The local control panel shall have all necessary devices meant for cooler
control viz.

(a) MCBs of adequate capacity for main supply.
(b) Protection against over load
(c) Protection against single phasing
(d)Selector switch for Manual/Automatic operation of individual pump
&groups of cooling fans.
(e) Selector switch for Local/Remote operation of individual pumps and
groups of cooling fans.
(f) Pump control ON/OFF/Test for each pump. (for applicable capacity)
(g) Fan control ON/OFF/Test for each fan.

25.6.4. The following additional terminals shall be provided in the cooler control cubicle
for remote indication.

196
a) Oil flow fail alarm.
b) Cooling fan trip(for each group of fans & standby)
c) Cooler pump trip (for each pumps in service & standby)
d) Cooler supply failure.
e) Low oil level alarm.
25.6.5. The following initiating contacts for lamp indicators shall be provided for local
as well as remote indication
(a) Cooling system is on 'Manual' control
(b) Cooling system is on 'Automatic control'.
(c) Selector switch is in 'Auto' or 'Manual'or 'Local'
(d) Pump 'ON', pump 'OFF' for each pump
(e) Fan 'ON' / 'OFF' for each group each group of fan and each pump.
(f) Oil flow failure.


26.0. GAS AND OIL ACTUATED RELAYS (BUCHHOLZ RELAY)

26.1. Double float gas detector relay (Buchholz relay) conforming to IS 3637 shall
be provided with the following:

a) Two electrically independent ungrounded contacts to cause an alarm and
tripping in the event of accumulation of gas and sudden changes in oil
pressure.

b) Shut off valve of 80mm on either side of the relay and flange coupling, to
permit easy removal , without lowering oil level in the main tank.

c) A drain plug at the bottom most point of the relay-casing.

d) A test cock suitable for a flexible pipe connection for checking its
operation and taking gas sample

e) A copper or stainless steel tube shall be connected from the gas collector
to a valve located at about 1200 mm above ground level to facilitate sampling,
with the transformer in service

f) Locking arrangement during transport.

26.2. The arrangement for mounting this relay, the associated pipe work shall be
such that all gas emitted from the transformer shall pass into the relay and mal-
operation of the relays shall not take place under normal service conditions.

27.0.TEMPERATURE INDICATORS/CONTROLLERS


197
27.1. Oil temperature indicator (OTI)

The transformer shall be provided with one 150 mm dial type, oil-temperature
indicator for indicating top oil temperature. The indicator shall have adjustable,
electrically independent ungrounded alarm & trip contacts with mercury switches, and
maximum reading pointer. The temperature sensing element shall be suitably located
in a pocket on the top of the transformer and shall be connected to the oil temperature
indicator by means of capillary tubing protected with a metal sheath. The accuracy
class of the OTI shall be 1.00 %.

27.2. Winding temperature indicator (WTI)

The transformer shall also be provided with a device for indicating the Spot
temperature of each winding (HV, IV & LV). It shall comprise the following:

a) Temperature sensing element suitably located on the top cover of the transformer
b) Image coil
c) Auxiliary CTs, if required to match the image coil, shall be mounted in the cooler
control cabinet.
d) 150 mm dial, local indicating instrument with maximum reading pointer, mounted in
the cooler control cabinet and two adjustable electrically independent, ungrounded
contacts with mercury switches (besides that required for control of cooling
equipment). The tripping contacts shall be adjustable to close between 60
o
C and
120
o
C and alarm contacts to close between 50
o
C and 100
o
C and both shall re-
open when the temperature has fallen by a desired amount between 5
o
C and 20
C. All contacts shall be adjustable on a scale. They shall be accessible on removal
of the cover and it shall be possible to check the operation of the contacts and
associated equipments. Connections from the contacts shall be brought down to
the terminal BLOCK , placed inside the marshalling Box. The accuracy class of the
WTI shall be 1.00 %.

e) Calibration device

28.0. MARSHALLING BOX

Tank mounted, vermin and weather proof marshalling box, shall be provided
with a controlled metal-clad heater to accommodate the following :

(a) Temperature indicators/controllers.

(b) Terminal blocks, made up of molded, non inflammable plastic material with
adequate size terminals, washers, binding screws/nuts for external wire
connections, a white marking strip for circuit identification and a molded plastic
cover.

198

(c) Suitable glands with gland plates for incoming and outgoing cables,
meant for oil level alarm, Temperature alarm/Trip, Buchholtz alarm/trip,
annunciation and indication provisions for RTCC panel etc.


29.0. AUXILIARY POWER SUPPLY CONTROL PANEL FOR OLTC AND COOLER
CONTROL

29.1. Auxiliary power supply shall be provided by the purchaser at one place for
OLTC control and cooler control.

29.2. Control cabinet for OLTC control and cooler control shall be of free standing,
floor mounting type.

29.3. Control cabinet can be made out of 3mm thick sheet steel or 10mm thick
aluminium plate / Aluminium casting. Hinged door shall be provided with padlocking
arrangement. Sloping Rain-hood shall be provided to cover all sides. 15mm thick
Neoprine or better type of gaskets shall be provided to ensure high degree of protection
as per IS2147. The painting shall be as specified earlier.

29.4. Auxiliary electrical equipments to be supplied by the tenderer shall be suitable
for operation on the following supply system :


a.

Power devices like drive motors rating
1 KW and above
415V, 3 phase 4 wire 50 Hz, neutral
grounded AC supply
b. Lighting, space heaters and fractional
KW motors
240V, single phase, 50 Hz neutral
grounded AC supply
c. Alarm, control and protective devices 220V, 2 wire DC supply

29.5. All AC loads shall be fed by one of the two feeders through an electrically
interlocked automatic transfer switch housed in any one of the local control cabinets.
Design features of the transfer-switch shall include the following:

a) Selection of one of the feeders as normal source and other as stand by
b) Upon failure of normal source, automatic transfer of loads from normal
source to the standby source after an adjustable time delay
c) Indication for failure of normal source and for transfer to standby
Source and also for failure to transfer shall be provided locally and as well as
in the remote tap changer control panel.
d) Automatic retransfer to normal source with an adjusted time delay,
following re-energisation of the normal sources.

199
e) The transfer and re-transfer shall not cause paralleling of the two sources
at any time.

29.6. Necessary Isolating-switches, MCBs and other components for the above power
supply transfer arrangement shall be in the scope of the supply of the supplier.

29.7. Bus bars, if used , shall be tinned copper of adequate cross section to carry the
normal current without exceeding the permissible temperature rise over an ambient
temperature of 40
o
C.

29.8. Isolating-switches shall be group operated units (3/4 pole for use on 3 phase
supply system and 2 pole for single phase supply system), quick make and break type
capable of breaking the rated current of the associated circuit safely. Switch handle
shall have provision for locking in both fully opened and fully closed positions.

29.9. Push button shall be rated for not less than 6 Amps, 415 V, AC or 2 Amps,
220/110V DC and shall be flush mounted on the cabinet door and provided with
appropriate name plates. Red, Green and Amber indicating lamps shall be flush
mounted.

29.10 For motors up to 5 KW, contactors shall be direct-on-line, air break, single throw
type and shall be suitable for making and breaking the stalled current of the associated
motor which shall be assumed equal to 6.5 times the full load current of the motor at
0.2 p.f.

For motors above 5 KW, automatic star-delta type starters shall be provided. 3
pole contactors shall be furnished for 3 phase motors and 2 pole contactors for single
phase motors. Reversing contactors shall be provided with electrical interlocks between
forward and reverse contactors. If possible, mechanical interlocks shall also be
provided. Contactors shall be suitable for uninterrupted duty and shall be of duty
category class AC4 as defined in IS:2959. The main contacts of the contactors shall be
silver plated and the insulation class for the coils shall be class E or better. The dropout
voltage of the contactors shall not exceed 70% of the rated voltage.

Contactors shall be provided with a three element, positive acting, ambient
temperature compensated, time lagged, hand reset type thermal overload relay with
adjustable setting, hand reset button shall be flush with the front door of the cabinet and
suitable for resetting with starter compartment door closed.

29.11. Single phasing preventer relay shall be provided for 3 phase motors to provide
positive protection against single phasing.

29.12. Mini starters shall be provided with No-volt coils whenever required.


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29.13. Purchaser's power cable will be 1100/650V grade stranded aluminium
conductor, PVC insulated, PVC sheathed, steel wire armoured and PVC jacketed cable.
All cable terminating accessories such as brass cable glands, lugs etc. shall be
included in the scope of supply.

29.14. Separate Terminal-Blocks shall be provided for circuits of various voltage
classes.

29.15. The terminal blocks shall be 1100V grade and have 10 Amps continuous rating.
They shall be fully enclosed with removable slip-on/clip-on covers and made of molded
non-inflammable plastic material with block and barrier molded integrally. Such blocks
shall have non-disconnecting stud type terminals, washers, nuts and lock nuts. All
terminals shall be clearly marked with identification numbers or letters to facilitate
connection to external wiring. No live metal shall be exposed at the back of the terminal
blocks.

29.16. In all terminal blocks at least 20% spare terminals shall be provided uniformly.

29.17 The terminal blocks meant for control circuits shall be suitable for connecting
minimum of 2 numbers of 2.5 sq.mm. Copper cable. Terminals meant for CT circuits
shall be capable of accommodating at least 2 numbers of 4 sq.mm. copper cable.

29.18. The terminal boards shall be mounted obliquely towards the rear doors to be
easily accessed to termination and to enable ferrule numbers to be read without
difficulty. The terminal boards shall be placed at least above a distance of 250mm from
the cable gland so as to permit satisfactory arrangement of multi core cable tiles.

29.19. Terminal board rows should be spaced not less than 150mm apart to permit
convenient access to wires and terminations.

29.20. Control cabinet shall be provided with a 230V incandescent lamp operated by a
door switch.

29.21. The cabinet shall be provided with a 240V, single phase ,5 amps, 3 pin socket
for hand lamp.

29.22. Space heaters shall be provided inside the cabinet with thermostat (preferably
PTC type) to prevent moisture condensation. The heaters shall be controlled by
suitably rated double pole miniature circuit breakers.

29.23. Signal lamps provided shall be of neon, screw type, with wire & resistors
enclosed in bakelite body. Each signal lamp shall be provided with a fuse integrally
mounted in the lamp body. If separate fuse units are used they shall be of the cartridge
type. Fuses shall be labeled.

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29.24. Electric measuring instruments shall be of moving iron type. Ammeters for
measuring currents upto 30 amps shall be directly connected while those for measuring
above 30 amps shall be connected through suitable CT's. Ammeter and Voltmeters
shall be provided with selector switches.

30.0. REMOTE TAP-CHANGER CONTROL PANEL

The Remote In-door Tap Changer control cubicle of height 2312 mm with
sufficient inner working space for easy access to the instruments, wherever
necessary, shall house the following:

30.1. Controls :

a) Repeater dial of winding temperature indicator with selector switches.
b) Push button switch to Raise/Lower the tap.
c) Tap position indicator (digital type).
d) Selector switch for Local/Remote operation.
e) Four position Selector switch for Independent/OFF/Master/Follower.
f) Emergency 'supply - off ' push button.
g) Relays, Heater, illumination lamps,MCBs etc.
h) Control selector switch for th fans of the cooler

30.2. LAMP INDICATIONS for the following (ON: Red indication; OFF: Green indication)
a) Cooling pump ON/OFF (Group)
b) Cooling fans ON/OFF (Group).
c) OLTC supply HEALTHY.
d) Cooler control on AUTOMATIC/MANUAL.
e) Tap change IN-PROGRESS.
f) Selector switch on `AUTO' or `MANUAL' or `LOCAL' for each fan groups.

30.3. Facia type annunciation scheme for the following trip, non-trip & alarm
INDICATIONS, suitable for 220V/110V DC operation.

a) Bucholtz Relay - trip
b) Tap Changer Surge Relay - trip
c) Pressure Relief Device -trip
d) Winding Temperature Indicator - Trip
e) Tap Changer Drive Motor trip
f) Cooling Fan trip (For each group of fans & standby)
g) Cooling Pump trip (For pumps in service & standby)
h) Bucholtz Relay - alarm
i) Winding Temperature Indicator - alarm
j) Oil Temperature Indicator - alarm

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k) Tap Changer Out of Step - alarm
l) Oil flow fail alarm
m) Low oil level - alarm
n) Cooler supply failure indication.
o) Tap change delay - indication
p) Air Cell Puncture indication
q) Spare contactors-4Nos.

31.0. ON-LINE CONTINUOUS CONDITION MONITORING SYSTEM

Parameters to be monitored : (1) DGA (Complete fault gases)
(2) Moisture content of oil.
(3) C and Tan of Bushings.
(4) Oil and Winding Temperature.

No. of devices required : 3 (one for DGA + Moisture , one for Capacitance &
Tan Delta of Bushings, one for oil and winding
temperature).

Specification applicable commonly to all the devices :

(1) Environmental Requirements : The device and its components are for outdoor
application and should satisfy the following:


Ambient Temperature : 10
o
C to + 50
o
C
Humidity : upto 95%


The devices shall be weather proof. The devices shall be of outdoor type and
should withstand all weather conditions like ambient temperatures upto 50
o
C, rain and
other adverse weather conditions. The materials should be corrosion proof and
complying with required IP class.

(2) Accessories : The system shall incorporate all essential accessories and spares
that are required for proper functioning.

(3) Calibration : The factory and site calibration details shall be stated.

(4) Test Certificate : The test certificates in triplicate for the materials furnishing the
results of the tests shall be forwarded and got approved before the materials are
despatched. In addition to the tests called for in the specification, the purchaser
reserves the right of having such tests as he desires carried out at his own expense to

203
satisfy himself that the materials conform to the requirement of this specification. The
materials may be rejected if the test results are not satisfactory.

(5) Power Supply to system : 240 V 50 Hz Ac.

(6) The system shall comply with all other standard requirements.

(7) The sensitivity and accuracy of the system should be demonstrated with appropriate
reference standards during the installation and later as per requirements.

(8) The system should be protected against over voltage, surges and all other likely
abnormal conditions.

(9) The instrument should give necessary alert messages, which should contain
historical and detailed information.

(10) The installation of the devices should be straight forward requiring no special
tooling or training.

(11) The System / Instrumentation should be easy to configure.

(12) The system should posses a control panel for user interface that could display
alerts. Also access to P.C. Through RS232 port/ other interfaces should be made
available. The necessary data / parameter should be displayed at the device and
means must be provided for displaying these parameter at the control room which may
be at a distance of 500m from the Transformer by cables/ fibre optics.

(13) The system should have the following communication modes.

(i) Local Access : Serial port for connection to a PC for the purpose of
configuration and data retrieval.

(ii) Remote Communication : The following remote communication options
should be available. RS232 : The data should be remotely accessible
via RS232 port using ASCII protocol. Necessary protocol commands etc
should be made available in the user manual and demonstrated at the
time of commissioning.

Ethernet TCP/ IP
Supervisory Input/ Output
The supervisory Input/ Output should offer a SCADA interface for the system.




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In addition to the above, the following are the device specific specifications :

I. On-line Capacitance and Tan of Bushings:

To continuously monitor the HV (230KV, 3 Nos.) and IV (110 KV, 3 Nos.)
Bushings of the Auto Transformer with expert system capable of detecting abnormalities
in the Bushing insulation and issuing alerts locally and remotely.

The system shall monitor two sets of Bushings with 3 Bushings in each set
associated with the same apparatus. Devices are to be fitted physically at the
Bushings for display for the Capacitance and Tan Delta values at the device and at
control room.

The following minimum parameters pertaining to individual Bushing should
be accessed through the P.C.
(i) Power Factor/ Dissipation Factor
(ii) Capacitance.
(iii) Rate of change of the above values.
(iv) Leakage current through the test tap.

_ The calculation and display should be automatic and integral part of the
instrument and should be able to indicate measuring status (LED/Buzzer/Display).

The instrument should be able to identify the problems and issue alerts/warnings
on the following conditions.

i. Absolute change in Power/Dissipation factor.
ii. Rate of change in Power/ Dissipation factor.
iii. Absolute change in capacitance.
iv. Rate of change in capacitance.


II. On-line DGA and Moisture Monitoring System :
To measure, display and continuously monitor Dissolved water content and the
following gases: Methane, Ethane, Ehtylene, Acetylene, Hydrogen, Carbon Monoxide
and Carbon Dioxide in the Transformer oil.

Detection range : Hydrogen (10ppm to 5000 ppm)
Methane (10ppm to 5000 ppm)
Ethane (10ppm to 5000 ppm)
Ethylene (10ppm to 5000 ppm)

205
Acetylene (5ppm to 5000 ppm)
Carbon Monoxide (50ppm to 1000ppm)
Carbone Dioxide (50ppm to 10000ppm)
Accuracy : High accuracy required.
Repeatability : Very good repeatability required.
Note : Any better range other than specified above is also preferred.

Dissolved water (H
2
O) in oil measurement:
Detection range : 5 ppm or less to saturation ; 2 or less to
100% RS.
Accuracy : High accuracy required.
Repeatability : Very good repeatability required.
Resolution : 1 ppm, 1% for RS or better.

III. Online Oil and winding temperature Monitoring system: To display accurately
the Top oil and winding temperature of the Auto Transformer.

The temperature measuring device should be based on digital technology and
the temperatures should be displayed at the Transformer and means to be provided for
display of the temperature at the control room. Reputed make is preferred.

The Transformer manufacturer should ensure that Online parameters from the
Online devices should be displayed at the Transformer Local Panel and at the control
room and also remotely through a web enabled system.

Necessary Remote access ports (RS232) with ASCII protocol to be provided
along with protocol commands in the user manual. All specified requirements,
calibration etc. normally required for Auto Transformer oil and winding temperature
gauges to be complied with.

IV. NOTE:

1. The online devices (Capacitance and Tan Delta, DGA, moisture system) supplied
alongwith the Transformer should have been already satisfactorily demonstrated

206
to R&D / TANGEDCO and approved ones should be procured and supplied by
the Transformer manufacturer.

2. Supplier shall guarantee the performance requirement for a period of not less
than 3 years for the above system.

3. Alert from the online devices should be wired to the control room in addition to
the display of parameters.

32.0 FITTINGS AND ACCESSORIES

The fittings and accessories, mentioned in this specification, are only indicative
and any other fittings which are generally required for satisfactory operation of the
transformer are deemed to be included.

33.0. CENTRE OF GRAVITY

The centre of gravity of the assembled transformer shall be low and as near the
vertical centre line as possible. The transformer shall be stable with or without oil. If
the centre of Gravity is eccentric, relative to track either with or without oil, its location
shall be shown in the "Outline" drawing.

34.0.CONTROL WIRING, TERMINAL BOARDS, FUSES ETC.

34.1. All wiring connections, terminal boards, fuses and links shall be suitable for
tropical atmosphere. Any wiring liable to be in contact with oil shall have oil resisting
insulation and the Board ends of stranded wire shall be sweated together to
prevent creepage of oil along the wire.

34.2. There shall be no possibility of oil entering into the connection boxes, used for
cables or wiring.

34.3. Panel connections shall be neatly and squarely fixed to the panel. All instruments
and panel wiring shall be run in PVC or non-rusting metal cleats of the limited
compression type. All wiring to a panel shall be taken from suitable terminal boards.

34.4. Where conduits are used, the runs shall be laid with suitable falls, and the
lowest parts of the run shall be external to the boxes. All conduit runs shall be
adequately drained and ventilated. Conduits shall not be run at or below ground level.

34.5. When 415 Volt connections are taken through junction boxes or marshalling
boxes they shall be adequately screened and "415 volts Danger" notices must be
affixed to the outside of the junction boxes or marshalling boxes.


207
34.6. All box wiring shall be in accordance with relevant IS. All wiring shall be of
stranded copper of 1100 grade and size not less than 4.00 sq.mm. for CT leads and
not less than 2.5 sq.mm. for other connections.

34.7. All wires on panels and all multicore cables shall have ferrules which bear the
same number at both ends.

34.8. At those points of interconnection between the wiring carried out by
separate contractors, where a change of number cannot be avoided, double ferrule
shall be shown on the appropriate diagram of the equipment.

34.9. The same ferrule numbers shall not be used on wires in different circuits on
the same panels.

34.10. Ferrule shall be of yellow insulating material and shall be provided with glossy
finish to prevent the adhesion of dirt. They shall be clearly and durably marked in black
and shall not be affected by damp or oil.

34.11. Stranded wires shall be terminated with tinned Ross countney terminals, claw
washers or crimped tubular lugs. Separate washers shall be used for each wire.
The size of the washers shall be suitable to the size of the wire terminated. Wiring
shall, in general, be accommodated on the sides of the box and the wires for each
circuit shall be separately grouped. Back of panel wiring shall be arranged so that
access to the connecting stems of relays and other apparatus is not impeded.

34.12. Wires shall not be jointed or tied between terminal points.

34.13. Wherever practicable, all circuits in which the voltage exceeds 125 Volts,
shall be kept physically separated from the remaining wiring. The function of each
circuit shall be marked on the associated terminal boards.

34.14. Where apparatus is mounted on panels, all metal cases shall be separately
earthed by means of copper wire or strip having a cross section of not less than 2.0
sq.mm. where strip is used, the joint shall be sweated.

34.15. All wiring diagram for control and relay panel shall preferably be drawn as
viewed from the back and shall show the terminal boards arranged as in service. All
diagrams shall show, which view is employed.

34.16. Multicore cable tails shall be so bound that each wire may be traced without
difficulty to its cable.


208
34.17. The screens or screen pairs of multicore cable shall be earthed at one end
of the cable only. The position of earthing connections shall be shown clearly on the
diagrams.

34.18. All terminal boards shall be mounted obliquely towards the rear doors to give
easy access to terminations and to enable ferrule numbers to be read without
difficulty.

34.19. Terminal board rows should be spaced adequately, not less than 100 mm
apart, to permit convenient access to wires and terminations.

34.20. Terminal boards shall be so placed with respect to the cable gland (at a
minimum distance of 200 mm), as to permit satisfactory arrangement of multicore
cable tails.

34.21. Terminal boards shall have pairs of terminals of incoming and outgoing wires.
Insulating barriers shall be provided between adjacent connections. The height of the
barriers and the spacing between terminals shall be such as to give adequate
protection while allowing easy access to terminals. The terminals shall be adequately
protected with insulating dust-proof covers.

34.22. No live metal shall be exposed at the back of the terminal boards.

34.23. All fuses shall be of the cartridge type.

34.24. Fuses and links shall be labeled.

35.0.QUALITY PLAN AND INSPECTION

35.1. The tenderer shall furnish the programme of manufacturing works well in
advance.

35.2. The purchaser or the accredited representative of the purchaser shall have
access to the contractor or sub-contractor's works at any time during working hours
for the purpose of inspection of manufacture and selection of samples of the materials
going into the equipment and testing. The contractor shall provide necessary facilities
for such inspection or test.

35.3. Documents like invoice or receipted chalans, detailing the source of supply of
raw materials and their specification, shall be shown by the supplier on demand either
during the manufacturing process or at the time of inspection of the transformer .

35.4. The core and coil assembly, shall be offered for inspection and to verify the
guaranteed technical parameters prior to connections and tanking. The readiness for

209
such inspection shall be intimated at least 15 days in advance. Further process of
manufacture of core and coil assembly, shall be taken up only after our approval in this
regard.

35.5. The transformers shall be completely assembled arrange for conducting all the
TYPE/SPECIAL/ROUTINE tests as per IS 2026 of latest issue at manufacturers work or
at the accredited laboratories, in the presence of purchaser or the accredited
representative of the purchaser. The readiness of the transformer with all its
accessories for testing/inspection shall be intimated at least 15 days in advance. The
transformer shall be despatched only after the approval of the test certificates by the
purchaser. .

36.0.TESTING

36.1. All the TYPE, ROUTINE & SPECIAL TESTS on the first unit and all the Routine
tests on the other units, as per IS 2026 of latest issue / IEC 60076 shall be carried out
at suppliers COST in the presence of purchaser or purchaser's representative.

36.2. The supplier shall ensure that the testing instruments and equipments used for
testing/measurements have calibration certificates issued by a recognised/standard
laboratory not earlier than one year from the date of testing.

36.3. The correction for the errors of measuring instruments / testing transformers and
resistance of test connections shall be applied, as specified in IEC before coming to
the conclusion on the test results.

36.4. One unit out of the ordered quantity will be selected at the discretion of
TANTRANSCO and it shall be tested for measuring No-load and load losses
concurrently at CPRI or any other Government Recognised High Voltage testing
laboratory as decided by TANTRANSCO. The arrangements towards testing shall be
made by the supplier and recouped from TANTRANSCO on actuals, if the losses are
proved to be within the guaranteed limits.
If the losses are found to be higher than the guaranteed values, necessary
compensation charges (for excess over losses) shall be levied as per the capitalization
formula furnished in the MANUAL on TRANSFORMER of the CBIP.

36.5 The Purchaser has the right to have the test carried out at his own cost by an
independent agency whenever there is a dispute regarding the quality of supply.

36.6 The Purchaser at its discretion may re-test the same Transformer or any
other Transformer (s) at a Govt. / or Govt. Recognized laboratory of his choice for
reconfirmation of the test results, particularly no load losses, load losses and

210
percentage impedance, which will be taken as the final and binding as per the clause
35.4 mentioned above.


37.0. Type/Special/Routine Tests :

37.1. i)The following Type /special tests as per IS 2026 of latest issue shall be
carried out on the first unit at Suppliers cost in the presence of TANTRANSCO
representative.

(a) Vacuum test on the transformer tank: The transformer tank shall be tested at
an internal pressure of 3.33 KN/sq.m. (25 torr) for one hour. The permanent
deflection of flat plates, after the vacuum has been released, shall not exceed
the values below and the performance of the transformer shall not be affected in
any way.

Horizontal length of Flat Plate
(mm).
Permanent deflection (
mm).
Upto and including 750 - 5
751- 1250 - 6.5
1251 to 1750 - 8.0
1751 to 2000 - 9.0
2001 to 2250 - 11.0
2251 to 2500 - 12.5
2501 to 3000 - 16.0
Above 3000 - 19.0

(b) Pressure test: The transformer tank shall be subjected to a pressure
corresponding to twice the normal head of oil or to normal pressure plus 35
KN/sq.m. whichever is lower. The applied pressure shall be measured at the
base of the tank and maintained for One hour. The equivalent air pressure
corresponding to oil pressure calculated at the base of the tank to be considered
for Air Pressure test. The permanent deflection of flat plates, after the
excess pressure has been released, shall not exceed the values specified
under the caption 'Vacuum test'.

(c) Temperature rise test at the lowest tap.

(d) Full wave lightning Impulse voltage withstand test on all three phases
including chopped impulses on principle tap and extreme taps.
(This test shall precede power frequency high voltage tests).

(e) Capacitance and Tan-delta measurement


211
(f) Zero sequence impedance test.

(g) Noise Level Test.

(h) Measurement of harmonic voltages

(i) Measurement of transformer oil required for first filling for entire
transformer including radiators, coolers, conservator etc.



37.2 STAGE & FINAL INSPECTION
The supplier shall offer the core, windings and tank of each transformer for
inspection by the purchasers representative(s). During stage Inspection, all the
measurements like diameter, window height, leg centre, stack width, stack thickness,
thickness of laminations etc. for core assembly, conductor size, Insulation thickness,
winding height, major and minor insulations for both H.V and L.V windings, length,
breadth, height and thickness of plates of Transformer tank, the quality of fittings and
accessories will be taken / determined. The supplier can offer for final inspection of the
transformers subject to clearance of the stage Inspection report by the purchaser.

37.3 ROUTINE TESTS

The following Routine tests as per IS 2026 of latest issue and special tests shall
also be carried out on all the transformers, at suppliers cost.

(a) Measurement of winding resistance on all taps.

(b) Measurement of voltage ratio on all taps and check of voltage vector relationship.

(c) Measurement of impedance voltage/short circuit impedance, load-loss & spill
current at principal and extreme taps. The test shall be repeated at 415 volts for
comparison during pre-commissioning tests at site.

(d) Measurement of No-load loss and current corresponding to normal & extreme taps
at 100%,90% and 110% of rated voltage.

(e) Measurement of insulation resistance.

(f) Dielectric Tests:
Power frequency withstand voltage test
Induced over voltage withstand test as per Clause 12.2.2 of IEC 60076-3 with PD
Measurement.


212
(g) Oil leakage test on transformer tank: The tank and oil filled compartments shall be
tested for oil tightness by completely filling with air/oil of viscosity not greater
than that of insulating oil, conforming to IS:335 1983/'87 at the ambient
temperature and applying a pressure, equal to the normal pressure plus 35
KN/sq.m. measured at the base of the tank. This pressure shall be maintained for a
period of not less than 12 Hours for oil and 1 Hour for air during which time no
leakage shall occur.

(h) Magnetic balance test.

(i) Measurement of No-load current with 415 Volts supply.

(j) Check of polarity and ratio, tests for knee point voltage, and magnetizing current for
Bushing current transformer.

(k) Tests on On- load tap changer ( fully assembled on transformer ) as per Clause
10.8 of IEC: 60076-1 as referred in Clause 5.3 of IEC:60214/2003.

(l) Measurement of neutral unbalance current.
(m) SFRA signature taken after completing all the routine test to be taken as base for
site measurement.

The test sequence shall be:- Tests on transformer tank, Heat run test, Oil leakage
test on the assembled transformer, Impulse test, Routine tests and Special tests.

37.4. FURTHER TESTS
i) The purchaser reserves the right of having other reasonable tests carried out
at his own expense either before transport or at site, to ensure that the transformer
complies with the requirements of our specification.
ii) It may also be noted that the purchaser reserves the right to conduct impulse
voltage withstand test in accordance with the IS, afresh on each ordered rating at
Purchasers cost even if the transformers of the same rating and similar design are
already tested. This test shall be carried out on a transformer either offered for
inspection or randomly from supply already made at site and under erection. The finding
and conclusion of these tests shall be binding on the supplier.

37.5. TEST CERTIFICATES
37.5.1. Six copies of the test certificates on the above type tests/ special tests/
routine tests with the endorsement of the inspecting officer shall be furnished to
the Superintending Engineer/400KV / 6th Floor, NPKRR Maaligai, 800, Anna salai,
Chennai -2.

37.5.2. The test report shall contain the following information.

213

i) Complete identification data, including serial No. of the transformer.
ii) Method of application where applied, duration, and interpretation of
results in each test.
iii) Details of Temperature rise corrected to 75
o
C .

37.5.3. The equipment will be rejected if test results are not in conformity with the
Guaranteed Technical particulars.

37.5.4. Besides the above test certificates, manufacturer's test certificates in respect of
the following accessories shall also be furnished in sixtuplicate.

a) Bushings (HV, IV, LV & Neutral).
b) Buchholtz relay and surge relay.
c) Magnetic oil level gauge.
d) Winding Temperature Indicator.
e) Oil Temperature Indicator.
f) Radiators.
g) Transformer oil(including Dissolved Gas Analysis tests)
h) OLTC

37.5.5. TYPE TEST FOR BOUGHT OUT COMPONENTS :

Tenderers are requested to furnish along with tender copy of type test certificates
for the bought out components in full shape as conforming to relevant IS/IEC standards
of latest issue obtained from a Government ./ Government Recognized Laboratory. The
above test certificates should accompany the drawings of the material/equipments, duly
signed under seal by the institution who have issued the type test certificate.

Otherwise the above type test certificates shall be furnished before the offer of
inspection for the first lot of materials/ equipments at no extra cost to Board and no
relaxation to Boards Delivery clause will be given on this accounts.

The above type test should have been conducted not earlier than five years (5
(Years) as on the date of tender opening. Non submission of above type test certificates
within the stipulated time will entail cancellation of Purchase Order without any further
reference to supplier.

The original type test certificate shall be furnished for verification on request. The
details of type test if already conducted should be furnished in the Section.-G.

37.5.6. The supplier shall also furnish test certificates to the effect that the withstand
capability of the insulation between the core and all core bolts , side plates &

214
structural frame has been tested with 2000 Volts AC for one minute after assembling
the core and prior to the despatch of the transformer .

37.6. TESTS AT SITE
After erection at site and prior to commissioning, the transformer shall be
subjected to the following tests by the Supplier in the presence of the purchaser.
(a) Insulation resistance test.
(b) Ratio and polarity test on all taps.
(c) All relevant tests on oil.
(d) Open circuit and short circuit test.
(e) Tests on the operation of OLTC.
(f) Tests on the protective devices and interlocks.
(g) Measurement of winding resistance at all taps.
(h) Vector group verification
(i) Capacitance and Tan-delta measurement on windings and bushings
(j) Dissolved gas analysis on transformer.(The test figures will form the base
values for comparison in future.).

38.0. DRAWING,TECHNICAL LITERATURE AND GUARANTEED TECHNICAL
PARTICULARS
38.1. (a) General out line drawing, showing front side elevations and plan views of
the transformer and all accessories and external features with detailed
dimensions, weights, crane lift for untanking and for erection/removal of
bushings, size of lifting lugs and pulling eyes, HV and LV terminal clearances,
live terminal to ground clearance, quantity of insulating oil, dimensional details
for foundation etc with list of fittings and accessories.
(b) Assembly drawings of HV, LV /cable box and Neutral bushings
(c) Mounting arrangement for cooling pipes, radiators, fans etc.
(d) Schematic control and wiring drawing and drawings showing
temperature indicator/recorder circuits, and control system for cooling
equipment.
(e) Drawing, showing construction and mounting details of marshalling
boxes.
(f) Drawing, giving details of name plate, terminal marking and connection
diagram.
(g) Drawing on OLTC gear assembly.
(h) Remote Tap Changer control panel.
(i) Remote Tap Changer control circuit.
(j) Drawing on Terminal Clamps.

The responsibility rests with the supplier in case of any corrections or
modification on scrutiny of the drawings.


215
38.2 Six complete sets of final drawings shall be supplied for the transformer,
sufficiently before the actual despatch of the equipment.

38.3. Six copies of all bulletins, complete instruction manuals for the erection,
operation and maintenance of the transformer are to be supplied, before they are
despatched.

38.4. Any approval given to the detailed drawings by the purchaser shall not relieve
the contractor of the responsibility for correctness of the design, completeness of the
equipment supplied and in the execution of the works in accordance with the terms of
specification.

39.0. REJECTION
39.1. The transformer may be rejected if any of the following conditions arise during the
tests or while in service.
(a) No load loss exceeds the guaranteed value.
(b) Load loss exceeds the guaranteed value.
(c) Percentage impedance values exceed by the guaranteed figure.
(d) Temperature rise of oil and or windings exceed the specified values.
(e) Transformer fails during impulse test.
(f) Transformer fails during power frequency voltage withstand test.
(g) If either of the test results conducted at factory and site (during pre-
commissioning test) are not satisfactory.
(h) Transformer has not been manufactured in accordance with the
specification and approved drawings.




















216
ERECTION

1.0 GENERAL:

1.1. Unless otherwise stated the work shall be carried out as per Section-K of CBIP
guidelines.

1.2. The following shall supplement the conditions already contained in the other
parts of these specifications and documents and shall govern that portion of the
work on this Contract to be performed at site.

1.3 The Contractor, shall nominate a responsible person as its representative at
site suitably designated for the purpose of overall responsibility and co-
ordination of the works to be performed at site.

2.0. SCOPE OF WORK

2.1. The scope of work shall be to make the transformer ready for testing and
commissioning and include the following

a) Placing of the transformer on the plinth and fixing of wheels and
carrying- out stop block welding including moving the transformer to
the plinth, where the transformer is supplied and unloaded near the
plinth.

b) The Contractor has to supply, lay, erect and weld M.S.Channel, Flat of
the 50x8 mm. sizes, including green painting and providing with
adequate bolts and nuts as applicable.

50x8 mm. Flat with suitable M.S.Channel for earthing with neutral
bushing at two different earth points of existing earth pit, Transformer
tank, Cooler fan and pumps. D.M.box RTCC panel & other accessories
body earthing with required standards.

(c) Erection of the following, wherever applicable:
(i) HV bushing with turrets
(ii) LV and neutral bushing with turrets.
(iii) Cable boxes
(iv) Bushing current transformers
(v) Conservators
(vi) Valves
(vii) Radiators
(viii) Fans/pumps
(ix) Buchholz relay

217
(x) Surge relay
(xi) Gaskets
(xii) Temperature indicators
(xiii) Others wherever stated
d) Erection of the Drive Mechanism Box, Marshalling at site with
equipment and RTCC Panel in the control room after removing the
existing panel, if any.

e) Filling of transformer oil in the transformer and OLTC under hot oil
circulation, vacuum drying wherever applicable/necessary to the
required level and circulation of oil till satisfactory results are obtained
before commissioning.

f) i) The Contractor scope of work shall include all the control cables
required for the successful commissioning of Auto/Power Transformers
including supply, laying, providing suitable glands ferrules, lugs,
termination etc., but not limited to the above mentioned for successful
commissioning of the transformer as per standard requirement.

1) Protection schemes of Auto/Power Transformer including differential
protection cable.
2) Indication/Annunciation scheme for cooler fan and pumps.
3) OLTC Remote operation
4) OLTC fan, pump D.M. power supply cable
5) DC cable from control room to Transformer
6) Scada scheme for Remote/Automation operation
7) CTs cable from CT secondaries to Marshalling Box and Marshalling
box to LV panel/RTCC panels
8) Any other control cable with required site for successful
commissioning of the transformer






9) Interconnection of cables for AC/DC panels to RTCC/LV panels


ii) All CT cables shall be 4 sq.mm. (minimum) and shall be copper,
armoured cables. The other cables that are to be provided shall be 2.5 sq.mm.
(minimum), copper multi-strand and armoured cables, separate cables for AC
and DC are to be used. The AC supply cables shall be sufficient to cater the
load of pumps, fans and the load of pumps, fans and the loads of transformer
for the AC panel around in the transformer end.

i) Additional adequate quantity of cable length shall be provided at
the Transformer end and at the RTCC/LV panels ends in case of shifting of
panels/ Transformers. All the cables shall be laid end to end without any
joints and it should be ensured that the cables so provided shall comply with

218
TNEB control cable specification and should be strictly adhered all the
control cables shall be neatly laid /buried in control cable duct/trench by
suitable dressing.

ii) However any additional work and in the schedule of cables shall
be discussed with the site Engineers/ TNEB Engineers before laying of
cables and necessary approval shall be obtained before connection to the
panels/ Transformer ends.
g) Painting as required will be carried out so as to maintain the finish of the
surface of the transformer and accessories prior to the erection of the same at
site.

h) Required assistance for testing and commissioning

Any other works not covered in items(a) to (h) but required for
satisfactory commissioning of the power transformer shall also to be carried out by
the contractor free of cost.

2.2. The supplier shall prepare a schedule of the works to be carried out with specific
periods for each item of work involved. All assembly and erection drawing shall be
made available at site.

2.3. If the commissioning of the transformer is delayed due to incompletion of erection
works, the Board has the right to recover an estimated amount for such pending
erection works from the contractor besides Levy of L.D. clause.

3.0. REGULATION OF LOCAL AUTHORITIES AND STATUTES

The Contractor shall comply with all the rules and regulations of local
authorities during the performance of its field activities. The Contractor shall also
comply with the Minimum Wages Act, 1948 and the payment of Wages Act (both of
the Government of India) and the rules made there under in respect of any
employee or workman employed or engaged by it or its Sub-Contractor.

4.0. OWNERS LIEN ON EQUIPMENT

The Owner shall have lien on all equipment including those of the Contractor,
brought to the Site for the purpose of erection, testing and commissioning of the
plant. The Owner shall continue to hold the lien on all such equipment throughout
the period of Contract. No material brought to the site shall be removed from the
site by the Contractor and/or its Sub-contractors without prior written approval of
the Site Engineer.

5.0. INSPECTION, TESTING AND INSPECTION CERTIFICATES

219

The provisions of the clause entitled inspection, Testing and Inspection
Certificates under Technical Specification applicable to the erection portion of the
Works. The Site Engineer shall have the right to re-inspect any equipment, even
though the same may have been previously inspected and approved by him at
the Contractors works, before and after the same are erected at Site. If by the
above inspection, the Site Engineer rejects any equipment, the Contractor shall
make good such rejected equipment etc., either by replacement or
modification/repairs as may be necessary to the satisfaction of the Site Engineer.
Such re-placements will also include the replacements or re-execution of such of
those works of other Contractors and/or agencies, which might have got damaged
or affected by the replacements or re-work done to the Contractors work.

6.0. ACCESS TO SITES AND WORKS ON SITE

6.1 The works so far as it is carried out on the Owner's premises, shall be carried
out at such time as the Owner may approve and the Owner shall give the
Contractor reasonable facilities for carrying-out the works.

6.2 In the execution of the works, no person other than the Contractor or its duly
appointed representative, Sub-Contractor and workmen, shall be allowed to do
work on the site except by the special permission, in writing of the Site Engineer
or his representative.

7.0. CO-OPERATION WITH OTHER CONTRACTORS

7.1 The Contractor shall co-operate with all other Contractors or tradesmen/
representative(s) of the Owner, who may be performing other works on behalf of
the Owner and the workmen who may be employed by the Owner and
doing work in the vicinity of the works under the Contract. The
Contractor shall also so arrange to perform its work as to minimise, to the
maximum extent possible, interference with the work of other Contractors and
their work-men. Any injury or damage that may be sustained by the
employee(s) of the other Contractors and the Owner, due to the Contractors
work shall promptly be made good by the Contractor at its own expense. The site
Engineer shall determine the resolution of any difference or conflict that may
arise between the Contractor and other Contractors or between the Contractor
and the workmen of the Owner in regard to their work. If the work of the
Contractor is delayed because of any acts of omission of another Contractor,
the Contractor shall have no claim against the Owner on that account other than
an extension of time for completing its works.

7.2. The Site Engineer shall be notified promptly by the Contractor of any defects in
the other Contractors works that could affect the Contractors works. The Site

220
Engineer shall determine the corrective measures, if any, required to rectify this
situation after inspection of the works and such decisions by the Site Engineer shall
be binding on the Contractor.

8.0. DISCIPLINE OF WORKMEN

The Contractor shall adhere to the disciplinary procedure set by the Site
Engineer in respect of its/its Sub-Contractors employees and workmen at site.
The Site Engineer shall be at liberty to object to the presence of any representative
or employee of the Contractor/its Sub-Contractor at the site, if in the opinion of the
Site Engineer such representative/ employee has misconduct himself or is
incompetent or negligent or other-wise undesirable. The Contractor shall remove
such person(s) objected to, and provide competent replacement in his place.

9.0. PROTECTION OF WORK
The Contractor shall have total responsibility for protecting its works till it is
finally taken over by the Site Engineer. No claim will be entertained by the Owner
or by the Site Engineer for any damage or loss to the Contractors works and the
Contractor shall be responsible for complete restoration of the damaged works to
original conditions, to comply with the specification(s) and drawings. Should any
such damage to the Contractors works occur because of any other party not being
under its supervision or control, the Contractor shall make its claim directly to the
party concerned without involving the Owner. If disagreement or conflict or dispute
develops between the Contractor and the other party or parties concerned
regarding the responsibility for damage to the Contractors works the same shall
be resolved as per the provisions of Clause 6.0 above titled co-operation with
other Contractors. The Contractor shall not cause any delay in the repair of such
damaged works because of any delay in the resolution of such disputes. The
Contractor shall proceed to repair the work immediately and no cause thereof will
be assigned pending resolution of such disputes.

10.0. EMPLOYMENT OF LABOUR

10.1 The Contractor will be expected to employ on the work only its regular skilled
employees with experience in the particular type of work. No female labour shall be
employed after darkness. No person below the age of eighteen years shall be
employed.

10.2 All traveling expenses including provisions of all necessary transport to and from
site, lodging allowances and other payments to the Contractors employees shall be
the sole responsibility of the Contractor.


221
10.3 The hours of work on the site shall be decided by the Owner and the Contractor
shall adhere to it. Working hours will normally be eight (8) hours per day-Monday
through Saturday.

10.4 Contractors employees shall wear identification badges while on work at Site.

10.5 In case the Owner becomes liable to pay any wages or dues to the labour or any
Government agency under any of the provisions of the Minimum Wages Act,
Workmen Compensation Act, Contract Labour Regulation Abolition Act or any
other law due to act of omission of the Contractor, the Owner may make such
payments and shall recover the same from the Contractor's bills.

10.1 The Contractor shall be provided with free supply of electricity for the purposes
of the Contract only, at one point in the project Site. The Contractor, at its own cost
shall make its own further distribution arrangement. All temporary wiring shall
comply with local regulations and will be subject to Site Engineer's inspection and
approval before connection to supply.


11.0. FACILITIES TO BE PROVIDED BY THE CONTRACTOR

11.1 Tools, scaffolding and tackle

11.1.1.The Contractor shall bring to site all the construction/erection equipment
tools, tackle, scaffolding etc required for pre-assembly, erection of the equipment
covered under the contract. He shall submit a list of all such materials to the Site
Engineer before the commencement of pre- assembly at Site.

11.1.2. The following items are generally required

(1) Lifting equipment:
(a) Derrick or mobile crane of adequate capacity.
(b) wire ropes
(c) pulley blocks
(d) chain blocks
(e) Manila ropes,
(f) shackles
(g) sleepers.

(2) Oil purifier with heating and vacuum facilities and hot oil resistant
hose pipes.
(3) Vacuum pump
(4) Oil storage tank.


222
11.1.3. The Owner shall have a lien on such goods for any sum or sums which may at
any time be due or owing to it by the Contractor.

11.1.4. After the completion of the Works, the Contractor shall not remove from the
Site, the materials such as construction equipment, erection tools and tackle,
scaffolding etc. without permission of the Site Engineer.

11.2. First - Aid

The Contractor shall provide necessary first-aid facilities for all its employees,
representatives and workmen working at the site. Adequate number of Contractors
personnel shall be trained in administering first-aid.

11.3. Cleanliness

11.3.1. The Contractor shall be responsible for keeping the entire allotted area clean
and free from rubbish, debris etc. during the period of Contract.

11.3.2. Waste oil shall be disposed off in a manner acceptable to the Owner. Under no
circumstances shall waste oil be dumped into uncontrolled drains.


12.0. FIRE PROTECTION

12.1. All the Contractors supervisory personnel and sufficient number of workers
shall be trained for fire-fighting and shall be assigned specific fire protection duties.
Enough of such trained personnel shall be available at the Site during the entire
period of the Contract.

12.2. The Contractor shall provide enough fire protection equipment of the types and
number for the ware-house, office, temporary structures, labour colony area etc.
Access to such fire protection equipment, shall be easy and kept open at all times.

13.0. SECURITY

The Contractor shall have total responsibility for all equipment and materials in
its custody, stored, loose, semi-assembled and/or erected by it at Site. The
Contractor shall make suitable security arrangements including employment of
security personnel to ensure the protection of all materials, equipment and works
from theft, fire, pilferage and any other damages and loss. All materials of the
Contractor shall enter and leave the work site only with the written permission of
the Site Engineer in the prescribed manner.

14.0. MATERIALS HANDLING AND STORAGE

223

14.1. All the equipment furnished under the Contract and arriving at Site shall be
promptly received, unloaded and transported and stored in the storage by the
Contractor.

14.2. The Contractor shall be responsible for examining all the consignment and
shall notify the Site Engineer immediately of any damage, shortage, discrepancy etc.
for the purpose of Site Engineers information only. However, the Contractor shall
be solely responsible for any shortages or damage in transit, handling and/or in
storage and erection of the equipment at site as well as for preferring all claims with
the underwriter(s). Any demurrage, wharfage and other such charges claimed by
the transporters, railways etc., shall be to the account of the Contractor.

14.3. The Contractor shall maintain an accurate and exhaustive record detailing out
the list of all equipment received by it for the purpose of erection and keep all such
record open for the inspection of the Site Engineer.

14.4. All equipment shall be handled very carefully to prevent any damage or loss.
No bare wire ropes, slings, etc. shall be used for unloading and/or handling of the
equipment without the specific written permission of the Site Engineer. The
equipment stored shall be properly protected to prevent damage either to the
equipment or to the floor where they are stored.

14.5. The Contractor shall ensure that all the packing materials and protection
devices used for the various equipment during transit and storage are removed
before the equipment are installed.

14.6. All the materials stored in the open or dusty location(s) shall be covered with
suitable weather-proof and flameproof covering material, wherever applicable.

14.7. The Contractor shall be responsible for making suitable indoor storage
facilities, to store all equipment which require indoor storage. Normally, all the
electrical equipment such as motors, control gears and consumables shall be
stored in the closed storage space.

15.0. CONSTRUCTION MANAGEMENT

15.1. The field activities of the Contractors working at site, will be
coordinated by the Site Engineer and the Site Engineer's decision shall be final
in resolving any dispute or conflict between the Contractor and other Contractors
and tradesmen of the Owner regarding scheduling and co-ordination of work.
Such decision by the Site Engineer shall not be a cause for extra compensation or
extension of time for the Contractor.


224
15.2. Time is the essence of the Contract and the Contractor shall be responsible for
performance of its works in accordance with the specified construction schedule.

16.0. PROTECTION OF PROPERTY AND CONTRACTOR`S LIABILITY

The Contractor shall be responsible for any damage resulting from its
operations. It shall also be responsible for protection of all persons including
members of public and employees of the owner and the employees of other
Contractors and Sub-Contractors and all public and private property including
structures, building, other plants and equipment and utilities either above or
below the ground.

17.0. WORK & SAFETY REGULATIONS

17.1. The Contractor shall ensure proper safety of all the workmen, materials plant and
equipment belonging to it or to the others, working at the site. The Contractor shall
also be responsible for provision of all safety notices and safety equipment
required by the relevant legislations and deemed necessary by the Site Engineer.

17.2. All equipment used in construction and erection by Contractor shall meet
Indian/International Standards and where such standards do not exist, the
Contractor shall ensure these to be absolutely safe. All equipment shall be strictly
operated and maintained by the Contractor in accordance with manufacturer's
operation manual and safety instructions and as per Guidelines/Rules in
this regard.

17.3. Periodical examinations and all tests for all lifting/hoisting equipment & tackle
shall be carried-out in accordance with the relevant provisions of Factories Act
1948, Indian Electricity Act and associated Laws/Rules in force from time to time.
A register of such examinations and tests shall be properly maintained by the
Contractor and will be promptly produced as and when desired by Site Engineer
or by the persons authorised by him.

17.4. No electric cable in use by the Contractor/Owner will be disturbed without prior
permission.

17.5. No repair work shall be carried out on any live equipment. The equipment must
be declared safe by the Site Engineer and a permit to work shall be issued by the
Site Engineer before any repair work is carried out by the Contractor. While
working on electric lines/equipment whether live or dead, suitable type and sufficient
quantity of tools will have to be provided by Contractor to
electricians/workmen/officers.


225
17.6. The Contractor shall employ necessary number of qualified, full time
electricians/electrical supervisors to maintain its temporary electrical installations.

17.7. In case any accident occurs during the construction/ erection or other associated
activities undertaken by the Contractor, thereby causing any minor or major or fatal
injury to its employees due to any reason whatsoever, it shall be the responsibility of
the Contractor to promptly inform the same to the Site Engineer in prescribed form
and also to all the authorities envisaged under the applicable laws.

17.8. The Site Engineer shall have the right at its sole discretion to stop the work, if in
its opinion the work is being carried out in such a way as may cause accidents and
endanger the safety of the persons and/or property, and/or equipment. In such
cases, the Contractor shall be informed in writing about the nature of hazards and
possible injury/accident and he shall comply to remove short-comings promptly. The
Contractor, after stopping the specific work, can, if felt necessary, appeal against
the order of stoppage of work to the Site Engineer within 3 days of such stoppage
of work and the decision of the Site Engineer in this respect shall be conclusive and
binding on the Contractor.

17.9. The Contractor shall not be entitled for any damages/compensation for stoppage
of work due to safety reasons as provided above and the period of such stoppage
of work will not be taken as an extension of time for completion of work and will not
be the ground for waiver of levy of liquidated damages.

17.10. The Contractor shall follow and comply with all Safety Rules, relevant
provisions of applicable laws pertaining to the safety of workmen, employees plant
and equipment as may be prescribed from time to time without any demur, protest
or contest or reservation. In case of any unconformity between statutory
requirement and Safety Rules referred above, the latter shall be binding on the
Contractor unless the statutory provisions are more stringent.

17.11. If the Contractor does not take all safety precautions and/or fails to comply with
the Safety Rules as prescribed by the Owner or as prescribed under the applicable
law for the safety of the equipment, plant and personnel and the Contractor
does not prevent hazardous conditions which may cause injury to its own
employees or employees of other Contractors, or Owner or any other person at
Site or adjacent thereto, the Contractor shall be responsible for payment of
compensation to the Owner as per the following schedule :-

a) Fatal injury or accident } Rs. 1,00,000/- ) These are
causing death } (per person ) applicable
for death injury to
any person
whosoever.

226
b) Major injuries or accident } Rs. 20,000/-
accident causing 25% or } (per person )
or more permanent disability }
to work men or employees }

Permanent disability shall have the same meaning as indicated in Workmen's
Compensation Act. The compensation mentioned above shall be in addition to the
compensation payable to the workmen/employees under the relevant provisions of
the Workmen's Compensation Act and rules framed there under or any other
applicable law as applicable from time to time. In case the Owner is made to pay
such compensation, the Contractor will be liable to reimburse the Owner such
amount(s) in addition to the compensation indicated above.

18.0. CODE REQUIREMENTS

The erection requirements and procedures to be followed during the
installation of the equipment shall be in accordance with the relevant ASME codes,
accepted good engineering practice, the Engineers Drawings and other applicable
Indian codes and laws and regulations of the Government of India.

19.0. CHECK OUT OF CONTROL SYSTEMS

After completion of wiring and cabling the Contractor shall check out the
operation of all control systems for the equipment furnished and installed under
these specifications and documents.

20.0. CABLING

20.1. All cables shall be supported by conduits or cable tray run in air or in cable
channels. These shall be installed in exposed runs parallel or perpendicular to
dominant surfaces with right angle turn made of symmetrical bends for fittings.
When cables are run on cable trays, they shall be clamped at a minimum intervals
of 2000 mm or otherwise as directed by the Site Engineer.

20.2. Each cable, whether power or control, shall be provided with a metallic or
plastic tag of an approved type, bearing a cable reference number indicated in the
cable and conduit list (prepared by the Contractor), at every 5 meter run or part
thereof and at both ends of the cable adjacent to the terminations. Cable routing
is to be done in such a way that cables are accessible for any maintenance and for
easy identification.

20.3. Sharp bending and kinking of cables shall be avoided. The minimum radii for
PVC insulted cables 1100 V grade shall be 15 D where D is the overall diameter of
the cable. Installation of other cables like high voltage, coaxial, screened,

227
compensating, mineral insulated shall be in accordance with the cable
manufacturer's recommendations. Wherever cables cross roads and water, oil,
sewage or gaslines, special care should be taken for the protection of the cables in
designing the cable channels.

20.4. In each cable run some extra length shall be kept at a suitable point to enable
one or two straight through joints to be made, should the cable develop fault at a
later date.

20.5. Control cable terminations shall be made in accordance with wiring diagrams,
using identifying codes subject to Site Engineer's approval. Multicore control
cable jackets shall be removed as required to train and terminate the conductors.
The cable jacket shall be left on the cable as far as possible to the point of the first
conductor branch. The insulated conductors from which the jacket is removed shall
be neatly twined in bundles and terminated. The bundles shall be firmly but not
tightly tied utilising plastic or nylon ties or specifically treated fungus protected
cord made for this purpose. Control cable conductor insulation shall be securely
and evenly out.

20.6. The connectors for control cables shall be covered with a transparent
insulating sleeve so as to prevent accidental contact with ground or adjacent
terminals and shall preferably terminate in Elmex terminals and washers. The
insulating sleeve shall be fire resistant and shall be long enough to over pass the
conductor insulation. All control cables shall be fanned out and connection made to
terminal blocks and test equipment for proper operation before cables are corded
together.

0o0

















228
ANNEXURE-1
STATEMENT OF TYPE TEST PARTICULARS
SL.
NO.
NAME OF THE TEST NAME OF LAB DATE OF TEST


1.

2.

For Transformer:

IMPULSE VOLTAGE TEST

TEMPERATURE RISE
TEST









NOTE: The Type test certificates should be furnished for the transformers of respective or
higher capacity/voltage class tested at CPRI/ Government recognized laboratory/ or in the
presence of Purchasers representatives as per relevant IS/IEC. The bid shall accompany
with Transformer type-test reports conducted within five years from date of tender. Bids
not accompanying the above type test reports of Transformer shall not be considered.



COMPANY SEAL: SIGNATURE :

DESIGNATION :
COMPANY :
DATE :






229
ANNEXURE II
TYPE, RATING AND TECHNICAL REQUIREMENTS
SNo DESCRIPTION REQUIREMENT
Maximum continuous rating (MVA)
(a) HV 100
(b) IV 100
1.
(c) LV 30
Maximum continuous rating and cooling
(a) ONAN 60%
(b) ONAF 80%
2.
(c) ODAF 100%
(a) ONAN/ONAF/ODAF 3. Type of cooling
(b) 1x100% or separately 2x50%
cooler bank
(c) 2 X 100% cooling pumps out of
which one is connected stand-by
(d) 2 fans as stand-by one for each
cooler bank.
Max. Temperature rise over ambient temperature of 45 deg. C

(a) Winding 55 deg.

C

(b) Oil 50 deg. C

(c)Limit of hot spot temperature with
average ambient temperature of
32 deg. C.
98 deg. C
4.


(d)Maximum hot spot temperature 140 deg C
5. Maximum flux density for the combined
effect of voltage and frequency variation.

1.6 Tesla
(i) Rated voltage (KV)
(a) H.V. winding
(b) I.V. winding
(c) L.V. winding

230
110
11
6.
(ii) Variation in the system voltage 10%
7. Number of phases 3
8. Rated frequency 50 5%
9. Voltage Ratio (KV) 230/110/11 KV
(i) Type of connection
(a) H.V. Star
(b) I.V. Star
(c) L.V. Delta
(ii) Vector group YnaOd1
10.
(iii) Neutral Effectively earthed
Type of winding
(a) H.V. Continuous Disc
(b) I.V. Continuous Disc
11.
(c) L.V. Continuous Disc
12. Max. current density of winding 300 A/cm
2

230


Sl.
No.
DESCRIPTION REQUIREMENT
Insulation levels HV IV LV Neutral
(1) Winding voltage KV (rms) 230 110 11 --
(2) Highest system voltage KV (rms) 245 132 36 17.5
(3) Lightning impulse withstand voltage
(KVp)
950 550 170 95
13.
(4) Power frequency rated short duration
withstand voltage (KV rms)
38 38 75 38
14. Duration of short circuit withstand capacity 2 seconds.
(a) Tap changer OLTC with remote control panel 15.
(b) Tapping range On HV winding for HV variation of
+10% to 10% in steps of 1.25%
(16 steps)
16. D.C. voltage for relays etc. 220/110 Volts
Percentage impedance (Tolerance 10%) Principal Tap
HV - IV 12.5
HV - LV 60.0
17.
IV - LV 50.0
18. Cooling medium/insulating oil EHV grade transformer oil
conforming to IS:335.
Maximum Losses .
(a) No-load loss 30 KW
(b) Load loss 190 KW
19.
(C) Auxiliary loss 7 KW
20. Termination arrangement Bushing type suitable for outdoor
operation.
Terminal bushings HV IV LV Neutral
(a) Voltage rating (KV rms) 245 145 36 36
(b) Current rating (Amps) 800 800 2000 2000
21.
(c) Impulse withstand voltage (KV Peak) 1050 650 170 170
Bushing Current transformers:
a) C.T. Ratio 600/1 for restricted earth fault protection
b) Accuracy class PS
c) VA Burden 30 30
d) Knee point voltage Shall be more than 40*I* (Rct+Ra) where
Rct = secondary resistance of the current transformer
Ra = lead resistance (2 ohms)

22.
e) Magnetising current Shall be less than 30 milli amperes at half the
knee point voltage.





231

Tank:
(i) Type Bell/Conventional
23.
(ii) Thickness (mm)
(a) Bottom
(b) Sides
(c) Top
(iii) Pressure release device
(a) Type
(b) Number

16
10
12

Safety valve type spring operated
2
Clearances (mm) 230KV 110KV 11KV
(a) Phase to Phase 2388 1200 280
24.
(b) Phase to Earth 2150 1050 178
25. Noise level Less than 81 db
26. Oil preservation Main Conservator


OLTC Conservator
Air cell type with 2 Nos. Silica gel
breathers associated with oil seal
in parallel, each one with a valve .
1 No. Silica gel breather with oil
seal.
27. Expected life period of the transformer 25 Years.





********************




















232
ANNEXURE II (A)
To be filled in by the tenderer
SCHEDULE OF GUARANTEED PERFORMANCE AND OTHER
TECHNICAL PARTICULARS OF TRANSFORMER

Sl
No.
ITEM VALUES
1. Name of the manufacturer and address
2. Applicable standards.
Continuous ratings under conditions
specified in I.S:2026(Part-I) 1977
Clause -3.
Type of cooling


ONAN/ONAF/ODAF
Rating in (MVA)
(i) With ONAN cooling
(ii) With ONAF cooling
(iii) With ODAF cooling
HV IV LV

Rated Voltage.
(i) HV (KV) (ii) IV (KV) (iii) LV (KV)

Voltage variation
Rated frequency (Hz)
Frequency variation
Number of phases.
3.


(a)
(b)



(c)

(d)
(e)
(f)
(g)
(h)
Current and power factor at rated load
and voltage on principal tap
(i) HV amps.
(ii) IV amps.
(iii) LV amps.

4. Connections: (i) HV, (ii) IV, (iii) LV
5. Connection Symbol.
6.

(a)




(b)




(c)

(d)

(e)
Maximum Temperature rise (above
peak ambient.
Temperature rise of oil. (By
thermometer) (C)
(i) At full ONAN rating
(ii) At full ONAF rating
(iii) At full ODAF rating
Temperature rise of winding (By
resistance method) (C)
(i) At full ONAN rating
(ii) At full ONAF rating
(iii) At full ODAF rating
Temperature gradient between winding
and oil (C)
Limit of hot spot temperature for which
the transformer is designed (C)
Time in minutes for which the


233
transformer can be run at full load
without exceeding the max. permissible
temperature at reference ambient
temperature when,


(i) Supply of fan is cut off but oil pumps
are working
(ii) Supply of oil pump is cut off but fans
are working
(iii) When supply of both fans and pumps
are cut off
(iv) Ambient peak temperature specified
Deg.C


7.
(a)
(b)
Tappings on windings on HV side.
Number of steps
Range of tappings for variation

8.
(a)

(b)

(c)


(d)
Losses (KW-MAX)
No-load losses at rated voltage and
Frequency at principal tap.
Load-losses at rated output rated
Frequency and corrected for 75C
Auxiliary losses at rated output, normal
ratio, rated voltage, rated frequency and
ambient temperature (KW)
Total losses at normal ratio inclusive of
auxiliary equipment losses (KW)
corrected to 75C.

9.
(a)
(b)
(c)
Resistance per phase (ohms)
H.V.winding.
I.V.winding.
L.V. winding

10.



(a)
(b)
(c
Positive sequence impedance on rated
MVA base at rated current and
frequency at 75C winding temperature
at,
Principal tap percent.
Highest tap percent.
Lowest tap percent

11 Zero Sequence impedance at reference
temperature of 75C at principal tap
percent .

12 Noise level in decibles when energised
at normal voltage and normal frequency
at
No-Load.


234
13. % Reactance at rated MVA base at
rated
Current and frequency percent
(i) At unity power factor
(ii) At 0.8 pf (lagging)

14. % Regulation at full load and 75C
Winding temperature expressed as a
percentage of normal voltage
(i) At unity power factor
(ii) At 0.8 p.f. (lagging)






15. % Efficiency at 75C winding temperature as
derived from guaranteed loss figures and at
UPF
(a) Full load percent
(b) 3/4 load
(c) 1/2 load
(d) 1/4 load

16. Short time rating for 2 seconds of
(a) HV winding
(b) L V winding

17. Permissible over loading
(a) HV winding
(b) L V winding

1
18.(a)
Over load capacity of transformer duration for
the following over loads starting with
transformer unexcited
(i) 10 %
(ii) 20 %
(iii) 30 %
(iv) 50 %
(v) 75 %
(vi) 100 %
(b) Overload capacity of transformer duration For
the following overloads, starting with
Transformer after continuous running on
Open circuit.
(i) 10 %
(ii) 20 %
(iii) 30 %
(iv) 50 %
(v) 75 %
(vi) 100 %


235
(c) Permissible emergency short time, loading of
the transformer immediately following full load
run
(i) 2 seconds.
(ii) 5 seconds.
(iii) 10 seconds.
(iv) 30 seconds.
(v) 1 minute .
(vi) 5 minutes.

19. Terminal arrangement
(i) High voltage (HV)
(ii) Intermediate Voltage (IV)
(iii) Low voltage (LV)
(iv) Neutral

20. Insulating and cooling medium
21. Test Voltage
(i) Lightning impulse withstand voltage (KVp)
(ii) Power frequency withstand test voltage
(dry and wet) ( kV rms)
(iii) Induced over voltage withstand voltage
(kV rms)
(iv) Voltage to earth for which star points of
the transformer LV windings will be insulated.
HV IV LV

22. External short circuit withstand capacity
(MVA) and duration (seconds)

23. Over flux withstand capacity of the
transformer.


236


1.
(a)
(b)
(c)




(d)





(e)

(f)



(g)





(h)
(i)

(j)
ADDITIONAL TECHNICAL PARTICULARS
Details of core
Type of core construction
Type of core joints
Flux density at rated voltage and frequency
and at principal tap Tesla
i) at rated voltage.
ii) at 110% rated voltage.
iii) at 90% rated voltage
Magnetising current on HV side at normal
ratio at and frequency and at
(i) 85 % of rated voltage
(ii) 100 % of rated voltage
(iii) 110 % of rated voltage
Power factor of magnetising current at
normal voltage ratio and frequency
(i) Material of core laminations (CRGO)
(ii) Thickness of core laminations (mm)
(iii) Specific loss of the core material watts per
kg
at working flux density
(i) Whether core construction is without
core bolts
(ii) Insulation of core bolt
(iii) Insulation of core bolt washers
(iv) Insulation between core lamination
(v) Core bolt insulation withstand voltage for
1 minute( kV rms )
Insulation of clamping plate
Describe location / Method of core
grounding.
Details of oil ducts in core

2. Method of making joints carrying current
3.
(a)
(b)
(c)

Details of winding
Type of winding
Material of winding conductor :-
Maximum current density of windings
(at rated current) and conductor area
(i) H.V.
(ii) I.V.
(iii) L.V.
(iv) Regulating
HV IV LV

(d) Whether HV windings are interleaved
(e) Whether windings are preshrunk
(f) Whether adjustable coil clamps are
provided for HV and LV windings

(g) Whether steel rings used for the
windings if so, whether they are split


237
(h)

Whether electro static shields are provided to
obtain uniform voltage

Insulating material used for
(I) HV winding
(ii) IV winding
(iii) LV winding
(iv) Regulating winding

Insulating material used between
(I) HV winding
(ii) IV winding
(iii) LV winding
(iv) Regulating winding and earth

Type of axial coil supports
(i) H.V. Winding
(ii) I.V. Winding
(iii) L.V. Winding

Type of radial coil supports
(i) H.V. winding
(ii) I.V. winding
(iii) L.V. winding
(iv) Regulating winding

(i)




(j)




(k)



(l)




(m)
Maximum allowable torque on coil clamping
bolts

4.
(a)


(b)

(c)

(d)

Bushings:
Make and type
(i) Rated Voltage class KV
(ii) Rated current (Amps)
Lightning impulse withstand test voltage
(1.2x50 micro second (KV peak)
Switching surge withstand test voltage
(KV peak)
Power frequency withstand test voltage
(i) Wet for 1 minute (KV rms)
(ii) Dry for 1 minute (KV rms)
HV IV LV & Neutral

(e)
(f)
(g)
(h)
(i)
(j)

(k)
(l)
Visible corona discharge voltage (KV rms)
Partial discharge level
Creepage distance in mm
Creepage distance (protected)
Whether test tap is provided
Quantity of oil in bushing and specification of
oil used (Kg)
Weight of assembled bushing (Kg)
Min. clearance height for removal of bushing
(mm)


238
5.
(a)
(b)
(c)

(d)
(e)
(f)
(g)
Details of bushing current transformers
Type and Make.
Ratio.
Class of Accuracy as per IS:2705 Part IV of
latest issue.
V.A.Burden.
Knee point voltage.
Magnetising current at knee point voltage.
Secondary resistance.
HV IV LV & Neutral

6. Minimum clearance (mm): In oil In air
---------------------------------------- ---------------------------------------
Betn. Phases Ph. to Gnd. Betn. Phases Ph. to Gnd.
---------------------------------------- ---------------------------------------
HV -
IV -
LV -
7.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Approximate weight.
Core steel kg:
Coil with insulation kg:
Core and winding kg:
Oil required for first filling kg:
Fittings & accessories kg:
Tank and fittings with Accessories kg:
Un tanking weight kg:
Total weight with oil and fittings kg:




8.
(a)
(b)




(c)
(d)

(e)

(f)
(g)
(h)
(i)

(j)
(k)
Details of Tank
Type of tank
Approximate thickness of sheet
(i) Sides (mm)
(ii) Bottom (mm)
(iii) Cover (mm)
(iv)Cooling tubes/Radiators (mm)
Materials of tank and construction
Vacuum to be maintained during oil filling in
transformer tank (torr)
Vacuum to which the tank can be subjected
without distortion (torr)
No of bi-directional wheels provided
Track gauge required for the wheels
Size of rail recommended for the track
Type and quantity of pressure relief device/and
pressure at which it operates
Whether tank shields provided if so, details
Details of painting at works and site













Transverse Longitudinal
Axis Axis

239
9.
(a)
(b)

Conservator
Total volume (Liters)
Volume between the highest and lowest visible oil
levels (Liters)

10.
(a)
(b)


(c)
(d)
(e)
Oil
Governing Standard
Specific resistance at
(i) 27C (ohms-cms)
(ii) 90C (ohms-cms)
Tan delta
Water content
Dielectric strength (Break down voltage)(KV)





(f)





(g)
Characteristic of oil after ageing test as per ASTM
D - 1934
(i) Specific resistance at 27C
(ii) Tan delta
(iii) Sludge content
(iv) Neutralisation number
Details oil preserving equipment offered

11.
(a)

(b)

(c)
(d)
(e)
(f)
(g)
Radiator
No. of banks attached whether attached/separate
Overall dimensions (lxbxh) (mm)

Total weight with oil (kg)
Total weight without oil (kg)
Thickness of radiator tube (mm)
Type of mounting
Vacuum withstand capability

12.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)



(j)
(k)
(l)
(m)
Cooling System
Make and type
No. of connected units
No. of stand by units
Rated power input
Capacity (cu.m/min) or (litres/min)
Rated voltage (volts)
Locked rotor current (Amps)
Efficiency of motor at full load (percent)
Estimated time constant in hours for
(i) Natural cooling
(ii) Forced air cooling
Temperature rise of motor at full load (C)
BHP of driven equipment
Temperature range over which control is
adjustable(C)
Whether the fans suitable for continuous
operation at 85 percent of their rated voltage
Fan Pump


240
13. Gas and oil operated relay make & type
14. Magnetic oil level gauge make & type
15 Temperature
controllers
(i) Make and Type
(ii) Permissible setting ranges for alarm and trip
(iii) Number of contacts
(iv) Current rating of each contact
(v) Diameter of the
dial
oil winding

16 (i) Minimum clearance height for lifting core
and winding from tank cover : mm:
(ii) Minimum
clearance height for lifting
tank cover:
mm:


17.

(a)
(b)
Shipping details
Approximate weight of heaviest package :kg
Approximate dimension of largest package :
l x b x h

18. Transformer will be transported with oil / gas

241
19.

(a)
(b)
(c)

(d)
(e)
(f)
(g)
(h)

(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)














Tap-changing equipment
Make
Type
Power flow-unidirectional /bi-directional/ restricted
bi-directional
Rated voltage to earth (KV)
Rated Current (Amps)
Step Voltage (Volts)
Number of steps
Control-Manual/Local electrical/Remote electrical
Line drop compensation provided/not provided.
Parallel operation
Protective devices
Auxiliary supply details
Approximate overall dimensions of tap changer
Approximate overall weight
Approximate mass of oil
Details of the OLTC control panel for installation in
the control room
(1)Tap change delay
(2)Tap change out of step
(3)Tap change drive motor trip
(4)Oil temperature alarm
(5)Winding temperature alarm
(6)Winding temperature trip
(7)Buchholz alarm
(8)Buchholz trip
(9)Tap changer surge relay trip
(10)Tap changer out of step alarm.
(11)Oil flow fail alarm
(12)Cooling fan trip(for each group of fans and
standby)


(13)Cooling Pump Trip(for working and standby
pump)
(14) Pressure relief device acted
(15) Cooler supply failure
(16) OLTC buchholz alarm
(17) Low oil level alarm

20. Driving mechanism box
(i) Make and Type
(ii) Details of apparatus proposed to
Be housed in the box.





242

21.
Weight of copper used (kg) HV IV LV


22
Weight of core steel used (Kg)

23.
Quantity of transformer oil used (K.litres) (including
cooling system, OLTC & conservator)


24.
Type of gaskets used in the transformer
25.
(a)
(b)
(c)
Overall Dimensions.
Length (mm)
Breadth (mm)
Height (mm)


26.
Expected life of transformer






























243
ANNEXURE II (B)
To be filled in by the tenderer
SCHEDULE OF GUARANTEED PERFORMANCE AND OTHER
TECHNICAL PARTICULARS OF ONLINE CONDITION MONITORING SYSTEM

I) Online DGA and Moisture Monitor

1. Manufacturers name and country -
2. Model/Type -
3. Parameters measured -
4. Measurement range and Accuracy and
Resolution for each parameters (min. &
Max.)
-
5. IS or equivalent standard -
6. Operating temperature range -
7. Communication ports RS 232 and RS 485
and protocols
-

II) Online Oil and Winding Digital Temperature Monitor

1. Manufacturers name and country -
2. Model/Type -
3. Measurement range and Accuracy and
Resolution (in C)
-
4. IS or equivalent standard -
5. Communication ports RS 232 and
RS 485 and protocols
-

III) Online Capacitance and Tan Delta Monitor

1. Manufacturers name and country -
2. Model/Type -
3. Measurement range and Resolution -
4. Operating temperature range -
5. IS or equivalent standard -
6. Communication ports RS 232 and
RS 485 and protocols
-









244
ANNEXURE III

FITTING AND ACCESSORIES TO BE SUPPLIED ALONG WITH EACH UNIT

1. Conservator with partition for main transformer and OLTC:

(1) For main transformer:

(a) 50 mm oil filling valve.
(b) 25 mm drain cum sampling valve with dummy plug.
(c) 50 mm filter valve with dummy plug.
(d) Lifting hooks.

(2) For OLTC conservator.

(a) 50 mm oil filling valve.
(b) 25 mm drain cum sampling valve with dummy plug.
(c) 25 mm shut-off valve.
(d) Prismatic oil level gauge.
(e) Surge relay.

2. Magnetic type oil gauge with low oil level alarm contacts.
3. 2 Nos. Silica gel breather associated with oil seal in parallel each one with a valve for
main conservator and 1 No. Silica gel breather associated with oil seal for OLTC
conservator.

4. Buchholz relay double float with alarm and trip contacts with shut off valves on either
side of the relay of size 80 mm.

5. Pressure relief device (safety valve type) with alarm contacts.
6. Pockets for thermometer on tank cover.
7. Oil temperature controller with maximum pointer and two sets of contacts, with
mercury switches.

8. Winding temperature controllers with maximum pointer and four sets of contacts with
mercury switches.

9. Valves.
(i) between cooler and tank.
(ii) One 100 mm drain valve with padlocking arrangement, located on the low
voltage side.
(iii) Two 50 mm filter valves at diagonally opposite corners with padlocking
arrangement for the bottom valve.
(iv) Two sampling valves of 25 mm with provision for fixing PVC pipe.
(v) One 15 mm air release plug.


245
10. 2 Nos. earthing terminals.

11. Rating, diagram, terminal marking, schematic wiring and valve position plates,
(stainless steel) of not less than 300 x 300 mm.

12. Inspection cover.
13. Bi-directional rollers with greasing duct and nipple.
14. Wiring upto marshalling box with PVC stranded copper cables of 1100 V grade from
various points.

15. Lifting and hauling facilities.
(i) Lifting lugs.
(ii) Pulling eyes.
(iii) Jacking pads at a height of 500 mm.
(iv) Latching lugs.
(v) Lifting eyes for the tank cover.
(vi) Fixed ladder with anti clamping device.

16. Weather-proof marshalling boxes for housing control equipment and terminal
connections.

17. OLTC gear with remote control panel comprising, among other things,

a) Necessary valves for filling drain and sampling of oil.
b) Conservator for OLTC.
c) Equaliser pipe with valve between divertor and main tank.
d) Drive mechanism box.
e) Local control panel with necessary wiring and with the following:

(i) Remote/Local selector switch.
(ii) Push button switch; Raise/off/lower.
(iii) Limit witch to prevent motor over-travel in either direction.
(iv) Counter.
(v) Electrically interlocked reversing contractors.
(vi) Heaters with switch and HRC fuse.
(vii) Master/follower selector switch.
(viii) Interior lighting
(ix) Auxiliary relays.
(x) Manual operating device.

(f) Remote control panel.

(i) Control push button switch: Raise/off/lower.
(ii) Independent/Off/Master/follower selector switch.
(iii) Lamp indications and initiating contacts as specified.
(iv) Remote top position indicator. (digital type)

246
(v) Alarm annunciation scheme for trip and non-trip alarm as
specified.
(vi) Local/remote selector switch for OLTC.
(vii) Provision with dummy plate for fixing differential relay in the
panel.

18. Cooling accessories:

(1) Requisite number of radiators with shut-off valves at top and bottom , air
release plug, drain plug and lifting eyes.

(2) Fans and pumps.

(3) Cooler control cubicle with necessary wiring and with the following:

(a) Lamp indications as specified.
(b) Initiating contacts.
(c) Selector switch for Local/Auto/Remote control
(d) Fan control switch for ON/OFF/Test.
(e) Pump control switch for ON/OFF/Test.


(4) Transformer oil required for first filling at site including wastage in
pre-commissioning process.

19. Bushings.

20. Bushing current transformers as specified on HV, IV, & LV.

21. Terminal clamps for HV, IV, LV and Neutral.

22. One set of spare gaskets for assembling at site.



-------------OOO--------------












247

TECHNICAL SPECIFICATION FOR CONTROL, PROTECTION AND SAS FOR
_GUINDY_ 230 / 110KV SS

SECTION-I: TECHNICAL GENERAL
1.0 TEST CERTIFICATE :

1.1 Test Certificates in triplicate for the materials furnishing the results of the tests as
per latest issue of ISS shall be forwarded and got approved before the
materials are despatched. In addition to the tests called for in the
specification the purchaser reserves the right of having such tests as he desires
carried out at his own expenses to satisfy himself that the materials conform
to the requirements of this specification. The materials may be rejected if the
test results are not satisfactory. The type test certificates (Photostat copies) as
per latest ISS shall be furnished with the tender for reference and date of type
test shall not be later than 5-years period. (Refer inspection clause 8 also for
the details of inspection/ tests.)

2.0 ROYALTIES AND PATENTS :

2.1 All Royalties for patents or the charges for the use or infringements thereof
that may be involved in the contract shall be included in the tender prices. The
tenderer shall protect the purchaser against any claim thereof.

3.0 GUARANTEED PARTICULARS:

3.1 The tenderer shall furnish all the particulars of the materials offered
against this specification. Unless full details are furnished, the tender may not be
considered.

4.0 DEPARTURE FROM SPECIFICATION:

4.1 Should the tenderer wish to depart from the provisions of this specification, he
shall list such departures separately and submit full particulars and reasons for
the departure in the form enclosed of this specification. Unless this is done,
the materials offered shall be considered to comply in every respect with the
terms and conditions of this specification.

248
5.0 RESPONSIBILITY:
5.1 The tenderer is responsible for safe delivery of the materials at the
destination stores. The tenderer should also include and provide for
security, protecting and packing the materials so as to avoid damages or loss
in transit.

6.0 PACKING :
6.1 The packing may be in accordance with the manufacturer's standard
practice. The contractor should however ensure that the packing is such
that the materials reach their destination without damages after transport
by Rail or Road.

7.0 MAXIMUM WEIGHTS AND DIMENSIONS OF PACKINGS:
7.1 The contractor is responsible for informing himself of the facilities that exist
for road and rail transport to site, the maximum packages which can be
conveyed by the Railway and crane lift available at the destination railway
station. The contractor is also responsible for any loss or damage during
transport.

7.2 Each case or package should be clearly marked and should contain detailed
packing list.

8.0 INSPECTION :
8.1 The purchaser shall have access to the contractor's works at any time during
working hours, for the purpose of inspecting the manufacture of the
materials and for testing the selected samples from the materials covered
by this specification. The contractor or the sub-contractor shall provide facilities
for testing such samples as per standards agreed between the supplier and the
purchaser.

8.2 The tenderer shall specify the international standards which are applicable
for the equipments to be quoted under this specification.

8.3 The purchaser reserves the right to conduct any other reasonable tests at
manufacturer's premises or at site. The purchaser shall be supplied with 2

249
copies of test result. A separate copy of format for type and routine tests to
be carried out on the equipments shall be enclosed with the Tender.

8.4 Tenderers are requested to furnish in their tenders the exact location of their
factory with address to enable inspection by TANTRANSCO if considered
necessary.

8.5 It should be the supplier's responsibility to arrange for inspection, despatch
etc., in time to keep up the delivery schedule. A reasonable time of atleast 15-
days shall be given to the TANTRANSCO for arranging inspection.

9.0 QUALITY PLAN :
9.1 You will prepare, submit and discuss with the Board and based on such
discussions finalise within 30 days (thirty days) from the date of the letter of
intent, detailed quality plans in the format as given in Schedules for all
components of the equipments manufactured by you, setting out during the
various stages of manufacture the quality practices and procedures to be
followed by your quality control organisation, the relevant reference
documents/standards/ acceptance level, inspection documentation raised etc.
In these quality plans, we will identify "Hold Points" beyond which work will
not progress without our consent in writing. For the
components/equipments procured by you for the purpose of this contract, your
purchase specifications and enquiries shall call for such quality plan of the
successful vendor which shall be discussed and finalised by you, in
association with us, in the aforesaid manner and the same shall form part of
your purchase order on your sub vendor. We also reserve our right to carryout
quality audit and quality surveillance of the system and procedures of your/your
vendor's quality management and control activities. However, such audit/
surveillance by us shall not relieve you of any of your responsibilities under the
terms of contract.

10.0 COMPLETENESS OF TENDER :
10.1 The tender should be complete with all details of illustrative &
descriptive literature and drawings. The tenderers shall furnish the complete
technical proposal with details of the equipments and scheme for
control,protection and SAS. Information regarding the country of manufacture
or origin of materials used in the manufacture of the articles should be

250
furnished. The tenderer should include all minor accessories even though not
specifically mentioned in this specification but which are essential for the
completeness of the materials ordered and which are required for efficient
operation of the equipment ordered. All offered software should be provided
with necessary original license. The tenderer shall not be eligible for any
extra charges in respect of such minor accessories, though not included in the
tender.

11.0 INTERCHANGEABILITY :
11.1 All similar parts and removable parts of similar items shall be interchangeable
with each other.

12.0 DESPATCH OF MATERIALS :
12.1 Manufacturing of equipments should be started only after approval of the
drawings. Despatch of items should be done only after approval of test
certificates. The destination and the name of the officers to whom advance
intimation regarding despatch to be sent will be intimated by the consignees in
the despatch instructions.

13.0 ELECTRICITY RULES :
All works shall be carried out in accordance with the latest provisions of the
Indian Electricity Act and the rules there under unless modified by this
specification.

14.0 EQUIPMENTS/MATERIALS AND WORKMANSHIP :
14.1 All the equipments shall be of the best class and capable of satisfactory
operation in the tropics with humid atmospheric conditions without distortion
or deterioration. Unless otherwise specified the equipment shall conform
to the requirements of the appropriate Indian or I.E.C. or other international
Standards. Where a specification covering the equipments in question has
not been published, the tenderer should specify to what extent they would be in
a position to accept the various provisions in the specification.

14.2 The workmanship shall be of the highest grade and the entire construction in
accordance with the best modern practice. The whole of the work shall be of the
highest class throughout well finished and of approved make. The entire

251
design and construction shall be capable of withstanding the severest
stresses likely to occur in actual service and of resisting rough handling during
transport.

14.3 The equipments should be designed to facilitate inspection and repairs and
to ensure satisfactory operation under atmospheric conditions prevailing at
site and under sudden variations of load and voltage as may be met with
under working conditions in the system including those due to faulty
synchronising and short circuits within the rating of the apparatus.
14.4 The design shall incorporate every reasonable precaution and provisions for
the safety of all those concerned in the operation and maintenance.
14.5 All the equipments should operate without undue vibration and with the least
practicable amount of noise.

15.0 DRAWINGS & MANUALS:
15.1 The scope of supply includes:
i. Drawings for SAS and protection panels towards design approval :2 sets.
With all the technical literatures.
ii. As-built drawings of all the panels & SAS :5 Copies.
iii. Operation & maintenance Manuals for equipments : 3 sets.

16.0 INSTALLATION AND TESTING:

Complete installation, testing and commissioning of relay panels and Sub-station
automation system is under the scope of the tenderer. Customization/ Design
Engineering should be done only in the presence of TAN TRANSCO Engineers.
The complete system test shall be performed on site together with the Site
Acceptance Test (SAT) . The SA system shall work continuously for a period of 3
months from the date of taking over of SA sytem by TAN TRANSCO. The defect
of minor nature shall be attended within 24 hours and defects of major nature
shall be attended within 3 days from the time of intimation during the SAT
period. This shall be adhered to strictly failing which the cycle of SAT period will
break. Once rectification of defects is done & intimation received from the
bidder, the TAN TRANSCO will give SAT period of three months starting from the
beginning. The completion of work should be certified by TAN TRANSCO.


252


TECHNICAL SPECIFICATION FOR PROTECTON RELAY PANELS
This specification provides the design, manufacturing, installation, testing and
commissioning of panels with relays and other associated equipments. All material and
works towards field interface of relay panels to the switchgears,CTs,PTs,power supply
equipment,communication equipment etc are in the scope of the bidder.
The equipment shall be capable of working satisfactorily in the intended environmental
conditions.

1.GENERAL
The manufacturer, whose relay panels and protective relays are offered, should have a
minimum of two years experience for having designed, manufactured, tested, supplied,
and commissioned the SAS, relay panels and protective relays up to 230 KV feeders
and 230 KV auto transformers. The panels are to be of simplex type, shall be
independent and totally closed having wiring access from front of the relay panel. The
relay panel shall be provided with swing door on front side and transparent protective
door covering the front of the swing door on which the relays and associated
equipments shall be mounted. The panels shall be completely metal enclosed and shall
be dust, moisture, vermin proof. The enclosure shall provide a degree of protection not
less than IP-31 in accordance with IS-2147. Panels shall have base frame with smooth
bearing surface, anti vibration strips/ pad made of shock absorbing materials shall be
placed between panels and base frame. All doors, removable covers shall be gasketted
all around with neoprene gaskets. Ventilating louver shall have screens and filters.
Cable entries to the panel shall be from the bottom. Necessary cable gland should be
fitted. Cable gland plates fitted on the bottom shall be connected to the earthing of
panel/station through a flexible braided copper conductor rigidly. Each panel shall be
provided with PTC heater rated for 240V single phase A.C. supply with controlling
thermostat. All equipments in the panel shall be mounted and completely wired to the
terminal blocks ready for external connection. The spare contacts shall also be wired
upto the terminal block. Each panel shall be provided with the interior lights (40 W,
fluorescent) controlled by door limit switch. A 230V single phase, 3 pin A.C. socket
15/5A with switch shall be provided in each panel for connection of hand lamps.
Accessories required for fixing the panel such as foundation bolts and nuts shall be
provided along with a panel.

2. DIMENSIONS
HEIGHT : 2312 mm (the height includes 100mm base frame and
12mm vibration pad)
Depth: 800mm

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Width: 800mm
Thickness of sheat: Front and rear side not less than 10SWG and top not
less than 14SWG.
DC voltage of the panels:- 220V DC

3. NAME PLATE, LABELS AND MARKINGS:
All the equipment mounted on front as well as those mounted inside the panel shall be
provided with individual name labels with equipment designation engraved. Also on the
top of each panel on front ,large and bold name plates shall be provided for circuit/
feeder designation. Name plate and labels shall be made of non rusting metal or 3 ply
lamicoid. Name plate shall be black with white engraving lettering. All relays and other
devices shall be clearly marked. Each switch /push button /indication lamp shall bear
clear inscription identifying its function. The size of the label shall be ; width- 1.5cm;
length as per the length of the inscription; the letter size 0.75cm.

4.PAINTING:
i) All sheet steel work shall be phosphated in accordance with IS-6005

ii) Oil, grease, dirt, swart, rust and scale shall be removed by adopting proper
cleansing procedure.

iii) After phosphating and thorough rinsing, the phosphate coating shall be sealed
with application of two coats of ready mixed stoved type zinc chromate primer.
The first coat shall be flash dried while the second coat shall be stoved.

iv) After application of primer, two coats of finishing synthetic enamel paint shall
be applied, each coat followed by stoving

v) The colour of the panel shall match with the existing panel colour of subject
station and normally of following choice for new station.

Exterior - stoved enamel grey
Interior - stoved enamel white
Bus frame - stoved enamel black
Finish - glossy surface treatment shall be done as per BIS.



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5.ENERGY METERS:

Electronic tri-vector meters shall be with facility for separate registering of KWH, KVAH
and KVARH consumption and also to record export/import and demands and their input
quantities. The accuracy of the meter shall be 0.5 class (Revenue certifiable metering)
and metering function should be based on true rms. The meter should be equipped
with Flash/NVRAM for storing the meter parameters and measurements. The meter
shall have communication facility with open protocol. It shall record and indicate the
measured parameters for a frequency variation of +/- 5 % and for A.C auxiliary supply
variation from -40% to +10% and shall have facility to communicate online parameters
as well as download stored data. The meters are to be integrated with the SAS for real
time data access and with remote configuration facility.

6. PANEL WIRING:

i) All wiring shall be provided with minimum 600V/1000V grade single core multi
strand copper conductor wires with PVC insulation and shall be flame, vermin,
and rodent proof. The minimum size of the stranded copper shall be :

a) for CT circuits 2.5sq.mm multistrand per lead
b) for all circuits other than CT circuits, 1.5sq.mm multistrand per
lead

All wiring shall be in accordance with the wiring diagram for functioning of
connected equipment.

ii) Flexible wires shall be used for wiring of devices on moving parts such as
swinging panels or panel door.

iii) Panel wiring shall be securely supported, neatly arranged, readily accessible
and connected to equipment terminals and terminal blocks. Wiring gutters and
troughs shall be used for this purpose.

iv) Cables/wires shall be uniformly bunched and tied by means of PVC belts and
carried in PVC carrying troughs. The position of the PVC carrying troughs and

255
having bunch of wires shall not give any hindrance for fixing or removing relay
casing, switches etc.

v) Wire termination shall be made with solder less crimping type and tinned copper
lugs, which firmly grip the conductor. Insulated sleeves shall be provided at the
wire terminations.

vi) Engraved core identification plastic ferrules marked to correspond with panel
wiring diagram shall be fitted at both ends of each wire.

vii) The wire number shown on the wiring shall be in accordance with IS 375.

viii) All wires directly connected to trip circuit breaker or device shall be distinguished
by addition of red colour unlettered ferrule.

ix) Interconnection to adjacent panels shall be brought to a separate set of terminal
blocks located near to the slots or holes to be provided at the top of the panel.
Arrangements shall be made for easy connections to adjacent panels at site and
wires for this purpose shall be provided and bunched inside the panel.

x) Bus wires shall run at the top the panels. The terminal blocks for the wires shall
be with isolating links.

xi) The terminal blocks used shall be minimum 600V/1000V grade and have 10A
continuous rating, moulded piece, complete with insulated barriers, stud type
terminals washers nuts and lock nuts suitable for operation with a tubular box
spanner or screw driver.

xii) Terminal blocks shall be arranged in vertical formation at an inclined angle with
sufficient space between terminal blocks with minimum of 150mm for easy
wiring.

xiii) Terminal blocks shall include a white fibre marking stripe with clear plastic, slip
on/clip on terminal covers. Marking on terminal strips shall correspond to wire
number and terminal number on the wiring diagrams.


256
xiv) There shall be minimum clearance of 250mm between the first row of terminal
blocks and the associated cable and plate or panel side wall.

xv) At least 20% of total terminal shall be provided as spare for further connections
and these spare terminals shall be uniformly distributed on all terminal blocks.

xvi) Wiring is preferable with the following colour code.
PT supply : Red, yellow, blue for phase and black for neutral.
CT circuits : Similar to above.
DC circuit : Gray for both positive and negative.
230V AC circuits : Black for both phase and neutral.
Earthing : Green.

7. EARTHING:

i) All panels shall be equipped with bus securely fixed along the inside base of the
panels. When several panels are mounted adjoining to each other, the earth bus
shall be made continuous and necessary connectors and clamps for this purpose
shall be included in the scope of supply.

ii) The size of the earth bus shall be made of tinned copper flat.

iii) The earth of the substation will be as per GIS specification, provision shall be
made on the earth bus bars of the end panels for connecting to the earth grid.
Necessary terminal clamps and connectors shall be included in the scope of
supply.

iv) All metal case of the relays, instruments and other panel mounted equipments
shall be connected to the earth bus by independent copper wires of size not less
than 2.5 sq.mm. The colour code of the earthing wire shall be green. Earthing
wire shall be connected on the terminals with suitable clamp connectors and
soldering shall not be permitted.

8. CIRCUIT DISTRIBUTION AND ISOLATION:


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i) Each relay panel shall be provided with necessary arrangements for receiving,
isolating and fusing of AC and DC supplies for various control of signaling,
lighting and space heaters.

ii) The incoming and sub circuit shall be separately provided with switch fuse units,
selection main and sub circuit fuse rating shall be such as to ensure selective
clearance of sub circuit faults.

iii) Potential circuit for metering and relaying shall be protected by fuses.

iv) All fuses shall be of HRC cartridge type conforming to IS2203 mounted on plug
in type fuse bases. All accessible live connection of fuse base shall be adequately
shrouded.

v) Fuse shall have operation indications for indicating blown fuse condition.
vi) Fuse carrier shall have imprints of fuse rating and voltage.
vii) Removable links should be provided at the output of each relay for trip output
and reclose output. Adequate space shall be left between fuse units when
arranged adjacently.

9. General requirements for numeric type protection relays
3. Technology shall be based on numeric type.
4. Equipped with Event recorder
5. Equipped with disturbance recorder
6. Equipped with fault recorder
7. Equipped with Ethernet ports for Bay level LAN interface
8. Support SNTP for time synchronization. Time stamping of events shall be of resolution
of 1ms.
9. Support IEC 61850 protocol
10. Equipped with communication port for relay configuration, Data and records retrieval.
11. Equipped with self monitoring feature during start up and always while in operation. A
relay fail alarm should be available in dry contact type alarm output.
12. Provided with the necessary software tools for complete configuration of the protection
relay, record retrieval, data retrieval.
13. Suitable to operate with the auxiliary DC supply voltage available in the sub-station.
14. Provision for display of alarms with LED/ LCD/Graphic display.
15. Support multiple relay settings for protection.

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16. All configuration files of the protection relay shall be stored in a non-volatile memory
and shall not be lost on absence of dc supply.
17. The relays should be suitable to be tested with universally acceptable testing kit.

10. RELAYS:
i) Unless or otherwise specified all auxiliary relays and timers shall be
supplied in non-draw out cases / plug in type modular Cases.
ii) Relays shall have the rating for 110V VT secondaries and 1 Amp CT secondaries.
Auxiliary relays and timers shall be designed for the DC voltage specified.
iii) Provision shall be made for isolation of trip circuits of each relay for the purpose
of testing and maintenance.

11. APPLICABLE REFERENCE STANDARDS:
IS 3231 electrical relays for power system protection
IS 8686 static protective relays
IEC 60529 Degrees of protection procured by enclosures (IP code 31).
IS 1248 & IS 2419 indicating instruments
IS 0722 energy meters, control switches (LV switching devices for
control and auxiliary circuits)
IS 0337,0337-1 -do-
IS 0297(part 1-3)dimensions for the mechanical structures of the
482.6mm (19)series
IS 0375 marking and arrangement for switch gear, busbars,
main connection and auxiliary wiring
IS 6875 control switches (LV switching devices for control and aux.circuits)
IS 0005 colour for ready mix paints
IS 1554(part I) PVC insulated cables upto and including 1000 volts
IS 3842(part I-VII) application guide for protection
IS 6005 code of practice for phospating iron and steel
IES 2555-1-0 electrical relays all-or-nothing elec. relays.
IEC 255-3,5,6,7,8,10,11,12,13,16 electrical relays for various specifications
IEC 255-21-2,3
IEC 255-22-1,2,3,4 electrical relays vibration and disturbance etc.
IEC 255-23 electrical relays contact performance
IEC 61850-3 EMI Immunity and environmental compliance(Electrical utility substations)

259
IEC 61850 All applicable parts of this standard certified by KEMA/ reputed laboratory.
Including type test certification/report for :
(c) Model implementation conformance statement (MICS)
(d) Protocol implementation conformance statement (PICS)
Note : For standards other than IS mentioned above, the equivalent or better IS
standards may be complied.
11. 230KV LINE PROTECTION:

MAIN-I & MAIN II DISTANCE PROTECTION:
The schemes shall :

(ii) Comply with the general requirements for numeric type relay furnished in this
technical specification document.
(iii) Be of Numerical type relays suitable for rated voltage of 110V phase to phase
and 63.5V phase to ground ; rated for 1A, DC: 220V
(iv) Have continuous current rating of 2 times the rated current and have high short
time current of atleast 70 times rated current for a period of 1sec
(v) Have a minimum of 3 forward and 1 forward / reverse selectable distance
protection zones
(vi) Have six independent loop measurements system to cater phase to phase and
phase to ground faults
(vii) Have MHO/polygonal characteristics for phase to phase fault and polygonal
characteristics for phase to earth fault. In case of polygonal characteristics X and
R should be independently settable.
(viii) the maximum operating time of the numerical distance protection relays shall be
as follows:
a) source impedance ratio 4 15
b) relay settings ohms 10 2
c) fault location % 60 60
d) fault resistance ohms 0 0
e) maximum operating time 45 for 45 for 3
in milli secs. including trip all fault phase and
relays with CVT 60 for all
other faults
(ix) have an impedance setting range of 0.25 120 ohm

260
(x) have a requisite independent continuously variable time setting with range 0-3
sec
(xi) Have a resetting time of less than 40 milli sec.
(xii) have facility for zero-sequence compensation for earth fault on all measuring
element
(xiii) be suitable for single and three phase tripping
(xiv) have switch-on-to-fault feature.
(xv) have LBB protection and synchro check function.
(xvi) Have cross polarization, assure 100% directional sensitivity for unbalance fault
and memory for balanced faults.
(xvii) Have programmable communication scheme for inter trip selectable for
permissive under reach, over reach, blocking and acceleration scheme.
(xviii) comply with weak-end in feed logic and current reversal logic.
(xix) Have feature to detect open conductor.
(xx) Have feature to detect VT (or CVT) fuse failure. It should detect single phase,
two phase and all three phase fuse failure condition both at relay panels and
fuses in the yard and take necessary precaution in measurement to block the
distance protection. However, during blocking period the relay shall have over
current protection facility for fault detection.
(xxi) Have power swing blocking protection. The power swing shall be detected by
rate of change of impedance with suitable characteristics. The blocking shall
have continuously adjustable time delay with setting range of not less than 2sec
or shall have feature to block the tripping as long as it exists. The relay shall
have feature to unblock during fault. It shall be explained how blocking is
effected during power swing for phase to earth fault, phase to phase faults and
three phase faults. In each case the relay shall have feature to unblock during
fault and with facility to block each distance zone independently.
(xxii) Include built-in high speed auto re-close relay for single shot, single phase re-
close with adjustable dead time setting of 0.1sec to 1sec, and with adjustable
reclaim time of 1 to 250sec.
(xxiii) Auto re-close relay shall be provided in both Main I and Main 2 as a built in
feature.
(xxiv) Have built in IDMT directional earth fault relay with adjustable setting range of
10 to 80% with characteristic curve for normal inverse, very inverse and
extremely inverse of both IEC and IEEE curves.
(xxv) Have an adjustable characteristic angle setting range 35 to 75 degrees.

261
(xxvi) Have built in disturbance recorder unit with minimum 8 analog and 12 digital
inputs and with minimum memory capacity to store at least 8 disturbance
records with each record of minimum 10 cycles. The sampling of analog inputs
shall be at least 16 per cycle. Shall have features to adjust pre fault and post
fault time.
(xxvii) Have programmable 12 nos. of opto inputs (minimum), 20 nos. output
(minimum) and opto voltage are field programmable.
(xxviii) Event recorder shall be able to store at least 80 time tagged events. The
resolution of event recorder shall be at least 1 millisecond.
(xxix) Have built in fault recorder with following features.
(xxx) Shall display the fault location either in percentage of line length
or in actual distance in kilometer based on reactance setting.
(xxxi) Shall have an accuracy of +/-3% or better and watch dog
output.
(xxxii) Have self diagnostic feature and watch dog output.
(xxxiii) The contact of the relay shall have the following minimum rating
Make and carry continuously : 5A
Make and carry for minimum 1 sec : 30A
Breaking capacity for DC when L/R is 40m sec. :30W
(xxxiv) Have metering function of class 1.0 accuracy or better and user
programmable display.
(xxxv) The relay shall have online monitoring function to check the under impedance
magnitutde.

12. 110KV LINE PROTECTION:
A. MAIN DISTANCE PROTECTION:
The schemes shall
2.3 Comply with the general requirements for numeric type relay furnished in
this technical specification document.
2.4 be of Numerical type relays of same version suitable for rated voltage of
110V phase to phase and 63.5V phase to ground ; rated for 1A, DC: 220V
2. Have continuous current rating of 2 times of the rated current and have high
short time current of at least 70 times rated current for a period of 1sec
3. Have a minimum of 3 forward and 1 forward / reverse selectable distance
protection zones.

262
4. Have six independent loop measurements system to cater phase to phase and
phase to ground faults
5. Have MHO/polygonal characteristics for phase to phase fault and polygonal
characteristics for phase to earth fault. In case of polygonal characteristics X & R
should be independently settable.
(iii) the maximum operating time of the numerical distance
protection relays shall be as follows:
a) source impedance ratio 4 15
b) relay settings ohms 10 2
c) fault location % 60 60
d) fault resistance ohms 0 0
e) maximum operating time 45 for 45 for 3
in milli secs. including trip all fault phase and relays with CVT 60 for all
other faults
(iv) have an impedance setting range of 0.25 120 ohm
(v) have a requisite independent continuously variable time setting with range 0-3
sec
(vi) Have a resetting time of less than 40 millisec.
(vii) have facility for zero-sequence compensation for earth fault on all measuring
element
(viii) be suitable for three phase tripping
(ix) have switch-on-to-fault feature.
(x) Have LBB protection and synchro check function.
(xi) Have cross polarization, assure 100% directional sensitivity for unbalance fault
and memory for balanced faults.
(xii) Have programmable communication scheme for intertrip selectable for
permissive under reach, over reach, blocking and acceleration scheme.
(xiii) comply with weak-end in feed logic and current reversal logic.
(xiv) Have feature to detect open conductor.
(xv) Have feature to detect VT (or CVT) fuse failure. It should detect single phase,
two phase and all three phase fuse failure condition both at relay panels and
fuses in the yard and take necessary precaution in measurement to block the
distance protection. However, during blocking period the relay shall have over
current protection facility for fault detection.
(xvi) Have power swing blocking protection. The power swing shall be detected by
rate of change of impedance with suitable characteristics. The blocking shall

263
have continuously adjustable time delay with setting range of not less than 2sec
or shall have feature to block the tripping as long as it exists. The relay shall
have feature to unblock during fault. It shall be explained how blocking is
effected during power swing for phase to earth fault, phase to phase faults and
three phase faults. In each case the relay shall have feature to unblock during
fault and with facility to block each distance zone independently.
(xvii) Have built in IDMT directional earth fault relay with adjustable setting range of
10 to 80% with characteristic curve for normal inverse, very inverse and
extremely inverse of both IEC and IEEE curves.
(xviii) Have an adjustable characteristic angle setting range 35 to 75 degrees.
(xix) Have built in disturbance recorder unit with minimum 8 analog and 12 digital
inputs and with minimum memory capacity to store atleast 8 disturbance records
with each record of minimum 10 cycles. The sampling of analog inputs shall be
atleast 16 per cycle. Shall have features to adjust prefault and post fault time.
(xx) Have programmable 8 nos. of opto input (minimum) 12 nos. output
(minimum) and opto voltage are field programmable.
(xxi) Event recorder shall be able to store atleast 80 time tagged events. The
resolution of event recorder shall be atleast 1 millisecond.
(xxii) Have built in fault recorder with following features.
(xxiii) Shall display the fault location either in percentage of line
length or in actual distance in kilometer based on reactance setting.
(xxiv) Shall have an accuracy of +/-3% or better and watch dog
output.
(xxv) Have self diagnostic feature and watch dog output.
(xxvi) The contact of the relay shall have the following minimum rating
Make and carry continuously : 5A
Make and carry for minimum 1 sec : 30A
Breaking capacity for DC when L/R is 40m sec. :30W
(xxvii) Have metering function of class 1.0 accuracy or better and user programmable
display(3D).

B. BACK-UP PROTECTION: DIRECTIONAL O/C &E/F RELAY:
The relays shall be of numerical type
2. Comply with the general requirements for numeric type relay furnished in this
technical specification document.
3. Features and characteristics.

264
DC operating voltage 220V DC
CT sec. current 1 Amp.
Current settings o/c 50 to 200% & E/F 10 to 80% in convenient steps
Time multiplier settings 0 to 1
Have built in IDMT directional O/C and E/F relay with characteristic curve for
normal inverse, very inverse, extremely inverse of both IEC and IEEE curves
4. directional element
P.T voltage 110 V A.C for phase o/c relay and e/f relay.
E/F fault 60 deg to 45 deg. Current lagging
5. rating of the contacts
make and carry continuously : 5A
make and carry for 0.2 secs : 30A
breaking capacity for DC when L/R is 40 m sec : 30W

6. operation indicators for each phase and earth fault shall be provided separately.
7. Comply with the general requirements for numeric type relay furnished in this
technical specification document.

13. BUS-BAR PROTECTION for 230KV / 110KV BUS:
Bus-Bar protection scheme shall
5 Comply with the general requirements for numeric type relay
furnished in this technical specification document.
6 be of low impedance numerical type.
7 have operating time of 15millisec at 5times setting value for all type
of fault.
8 operate selectively for each busbar.
9 be stable for through fault condition upto 40KA fault level.
10 incorporate check zone feature for each phase and clear zone indication.
11 shall include one overall check zone protection in addition to single/double zone
specified.
12 incorporate continuous supervision of CT secondaries against any possible open
circuit and if it occurs, shall render the relevant zone of protection inoperative
after a time delay and initiate an alarm.
13 be phase segregated type with separate relay for each phase and provide
independent zone of protection. If bus section is provided, then each side of the
bus section shall have separate set of bus bar protection scheme.

265
14 be transient-free in operation.
15 includes continuous DC supply supervision.
16 include provision for protection IN/OUT for each zone and check zone.
17 be rated for 1Amps.
18 the relay must have rejection and shall not operate on second and third
harmonics. Second harmonic rejection ratio 2:1 minimum, third harmonic
rejection ratio 40 :1 minimum.
19 the high speed tripping relays (96) for tripping each feeders on actuation of bus
bar protection shall be on respective feeder relay panels and necessary provision
for running the tripping bus wires to actuate these relays shall be made.
20 should have provision for supporting three numbers of additional feeders/
circuits as spare.(for 230KV and 110KV)
21 The bus bar protection relay should support various bus architectures selectable
by means of the relay configuration (Single bus bar, Double bus bar, Breaker and
a half bus bar, two section bus bar with a bus tie, Double bus bar with transfer
bus and tie breaker) for its bus bar protection.
18. The relay shall incorporate dynamic bus replica and provide necessary end
zone fault protection depending on the bus bar protection CTs location.

14. TRANSFORMER PROTECTION:
(a) BIAS DIFFRENTIAL PROTECTION RELAY FOR TWO WINDING
TRANSFORMER PROTECTION:

(b) Comply with the general requirements for numeric type relay furnished in this
technical specification document.
(c) three phase with faulty phase identification.
(d) shall have instantaneous high set feature with facility to adjust 5 to 20 times
normal current.
(e) shall have second harmonic and 5
th
harmonic restraint feature to avoid tripping
during magnetizing inrush. The second harmonic content in the range of 15 to
25% . Transformation inrush restraint functionality shall be provided.
(f) The protection relay shall be equipped with Over excitation protection (ANSI 24).
(g) The protection relay shall be equipped with thermal overload protection.
(h) The differential protection shall have adjustable characteristics with adaptive
differential feature to maintain stability in case of through faults.
(i) The protection relay shall be equipped with unrestrained differential protection
element for fast tripping on heavy internal faults.

266
(j) the disturbance recording functions should be integrated in the relay module.
The disturbance recorder shall have facility to record at least 4 numbers of digital
signals apart from digital signal from the relay and currents in HV&LV winding.
(k) Facility to set transformer vector group and CT ratio selection/ correction through
software.
(l) Rated current of 1 amp.
(m) Thermal withstand current continuous 2 amps and for 1 sec 70 amps.
(n) Rated voltage: as per station DC nominal voltage.
(o) Basic bias setting 20 to 40% in steps 10% or 15 to 45% in steps of 15%.
(p) Operating current setting range 15 to 30%.
(q) have operating time not greater than 35ms at 3 times normal current.
(r) Maximum operating time for instantaneous operation: 25ms +/-4% of set value.
(s) Recording memory capacity: 5secs.
(t) Shall have inbuilt restricted earth fault protection inbuilt over fluxing protection
and inbuilt LBB protection.

B. BACKUP NON-DIRECTIONAL OVER CURRENT PROTECTION WITH HIGH
SET INSTANTANEOUS FOR HV:
1. Comply with the general requirements for numeric type relay furnished in
this technical specification document.
2. IDMT Characteristics with NI/EI/VI/definite characteristics with a variable setting
range of 50 to 200% of rated current of one ampere in steps of 10%. Time
multiplier range 0.05 1.0 in steps of 0.05.
3. Provided with Hand reset flags/LED indicators.
4. High set feature 500-2000% of rated current

C. BACKUP NON-DIRECTIONAL OVER CURRENT RELAY FOR LV:
(ii) Comply with the general requirements for numeric type relay furnished in this
technical specification document.
2. IDMT Characteristics with NI/EI/VI/definite characteristics with variable setting
range of 50 to 200% of rated current of one ampere in steps of 10%. Time
multiplier range 0.05 1.0 in steps of 0.05.
3. Provided with Hand reset flags/LED indicators
4. High set feature 500-2000% of rated current.


267
NOTE : The back up protection relays 14.B & 14.C are separately required even
if it is a inbuilt feature of the main relay.

15. MISCELLANEOUS PROTECTION
15.1 D.C. Supply Supervision Relay.
The relay shall monitor continuously D.C. Supply to Protection System. The de-
energization of this relay will indicate the DC Supply failure. Auxiliary supply for
the relay is220V DC. The relay shall have a time delay on drop off of not less
than 100 milli second. The relay shall be provided with operation indicators
(Reverse flag) self reset. Sufficient number of contacts potential free may be
provided. Separate relays for dual source are to be provided.

15.2 Trip Circuit Supervision Relays.
The relays shall supervise the healthiness of trip circuit continuously (Both pre-
closing and post-closing conditions of the circuit breakers). The relay shall be
capable of monitoring the healthiness of each phase trip coil and associated
circuits of the circuit breaker during ON and OFF conditions. The relay shall
work on 220V dc with allowable margin as the case may be. The relay shall
have adequate contacts for providing connection to alarm and event logger, self
reset. The relay shall have a time delay on drop off of not less than 200 milli
seconds and provided with Operation indicators. The short circuiting of any
series resistance provided in this relay or short circuiting the coil of the relay
should not energize the trip coil of the breaker.

15.3 Tripping (Master) Relay :
- For tripping of feeder / transformer breakers in a station on operation of
protective relays and for interlock purposes. The relay shall be voltage rated for
220V dc with allowable margin of variation, be instantaneous (Operating time not
exceed 10 milli seconds).

- Reset within 20 milli seconds.
- Hand/electrical reset type
- Have adequate contacts to meet the requirement of scheme, other
functions like autoreclose relay, LBB relay as well as to cater to associated
equipments like SER, DR etc., to be provided with operation element/ coil.


268

15.4 Under Frequency Relay :
Comply with the general requirements for numeric type relay furnished in
this technical specification document.The relay shall be highly reliable and
immune to transient and surges. The relay shall have a discrete (digital)
selection unit with built in timer and tripping relay to activate tripping. The relay
shall have two elements for frequency supervision alternatively for under or over
frequency detection with independent separate adjustable timer. The relay shall
have time setting ranges of 0-5 sec. in steps of 0.02 sec. The relay shall have
two elements atleast for supervision of frequency gradient df/dt (rate of change
of frequency). The relay shall be suitable for 110V AC and Auxiliary DC voltage
of 220V. The programmable frequency range shall be 45 Hertz to 55 Hertz in
very minimum possible steps of 0.1 Hz. with operation accuracy of approximately
+ 50 milli Hz. The protective function can be assigned individually to the output
relays. Necessary LED indications for operation, parameter selection etc., need
be provided. df/dt setting range selectable between 0.2 to 0.5 Hz./sec. in steps
of 0.1 Hz./sec. with operation accuracy of approximately 5 milli Hz./sec. Under
frequency relay should be independent even if it is a built in feature of other
protective relays.

15.5 Check Synchronizing relay:-
Synchro check function should be part of the main relay.


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SECTION-III
TECHNICAL SPECIFICATION FOR SUB-STATION AUTOMATION SYSTEM
(SAS)

1) GENERAL :

This specification provides for complete Design & Engineering, Manufacture, FAT
(Factory acceptance test), packing, shipment, insurance, transport and delivery to site,
installation, testing and commissioning with SAT (Site acceptance test) of the substation
automation system completely as described in the following sections to control and
monitor the 230 KV and 110 KV bays and the auto transformer equipments at GUINDY
230KV/110KV substation. All material and works towards field interface of SAS to the
switchgears,CTs,PTs,power supply equipment,communication equipment etc are in the
scope of the bidder. The details of equipments to be controlled are given in the single
line diagram.

The substation automation system shall be installed to control and monitor all the
substation equipments from Local Control room as well as from the remote load
dispatch centre/ Master.

The SAS shall be based on a decentralized architecture and on a concept of bay-
oriented, distributed intelligence.

Functions shall be decentralised, object-oriented and located as close as possible to the
process.

The main process information of the station shall be stored in distributed databases.
The typical SAS architecture shall be structured in two levels i.e. station and bay level.
The database sizing shall be sufficient to accommodate future expansions.

At bay level, the IEDs shall provide all bay level functions regarding control, monitoring
and protection, inputs for status indication and outputs for commands. The IEDs should
be directly connected to the switchgear without any need for additional interposition of
transducers. The bay control units shall be equipped with I/O modules inherently in the
unit with out external I/O modules for interfacing with the process inputs and outputs,
However, all the commands extending for control of switchgear shall be routed through

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suitable trip/ aux. Relays. The Bay control IED should be provided with sufficient
number of programmable I/Os.

Each bay control IED shall be independent from each other and its functioning
shall not be affected by any fault occurring in any of the other bay control units
of the station. The bay control unit shall be fed from redundant DC power
supplies which may implemented with redundant power supply modules in the
BCU or with automatic DC source selection with a suitable auxiliary relay.

The data exchange between the electronic devices on bay and station level shall
take place via the communication infrastructure. This shall be realized using fiber
optic cables, thereby guaranteeing disturbance free communication. The fiber
optic cables shall be run in suitable conduit pipes. Data exchange is to be
realized using IEC 61850 standards with a external managed switched Ethernet
communication infrastructure in decentralized ring configuration.
a. All the numerical IEDs must be fully IEC 61850 compliant and must have
the following features.
b. Peer-to-peer communication using GOOSE messages (IEC 61850) for
interlocking.
c. Interoperability with third party IEC 61850 compliant devices
d. Generate XML file for integration/engineering with vendor independent
SCADA systems.
e. Should be directly connected to the inter bay bus on IEC 61850 without
the use of any gateways. Connections of bay protection IEDs to the IEC
61850 bus through the bay control units are not acceptable.
The sub-station configuration language shall be based on XML format shall be defined
for system configuration and the same shall be furnished for system integration and
end user.
Failure of one set of fiber shall not affect the normal operation of the SAS.
However, it shall be alarmed in SAS. Each fiber optic cable shall have adequate
spare fibers.

At station level, the entire station shall be controlled and supervised from the
station HMI. It shall also be possible to control and monitor the bay from the bay
level equipment at all times, accordingly a graphic user interface (GUI) display
shall be provided in each bay control unit. The GUI display in the BCU shall

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display the status of the bay devices (breakers, isolators, switches etc) in real
time along with the related measurands. All alarms related to the respective bay
shall be displayed in the BCU through its LEDs or in its GUI display as an alarm
list/scroll. A TNC switch shall be provided for each breaker in the respective relay
panel of the bay for facilitating manual operation for facilitating operation in
emergency condition. The BCUs shall be located in the respective relay panel
itself and Multiple BCUs shall not be housed in a single panel.


Clear control priorities shall prevent operation of a single switch at the same time
from more than one of the various control levels, i.e. station HMI, bay level or
apparatus level. The priority shall always be on the lowest enabled control level.

The station level contains the station-oriented functions, which cannot be
realized at bay level, e.g. alarm list or event list related to the entire substation
etc.

All the data cabling & other interconnections shall be through fibre optic cables
wherever possible except for power supply. All material and works towards field
interface of SAS equipments to the switchgears,CTs,PTs,power supply
equipment,communication equipment etc are in the scope of the bidder.

Communication with the remote control centers State Sub-load Dispatch Centre through
Gateway on IEC 60870 5 101/104 of SCADA/EMS system through PLCC Modems.
This interface shall support communication to the remote control centre on IEC 60870
5 101/104 through redundant communication ports. TAN TRANSCO Engineers shall
be co-coordinated for integration. The data should be made available for the polling
schedule of the SCADA/EMS system at State Sub-load Dispatch control centre. Any
support required for completing the task shall be in bidders scope.

h) FUNCTIONAL REQUIREMENTS :
i) Control of all equipments mentioned in the Single Line diagram.
j) Supervisory function (i.e.) Data Acquisition, Processing, Monitoring,
Analysis and Diagnostic,
k) Data Exchange
l) Report Generation and Printing.

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m) CONTROL:
Basic Functions :
n) To execute commands from both operator work stations HMI.
o) Select before execute commands.
p) Operation of all 230 KV and 110 KV Circuit breakers and all the associated
motorized Isolators through output contacts of corresponding BCUs.
q) Operation of On load Tap Changer: Manual Operation from HMIs through BCU is
envisaged.
r) Provide interlocking of different switchgear/isolators for their correct and safe
operation.
s) Monitoring of Circuit breakers, Isolators and Earth Switch contacts (status)

t) OTHER FUNCTIONS:
u) Switching sequences.
v) Time synchronizing through GPS.
w) Monitoring of DC system.
x) Monitoring of fire-protection system.
y) Monitoring of DG operation.
z) Changing relay settings of all numerical relays from Engg./DR works
station with suitable software.
aa) Storage of data.
bb) Collection of disturbance record files from various relays and analysis of the
same from Engg/DR works station with suitable software.
cc) Auto re closure selection and monitoring.
dd) Bus PT change-over.
ee) Carrier IN/OUT selection.
ff) Synchro check provision.

gg) INTERLOCKING:
The interlocking function provision through logic gates prevents unsafe operation
of equipments such as breakers ,isolators and earthing switches for all switching
operation within a bay or station . An override function at Bay level shall be
provided, which can be enabled to by-pass the interlocking function via a
key/password, in cases of maintenance or emergency situations. This over ride
function should be accessed with higher level pass word security.

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hh) SUPERVISORY FUCTION: DATE ACQUISITION, PROCESSING
MONITORING, ANALYSIS AND DIAGNOSTICS.
The status of each switchgear, e.g., circuit breaker, isolator, transformer tap
changer etc., shall be continuously acquired through polling sequences. ie.,
- Polling on request
- Automatic Polling (Every 5sec, 10sec,.)
- Polling by exception (change of digital status)
Every detected change of position shall be immediately visible on the screen in
the single-line diagram, recorded in the event list, Alarms shall be initiated in
cases when spontaneous position changes have taken place.

Each position of an apparatus shall be indicated by two binary auxiliary switches
which are opposite each other in normally closed (NC) and normally opened
(NO) position. An alarm shall be initiated if these position indication indicate an
excessive running time of the operating mechanism to change position through
watchdog timers.

7) DATA ACQUISITION, PROCESSING AND MONITORING:

Conventional interlock through hardware wiring is to be provided in addition to
the software interlock. The BCU shall be located in the relay panel itself. The
main and redundant station HMI should be located in the operator table. The
distance between the BCU and the HMI will vary according to site conditions
during execution. Bay control shall be provided to each bay and the number of
bays to be provided in each substation as per SLD is furnished in the bill of
materials.
The SA system shall acquire data (analog and digital inputs) from 1)
Numerical relays Electronic Energy meters (to be made available in all the
feeders, transformers both HV & LV sides). 2) OLTC, Battery charger etc.,. Data
for the system shall be acquired as hard wired input for all station equipments
stated in the single line diagram.

Automatic Disturbance File Transfer
All recorded data from the IEDs with integrated disturbance recorder
systems shall be automatically uploaded to a station HMI database. A

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dedicated computer as relay engineers console (EWS) shall be offered for
analysis of records additionally.


DATA REQUIRED:

KW, KVA, V,I, PF, kWh, kVah and kVarh from electronic energy meters (four
quadrant type) , bus voltage and frequency for the 230KV and 110KV system
shall be measured and communicated on Modbus or standard IEC protocol to
SAS and values shall be obtained and displayed in both HMIs.

Provision shall also be available for extracting these measurements from the
relays and BCUs in addition to following protection function data (not
exhaustive).

a. For each 230KV feeders
main I distance relay tripping
main II distance relay tripping
LBB relay actuation
Dc fail for source 1 & 2
Fuse failure
Auto reclose
Carrier send
Carrier received
Fault reports including zone,phase, Fault I,V & Location in k.m

b. For each 110KV feeders
main distance relay tripping
LBB relay actuation
Dc fail for source 1 & 2
Fuse failure
Fault reports including zone,phase, Fault I,V & Location in k.m

c. For each transformer(230KV/110KV) separately
differential relay tripping
over current relay for HV tripping

275
over current relay for LV tripping
master relays(1 & 2 separately)
LBB relay actuation
Dc fail for source 1 & 2
Bucholz relay alarm
Bucholz relay trip indication
Oil/winding temperature alarm
PRD acted
Fault I& V

d. For each breaker
Status ON/OFF
Air/gas pressure low
Air/gas pressure lockout
Pole discrepancy actuation
TSR (common for all trip coil per circuit breaker)
e. Isolator ON/OFF
f. earth switch On/Off
g. Others
Bus bar protection actuation for 230KV and 110KV buses. CT circuit supervision
for above bus bar protection(common for each voltage). In case the bus bar
protection relays provided with communication port the zone operation and CT
supervision function shall be acquired on the communication interface or DI.
The measured values shall be displayed locally, on the HMI, Threshold
limit values shall be selectable for alarm actuation.

Basic monitoring functions are:
39 Switchgear status indication
40 Measurements (U, P, Q, F)
41 Event list
42 Alarm list
43 Status and display of DC system
44 Status of display of fire protection system
45 Acquisition of alarm and fault record from protection relays
46 Disturbance records
47 Trend curves

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8) DATA EXCHANGE:
DATA EXCHANGE TO REMOTE CONTROL CENTRE

All data,records etc as available from all the SAS devices including protection
relays and meters shall be exchanged with Remote control centre through the
gateway equipment with out the aid of Station HMI servers. The gate way
equipment shall be equipped with sufficient memory for data, records etc and
shall support IEC 61850 protocol towards the SAS and IEC 60870 5 101/104
towards the remote control centre.

9) REPORT GENERATION:
Substation Automation System shall record all activities, switching,
changes etc., made in a substation.
Following shall be Automatically monitored:
-Status
-Events, alarms
-Limit values.
Following printouts shall be available from the printer and shall be printed on
demand:
(ii) Hourly voltage and frequency curves.
(iii) Trend curves for MW & MVAR.
(iv) Printouts of the maximum and minimum.
(v) Printout on demand for MW, MVAR, Current, Voltage on
each feeder and transformer tap position, status of pumps
and fans for transformer.
(vi) Printout on demand system frequency and average
frequency.
(vii) Daily, weekly and monthly reports are required. The SA
system shall be capable of delivering the same.

10) OTHER FUNCTION:
TIME SYNCHRONISATION
The Time synchronization equipment shall receive the co-ordinate Universal Time
(UTC) transmitted through Geo Positioning Satellite System (GPS) and
synchronize equipments to the Indian Standard Time in substation. The times

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synchronization of all the relevant SAS equipments shall be realized using the
SNTP protocol through the SAS LAN.

Time synchronization equipment shall include antenna & its mounting
facility, all special cables and processing equipment etc.

The GPS antenna shall have adequate protection from wind, lightning etc.
and shall be mounted anywhere in the Substation roof at a place preferable by
the purchaser

It shall be compatible for synchronization of all the SAS equipments
through the SAS LAN Event Loggers, Disturbance recorders and SCADA at a
substation through Ethernet realized through optic fiber bus.

The synchronization equipment shall have 2 micro second accuracy. Equipment
shall give real time corresponding to IST (taking into consideration all factors like
voltage and temperature variations, propagation and processing delays etc.)
Equipment shall meet the requirement of IEC 60255 for storage and
operation.
The system shall be able to track the satellites to ensure no interruption of
synchronization signal.
The output signal from each port shall be programmable at site for either
one hour, half hour, minute or second pulse, as per requirement.
The equipment shall have a periodic time correction facility of one-second
periodicity.
Equipment shall have real time digital display in hour, minute, second (24
hour mode) and have a separate time display unit (100 mm display high) at a
suitable height in the control room.

11) HMI FUNCTIONS:
PRESENTATION AND DIALOGUES
GENERAL
The Local HMI for Operation & Engineers console shall provide basic
functions for supervision and control of the substation. The operator shall give
commands to the switchgear on the screen via mouse clicks or soft-keys
through keyboard. The HMI shall provide the operator with access to alarm and

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events displayed on the screen. Besides these lists on the screen, there shall be
a print out of hard copies of alarm or events.
Following standard display shall be available from the HMI:

* Single line diagram showing the switchgear status
and measured vales.
* Control dialogues.
* Measured values
* Alarms list.
* Events list.
* System status.
* A/R selection
* PT selection/ CT selection (one and half breaker scheme)
* Carrier status
* Tripping selection

21 SYSTEM SUPERVISION DISPLAY:
The SA system shall be comprehensively self-monitored and faults will be
immediately indicated to the operator before they develop into serious situation.
Such faults are recorded as faults in a system supervision display. The display
shall cover the status of the entire substation including all switchgear, Numerical
relays and communication links. Dynamic colouring of single line diagram with
load, power factor voltage. Bay view to zoom all the parameter.

22 EVENT LIST
The event list shall contain events with time tag (universal time synchronization
with GPS) , which are important for the control and monitoring of the substation.
The date and time has to be displayed for events. The events shall be
registered in a chronological events list in which the type of event and its time of
occurrence are indicated. It shall be possible to store all event in the HMI. The
information shall be obtainable also from printed event log.

23 ALARM LIST:
Fault and error occurring in the substation shall be listed in an alarm list and
shall be immediately transmitted to the control centre. The alarm list shall
substitute a conventional alarm table, and shall constitute an evaluation of all

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station alarm however alarm and visual must be provided on receiving alarm. It
shall contain unacknowledged alarms and persisting faults. Date and time of
occurrence shall be indicated. Historical data sizing for storing Data for 35 days
shall be available in the SA system. The capacity of the server is to be designed
accordingly. Also necessary hardware and software to copy and store data from
server should be provided. The data collected shall not be lost due to overflow.
Whenever overflow is likely to occur, the date shall be archived into storage
media like CD so that there is no change of losing historical data.

24 RIGHTS:
(viii) local HMI: shall be able to get data from all the equipments
for monitoring and control.
Engineering/DR work station: shall have the facility for relay setting and analysis
of faults by acquiring disturbance recorder data from Numerical relays.
The alarm list consists of a summary display of the present alarm
situation. Each alarm shall be reported on one line that contain.
(u) The alarm date and time.
(v) The name of device in alarming state.
(w) A descriptive text.
(x) The acknowledgement state.
The operator shall be able to acknowledge alarms, which shall be either
audible or only displayed on the monitor. Acknowledged alarms shall be
marked at the list. Filters for selection of a certain type or group of alarm shall
be available as for events.

8 SYSTEM TESTING:
The supplier shall submit a test specification for factory acceptance test (FAT)
and commissioning tests of the station automation system for approval. If the
complete system consists of parts from various suppliers or some parts are
already installed on the site, the FAT shall be sub-system tests. In such a case,
the complete system test shall be performed on site together with the site
acceptance test (SAT).

9 EXTENDABILITY IN FUTURE:
Offered substation automation system shall be suitable for extension in future for
additional bays. During such requirement, all the drawings and configurations,

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alarm/event list etc. displayed shall be designed in the such a manner that its
extension shall be easily performed by the Engineers authorized. During such
event, normal operation of the existing substation shall be unaffected and
system shall not require a complete shutdown.

10 RELIABLITY AND AVAILABLITY:
The bidder shall select & design & supply the SAS for the overall availability
of 99.98% with the following understanding.
The SA system shall be designed to satisfy the very high demands for
reliability and availability concerning.
10.3.1.1.1 Solid mechanical and electrical design
10.3.1.1.2 Security against electrical interference (EMI).
10.3.1.1.3 High quality components and TAN TRANSCOs.
10.3.1.1.4 Modular, well-tested hardware.
10.3.1.1.5 Thoroughly developed and tested modular software.
10.3.1.1.6 Easy-to-understand programming language for application
programming.
10.3.1.1.7 Detailed graphical documentation and application software.
10.3.1.1.8 Built-in supervision and diagnostic function.
10.3.1.1.9 Panel design appropriate to the harsh electrical environment
and ambient conditions.
10.3.1.1.10 Panel grounding immune against transient ground potential
rise.

19) Documentation:
The following documentation to be provided for the system in the course of
the project shall be consistent, CAD supported, and of similar look/feel:
38.0 List of Drawings.
39.0 Substation automation system architecture.
40.0 Block Diagram.
41.0 Guaranteed technical parameters,
42.0 List of Signal-Analogue/Digital.
43.0 Schematic diagrams.
44.0 List of Apparatus.
45.0 List of Labels.
46.0 Logic Diagram.

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47.0 Test schedule and reports of FAT/SAT
48.0 Product Manuals
49.0 Operators Manual.
50.0 Listing of software and loadable in CD ROM.
3 sets of CD ROM containing all the as built documents/drawing shall be
provided.
Also the final documentation shall provide:
- The System specification description (SSD) file that outlines this
substation automation project.
- IED capability description file (ICD) that describes the available functions logical
nodes and services available from IED.
- Substation capability description file (SCD) that describes the relationship
among the IEDs in the substation automation system and their information
exchange strutcture.
- Configured IED description file (CID) that is final file to download into IED to
enable its configuration.

10 HMI SERVERs:
The HMI server functionality and operator work station facilities may be integrated
in the station HMI (Main) as well as in the redundant station HMI. The HMI servers
should run on a industrial grade computer. The redundant station HMi server shall
operate in hot standby mode and vice versa in case of a switcher over. The real
time data base of the main and redundant HMi servers shall be synchronized at all
times with out loss of real time data in case of a switchover. One remote client
facility for Station HMI access with relevant licenses and software shall be
provided. All computers including HMI servers, Work stations etc shall be provided
with comprehensive anti-virus protection and cyber protection as appropriate.

11 Engineering Work station
The engineering work station should be provided in a industrial grade PC. The
engineering work station should be equipped for :
- Data retrieval and analysis of recorded data from SAS devices including
disturbance records, fault records, event records etc
- Remote configuration of SAS IEDs, Numerical protection relays, Digital Energy
meters etc. All relevant software tools is to be provided for this purpose.
- Client access facility to station HMI with all the relevant softwares.

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The engineering works station shall be provided with a simple Network
Management System (NMS) software for following management functions of
Ethernet switches, SAS devices supporting SNMP.
a. Configuration Management
b. Fault Management
c. Performance Monitoring

This system shall be used for management of communication devices and
other IEDs in the system. This NMS shall be easy to use, user friendly and menu
based.
The Engineering work station shall be provided with comprehensive anti-virus
protection and cyber protection as appropriate.

12 Metering PC
A desktop computer complete with operating system, 320GB hard disk, key board,
mouse, 25inch colour TFT monitor, all relevant original software and tools for
viewing in real time and generating reports relevant to metering data. The
metering data from the meters shall be integrated in to the station HMI servers in
real time through the SAS LAN and the same shall be available from the HMI server
to the metering PC as a client. All HMI servers shall be provided with
comprehensive anti-virus protection and cyber protection as appropriate.

13 COMMUNICATION NETWORK:
All the SAS equipments that are to be integrated with the SAS should be
provided with suitable communication ports to connect to the LAN and support
IEC 61850 protocol. Digital energy meter may be integrated with the IEC 61850
inter bay bus suitably through data concentrators / media converters. Redundant
LANS shall be provided at station level. At the bay level a self healing ring
architecture shall be provided. The station LANs shall be separate from the bay
level LANs. The ring LAN architecture shall have the RSTP or equivalent feature.
The proposed LANs shall be equipped with 802.1Q VLAN facility.
Alternate Communication architecture for SAS and bay level LANs may be
proposed if proven to provide better performance and reliability.

14 CAPACITY:

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The system should be capable of handling upto 100 IEDs and 10,000 data
points.

25) SEQUENCE OF EVENTS (SOE) FEATURE:
To analyze the chronology or sequence of events occurring in the power system,
time tagging of data is required which should be achieved through SOE feature
of SA. The server should have an internal clock with adequate stability. The
Server time should be set from time synchronization messages received from
GPS equipment to be supplied by bidder. The Server should maintain a clock and
should time-stamp the digital status data. Any digital status input data point in
the Server should be assignable as an SOE point. Each time a SOE status
indication point changes the state, the Server should time-tag the change and
store in SOE buffer within it. SOE shall be transferable to the Remote Control
Centre through the IEC 60870-5-101 gateway. The time resolution for SOE
should be 1 ms at point of acquisition.

26) ETHERNET SWITCHES:
The Ethernet switches used for creating the LAN network should meet the
specification as laid down in the IEC 61850 standard and should be of
managed type SNMP based. The Ethernet switches should comply to IEC
61850-3 standard/equivalent for EMI Immunity and environmental
compliance pertaining with Electrical utility substations applications.

27) Gateway Equipment
The Gateway equipment shall conform to the following technical requirements:
- The gateway equipment shall be based on embedded technology with out
moving parts.
- The gateway equipment shall comply to IEC 60255 standards / Equivalent IS
for EMC and Environmental compliances.
- Support IEC 61850 protocol, IEC 60870-5-101/104 protocol.
- Perform the data concentration by directly collecting data from the bay level
devices and provide the same to the remote LDC/Master with out the aid of the
SAS HMI servers.
- The gateway device should be equipped with sufficient memories for firmware,
Configuration data, Process data, records.
- Equipped with redundant communication ports for SAS interfaces as well

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as for remote LDC/Master interfaces.
- Gateway shall be equipped with redundant power supply modules and
communication modules.
- Equipped to run high speed programmable logic control function that
includes provision for implementing station level interlocks and automation
logic as necessary.
- Necessary software with original license for Anti-virus protection with
Relevant firewall should be provided for operating system based on MS
windows.

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Station
HMI
Redundant
Station
HMI
Engg. WS Metering
PC
Event
Printer
Report
Printer
Protocol
converter
Device
Meter
Meter
GPS
SYSTEM
BCU BCU
Gateway
Device
Communication
terminal
Equipment


CONCEPTUAL DIAGRAM FOR SAS











STATION LAN (Redundant )







IEC 60870-5-101/104




.
.







BAY LEVEL LAN (IEC 61580, RING TOPOLOGY)





Redundant
Communication
lines
Towards
LDC

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Numeric
protection
relays
Numeric
protection
relays

. . . .

28) UPS specification :
The UPS shall conform to applicable parts of IEC 62040/ Equivalent standards.
The UPS system shall include the following:
- UPS equipments supplying load at 0.8 lagging power factor,
-Maintenance free VRLA batteries for UPS system with backup duration,
- The UPS shall be designed for continuous-duty, on-line operation and shall be based
on solid- state design technology to provide uninterrupted power supply for
computersystem and associated items. The control of the UPS system shall be
microprocessorbased providing monitoring and control of rectifier/charger,
Inverter,static switches,firing and logic control.
- The UPS shall provide continuous regulated sine wave AC power to the connected
loads.
- The UPS electronic equipment and associated circuitry & all devices shall be housed in
freestanding enclosures/panels.
- In the event of a loss of AC source, the UPS equipment shall provide uninterrupted
power to the specified loads from the output of the UPS inverter
subsystems through its batteries.
- The UPS shall be suitable for operating with input of 230V AC (1-Phase) or 415 Volt
AC(+10% to -15%; 3-phase,4-wire), 50 Hz (47.5 to 52.5 Hz) as well as 220VDC.
- The overall efficiency of the UPS, input to output, shall be a minimum of 90 percent
with the batteries fully charged and operating at full load and unity power factor.
- The UPS shall be provided with potential free contacts for its equipment
faulty alarms.

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SECTION-IV
BILL OF MATERIALS FOR PROTECTION RELAY PANELS

I. BOM FOR 230 KV Feeder Relay Panel

1) Electronic Energy meter (four quadrant )for import
and export with RS 232/ RS 485 Port for communication
along with necessary software ( 110V, 1A,0.5 Class) 1No

2) Main-I Protection: Numerical distance relay with six loop
measurement, suitable for Single phase and three phase
tripping with power swing blocking , Carrier inter-trip,
with Single phase auto-reclose, LBB, PT fuse failure
synchro check distance to fault location, 81U,81R,disturbance
recorder and SER. 1No

3) Main-II Protection: Same as Main-I Protection specification,Main-II
Relay manufacturer should be different from that offered 1No
for main-I relay

4) Under frequency relay with fast acting self reset & contact multiplier 1 No
relay

5) Bay control Unit 1No

6) TNC Switch 1 No

7) Three phase trip relay with hand reset contact and hand reset flag 2 Nos

8) single phase Trip relay with self reset contacts 3 nos
(Applicable for 1 ph type breaker with Auto re-closure application)

9) Trip Circuit Supervision relay ( pre close and post close) 2nos/6 Nos
(quantity applicable as per 1-ph or 3-ph breaker)

10) D.C. Supervision relay 2 Nos

11) Five element high burden hand reset with flag
indication relay for breaker annunciation with a
minimum of four set of N/O contact 1 No

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12) Indication for carrier healthy to both main I and main II 2 Nos

13) A/R On/Off switch 1 No

14) Carrier cut in/Cut off switch / P.B 2 Nos

15) Trip transfer switch -lockable type 1No
(Applicable only for main and transfer bus type with TBC)

16) Auxiliary relays and timers to fulfill scheme As required

17) Supervision relay for Main I & Main II trip relays 2 nos

18) Supervision relay for B/B protection trip relay 1 No.

19) P.T. selection scheme with bistable relays 1 Set

20) Highly Speed tripping relay(96) for B/B protection 1 No

21) Remote access block switch (For numeric relay) 1 No.

22) LBB isolation link 1 No.

23) Standard relay panel accessories as described in this technical specification
document.

Note :
1. Functions of supervision relays, trip relays,selector switches,auxiliary relays
may be incorporated in a multifunction IED subject to approval of TAN
TRANSCO design approval. Such scheme should be designed such that a
single point of failure in the IED should not cause simultaneous failures of
Main-I and main-II protection scheme. The IED should conform to the
Specification for the general requirements for numeric relay and equipped
with redundant power supply modules.

II.BOM FOR 230/110 KV Auto transformer Relay panel

1. Electronic Energy meter (four quadrant)for import and export
with RS 232/ RS 485 post for communication along with necessary 1 No
software (110V, 1A, 0.5 class)


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2. Numerical biased differential protection for two winding
Transformer with REF,LBB, over fluxing and synchro check
Features 1 No

3. Numerical non-directional over current protection relay with
LBB and high set for HV side 1 No

4. Numerical non-direction over current protection relay with
LBB and high set for LV side 1 No

5) Numerical distance protection relay with LBB 1 No
(For downstream feeder backup protection)
6) Bay control unit for HV and LV 2 Nos

7) TNC Switch 2 Nos

8) Three Phase trip relay with hand reset contact and 2 Nos
hand reset flag.

9) Trip circuit supervision relay for HV and LV trip coils
(pre close and post close) 8 Nos

10) D.C. supply supervision relay for HV and LV 3 Nos

11) Five element high burden hand reset with flag indication
relay for breaker communication with a minimum of 4 set
of N/O contacts ( for HV and LV ) 2 Nos

12) Supervision relay for Main,Backup and B/B protection Trip relays 4 Nos

13) Auxiliary relays and timers to fulfill scheme As required

14) Trip transfer switch (lockable type) 1No
(Applicable only for main and transfer bus type with TBC)

15) P.T. selection scheme with bistable relays ( for HV and LV ) 2 Sets.
16) High Speed tripping relay (96) for B/B protection 2 Nos

17) LBB isolation link 1 No.

18) Standard relay panel accessories as described in this technical specification

290
document.

19) Digital Voltmeter (LED Display for Bus voltage) 1 No

20) Digital Frequency meter (LED Display) 1 No.

21) Selector switch (for voltmeter) 1 No.

22) Selector switch (for frequency meter ) 1 No.

23) Indication lamps (for checking bus PT ) 3 Nos.

24) Relay for Automatic DC selection 1 no.

Note :
1. Items 19 through 23 are applicable only if there is no 230KV transfer bus coupler
breaker230KV Bus coupler breaker in the single line diagram.

2. Functions of supervision relays, trip relays,selector switches,auxiliary relays
may be incorporated in a multifunction IED subject to approval of TAN
TRANSCO design approval. Such scheme should be designed such that a
single point of failure in the IED should not cause failure of the protection
scheme. The IED should conform to the Specification for the general
requirements for numeric relay and equipped with redundant power supply
modules.

III. BILL OF MATERIALS FOR 230KV / 110KV BUS BAR PROTECTION RELAY
PANEL :
1) Set of low impedance bus bar protection scheme of
Numerical type for single/double zone with check
zone for 230/110KV bus (as per single line diagram 1 Set
enclosed plus 3 numbers spare feeders in each sub-
section)

2) DC supervision relays 2 Nos

3) Bus bar cut IN/OUT switch Main and check zones. As required

4) Auxiliary relays for automatic DC source selection As required

5) Auxiliary relays and timers to fulfill scheme As required


291
6) 3 Phase trip relay (96) (shall be be a part of relay panel of the
respective panels) As required

7) Marshaling box ; out door type with dimension
1300x950x500(HxWxD)mm with circuit label stud As required
type terminal blocks in sufficient quantity to
accommodate CT termination

8) Supervision relay for B/B protection As required
trip relays (shall be a part of relay panel of the
respective panels)

9) Relay for Automatic DC selection 1 no.
10) Standard relay panel accessories as described in this technical specification
document.

IV. BILL OF MATERIALS FOR 230 KV /110 KV BUS COUPLER/BUS SECTION
BREAKER RELAY PANEL :

1) Numerical non directional over current and earth fault
relay with LBB and synchro check 1No

2) Bay control unit 1No

3) TNC Switch 1 No.

4) 3 Phase trip relay with hand reset contact and hand reset Flag 2Nos

5) Trip Circuit supervision relay 2nos/6 Nos
(quantity applicable as per 1-ph or 3-ph breaker)

6) DC supervision relays 2Nos

7) Five element high burden hand reset with flag 1No
indication relay for breaker annunciation with a
minimum of four set of N/O contact)

8) Supervision relay for Main,Backup and B/B protection Trip relays 3Nos

9) Auxiliary relays and timers to fulfill scheme As required

10) High Speed tripping relay (96) for B/B protection 1No

292

11) Digital Voltmeter (LED Display for Bus voltage) 2 Nos.

13) Digital Frequency meter (LED Display) 2 Nos.

14) Selector switch (for voltmeter) 2 Nos.

15) Selector switch (for frequency meter ) 2 Nos.

16) Indication lamps (for checking bus PT ) 6 Nos.

17) LBB isolation link 1 No.

18) Relay for Automatic DC selection 1 no.
19) Standard relay panel accessories as described in this technical specification
document.

Note :
1. Functions of supervision relays, trip relays,selector switches,auxiliary relays
may be incorporated in a multifunction IED subject to approval of TAN
TRANSCO design approval. Such scheme should be designed such that a
single point of failure in the IED should not cause simultaneous failures of
Main-I and main-II protection scheme. The IED should conform to the
Specification for the general requirements for numeric relay and equipped
with redundant power supply modules.


V. BILL OF MATERIALS FOR 230 KV TRANSFER BREAKER RELAY PANEL:

1) Numerical non directional over current and earth fault
relay with LBB and synchro check 1No

2) Bay control unit 1No

3) TNC Switch 1 No.

4) 3 Phase trip relay with hand reset contact and hand reset Flag 1No

5) Trip Circuit supervision relay 2nos/6 Nos
(quantity applicable as per 1-ph or 3-ph breaker)

6) DC supervision relays 2Nos

293

7) Auxiliary relays and timers to fulfill protection & control As required
scheme

8) High Speed tripping relay (96) for B/B protection 1No

9) Supervision relay for trip relay 1 No.

10) Supervision relay for B/B protection trip relay 1 No.

11) Remote access block switch (For numeric relay) 1 No.

12) LBB isolation link 1 No.

13) Relay for Automatic DC selection 1 no.
14) Standard relay panel accessories as described in this technical specification
document.
Note :
1. Functions of supervision relays, trip relays,selector switches,auxiliary relays
may be incorporated in a multifunction IED subject to approval of TAN
TRANSCO design approval. Such scheme should be designed such that a
single point of failure in the IED should not cause simultaneous failures of
Main-I and main-II protection scheme. The IED should conform to the
Specification for the general requirements for numeric relay and equipped
with redundant power supply modules.


VI. BOM FOR 110 KV Feeder Relay Panel

1) Electronic Energy meter (four quadrant) for import
and export with RS 232/RS 485 Port for communication
along with necessary software ( 110V, 1A,0.5 Class) 1No

2) Main-I Protection: Numerical distance relay with six loop
measurement, suitable for Single phase and three phase
tripping with power swing blocking , Carrier inter-trip, with 1 No.
Single phase auto-reclose, LBB, PT fuse failure synchro
check distance to fault location, disturbance recorder
and SER.

3) Backup protection: Numerical directional over current and
earth fault relay with LBB (separate relay is required even

294
if the function is part of main I protection) 1No

4) Bay control Unit 1No

5) TNC Switch 1 No.

6) Three phase trip relay with hand reset contact
and hand reset flag 2 Nos

7) Trip Circuit Supervision relay ( pre close and post close) 2nos/6 Nos
(quantity applicable as per 1-ph or 3-ph breaker)

8) D.C. Supervision relay 2 Nos

9) Five element high burden hand reset with flag 1 No.
indication relay for breaker annunciation with a
minimum of four set of N/O contact

10) Auxiliary relays and timers to fulfill scheme As required

11) Supervision relay for Main,Backup and bus bar trip relays 3 nos

12) P.T. selection scheme with bistable relay 1 Set

13) Highly Speed tripping relay(96) for B/B protection 1 No

14) Remote access block switch (For numeric relay) 1 No.

15) Standard relay panel accessories as described in this technical specification
document.

16) LBB isolation link 1 No.
Note :
1. Functions of supervision relays, trip relays,selector switches,auxiliary relays
may be incorporated in a multifunction IED subject to approval of TAN
TRANSCO design approval. Such scheme should be designed such that a
single point of failure in the IED should not cause simultaneous failures of
Main and backup protection scheme. The IED should conform to the
Specification for the general requirements for numeric relay and equipped
with redundant power supply modules.



295
VII. Standard relay panel accessories:
1. Test Terminal Block,Test switch As required
2. Cubical illumination lamp(CFL type) with drop switch 1
Set
3. Space heater with thermostat and On/Off switch 1 Set
4. 5A/15A, 3pin power socket with 3pin and 1 Set
On/Off switch
5. DC fail test/accept button 2 Each

General: The following items are included under the scope of supply for
relay panels and for SAS equipments

1. Manuals (hard copy & soft copy) 3 Sets.
2. As built drawings (hard copy & soft copy) 5 Sets.


296

SECTION V. BILL OF MATERIALS FOR SAS
Sl.
No
Description Unit Qty
1. Industrial grade computer for station HMI (Complete with
computer,KB,Mouse,500GB HDD,29 TFT Monitor, All
relevant software for applications, operating system)
Nos.
2
2. Engineering work station (Complete with Industrial grade
computer, KB,Mouse, 500GB HDD,29 TFT Monitor, All
relevant softwares, operating system )
No.
1
3. Metering PC (Complete with computer,KB,Mouse,500GB
HDD,25 TFT Monitor, All relevant software for
applications, operating system)
No.
1
4. Gateway Panel (Complete with panel, gateway device,
Hooter-2nos for substation urgent & non-urgent alarms)
No.
1
5. Communication equipment (Complete with
MODEMs,media interface device etc for gateway
redundant interface to LDC)
sets
2
6. Bay Control Unit Nos. As required.
(Refer note
below.)
7. Ethernet Switch Nos. As required.
(Refer note
below.)
8. General printer (A3 Colour LASER Jet Printer) No. 1
9. Report printer (A4 Colour LASER Jet Printer) No. 1
10. LAN accessories (Includes all cables and associated cable
ducts, media converters etc for LAN)
Lot 1
11. Time synchronization system (GPS with all
accessories,Antenna, cables,software etc)
Set
1
12. Configuration tools for SAS equipments (Includes
relevant software tools, accessories for configuration
of SAS devices, protection panel devices. Seperate
Set
1

297
Laptop computer should be included under this item
if the laptop computer offered under relay test kit
does not support installation and running the
configuration tools satisfactorily)
13. Numeric relay testing kit with all associated software
(suitable for testing of numeric relays) of reputed make
with IEC61850 software for GOOSE subscription &
publishing, rugged carry case and necessary accessories.
(OMICRON CMC356 /MEGGAR MPRTS 3P 8430 / PONOVO
PW636i / Equivalent or better).
Set
1
14. Relevant manuals as per SA specification. Lot 1
15. Furniture : Chair suitable for operator-revolving type Nos. 3
16. Furniture : Separate tables suitable for housing i. SAS
computers, ii. Engg. Work station iii. printers.
Lot
1
17. Furniture : Tables with drawers suitable for housing all
the drawings & manuals of the SAS and protection
system.
Lot
1
18. UPS (VA rating should be 150% of load to supply for
2 Hours. Load includes SAS servers, SAS LAN
devices, Engineering work station.)
No.
1
Note:
1.Refer enclosed Single line diagram for verifying the total quantity of BCUs. Dedicated
BCU should be provided for each of the 230KV bays as well as each of each of the
110KV bays.
2. Media type (PLCC or Fibre optic media or leased line ) for gateway interface to the
remote load dispatch centre would be known during project execution.
3. The SAS should be equipped and ready for integrating data from future protection &
control panels for 400KV bays 7nos in the subject sub-station which requires :
a. Necessary data base licenses for the HMI servers and other equipments as
applicable.
b. Providing sufficient ports in the Ethernet switches of SAS LAN to interface the
protection panels pertaining with future 7nos 400kv bays.
c. SAS hardware and software to be equipped to integrate the metering data from
meters for future 400KV bays-7nos.

298
SECTION:VI. List of items under scope of supply / works for Control,
protection and Substation Automation System (SAS) for GUINDY 230/110KV
Substation

REFER ANNEXURE-I







299
SECTION-VII: GURANTEED TECHNICAL PARTICULARS

(e) GUARANTEED TECHNICAL PARTICULARS FOR DISTANCE PROTECTION
NUMERICAL RELAY:
1. Make & Type :
2. Rated voltage, current and frequency :
3. Short time current rating :
4. No. of independent loop measurement :
for phase fault and earth fault.
5. No. of zones :
6. Characteristic of relay for phase and :
Earth fault.
7. Range of ohmic setting :
8. Maximum operating time for the :
case mentioned under Sl.No.6, Part-II,
Section-II, Technical Specification.
i) System impedance ratio
ii) Relay setting (Ohms)
iii) Fault locations
(as % of relay setting)
iv) Fault resistance (Ohms)
v) Maximum operating time
(milli seconds)
9. Resetting time :
10. Zone time setting range :
11. Facility for Zero sequence :
Compensation for earth fault for
zone 1, zone 2 & zone 3.
12. Method adopted for achieving :
100% direction sensitivity in case
of balanced/unbalanced faults and
frequency range for detecting the same.
13. Whether suitable for single phase and :
three phase tripping.
14. Facility for switch on to fault feature :
15. Facility for carrier aided tripping :
16. Facility for weak end in feed :
logic and current reversal logic.
17. VT fuse failure detection:

a) Whether detects single phase :
two phase, three phase PT fuse

300
failure at Control room and yard.

b) Method of detection :
c) Whether block distance :
protection in case of condition (a).
d) Whether distance protection :
is allowed for tripping in case of
fault when there is PT fuse failure.
18. Power swing blocking
a) Detection method :
b) Blocking time :
c) Details of combination of Zones :
that can be blocked.
19. a) Details of trip contacts :
b) Details of additional contacts :
provided.
20. Details of Auto reclose relay:
a) Dead time setting :
b) Reclaim time setting :
c) Synchro check facility :
d) Facility to initiate from main-2 :
21. Details of IDMT directional earth :
fault relay.
a) Setting range :
b) Characteristic curve at 10 :
times of set value.
22. Characteristic angle range of distance :
relay.
23. Details of Disturbance recorder :
a) No. of Analog input :
b) No. of Digital input :
c) Memory capacity to store records:
d) Facility to down load and :
analys the recording.
24. Details of fault locator :
a) Whether in built :
b) Whether accurate for all :
operating conditions.
25. Communication port details :
26. Details of software needed for setting, :
down loading, fault analysis and
programmable logic control.

301
27. Whether self diagnostic feature :
is provided.

28. Whether time Synchronising facility :
is available.
29. Have relevant IEC standards for relays
and communication ports. :

******


(f) GUARANTEED TECHNICAL PARTICULARS FOR Transformer Biased
Differential Relay:


1. Make & Type :
2. Rated DC Voltage :
3. Current Rating :
Continuous :
For 1 Sec. :
3. Two Winding Relay :
4. Operating time at 3 times normal current:
5. Operating time for instantaneous operation:
6. Bias setting range with steps :
7. Availability of faulty phase identification :
8. Availability of instantaneous High set
9. feature with current setting range :
10. Range of second harmonic restrain
feature available. :
11. Availability of continuous self monitoring
and diagnostic features. :
12. Transformer vector group and CT ratio
selection/corrections through software.

Disturbance recorder:

a) No. of external digital signal
that can be recorded. :
b) Facility to record currents in
HV & LV Winding.

:

302
Memory Capacity of D.R:

Fault records :
No. of fault records that can be stored :

Details of ports available with protocol :

(g) GUARANTEED TECHNICAL PARTICUALRS FOR DIRECTIONALAND NON
DIRECTIONAL OVERCURRENT AND EARTH FAULT RELAYS:

1. Description :
Model No. & Make :
2. DC Operating Voltage & its Range :
3. Selectability between definite :
time & IDMT O/C function.
4. Over current setting range :
Phase fault :
Earth fault :
Time setting range and steps :
5. High set Over current setting range : (Not applicable for non
Phase fault. : directional over current relays
Earth fault : for LV side of transformer)
Time setting range and steps :
6. IDMT characteristics :
7. P.T. Voltage :
8. Relay characteristic angle :
settable for Phase fault and
Earth fault.
9. Operating time for instantaneous :
element.
10. Indications provided :
11. Communication ports provided :
12. Protocols supported :
13. Disturbance Recorder Details :
a. No. of analog input.
b. No. of digital input.
c. Sampling rate.
d. Maximum storage capacity
14. Event Recorder Details :
a. Maximum no. of events.
b. Resolution.
15. Sampling rate & frequency :

303
16. Self diagnostic feature provided :
17. Availability of Time Synchronisation
facility :
18. Reset ratio :
19. Resetting time :
20. Other features available :

IV. GUARANTEED TECHNICAL PARTICULARS FOR BUS BAR
PROTECTION RELAY:
1) Make & Type.
2) Numerical.
3) Low Impedance.
4) Maximum operating time at 5 times setting without output relay.
5) CT supervision feature.
6) Phase segregated type or not.
7) Current or Voltage setting range.
8) Availability of faulty phase indication.
9) Availability of check feature.
V. GUARANTEED TECHNICAL PARTICULARS FOR UNDER FREQUENCY RELAY:
1) Make & Type :
2) Frequency setting range
with Step and Accuracy :
3) Rate of change of
frequency setting range with
Step and Accuracy :

4) Time setting range with
Step and Accuracy. :
VI. GUARANTEED TECHNICAL PARTICULARS FOR BAY CONTROL UNIT:
1. Make & Model No. :
2. Maximum Input/Output Capabilities :
a. Max. Single Status indications :
b. Max. Double Status indications :
3. Data transmission speeds
supported by BCU. :

5. Availability of communication ports

304
for communication with
(a) Master Station. :
(b) Energy meters. :
(c) Relays. :
(d) Configuration & Maintenance tool. :
(e) Local SCADA Systems. :

5.. Whether necessary H/W & S/W
provided to operate with the
above media. :

6. Ability to communicate with
multiplemaster with common or
different protocols. :

7. Whether communication port
can be expanded. If so, How
many Communication ports in
one card. :

8. Facility to modify and down load
BCU configuration from Remote
Control centre. :

9. Whether IRIGB/DCF77/STNP
interface provided in the BCU for
synchronization with external clock.:

10. Whether provision available to
down load Analog & Accumulator
data, Disturbance and event data
from Numerical relays. :
12. Whether BCU can support Ethernet
LAN connection. :
13. Resolution of time stamping of SOEs:
14. Available control outputs. :

15. Whether security & safety
features provided for control O/P :

16. Rating of control output relays
provided :

305

17. Provision of Electrical isolation
between all the functional TAN TRANSCOs
and field connections.

18. Provision of sufficient provision
in the BCU to protect from natural
hazards viz lightning & thunder
systems. :

19. Whether self diagnostics provided:

20. Input Dc power supply to BCU :

21. Environmental requirements :
i) Operating temperature :
ii) Relative humidity :
iii) Whether type tested for :
continuous operation at
55C for 48 hours followed
by continuous operation at
normal ambient temperature
for 240 hours.

22. Software requirements :
1. Operating System :

2. Automatic restart of the BCU upon
power restoration, memory parity
errors, hardware failures and
upon manual request. :
3. Diagnostic software for checking
the hardware errors and other
functions of the BCU. :
4. Whether diagnostic software is
user interactive . :
5. Whether configuration and maintenance :
tool with all required hardwares (other
than Laptop PC) and software.



306
VII. GUARANTEED TECHNICAL PARTICULARS FOR GATEWAY EQUIPMENT:
1. Make & Model No. :
2. Operating system :

3. Processing platform :
(Embedded technology? Processing capacity etc)

i) Memory for data (Type and capacity) :
j) Memory for programm (Type and capacity) :
k) Facility for programmable logic functionality :
iv. Maximum digital Input/Output Capabilities :
(Mention for programme, data/records etc with type i.e non-voltaile/Flash
etc.)

5. Availability of communication ports
(Mention media, protocol, transmission speed)

i. Towards Master Stations :

ii. Towards SAS LAN/Bay level LAN :

307
SECTION-IX : STATEMENT OF TYPE TEST PARTICULARS

Sl.No. Material and Name of Test Name of Lab Date of Test
1
2
3
.
.
NOTE:
The above type tests should have been conducted in any reputed Laboratory
within five (5) years from the date of Tender Opening.

BIDDER SEAL
DATE SIGNATURE
DESIGNATION
BIDDER NAME

308
ANNEXURE-I
List of items under scope of supply / works for Control, protection and
Substation Automation System (SAS) for GUINDY 230/110KV Substation



Sl.
No.
Description Unit Qty.
1. 230kV/110KV Auto transformer relay panel Nos. 3
2. 230Kv feeder Relay Panel Nos. 5
3. 230Kv Bus bar protection relay panel No 1
4. 230kV transfer breaker relay panel No. Not applicable.
5. 110Kv feeder relay panel Nos. 7
6. 110Kv Bus bar protection relay panel No 1
7. 110kV Bus section relay panel
No. Not applicable.
8. Synchronizing Panel
Nos 1
9. Sub-station Automation system (Complete as per BOM for
SAS Comprising 18Electrical Bays as per the SLD)
Lot 1
10. Installation, testing & commissioning of relay panels &
complete SAS (Comprising 18 Electrical Bays as per the
SLD)
Lot 1
11. Training on SAS & protection relays (as per specification) Lot 1

Note :

1. All items involving supply of material such as protection panels,SAS includes design,
engineering, manufacture,FAT and delivery.
2. All quantities of relay panels and Electrical bays involved shall be verified with the
Single line diagram for the sub-station.












309


TECHNICAL SPECIFICATION FOR LEAD ACID BATTERIES

1.0 The specification provides for 220V/535Ah Tubular type lead-acid stationary
batteries in Transparent (SAN) container along with accessories as detailed
below:

3.0 APPLICABLE STANDARDS (LATEST REVISION)
3.01 IS-1885: Electrical vocabulary, secondary cells and batteries
IS-1651: Lead acid batteries with Tubular positive plates.
IS-1069: Water for storage batteries
IS-266: Sulphuric acid for storage batteries
IS-8320: General requirements for methods of tests for
lead-acid Storage batteries.
IS-6071: Synthetic separator for lead acid batteries.
IEEE-485: IEEE Recommended practice for sizing of large
lead acid Storage batteries for generating stations
and substations.
IEEE-484: Recommended practice for design and installation
of Storage batteries.
IEC 896-1: Stationary Lead acid Batteries.

4.0 DESIGN AND CONSTRUCTIONAL FEATURES OF BATTERY.
4.01 Type
The battery shall be lead acid Tubular type in Transparent
SAN container. Sealed Maintenance Free VRLA type/ Nickel Cadmium type batteries
are not acceptable.
4.02 Positive Plates:
The plates shall be of first class material and workmanship and shall be free from
blow-holes, cracks and other imperfections. The tubular positive plates shall consist of a
suitable bar with spines cast of suitably alloyed lead to give adequate mechanical
strength and minimum electrical resistance.
The tubular spines shall be cast of an alloy of Pb and Antimony with Antimony
content not greater than 3% by weight. The casting shall be done using proper
controlled procedure preferably using high pressure casting machine with an operating
pressure not less than 90-100 Bars. Low antimony alloy (not greater than 3%) will
ensure low water loss and a guaranteed topping up frequency of not more than once in
6 months. High pressure cast spines will ensure a long life and trouble-free operation.
Porous, acid resistant and oxidation resistant tubes shall be inserted one over
each spine. After insertion, the tube shall be adequately filled and packed with active

310
material (preferable through a rotary shaking machine) before their lower ends are
closed by common plastic bar. The construction and material of tube shall be such as to
reduce the loss of active material and shall be able to withstand normal internal
stresses developed during service.
4.03 Negative Plates:
The negative plates shall be of flat pasted type. The pasting shall be done on an
automated machine for better control of process parameters. It should have adequate
mechanical strength and would be so designed that active material is maintained in
intimate contact with the grid under normal working conditions throughout the life of
the battery. Lead antimony alloy grid with maximum 3% antimony content or lead
calcium alloy grid shall be used.
4.04 Separators:
The separators shall be microporous polyethylene envelope type to
avoid direct as well as side shorts. It should be acid resistant, chemically inert and
should have excellent oxidation resistance and high degree of porosity to ensure
minimum internal resistance. The average pore size shall be less than 1 micron. It
should not exhibit any tendency to swell or shrink at temperature encountered during
operation. Microporous synthetic separators shall conform to latest IS:6071. The
internal resistance factor of the separators shall assure high discharge characteristics
under all operating conditions. Proper arrangement to keep end plates in position shall
be furnished by the bidder alongwith his offer.
Buffers/spring: Suitable buffers / springs shall be provided in the
cells to keep the end plates in position. These shall have adequate length and strength.
4.05 Containers:
Containers shall preferably be made of transparent SAN ( styrene acrylonitrile)
copolymer giving excellent clarity, outstanding chemical resistance, rigidity and
toughness with very high insulating qualities which eliminate the need for separate cell
insulators. It shall have adequate mechanical strength to prevent bulging, cracking etc,
during the life span of battery when operating under expected temperature range and
due to action of static and dynamic loads and the action of electrolyte. These containers
should enable the electrolyte level and the cell condition to be monitored at a glance.
The containers shall conform to latest edition of applicable standards. A copy of the
such standard in english shall be enclosed along with the offer.
Battery containers shall be subjected to type, Routine and Acceptance
Tests as per the requirements of applicable standards. The containers of the label
attached firmly to the containers shall be marked with the information as per
requirements of the above standard. The suppliers manufacturers test certificates
shall be submitted by the tenderer for the scrutiny of the purchaser.
4.06 Cell Lids:
It should be moulded from opaque SAN and sealed to the container. It should
be easily removable if the need arises Terminal post shall be suitably sealed at the lid to
prevent escape of acid spray, by means of rubber grommets, sealing compound or

311
other suitable device. The positive and negative terminal posts shall be clearly and
indelibly marked for easy identification.
4.07 Microporous Ceramic Vent Plugs: The vent plugs should be specially
designed incorporating a microporous ceramic filter which effectively returns
all acid spray to the cell, but allow free exit of oxygen and hydrogen which is
generated at the end of boost charging. On removal, the plugs shall permit
drawing of the electrolyte sample for servicing and of checking of the
electrolyte level. The vent plug should preferably be flame retardant type to
prevent any fire hazard in the battery room.
4.08 Connectors:
Connectors shall be of lead plated copper. The lead coating shall be adequate
and tenacious. Minimum thickness of lead coating shall be 50 microns. Connectors
should be adequately designed to carry maximum duty cycle as specified and shall offer
minimum resistance. The current density for copper connectors shall not be more than
1.5 Amps/ Sq.mm. While considering the terminal voltage of the cell at the time of
testing for discharge, the voltage drop due to inter-row and inter-cell connectors shall
be considered. Connectors shall be adequately designed to withstand various stresses
due to temperature changes, attack of acid and dynamic forces that could occur during
the operation of the battery.
Necessary transparent shrouds to cover all the inter row, inter cell and terminal
connectors shall be provided.
The cross section of cell connectors should not less than 75 sqmm .

4.09 Fasteners :
Fasteners shall be of high tensile steel with lead coatings should be provided.
4.10 Electrolyte:
The electrolyte shall be battery grade sulphuric acid conforming to latest edition
of relevant IS 266. The strength of the electrolyte in the cell during operation shall
conform to the governing IS specification for the cell. Required quantity of electrolyte
for the initial filling with 10% extra quantity shall be supplied in no-returnable non-
degradable acid resistant strong plastic containers.
4.11 Water:
Water used in preparation of electrolyte and also to bring the level of electrolyte
to the correct position during the course of operation or testing shall conform to the
latest edition of IS-1069
4.12 Terminal Post:
Positive and negative terminal posts of the cells shall be clearly and unmistakably
identifiable. Terminal posts shall be designed to accommodate external bolted
connections conveniently and positively. All metal parts of the terminals shall be of lead
coated type. Bolts, heads and nuts, except seal nuts, shall be hexagonal and shall be
lead coated. Terminal posts shall be adequately fixed or removed. The junction

312
between terminal posts and cover and between the cover and container shall be
adequately sealed to prevent any seepage of the electrolyte. All terminals shall be
provided with insulated covers.
The pole terminal should be of lead with a brass core insert, which shall increase
the conductivity. The pole should have a double layered protection against crevice
corrosion. The lead lining of the terminal should be protected against any contact with
the electrolyte at the place where it emerges out of the cell interior through an
injection moulded plastic encapsulation.
5.0 ACCESSORIES (for each set of Battery)
a Digital Hydrometer with temperature compensation
calibrated to read second decimal place
1 Nos
b Thermometer 0 to 100 degree centigrade with
specific gravity correction scale-accuracy<0.5
0
C
1 No
c
Digital 3-0-3V Cell testing Voltmeter shall be
provided with fine scales .Accuracy class
shall be 0.5 or better and resistance not less than
1000 ohms
1 No.
d wall mounting teak-wood for thermo-meters. 1No
e plastic funnels 1No
f rubber syphone 1No
G
Stand insulators +5% extra.
Lot
H
Cell insulators +5% extra.
Lot
i
Cell numbering tags with fixing arrangement.
Lot
J
Teakwood, cable clamps with hardware.
Lot
k
Ampere-hour meter[10 hour discharge
rate] of 120 300 AH range
1No
L
Cell interconnectors (extra)
4Nos
m
Fastners for the above
4Nos
n
Junction box with suitable fuse arrangements of
adquate rating to be mounted on the battery
stands for terminating battery terminals.
1No
o
Suitable wrenches for the Battery Terminals and
bolts
1 set
p
Cell lifting straps
1 No
q Digital multimeter of repute make-(local makes will 1No

313
not be accepted)
r load bank of suitable rating with taps for testing for
every 5 battery sets supplied
1No


6.0 VOLTAGE :
The cell voltage shall not exceed 2.25 volts with a continuous low rate floating
charge and shall not be less than 1.85 volts at the end of the emergency discharge.

7.0 OPERATION:
The D.C Battery shall be operated without an intentional ground. For indicating
the incidence and degree of a ground fault on the D.C control circuitry, the mid point of
the battery shall be earthed through an ammeter of high resistance. The high
resistance shall be so proportional that the current flowing under the worst earth fault
shall not exceed 250 mA.
It should be noted that, the 220V batteries are to be accommodated in the
Battery Room and should operate satisfactorily over the entire range of ambient
temperature of 0
0
C to 50
0
C and relative humidity of 95%.

8.0 General Requirements for Tests
Specific Gravity of Electrolyte:
The specific gravity of a fully charged cells shall be adjusted to
1.200+/- 0.005 at 27 deg. C as per the requirement of IS 1651 (latest revision)

Temperature Correction:
The capacity of the cell shall be corrected to 27 deg. C using the
proper temperature correction factor pertaining to the type of the cell and the
rate of discharge. The temperature correction should be made using factors
supplied by the manufacturer but shall generally conform to some national or
international standard for the similar type of cell.

Observations:
The observations, during any test shall be performed as
specified in IS 1651 (latest revision)

8.1 Test for Capacity:
The cell shall be tested for its rated capacity output. The
fundamental requirement shall be a discharge for 10 hours whilst discharge at other
rates, may also be performed.
The capacity output, at the first discharge, corrected to 27 deg.
C shall not be less than 85% of the rated capacity of the cell. The cell shall reach 100%

314
of its rated capacity within 5 charge discharge cycles.

8.2 Test for Charging Efficiency:
Since the cells are expected to operate at various state of
charge (SOC), the charging efficiencies at various depth for discharge needs to be
measured and standardized for this application.

The cell appropriate for this application should have the
following charging efficiencies:

80% SOC 80%
10% SOC 90%

8.3 Water loss:
The cell/ battery after being fully charged shall be kept
on a float charge of 2.4 volts per cell at a temperature of 40 deg. C for 21 days at a
stretch. The loss of water due to evaporation and self discharge shall not be more than
0.65 grams per Ah.

The battery shall reach an equilibrium state of charge
within 72 hours of such charging. This shall be indicated by the float current after 72
hours of constant float. The float current shall not be more than 3 mA per Ah.

9.0 WOODEN STANDS:
The stand shall be double row double tier. The stand shall be
made of seasoned teakwood as per approval of the drawing. The proposed drawing for
double row double tier may be enclosed along with the tender offer. It will be required
to supply sufficient quantity of paint in separate containers for applying 3 coats for each
stand with Cell No.
9.1 Marking:
Each cell shall be marked to meet the requirements of relevant Indian standards.
In addition, each cell shall be legibly numbered serially to identify the cell during
manufacture, testing, installation and operation of battery to identify after having
assembled into battery bank in battery racks.
Following marking however, shall be provided.
[i] Manufacturers name, type and trade mark.
[ii] Nominal voltage.
[iii] AH capacity at 10 hours rate with specified end cell
voltage.
[iv] Cell number.

315
[v] Upper and lower electrolyte level.
[vi] Type of positive plate.
[vii] Type of container.
[viii] Date of manufacture [ month and year] or [week and
year].
A set of loose stickers shall be provided to mark the cells
position in the assembled battery bank at site so that a cell removed for maintenance
can be put back in original position.

10.0 TYPE TEST CERTIFICATE:
The type test certificates for 220V/535Ah battery (Attested xerox copies) as
per latest ISS shall be furnished by the tenderer.
The bidder shall submit the test reports along with his offer for the
following type tests,
a Verification of constructional requirements.
b Verification of dimensions.
c Test for capacity.
d Test for retention of charge.
e Endurance Test.
f Ampere-hour and watt-hour efficiency test.
g Test for voltage during discharge.
If the type test report [s] does/do not meet the requirements
as per this specification,TANTRANSCO at its discretion may ask the supplier to conduct
the above type tests [s] at the suppliers cost in the presence of TANTRANSCO
representative without any financial liability to TANTRANSCO.
Special Tests :
The bidder shall submit the test reports alongwith his offer for the
following special tests, conducted on the offered samples as per relevant National
Standard[s] within five years from the date of opening of the bid and test witnessed by
any Government Department / Government undertaking, failing which the offer is liable
for rejection.
a) Test for Charging Efficiency
b) Water loss

316

11.0 ACCEPTANCE/ROUTINE TESTS:
All the acceptance and routine tests as stipulated in the relevant standards shall
be carried out by the supplier in the presence of Boards representative. The Test
Certificates submitted in triplicate for approval before despatch. Following acceptance
tests shall be carried out in the presence of TNtranscos officer.
a) Verification of Dimensions
b) Verification of marking and packing
c) Test for capacity and
d) Test for voltages during discharge & Ampere-hour and watt- hour
efficiency test

Immediately after finalisation of the programme of acceptance/
routine tests the supplier shall give sufficient advance intimation atleast 15 days in
advance to the Board to enable to depute its representative for witnessing the tests.
The Purchaser may at his discretion undertake test for capacity
and voltage during discharge after installation of the battery at site without any extra
cost. The supplier shall arrange for all necessary equipments including the variable
resistor, tools, tackles and instruments for the tests. If a battery fails to meet the
guaranteed requirement, TNEB shall have the option of asking the supplier to replace
the same within 15 [fifteen] days from the date of declaring the same to be
insufficient/failed / not as per the specification [s].

12.0. FACTORY INSPECTION
During the course of manufacture, purchasers representative shall have the right
to expedite and or inspect the materials, workmanship, labour and the progress of
manufacture of the equipment on order and may reject any material which is defective
or unsuitable for the purpose intended or which is not in accordance with the
specification. Supplier, upon demand by the purchaser or his representative, shall
remedy or replace such defective or unsuitable material. Supplier shall provide all
reasonable inspection facilities to purchasers inspector. The supplier shall give notice
of readiness so that the purchasers representative may witness such final and
acceptance tests before shipment. Purchasers representative may at any time inspect
and copy any or all test data. No material being furnished shall be shipped until factory
inspection to the satisfaction of the purchaser and/or his representative had been
made. Such inspection and approval shall not relieve the supplier from full
responsibility for furnishing equipment, conforming to the requirements of the purchase
order nor prejudice any claim, right or privilege which the purchaser may have, because
of the use of defective or unsatisfactory equipment, should the inspection be waived by
the purchaser, such waiver shall not relieve the supplier in any way from his contractual
obligations. All tests required including repeated tests and inspections, that may be

317
necessary owing to the failure to meet any tests specified shall be made at suppliers
expense. If the equipment fails to pass the tests specified, purchaser shall have option
to reject them. Additional tests shall be made to locate the failure and reconstruction.
Testing shall be repeated to prove that the rebuild equipment meets the requirements
in all respects.

13.0. DRAWINGS TO BE SUPPLIED ALONG WITH TENDER:
Tenderer shall submit along with the tender the following:
i) General arrangement of cells and battery assembly.
ii) General arrangement showing the inter-connections.
iii) Graphics showing the performance of material
iv) Drawing for the wooden stand.
v) Instruction manuals for initial charging and subsequent
charging.
vi) Pamphlets and technical literature giving detailed information
of the batteries offered.
vii) The following characteristic curves, to be furnished
alongwith the tender.

a.Battery discharge curves at various rates between one minute and 10 hour
rate.
b.Curves showing the relation between the specific gravity and amount of charge
in the battery for both charging and discharging conditions.
c.Curve of internal resistance at the end of various discharge rates .
d.Curves showing the relation between cell voltage and charging current when
charged at Finishing rate,High starting rate & Two step charging by starting and
finishing rate.
(No block diagrams are acceptable. Tenders are liable for
rejection if details schematic drawings are not submitted).

All drawings shall be in English Language and in Meteric System of units.
The supplier shall also submit three sets of instruction
manuals/leaflets/photographs.









318
GUARANTEED TECHNICAL PARTICULARS FOR 220V/535Ah TUBULAR TYPE
LEAD ACID STATIONARY BATTERIES
(To be filled in by the tenderer in full shape for the battery )

1. Type and Make
2. Normal battery voltage 220V
3. Number of cells in battery 110 Nos
4. Discharge capacity at 3 hour rate Amps
Hrs.
5. Discharge capacity at 10 Hour rate Amps
Hrs.
6. Normal charging rate Amps
7. Maximum charging rate Amps
8 Capacity in Ampere of battery
Amps/end voltage
a) 1 Minute load
b) 1 Hour load
c) 2 Hour load
d) 3 Hour load
e) 5 Hour load
f) 8 Hour load
g) 10 Hour load.
9. Open circuit voltage of each battery cell.
1.Fully charged
2.Floating condition.
3.When completely discharged at.
a.10hr. rate
b.5hr .rate
c.1 hr rate
d. hr. rate
e.1 minute rate
f.1 second rate.

Normal charging time after complete discharge Hrs.
10. Minimum current required for initial charging Amps
11. Time required for initial charging at the above current Hrs.
12 Watt hour efficiency when discharged at 10 hours rate %
12. Ampere hour efficiency %

319
Guaranteed AH efficiency at 10 hour rate of discharge
in percent
%
Number of positive and negative plates in each cell and
dimension of each plate

13 Surface area of plates Sq mm
14 Nominal cell voltage
15 Internal resistance for each cell
1.Fully charged condition
2.Fully discharged condition
3.Floating condition

16 Resistance of the battery including with connection
between the cells

17. Short circuit current (Amps)
Allowable duration of short circuit
18. Dimension of battery stand (LxBxH)
19. Number of tiers and rows used for the stand
20. Weight of lead required per cell in Kg. Kg.
21. Weight of antimony required per cell in Kg. Kg.
22. Thickness, type and material of the separators
23 Material of container
24 Material of cell connectors
25 Thickness of lead coating on connectors
26. Cross section of cell connectors
27 Material of battery stand
28 Amount of electrolyte per cell required for first filling
29 Specific gravity of electrolyte at 15, 27&50 Deg C
30 Recommended specific gravity of electrolyte at the end
of a full charge

31 Expected specific gravity of electrolyte at the end of the
discharge at the specified rate

Maximum electrolyte temp. that the cells can
withstand without injurious effect.
1.Continuously
2.short period.

32 Recommended float charging current current and
voltage Amp. volts

33. Recommenced boost charge current and voltage Amp.
volts

Recommended interval at which battery should be

320
discharged at 10 hour rate and quick charged.
34. Time required for boost charge from discharge current
35. Recommended trickle charging rate for different type of
working

36. Overall dimensions of each cell/battery
37 Distance between the centres of cells when erected
38 Weight of cell/battery complete with acid
39 Recommended maximum period of storage
Guaranteed life of battery in years
Estimated life of battery in years

TECHNICAL SPECIFICATIONS FOR BATTERY CHARGERS FOR 220V/535Ah
CAPACITY BATTERIES WITH DC DISTRIBUTION PANELS

1.0 Intent of Specification
This section of the specification covers design, manufacture, testing,
supply of battery charger with all materials and accessories required for various Stations
for boost, float and trickle charging for 220V/535Ah lead acid battery set for distribution
of DC supply with efficient and trouble free operation to various equipments in
substations as detailed below.
1.1. Supervision of erection and commissioning of chargers at the substation shall have
to be undertaken and rates for the same shall be indicated along with the offer.

1.2 Scope
1.2.1 The brief requirement for each station is detailed below :
A Charger panel consisting of a separate boost charger and separate
float charger with trickle charging as detailed else where in the specification.
1.2.2 The battery charger together with the battery bank and DC distribution
board shall constitute a 220V DC source for supply to various equipments in
the main receiving stations. In addition to this, the charger shall be capable
of being used for initial charging, trickle charging and equalizing charge as stipulated by
battery manufacturer. The arrangement for end cell tapping, if required will be
provided, so that while boost charging, the battery AC supply voltage fails or float
charger feeding loads develops trouble, at least about 84 cells (84 x 2.62 volts = 220V)
are connected across the load and part of battery continue to meet the DC requirement
till change over takes place and full battery is put across the load. The detailed circuit
arrangement is explained else where in the specification.

1.3 CODES & STANDARDS:
1.3.1 The material shall conform in all respects to the relevant Indian Standard
Specifications with latest amendments thereto.

321
-------------------------------------------------------------------------
Indian Standard Title
ISS 7204/1980 Stabilized Power Supplies D.C. Out put

ISS 2208/1962 H.R.C cartridge fuse links for voltage above 650 volts
------------------------------------------------------------------------------------

1.4 DESIGN CRITERIA
1.4.1 The Battery charger will constitute the DC power supply source for all stations
loads.
1.4.2 The equipment will be installed indoor in a clean but hot, humid and tropical
atmosphere.
1.4.3 The battery charger combination shall be such as to ensure continuity of DC
supply at load terminals at all times without even momentary interruption.
1.4.4 Further, the voltage at load terminals shall never exceed the limits of 10% and
15% of nominal, system concept.
1.4.5 For connecting battery and battery charger , 30 meters of 2 core 70 sqmm
unarmoured copper cable shall be used including cable for the 84 th cell tapping.
1.5 System Concept
1.5.1 The battery charger panels shall consists of the following for a system envisaged
for dual battery with dual charger system such that one battery bank is always in float
mode. There must be an interlock in the system such that in the event of failure of one
charger, the other charger shall take care of both battery set.
a) A Charger panel consisting of separate boost and float charger suitable for
charging, equalizing charging and trickle charging of battery sets 220V 535Ah
besides meeting continuous and emergency DC loads as detailed else where
in the specification.
The above modes of charging both automatically and manually
shall be through manually operated Auto / manual selection switch.

322
b) The boost charger shall be capable of initially charging of the 220V/ 535AH
battery at quick rate after an emergency or after a discharge test or for giving
periodical curative charge once or twice a year as per battery manufacturers
recommendations.
c) The float charger shall always be connected to the DC load and
shall maintain a steady voltage of 220V, plus or minus 1 % using a
constant potential controller.
d) The float charger shall be provided with an automatic current limiting facility
such that when float charger out put current exceeds 10% above the rated
current, the float charger voltage should be brought down automatically so
that the float charger output current does not exceed the set value.
e) The chargers shall have built-in automatic voltage control and load
limiting features. The voltage regulator shall automatically sense,
monitor and regulate the D.C. voltage to within + or - 1% of the
set value from No load to full load and under A.C. input supply
voltage and frequency fluctuations. Load limiting features shall
automatically reduce the output voltage of the charger on loads more
than the rated load.
1.5.2 During normal condition the float charger shall be on and working in
parallel with DC load and battery. The rating of the float charger shall be
such as to meet the float charge current requirement of the battery plus the
continuous DC load, the details of which is given else where in the
specification. While boost charging the battery set shall be across boost
charger and float charger shall be across the load.
1.5.3 During the boost charging, if there is an AC supply failure, the battery
should automatically be connected to the load to maintain continuity of DC
supply.
1.5.4 Further, to have battery supply across load even during short interval
of change over period and if float charger develops trouble, the 84
th
cell of
the battery should be capable of being connected through a blocker diode to
the load so that under boost charging condition the float charger, the
continuous DC load and battery up to 84th cell are in parallel.
1.5.5 The charger shall have provision for regenerative discharge of battery

323
bank.

1.6 RATING :
The ratings for boost charger, trickle charger, float charger and
emergency lighting change over system shall be as detailed below :
Sl.
No.
Particulars Required value
a. Boost charger
i) Range of voltage
ii) Continuous current rating
220V, 535AH
190V to 300V
100 Amps @ 50
degree temp.
b. Trickle charger and float charger
i) Range of voltage
ii) Continuous current rating float

iii) Trickle charger current

200V to 280V
80 A @ 50 degree
temp.
0-3 A

1.7 Detailed specification for charger panel.
The battery charger shall be supplied complete with all devices including but not
limited to the following. If any device/components felt is required at the time of
approval of drawings, the same shall be provided without any extra cost.
1.7.1 Charger : Float and Float-cum-Boost

1.7.2 Type : Solid-state, full wave, fully controlled.

1.7.3 Enclosure : Sheet steel enclosure

1.7.4 Enclosure degree of protection : IP-42

1.7.5 A.C. Input

a. Supply : 415V, 3 phase, 50 Hz, 4 wire.

b. Voltage variation : _15% to +10%

c. Frequency variation : _5%

d. Combined voltage +
frequency variation : 10% (absolute sum)

e. Short-circuit level : 50 KA r.m.s.

324
symmetrical.

f. System earthing : Solidly earthed.

1.7.6 D.C. Output

a. Float charger : Continuous D.C. load
plus 25% margin plus float charging
battery. (values specified)

b. Boost charger :Restoring fully discharged battery to
fullcharge condition in 10-hours with
25% margin over maximum charging
rate. (values specified)

1.7.7 Performance Requirements
a. The output voltage of the charger shall be regulated within 1% of the set
value for any load variation from 0 to 100% and A.C. input voltage and
frequency variations as indicated above in 7.5.

b. The ripple content in charger D.C. output shall be limited to 1%.
The percentage efficiency of charger shall be greater than 80% at
0.8 power factor.

1.8.1 Each charger panel shall consists of
I ) Charger Panel For 220V/535Ah
a) A Boost charger operating on AC input voltage of 415 volts
15 % to +10%, three phase, 50hertz, shall be capable of boost charging
the battery comprising of 110 Nos. 2V 535AH lead acid cells upto a
maximum cell voltage of 2.7V per cell, consisting of the following
components.
i) One No. triple pole and neutral pole ON / OFF AC
input switch of adequate rating or A.C. 3-pole miniature circuit
breaker of suitable capacity
ii) Required Nos. of HRC fuses with base, fittings etc. for DC output &
AC input.
iii) Three Nos. of pilot lamps for indicating availability of 3 phase
supply.

325
iv) One No. AC contactor triple pole with ON/OFF push
button with O/L relay
v) One constant potential controller for error detection, load
current detection, amplification etc., so that the Boost charger
output voltage is maintained automatically to the required value,
with input voltage variation detailed above.
vi) One 3Ph naturally air cooled transformer liberally rated for the
rectifier rating specified with + 2.5% taps on input side for input
voltage correction by means of selection switch mounted on the
front of the panel which can be operated on load for changing the
taping of the input transformer.
vii) Three Nos. ballast chokes, if required.
viii) a) One set of 3- phase full wave bridge connected silicon
rectifier, with zener type thyristor with simple smoothening circuits,
liberally rated to meet the continuous current rating specified with
stepless voltage control.
b) One set ripple filtering device to limit the ripple content to
less than 1%
ix) One double pole moulded case circuit breaker backed by HRC fuses
on DC output side.
x) A set of indicating lamps for DC on indication & A.C supply
indication
xi) One DC ammeter moving coil type with shunt etc., for measuring
DC output /charge / discharge current and one ammeter for
measuring load current.
xii) One moving coil voltmeter with selector switch to read boost
charge voltage, float charge voltage, battery tap and off and one
volt meter for AC input voltage.

326
b) A float charger operating on AC input voltage of 415 V 15% to + 10%,
three phase 50Hz shall be such as to meet the float charge current
requirement of the 110 Nos. 2V, 535AH and 220V/300Ah lead acid cells
battery plus the continuous DC load, consisting of the following
components.
i) One AC input triple pole & neutral pole ON/OFF switch of adequate
rating rating or A.C. 3-pole miniature circuit breaker of suitable
capacity
ii) Three Nos. of HRC fuses with fittings.
iii) Three Nos. of pilot lamps.
iv) One No. AC contactor triple pole with ON/OFF push
button with O/L relay
v) One constant potential controller for error detection, load
current detection, amplification etc., so that the float charger
output is adjusted automatically such that the battery voltage is
around 220 volts with load current and input voltage variation
detailed above (both) occurring simultaneously.
vi) One auto manual change over switch.
vii) One raise / lower push button for manual operation.
viii) One main transformer, 3 phase, natural cooled, liberally rated for
the rectifier rating specified with
+ 2.5% taps on input side for input voltage correction by means of
selection switch mounted on the front of the panel which can be
operated on load for changing the tapping of the input transformer.
ix) a) One set of 3 phase full wave bridge connected silicon
rectifier with zener type thyristor with simple smoothening circuit
liberally rated to meet the continuous current rating specified with
step less voltage control.

327
b) One set of smoothing choke to limit the ripple content
to less than 1%.
x) One moulded case circuit breaker to control float charger DC
output.
xi) Required Nos. of HRC fuses with base fittings etc for DC output and
AC input.
xii) One moving coil ammeter for float charger current.
xiii) One center zero milli ammeter to measure trickle charging current
to the battery.
1.9. The battery chargers shall also comprise the following equipment.
i) One set of single pole two way on and off, suitably rated change over switch
for selection of Battery Float/ Boost mode (one for each battery bank)
ii) A suitable volt meter with selector switch shall be provided on the
panel to indicate phase to phase and phase to ground voltage of the
incoming supply.
ii) One centre zero D.C. Ammeter to be provided in the negative
terminal of the battery for reading charge/ discharge current of
the battery. The Ammeter range shall be 100-0-100A for 535Ah
and 50-0-50A for 300Ah.

iii) Internal light operated on 230 Volts single phase, 50 C/S, A.C.
system with door opening/closing ON/OFF switch.
iv) 2 Nos. earthing lugs suitable for receiving 120 sq.mm copper
conductors.
v) Space heaters suitable for operation AC 230 V, 1 Amp, 50 c/s.

vi) Heater ON/OFF switch.

vii) Cable glands for all the external cables.

viii) Single phase preventor

328

ix) 1 MCCB triple pole for connection of 110
th
cell and 84
th
cell positive and for first
cell negative for 110V.
x) D.C. contactor of suitable rating for connecting 110
th
cell to the
Positive D.C. bus, inter-locked with A.C. contactor provided in the
boost charger.
xi) 1 No. silicon blocking diode connected to 84
th
cell and the D.C.
positive bus to maintain continuity of D.C. supply to the D.C. bus
in the event of A.C. failure while boost charger in service and to
avoid short circuit of 110
th
cell positive and the 84
th
cell positive.

xii) Suitable no. of earth leakage circuits for annunciation both audible and
visual with push button for reset.
xiii) One set of milli-ammeter to indicate the leakage current when the
mid point of the battery is earthed.
xiv) A set of audible and visual alarm annunciation scheme with all
necessary accessories to acknowledge reset and test scheme as also
other necessary relays, with the following facia window.
i. AC Mains fail
ii. AC Mains fail in any phase.
iii. AC input fuse failure for boost charger
iii AC input fuse failure for float charger
iv Float Charger DC Fail
v Boost Charger DC Fail
vi. DC Earth Fault
vii Rectifier fuse fail
viii Rectifier control supply failure
ix Filter fuse fail

329
x. Blocking Diode fail
xi. Load Bus DC fail
xii. Boost charger over load
xiii. Float charger overload
xiv Under voltage of the battery
xv Over voltage of the battery
xv) Necessary relays for the above shall be provided wherever necessary.
Potential free contacts (minimum 3 nos) shall be provided.

xvi) Necessary provision for self diagnostic alarm for any internal faults in the
charger.
xvii) The D.C. system shall be provided with a continuous earth leakage
indicating milli-Ammeter, suitable for operation with an earth fault on
either pole together with a relay to give alarm and visual indication for an
earth fault on the D.C. system.

xviii) Necessary relays for annunciation for faults mentioned above shall be
provided. They shall be suitable for operation of 220V D.C. supply with +
10% to 15% variation. Necessary circuitry for canceling alarm shall be
provided. On canceling the alarm, the sound only should go and
lamp should continue till the fault is rectified/cleared.

xix) Necessary contacts for SCADA operations shall be provided.
xx) In the event of A.C. supply failure, when the battery is on boost
charge, the available battery capacity shall be automatically connected to
the D.C bus.

xxi) All fuses shall be HRC non-deteriorating type. Unless otherwise
specified, the fuses shall be of class-4 (80KA prospective breaking

330
current) for A.C. circuits and class-2(33 KA prospective D.C. current)
for D.C. circuits.

xxii) A block diagram to indicate the general protection features
provided for the charger shall be furnished along with the Bid.
xxiii) The float charging equipment and boost charging equipment
shall be mounted in a metal enclosed, sheet steel cubicle, indoor floor
mounting, free standing type. It shall be totally enclosed, completely dust
tight, weather and vermin proof. The cubicle shall be adequately
ventilated with louvers to facilitate the cooling of transformers and
rectifiers. The ventilating openings shall be less than 3 mm size. The
panel shall be complete with internal wiring, terminal board for internal
and external connections. The panel shall be made out of suitable angles
and M.S. Sheet of 16 SWG for the front,18 SWG for the back, top and
sides, and 14 SWG for the bottom. The height of the panel shall be 1800
mm and depth 600 mm and panel shall have suitable width to
accommodate the charging equipment. i.e., adequate clearance / space
should be provided between item to item in the charger, to facilitate easy
handling at the time of attending on repairs. The charger shall be
provided with hinged type rear doors.
NOTE :
All MCCB shall be of breaking capacity of 25 KA with over load and short circuit
protection.
[c) IMPORTANT NOTE :
a) Fuses for DC output and AC input shall be brought on
the front of the panel and cutouts provided.

331
b) Semi conductors devices, Power failure, relay alarms on Ac failure
and to disconnect all internal charger loads from battery to prevent
unnecessary discharging during power failure.
c) Printed circuit shall be accommodated in modules, plug in
type, and similar modules shall be interchangeable in
standard socket chasis.
1.10 INTEREFRENCE AGAINST RF-CIRCUITS:
The equipment shall be efficiently screened against interference to
radio as also other communications equipment, which may be installed in the same
building. All the sources of noise shall be fitted with Re-suppressors generally in
accordance with relevant ISS/IEC.
1.11 Ground Bus :
For ensuring the rigid connection the minimum section of the ground
bus shall not be less than 160 Sq. mm. The ground bus shall be earthed solidly and
connected to the purchasers station main earthing system through 50 x 6 mm G.I flat
with 2 bolts of M12 size.

2.0 220V DC Distribution Boards
The D.C. distribution Panels shall be of rugged construction, designed
for working satisfactorily under the severest operating and climatic conditions and
shall conform to the relevant ISS of latest issue.
The 220 V Distribution panels cabinet shall be of indoor type suitable
for floor mounting on steel frame work on cement concrete pedestal.
The thickness of the sheet steel shall be as follows :-
Front & Base Frame : Not less than 3mm
Top, Sides and rear : Not less than 2mm
The cabinet shall be fabricated with the M.S. Sheet steel by suitably folding the
sheet to achieve required strength.

332
The panel shall be painted with two coats light grey enamel paint to Shade 631
of IS 5 for exterior finish and glossy white for interior finish. All hardwares shall be
hot dip galvanized to avoid corrosion.
The panel shall be vermin proof. Hinged twin doors shall be provided on the
rear side, vermin proof louvers with copper/brass/stainless steel wire mesh shall be
provided on the rear doors, lever type locking handle shall be provided for doors. The
cable entry shall be from bottom and detachable gland plates in two halves shall be
provided with 25 mm diameter. Rubber gasket shall be provided for joints. HRC fuses
shall be provided for DC lightning circuit, A.C. supply, D.C. control and annunciation
bus.
The height is inclusive of height of 100mm vase support frame.
(a) Anodised Aluminium Labels shall be provided for all instruments, switches,
push buttons, lamps, fuses and for name plate details of the panel.
(b) Grouting holes and bolts shall be provided. Vermin proof ventilating louvers
switch stainless steel/Copper/Brass wire mesh shall be provided on the rear
doors of the panel.
(c) In addition to earth fault relay 2 Nos. push button switches and
resistors shall be provided for instant indication of positive to ground
fault and negative to ground fault to check the earth leakage relay
and associated audio and visual indication at a stroke.
(d) Necessary indication lamps with related accessories shall be provided
to distinctly indicate the acknowledged state of annunciation scheme.
(e) The A.C. supply (230 V 15%) shall be wired neatly and kept
separately from D.C. supply.
(f) The bus bars shall be of electrolytic grade copper only.
(g) TERMINATION OF CABLE :

333
Incoming and outgoing cables shall be terminated in suitable rated stud
and nut type terminal block. Necessary clearance shall be maintained for
easy wiring, 20% spare terminals shall be provided for future connection.
(h) INSULATION :
The cabinet wiring and all equipments shall withstand a power frequency
high voltage of 2 KV for one minute between each point to ground and
between circuits.






















334
220V DC Distribution Panel Components


Sl.No. Description Rating Quantity
1. MCCB with instantaneous O/L setting for
controlling the incoming DC supply.
150 Amps 1 No.
2. D.C. double pole miniature circuit breaker 30 Amps 15 Nos.
3. Panel lamp with door switch and space heater with
control switch
230V AC 1 set
4. Size of copper D.C. bus bars of rectangular cross-
section
(Length not less
than 500mm)
25 x 6 mm
5. Size of earth bus also of rectangular size (Length not less
than 500 mm)
25 x 3 mm
6. (d) Size of the incoming and outgoing connections
of MCCB
Braided / flexible
copper wire 75
sq.mm
7 (e) D.C. Distribution (Standard flexible copper
wire)
10 Sq.mm
8 (f) A.C. Circuits and D.C. lighting 2.5 Sq.mm 100 x
50 x 50mm
9. (a) Base support frame
10 (b) Thickness and Colour of base frame Sheet steel of not less than 3mm thick
painted with black Enamel paint.

NOTE :

1. The annunciation scheme should be capable of giving both audible and visual
(lamp) indication for one or more faults occurring subsequently even before
normalizing the earlier fault/faults.
2. The DC for annunciation scheme shall be taped off at the incoming side of the main
MCCB and provided with 2A HRC fuses and links

2.1 SPACE HEATERS AND LIGHTING OUTLETS :

(i) Space heaters (PTC) shall be provided inside all cubicles and panels to prevent
condensation of moisture. The wiring of space heaters shall be protected with
porcelain beads for suitable thermal insulation for a safe length.All lighting outlets
with the switches etc., shall be provided inside each entrance door at the back of
the panels.

335
2.2 WIRING
The internal power and control wiring of the charger shall be of adequate rating
as recommended by cable manufacturers and relevant IS.
The interconnecting cables or bus bars carrying load current from the main
transformers secondary onwards upto and including DC output bus bars shall be PVC
insulated 1100V grade stranded copper conductor. Interconnecting leads in the control
circuits and leads of filter capacitors shall also be of 2.5 sqmm copper conductors. Ends
of all load current carrying cables shall be fitted with copper lugs of adequate rating and
shall be soldered or crimped effectively to the conductor to ensure that the
temperatures rise at the joints does not exceed that of the conductors. All cabling and
wiring shall be neatly secured in position and adequately supported. All cables and wire
carrying AC supply shall be kept separate from other cables. The colour scheme
employed for the cabling and wiring shall be shown in the suppliers instructions manual.
The colour scheme employed shall be as follows :
i. For AC Circuits - Grey
ii. For DC Circuit - Positive -Red
Negative -Black
Earth -Green
All outgoing wiring shall be brought out to terminals on terminal blocks provided
with 10% additional terminals. The terminal end shall be provided with suitable
identification marks. All the terminals shall be of nut and stud type.
2.3 MIMIC DIAGRAM :
The mimic diagram shall be incorporated with red and green lamps for indicating
air circuit breakers position. Switchboard purpose, built in resistor type lamps of low
watt consumption inter changeable and suitable for easy replacement shall be provided.
LED lamps are also acceptable.
2.4 EARTHING :

336
Earthing of a dead metallic part of bodies of the equipment on the panels shall
be done with a soft drawn single conductor bare copper. Main connection shall have
minimum area of 14.5 mm and the main earthing connection to the earthing bus bar,
65 sq. mm these wires shall be connected to suitable terminals and clamp junctions.
Soldered connections shall not be employed. The no. of earthing terminals shall be two
for the whole assembly of panels.
2.5 INDICATING INSTRUMENTS :
All instruments shall be of the square switch board type, of 96 Sqmm. Size back
connected, suitable for semi flush mounting and provided with dust light cases for
tropical use with dull black enamel finish. The accuracy class shall be 1.5. The
instruments shall be approximately 96 mm square with 270 deg. C scale .The dials
shall be made of such materials as to ensure freedom from wrapping, fading and
discolouring. Marking on scales shall be black on white background. The dials of the
instruments shall be of 240
0
scale. All instruments shall have practicable laboratory
means of adjustments to accuracy. The limits of error shall be those permissible for
switchboard instruments as per IS-1248 or BSS-87.

2.6 Regulation :
The DC output shall be maintained at + 1% for input variation of + 10% to
-15% from no load to full load and input frequency variation from 47.5 Hz to
52.5 Hz and also when all three variations occur simultaneously. The power
factor shall not be less than 0.65.

2.7 TYPE TESTS :
Type test certificates as per relevant standards shall be furnished by the
tenderer. as per latest ISS. The initial payment for the materials will be released
only after approval of type test certificate from this office.
a) Type tests of battery charger : Radio Frequency interference test.

337
b) Routine tests on Battery charger :-
All the acceptance and routine tests as stipulated in the relevant standards
shall be carried out by the supplier in the presence of Boards representative.
The Test Certificates submitted in triplicate for approval before despatch.
Following acceptance tests shall be carried out in the presence of TNEBs officer.
i) Insulation resistance test. (HV test)
ii) Voltage regulation check from 0 to 100% load with + 10% voltage
variation.
iii) Ripple content measurement
iv) Heat run test on current limiting value
c) Routine tests on DC Distribution Panel
i) Visual examination and Dimensional check.
(ii) Quantitative check.
(iii) Functional check of MCCBs, MCBs.
(iv) Power frequency high voltage withstand test for all wiring and
equipments.
(v) I.R. Value measurement
d) Routine tests on component parts.

a) Burning test for PCBs. Assembled PCB burning test at 70
Deg.C. for seventy-two (72) hours with loaded condition.

b) Rapid temperature cycling tests at 70 Deg.C. and 0 Deg.C
for thirty (30) minutes at each temperature for (five) 5 cycles.
c) Routine and type test certificates for components like
contactors, relays, instruments, SCR/PWM transistors,
Diodes, Condensor, Potentiometer, semi- conductors, push
buttons to be furnished for review whenever required.
d) Immediately after finalisation of the programme of
acceptance/routine tests the supplier shall give sufficient
advance intimation atleast 15 days in advance to the Board to
enable to depute its representative for witnessing the tests.



338
2.8 TENDER DRAWINGS:
Duplicate copies of the relevant drawings shall be submitted along with the
tender.
2.9 DRAWINGS TO BE SUPPLIED ALONG WITH TENDER

The successful tenderers shall forward within 15 days from the date of
receipt of purchase order, four sets of the drawings for the purchasers
approval. Drawings which are satisfactory for approval on the first submission
will be approved and one copy of the approved prints will be returned. The
drawing not satisfactory for approval on the first submission will be returned to
the supplier for re-submission.
i) Details of construction of cubicles and complete drawings of the switch
board indicating full details of the location switches, instruments, relays,
bus bars, cable glands, support etc.
ii) Wiring and cabling diagram for all the circuits. All devices shall be
numbered according to the international convention.
iii) Details of construction of boost and float charger

Tenders will be liable for rejection if detailed schematic drawings are not
submitted.
Any shop work done prior to the approval of drawings shall be at the suppliers
risk. Supplier shall make any change in the design which are considered necessary to
make the equipment conform to the provisions and indent of the purchase order
without any additional cost to the purchaser.
The supplier shall supply the purchaser within 15 days of receiving an approved
print, one reproducible master print plus two prints of each of the approved drawings.
In case the supplier resubmit a revision or change for approval, such resubmission shall
be by four prints.

339
The supplier shall send 5 copies of approved drawings to each consignee
Superintending Engineers (after approval) and also two sets alongwith battery charger
while despatch.
All drawings, part lists, assembly procedures etc., shall bear a readily identifiable
number etc., drawing number and each subsequent revision or addition to the drawing
shall be identified by a revision number.
Checking and approval of the above documents by the purchaser is for the
benefit of the purchaser and shall not relieve the supplier from full responsibility for
ensuring correct interpretation of design, drawings and specifications or for the
completeness and accuracy of the shop drawings and relevant specifications.
Supplier shall record all deviations, corrections, omissions, changes etc., occuring
throughout the manufacturing, assembly and testing phases.
All drawings shall be in English language and in Metric System of Units.
Non-supply or part supply of drawings, literature and manuals will be
deemed as incomplete supply of switchboard.
Foundation drawings indicating the details of foundation bolts cable
entries and trenches, etc.,
Elementary diagrams of all controls, metering, protection, annunciation
and other circuits, panel wise. All devices shall be according to SA CODE.
Schematic diagrams of PCBs and charger.
Dimensional outline of charger drilling diagram and special mounting
arrangement if any of each type of various devices.










340
220V DC Distribution Board
As per specification
01. Name of the manufacturer and place of
manufacture
To be furnished by bidder.
02. a. Overall dimension of the panel in
mm.
Height x width x Depth
2312 mm x 600 mm x
600 mm
b. Thickness of sheet metal in mm
Front 3 mm
Sides, Top and rear 2 mm
Rear : Door 2 mm
c. Dimension of base support frame in
mm
100 mm x 50 mm x 50 mm
(ii) Thickness of base frame mm 3 mm
d. Colour shade
(i) Exterior finish
IS 631
Light Grey
(ii) Interior finish
(iii) Base frame
White
Black
e. Materials of wire mesh for the louvers Brass
f. Whether detachable gland plate in
two halves provided at bottom
Yes.
f. Whether door with lift off hinges
provided for the rear with built in locking
system
Yes

g. Whether panel designation label is
provided
Yes
3. SWITCH BOARD WIRING

341
a. Power frequency high voltage
insulation level of panel
2 KV 50 HZ for one minute.
b. Sizes of 1100V grade PVC insulated
electrolytic grade flexible stranded
copper wires in sq.mm.
Multi strandard copper wire
as per IS.
CIRCUITS
(i) D.C. Distribution 10 Sq.mm.
(ii) D.C. Annunciation / Control 2.5 Sq.mm.
(iii) AC (230 V) 2.5 Sq.mm
(iv) Earthing
(v) Size of electrolytic grade copper flat
for DC positive and negative bus bars in
mm
25 x 6 mm
Length not less than 500
mm
(vi) Size of electrolytic grade copper flat
for earth bus in mm
25 x 3 mm
















(vii) Type of terminal provided High dielectric phenolic
moulded with insulation
barrier with stud and nut
type.
4. VOLTMETER
a. Make AE/IMP/Nippon/Meco.
b. Type Flush mounting type.
c. Accuracy class Class 1.0.
d. Maximum scale range 0-150 V/0-75A
e. Rating Continuous

f. Size 144 mm x 144 mm
5. PUSH BUTTON

342
(i) Positive to Earth
(a) Type Flush Mounting Type.
(b) Make Captron/Vishnow/TC/Flush
Red.
Colour of Push Button Black

(d) Type of operating knob Flush Type
6. Whether internal wiring conform to
relevant IS.
Yes.
7. Whether industrial Siren is provided. To be provided.
8. Whether Pip-Pip Horn is provided. To be provided.
9. Whether testing facility is provided to
check the operation of the DC earth fault
relay.
To be provided.
10. Rating of space heater 60 W 230 V AC
11. Whether No. of HRC fuses as per
specification.
To be provided.
12. Whether AC and DC terminals kept
separate
Yes.















343
A.C. PANELS FOR 230 KV SS

1.0. GENERAL ARRANGEMENT & STANDARDS
1.1. The medium voltage AC panels to be supplied would be of cubicle type with
switches and other accessories mounted and connected to the bus suitable for 440
volts, 50 cycles, 3 phase AC supply system.

1.2. Each panel shall have the following dimensions:
Height : 2312mm (including the height of base support channel frame of size
100 x 50mm made out of not less than 3mm thick sheet)
Depth : 600 mm
Width : 800 mm

1.3. The panel shall be folded type construction and fabricated out of sheet steel of
thickness as follows,
Front, Rear and Base Frame : Not less than 3mm
Side, Top and Bottom : Not less than 2mm

1.4. Each panel shall be provided with ventilation louvers with stainless steel / Brass
wire mesh on the rear doors of the panel and should be vermin proof.

1.5. The cable gland plate at bottom should be in two halves and detachable type.

1.6. The rear side of the panel shall be provided with twin hinged doors with lever
type locking handle.

1.7. Four numbers grouting holes and grouting bolts shall be provided at the bottom.

1.8. All the hardwares used shall be hot dip galvanised.

1.9. The painting of the panel should be done as per IS-6005-1970 or latest issue and
finished with light grey colour, paint of shade 631 of IS-5 for outside and glossy white for
inside. The base support frame shall be painted black in colour.

1.10. RED, YELLOW, BLUE colour Neon lamps shall be provided for R, Y,B phase
indications at the top of the panel with 5A slide lock fuses.

1.11. One number 60 watts B.C. lamp shall be provided inside the panel for panel
illumination and operated by rear door through door switch for ON/OFF operation.

1.12. Each panel comprises of three zones as detailed below:
Top Zone : Instruments
Middle Zone : Miniature circuit breakers for outlets

344
Bottom Zone : Main switch and CT
It shall be possible to open each zone from the front side to enable inspection of
defects if any without disturbing other zone. Each zone shall be provided with hinged
doors. The hinges shall be at left hand side and bolting arrangement shall be at right
hand side corners for locking, Anodized Aluminium Caution Board to the following effect
shall be provided on the front and rear sides of the panels.

CAUTION : SWITCH OFF THE STATION TRANSFORMER SUPPLY AND
GENERATOR SUPPLY BEFORE OPENING THE DOORS
2.0. STANDARDS
All the materials and equipment shall comply in all respects with the
requirements of the latest standards furnished hereunder.

a. ISS-8623 Specification for factory built assembly of switch gear and
control gear for voltages upto and including 1000V
AC/1200 V AC.
b. ISS-4237 General requirements for switchgear and control gear for
voltages not exceeding 1000V
c. ISS-2147 Degree of protection provided by enclosures for LV
switchgear and control gear
d. ISS-3072 Code of practice for installation and maintenance of
switchgear
e. ISS-2075 Current Transformer
f. ISS-2516 AC circuit breaker (Part-I, II etc)
g. IEC-408/1972 Short time withstand test
h. ISS-6005 Surface treatment for M.S. sheets
i. CBIP-Technical
Report July
1996or the latest
amendments

Static Trivector Meter with 0.5 class accuracy and with
RS 485 Mod Bus Communication Port
j. IS:1248 Indicating Instruments
Wherever a standard is specifically mentioned, it is understood that the
corresponding standard or standard from amongst the source mentioned above shall
also apply. It is however understood that the material offered shall comply with one
consistent set of standards except in so far as they are modified by the requirements of
these specification.

3.0. BUS BARS
Hard drawn electrolytic grade copper bus bars of rectangular size shall be
provided for phases and neutral. Bus bars shall be completely wrapped with phase
identification colour PVC tapes to avoid exposed live portion. Necessary holes may be
drilled in bus bars at suitable places to connect the incoming and outgoing leads,
copper conductors with lugs will be connected to these holes using suitable brass bolts.

345
The clearance of live parts between phases and to the earthed metal parts of the panel
shall be adequate and conform to ISS of latest issue.
The bus bars shall be fixed inside the panel in vertical formation on the right side
of the panel when viewed from rear side.

3.1. SIZE OF BUS BARS:

Sl.
No.
Panel for For Phases For Neutral For Earth
a. 230 KV SS 50mmx6mm 25mmx6mm 25mmx3mm

The length of the bus bars should not be less than 1000 mm.

4.0. INTERNAL WIRING
Internal wiring should be done by the supplier. Internal connections from main
incoming MCCB to the bus bars and from the bus bars to the outgoing MCBs and then
to the terminal blocks from the switches should be done by electrolytic grade standard
flexible copper wires with PVC insulation of 1100V grade of the following sizes. The
ferrule shall be provided at the ends for identification purposes.
Rating of switches Amps Size of insulated copper wire
400 min 150 sq.mm
200 min. 70 sq.mm.
100 min. 35 sq.mm.
60 min. 15 sq.mm.
30 min. 5 sq.mm.
15 min. 2.5 sq.mm.

All auxiliary wiring (current and voltage) for meters etc., should be done with multi
stranded copper PVC wires, open live terminal inside the panel should be above
300mm from bottom of the panel.

5.0 DETAILS OF INSTRUMENTS AND SWITCHES

5.1 PANEL for 230 KV SS

5.1 .1 TOP ZONE : (INSTRUMENTS)

a. 1 No. The static trivector meter with 0.5 class accuracy and with
RS485 MOD BUS Communication port shall be of 3 phase 4wire
440V, 1A, 50 Hz capable of measuring and displaying the following
electrical quantities for polyphase balanced or unbalanced loads.
KWh, KVARh, KVAh, KVA MD, rising demand for elapsed time, PF,
frequency count for number of MD resets, phasewise details of

346
current and voltage, real time and segment check display. The
above parameters should have scroll lock arrangements, so as to get
the display of any one parameters continuously. In addition the push
button display mode is also essential. The push button shall have a
sealing arrangement.

5.1.2. MIDDLE ZONE : (OUTGOING SUPPLY)

There shall be two bus sections viz.,Main bus and Auxiliary bus.

Station transformer supply shall be made available in the main bus.The following
outlets shall be provided from the main bus.


a. 2 Nos. 100 Amps, 3 phase, 3 pole, 440V moulded case circuit
breaker.(Thermal magnetic type)
b. 7 Nos. 60 Amps, 3 phase, 3 pole, 440V miniature circuit breaker
c. 4 Nos. 30 Amps, 3 phase,3 pole, 440V miniature circuit breaker
d. 10 Nos. 30 Amps, single phase, two pole, 230V miniature circuit breaker
e. 1 No. Digital Type frequency meter (Display with four digits and 12mm
height) to indicate 50 cycles per second

GENERATOR SUPPLY shall be made available from diesel generator panel in
auxiliary bus. The following outlets shall be provided from the auxiliary bus.
(a) 2Nos. :30 Amps, 3phase, 3pole, 440V miniature circuit breaker.


5.1.3 BOTTOM ZONE : (INCOMING SUPPLY)

a. 1 No 400 Amps, 3 phase, 3 pole, 440 Volts, moulded case circuit breaker
(Thermal magnetic type) with fixed instantaneous O/L settings for
controlling the incoming supply availed from station transformer.The
main bus in the middle zone will be energised by this MCCB
b. 1 No. 60 Amps, 3 phase, 3 pole, 440 Volts, moulded case circuit breaker
(Thermal magnetic type) with fixed instantaneous O/L settings for
controlling the incoming supply availed from diegel generator
set..The auxiliary bus in the middle zone will be energised by this
MCCB.
c. 3 Nos. LT single phase CT of ratio 200/1A shall be provided with metering
class accuracy 0.5 .


6.0 OTHER DETAILS

347
a. Name plate of the panel board may be provided at the top of front side of the panel.
b. 2 Nos. Earthing terminals shall be provided for each panel.

c. Provision shall be made for adequate accessibility for each switch for the incoming
and outgoing cable connections purposes.

d. Each panel may be assigned with a serial number.

e. 5A, rewirable slide lock fuses may be provided for the phase indication lamps,
cubicle illuminating lamps, static trivector meter potential supply and voltmeter.

f. All meters, crack switches, fuse units shall have circuit indicating label.


7.0. BRAND NAMES:

The brand names for various equipment and instruments shall be as per clause-
16.0

8.0. INSTRUMENTS:

The Static Trivector Meter shall conform to CBIP Specification Technical Report
No.88 July 1996 or to the latest issue with 0.5% accuracy class and with RS485 MOD
Bus Communication Port.
The meters covered under this specification shall conform to latest
issues/amendments of the standards given below:

India Standard No Title International &
internationally
Recognised standard
IS 14697 of 1999 and the
CBIP Technical Report
No.88 (Revised July
1996) and its latest
amendments.
Specification for AC
Static HT Trivector
Meters 110V/1A Class
0.5
IEC 687/1992

Equipment conforming to the above standards, which ensure equal or higher
quality than the standards mentioned above would also be acceptable.

The meters shall also have an optical port in addition to RS 485 Mod Bus
Communication port for automatic data logger system in Sub-Station for energy
Balancing and Accounting. Besides the meter supplied shall be with pulse output for
KWHr pulse. Suitable window based software with compatible software for data logging

348
in the Sub-Station shall be supplied along with the meters and the same to be installed
in the Sub-station PCs.

The current transformer secondary leads shall be provided with shorting links,
test links and isolating facilities, All moulded case circuit breakers shall be of 25KA
rupturing capacity and miniature circuit breakers shall be of 10 KA rupturing capacity.

The Voltmeters, frequency meter, shall be of flush type.

9.0 . TERMINAL BLOCKS:

All terminals shall be of Disconnecting Type. Necessary clearance viz., 100mm
between 2 sets of terminal block, 250mm between terminal block and associated cable
gland plate ,shall be maintained.
Separate neutral terminal shall be provided at the terminal block, adjacent to the
phase terminals of each outlets for terminating neutral of the respective outlets.
Adequate spare terminals may be provided for future additions (20% of the terminals
used).

10.0. INDICATION LAMPS: All indicating lamps shall be Neon type.

11.0. DRAWINGS:

11.1. The supplier shall forward within 15 days from the date of receipt of purchase
order, four sets of the below mentioned drawings for the purchasers approval.
Drawings which are satisfactory for approval on the first submission will be approved
and one copy of the approved print will be returned. The drawings not satisfactory for
approval on the first submission will be returned to the supplier for re-submission.
i. Drawings showing the front elevation of the panel.
ii. Drawings showing the bus bar arrangement.
iii. Drawings showing the lateral cross-section indicating mounting
arrangement of switches.
iv. Drawings showing the cable entry arrangement.
v. Drawings showing the foundation details.
vi. Single line diagram of metering and protection arrangements.

Any shop work done prior to the approval of drawings shall be at the suppliers
risk. Supplier shall make any change in the design which are considered necessary to
make the equipment conform to the provisions and indent of the purchase order without
any additional cost to the purchaser.

11.3. The supplier shall supply the purchaser within 15 days of receiving an approved
print, one reproducible master transparancy and two prints of each of the approved
drawings.

349

11.4. The supplier shall send 5 sets of approved drawings and instruction manuals to
each consignee and also two sets alongwith the panels while despatch.
3 sets of instruction manuals shall be supplied within one week from the date of
approval of drawings to Superintending Engineer/Transmission II/Chennai-2.

All drawings, part lists assembly procedures etc., shall bear a readily identifiable
number, drawing number etc., and each subsequent revision or addition to the drawing
shall be identified by a revision number.

Checking and approval of the above documents by the purchaser is for the
benefit of the purchaser and shall not relieve the supplier from full responsibility for
ensuring correct interpretation of design, drawings and specifications or for the
completeness and accuracy of the shop drawings and relevant specifications.

Supplier shall record all deviations, corrections, omissions, changes etc.,
occuring throughout the manufacturing, assembly and testing phases.


12.0. DESCRIPTIVE LITERATURE AND PAMPHLETS:
Full descriptive particulars of the items used in the A.C. panel and necessary
drawings showing the connection details with pamphlets should be furnished. The
details of MCBs and MCCBs that are used for assembling these panel should be
furnished.

13.0. ROUTINE TESTS:
The following routine tests shall be conducted on the panels in the presence of
Boards Engineer and Test Certificates submitted in triplicate for approval before
despatch.
a. Dimensional check.
b. Visible and quantitative check
c. Wiring connection and function check of meters, MCB, MCCB, switches etc.
d. High voltage power frequency withstand test / 2KV for one minute
e. I.R. value of all switches and cubicle.

14.0 Brand Names
The Brand Names for various equipment and Instruments shall be as below.
1. Static Trivector Meter ABB, L&T, SECURE/
2. LT CT JAYANTHI ELECTRIC / KAPPA/
PRECISION / VOLTAMPS
3. 60A, 30A, 15A miniature circuit
breakers
4. 400A, 200A, 100A and 50A moulded
case circuit breakers
} ANDREW YULE/ CH /AXIOM
} CROMPTON GREAVES/ GE
} L&T / MDS / SIEMENS /
} STANDARD / S&S/C&S

350
5. Digital Frequency Meter PLA/MECO/NIPPEN.
6. Voltmeter AE/MECO/NIPPEN
7. Switches KAYCEE / MICRON / SWITRON
NOTE : Only specified make is acceptable by TNEB. The tenderers should not quote
"as equivalent" in any case.

NOTE : 1) The copies of the Type Test Certificates for the bought out components shall
be furnished before the offer of materials for inspection.
2) The above Type Tests should have been conducted in a Government/
Government recognised laboratory as per relevant IS/IEC not earlier than Five (5)
years on the date of tender opening.



































351


TECHNICAL SPECIFICATION FOR SUPPLY OF 25 KVA DIESEL GENERATOR SETS

1.0 CODES AND STANDARDS:
2.1 BSS-5514 - Diesel Engines for general purposes
2.2 BSS. 2613 - Electrical performance of rotating electrical machines
2.3 ISS-4722 - Rotating Electrical machines
2.4 IS-8623 - Specification for factory built, assembly of switchgear
and control gear for voltages upto and including
1000V/1200V A.C.
2.5 IS-4237 - General requirements for switchgear and control gear
for voltages not exceeding 1000V.
2.6 IS-2147 - Degree of protection provided by enclosures for LV
switchgear
2.7 IS-3072 - Code of practice for installation and maintenance of
switchgear
2.8 IS-2075 - Current Transformer
2.9 IS-2516 - A.C. Circuit Breaker (Part-II, II etc.,)
2.10 IEC-408/72 - Short time withstand test
2.11 IS-6005 - Surface treatment for M.S. Sheets
2.12 IS-2203 - HRC Cartridge type fuses
2.13 IS-722 - Energy Meter

2.0 PERFORMANCE REQUIREMENTS:
The Diesel Generator set and accessories shall be so designed as to meet the
following requirements:
(i) The unit shall be capable of starting from cold conditions, reaching
synchronous speed and taking up load without undue wear and stresses
on equipments.
(ii) The unit shall be capable of delivering continuously at the generator
terminals the nett output specified, with invisible exhaust.
(iii) The unit shall be capable of delivering a peak output of 10%. In excess
over the rated output for a period of one hour out of total of twelve
consecutive hours of operation without exceeding permissible temperature
limits and with a very little visible exhaust. The unit shall be continuously
rated to supply power for long periods.
(iv) The unit shall be capable of meeting the specified performance when
using diesel oil as recommended by the supplier.
(v) The unit shall operate up to 110% of the rated speed over the entire
range of output without undue vibration and noise.


352
3.0 QUALITY OF MATERIALS
All materials used in the construction of the work shall be of the best quality
obtainable of their respective kinds and comply in all respect with the standards
and tests laid down in the appropriate British Standard specification. Where a
British Standard Specification covering a material is not published, the standards
and tests adopted by American Society for testing materials shall be adopted.

4.0 WORKMANSHIP
All workmanship must be first class in every respect and in accordance with the
best modern practice. Working surfaces must be accurately and finely finished.
All working parts of the machines and their connections shall be finished in the
best possible manner and with the utmost precision.

All electrical machinery shall be designed to work without undue noise
and special precautions must be taken to provide machine that will run
quietly without any vibration.

5.0 DIESEL ENGINE:
(a) The diesel engine shall be vertical, single acting, mechanical injection
type. The horse power rating required, auxiliaries, guarantee of fuel
consumption, parallel operation, governor performance and torsional
vibration shall be in accordance with BS-5514 or approved equivalent.
(b) The diesel engine of suitable capacity (not less than a nett
output of 32bhp at 1500 rpm for 25KVA sets) cold start,
air/water cooled 4 stroke cycle compression engine with
complete standard accessories and fittings.
(c) The fuel consumption at no-load and fuel consumption at rated
output and 50% shall be furnished.
(d) The percentage of overload that can be permitted and the duration
shall be furnished.

6.1 ELECTRICAL STARTING SYSTEM:
Starting system shall be suitable for manual electrical starting. The
starting system offered shall be complete with starter motor, batteries,
battery charger, other required instruments, accessories, control
switches and interconnecting cable.

6.2 GOVERNOR SYSTEM
The type of governor shall be indicated. The governor shall conform to BS-5514
or approved equivalent. The governor characteristic shall comply with
requirements of Class-A Governing of BS-5514 (latest amendment) or approved
equivalent.

353

The governor shall have the following features;

(i) An over speed trip mechanism shall be provided automatically shutoff fuel
in case the set speed reaches above 110% of rated speed. The engine
speed at which the mechanism trips the engine shall be adjustable.
(ii) An emergency stop push button shall be provided, which when operated
will trip the engine.


6.0 GENERATOR
(a) The generator shall have Class-H insulation for stator and rotor.
(b) The live and needful ends of each phase winding of the generator shall
be brought out and suitably terminated. Supplier shall provide suitable
clamping arrangements for connecting the cables to the machine
terminals. The terminals shall be suitably enclosed to prevent short
circuits by rodents etc., suitable cable glands shall be provided on the
enclosures to facilitate entry of the above cables.
(c) All parts of generator and accessories shall be designed to withstand
all electrical, mechanical and other stresses which may be experienced
during operation, including short circuit and over speed conditions.
(d) The generator shall be provided with two (2) grounding terminals with
clamps for connection to purchasers gruonding grid.

7.1 EXCITATION SYSTEM
(a) The excitation system shall be so designed or protected, that harmful
over voltages cannot occur at the main exciter commutator due to
combined effect of maximum exciter field current and machine over
speed.

(b) The exciter shall be provided with two (2) diametrically opposite
ground terminals with clamps suitable for connection to purchasers
grounding grid.

7.2 VOLTAGE REGULATORS

(a) The generator shall be capable of operation over a range of +/-5% if the rated
voltage.
(b) The voltage drop from no-load to full load shall not exceed 3%.

7.3 CONTROL SYSTEM FOR DIESEL GENERATOR

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(a) All the sequence involved in the complete startup of the diesel engine set and
bringing upto the rated speed and voltage shall take place automatically. Vendor
shall provide all the necessary accessories required for this purpose.
(b) It should also be possible to start the engine manually. Please note that except
for the starting impulse which is manual, all other starting operations shall be
automatic.
(c) A tripping push button shall be made available in the Control schematic to relieve
the set from its load when the set is running irrespective of the mode of
operation.

7.4 TRIPPING CONDITIONS
The Diesel Generator shall be tripped under the following conditions:-
(a) Over speed above 110% of the rated speed of the diesel generator set.
(b) Low lubricating oil pressure after the engine has attained 90% of its rated speed.
(c) Cylinder Head Temperature high.
(d) Generator faults.
All sending devices and required contractors are included in the scope of supply.
These devices shall be suitable for operation on ungrounded D.C. system.

7.0 CONTROL AND ANNUNCIATOR PANEL
The panel shall be free standing, floor mounting sheet steel clad indoor type with
front hinged, rear removable, undrilled and removable bottom. The sheet steel
used shall be of 12SWG.

The control panel shall have the following instruments, switches, relays, fuses,
etc.,
(i) A.C. Voltmeter of range 0-600V to read the generated voltage (phase to
phase and phase to neutral).
(ii) A.C. Ammeter suitable for 25KVA and 75KVA, 415V (0 to 100A) to read the
load current.
(iii) Selector switches for the above voltmeters and ammeters.
(iv) Frequency meter of range 45 50-55 Hz to read the frequency of the
generated voltage.
(v) 3 Phase, 4 Wire Kilowatt Hour meter to measure the energy generated.
(vi) Service hour meter to record the time of operation of DG set.
(vii) D.C. Voltmeter of suitable range to read the battery voltage.
(viii) D.C. Ammeter of suitable range to read the battery charger current and load
current (i.e) centre zero ammeter.
(ix) Solenoid relays for starting and stopping DG set.
(x) Overload relay to protect the generator from overload as well as to give
annunciation.
(xi) Earth fault relay to trip the generator as well as to give annunciation.

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(xii) Current Transformers of suitable ratio for metering and protection purposes.
(xiii) H.R.C. Fuses for power circuits and control circuits for protection for both A.C.
and D.C.
(xiv) Indicating lamps and hooter for visual and audible indication.
(xv) Push buttons for control purpose and acknowledging the annunciation.
(xvi) Four pole double throw change over switch of suitable capacity to change the
load from main to DG set.

NOTE : ALL INSTRUMENTS/RELAYS/SWITCHES/FUSES SHALL
POSITIVELY BEAR ISI CERTIFICATION MARK.

The control and annunciation panel shall be wired with suitable engraved
designation labels. The panel shall have provision for receiving incoming and
outgoing cables through undrilled gland places at the bottom. All
instruments/relays/switches shall be of flush mounting type.

The window type annunciators shall give visual and audible indication for the
following conditions:-

1. Cylinder Head Temperature high
2. Lubricating oil pressure low.
3. Engine over speed
4. Generator over load
5. Ground fault on the system
6. Spare windows 2 Nos.

The Annunciation system shall be provided with:-

a. One flasher relay
b. One push button for acknowledging the audible alarm while the
visual indication shall persist till normalcy it restored to the system
c. Auto Reset facility and
d. One push button for testing the indicating lamps.

On occurrence of a fault the audible alarm shall sound and the appropriate
window shall blink. The audible alarm will be silenced and visual indication shall
be in steady glow condition if fault persists while pressing the acknowledge the
push button. The visual indication shall, however persist till the relevant fault
contracts reset.

After acknowledgement of one fault by the acknowledge push button, the alarm
circuit shall be ready to operate for another fault.

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Control circuits shall work on the D.C. of the Engine Battery.

Supplier shall provide all necessary sensing devices to detect the abnormal
conditions and necessary associated relays and accessories to initiate appropriate
protective action and annunciation. These shall be suitable for operation on
ungrounded D.C. system.

Additional contacts shall be made available on the sensing relays, annunciator
relays for remote annunciation.

A detailed schematic shall be furnished with wiring details, write-ups and
pamphlets.

8.0 BEARING, LUBRICATION & FOUNDATION BOLTS:

9.1 Each bearing shall be provided with a system of continuous lubrication, either by
split oil rings or any other approved method with an oil reservoir, a sight feed
fitted with gauge glass to show the amount of oil in the bearing and draw-off
cock at the bottom. Each bearing shall be provided with dust proof, fault lined
self-closing cover with grease packed grooves in the cover to prevent dust from
reaching the oil. Where oil cups, grease cups or similar lubricators are
employed, they shall be attached and connected so as to be accessible for
inspection and adjustment during the operation of the machinery.
9.2 Each machine shall be provided with a complete set of foundation bolts, nuts,
washers, iron tubes etc.,
9.3 Anti-vibration mountings should also be provided to limit vibrations to the safe
level as per the Standards.

9.0 TOOLS AND SPARE PARTS:
10.1 One complete set of tools spanners and special tools necessary for assembling
and dismantling the plant shall be supplied along each with DG SET. A set of
spares for each 25KVA DG set & 75KVA DG set shall be supplied FREE of cost as
per Annexure.


10.2 SERVICE TOOLS:
A suitable tool board complete with all necessary tools required for servicing the
diesel generator set shall also be supplied with relevant instruction booklets.

10.0 NAME PLATE

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All machines shall have metal plates fixed in approved positions, with the name
of the makers and full particulars of the rating clearly marked thereon.

The year of manufacture of Diesel Engine, alternator, control & annunciation
panel and other switch gears and purchase order details shall positively be
furnished in the name plates.

11.0 DRAWINGS
The supplier shall submit the following drawings for approval since the
Board has to determine the design and layout of the installations:-

a. General layout and assembly drawings of the equipment and the
auxiliaries, showing clearance and grouting details.
b. Layout of control gear, control boards, etc., with wiring drawings and
cable schedule.
c. Arrangement of terminal equipment.
d. Schematic diagram of control circuits and control and annunciation panel
circuit (wiring diagram).
e. Drawings showing the critical dimensions of Diesel Engine, alternator,
control and annunciation panel etc., and respective individual weights,
vibration pads, lifting hook positions etc.,

12.0 TESTS AND CERTIFICATES:

a. TYPE TESTS
The tenderers are requested to enclose with their tender, a copy of the type
test certificates for all the equipments offered in full shape conforming to
latest issue of IS obtained from a Government/ Government recognised lab.
The above type test certificates should accompany the drawings for the
equipments duly signed under seal by the institution who has issued the type
test certificate. The above type test should have been conducted not earlier
than 5 years on the date of tender opening.

Type tests on base Diesel Engine shall conform to IS-10002 and Type tests
on Alternator shall conform to IS-4722:1968 Clause 20.3.2.1 or their latest
equivalents.

b. ROUTINE TESTS
i. On base Diesel Engine: (to be carried out in the presence of Boards
Engineer free of cost to the Board at the works of the Diesel Engine
Manufacturer).


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1. Rating Test as per IS:10000-Part-VIII
2. Fuel Consumption Test as per IS:10000-Part-VIII
3. Governing Test as per IS:10000-Part-VI

ii. On Alternator: (to be carried out in the presence of Boards Engineer free
of cost to the Board at the works of the alternator manufacturer).

1. Measurement of resistance of windings
2. Measurement of insulation Resistance of windings.
3. High voltage Tests
4. Open circuit characteristics
5. Short circuit characteristics
6. Voltage Regulation Tests
7. Full load temperature rise test on any one alternator by resistance method
using Kelvins Double Bridge.

All these tests shall conform to IS:4722-1968 Clause-20.3.2.2 and IS:7132 or
their latest equivalents.

c. TESTS ON ASSEMBLED SET BEFORE DELIVERY

The following tests shall be conducted as per IS:10000 series on the fully
assembled diesel generator sets before delivery in the presence of Boards
Engineer free of cost to the Board.

I. One hour run upto full load at unity power factor.
II. One hour at full load at unity power factor allowed by one hour at
110% of rated load at unity power factor continuously.
III. Voltage regulation test.
IV. Functional checks of control and protection circuits.

The supplier shall furnish copies of test certificates of the tests conducted on
the equipments and shall despatch the diesel generator sets only after
approval of these test reports by the Superintending Engineer/Transmission.

13.0 PERFORMANCE GUARANTEE

The following items of performance shall be guaranteed by the supplier in
respect of the diesel generator set and its auxiliaries when operating under the
specified site conditions:

I. Fuel consumption at full load.

359
II. Lubricating oil consumption at full load.
III. 10% over load for one hour without overheating or showing
signs of undue stress and within specified frequency variation.
IV. Freedom from vibration and noise.
V. Generator efficiency at quarter, half, three-quarter and full load.
VI. Voltage regulation response.
VII. Governor response, overspeed trip and overspeed capability.
VIII. Nett electrical output.

In addition to the above, the supplier shall guarantee the following:-
a. Quality and strength of materials used.
b. Adequate factors of safety for all parts of equipments to withstand
the mechanical and electrical stresses developed therein.
c. Satisfactory commissioning of the generator set at site.

14.0 PAINTING

A. Machined and finished surfaces shall be protected against information of
rust and corrosion by application of suitable rust inhibitors.
B. All steel surfaces which are to be painted shall be thoroughly degreased,
cleaned and given one shop coat of primer before assembly.
C. All castings shall be sand blasted, degreased and cleaned before painting.
D. The finishing coat must be finished off with 3 coats of standard enamel
paint.

Also, the shaft, the stator cores, rotor, bed plates and other metallic
surfaces of the diesel generator set shall be able to withstand corrosion
due to surface moisture during transport and prolonged shutdown.

15.0 ERECTION AND COMMISSIONING
The following tests are to be conducted at site while commissioning:
I. Rating test as done before delivery.
II. High voltage test at 75% of initial test voltage.
III. Winding resistance test.
IV. Voltage regulation test.
V. Temperature rise test and
VI. Governing test.






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16.0 LIST OF SPARE PARTS FOR EACH 25KVA DG SET TO BE SUPPLIED
FREE OF COST

FOR ENGINE 25KVA
1 Oil seal 1 Set.
2 Lub. oil filter 3 Nos.
3 Diesel primary fuel filter 3 Nos.
4 Diesel secondary fuel filter 3 Nos.
5 Sealing ring between lub. oil
filter cover and bowl
2 Nos.
6 Sealing ring 2 Nos.
7 Vee belt 2 Nos.

































361
250 KVA 11KV/433V DISTRIBUTION TRANSFORMER

1. STANDARD:

Except where modified by this specification, the transformer shall comply with the
requirements of IS-2026. IS-1180, IS.3347. IS.7421. IS.2099 and IS.335 of the latest issue.

2. MATERIALS AND WORKMANSHIP:

All the materials used in the construction of the transformers and accessories shall
be of the highest quality. The entire design and construction should be capable of withstanding
the severest stresses likely to occur in actual services and capable of resisting rough handling
during transport. The workmanship shall be of the highest grade and entire construction in
accordance with the best modern practice.

3. CAPACITY:

The transformers shall have a maximum continuous rating as per IS.2026 at the secondary
terminals of the specified KVA output as per Schedule-A.

4. TYPE:

The distribution transformers shall be of the double wound type with three phase, oil
immersed, naturally cooled core type suitable for outdoor installation and for operation in
highly humid tropical climate and in lightning or non-lightning areas and at an altitude of 0 to
1000 meters with range of temperatures varying from 5 to 50 Deg.C.

5. FREQUENCY:
The distribution transformer shall be designed to work at a standard frequency of 50
cycles per second and must be capable of operating satisfactorily at any frequency between
48.5 and 51.5 cycles per second.

6. FLUCTUATION IN VOLTAGE:
The transformers shall be rated suitable for operation for voltage upto plus or minus
12% on the H.V.side and frequency variation plus or minus 3%.

7. NATURE OF LOAD:
The Distribution Transformer will be used for supplying a mixed power and lighting loads.

8. TEMPERATURE RISE:
The maximum temperature rise shall not exceed the limit of 55 Degree C. (measured
by resistance) for the transformer winding & core and 45 Degree C. (measured by
thermometer) in top oil over an ambient temperature of 50 Deg.C, when tested in accordance
with IS.2026.

9. OVER LOAD CAPACITY OF THE TRANSFORMER:

362

The transformer shall be capable of carrying without injury, momentary and
alternatively sustained overloads of duration as per Indian Standards under various conditions
of operation, rated voltage and frequency being maintained. The overload capacity of
transformer for two hours (i) Starting from cold and (ii) after continuous full load run shall be
clearly stated.

10. VOLTAGE RATIO:

The normal no load operation voltage ratio shall be as stated in the Schedule-A and
the tolerance is as per IS.2026.

11. CONNECTIONS AND GROUP SYSTEM:

The transformer windings shall be delta connected on the HV side and star connected on
the LV side. The group symbol of the transformers shall be DY11, as specified in IS 2026 of
latest issue so as to produce a positive displacement of 30 Deg. 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.

12. LOSSES & IMPEDANCE:

The losses and impedance at rate voltage shall be as specified in Statement of
Schedule-F subject to tolerance as per IS.2026. The full load losses and impedance shall be
calculated at 75 Deg. C for this purpose.


13. NEUTRAL CURRENT:

The neutral current shall not be more than 2% of the rated full load current in
respect of 100 KVA capacity transformers and shall not be more than 3% in respect of
200,250 & 500 KVA transformers.


14. REGULATION:

The inherent regulation at normal balance load at unity and 0.8 (lag) power factors at
a temperature of 75 Degree C. shall be stated in the tender and the tenderers shall guarantee
these performance figures. .


15. PARELLEL OPERATION:

All the transformers of the same voltage ratio shall be exactly the same design
and operating characteristics such that they shall give perfectly satisfactory operation when
run in parallel and share the load in proportion of their rated KVA within the limits of

363
tolerance laid down in IS.2026 of latest issue. Transformers of the same rating shall be
absolutely identical and inter-changeable in all respect.

16. HEAT DISSIPATION:
16.1 Heat dissipation by tank walls excluding top and bottom should not be less than 500 W/
sq.m.

17.0. TRANSFORMER CORE :

17.1. The transformer core shall be built up of high grade cold rolled grain oriented annealed
(CRGO) laminations, having low loss and good grain properties, coated with hot oil proof
lamination insulation, bolted together and to the frame firmly to prevent undue vibration or
noise. The complete design of the core must ensure permanency of the core losses with
continuous working of the transformers. The value of flux density allowed in the design shall
be clearly stated in the offer.

17.2. The tenderers should indicate in their tender the type and grade of core materials used
for manufacture of the transformers. They should also indicate their concurrence ( in case
the purchase orders are placed on them to furnish the proof of purchase of such core
material (invoice copy) along with the Certificate for having availed the CENVAT benefits if
availed. They should also furnish the calculations for arriving at the maximum flux density
and the losses for such core materials proposed to be used by them.

17.3. Flux density: The maximum flux density at any point shall not exceed 1.55
webers/sq.m. at normal voltage and frequency.

17.4. The transformer core shall not be saturated for any value of V/f ratio to the extent of
112.5% of the rated value of V/f ratio (i.e. 11000/50 or 22000/50 due to the combined effect
of voltage and frequency) upto 12.5% without injurious heating at full load conditions and
will not get saturated. The tenderer shall furnish necessary design data in support of this
situation.

17.5. The no load current at rated voltage and at 112.5% of rated voltage shall not exceed
the values given in the Statement of Schedule-F of this specification.

17.6. The test for magnetic balance by connecting the LV phase by phase to rated phase
voltage and measurement of an-bn-cn voltages will be carried out and test results furnished.

17.7. The number of steps of core, Diameter of the core and the Effective Area of the core
should be as per the values given in Schedule-F of this specification.

17.8. The weight of core only and weight of core and windings should be furnished in the
guaranteed technical particulars failing which the tender is liable for rejection.

17.9. 1% tolerance is permissible for core dimensions.


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18.0. CORE CLAMPING:
18.1. The core clamping channel shall be of size as specified in Schedule-F with 2 Nos.
MS nut bolts for efficient clamping.

18.2. The top yoke channels to be reinforced by adequate size of MS flat with thickness not
less than 6 mm, at equidistant if holes/ cutting is done for LT lead so as to avoid bending of
channel.
18.3. MS channels shall be painted with oil and corrosion resistant paint before use.

18.4. MS rods shall be used as tie rods and key studs as specified in Schedule-F and
shall be efficiently insulated.
18.5. Core base and bottom yoke shall be supported with MS channel as specified in
Schedule- F with proper bolting together. In no case, flat or cut channels shall be
accepted.

18.6. All bottom & top yoke key studs, tie rods shall be painted with oil and corrosion
resistant paint before use.

18.7. Suitable eyes or lugs shall be provided in the channels abetting the top yoke for lifting
the core and windings out of the tank. The core shall be effectively earthed to the tank.
19.0. WINDINGS AND INSULATION:

19.1. Both H.T. and L.T. windings should be double paper covered insulated with
aluminium windings / Copper windings as indicated in Schedule-F.

19.2. The insulation materials to be used for the windings shall be suitable for satisfactory
service in tropical climates in this country and for full load operation as per ISS. DPC insulation
shall be provided for high voltage as well as low voltage windings.

19.3 Electrical grade plain insulation Kraft paper shall be used for inter
layer insulation of the HV and LV coils. Press Board blocks shall be used for top and bottom
yoke insulation.

19.4. The conductor cross section of the windings for H.V. and L.V.
should not be less than as furnished in Schedule-F. 1% tolerance is permissible for the
dimensions for the windings.

19.5. Current density: The current density for HV and LV should not be more than 2.8
A/sq.mm. for Copper and 1.6 A/sq.mm for Aluminium conductor.

19.6. The L.T. windings shall be cylindrical and concentric with H.T.windings on the outer
side. The arrangements of the windings must be such that there is electrical and
magnetic balance under all conditions of operation. The arrangements shall permit free
circulation of the oil to ensure the absence of hot spots. All similar coils shall be

365
interchangeable. It is essential that the windings shall be subjected to thorough
shrinking at factory site. Adjustable devices shall be provided for taking up any possible
shrinking of windings in service. The general design and construction of the
transformers and bracings of the windings shall be such that no mechanical movements
of the coils will be possible with dead short on either side of the transformer. The short
circuit ratings of the transformers shall be as per IS.2026 of latest issue.

19.7. The LV winding shall be in even layers so that the neutral formation will be at top.

19.8. If the axial length of HV/LV coils is required to be on the higher side due to practical
problems during manufacture, the increase in axial length is accepted and this shall be
accommodated by the end insulation space of 25 mm (11 KV) provided for both

19.9. at the top & bottom. It may be ensured that sufficient increased end insulation is
provided both at top & bottom.

20.0. END TURNS INSULATION:
The insulation of the end turns of HV windings shall be so designed as to withstand the
Impulse Voltage test as per IS.2026-1977. It may clearly be indicated as to whether
reinforcement to the end turns insulation is provided or not and if provided, the extent of end
turns for which insulation reinforcement is provided shall be furnished.

21.0. INTERNAL CONNECTIONS:
21.1. H.V. Windings :

21.1.1. In case of H.V. Winding ,all jumpers from winding to bushing shall have cross section
larger than winding conductor.

21.1.2. In case of Al./Cu winding, Delta joints shall be with brazing only.

21.1.3. Lead from delta joint shall be brazed to the lug strip which in turn is to be connected to
bushing rod.

21.2. L.V.Winding:
21.2.1 L.T. Star point shall be formed of Al./Cu. flat of sufficient length. Lead from
winding shall be connected to the flat by brazing.

21.2.2 Firm connections of L.T.Winding to bushing shall be made of adequate size of 'L'
shaped flexible sheet. Connection of L.T.Coil lead to "L" shape flexible sheet shall be
by brazing.

21.2.3 "L" shape flexible sheet shall be clamped to L.V.Bushing metal part by using nut,
locknut and washers.

21.2.4 For Aluminium windings, L & T Alkapee aluminium brazing rods with suitable flux
shalll be used.

366
For copper windings, silver brazing alloy shall be used.

22.0. CLEARANCES:
The clearances in respect of the following shall not be less than the values specified
in Schedule-F.
i) Radial clearance of LV coil to core with insertion of cylindrical press board
insulation (Wrap on Core) and balance radial clearance shall be filled with oil.
ii) Radial clearance between HV & LV windings.
iii) Phase to Phase clearance between HV conductors.
iv) Minimum electrical clearance between the winding and body of the tank (between
inside surface of the tank and outside edge of the windings)
v) Minimum End insulation to Earth.
vi) Thickness of paper insulation for HV coil as per I.S.2026 Part-III (1981)
vii) Thickness of paper insulation for LV coil as per I.S.2026 Part-III (1981)
viii) Thickness of the locking spacers between HV coils
ix) Minimum external clearances of bushing terminals.
x) Thickness of paper insulation for tap lead shall be 1.5 mm.
23.0. TANK:

23.1. The transformer tank shall be of robust construction and shall be built of electrically
welded M.S.plate of suitable thickness not less than 5 mm for the bottom and top and
not less than 3.15 mm for the sides. The tank should be sand blasted or cleaned by
Chemical process and then coated with paint conforming to No.632 of IS.5-1961 or the
latest issue. For inside of the tank suitable varnish coating shall be provided. The Tank
should be pressure tested and should withstand the value indicated in the Statement of
the Schedule F of the Contract. Welding should be done on both sides of the plates
forming the side walls, top and bottom of the transformer tank.

23.2. All joints of the transformer tank and fittings shall be hot oil tight and no bulging shall
occur during service. In order to facilitate easy removal of the core and windings, the
transformer core and windings shall be positioned such that it can be lifted easily from
the tank. The tank plate and the lifting lugs shall be of such strength that the
complete transformer when filled with oil may be lifted by means of the lifting shackle.

23.3. Top cover plate shall be slightly sloping approximately 6 mm towards HV bushing
downwards so as to avoid entry of water through the cover plate gasket. The top
cover shall have no cut at point of lifting lug. The tank shall be fabricated by welding
with not more than two joints for the tank. No horizontal or vertical joints in tank side
walls and its bottom or top cover will be allowed. In addition, the cover of the main
tank shall be provided with an air release plug.

23.4. Stiffners: The tank shall be reinforced by welded angle on the outside walls on the
edge of the tank to form two equal compartments for 100 KVA rating and three equal
compartments for 200, 250 & 500 KVA ratings. If necessary, vertical stiffners shall be
provided for the required rigidity. The permanent deflection is not more than 5 mm

367
upto 750 mm length and 6 mm up to 1250 mm length with transformer tank without
oil subjected to a pressure of 0.35 kg/sq mm.

23.5. Lifting Lugs: Two Nos. welded heavy duty lifting lugs of MS plate 8 mm thick
suitably reinforced by vertical support flat of same thickness as of lug welded edgewise
below the lug on the side wall up to reinforcing angle shall be provided to lift the
transformer complete with oil. The lugs may be positioned in such a way that when a
sling is used it does not foul the bushings or conservator.

23.6. Lifting Hooks for top cover : 2 Nos. hooks on MS plate of adequate size may be
provided to lift the tank cover.

23.7. Top cover fixing bolts: GI nut bolts of 1/2" dia with one plain washer shall be used
for top cover fixing spaced at 4" apart.


23.8. Gaskets & Sealing washers: 5 mm thick (for 100 KVA capacity) and 6 mm thick (
for 200, 250 & 500 KVA capacities) oil and heat resistant Neoprene rubberised
corksheets, conforming to type B/C Part-II, I.S. 4253 will be placed between the tank
and cover plate. Accordingly sealing washers for items like drain plug etc are to be
provided.
24.0. CONSERVATOR:

24.1. The total volume of conservator shall be such as to contain 10% of total quantity of
oil. Normally 3% quantity of the total oil will be contained in the conservator.
Dimension of the conservator shall be indicated in the General Arrangement Drawing.

24.2. Oil level indicator with minimum oil level marking shall be provided on the side which
will be with fully covered detachable flange with single gasket and tightened with MS
nut-bolt.

24.3. The conservator shall be provided with the drain plug and a filling hole (30 mm dia)
with cover)

24.4. The cover of the main tank shall be provided with 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.

24.5. The Pipe from conservator tank connecting to main tank shall be of 30mm to 50 mm
dia, according to the capacity of the transformer.

24.6. The inside diameter of the pipe connecting the conservator to the main tank shall be
within 30 mm to 50 mm according to the capacity of the transformer 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 (-) 5 Degree C. should be above the sump level.

368

25.0. OIL:
25.1. The insulating oil used in the transformers shall comply with the requirements such as the
characteristics of oil, specific resistance, dielectric dissipation factor and flash points electrical
strength, etc. specified in IS.335 of latest issue. All the transformers shall be supplied with the
necessary quantity of oil. The oil content should not be less than that prescribed in the
Statement of Schedule-F, after absorption by the core and windings. The following shall also
be included:
(a) Schedule of Deviation from specified standards.
(b) Schedule of deviation from specified test requirements specified in the
relevant and present specifications.

26.0. RADIATORS:

26.1. Heat dissipation by fin type radiator 1.25 mm thick shall be worked out on the basis of
manufacturers data sheet. The tenderer should submit the calculation sheet.

26.2. The radiators may be fixed at right angle to the sides or diagonally. The size of the
radiator shall be such that it covers atleast 50% of bottom yoke, full core & complete
top yoke.
26.3. The radiators provided must be adequate. There should be a clear gap of 75 mm
between the tank / stiffner if any and the radiators, so that the belting angles one on
each longer side of the tank can be fixed. The radiators shall not hinder the passage of
belting angles.
27.0. BUSHINGS:
27.1. The transformer shall be of the outdoor type with bushing insulator terminals on the HV
and LV sides as specified in the Drawing & Statement of Schedule-F attached hereto
and should be provided on the sides of the tank. The bushings should be of porcelain,
brown glazed type, H.V. conforming to IS.2099 of latest issue and L.V. conforming to
IS.7421-1974 of the latest issue.

27.2. The HV Bushings rods and other metal parts shall be of brass. LV bushings rods shall
be of copper and the other metal parts of brass. Bushing rods are to be firmly mounted
with three nuts inside and also outside the tank. The dimensions shall conform to
I.S.3347 of latest issue.

27.3. HV Bushings shall be of single piece type and LV bushings may be of double piece. For
11 KV, 12 KV rating bushings and for 22 KV, 24 KV rating bushings shall be used. For
433 volts, 1.0 KV terminal bushing shall be used. Bushings of the same voltage class
shall be interchangeable. The bushings shall be mounted on the side of the tank and
not on the top cover. Only one sheet metal pocket with turret shall be provided for
mounting of HV bushings. Sheet metal pocket shall be designed in such a way that all
HV bushings shall remain at equidistance. Bushings having type tested as per IS:3347
shall only be acceptable.

28.0. BUSHING TERMINALS:

369

28.1. Brass rods 12 mm dia for HT shall be provided for all capacities and ratings . Copper
rods of 12 mm dia for LT may be provided for 100 KVA /11 KV capacity Transformers
and 20 mm dia for 200 & 250 KVA capacities for both 11 KV & 22 KV ratings. Copper
rods of 30 mm dia for LT shall be provided for 500 KVA capacities for both 11 KV & 22
KV ratings.

28.2. HT/LT bimetallic connectors conforming to IS.5561 shall be provided.

29.0. BUSHING METAL PARTS & TERMINALS:

29.1. The bushing porcelain and metal parts shall conform to the following specifications:
------------------------------------------------------------------------------------
Voltage Indian Standard Indian standard for
Class for porcelain parts metal parts
------------------------------------------------------------------------------------
UP to 1 KV IS.3347 (Part-1 Sec.I IS.3347 (Part-I Sec.I)
Bushings 1979 or the latest 1979 or the latest
ISS if any. ISS if any.

12 KV IS.3347 (Part-III IS.3347 (Part-III
Bushings Sec-I) 1972 or the Sec.2) 1967 or the
Latest issue, if any. Latest issue, if any.

24 KV IS.3347 (Part-IV IS.3347 (Part-IV
Bushings Sec-I) 1972 or the Sec.2) 1967 or the
Latest issue, if any. Latest issue, if any.
------------------------------------------------------------------------------------
30.0. TAPPINGS:
30.1. Tappings shall be provided on the H.V.windings for variation of voltage on the L.V.side
from -9% to +3% of the rated voltage in five steps of 3% and shall be controlled by an
externally hand operated off-circuit tap changing switch. The tap changing gear should
be provided with an indicator arrangement in aluminium anodised plate to show the tap
position. Switch position 1 shall correspond to the maximum plus tapping. Provision
shall be made for locking the tapping switch handle in position.
30.2. The operating lever of Tap switch should be provided at the side of the tank and not on
top of the tank cover.

31.0. EXPLOSION VENT:

31.1. The explosion vent like swan's neck is to be fitted at an angle of about 75 deg. to the
horizontal to avoid direct splashing of rain water on the diaphragm. The diaphragm
shall be made of Hylam Sheet of thickness 0.3 mm to avoid absorption of moisture.

31.2. Steel net with bigger holes may be provided before the diaphragm and the distance
shall be 12 mm minimum. The pipe dia of the explosion vent shall be 70 mm fixed by

370
welding on sufficient size of hole on the top of the tank to handle more oil to flow out in
quicker time and to reduce pressure inside the tank.


31.3. The thickness of pipes in the case of vent pipe and the conservator shall be sufficient to
avoid weak metal parts which would give way under pressure. The inside of the vent pipe shall
be treated with anti corrosive paints as done in the case of main tank.

32.0. BREATHER:
The breather should be plain breathing device comprising an inverted "U" pipe with
silicagel type. The breather joints will be screwed type. It shall have die cast aluminium body
or Propyline materials and inside container for silicagel shall be tin sheet in case of Aluminium
die cast breather. The volume of breather shall be as per Statement of Schedule-F.

33.0. TANK BASE CHANNEL:

It should be of two numbers of 100 mm x 50 mm for 250 KVA ratings transformers.
The tank base channels shall be of sufficient length so as to facilitate for pole mounting and
plinth/platform mounting. Base channel shall be welded to the bottom of the tank across the
longitudinal side of the tank.

34.0. PAINTINGS:
34.1. The tank should be sand blasted or cleaned by chemical process before painting. The
transformers should be given a primary coat of red lead (not red oxide) or other suitable
anticorrosive paints and finished with two coats of colour paint of dark admiralty grey
shade of oil & weather resistant quality

The above paints should conform to No.632 of IS.5 /1961 or latest issue.
35.0. TERMINAL LEAD AND MARKINGS:

35.1. The transformers shall have suitable terminals on both the HV and LV sides.

35.2. All leads including tapping and neutral shall be insulated and rigidly supported and
shall be easily accessible without need for removing the windings from the tank.

35.3. Unless otherwise specified, the phase and neutral leads shall be brought out of the tank
through porcelain bushing insulators which must be of suitable design to prevent failure
due to line or lightning surges, system faults or switching operation.

35.4. The physical positions of terminals relative to one another shall be as per IS.2026 of
latest issue.

35.5. The high voltage phase windings shall be marked both on the terminal board inside
the tank and on the outside with capital letters 1U, 1V & 1W and the low voltage
windings of the same phase marked by corresponding letters 2U, 2V & 2W and neutral
point terminal being indicated by the letter 'N'.

371

35.6. These letters shall be assigned to the windings respectively from the left to the right
facing the side carrying high voltage terminals.

35.7. The vector diagram plate shall clearly indicate the methods adopted for making the
terminals, both outside and interior.

36.0. FITTINGS:

36.1. Standard fittings in line with the manufacturer's practice shall be provided on each
transformer including the following.

1. Two earthing terminals (with lugs & markings)

2. Oil level guage with minimum oil level marking

3. Lifting Lugs & Hooks

4. Name plate of aluminium anodised material with non-detachable terminal marking plate,
showing the relative physical position of the terminal and their markings as marked on plate
shall be filled in a visible position. The transformer shall also be provided with non-
detachable rating plate of aluminium anodised material fitted in a visible position. The
relative position of the tapping switch and corresponding voltages may also be shown on
the rating plate. The entries of the rating plate shall be indelibly marked (for example by
etching, engraving or stamping). The above shall be as given IS.1180/ Part-I.

5. Silicagel Breather

Drain cum sampling valve of Dia 20 mm or 32 mm as applicable with steel plug of Dia 20 mm
or32 mm as applicable.
6. A filtration valve of Dia 20 mm or 32 mm with a steel plug of 20 mm or 32 mm as
applicable.

7. Thermometer pocket, with a cover to avoid collection of rain water

8. Conservator with drain plug

9. Oil filling hole with cap on conservator

10. Air Release Plug

11. Radiators

12. Explosion Vent ( except for 100 KVA/11 KV transformers) &

13. Off-Circuit Tap changing switch. ( except for for 100 KVA/11 KV transformers)

372

37. DRAWING:
One copy of the Dimensional Drawing and Internal Assembly Drawing of the
transformer complete with all fittings and accessories (vide clause-36) and all the rated
guaranteed technical parameters shall be submitted along with the tender.

50.0 TOLERANCES:
Unless otherwise specified herein, values of the parameters of the transformers should
be within the tolerance permitted in IS-2026 & IS-1180 and other IS. as per clause-1.

39.0. GUARANTEED PERFORMANCE PARTICULARS:

The Guaranteed Performance particulars should be furnished and should be
guaranteed.

40.0. GUARANTEED TECHNICAL PARAMETERS:

The Guaranteed Technical Parameters should be furnished Supplies received with
variation/ deviation from the guaranteed values will be liable for rejection.

41.0. INSPECTION:

All tests and inspection shall be made at the place of manufacturer, unless otherwise
specifically 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 supplied in accordance with the Technical
Terms specified. 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 quality of supply.

42.0. QUALITY PLAN: STAGE INSPECTION FOR ENFORCEMENT:

42.1. Stage inspection will be carried out by the purchaser's representative at the following
consumer's hold points.

(i) On completion of core & winding assembly
(ii) After fabrication of tank.

At the time of these inspections, the raw materials such as core sheets, winding conductor,
insulating paper, oil and M.S.plate will be verified for quality, by scrutiny of the documentary
evidences for the purchase of these materials from the standard manufacturers and along with
the test certificates.

43.0 TEST AND TEST CERTIFICATE:

43.1. ACCEPTANCE TEST:


373
43.1.1. The Tenderer should have adequate testing facility at the manufacturer's works so
also arrangement for measurement of losses, resistances, details of which will be
furnished by the tenderer.

43.1.2. All transformers shall be subjected to the tests detailed in Schedule-C at the
manufacturer's works as per IS.2026 and IS.1180, IS.2099, IS.335 & IS.7421 of the
latest issue.

43.2.0. TYPE TESTS:

43.2.1. The Tenderers should submit the copy of the Type Test Certificates along with the
tender inside the Envelop-A , after conducting the following Type Tests at Government
Institute/Undertaking.

(i) Impulse voltage withstand Test as per clause No.13 of IS.2026
(Part-III) / 81.
Impluse voltage withstand test shall be for 75 KV & 125 KV for
11 KV & 22 KV class transformers respectively.
(ii) & Dynamic Short Circuit Withstand Test showing No load losses & load losses at 75
Deg.C.

The Type Test Certificates should conform to the Technical Terms detailed in
Section-VI of this specification.

43.2.2. The above Type Test Certificates should not be dated earlier than five (5) years as
on the date of tender opening.

43.3. ROUTINE TESTS:

The routine test certificate in duplicate for each of the transformer shall be furnished
to the purchaser for approval .
43.4. STRIP TESTS:

43.4.1 One Unit will be subjected to strip test at supplier's premises during the course of
Stage Inspection in accordance with Schedule-C.

43.4.2 2% of the ordered quantity will be subjected to strip test at the Boards premises
in accordance with Schedule C

43.5. SPECIAL TESTS:

The transformers shall be subjected to any other special tests considered by the
purchaser during the contract period. Cost of such special tests will be borne by the Purchaser.
If the results are not satisfactory, the cost of testing will be recovered from the supplier besides
rejection of the materials.


374
44.0. SCHEDULES & DRAWINGS:


45.0. DRAWINGS:
Actual dimensional General Arrangement Drawing and Internal Assembly Drawings in
line with Schedule-F should be furnished along with the tender.








































375
SCHEDULE
GUARANTEED TECHNICAL PARTICULARS TO BE FURNISHED ALONG WITH THE TENDER
SPECIFICATION No 250 KVA /11 KV
Sl No. Details
1 Maker's name and Address :
Phone No :
Fax No. :
E Mail :
2 Brand / Name :
3
Voltage between phases at rated full
load


a) HV Side : KV
b) LV Side : KV

4 Nominal ratio of transformer :

5
Maximum Hot spot temperature for
which unit is designed
:

Degree C


6 Type of cooling provided : Amps/sq mm.

7
Maximum current density in winding
at CMR


a) HV Windings : Amps/sq mm.
b) LV Windings : Amps/sq mm.

8
Resistance at rated current and
frequency


a) HV Windings / phase : Ohms
b) LV Windings /phase : Ohms

9 No Load Loss at
a) Normal voltage and frequency : KW

b)
Maximum voltage and normal
frequency, ie. at 112.5% of rated
voltage
: KW


10
Full load loss at rated full load current
at 75 Deg. C at principal tapping
: KW



376
11
Total losses at rated voltage and
frequency
: KW (As per IS Tolerance)

12 Reactance drop on full load : %

13
Reactance of windings per phase at
75 Deg C.
: Deg C


14 Impedance drop on full load :

15 Percentage impedance at 75 Deg C. : % (As per IS Tolerance)

16 Regulation at full load at 75 Deg C.
a) at UNITY P.F. : %
b) at 0.8 P.F. lag : %

17
Efficiency at maximum permissible
temperature at


At Unity P.F. At 0.8 lag
a) 100 % load : % %
b) 75 % load : % %
c) 50 % load : % %
d) 25 % load : % %
e) 125 % load ` : % %

18 Over load capacity for two hours
a) Starting from cold : As per IS 6600
b) After continuous full load run : As per IS 6600

19
Impulse strength of HV windings
(State Wave form adopted )
:
KV

20 Total radiating surface : sq mm

21 Type of tank & construction :

22 Oil Data
BDV at the time of filling : KV

23 Location of Conservator :

377

24
Insulation Materials used between
H.V. & L.V. Windings
:


25 Insulation Materials Used for
a) Tapping :
b) Tapping Connection :

26
Whether windings are dried under
vaccum and flooded with hot dry oil
:


27 Percentage end turn reinforcement :

28 Thickness of core plates : mm

29 Test voltage for
a) Over potential : KV on HV side
b) Induced voltage :

30 Insulation of core laminations :

31
Does the name plate include all
particulars as per IS 1180 Part-I/1981
:


32
Minimum qty of oil for first filling after
observation by the core and the
windings
: Litres


33 Voltage per turn : volts

34 Painting :

35 Make of the Bushings :

36
Rating of the Bushing as per IS 2099
& IS. 7421


a) HV Windings : KV
b) LV Windings : KV

HV LV

378
37
Dry power frequency withstand
voltage for HV & LV
:

KV
KV

38
Wet power frequency withstand
voltage for HV & LV
:

KV KV

39 Dry standard lightning impulse voltage : KV KV

40
Visible (power frequency) discharge
voltage for HV & LV)
:


41
Power frequency puncture withstand
voltage for LV & HV
:

Signature of Tenderer with seal


TESTS TO BE CARRIED OUT INCLUDING QUALITY PLAN ENFORCEMENT
The completely assembled transformers & accessories shall be subjected to
the following tests at manufacturer's works. Government Institutes/Undertaking before
supply, except where otherwise stated, in accordance with I.S.2026. I.S.1180 (Part-I).
I.S.2099 and I.S.335 of the latest issue.

A. ROUTINE TESTS:

a) Test for polarity
b) Measurement of winding resistance. (HV & LV)
c) Measurement of voltage ratio and check of voltage vector relationship
d) Measurement of Impedance voltage/short circuit impedance (Principal
Tapping) and load loss.
e) Measurement of No Load Loss and current
f) Measurement of insulation resistance
g) Induced over voltage withstand test
h) Separate source voltage withstand test.

B. TYPE TESTS :
a) Air pressure test as per I.S.1180/Part-I
b) Unbalanced current Test. The values of unbalanced current indicated
By the ammeter shall not be more than the percentage limit furnished
in Schedule-F.
c) Temperature rise test
d) Lightning Impulse test

379
e) Dynamic Short Circuit withstand test, showing the No Load Losses and
Load Losses at 75 Deg. C.
The test certificates shall include a statement of efficiency of the transformers of
various loads at unity and 0.8 power factor lag.

TESTS AT SITE:
The purchaser reserves the right of conducting any or all the tests on the
transformers after arrival at site and the contractor shall guarantee the test certificate
figures under actual service conditions.

C. STRIP TEST :
(1) One Unit will be subjected to strip tests at supplier's promises during the course of
stage inspection by the Third Party Inspection Agency/ Board Inspection Engineers
authorized by the Board. The transformers are liable to be rejected if purchase order
requirement are not met in respect of the minimum / maximum values specified in the
P.O. or Guaranteed Technical & Performance particulars.

(2) Board is at liberty to conduct strip test for 2% of the ordered quantity subject to a
minimum of one number will be subjected to stripping test at Boards site in the
presence of suppliers representative and the special committee constituted by the
Board and within 15 days from the date of receipt of intimation by the Superintending
Engineer/MM-II. If it is found that the distribution transformer is not meeting the
Specification requirements and the values specified in the Purchase order or
Guaranteed Technical & Performance particulars, all the transformers in that particular
consignment are liable to be rejected.

(3) Dismantling and reassembling charges will be borne by the supplier. However
minor facilities such as transport( stores to Special Maintenance) drying oven , oil filters,
cranes etc., needed for conducting the strip test and subsequent reassembly by the
supplier shall be provided by the consignee Superintending Engineers free of cost.
.
D. QUALITY PLAN:
Stage inspection will be carried out by the purchaser's representative at the
following consumer's hold points.
(1) On completion of core & winding assembly
(2) After fabrication of tank
At the time of these inspections, the raw materials such as core sheets, winding
conductor, insulating paper, oil and M.S.Plate will be verified for quality, by scrutiny of
the documentary evidences for the purchase of these materials from the standard
manufacturers and along with the test certificates.



380

SCHEDULE -
GUARANTED VALUE TO BE ADOPTED BY THE TENDERERS:
Sl No. Details
Value
250 KVA/11KV


1 a) No-Load Losses (watts) (*)
: 400


b) Magnetising current in percentage of rated full
load current at rated voltage (with IS tolerance)
.
: 2


c) Magnetising current in percentage of rated full
load current at 112.5 % of rated voltage.
(with IS tolerance)
: 4


d) Power factor of magnetising current (lag -
maximum)
: 0.2


e) Neutral current masured by Ammeter.(max) in %
of full load current
: 3


2 Full loadloss at rated (*) full load current at 75
Deg. C at Principal tapping (watts)
:
3340 + IS
Tolerence.


3 Percentage impedence at 75 Deg.C.
:
5 % + IS
Tolerance


4 Minimum qty of oil for first filling after absorption
by core & windings. (litres)
: 380


5 External Clearance of Bushing Terminals in mm (minimum)
a) HV Phase to Phase
: 280
b) HV Phase to Earth
: 140
c) LV Phase to Phase
: 75
d) LV Phase to Earth
: 40


6 Maximum flux density at normal voltage and
frequency at any point.(Weber /sq. m) (max)
: 1.55



381
7 Maximum temperature rise of
:
a) Windings by resistance Deg. C
: 55
b) core by thermometer
: 55
c) Oil by thermometer
: 45
d) Ambient temperature over which Temperature
rise is calculated
: 50


8 Tank test pressure (Kg/sq cm) (minimum)
: 0.35




9 Thickness of paper insulation for tap lead in
mm (minimum)
: 1.5


10 Weight of the following (Kg)
:
Core (tolerance 1 % )
: 443
Windings (tolerance 1 %)
: 106


11 Dimensions of the inter connecting pipe
between conservator & Tank (Nominal)
: 50 mm
12 Explosion vent
:
a) Pipe Dia (Nominal)
: 70 mm
b) Diaphragm material
: Hylam
c) Diaphragm thickness (maximum)
: 0.3 mm
d) Distance between wire mesh and the Diaphragm
(Minimum)
: 12 mm
13 Breather

a) Capacity in Grams
: 500

b) Body material :
Diecast
aluminium or Poly
propylene
c) Inside container material
: Tin sheet


14 Bushing Road

a) HV material
: Brass
HV dia
: 12 mm
b) LV material
: Copper mm
LV dia
: 20 mm
c) Nuts for bushing rods


382
HV materials
: Brass
HV Nos
: 3 + 3
LV materials
: Brass
LV Nos.
: 3 + 3


15 Number of Turns

LT
: 38
HT
: 1722
SIGNATURE OF
THE TENDERER

































383


SCHEDULE I
MEASUREMENTS OF CORE & WINDINGS
250KVA/11KV/433V DT

DESCRIPTION
Technical
Parameters
As offered by firm
CORE
A LEG CENTRES mm 345
B WINDOW HEIGHT mm 440
C CORE CIRCLE mm 167
D NO OF STEPS 7
EFFECTIVE CORE AREA sq.mm 191.8
LV COIL
E/F OUTER / INSIDE DIAMETER mm 229/175
G AXIAL LENGTH mm 390
CONDUCTOR CROSS SEC. Sq.mm 219
LV STRIP SIZE (BARE) (a) AXIAL mm 10
(b) BREADTH mm 3.66
NO OF CONDUCTORS IN LV 6
LV INTERLAYER CLEARANCE mm 3.00
LV STRIP ARRANGEMENT 2 x 3
HV COIL NO. OF HV COIL PER PHASE 6
H/I OUTER /INSIDE DIAMETER MM 335/251
J AXIAL LENGTH mm 390
CONDUCTOR CROSS SECT sq mm 4.92
HV/LV
COIL
CONDUCTOR INSULATION DPC
K INSULATION BETWEEN TAP COILS mm 10
L BASE FLAT INSULATION mm 1.5
RADIAL CLEARANCE BETWEEN CORE AND
LV COIL mm
4.00
N WEDGES BETWEEN HV & LV COILS NO. 8
O GAP BETWEEN HV & LV mm 11
P FRAME CHANNEL INSULATION mm 1.5
Q PHASE BARRRIER mm 2x1
R END INSULATION BLOCK mm 25
S CLEARANCE TO TANK WALL FROM HV
WDG
50
LENGTH / BREADTH mm 60
T BOTTOM FRAME SIZE mm x mm 100 x 50
U BASE CHANNEL SIZE mm x mm 100 x 50

384
V NO OF SPACERS BET HV COIL / CIRCLE 8
THICKNESS OF SPACERS mm 10
W INTER PHASE CLEARANCE mm 10
X TIE RODS SIZE & No. 8 Nos. of 16 mm
Y KEY STUD SIZE & No. 8 Nos. of 16 mm
Z TAP CHANGER +3 TO (-) 9 % (+) 3% to 9%







































385
Ventilation and Climatization

1.1 Air-Conditioning

(a) Suitable ventilation and air-conditioning system shall be provided to achieve proper
working environment in the Sub Station.

(b) Central control room, service room for O&M personnel shall be air conditioned. Air-
conditioned areas shall be maintained at about 25C and 50 % relative humidity for
comfort conditions.

(c) As split type air conditioners have to be used for control room, at least one unit
shall be kept as standby.

(d)Guarantee for Air Conditioner If the compressor fails within three years of
installation, the entire unit shall be replaced absolutely FREE and 12 months of full
guarantee for all parts and services after commissioning shall be given.

(e)Codes and standards

(i) The construction performance and testing of the air conditioner shall be as
per IS 1391 : Part 2 : 1992
(ii) The product shall comply with the essential requirements of the relevant
European health, safety and environmental protection. It shall be affixed with
the CE marking

(f)All the required materials including copper tubes labor, tools, staging materials and
consumables etc., for completing the work shall be supplied.

(g) The air conditioners shall be of reputed make and it shall be got approved along
with design calculations for total capacity and no of the air conditioners required.

2. Ventilation
(a) The type of ventilation systems for non-air conditioned areas shall be as under:
- 33 kv switchgear rooms, GIS Bay and cable gallery : Ventilation ducts

- Other part of the building : Mechanical ventilation system with Exhaust fans

(b)Industrial Exhaust fan of suitable capacity (min 5 Hp) should be provided in the GIS
bay to bail out any SF 6 gas leak from the equipments. The ducts shall be of galvanized
steel .Full guarantee for 24 months for all parts and services after commissioning shall
be given.

386

(c) All the required materials, labour, tools, staging materials and consumables for
completing the work shall be supplied.
(d)Ventilation duct shall be perforated polythene tubing system consisting of one or
more inflatable polythene ducts suspended overhead from steel wires or clamped on
the wall sides. Rows of small holes in the sides of the ducts shall produce jets of air,
with enough throw to create continuous gentle air movement throughout the building.
Unnecessary elbows, tee-pieces, y-pieces, splitters etc. shall be avoided.
While designing the ducts, the number and size of the holes (Perforation) most suitable
for the duct diameter and airflow shall be calculated and provided. Minimum Perforation
Diameter shall be 2 inches.
(e)Ventilation duct shall consist of a fan suspended in the roof space at one end of the
building which draws fresh air in from outside. Ventilation ducting is connected to the
fan and runs down the length of the building. Holes cut into the sides of the ventilation
ducting distribute the fresh air in a series of high pressure jets.

(f) The fan shall be chosen so that it produces the required air flow at the optimum
static pressure.
Minimum static pressure - 75pa (6mm water gauge)

Optimum static pressure - 125pa (12mm water gauge)

Maximum static pressure - 150pa (14mm water gauge)

The fan size should be chosen as follows:
Propeller fan diameter = duct diameter x 0.8

Axial fan diameter = duct diameter

Centrifugal fan area = duct area

Where an exact match is not available a reducer to the fan outlet, and next smallest
duct size can be used in such a way that the airflow shall be within the required
range. The use of fan speed control should be avoided. Large fans can also be replaced
with more smaller fans each with there own ducts wherever possible. Provision shall be
available to switch them in steps.


387
(g) Air temperature inside inflatable duct systems shall be maintained Maximum air
temperature - 150 degrees Fahrenheit (65 degrees centigrade)Minimum air
temperature - 41 degrees Fahrenheit ( 5 degrees centigrade)
An air straighteners and air filters shall be fitted on the upstream of the fan and after
elbows or tee-pieces to reduces air turbulence inside the duct, improving air
distribution and reducing duct fatigue caused by flapping.

(h) The ventilation system shall be of reputed make and it shall be got approved along
with design calculations for total capacity, air flow and no of the units required. The
quantities mentioned in the schedule are tentative.
36 months of full guarantee for all parts and services after commissioning shall be
given.

(i) The fire resistive performance of a ventilation duct assembly shall be in accordance
with the requirements of ISO 6944-1985, "Fire Resistance Tests - Ventilation Ducts."




























388
1.0 Electric overhead traveling (EOT) crane and mono rail crane

1.1 GENERAL
(a) The cranes shall comply with the requirements and standards of latest versions of
relevant IS / IEC standards. The span of the crane shall be fixed in such a way that the
travel and lift of the main and auxiliary hooks of the crane as well as the hook limits
shall be adequate for the assembly and disassembly of the main equipment. The lift
above the service bay (upper limit) shall be adequate to hoist and carry the equipments
to assemble and disassemble. The lift below the service bay (lower limit) shall be fixed
in such a way as necessary for assembly and disassembly of the equipments.

(b) The hook and wire rope capacity shall be taken as 10% more than the maximum
weight to be lifted inclusive of the weight of the lifting beam.

(c) The provision of radio remote control and variable voltage variable frequency
(VVVF) drive for various crane motions for the purpose of precision speed control shall
be made available for the cranes.

(d) The radio remote control equipment, wherever provided shall conform to all
applicable Government rules and regulations. The frequency of operation shall be in the
requisite frequency band as per relevant standards.

(e)Codes and standards:
IS 807 : 2006 - Design, Erection and testing (Structural Portion) of
Cranes and Hoists - Code of Practice (Second Revision)

IS 3177 : 1999 - Code of Practice for Electric Overhead Traveling
Cranes and Gantry Cranes other than Steel Work Cranes (Second Revision) This code
covers mechanical, electrical, inspection and testing requirements relating to the
design, manufacturing and erection of electric overhead traveling cranes, portal and
semi - portal cranes, single girder, double girder or mono-box type.

IS 13834 : Part 1 : 1994 - Cranes - Classification Part 1 General
IS 13870 : Part 1 : 1993 - Cranes and lifting appliances -
Selection of wire ropes Part 1 General

(f) Full guarantee of 24 months for all parts and services after commissioning shall be
given. Any defects arising during the guarantee period shall be rectified free of cost.

(g) 5 sets of layout drawing and maintenance manual of the crane shall be given after
commissioning.


389
(h) All the required materials, labour, tools, staging materials and consumables for
completing the work shall be supplied

(i)Cables & Wiring: The cables laid from control panel to girder end junction box, DSL to
Main switch to Protection panel shall be 1100V grade armored PVC copper cables
confirming to IS 1554 with latest amendments. The trailing cables laid on Coburn
track(Cross conductor system with Coburn track) shall suitably rated for 1100v grade
bare copper flexible cables confirming to relevant IS standards. The end termination of
all cables shall be with copper lugs, , pins, glands etc. and shall be ferruled with
numbers. The details including cable size calculations, make of the cables, lay out
drawings etc. shall be submitted for prior approval. Separate control panel shall be
provided for protective circuit, Hoist, LT & CT

(j)The motors shall be of reputed make like ABB, Siemens, AEI, and GEC only.
Confirming to appropriate code of standard. The crane to shall be of reputed make and
it shall be got approved.

1.2 Electric overhead traveling (EOT) crane
REQUIREMENTS
DESIGN :- Compact dimensions, low weight, easy to operate and easy to maintain with
Coburn track wiring.

MOTORS :- Motors shall preferably be heavy duty squirrel cage induction motors for
hoists and cranes .Slip ring induction motors will also be acceptable if heavy duty
cranes are required as per design requirement.

GEAR BOXES :- Precision flat helical / spur gear units in light alloy housings with case-
hardened gears, high-grade surface treatment and permanent oil / grease lubrication.
All the couplings shall be of spring grid / Gear type couplings

BRAKES :- Single / Dual-disc electromagnetic DC brakes featuring automatic braking on
power failure Or Electro hydraulic thruster operated type.

LIMIT SWITCHES :- Shall be provided to prevent over hoisting & over lowering of hook.

PUSH BUTTON STATIONS :- Extra light, handy, easy to operate, aluminum, fabricated
from extruded section.

SOFT STARTS :- Electric / Electronic soft start modules electrically coupled to the long
travel drives to achieve jerk free, cushioned & smooth starts.


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MAINTENANCE PLATFORM WITH HAND RAILING: - Easy, simple & safe maintenance of
the Crane extended partially or totally along the girder.

Normal speed creep speed:

(i) Main hoist 1m / min (Normal speed) 0.2m / min(Creep speed)
(ii) Cross travel 12m / min
(iii) Bridge long travel 25m / min

1.3 UNDERSLUNG CRANES (With Electric Hoist):-
REQUIREMENTS

DESIGN :- Compact dimensions, low weight, easy to operate and easy to maintain as
per IS 3938 Class II duty operations and use.

MOTORS :- Sturdy cylindrical / conical rotor pole-changing motors with continuous cast
aluminum sections, integrated safety brakes insulation protection confirming to IS 325.

GEAR BOXES :- Precision flat helical / spur gear units in light alloy housings with case-
hardened gears and anti friction bearings on both sides, high-grade surface treatment
and permanent oil / grease lubrication.

BRAKES :- Single / Dual-disc electromagnetic DC brakes featuring automatic braking on
power failure.

LIMIT SWITCHES :- Shall be provided to prevent over hoisting & over lowering of hook.

PUSH BUTTON STATIONS :- Extra light, handy, easy to operate, aluminum, fabricated
from extruded section.

SOFT STARTS :- Electric / Electronic soft start modules electrically coupled to the long
travel drives to achieve jerk free, cushioned & smooth starts.











391
2.0 Fire detection, alarm, protection and Fighting system

2.1Fire detection and alarm

(a) A comprehensive fire detection, alarm as well as fire protection system shall be
installed for the Station in conformity with relevant IS. In addition, all buildings shall
conform to National Building Code. Fire protection system shall be designed as per the
guidelines of Tariff Advisory Committee (TAC) established under Insurance Act 1938
and /or NFPA.

(b) Automatic fire detection and alarm system shall be intelligent and addressable type
and shall be provided to facilitate detection of fire at the incipient stage and give
warning to the staff.

(c) Major equipment to be used for fire detection and protection system shall be in
accordance with Indian Standards or UL (Underwriters Laboratories, USA) or FM
(Factory Mutuals, USA)

2.2 Fire protection system

All major and minor fire risks in the Station shall be protected against fire by
suitable automatic fire protection systems. Following systems shall be generally adopted
for various fire risks:

(i) Passive fire protection measures such as fire barriers for cable galleries etc., fire
retardant coatings, fire resistant penetration sealing for all openings in floors,
ceilings, walls etc., fire proof doors etc. shall be provided to prevent spreading
and for containment of fire.

(ii) Automatic medium velocity water spray system, complying with TAC
guidelines, shall be provided for the cable galleries, cable vaults, cable
spreader rooms, cable risers, etc.

2.3 Fire Fighting System

(1) Proper attention shall be given to isolation, limiting and extinguishing of fire so as to
prevent damage to costly equipments, reduce chances of serious interruption of power
supply and ensure safety of personnel. The layout of the sub- station itself shall be such
that the fire shall not spread from one to other equipment and areas as far as possible.


392
(2) Fire hydrant, carbon dioxide (CO2) type fire extinguisher or dry chemical powder
type fire extinguisher conforming to relevant IS shall be provided at various locations to
cover the entire Station.


(3) Adequate Number and quantity complying with TAC guidelines, shall be provided

(4) Dedicated fire water storage 1 lakh litre capacity and pumping facilities shall be
provided for the fire fighting system as per TAC guidelines. Main fire water pumps shall
be electrically driven and standby pumps shall be diesel engine driven.

(5) Portable fire extinguishers as per TAC guidelines shall be provided for each
room/area of sub- station in addition to fixed fire protection system to extinguish fire in
its early phase to prevent its spread.





























393
3.0 Earthing system

3.1 General
AC system: Solidly earthed
DC system: Unearthed

The earthing system shall be designed for a life expectancy of at least forty (40) years
and for maximum system fault current or 40kA for 3.0 sec, whichever is higher.

The minimum rate of corrosion of COPPER used for earthing conductor shall be
considered as 1% per year while determining the conductor size.
Grounding and lightning protection for the entire Station shall be designed and provided
in accordance with relevant IEEE Standards.
The soil resistivity at the substation is
Combined earth resistance shall be 0.1 ohms

3.2 Earth electrode
Grounding protection for the entire Station shall be provided with earth electrode made
of copper rod of cross section 240 sq mm and 15 mts length. At least 2 no earth
electrode shall be provided for the sub station building diagonally opposite. The
electrode shall be embedded in 150 mm dia hole driven by auguring and filled with
bentonite and carbon powder mixture. Similarly at least 1 no earth electrode shall be
driven for each Transformer. All the earth electrodes shall be submerged 1 mt below
the basement floor level

Resistance of each earth electrodes shall be measured and recorded.

3.3 Earth electrode inter-connection

The earth electrodes provided for the sub station building shall be inter-
connected with each other by providing 240 sq mm stranded bare copper conductor
and copper clamps. The copper conductor loop shall cover entire perimeter of the
substation

Similarly the earth electrodes provided for the Transformers shall be inter-
connected with each other by providing 240 sq mm stranded bare copper conductor
and copper clamps. The copper conductor loop shall cover entire perimeter of the
Transformers plinth.

Both the loops shall be inter- connected at least at 2 locations with each other
by providing 240 sq mm stranded bare copper conductor and copper clamps.


394
Combined earth resistance shall be measured and recorded. The value shall
be less than 0.1 more earth electrodes can be added, if it is necessary to achieve the
required combined resistance.

3.4 Earth mat risers

Earth mat risers shall be of copper flats with cross section area of 240 sq mm
connected at 5mts interval to the copper conductor loop below the basement floor level
by copper clamps. These risers shall be brought up from the floors, through 140 mm
PVC pipe filled with fire proof insulating compound.

3.5 Earth mat layout

These earth mat risers shall be looped or inter-connected through out the inner
periphery of each room by providing 240 sq mm copper flats by brazing or fastening
stainless steel bolt and nuts, 300 mm above floor level and secured to the wall by
copper cleats. Forming earthmat layout. At the entrance of any room it should be fixed
below the floor level. All the earthing connections required for any equipment, and
equi-potential earth mat in any particular room shall be taken only from this copper flat
earth mat layout in that particular room, by providing 240 sq mm copper flat 100 mm
below the floor level .
Similarly for connecting the transformers and power cables, 240 sq mm
copper flat earth mat risers shall be connected to the copper conductor loop, where
ever earthing connection is required for the equipments.



















395
ILLUMINATION
STANDARDS:
The electrical installations shall be carried out as per IS.732.

LIGHTING LEVELS:
A general distribution and protection panel has to be provided in the building.

LIGHTING:
The power and number of ceiling-mounted lighting fixtures are determined to
provide the following intensities of illumination or adequate illumination.
+ Corridors : 200 lux
+ Cable floor-basement : 100 lux
+ Toilets : 100 lux
+ Control room : 100 lux
+ Offices : 250 lux
+ 110KV compartment room : 250 lux
+ Battery room : 100 lux
+ Rectifier room : 100 lux
+ Basement : 100 lux
+ Air-conditioning : 250 lux
+ Stairs : 100 lux
+ Stores : 250 lux
+ Spares & tools : 250 lux
Provision of Socket:220V single phase + earth (16A or 20A) corridor
+ Offices : 2
+ Basement : 1
+ Stores : 1
+ Spares tools : 1

396
+ Conference room : 1
+ Rectifier room : 1
+ 110 and 33KV compartment room : 4
+ Control room : 2

LIGHTING MATERIALS:
All the room must be equipped of adequate fluorescent electric lamps. These
ones must be sealed in the incandescent reflector or in any other way. These fittings
shall be dust-proof. These ones must be agreed by the purchaser.
A special connector must be installed at the entrance of the sub-station. This
switch will extinguish all the lighting of the building.
The security lighting shall be performed by automatic emergency exit light and
shall be on when the power is down.
The handling emergency light must be located in specified areas on each level of
the building in the drawings.
In specified area the contractor must use adequate lighting such as explosion
proof light or equivalent type fluorescent lamp, emergency lamp, emergency exit lamp,
filament lamp, tight double lamp, handling emergency lamp.
All the different units used on the site must fit the Indian standards and must be
agreed by the purchaser. The height of the lamps must be agreed by the purchaser.









397
110KV CABLE ACCESSORIES

1.0 DESCRIPTION OF INDOOR/OUTDOOR SEALING END REQUIRED:
1.1 Indoor/Outer Sealing end (termination) shall be suitable for the cable specified. The
connection of the cables at GIS shall be made through SF6 filled cable connection
enclosures. A general arrangement of the GIS compartment will be furnished..

1.1 For terminating the cables in the sub-stations, pre-molded sealing ends suitable for
heavily industrial and saline polluted atmospheric conditions as per relevant IEC/IS
shall be supplied along with the cables. The sealing ends shall conform to the latest
International Standards apart from the specification for the cable mentioned above.
Design tests shall be performed on two Outdoor Sealing Ends and one joint unless
the tests have already been done, in which case, a certificate of proof shall be
submitted.

1.2 The internal electric stress in the sealing end shall be controlled by the premoulded
silicon rubber/EPDM rubber cone arrangement. The outside bushing shall be of
silicon/EPDM rubber and shall be weather-proof and of good quality, suitable for use
in locations of severe coastal pollution. The creep age (mm/KV) should conform to
relevant standards. The design of the termination should be such a way that it does
not involve plumbing of any metal parts and should have provision to control cable
sheath current.

1.3 Each outdoor type sealing end shall be supplied complete with mounting plate
insulators to insulate the Sealing End from the supporting structures
and to control the cable sheath current. Phase to phase clearance of
sealing end should match with other terminal equipment.

1.4 The required Bi-metallic Terminal connectors shall be supplied free of cost along
with the Sealing Ends to suit the jumper conductor. Size of jumper conductor will be
furnished to the successful bidder.

1.5 The vendor shall provide sheath bonding cable of size 240 sq.mm copper flexible
conductor with HDPE insulation cover from termination to the earthing point through
single phase link box.

1.6 Earthing at termination: Minimum two earth pits have to be provided for each 110 KV
feeder end. Earth pit should be augured for 5m & 150mm dia bore and 40mm dia
MS rod for a length of 5.5m should be driven in to the earth pit and filled with
sufficient quantity of Bentonite. MS flat 75x8mm should be used to inter connect the
earth pits with sub station earth mat and for earthing termination structures. At each
termination end feeder name board in plastic shall be provided. The cost shall be
included with the termination structure to be supplied.

398

TECHNICAL SPECIFICATION FOR MAINTENANCE FREE 11 KV RING
MAIN UNIT SWITCHGEAR
1.0. SCOPE
1.1 Design, Engineering, Manufacture, assembly, Stage testing, inspection
and testing before supply and delivery at site, Erection, Installation, testing &
Commissioning of Ring Main units outdoor type SF6 (with 2 numbers Load break
Isolators for 11 KV Incoming & Out going cables and VCB/ SF6 Breaker for
Distribution Trans former)

1.1.1 This Specification provides for design, manufacture, inspection and testing
before despatch, packing and delivery F.O.R.(Destination) of SF6 insulated RMUs
with necessary take off terminal units for future automations, other accessories
and auxiliaries equipments and mandatory spares, described herein
The objective of the RMUs is for extremely small construction width, Compact,
maintenance free, independent of climate, easy installation, operational
reliability, Safe and easy to operate, minimum construction cost, minimum site
work and minimum space requirement.

1.2. The RMUs shall conform in all respects to high standards Of Engineering
design, workmanship and latest revisions of relevant standards at the time
of offer and purchaser shall have the right to reject any work or material
which in his judgment is not in full accordance therewith.

1.3. The type of the 11 KV circuit breaker shall be either SF6/VCB and
insulating medium for load break isolators, Earth switch, 11 KV Buses and
other associated equipments should be SF6 gas.


2.0 GENERAL
The Ring Main Unit shall be installed at 11 KV junction points to have continuous
supply by isolating faulty sections. The RMU shall be extensible and consists of
the following combinations of load break switches and Circuit breakers for a
nominal voltage of 12 KV using SF6 gas as insulating and SF6 /Vacuum as arc
quenching medium.

The RMU and combition shall be erected at outdoor, tropicalised and outdoor
metal enclosed type. The RMU metal parts shall be of high thickness high tensile
steel which must be grit/short blasted, thermally sprayed with Zinc alloy,
phosphate and subsequently painted with polyurethane based powder paint, the
overall paint layer thickness shall be not less than 150 microns.


399
Relevant IE rules for clearances, safety and operation inside the enclosure shall
be applicable. The enclosure shall be IP 54 and type tested for weather proof at
EREDA/CPRI.

All live parts except for the cable connections shall be insulated with SF6
gas. The SF6 enclosure shall be made of robotically welded stainless
steel/Metallised Cast Resin.

The cubicle shall be metal enclosed with a sheet steel of high thickness
and provided with a pressure relief arrangement away from operator.
Both the load break switches and the tee off circuit breaker shall be
suitable for motorization in future.
Any accidental over pressure inside the sealed chamber shall be limited by
the opening of a pressure-limiting device in the rear/top part of the enclosure.
Gas will be release to the rear of the switchboard away from the operator to
ensure safety of the operating personnel and all the manual operations will be
carried out on the front of the switchboard.

The Entire units of RMU shall be in a single compact metal clad, outdoor
type suitable for all weather conditions. The switchgear and bus bar shall all be
filled with SF6 at 0.5 bar G/IEC/IS Standards relative pressure to ensure the
insulation and breaking functions. The enclosure must be sealed for life and shall
meet the sealed pressure system criterion in accordance with the IEC 298
standard. The RMU must be a system for which no handling of gas is required
throughout the 20 years of service life.
The enclosure for switchgear and metallic RMU housing shall have a
design such that in the event of an internal arc fault, the operator shall be safe.
This should be in accordance with IEC 298 and releavent Test certificates shall
be submitted relay with the Tender.

Suitable temperature rise test on the RMU with enclosure shall be carried out &
test reports shall be submitted with tender for technical bid evaluation.

Each switchboard shall be identified by an appropriately sized label, which
clearly indicates the functional units and their electrical characteristics.

The switchgear and switchboard shall be designed so that the position of
the different devices is visible to the operator on the front of the switchboard
and operations are visible as well.

The entire system shall be totally encapsulated. There shall be no access
to exposed conductors. In accordance with the standards in effect, the

400
switchboards shall be designed so as to prevent access to all live parts during
operation without the use of tools.

The entire 11 KV RMU are insulated by inert gas (SF6) suitable for operating
voltage up to 12 KV respectively. The 11 KV circuit breakers must be VCB/SF6
breaker. It is necessary to fit an absorption material in the tank to absorb the
moisture from the SF6 gas to regenerate the SF6 gas following arc interruption.
The SF6 insulating medium shall be constantly monitored via a temperature
compensating gas pressure indicator offering a simple indication. All the
combination of the RMUs should have the required SF6 insulation by providing
necessary gas chamber capacity.

Sulphur Hex fluoride Gas(SF6 GAS)
The SF6 gas shall comply with IEC 376,376A,and 376B and shall be suitable in all
respects for use in 11 KV panels under the operating conditions. The SF6 shall be
tested for purity, dew point air hydrolysable fluorides and water content as per
IEC 376,376A and 376B and test certificate shall be furnished to the owner
indicating all the tests as per IEC 376 for each Lot of SF6 Gas . The metallic
enclosure should be tested for leakage at site.

3.0 STANDARDS
Unless otherwise specified elsewhere in this Specification, the RMU, Switchboard
(Switchgear), Load break isolators, Instrument Transformers and other
associated accessories shall conform to the latest revisions and amendments
thereof of the following standards.
1) IEC 60 298/IEC 62 271-200/IS 12729:1988 - General requirement for
Metal Enclosed Switchgear

2) IEC60129/IEC62271-102/IS 9921 - Alternating current disconnectors
(Load break isolators) and earthing switch

3) IEC 62 271-100/IEC 60 056/IS 13118:1991 - Specification for alternating
IEC 62 271-200 current circuit
breakers.

401
4) IEC 62 271-1/IEC 60694 - Panel design, SF6/Vacuum Circuit Breakers

5) IEC 60044-1/IEC 60185/IS 2705:1992 - Current Transformer
7) IEC 60265/IS 9920:1981- High voltage switches.
8) IEC 376 - Filling of SF6 gas in RMU.
9) IEC 60273/IS :2099 - Dimension of Indoor & Outdoor post insulators
with voltage > 1000 Volts.

10)IEC 60529/IS 13947(Part-1) - Degree of protection provided by
enclosures for low voltage switchgear and
control gear.
11) Indian Electricity Rules/Bills
Equipment meeting with the requirements of any other authoritative standards, which
ensures equal or better quality than the standard mentioned above shall also be
acceptable. If the equipments, offered by the Bidder conform to other standards,
salient points of difference between the standards adopted and the specific standards
shall be clearly brought out in relevant schedule. In case of any difference between
provisions of these standards and provisions of this specification, the provisions
contained in this specification shall prevail. One copy of such standards with authentic
English Translations shall be furnished along with the offer.(Hard copy)


4.0. THE STANDARDS MENTIONED ABOVE ARE AVAILABLE FROM:

REFERENCE/ NAME AND ADDRESS FROM WHICH THE
ABBREVIATION STANDARDS ARE AVAILABLE

IEC INTERNATIONAL ELECTRO-TECHNICAL
COMMISSION,

BUREAU CENTRAL DE LA COMMISSION, ELECTRO TECHNIQUE INTERNATIONAL,
1, RUE DE VEREMBE, GENEVA,
SWITZERLAND.

ISO INTERNATIONAL STANDARD ORGANISATION



402
6.0. RMU OUTDOOR METAL CLAD
The RMU enclosure must be a metallic, it follows an industrialized process of
manufacturing. The RMU shall be of single bus bar SF6 gas insulated outdoor,
tropicalised and metal enclosed type. The RMU metal parts shall be made of high
thickness high tensile steel which must be grit/short blasted, thermally sprayed
with Zinc alloy, phosphate and subsequently painted with polyurethane based
powder paint, the overall paint layer thickness shall be not less than 150
microns.The rating of enclosure shall be suitable for operation on three phase,
three wire, 11 KV, 50 cycles, A.C. System with short-time current rating of 20KA
for 3 seconds with Panels.

7.0. ISOLATORS (LOAD BREAK TYPE)

The load break isolators for Incoming and Outgoing supply must be provided and
the load break isolators are fully insulated by SF6 gas. The load break isolators
shall consist of 630 Amp fault making/load breaking spring assisted ring
switches, each with integral fault making earth switches. The switch shall be
naturally interlocked to prevent the main and earth switch being switched ON at
the same time. The selection of the main and earth switch is made by a lever on
the facia, which is allowed to move only if the main or earth switch is in the off
position. The load break isolators should have the facility for future remote
operation. Each load break switch shall be of the triple pole, simultaneously
operated, non automatic type with quick break contacts and with integral
earthing arrangement.

8.0. EARTHING OF ISOLATORS AND DISTRIBUTION TRANSFORMER
BREAKERS (EARTH SWITCH)
Necessary arrangements are provided at Load break isolators / Distribution
Transformer Breaker for selecting Earth position. Mechanical interlocking systems
shall prevent the RMU function from being operated from the ON to Earth On
position without going through the OFF position.

9.0. DISTRIBUTION TRANSFORMER BREAKER (SF6 / VACUUM)

The SF6/VCB breaker for the controlling of DT must be provided inside the
outdoor metal clad and insulated by SF6 gas.
The SF6/VCB circuit breaker must be a spring assisted three positions with
integral fault making earth switch. The selection of the main/earth switch lever

403
on the facia, which is allowed to move only if the main or earth switches is in the
off position.
The manual operation of the circuit breaker shall not have an effect on
the trip spring. This should only be discharged under a fault (electrical) trip; the
following manual reset operation should recharge the trip spring and reset the
circuit breaker mechanism in the main off position.
The circuit breaker shall be fitted with a mechanical flag, which shall
operate in the event of a fault (electrical) trip occurring. The tripped flag should
be an unambiguous colour differing from any other flag or mimic.
Both the circuit breaker and ring switches are operated by the same
unidirectional handle.
The protection on the circuit breaker shall comprise of the following
components:The circuit breaker unit fitted with 3 class X protection CTs, a low
burden trip coil and auxiliary switch assembly allowing the use of a self
powered (No external DC or AC source required) IDMT protection
relays (Numeric/Micro processor based) 3 x over current and earth fault
element shall be Definite Time type relay . The protection system should be
suitable for protecting transformers of rated power from 250 KVA on wards. The
relay should be housed within a pilot cable box accessible. A facility of provision
for the delay of transformer in-rush current shall be provided on relay to avoid
nuisance tripping.
10.0. BUSHINGS
The units are fitted with the standardized bushings that comply with IEC
standards. All the bushings are the same height from the ground and are
protected by a cable cover.
11.0. CABLE BOXES
All the cable boxes shall be air insulated suitable for dry type cable terminations.
The cable boxes at each of the two ring switches suitable for accepting HV
cables of sizes 3c x 300/3c x 120 sq.mm and circuit breaker cable suitable up to

404
3c x 120 sq.mm.. Necessary Right angle Boot should be supplied to the cable
terminations .The type of the Right angle Boot should be cold applied
insulating Boot.

12.0. CABLE TESTING FACILITY

It shall be possible to test the cable without opening the cable boxes.

14.0.VOLTAGE INDICATOR LAMPS AND PHASE COMPARATORS
The RMU shall be equipped with a voltage indication to indicate whether or not there is
voltage on the cable. There should be a facility to check the synchronization of phases
with the use of external device. It shall be possible for the each of the function of the
RMU to be equipped with a permanent voltage indication as per IEC 601958 to indicate
whether or not there is voltage on the cables.

15.0. WIRING & TERMINALS:
The wiring should be of high standard and should be able to withstand the tropical
weather conditions. All the wiring and terminals (including take off terminals wiring for
future automation, DC, Control wiring), Spare terminals shall be provided by the
contractor. The wiring cable must be standard single-core non-sheathed, Core marking
(ferrules), stripped with non-notching tools and fitted with end sleeves, marked in
accordance with the circuit diagram with printed adhesive marking strips.
The wiring should be of high standard and should be able to withstand the
tropical weather conditions. All wiring shall be provided with single core multistrand
copper conductor wires with P.V.C insulation and shall be flame retardant low smoke
type.
The wiring shall be carried out using multi-strand copper conductor super flexible PVC
insulated wires of 650/1100V Grade for AC Power, DC Control and CT circuits. Suitable
colored wires shall be used for phase identification and interlocking type ferrules shall

405
be provided at both ends of the wires for wire identification. Terminal should be
suitably protected to eliminate sulphating. Connections and terminal should be able to
withstand vibrations. The terminal blocks should be stud type for controls and
disconnecting link type terminals for CT leads with suitable spring washer and lock nuts.

Flexible wires shall be used for wiring of devices on moving parts such as
swinging Panels (Switch Gear) or panel doors. Panel wiring shall be securely supported,
neatly arranged readily accessible and connected to equipment terminals, terminal
blocks and wiring gutters. The cables shall be uniformly bunched and tied by means of
PVC belts and carried in a PVC carrying trough.

The position of PVC carrying trough and wires should not give any hindrance for
fixing or removing relay casing, switches etc., Wire termination shall be made with
solder less crimping type of tinned copper lugs. Core identification plastic ferrules
marked to correspond with panel wiring diagram shall be fitted with both ends of each
wire. Ferrules shall fit tightly on the wire when disconnected. The wire number shown on
the wiring shall be in accordance with the IS.375.

All wires directly connected to trip circuits of breaker or devices shall be distinguished by
addition of a red color unlettered ferrule.

Inter-connections to adjacent Panels (Switch Gear) shall be brought out to a separate
set of Terminal blocks located near the slots or holes to be provided at the top portion of
the panel. Arrangements shall be made for easy connections to adjacent Panels (Switch
Gear) at site and wires for this purpose shall be provided and bunched inside the panel.
The bus wire shall run at the top of the panel. Terminal block with isolating links should
be provided for bus wire. At least 10% of total terminals shall be provided as spare for
further connections. Wiring shall be done for all the contacts available in the relay and
other equipment and brought out to the terminal blocks for spare contacts. Color code

406
for wiring is preferable in the following colours. Voltage supply Red, Yellow, Blue for
phase and Black for Neutral
CT circuits similar to the above
DC circuits Grey for both positive and negative

250V AC circuits Black for both phase and neutral
Earthing Green

The wiring shall be in accordance to the wiring diagram for proper functioning of
the connected equipment. Terminal blocks shall not be less than 650V grade and shall
be piece-molded type with insulation barriers.

The terminal shall hold the wires in the tight position by bolts and nuts with lock
washers. The terminal blocks shall be arranged in vertical formation at an inclined
angle with sufficient space between terminal blocks for easy wiring.

The terminals are to be marked with the terminal number in accordance with the
circuit diagram and terminal diagram. The terminals should not have any function
designation and are of the tension spring and plug-in type.

17.0. EARTHING

The RMU outdoor metal clad, Switch Gear, Load break isolators, Distribution
Transformer, R.S.Joists, M.S. Channels / M.S. Angles etc., shall be equipped with an
earth bus securely fixed along the base of the RMU.

COPPER Earth spikes over the R.S.Joists must be provided for protection of
the Distribution Transformer and RMU . The spikes should be earthed to ground
earth pit by providing necessary separate M.S. Flat along the leg member of the R.S.
Joist.


407
The contractor must provide separate earthing pits and earth bus for the following
and the same shall be interconnected by using M.S. Flats
1. RMU Outdoor metal body, (Switch Gear & Load break isolators)
Distribution Transformer tank, R.S.Joists, M.S.Channels, Earth
Spikes and other metal parts,
2. Distribution Transformer Neutral.

The size of the earth bus shall be made of IEC/IS standards with tinned
copper flat for RMU and M.S.Flat for Distribution Transformer, earth spike
and neutral earthing. Provision shall be made on end of RMU for connecting the
earth bus to the earth grid by erecting suitable 2 earth pipes of 40mm dia MS rod
of 3 mts in pits. Both the earth pipes are also to be connected in a grid formation.
Necessary terminal clamps and connectors shall be included in the scope of supply.
NOTE: If there are two or more Distribution Transformers, separate Earth
Pipes in a pit should be provided for each Transformer Neutral and it shall be
connected with the main Earth grid.
All metal parts of the switchgear which do not belong to main circuit and
which can collect electric charges causing dangerous effect shall be connected to the
earthing conductor made of copper having CS area of minimum 75 mm . Each
end of conductor shall be terminated by M12/equivalent quality and type of terminal
for connection to earth system installation. Earth conductor location shall not
obstruct access to cable terminations.
The following items are to be connected to the main earth conductor by rigid or
copper conductors having a minimum cross section of 75 mm (a) earthing
switches (b) Cable sheath or screen (c) capacitors used in voltage control devices, if
any.
All metallic cases of the relays, instruments and other panel mounted
Equipments shall be connected to the earth bus by independent copper wires of
size shall be made of IEC/IS standards. The colour code of earthing wire shall
be green. Earthing wires shall be connected on the terminals with suitable clamp
connectors and soldering shall not be permitted.

18.0 CIVIL WORKS
The work shall include the following
1)Mass plinth foundation for mounting RMU and associate combination of
Isolators and Breakers
2)Mass plinth foundation for R.S.Joists for mounting DTs foundation for DTs suit
to the site conditions.

408
3)Foundation at water locking area shall be elevated, additional cost will not be
provided.

19.0 STRUCTURE FOR DISTRIBUTION TRANSFORMER:

The Distribution Transformer structure has to be fabricated with the following
materials:
1) RS Joists for leg member : 150 x 75 mm
2) MS angle for seating : 65 x 65 x 6 mm
3) Chequered Plate : 8 mm thickness.
4) PVC Pipes : 140 mm dia. or higher size wherever required.
5) Arrangement for collection and discharge of oil deposit from transformer
seating platform to ground is to be provided.
6) Necessary cement collar for Earth pit.
Wherever 2 distribution transformer combinations comes, necessary
arrangements for providing extra R.S. Joists, chequered plate, ms angle and
Earthing must be made.
Necessary indicative drawing for the same is enclosed. However if necessary, the
drawings suitable as per site conditions shall be designed, and got approved
from TNEB, before fabrication and erection at site. Any saving and material will
be recovered.All the Bolts ,Nuts fasteneretc shall be galvanized.All structures
should be painted with three coating of aluminium.

20.0. ACCESSORIES & SPARES:

The following spares and accessories shall be supplied along with the
main equipments at free of costs. This shall not be included in the price
schedule.
1) Charging lever for operating load break isolators & circuit breaker of each
RMU
2) Kit for identifying SF6 gas leakage 5 numbers
3) All pressure gauges indications 5 numbers
4) Necessary SF6 gas filling plant with adopter and tools etc for filling SF6 gas
at Site --2 Nos
5) Necessary gas cylinders with adopter ,pressure gauge for storage of SF6 gas
2 Nos
6) Any other spares & Tools, which are all essentially required at the time of
emergency and routine maintenance.
Provision shall be made for padlocking the load break switches/ Circuit
breaker, and the earthing switches in either open or closed position with lock &
master key.


409
21.0.TESTING OF EQUIPMENT & ACCESSORIES:

Provision for testing CTs, Relays, Breakers and Cables shall be made available.
Procedure and schedule for Periodical & Annual testings of equipments, relays,
etc. shall be provided by the supplier.

22.0. TESTS:

22.1 ACCEPTANCE AND ROUTINE TESTS
All acceptance and routine tests as stipulated in the latest IEC- shall be carried
out by the supplier in the presence of Boards representative. The supplier shall
give at least 7 days advance intimation to the Board to enable them to depute
their representative for witnessing the tests. The cost towards transport, stay
and other expenses shall be borne by the supplier.

22.2. ADDITIONAL TESTS

The Board reserves the right for carrying out any other tests of a reasonable
nature at the works of the supplier/laboratory or at any other recognized
laboratory/research institute in addition to the above mentioned type,
acceptance and routine tests at the cost of the Board to satisfy that the material
complies with the intent of this specification.

22.3. PRE-COMMISSIONING TESTS

The supplier has to arrange all the pre-commissioning tests in the
presence of the Board testing engineer and necessary drawing manual and
periodical test tools shall be arranged to be supplied. Also outdoor test for RMU
should be conducted.
The above tests are the responsibility of the contractor till the RMUs are
put in to service.

23.0.INSPECTION:
The inspection may be carried out by the Board at any stage of
manufacture. The supplier shall grant free access to Boards representative at a
reasonable time when the work is in progress. Inspection and acceptance of any
equipment under this specification by the Board shall not relieve the supplier of
his obligation of furnishing equipment in accordance with the specification and
shall not prevent subsequent rejection if the equipment is found to be defective.

410

The supplier shall keep the Board informed in advance, about the
manufacturing programme so that arrangement can be made for inspection. The
Board reserves the right to insist for witnessing the acceptance/routine testing of
the bought out items. The Board has rights to inspect the suppliers premises for
each and every consignment for type & routine test. The cost towards transport,
stay and other expenses shall be borne by the supplier.

No material shall be dispatched from its point of manufacture unless the material
has been satisfactorily inspected and tested / unless the same is waived by the
Board in writing.

24.0. QUALITY ASSURANCE PLAN:

The bidder shall invariably furnish following information along with his offer.
(i) Statement giving list of important raw materials including but not
limited to
(a) Contact material
(a) Insulation
(c) Sealing material
(d) Contactor, limit switches, etc. in control cabinet.

Name of sub-suppliers for the raw materials, list of standards according to
which the raw materials are tested, list of test normally carried out on raw
materials in presence of Bidders representative, copies of test certificates.
ii) Information and copies of test certificates as in (i) above in respect of bought
out accessories.
iii) List of areas in manufacturing process, where stage inspections are
normally carried out for quality control and details of such tests and
inspections.
iv) Special features provided in the equipment to make it maintenance
free.
v)List of testing equipment available with the Bidder for final testing of Rmus and
associated combinations vis--vis, the type, special, acceptance and routine tests
specified in the relevant standards. These limitations shall be very clearly
brought out in the relevant schedule i.e. schedule of deviations from specified
test requirements. The supplier shall, within 15days from the date of receipt of
Purchase Order submit following information to the Board.

i) List of raw materials as well bought out accessories and the names of

411
sub-suppliers selected from those furnished along with offer.

ii) Necessary test certificates of the raw material and bought out accessories.

iii) Quality Assurance Plan (QAP) with hold points for Boards inspection. The
quality assurance plan and hold points shall be discussed between the Board
and supplier before the QAP is finalised.

The supplier shall submit the routine test certificates of bought out items and
raw material, at the time of routine testing of the fully assembled breaker.


26.0 DOCUMENTATION

All drawings shall conform to relevant International Standards
Organization (ISO) Specification. All drawings shall be in ink and suitable for
microfilming.


27.0.DRAWINGS

The tenderer shall submit along with his tender dimensional general
arrangement drawings of the equipments, illustrative and descriptive literature in
triplicate for various items in the RMUs which are all essentially required for
future automation.

i) Schematic diagram of the RMU panel
ii) Instruction manuals
iii) Catalogues of spares recommended with drawing to indicate each
items of spares
iv) List of spares and special tools recommended by the supplier.
v) Copies of Type Test Certificates as per latest IS/IEC.
vi) Drawings of equipments, relays, control wiring circuit, etc.
vii) Foundation drawings of RMU and D.T.Structure.
viii) Dimensional drawings of each material used for item Vii.
ix) Actual single line diagram of RMU/RMUs with or without Extra combinations
shall be made displayed on the front portion of the RMU so as to carry out the
operations easily.

The following should be supplied to each consignee circle along with the
initial supply of the equipments ordered.

412

5 copies of printed and bound volumes of operation, maintenance and erection
manuals in English along with the copies of approved drawings and type test
reports etc.

3 sets of the manuals as above shall be supplied to the Chief
Engineer/Distribution/Chennai North Region. A soft copy of the all Technical and
Drawing furnished in a CD

28.0. NAME PLATE:

Each RMU and its associated equipments shall be provided with a
nameplate legible and indelibly marked with at least the following information.
(a) Name of manufacturer
(b) Type, design and serial number
(c) Rated voltage and current
(d) Rated frequency
(e) Rated symmetrical breaking capacity
(f) Rated making capacity
(g) Rated short time current and its duration
(h) Purchase Order number and date
(i) Month and Year of supply
(j) Rated lighting impulse withstand voltage
(k) D.C. component of current.
(l) Feeder name(Incoming and Out going),DTs Structure name,11000Volts
Dangers etc.

NOTE: i) The word rated need not appear on the name plate.
Recognized abbreviations may be used to express the above
particulars.
ii)Whether the circuit breaker is fitted with closing/tripping devices
necessitating an auxiliary supply shall be stated either on the circuit breaker
name plate or any other acceptable position.

29.0. ERECTION AND COMMISSIONING:

All the erection works like Transportation, erection of RMUs with necessary take
off terminal units for future automations, foundation structures for RMUs which
includes civil & concrete works, foundation structures for R.S.Joists for mounting
DTs, earthing, Control cable wiring etc. shall be erected, tested & commissioned
under turnkey basis. The released Distribution Transformers /New Distribution
Transformers and the associated power cables alone will be provided by TNEB

413



31.0. TECHNICAL SPECIFICATION FOR RMU

I. 11KV Bus Bar

Type of material : Copper
Current Carrying Capacity : 630 Amps.
Short time rating current for 3 secs. : 20 KA
Insulation of bus bar : SF6
Bus bar connections : Anti-oxide grease

II. Parameters for Switch Gear of DT and load break isolators
Type : Metal enclosed
No of Phases : 3
No. of poles : 3
Rated voltage :12 KV
Operating voltage :11 KV(+10% to 20%)
Rated lightning impulse withstand voltage :75 KV
Rated power frequency withstand voltage :28 KV
Insulating gas :SF6
Rated filling level for insulation :0.5 bar/As Per IEC.
Max.permissible site altitude at the above gas pressures : 1000m
(The operating pressure has to be adjusted for greater altitudes)
Rated short time current :20 KA.
Rated short time :3s
Rated peak withstand current :50 KA.

Operating mechanism: Circuit breaker with spring assisted anti reflex
mechanism.
Rated current (Bus): :630 A
Rated current (breaker) :200 A
Circuit Breaker interrupter :SF6/VCB
Rated frequency : 50 Hz

414
Rated operating sequence :O-3min- CO
Number of mechanical/Remote operations for earthing As per IEC
& Ring switches & Number of mechanical/ 60298
remote operations for circuit breakers
III.PRINCIPAL FEATURES

Sl No DESCRIPTION DT
breaker
1 Circuit label Yes
2 Mimic diagram Yes
3 Supply voltage indication Yes
4 Current Transformer Yes
5 Self Powered based Microprocessor
based IDMT Relay (3OL)/EL
Yes
6 Anti Reflexing Relay Yes

7 Interlock to defeat the operation of the
line side earthing when the line side
isolator is ON.
Yes
8 Interlock to defeat the operation of the
earthing when the breaker is in service
position and is ON.
Yes
9 Local /Remote Switch Yes
10 Breaker ON/OFF indication Yes
11 Spring Charge indication / Spring
assisted mechanism.
Yes
12 Fault Tripping indication Yes
13 Bus bar end caps Yes
14 Whether the SF6 gas pressure gauge
indicator and filling arrangement.
Yes
15 Whether the spring assisted mechanism
with operating handle for ON/OFF.
Yes
16 Whether the earth positions with
arrangement for padlocking in each
position and independent manual
operation with mechanically operated
indicator are provided
Yes
17 RMUs are provided with necessary take
off terminals for future automation.
Yes

415

IV.3 Load break switch(Isolators)
Type : SF6 load breaking and fault making.
Rated current :630 A
Fault making capacity(KA peak min.) : 50 KA
V. Earthing switch for 11 KV Line side Isolation and DT
Rated short time current :20 KA.
Rated short time :3s
Rated peak withstand current :50 KA
Interlocking facility: 1) Between 11 KV Line side isolator ON& Earthing.
2) Between 11 KV DT side breaker on close condition &
Earthing.
VI. Current Transformers for breaker
CT Type : Tape wound
CT Description :The CTs of DT breaker shall be
suitable for sensing the minimum
primary variable current in the
order of 10-60 A and the secondary
current for the CT is 1 A. The CT
shall be housed in outside SF6
chamber for testing and
Maintenance
Accuracy Class : class X/5P10 protection
Rated burden : Suitable for self powered relay.

34.0 TERMINATIONS
The Terminations should be provided by the contractor at the following places in
RMU.

416
1) Incoming cable to Isolators
2) Outgoing cable from Isolators
3) Outgoing cable from Dt Breaker of RMU to the DT HT
4) Incoming cable to DT HT side.
The terminations should be suitable for Indoor of the RMU & outdoor of the DT.
The terminations shall be Heat shrinkable. Necessary suitable clamps shall be
provided. The size of the cable will be 11KV 120 sqmm XLPE cable.


SCHEDULE OF GUARANTEED PARTICULARS FOR OUTDOOR METAL CLAD

01.
02.
03.
04.
05.
06.

07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19







417
SCHEDULE OF GUARANTEED PARTICULARS FOR DT BREAKER

01.
02.
03.
04.
05.
06.

07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.




418
SCHEDULE OF GUARANTEED PARTICULARS FOR LOAD BREAK ISOLATORS &
EARTHING ARRANGEMENTS

SL.NO. DESCRIPTION ISOLATORS EARTHING
SWITCH
FOR DT &
ISOLATOR
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19
20
21















419
SCHEDULE OF GUARANTEED PARTICULARS FOR CURRENT TRANSFORMERS

01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.








420
SHEDULE OF GUARANTEED TECHNICAL PARTICULARS FOR SELF POWERED
MICRO PROCESSOR BASED NUMERICAL RELAYS


01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
















421
SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS FOR DRAWINGS.

The contractor shall supply the following drawings.

01.
02.
03.
04.
05.
06.
07.
08.

Three copies of the drawings shall be submitted to this office for approval.



























422
TECHNICAL SPECIFICATION FOR CIVIL WORKS

CONCRETE AND ALLIED WORKS

1.1. SCOPE
This Specification covers the general requirements for concrete to be
used on jobs using on-site production facilities including requirements in regard to
the quality, handling, storage of ingredients, proportioning, batching, mixing and
testing of concrete and also requirements with regard to the quality, storage,
bending and fixing of reinforcement. This also covers the transportation of concrete
from the mixer to the place of final deposit and the placing, curing, protecting,
repairing and finishing of concrete.

1.1.1 The two parts viz. Specific Technical requirement for the project and this
specification are complementary and are to be read together for correct
interpretation of the provisions of this specification. Where requirement of the
two sections conflict ,those of Specific Technical requirement for the project shall
govern.

1.1.2. It shall be very clearly understood that the specifications given herein are brief
and do not cover minute details. However ,all works shall have to be carried out
in accordance with the relevant standards and codes of practices or in their
absence in accordance with the best accepted current Engineering practices or
as directed by ENGINEER from time to time. The decision of ENGINEER as
regards the specification to be adopted and their interpretation and the mode of
execution of work shall be final and binding on CONTRACTOR and no claim
whatsoever will be entertained on this account.

1.2 APPLICABLE CODES AND SPECIFICATIONS
All standards, tentative Specification, Specifications, Codes of practice referred
to herein shall be the latest editions including all applicable official amendments
and revisions. In case of discrepancy, between this Specification and those
referred to herein, this Specification shall govern.
(f) MATERIALS

1. I.S.269 - Specification for ordinary, rapid Hardening and
low heat Portland cement.
2. I.S.1489 - Specification for Portland -pozzolana Cement.
3. I.S.650 - Specification for standard sand for testing of
cement.
4. I.S.383 - Specification for coarse and fine aggregates From
natural sources for concrete.

423
5. I.S.2386 - Methods of test for aggregate for concrete (Parts
I to VIII)
6. I.S.516 - Method of test for strength of concrete.
7. I.S.1199 - Method of sampling and analysis of concrete.
8. I.S.3025 - Method of sampling and testing (Physical and
Chemical) of water used in industry.
9. I.S.1139 - Specification for hot rolled mild steel, medium
tensile steel and high yield strength steel
deformed bars for concrete reinforcement.
10. I.S.1786 - Specification for cold worked steel high strength
deformed bars for concrete reinforcement.
11. I.S.4990 - Specification for plywood for concrete shuttering
work.
12. I.S.2645 - Specification for integral cement water proofing
compounds.
13. I.S.4461 - Cold worked steel bars for the reinforcement of
concrete.
14. I.S.4031 - Methods of physical tests for hydraulic cement.

(b) EQUIPMENT
1. I.S.1791 - Specification for batch type concrete mixers.
2. I.S.2505 - Specification for concrete / vibrators (immersion
type)
3. I.S.2750 - Specification for steel scaffoldings.

(c) CODES OF PRACTICE FOR CONCRETE
1. I.S.456 - Code of practice for plain and reinforced concrete.
2. I.S.3935 - Code of practice for construction.
3. I.S.2751 - Code of practice for welding of mild steel bars
used for reinforced concrete construction.
4. I.S.2502 - Code of practice for bending and fixing of bars for
concrete reinforcement.
5. I.S.3558 - Code of practice for use of immersion
Vibrators for consolidating concrete.
6. I.S.3414 - Code of practice for design and installation of
joints in building.
7. I.S.4014 - Code of practice for steel tubular (Part I & II)
scaffolding.
8. I.S.2571 - Code of practice for laying in-situ cement concrete
flooring.
9. I.S.1343 - Code of practice for pre stressed concrete.

424

(c) CONSTRUCTION SAFETY
1. I.S.3696 - Safety code for scaffolds and ladders (Part I & II)
(e) MEASUREMENT
1. I.S.1200 - Method of measurement of building works.
2. I.S.3385 - Code of Practice for measurement of Civil Engineering
works.
Note:
In the event that state, city or other Government bodies have
requirements more stringent than those set forth in this Specification,
such requirements shall be considered part of this specification and
shall supersede this Specification where applicable.

1.3. MATERIALS FOR CONCRETE
The ingredients to be used in the manufacture of standard concrete shall
consist solely of a standard type Portland cement, clean sand, natural
coarse aggregate, clean water, and admixtures, if specially called for on
drawings or specifications.

The quality of materials, method, control, manufacture and transportation
of all concrete irrespective of mix, whether reinforced or otherwise, shall
conform to the applicable portion of this specification.
ENGINEER shall have the right to inspect the sources of materials, the
layout and operation of procurement and storage of materials, the
concrete batching and mixing equipment, and take quality control systems
such an inspection shall be arranged of concrete work.

1.3.1 CEMENT

a) Unless otherwise specified in Section C or called for by ENGINEER/
OWNERS, cement shall be ordinary Portland cement conforming to not
less than Grade 43 of relevant I.S. and in 50-kg bags. The use of bulk
cement will be permitted only with the approval of ENGINEER. Changing
of brands on type of cement within the same structure will not be permitted
without approval of ENGINEER.

a) While purchasing cement or before commencing the work for every batch
of cement consignments, the CONTRACTOR should satisfy himself about
the quality of cement by conducting initial test on concrete cubes in the
presence of the representative of the PURCHASER and only after
establishing the suitability, the cement should be used on work. To have
quick evaluation results, the

425
above specimens should be cured by steam curing and tested
immediately at CONTRACTORs cost at an approved laboratory.
CONTRACTOR shall not be entitled to any claim of any nature on this
account.

1.3.2. AGGREGATES
a) `Aggregate in general designates both fine and coarse inert materials
used in the manufacture of concrete. `Fine Aggregate is aggregate most
of which passes through 4.75mm IS sieve. `Coarse Aggregate is
aggregate most of which is retained on 4.75mm IS sieve.

b) All fine and coarse aggregates proposed for the use in the work shall be
subject to ENGINEER's approval and after specific materials have been
accepted, the source of supply of such materials shall not be changed
without prior approval of ENGINEER.

A c) STORAGE OF AGGREGATES

All coarse and fine aggregates shall be stacked separately in stock piles in
the material yard near the work site to avoid inter-mixing of different
aggregates. Contamination with foreign materials and earth during storage
and while heaping the materials shall be avoided. The aggregate must be
of specified quality not only at the time of receiving at site but more so
at the time of loading into mixer. Coarse aggregates shall be piled in layer
not exceeding 1.20 metres in height to prevent coning or segregation.
Each layer shall cover the entire area of the stockpile before succeeding
layers are started. Aggregates that have become segregated shall be
rejected. Rejected materials after remixing may be accepted, if
subsequent tests demonstrate conformity with required gradation.

d) SPECIFIC GRAVITY
Aggregates having a specific gravity below 2.6 (Saturated surface dry
basis) shall not be used without special permission of ENGINEER.

1.3.3. FINE AGGREGATE
Fine aggregate except as noted above, and for other than lightweight
concrete shall consist of natural sand to I.S.383. The sand shall be clean,
sharp, hard, strong and durable and shall be free from dust, vegetable
substances, adherent coating, clay alkali, organic matter, mica, salt, or
other deleterious substances, which can be injurious to setting
qualities/strength/durability of concrete.

i) SCREENING AND WASHING

426
Sand shall be prepared for use by such screening or washing, or both as
necessary to remove all objectionable foreign matter while separating the
sand grains to the required size fractions.

ii) FOREIGN MATERIAL LIMITATIONS
The percentages of deleterious substances in sand delivered to the mixer
shall not exceed the following.
Percent by weight
Uncrushed Crushed
i) Material finer than 75micron I.S. sieve 3.00 15.00
ii) Shale 1.00 --
iii) Coal and lignite 1.00 1.00
iv) Clay lumps 1.00 1.00
v) Total of all the above substances
including items (i) to (iv)for uncrushed 5.00 2.00
sand and items (iii) and (iv)
for crushed sand


iii)GRADATION
Unless and otherwise directed or approved, the grading of sand shall
be within the limits indicated hereunder:

I.S.Sieve Designation Percentage passing for
grading Zone-I Zone-II Zone-III Zone-IV
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-90 90-100
600 micron 15-34 35-59 60-79 80-100
300 micron 5-20 8-30 12-40 15-50
150 micron 0-10 0-10 0-10 0-15

Where the grading falls outside the limits of any particular grading zone of
sieves, other than 600 I.S. Sieve, by total amount not exceeding 5
percent, it shall be regarded as falling within that grading zone. This
tolerance shall not be applied to percentage

427
passing the 600 micron I.S. sieve or to percentage passing any other
sieve size on the coarser limit of Grading Zone-I or the finer
limit of Grading Zone-IV. Fine aggregates conforming to Grading
Zone-IV shall be used unless mix designs and preliminary tests have
shown its suitability for producing concrete of specified strength and
workability.

iv) FINENESS MODULUS
The sand shall have fineness modulus of not less than 2.2 or more than
3.2. The fineness modulus is determined by adding the cumulative
percentages retained on the following I.S. sieve sizes (4.75mm, 2.36mm,
1.18mm, 600 micron, 300 micron and 150 micron) and dividing the sum by
100.

1.3.4. COARSE AGGREGATE
Coarse aggregate for concrete, except as noted above and for other than
lightweight concrete shall conform to I.S. 383. This shall consist of natural
stone and shall be clean, and free from elongated, flaky or laminated
pieces, adhering coatings, clay lumps,coal residue, clinkers, slag,
alkali, mica, organic matter of other deleterious matter.

l) GRADING
Coarse aggregate shall be either in single size or graded. In both
cases, the grading shall be within following limits.
----------------------------------------------------------------------------------------
IS Percentage Passing for Percentage
Sieve single aggregate of passing for
Desig- nominal size graded aggregate of
nation nominal size
--------------------------------------------------------------------------------------------------
40 20 16 12.5 10 40 20 16 12.5
mm mm mm mm mm mm mm mm mm
---------------------------------------------------------------------------------------------------
63mm 100 -- -- -- -- 100 -- -- --
40mm 85-100 100 -- -- -- 95-100 100 -- --
20mm 0-20 85-100 100 -- -- 30-70 95-100 100 --
16mm -- -- 85-100 100 -- -- -- 90-100 -
10mm 0-5 0-20 0-30 0-45 85-100 10-35 25-55 30-70 40-85
4.75mm -- 0-5 0-5 0-10 0-10 0-10 0-10 0-10 0-10
2.36mm -- -- -- -- 0-5 -- --- --- ---


428
The pieces shall be angular in shape and shall have granular or crystalline
surfaces. Friable flaky and laminated pieces, mica and shale,
if present, shall be only in such quantities that will not, in the opinion of
ENGINEER, affect adversely, the strength and/or durability of concrete.
The maximum size of coarse aggregate shall be 40mm for class A
concrete and 20mm for class B concrete. The maximum size of coarse
aggregate shall be the maximum size specified above but in no case
greater than 1/4 of the maximum thickness of the member, provided that
the concrete can be placed without difficulty so as to surround all
reinforcement thoroughly and fill the corners of the form. For heavily
reinforced concrete member, the nominal maximum size of the aggregate
shall be 5mm less than the minimum clear distance between the
reinforcing main bars or 5mm less than the minimum cover to the
reinforcement whichever is smaller. The amount adherent shall not
exceed 1% when determined by laboratory sedimentation tests as per
I.S.2386. After 24 hours immersion in water, a previously dried sample
shall not have gained more than 10% of its over dry weight in air, as
determined by I.S.2386.

i) FOREIGN MATERIAL LIMITATIONS
The percentage of deleterious substance in the aggregate delivered
to the mixer shall not exceed the following:
Percent by weight
Uncrushed Crushed
i) Material finer than 75
micron I.S.sieve 3.00 3.00

ii) Coal and lignite 1.00 1.00

iii)Clay lumps 1.00 --

iv) Soft Fragments 3.00 --

v) Total of all the above
substances 5.00 --

1.4. WATER
a) Water used for both mixing of mortar / concrete and curing shall be free
from injurious amounts of deleterious materials. Potable water is generally
satisfactory for mixing of mortar / concrete and curing concrete. The
relevant essential Water tests pertaining to access the suitability for

429
construction standards shall have to be done before commencement of
work.

b) The suitability of water for making concrete shall be ascertained by the
compressive strength and initial setting time test specified in I.S.456. The
sample of water taken for testing shall be typical of the water proposed to
be used for concreting, due account being paid to seasonal variation. The
sample shall not receive any treatment before testing other than that
envisaged in the regular supply of water proposed for use in concrete.
The sample shall be stored in a clean container previously rinsed out with
similar water.

c) Average 28 days compressive strength of atleast three 150mm concrete
cubes prepared with water proposed to be used shall not be less than
90% of the average strength of three similar concrete cubes prepared with
distilled water.

d) The initial setting time of test block made with the appropriate test cement
and the water proposed to be used shall not be less than 30minutes and
shall not differ by more than 30 minutes from the initial setting time of
control test block prepared with the appropriate test cement and distilled
water. The test blocks shall be prepared and tested in accordance with
the requirements of I.S.4031.

e) Where water can be shown to contain an excess of acid, alkali, sugar or
salt, ENGINEER may refuse to permit its use. As a guide, the following
concentrations represent the maximum permissible values.

(i) To neutralise 100 ml sample of water, using phenolphthalein as indicator, it
should not require more than 5 ml. of 0.02 Normal NaOH. The details of
test shall be as given in IS.3025.

(ii) To neutralise 200ml sample of water using methyl orange as an indicator, it
should not require more than 10ml of 0.1. Normal HCL. The details of test
shall be as given in IS.3025.

(iii) Presence of solids, when tested in accordance with the method indicated
below, shall not exceed the following :
Percent Method of Test
(Ref. to Clause No. in
S.3025/60)
Organic 0.02 10 & 11 (Organic Solids
Total solids minus Ignited Residue)

430
Inorganic
Sulphates (as SO
4
) 0.30 11 (Ignited residue)
Alkali 0.05 20
Chlorides (as Cl) 0.20 24



1.5. REINFORCEMENT
i) SUPPLY
The supply of steel shall be arranged by the contractor himself.
Reinforcement if supplies are arranged by CONTRACTOR shall be either
plain round mild bars Grade 1 as per IS.432 (Part 1) or medium tensile
steel bars as per IS.432 (Part 1)and deformed bars of Fe 415 grade as
per IS:1786. Wire mesh or fabric shall be in accordance with IS 1566.
Substitution of reinforcement will not be permitted except upon written
approval from ENGINEER.

No advance amounts shall be paid to the contractor towards purchase of
steel.

Note
The tenderer, in his tender, shall give details of Fe 415 grade. viz. sizes
(diameter) available, necessary test reports and manufacturers certificate
on the every consignment of steel that are brought to site shall be
furnished to the Engineer then and there and approval of Engineer shall
be obtained before proceeding the works.

ii) STORAGE

a) The reinforcement shall not be kept in direct contact with the ground but
stacked on top of an arrangement of timber sleepers or the like.

b) If the reinforcing rods have to be stored for long duration, they shall be
coated with cement wash before stacking and/or be kept under cover or
stored as directed by ENGINEER.

c) Fabricated reinforcement shall be carefully stored to prevent damage,
distortion, corrosion and deterioration.

iii) QUALITY


431
a) All steel shall be of Grade-I quality unless specifically permitted by
ENGINEER. No re-rolled material will be accepted. If demanded by
ENGINEER, CONTRACTOR shall submit the manufacturers test certificate
for steel. Random tests on steel supplied by CONTRACTOR may be
performed by OWNER as per relevant Indian Standards. All costs incidental
to such tests shall be at "CONTRACTOR's expense. Steel not conforming to
Specifications shall be rejected.

b) All reinforcement shall be clean, free from grease, oil, and paint, dirt loose
mill scale, loose rust, dust bituminous material or any other substances that
will destroy or reduce the bond. All rods shall be thoroughly cleaned before
being fabricated. Pitted and defective rods shall not be used. All bars shall be
rigidly held in position before concreting. No welding of rods to obtain
continuity shall be allowed unless approved by ENGINEER. If welding is
approved, the work shall be carried out as per I.S.2751 according to best
modern practices and as directed by ENGINEER. In all cases of important
connections, tests shall be made to prove that the joints are of the full
strength of bars welded. Special precautions, as specified by ENGINEER,
shall be taken in the welding of cold worked reinforcing bars and bars other
than mild steel.

iv) LAPS
Laps and splices for reinforcement shall be as shown on the drawings.
Splices in adjacent bars shall be staggered and the locations of all splices,
except those specified on the drawings, shall be approved by ENGINEER.
The bars shall not be lapped unless the length required exceeds the
maximum available lengths of bars at site.

v) BENDING

a) Reinforcing bars supplied bent or in coils, shall be straightened before
they are cut to size. Straightening of bars shall be done in cold and without
damaging the bars. This is considered as a part of reinforcement bending
fabrication work.

b) All bars shall be accurately bent according to the sizes and shapes shown
on the detailed working drawings/ bar bending schedules. They shall be
bent gradually by machine or other approved means. Reinforcing bars
shall not be straightened and re-bent in a manner that will injure the
material. Bars containing cracks or splits shall be rejected. They shall be
bent cold, except bars of over 25mm in diameter which may be bent hot if
specifically approved by ENGINEER, Bars which depend for their strength
on cold working, shall not be bent hot, shall not be heated beyond cherry

432
red colour (not exceeding 845C) and after bending shall be allowed to
cool slowly without quenching. Bars incorrectly bent shall be used only if
the means used for straightening and re-bending be such as shall not, in
the opinion of ENGINEER, injure the material. No reinforcement shall be
bent when in position in the work without approval, whether or not it is
partially embedded in hardened concrete. Bars having kinks or bends
other than those required by design shall not be used.


vi) FIXING
Reinforcement shall be accurately fixed by any approved means
and maintained in the correct position shown in the drawings by the use of
blocks, spacers and chairs as per IS.2503 to prevent displacement during
placing and compaction of concrete. Bars intended to be in contact at
crossing points shall be securely bound together at all such points with
number 16 gauge annealed soft iron wire. The vertical distances required
between successive layers of bar in beams or similar members shall be
maintained by the provision of mild steel spacer bars at such intervals that
the main bars do not perceptibly sag between adjacent spacer bars.

vii) COVER
The cover to reinforcement shall be in accordance with clause 26.4 of IS
456-2000. Unless indicated otherwise on the drawings, clear concrete
cover for reinforcement (exclusive of plaster or other decorative finish)
shall be as follows:
a) At each end of reinforcing bar, not less than 25mm or less than twice the
diameter of the bar.
b) For a longitudinal reinforcing bar in a column, not less than 40mm, not less
than the diameter of the bar. In case of columns, of minimum dimension
of 200mm or under with reinforcing bars of 12mm and less in diameter, a
cover of 25mm may be used.
c) For longitudinal reinforcing bars in a beam, not less than 25mm, nor less
than the diameter of the bar.
d) For tensile, compressive, shear or other reinforcement in a slab or wall not
less than 15mm nor less than diameter of such reinforcement.
e) For any other reinforcement not less than 15mm nor less than the
diameter of such reinforcement.
f) For footings and other principal structural members in which the concrete
is deposited directly against the ground, cover to the bottom reinforcement
shall be 75mm. If concrete is poured on layer of lean concrete the bottom
cover may be reduced to 50mm.
g) For concrete surface exposed to the weather / the ground after removal of
forms, such as retaining walls, grade beams, footing sides and top etc.,

433
not less than 50mm for bars larger than 16mm dia nor less than 40mm for
bars 16mm dia or smaller.
ii) Increased cover thickness shall be provided as indicated on the drawings,
for surfaces exposed to the action of harmful chemicals (or exposed to
earth contaminated by such chemical), acid, alkali, saline atmosphere,
sulphurous smoke etc.
i) For reinforced concrete members, totally or periodically
immersed in sea water or subject to sea water spray, the cover of
concrete shall be 50mm more than specified in (a) to (e) above.
j) For liquid retaining structures, the minimum cover to all steel shall be
40mm or the diameter of the main bar, whichever is greater. In
the presence of sea water and soils and water of a corrosive character
the cover shall be increased by 10mm.
k) Protection to reinforcement in case of concrete exposed to harmful
surroundings may also be given by providing dense impermeable concrete
with approved protective coatings, as specified on the drawings. In such a
case, the extra cover mentioned in (h) and (i) above, may be reduced by
ENGINEER to those shown on the drawings.
l) The correct cover shall be maintained by cement mortar cubes or other
approved means. Reinforcement for footings, grade beams and slabs on
subgrade shall be supported on precast concrete blocks as approved by
ENGINEER. The use of pebbles or stones shall not be permitted .
m) The 28 days crushing strength of cement mortar cubes precast concrete
cover blocks shall be atleast equal to the specified strength of concrete in
which these cubes blocks are embedded.
n) The minimum clear distance between reinforcing bars shall be in
accordance with IS.456 or as shown in drawings.

viii) INSPECTION
Erected and secured reinforcement shall be inspected and approved by
ENGINEER prior to placement of concrete.

1.6. CONSISTENCY AND SLUMP
a) The concrete mix proportions chosen should be such that the concrete is
of adequate workability for the placing conditions of the concrete and can
properly be compacted with the means available. Suggested ranges of
workability of concrete measured in accordance with IS 1199 are given
below:
Placing Conditions Degree of
Workability
Slump
(mm)

434
Blinding concrete; Shallow sections;
Pavements using pavers
Very low See5.6.b
below
Mass concrete; Lightly reinforced
Sections in slabs, Beams, walls,
columns; Floors; Hand placed
pavements; Canal lining; Strip footings.
Low 25-75
Heavily reinforced sections in slabs,
beams, walls, columns, slip formwork,
Pumped concrete.

Medium


50-100
75-100
Trench fill, In situ piling. High 100-150
Tremie concrete




Very
high

See 5.6.c
below
NOTE:
For most of the placing conditions, internal vibrators (needle
vibrators) are suitable. The diameter of the needle shall be
determined based on the density and spacing of reinforcement
bars and thickness of sections. For tremie concrete, vibrators
are not required to be used.

b) In the 'very low" category of workability where strict control is
necessary, for example pavement quality concrete, measurement of
workability by determination of compacting factor will be more
appropriate than slump (see. IS 1199) and a value of compacting factor
of 0.75 to 0.80 is suggested.

c) In the 'very high' category of workability, measurement of workability
by determination of flow will be appropriate (see IS 9103)

1.7. TESTING OF CUBES
Arrangement shall be made by CONTRACTOR to have the cubes tested
in an approved laboratory at his expense, with the prior consent of the
ENGINEER.

i) SAMPLING FOR STRENGTH OF CONCRETE
At least 6 test cubes of each class of concrete shall be made for every 15
cu.m. concrete or part thereof. At least one sample shall be taken from
each shift. Such samples shall be drawn on each day for each type of
concrete. Of each set of 6 cubes, three shall be tested at 7 days age and

435
three at 28 days age. The laboratory test results shall be tabulated and
furnished to ENGINEER. ENGINEER will pass the concrete if the
acceptance criteria as per clause 16 of IS: 456-2000 are met with.

ii) NOMINAL / DESIGN MIX CONCRETE
Concrete grade shall be designated on drawings. Concrete in the works
shall be "DESIGN MIX CONCRETE or "NOMINAL MIX CONCRETE.
Design mix is preferred to nominal mix. If design mix
concrete can not be used for any reason on the work for Grades M20 or
lower, nominal mixes may be used with permission from Engineer.
CONCRETE grade M20 and above shall be DESIGN MIX CONCRETE.

a) DESIGN MIX CONCRETE
For Design Mix Concrete, the mix shall be designed according to
IS: 10262 and SP: 23 to provide the grade of concrete having the required
workability and characteristic strength not less than
appropriate values given in IS: 456. The design mix shall in addition be
such that it is cohesive and does not segregate and should result in dense
and durable concrete and also capable of giving the finish as specified.
For liquid retaining structures, the mix shall also result in water tight
concrete. The CONTRACTOR shall exercise great care while designing
the concrete mix and executing the works to achieve the desired result.
The minimum cement content for different grades of Concrete for RCC /
P.C.C works shall be as per IS 456-2000 or as specified in the
drawings/schedule.

It shall be CONTRACTOR's sole responsibility to carry out the mix designs
in a reputed Institution / Research Institute at his own cost. He shall furnish
to ENGINEER at least 30 days before concreting operations, a statement
of proportions proposed to be used for the various concrete mixes and the
strength results obtained. The strength requirements of the concrete mixes
ascertained on 150mm cubes as per IS: 516 shall comply with the
requirements of IS: 456.

(g) CONSISTENCY

Slump tests shall be carried out as often as demanded by ENGINEER and
invariably from the same batch of concrete from which the test cubes are
made. Slump tests shall be done immediately after sampling.

1.8. ADMIXTURES


436
Admixtures may be used in concrete only with the approval of ENGINEER
based upon evidence that, with the passage of time, neither the
compressive strength nor its durability reduced. Calcium chloride shall not
be used for accelerating setting of the cement for any concrete containing
reinforcement, or embedded steel parts. When calcium chloride is
permitted to be used, such as in mass concrete works, it shall be
dissolved in water and added to mixing water in an amount not to exceed
1 percent of the weight of the cement in each batch of concrete. When
admixtures are used, the designed concrete mix shall be corrected
accordingly. Admixtures shall be used as per manufacturers instructions
and in the manner and with the control specified by ENGINEER. No extra
cost will be paid for admixtures .

Water Proofing Agent
Where specified and approved by ENGINEER, water proofing agent
conforming to IS.2645, shall be added in quantity specified by Engineer.

1.9. TESTS
a) Engineer if he so desires may order tests to be carried out on cement,
sand, coarse aggregate, water in accordance with the relevant Indian
Standards.

Tests on cement shall include
i) fineness test
ii) test for normal consistency
iii) test for setting time
iv) test for soundness
v) test for tensile strength
vi) test for compressive strength
vii) test for heat of hydration (by experiment and by calculations) in
accordance with IS: 269.

Tests on sand shall include.
i) Sieve test
ii) test for organic impurities.
iii) Decantation test for determining clay and silt content
iv) specific gravity test
v) test for unit weight and bulkage factor
vi) test for sieve analysis and fineness modulus.

Tests on coarse aggregate shall include.
i) Sieve analysis

437
ii) specific gravity and unit weight of dry, loose and clodded aggregate.
iii) Soundness and alkali aggregate reactivity.
iv) Petrographic examination.
v) Deleterious materials and organic impurities.
vi) Test for aggregate crushing value.
vii) Any or all these tests would normally be ordered to be carried out only if
ENGINEER feels the materials are not in accordance with the
specifications or if the specified concrete strengths are not obtained and
shall be performed by CONTRACTOR or at an approved test laboratory

b) If the test cubes of the work do not give the stipulated strengths,
ENGINEER reserves the right to ask CONTRACTOR to dismantle such
portions of the work, which in his opinion are unacceptable and re-do the
work to the standard stipulated at CONTRACTORs cost. The unit rate for
concrete shall be all-inclusive, including making preliminary mix design
and test cubes, works-cubes, testing them as per Specification, slump
tests, optional tests, etc. complete.

c) LOAD TEST ON MEMBERS OR ANY OTHER TESTS:
In the event of any work being suspected of faulty materials or
workmanship or both, ENGINEER requiring its removal and reconstruction
may order, or CONTRACTOR may request that it should be load tested in
accordance with the following provisions.

i) The test load shall be 125 percent of the maximum superimposed load for
which the structure was designed. Such test load shall not be applied
before 56 days after the effective hardening of concrete. During the test,
struts strong enough to take the whole load shall be placed in position
leaving a gap under the members. The test load shall be maintained for 24
hours before removal.

ii) If within 24 hours of the removal of the load, the structure does not show
a recovery of at least 75 percent of the maximum deflection shown during
the 24hours under load, the test loading shall be repeated after a
lapse of at least 72hours. The structure shall be considered to have failed
to pass the test if the recovery after the second test is not at least 75
percent of the maximum deflection shown during the second test. If the
structure is certified as failed by the ENGINEER, the cost of the load test
shall be borne by the CONTRACTOR.

iii) Any other tests, e.g. taking out in an approved manner concrete cores,
examination and tests on such cores removed from such parts of the

438
structure as directed by ENGINEER, sonic testing etc. shall be carried out
by CONTRACTOR if so directed.

UNSATISFACTORY TESTS

Should the results of any test prove unsatisfactory, or the structure shows
signs of weakness, undue deflection or faulty construction CONTRACTOR
shall remove and rebuild the member or members involved or carry out
such other remedial measures as may be required by ENGINEER/
OWNER. CONTRACTOR shall bear the cost of redoing, unless the failure
of the member or members to fulfil the test conditions is proved to be
solely due to faulty design.

1.10. PREPARATION PRIOR TO CONCRETE PLACEMENT, FINAL
INSPECTION AND APPROVAL
(y) Before the concrete is actually placed in position, the inside of the
formwork shall be inspected to see that they have been cleaned and oiled.
Temporary openings shall be provided to facilitate inspection, especially at
bottom of columns and wall forms, to permit removal of saw dust, wood
shavings, binding wire, rubbish, dirt etc. Openings shall be placed or holes
drilled so that these
materials and water can be removed easily. Such openings/ holes shall
be later suitably plugged.

(b) The various trades shall be permitted ample time to install drainage and
plumbing lines, floor and trench drains, conduits, hangers, anchors,
inserts, sleeves, bolts, frames, and other miscellaneous embedment to be
cast in the concrete as indicated on the drawings or as is necessary for
the proper execution of the work. CONTRACTOR shall co-operate fully
with all such agencies, and shall permit the use of scaffolding, formwork
etc. by other trades at no extra cost.

(c) All embedded parts, inserts etc. supplied by OWNER or CONTRACTOR
shall be correctly positioned and securely held in the forms to prevent
displacement during depositing and vibrating of concrete.

(d) All anchor bolts shall be positioned and kept in place with the help of
properly manufactured templates unless specifically waived in writing by
ENGINEER. The use of all such templates, fixtures etc. shall be deemed
to be included in the rates.

(d) Slots, openings, holes, pockets etc. shall be provided in the concrete work
in the positions indicated in the drawings or as directed by ENGINEER.

439

(f) Reinforcement and other items to be cast in concrete shall have clean
surfaces that will not impair bond.
(g) Prior to concrete placement all work shall be inspected and approved by
ENGINEER and if found unsatisfactory, concrete shall not be poured until
after all defects have been corrected at CONTRACTORs cost.

(h) Approval by ENGINEER of any and all materials and work as required
herein shall not relieve CONTRACTOR from his obligation to produce
finished concrete in accordance with the drawings and Specifications.

(i) RAIN OR WASH WATER
No concrete shall be placed in wet or on a water-covered surface. Any
concrete that has been washed by heavy rains shall be entirely removed,
if there is any sign of cement and sand having been washed away from
the concrete mixture. To guard against damage, which may be caused by
rains, the works shall be covered with tarpaulins immediately after the
concrete has been placed and
compacted before leaving the work unattended. Any water accumulating
on the surface of the newly placed concrete shall be removed by approved
means and no further concrete shall be placed thereon until such water is
removed. To avoid flow of water over/ all-round freshly placed concrete,
suitable drains and sumps shall be provided.

(j) BONDING MORTAR
Immediately before concrete placement begins, prepared surfaces except
formwork, which will come in contact with the concrete to be placed shall
be covered with a bonding mortar.

1.11. TRANSPORTATION
a) All buckets, containers, or conveyer used for transporting concrete shall
be mortar-tight. Irrespective of the method of transportation adopted,
concrete shall be delivered with the required consistency and plasticity
without segregation or loss of slump. However, chutes shall not be used
for transport of concrete without the written permission of Engineer and
concrete shall not be re-handled before placing.


b) RETEMPERED OR CONTAMINATED CONCRETE

Concrete must be placed in the final position before it becomes too stiff to
work. On no account water shall be added after the initial mixing.

440
Concrete, which has become stiff or has been contaminated with foreign
materials shall be rejected and disposed off as directed by ENGINEER.

c) CLEANING OF EQUIPMENT
All equipment used for mixing, transporting and placing of concrete
shall be maintained in clean condition. All pans, buckets, hoppers,
chutes, pipelines and other equipment shall be thoroughly cleaned after
each period of placement.

1.12 PROCEDURE FOR PLACING OF CONCRETE: ENGINEERS
APPROVAL OF EQUIPMENT & METHODS
a) Before any concrete is placed, the entire placing programme, consisting of
equipment, layout, proposed procedures and methods shall be submitted
to ENGINEER for approval if so demanded by ENGINEER and no
concrete shall be placed until ENGINEER's approval has been received.
Equipment for conveying concrete shall be of such size and design as to
ensure a practically continuous flow of concrete during depositing without
segregation of materials considering the size of the job and placement
location.

b) TIME INTERVAL BETWEEN MIXING AND PLACING
Concrete shall be placed in its final position before the cement reaches its
initial set and concrete shall normally be compacted in
its final position within thirty minutes of leaving the mixer, and once
compacted it shall not be disturbed.

c) AVOIDING SEGREGATION
Concrete shall, in all cases, be deposited as nearly as practicable directly
in its final position, and shall not be re-handled or caused to flow in a
manner which will cause segregation, loss of materials, displacement of
reinforcement, shuttering or embedded inserts or impair its strength. For
locations where direct placement is not possible, and in narrow forms,
contractor shall provide suitable drop and "Elephant Trunks to confine
the movement of concrete. Special care shall be taken when concrete is
dropped from a height, especially if reinforcement is in the way,
particularly in columns and thin walls.

d ) PLACING BY MANUAL LABOUR
Except when otherwise approved by Engineer, concrete shall be placed in
the shuttering by shovels of other approved implements and shall not be
dropped from a height more than 1.0metre or handled in a manner, which
will cause segregation.

441

e) PLACING BY MECHANICAL EQUIPMENT
i) The following specification shall apply when placing of concrete by use of
mechanical equipment is specifically called for while inviting bids or is
warranted considering the nature of work involved. The control of placing
shall begin at the mixer discharge. Concrete shall be discharged by a
vertical drop into the middle of the bucket or
hopper and this principle of vertical discharge of concrete shall be adhered
to throughout all stages of delivery until the concrete comes to rest in its
final position.

ii) TYPE OF BUCKETS
Central-bottom-dump buckets of a type that provides for positive
regulation of the amount and rate of deposition of concrete in all dumping
position, shall be employed.

iii) OPERATION OF BUCKET
In placing concrete in large open area, the bucket shall be spotted directly
over the position designated and then lowered for dumping. The open
bucket shall clear the concrete already in place and the height of drop
shall not exceed 1.00m. The bucket shall be opened slowly to avoid high
vertical bounce. Dumping of buckets on the
swing in any manner, which results in separation of ingredients or
disturbance of previously placed concrete, will not be permitted.

f) PLACEMENT IN RESTRICTED FORMS
Concrete placed in restricted form by barrow, buggies, cars, short chutes
or hand shovelling shall be subject to the requirements for vertical delivery
of limited height to avoid segregation and shall be deposited as nearly as
practicable in its final position.

1.13. CHUTING
Where it is necessary to use transfer chutes ,specific approval of Engineer
must be obtained to type ,length, slopes ,baffles, vertical terminals and
timing of operations . These shall be so arranged that an almost
continuous flow of concrete is obtained at the discharge and without
segregation .To allow for the loss of mortar against the sides of the
chutes, the first mixes shall have less coarse aggregate. During cleaning
of chutes ,the waste water shall be kept clear of the forms. Concrete shall
not be permitted to fall from the end of the chutes by more than
1m.Chutes when approved for use shall have slopes not flatter than
1vertical :3 horizontal and not steeper than 1vertical :2 horizontal. Chutes
shall be of metal or metal lined and of rounded cross section .The slopes

442
of all chute sections shall be approximately the same .The discharge end
of the chutes shall be maintained above the surface concrete in the
forms.

1.14 PLACING CONCRETE IN LAYERS
Concreting, once started, shall be continuous until the pour is completed.
Concrete shall be placed in successive horizontal layers of uniform
thickness ranging from 150 to 900 mm as directed by Engineer. These
shall be placed as rapidly as practicable to prevent the formation of cold
joints or planes of weakness between each succeeding layer within the
pour. The thickness of each layer shall be such that it can be deposited
before the previous layer has
stiffened. The bucket leads or other units of Deposit shall be spotted
progressively along the face of the layer with such overlap as will facilitate
spreading the layer to uniform depth and texture with a minimum of
shovelling. Any tendency to segregation shall be corrected by shovelling
stones into mortar rather than mortar on to stones. Such a condition shall
be corrected by redesign of mix or other means, as directed by Engineer.

1.15. BEDDING OF LAYERS

The top surface of each pour and bedding planes shall be approximately
horizontal unless otherwise instructed.


1.16. COMPACTION
Concrete shall be compacted during placing, with approved vibrating
equipment until the concrete has been consolidated to the maximum,
practicable density, is free of pockets of coarse aggregate and fits rightly
against all form surfaces, reinforcement and embedded fixtures. Particular
care shall be taken to ensure that all concrete placed against the form
faces and into corners of forms or against hardened concrete at joints is
free from voids or cavities. The use of vibrators shall be consistent with
the concrete mix and caution exercised not to over vibrate the concrete to
the pointing that segregation result.

i) TYPE OF VIBRATORS
Vibrators shall conform to IS specifications. Type of vibrator to be used
shall depend on the structure where concrete is to be placed. Shutter
vibrators to be effective, shall be firmly secured to the formwork which
must be sufficiently rigid to transmit the vibration and strong enough not to
be damaged by it. Immersion vibrators shall have "no load frequency,
amplitude and acceleration as per I.S.2505 depending on the size of the

443
vibrator. Immersion vibrators in sufficient numbers and each of adequate
size shall be used to properly consolidating all concrete. Tapping
of external vibrating of forms by hand tools or immersion vibrators will not
be permitted.



ii) USE OF VIBRATORS
The exact manner of application and the most suitable machines for the
purpose must be carefully considered and operated by experienced men.
Immersion vibrators shall be inserted vertically at joints not more than
450mm apart and withdrawn when air bubbles cease to come to the
surface. Immersion vibrators shall be withdrawn very slowly. In no case
shall immersion vibrators be used to transport concrete inside the vibration
at the top of a lift e.g. in column or wall.

iii) MOULDING SUCCESSIVE BATCHES
When placing concrete in layer, which are advancing horizontally as the
work progress, great care shall be exercised to ensure adequate vibration,
blending and moulding of the concrete between the succeeding layers.

iv) PENETRATION OF VIBRATOR
The immersion vibrator shall penetrate the layer being placed and also
penetrate the layer below while the under layer is still plastic to ensure
good bond and homogeneity between the two layers and prevent the
formation of cold joints.

v) VIBRATING AGAINST REINFORCEMENT
Care shall be taken to prevent contact of immersion vibrators against
reinforcement steel. Immersion vibrators shall not be allowed to come in
contact with reinforcement steel after start of initial set. They shall also not
be allowed to come in contact with forms or finished surfaces.

vi) USE OF FORM ATTACHED VIBRATORS
Form attached vibrators shall be used only with specific authorisation of
ENGINEER.

vii) USE OF SURFACE VIBRATORS
The use of surface vibrators will not be permitted under normal conditions.
However, for thin slabs, such as highways, runways and similar
construction, surface vibration by specially designed vibrators may be
permitted, upon approval of ENGINEER.

444

1.17. STONE POCKETS AND MORTAR PONDAGES
The formation of stone pockets or mortar pondages in corners and
against faces of forms shall not be permitted. Should these occur, they
shall be dug out, reformed and refilled to sufficient depth and shape for
thorough bonding, as directed by ENGINEER.

1.18. PLACEMENT INTERVAL
Except when placing with slip forms, each placement of concrete in
multiple lift work, shall be allowed to set for at least 24 hours after the final
set of concrete and before the start of a subsequent placement.

1.19. SPECIAL PROVISION IN PLACING
When placing concrete in walls with openings, in floors, of integral slab and
beam construction and other similar conditions, the placing shall stop
when the concrete reaches the top of the opening in walls or bottom
horizontal surface of the slab, as the case may be. Placing shall be
resumed before the concrete in place takes initial set, but not until it has
had time to settle as determined by ENGINEER.

1.20. PLACING CONCRETE THROUGH REINFORCING STEEL

When placing concrete through reinforcing steel, care shall be taken to
prevent segregation of the coarse aggregate. Where the congestion of
steel make placing difficult it may be necessary to temporarily move the
top steel aside to get proper placement and restore reinforcing steel to
design position.


1.21. BLEEDING
Bleeding or free water on top of concrete being deposited into the forms
shall be a cause to stop the concrete pour and the conditions
causing this defect corrected before any further concreting is resumed.

1.22. CONSTRUCTION JOINTS AND KEYS
a) Concrete shall be placed without interruption until completion of the part of
the work between predetermined construction joints, as specified herein
after. Time lapse between the pouring of adjoining units shall be as
specified on the drawing or as directed by ENGINEER.

b) If stopping of concreting becomes unavoidable anywhere, a properly
formed construction joint shall be made where the work is stopped. Joints

445
shall be either vertical or horizontal, unless shown otherwise on drawings.
In case of an inclined or curved member, the joints shall be at right angles
to the axis of the member. Vertical joints in walls shall be kept to a
minimum. Vertical joints shall be formed against a stop board: horizontal
joints shall be level and wherever possible arranged so that the joint lines
coincide with the architectural features of the finished work. Battens shall
be nailed to the formwork to ensure a horizontal line and if directed, shall
also be used to form a grooved joint. For tank walls and similar work,
joints shall be formed as per I.S.3370.

Concrete that is in the process of setting shall not be disturbed or shaken
by traffic either on the concrete itself or upon the shuttering. Horizontal
and vertical construction joints and shear keys shall be located and shall
conform in detail to the requirements of the plans unless otherwise
directed by ENGINEER. Where not described, the joint shall be in
accordance with the following.

1.23. COLUMN JOINT
In a column, the joint shall be formed 75mm below the lowest soffit of the
beams including haunches if any. In flat slab construction, the joint shall
be 75mm below the soffit of column capital. At least 2 hours shall elapse
after depositing concrete in columns, piers or walls, before depositing in
beams, girders or slabs supported thereon.

1.24 BEAM AND SLAB JOINTS
Concrete in a beam shall be placed throughout without a joint but if the
provision of a joint is unavoidable the joint shall be vertical and at the
centre or within the middle third of the span unless or otherwise shown on
drawings. Where a beam intersects a girder,
the joints in the girder shall offset a distance equal to twice the width of the
beam and additional reinforcement provided for shear. The joints
shall be vertical throughout the full thickness of the concrete member. All
joints in a slab shall be vertical and parallel to the principal reinforcement.
Where it is unavoidably at right angles to the principal reinforcement, the
joint shall be vertical and at the middle of the span.

1.25. JOINT IN LIQUID RETAINING STRUCTURES
Vertical construction joints in watertight construction will not be permitted
unless indicated on the drawings. Where a horizontal construction joint is
required to resist water pressure, special care shall be taken in all phases
of its construction to ensure maximum water tightness.

1.26. DOWELS

446
Dowels for concrete work, not likely to be taken up in the near future, shall
be wrapped in tar paper and burlap.

1.27. MASS FOUNDATIONS
Mass foundations shall be poured in lifts not exceeding 1.5m in height
unless otherwise indicated on the drawings or approved by Engineer.

1.28. TREATMENT OF CONSTRUCTION JOINTS ON RESUMING
CONCRETING
A drier mix shall be used for the top lift of horizontal pours to avoid
laitance. All laitance and loose stones shall be thoroughly and carefully
removed by wire brushing/backing and surface washed.

Just before concreting is resumed, the roughened joint surface shall be
thoroughly cleaned and loose matter removed and then treated with a thin
layer of cement grout of proportion specified by Engineer and worked well
into the surface. The new concrete shall be well worked against the
prepared face before the grout mortar sets. Special care shall be taken to
obtain thorough compaction and to avoid segregation of the concrete
along the joint plane.

1.29 CURING, PROTECTING, REPAIRING AND FINISHING
CURING
jj) All concrete shall be cured by keeping it continuously damp for the period
of time required for complete hydration and hardening to take place.
Preference shall be given to the use of continuous sprays, or ponded
water, continuously saturated coverings of sacking, canvas, hessian or
other absorbent materials, or approved
effective curing compounds applied with spraying equipment capable of
producing a smooth, even textured coat. Extra precautions shall be
exercised in curing concrete during cold and hot weather as outlined
herein after. The quality of curing water shall be the same as that used for
mixing concrete.

ii) Certain types of finish or preparation for overlaying concrete must be done
at certain stages of the curing process and special treatment may be
required for specific concrete surface finish.

iii) CURING WITH WATER
Fresh concrete shall be kept continuously wet for a minimum period of 10
days of placing of concrete, following a lapse of 12 to 14hours

447
after laying concrete. The curing of horizontal surfaces executed during
winds shall however begin immediately the concrete has hardened. Water
shall be applied to unformed concrete surfaces, within 1hour after
concrete has set. Water shall be applied to formed surfaces immediately
upon removal of forms. Quantity of water applied shall be controlled so as
to prevent erosion of freshly placed concrete.

iv) CONTINUOUS SPRAYING
Curing shall be assured by use of ample water supply under pressure in
pipes, with all necessary appliances of hose, sprinklers
and spraying devices. Continuous fine mist spraying or sprinkling shall be
used unless otherwise specified or approved by ENGINEER.


v) ALTERNATIVE CURING METHODS
Wherever in the judgement of ENGINEER, it may be necessary to omit
the continuous spray method, covering of clean sand or other approved
means such as wet gunny bags which will prevent loss of moisture from
the concrete, may be used. No type of covering will be approved which
would stain or damage the concrete during or after the curing period.
Covering shall be kept continuously wet during the curing period.

vi) CURING EQUIPMENT
All equipment and materials required for curing shall be on hand and
ready for use before concrete is placed.

vii) PROTECTING FRESH CONCRETE
Fresh concrete shall be protected from the elements, from defacements
and damage due to construction operations by leaving forms in place for
an ample period as specified later in this
specification. Newly placed concrete shall be protected by approved
means such as tarpaulins from rain, sun and winds. Steps as approved by
Engineer shall also be taken to protect immature concrete from damage
by debris, excessive loading vibration, abrasion or contact with other
materials etc. that may impair the strength and or durability of the
concrete. Workman shall be warned against and prevented from
disturbing green concrete during its setting period. If it is necessary that
workmen enter the area of freshly placed concrete, ENGINEER may
require that bridges be placed over the area.

viii) REPAIR AND REPLACEMENT OF UNSATISFACTORY
CONCRETE

448
a) Immediately after the shuttering is removed, the surface of concrete shall
be very carefully gone over and all defective areas called to the attention of
ENGINEER who may permit patching of the defective areas or also reject the
concrete unit either partially or in its entirety. Rejected concrete shall be
removed and replaced by CONTRACTOR at no additional expense to owner.
Holes left by form bolts etc. shall be filled up and made good with mortar
composed of one part of cement to one and half parts of sand passing 2.36
mm IS sieve after removing any loose stones adhering to the concrete. Mortar
filling shall be struck off flush at the face of the concrete. Concrete surfaces
are finished as described under the particular items of work.

b) Superficial honey combed surface and rough patches shall be similarly
made good immediately after removal of shuttering, in the presence of
ENGINEER and superficial water and air holes shall be filled in. The
mortar shall be well worked into the surface with a wooden float. Excess
water shall be avoided. Unless instructed otherwise by ENGINEER, the
surface of the exposed, concrete placed against shuttering shall be
rubbed down immediately on removal of shuttering to remove fine or other
irregularities, care being taken to avoid damaging the surface. Surface
irregularities shall be removed by grinding.

c) If reinforcement is exposed or the honey combing occurs at vulnerable
position e.g. ends of beams and columns it may be necessary to cut out
the member completely or in part and reconstruct. The decision of
Engineer shall be final in this regard. If only patching is necessary, the
defective concrete shall be cut out till solid concrete is reached (or to a
minimum depth of 25mm) the edges being cut perpendicular to the
affected surface or with a small under cut if possible. Anchors, tees or
dovetail slots shall be provided whenever necessary to attach the new
concrete securely in place. An area extending several centimetres beyond
the edge
and the edges and the surfaces of the prepared voids shall be saturated
with water for 24 hours immediately before the patching material is placed.

d) USE OF EPOXY
The use of epoxy for bonding fresh concrete used for repairs will be
permitted upon written approval of ENGINEER. Epoxies shall be applied
in strict accordance with the instructions of the manufacturer.

e) METHOD OF REPAIR
Small size holes having surface dimension about equal to the depth of the
hole, holes left after removal of form bolts, grout insert holes and slots cut
for repair of cracks shall be repaired as follows. The holes to be patched

449
shall be roughened and thoroughly soaked with clean water until
absorption stops. A 5mm layer of grout of equal parts of cement and sand
shall be well brushed into the surface to be patched, followed immediately
by the patching concrete, which shall be well consolidated with a wooden
float and left slightly proud of the surrounding surface. The concrete patch
shall be built upon weather conditions, it shall be worked off flush with a
wooden float and a smooth finish obtained by wiping with Hessian, a steel
trowel shall be used for this purpose. The mix of patching shall be of the
same materials and in the same proportions as that used in the concrete
being repaired, although some reducing in the maximum size of the
coarse aggregates may be necessary and the mix shall be kept as dry as
possible. Mortar filling by air pressure (guniting) shall be used for repair of
areas to large and/or too shallow for patching with mortar. Patched
surfaces shall be given a final treatment to match the colour and texture of
the surrounding concrete. White cement shall be substituted for ordinary
cement, if so directed by ENGINEER to match the shade of the patch with
the original concrete.

f) CURING OF PATCHED WORK
The patched areas shall be covered immediately with an approved non
staining, water-saturated material such as gunny bags, which shall be kept
continuously, wet and protected against sun and wind for a period of 24
hours. Thereafter, the patched area shall be kept wet continuously by a
final spray of sprinkling for not less than 10days.

g) APPROVAL BY ENGINEER
All materials, procedures, and operations used in the repair of concrete
and also the finished repair work shall be subject to the approval of
ENGINEER. All fillings shall be tightly bonded to the
concrete and shall be sound, free from shrinkage cracks after the fillings
have been cured and dried.

ix) FINISHING
a) This specification is intended to cover the treatment of concrete surface of
all structures. Areas requiring special finish not covered by this
specification shall be clearly indicated on the drawings and special
specifications shall be furnished.

b) FINISH FOR FORMED SURFACES
The type of finish for formed concrete surfaces shall be as follows, unless
otherwise specified by the ENGINEER.


450
For surface against which backfill or concrete is to be placed, no treatment
is required except repair of defective areas.

For surface below grade which will receive water proofing treatment the
concrete shall be free of surface irregularities, which would interfere with
proper application of the waterproofing materials which is specified for
use.

Unless specified, surface which will be exposed when the structure is in
service shall receive no special finish, except repair of damaged or
defective concrete, removal of fins, and abrupt irregularities, filling of holes
left by form ties and rods and clean up of adhering debris.

c) Surfaces which will be exposed to the weather and which would normally
level shall be sloped for drainage, unless the drawing specifies a
horizontal surface or shows the slope required, the tops of narrow
surfaces show the slope required, the tops of narrow surfaces such as
stair treads, walls, curbs, and parapets shall be sloped across the width
approximately 1 in 3. Broader surfaces such as walkways, road, parking
areas and platforms shall be sloped about 1 in 50. Surfaces that will be
covered by backfill or concrete, subfolders to be covered by backfill or
concrete, sub-floors to be covered with concrete topping, terrazzo or
quarry tile, and similar surfaces shall be smooth screeded and levelled to
produce even surfaces.

d) STANDARD FINISH FOR EXPOSED CONCRETE
Exposed concrete shall mean any concrete, other than floors or
slabs, exposed to view upon completion of the job. Unless otherwise
specified on the drawings, the standard finish for exposed concrete shall
be smooth finish. A smooth finish shall be
obtained with the use of lined or plywood forms having smoothed and
even surfaces and edges. Panels and form linings shall be of uniform size
and be as large as practicable and installed withclosed joint. Upon
removal of form the joint marks shall be smoothed off
and all blemishes, projections etc. removed leaving the surfaces
reasonably smooth and unmarred.

e) INTEGRAL CEMENT CONCRETE FINISH
When specified on the drawings an integral cement concrete finish of
specified thickness for floors and slabs shall be applied either monolithic
or bonded, as specified on the drawings, as per IS 2571. The surfaces
shall be compacted and then floated with a wooden float or power floating
machine. The surface shall be tested with a straight edge and any high

451
and low spots eliminated. Floating or trowelling of the finish shall be
permitted only after all surface water has evaporated. Dry cement or
mixture of dry cement and sand shall not be sprinkled directly on the
surface of the cement finish to absorb moisture or to stiffen the mix.

f) RUBBED FINISH
A rubbed finish shall be provided only on exposed concrete surfaces as
specified on the drawings. Upon removal of forms, all fins and other
projections in the surfaces shall be carefully removed, offsets levelled and
voids and/or damaged sections immediately saturated with water and
repaired by filling with concrete or mortar of the same composition as was
used in the surface. The surfaces shall then be thoroughly wetted and
rubbed with carborundum or other abrasive. Cement mortar may be used
in the rubbing, but the finished surfaces shall not be brush coated with
either cement or grout after rubbing. The finished surfaces shall present a
uniform and smooth appearance.

g) PROTECTION
All concrete shall be protected against damage until final acceptance by
ENGINEER/OWNER.

1.30. FORM WORK
i) The formwork shall consist of shores, bracing, sides or beams and
columns bottom of slabs, etc., including ties, anchors, hangers, inserts etc.
complete which shall be properly designed and planned for the work.
False work shall be so constructed that vertical adjustments can be made
to compensate for take up and settlements. Wedges may be used at the
top or bottom of timer shores, but not at both ends, to facilitate vertical
adjustment or dismantling of a formwork. Only steel scaffolding and steel
centering materials should be used for all RCC works.

ii) DESIGN OF FORMWORK
The design and engineering of the formwork as well as its construction
shall be the responsibility of CONTRACTOR. If so instructed, the
drawings and/or calculations for the design of the form work shall be
submitted to ENGINEER's approval and thereon. Such approval shall not
however relieve contractor of the full responsibility for the design and
construction of the form work. The design shall take into account all the
loads vertical as well as lateral that the forms will be carrying including
live and vibration loadings.

iii) TOLERANCES

452
Tolerance is a specified permissible variation from lines, grade or
dimension given in drawings. No tolerances specified for horizontal or
vertical building lines or footings shall be construed to permit
encroachment beyond the legal boundaries. Unless otherwise specified,
the tolerances on the shapes, lines and dimensions will be permitted as
per I.S. 456:2000.

iv) TYPE OF FORM WORK
Form work may be of timber, plywood, metal, plastic or concrete. For
special finishes the formwork may be lined with plywood, steel sheets,
oil tempered hard board, etc. Sliding forms and slip forms may be used
with the approval of ENGINEER.

v) FORMWORK REQUIRERMENTS
a) Forms shall conform to the shapes, lines, grades and dimensions
including camber of the concrete as called for on the drawings. Ample
studs, walers, braces, ties, straps, shores, etc. shall be used to hold the
forms in proper position without any distortion whatsoever until the
concrete has set sufficiently to permit removal of forms. Forms shall
be strong enough to permit the use of immersion vibrators. In special
cases, form vibrators may also be used. The shuttering shall be close
boarded. Timber shall be well seasoned, free from sap, shakes, loose,
knots, worm holes, warps or other surface defects in contact with
concrete. Faces coming in contact with the concrete shall be free from
adhering grout, plaster, paint, projecting nails, split, or other defects, joints
shall be sufficiently tight to prevent loss of water and fine materials from
concrete.

b) Plywood shall be used for Exposed Concrete surfaces. Where called
for, Sawn and wrought timer may be used for unexposed surfaces. Inside
faces of forms for concrete surfaces, which are to be rubbed, finish shall
be planed to remove irregularities or unevenness in the face. Formwork
with linings will be permitted.

c) All new and used form timber shall be maintained in a good condition
with respect to shape, strength, rigidity, water tightness, smoothness
and cleanliness of surfaces. Form timber unsatisfactory in any respect
shall not be used and if rejected by ENGINEER shall be removed from
the site.

d) Shores supporting successive storeys shall be placed directly over those
below or be so designed and placed that the load will be transmitted

453
directly to them. Trussed supports shall be provided for shores that
cannot be secured on adequate foundations.

e) Formwork, during any stage of construction showing signs of distortion or
distorted to such a degree that the intended concrete work will not
conform to the exact contours indicated on the drawings shall be
repositioned and strengthened. Poured concrete affected by the faulty
formwork, shall be removed entirely and the formwork corrected prior to
placing new concrete.

f) Excessive construction camber to compensate for shrinkage, settlement etc.
that may impair the structural strength of members will not be permitted.

g) Forms for substructure concrete may be omitted when in the opinion of
ENGINEER the open excavation is firm enough to act as the form. Such
excavations shall be slightly larger than required by the drawings to
compensate for irregularities in excavation and to ensure the design
requirements.

h) Forms shall be so designed and constructed that their removal will not
damage the concrete. Face formwork shall provide true vertical and horizontal
joints conforming to the architectural features of the structure as to location of
joints and be as directed by ENGINEER.

i) Where exposed smooth or rubbed concrete finishes are required the form
shall be constructed with special care so that resulting concrete surfaces
require a minimum finish.

vi) BRACINGS, STRUTS AND PROPS
Shuttering shall be braced, strutted, propped and so supported that it
shall not deform under weight and pressure of the concrete and also due
to the movement of men and other materials. Bamboo shall not be used
as props or cross bearers. The shuttering for beams and slabs shall be so
erected that the shuttering on the sides of the beams and under the
soffit of slabs can be removed without disturbing the beam bottoms. Re-
propping of beams shall not be done except when props have to
be reinstated to take care of construction loads anticipated to be in
excess of the design load. Vertical props shall be supported on wedges
or other measures shall be taken where by the props can be gently
lowered vertically while striking the shuttering. If the shuttering for column
is erected for the full height of the column, one side shall be left open
and built up in sections as placing of concrete proceeds or windows may

454
be left for pouring concrete from the sides to limit the drop of concrete to
1.0m or as directed by ENGINEER.

vii) MOULD OIL
Care shall be taken to see that the faces of formwork coming in contract
with concrete are perfectly cleaned and two coats of mould oil or any other
approved materials applied before fixing reinforcement and placing
concrete such coating shall be insoluble in water, non-staining and not
injurious to the concrete. It shall not become flaky or be removed by rain
or wash water. Reinforcement and/or other items to be cast in the
concrete shall not be placed until coating of the forms is complete.
Adjoining concrete surfaces shall also be protected against contamination
from the coating material.

viii) CHAMFERS AND FILLETS
All corners and angles exposed in the finished structure shall be
formed with mouldings to form chamfers or fillets on the finished concrete.
The standard dimensions of chamfers and fillets, unless otherwise
specified, shall be 20mm x 20mm. Care shall be exercised to ensure
accurate mouldings. The diagonal face of the moulding shall be
planed or surfaced to the same texture as the forms to which it is
attached.

ix) VERTICAL CONSTRUCTION JOINT CHAMFERS
Vertical construction joints on faces, which will be exposed at the
completion of the work, shall be chamfered as above except where not
permitted by ENGINEER for structural or hydraulic reasons.

x) WALL TIES
Wire ties passing through the walls shall not be allowed. In their
place bolts passing through sleeves shall be used.



xi) REUSE OF FORMS
Before reuse, all forms shall be thoroughly scrapped, cleaned, nails
removed, holes that may leak suitably plugged and joints examined and
when necessary, repaired and the inside retreated to prevent adhesion,
to the satisfaction of ENGINEER. Warped
timber shall be resized. CONTRACTOR shall equip himself with
enough shuttering to complete the job in the stipulated time.


455
xii) REMOVAL OF FORMS
The stripping time for forms shall be in accordance with clause 11.3 of
IS 456-2000.

CONTRACTOR shall record on the drawing or a special register the date
upon which the concrete is placed in each part of the work and the date
on which the shuttering is removed there from.

In no circumstances shall forms struck until the concrete reaches a
strength of at least twice the stress due to self weight and any
construction/erection loading to which the concrete may be subjected
at the time of striking formwork.

In normal circumstances (generally where temperatures are above 20
o
C)
forms may be struck after expiry of the following periods:
------------------------------------------------------------------------------------
Type of Form work Minimum Period
Before Striking
Form work.
-----------------------------------------------------------------------------------
a) Vertical formwork to columns, walls, 16-24 hours
beams.
b) Soffit formwork to slabs 3 days
(Props to be refixed immediately
after removal of formwork)
c) Soffit formwork to beams 7 days
(Props to be refixed immediately
after removal of formwork)
d) Props to slabs:
1) Spanning up to 4.5m 7 days
2) Spanning over 4.5m 14 days
e) Props to beams and arches:
1) Spanning up to 6m 14 days
2) Spanning over 6m 21 days
------------------------------------------------------------------------------------
Striking shall be done slowly with utmost care to avoid damage
to raises and projections and without shock or vibration by gently
easing the wedges. If after removing the form work, it is found that
timber has been embedded in the concrete, it shall be removed and
made good as specified earlier.

456
Reinforced temporary opening shall be provided, as directed by
ENGINEER to facilitate removal of formwork which otherwise may be in
accessible.

Tie rods, clamps, form bolts, etc. which must be entirely removed from
walls or similar structures shall be loosened not sooner than 24 hours
nor later than 48 hours after the concrete has been deposited. Ties,
except those required to hold forms in place, may be removed at the
same time. Ties withdrawn from walls and grade beams shall be pulled
towards the inside face. Cutting ties back from the faces of walls and
grade beams will not be permitted.

For liquid retaining structures no sleeves for through bolts shall be
used nor shall through bolts be removed. The bolts, in this case,
shall cut at 25mm depth from the surface and then the hole shall be made
good by sand cement mortar of the same proportions as the concrete just
after striking the form work.

1.31. FOUNDATION BEDDING, BONDING AND JOINING
i) All surfaces upon or against which concrete will be placed shall suitably
prepared by thoroughly cleaning, washing, dewatering,as may be
indicated in the plans or directed by ENGINEER, to meet
the various situations encountered in the work.

ii) Prior to construction of form work for any item where soil will act as
bottom form, approval shall be obtained form ENGINEER as to the
suitability of the soil.

iii) PREPARATION OF EARTH STRATA OF FOUNDATIONS
All earth surfaces upon which or against which concrete is to be
placed shall be well compacted and free form standing water, mud or
debris. Soft yielding soil shall be removed and replaced with suitable
earth well compacted as directed by ENGINEER where specified, lean
concrete shall be provided on the earth stratum for receiving
concrete. The surface of absorptive soils against which concrete is to be
placed shall be made moisture thoroughly so that no moisture will be
drawn from the freshly placed concrete and later shall help to cure the
concrete.

iv) PREPARATION OF CONCRETE SURFACES
The preparation of concrete surfaces upon which additional concrete is to
be placed later, shall preferably be done by scarifying and cleaning while
the concrete is between its initial and final set. This method shall be

457
used wherever practicable and shall consist of cutting the surface with
picks and stiff brooms and by use of an approved combination
of air and water jet as directed by ENGINEER. Great care shall be taken
in performing this work to avoid removal of too much mortar and
the weakening of the surface by loosening of aggregate. When it is not
practicable to follow the above method, it will be necessary to employ air
tools to remove laitance and roughen the surface. The final required
result should be a pitted surface from which all dirt, unsound concrete
laitance and glazed mortar have been removed.

v) BONDING TREATMENT (MORTAR)
a) After rock or concrete surfaces upon which new concrete is to be
placed have been scarified, cleaned, and wetted as specified herein,
they shall receive, a bonding treatment, immediately before placement
of the concrete.

b) The bonding medium shall be a coat of cement-sand mortar. The mortar
shall have the same cement- sand proportions as the concrete, which
shall be placed on it. The water-cement ratio shall be determined by
placing conditions and as approved by ENGINEER.

c) Bonding mortar shall be placed in sufficient quantity to completely cover
the surface about 10mm thick for rock surface and about 5mm thick for
concrete surfaces. It shall be brushed or broomed over the surface and
worked thoroughly into all cracks, crevices and depressions.
Accumulations or puddles of mortar shall not be allowed to settle in
depressions and shall be brushed out to a satisfactory degree, as
determined by ENGINEER.

d) Mortar shall be placed at such a rate that it can be brushed over the
surface just in advance of placement of concrete. Only such area shall be
covered with concrete before initial set in mortar taken place. The
amount of mortar that will be permitted to place to any one time, or the
area, which it is to cover, shall be in accordance with ENGINEER's
directions.



vi) CLEANING AND BONDING FORMED CONSTRUCTION JOINTS
Vertical construction joints shall be cleaned as specified above or by other
methods approved by ENGINEER. In placing concrete against formed
construction joints, the surfaces of the joints, where accessible, shall be
coated thoroughly with the specified bed joint bonding mortar immediately

458
before they are covered with concrete or by scrubbing with wire brooms
dipped into the fresh concrete. Where it is impracticable to apply such a
mortar coating, special precautions shall be taken to ensure that the new
concrete is
brought into intimate contact with the surface of the joint by careful
puddling and spading with aid of vibrators and suitable tools.

vii) EXPANSION AND CONTRACTION JOINTS
Provision shall be made for expansion and contraction in concrete by use
of special type joint located as shown on the drawing. Contraction by joint
surfaces shall be treated as directed by the specification on the drawing or
as directed by ENGINEER.

1.32. HOT WEATHER REQUIREMENT
a) All concrete work performed in hot weather shall be in accordance with
I.S: 456 except as herein modified.

b) Admixture may be used only when approved by ENGINEER.

c) Adequate provisions shall be made to lower concrete temperatures
by cool ingredient, eliminating excessive mixing, preventing exposure of
mixers and conveyors to direct sunlight and the use of reflective paint on
mixers etc. The temperature of the freshly placed concrete shall not be
permitted to exceed 38 C.

d) Consideration shall be given to shading aggregate stockpiles from direct
rays of the sun and sprayings stockpiles with water, use of cold water
when available, and burying insulating shading and/or painting white the
pipe lines and water storage tanks and conveyance.

e) In order to reduce loss of mixing water the aggregates, wooden
forms, sub-grade, adjacent concrete and other moisture absorbing surfaces
shall be well wetted prior to concreting placement and finishing shall be
done as quickly as possible.

f) Extra precautions shall be taken for the protection and curing of concrete.
Consideration shall be given to continuous water curing and protection
against high temperatures and drying hot winds for a period of at least
7days immediately after concrete has set and after which normal curing
procedures may be resumed.

1.33. PLACING CONCRETE UNDER WATER

459

i) Under all ordinary conditions all foundations shall be completely
dewatered and concrete placed in the dry. However, when concrete
placement under water is necessary, all work shall conform to IS.456 and
the procedure shall be as follows:

ii) METHOD OF PLACEMENT
Concrete shall be deposited under water by means of tremies, or drop
bottom buckets of approved type.



iii) DIRECTION, INSPECTION AND APPROVAL
All works requiring placement of concrete under water shall be designed,
directed and inspected with due regard to local circumstance and
purposes. All under water concrete shall be placed according to the plans
or specifications and as directed and approved by ENGINEER.

1.34. PRECAST CONCRETE
i) Pre-cast units shall comply with I.S: 456 and with the following
requirements:
All pre-cast units shall be cast on a suitable bed or platform with firm
foundation and free from wind. CONTRACTOR shall be responsible for
the accuracy of the level or shape of the bed or platform. A suitable serial
number and the date of casting shall be impressed or painted on each
unit.

ii) STRIKING FORMS
Side shutters shall not be struck in less than 24 hours after depositing
concrete and no pre-cast unit shall be lifted until the concrete reaches
strength of at least twice the stress to which the concrete may be
subjected to at the time of lifting.

iii) PRECAST UNITS
The lifting and removal of precast units, that shall be undertaken without
causing shock, vibration or undue bending stresses to or in the units.
Before lifting and removal takes place, CONTRACTOR shall satisfy
ENGINEER or his representative that the methods he proposes to adopt
for these operations will not over stress or otherwise affect seriously the
strength of the precast units. The reinforced side of the units shall be
distinctly marked.


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iv) CURING
All precast work shall be protected from the direct rays of the sun for at
least 7 days after casting and during that period each unit shall be kept
constantly watered or preferably be completely immersed in water if the
size of the unit so permits. Otherwise curing practice as given in clause D
1.29 shall be followed.

1.35. SLOTS OPENING ETC.
Slots, openings, or holes, pockets etc. shall be provided in the concrete
work in the positions indicated in the drawings or as directed by
ENGINEER. Any deviation from the approved drawings
shall be made good by CONTRACTOR at his own expense without
damaging any other work. Sleeves, bolts, inserts etc. shall also be
provided in concrete work where so specified.


1.36. INSPECTION
i) All materials workmanship and finished construction shall be subject to the
continuous inspection and approval of ENGINEER.
ii) All materials supplied by CONTRACTOR and all work or construction
performed by CONTRACTOR rejected as not in conformity with the
specifications and drawings shall be immediately replaced at no
additional expense to the OWNER.
iii) Approvals of any preliminary materials or phase work shall in no way
relieve the CONTRACTOR from the responsibility of supplying concrete
and or producing finished concrete in accordance with the specifications
and drawings.
iv) All concrete shall be protected against damage until final acceptance by
OWNER or his representative.

v) CLEAN-UP
a) Upon the completion of concrete work, all forms, equipment construction
tools, protective covering and any debris resulting from the work shall be
removed from the premises.

b) All debris i.e., empty containers, scrap wood etc. shall be removed to
"Dump" daily or as directed by ENGINEER.

c) The finished concrete surfaces shall be left in a clean condition satisfactory
to ENGINEER.

1.37. ACCEPTABLE CRITERIA

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Any concrete work shall satisfy the requirements given below individually
and collectively for it to be acceptable.
a) Properties of constituent materials
b) Characteristic compressive strength
c) Specified mix proportions
d) Minimum cement content
e) Maximum free water /cement ratio
f) Workability
g) Temperature
h) Density of fully compacted concrete
i) Curing
j) Tolerances in dimensions
k) Tolerances in levels
l) Durability
m) Surface finishes
n) Special requirements such as
i) Water tightness
ii) Resistance to aggressive chemicals
iii) Resistance to freezing and thawing
iv) Improved fire resistance
v) Wear resistance
vi) Resistance to early thermal cracking

The ENGINEER s decision as to the acceptability or otherwise of any
concrete work shall be final and binding on the CONTRACTOR.
For work not accepted, the ENGINEER may review and decide whether
remedial measures are feasible so as to render the work acceptable. The
ENGINEER shall in that case direct the CONTRACTOR to undertake and
execute the remedial measures. These shall be expeditiously and
effectively implemented by the CONTRACTOR. Nothing extra shall
become payable to the CONTRACTOR by the OWNER for executing the
remedial measures.

1.38 MODE OF MEASUREMENT AND PAYMENT
i) The unit rate for concrete work under various categories shall be all
inclusive and no claims for extra payment on account of such items as
leaving holes, embedding inserts, etc. shall be entertained unless
separately provided for in the schedule of quantities. No extra claim shall
also be entertained due to change in the number, position and/or
dimensions of holes, slots or openings, sleeves, inserts or on account of
any increased lift or scaffolding etc. All these factors should be taken into
consideration while quoting the unit rates. Unless consideration while

462
quoting the unit rates. Unless provided for in the schedule of quantities the
rates shall also include fixing inserts in all concrete works, whenever
required.

ii) Payments of concrete will be made on the basis of unit rates quoted for the
respective items in the schedule of quantities. No deduction in the concrete
quantity will be made for the reinforcement, inserts etc. and opening less
than 1/20 of a sq.m. in area where concrete is measured in sq.m and 1/150
cu.m. Where concrete is measure in cu, Metres. Where no such deduction
for concrete is made, payment for shuttering work provided for such holes,
pockets etc. will not be made. Similarly the unit rates for concrete work
shall be inclusive or exclusive of shuttering as provided for in the schedule
of quantities.

Where formwork is paid for separately, it shall be very clearly understood
that payment for formwork is inclusive of form work, shuttering, shoring,
propping, scaffolding etc. complete.
Payment for beams will be made for the quantity placed on the depth being
reckoned from the underside of the slabs and length measured as the clear
distance between supports. Payments for columns shall be made for the
quantity based on height reckoned upto the underside of slabs.

The unit rate for precast concrete members shall include form work,
mouldings, finishing, hoisting and setting in position including setting
mortar, provision of lifting arrangement etc. complete. Only if
reinforcement is used it shall be measured and paid for separately under
item rate.

D.2 SPECIFICATION FOR GENERAL BUILDING WORKS
2.1. SCOPE:
This specification covers the general requirement for brick masonry, plastering,
flooring, doors, windows, ventilators, wood work, water proofing, false ceiling,
painting and such other related work forming a part of this job which may be
required to be carried out though not specifically mentioned above. The work
under this specification shall consist of furnishing of all tools, plants, labour,
materials, any and everything necessary for carrying out the work.

2.2.0 APPLICABLE CODES AND SPECIFICATIONS :
2.2.1 This specification covers standards and specifications and are made a part of
this specification. All standards, tentative specifications, specifications, codes of
practices referred to herein shall be the latest edition including all applicable
official amendments and revisions.


463
In case of discrepancy between this specification and those referred to herein,
this specification shall govern:
IS.1077 - Common burnt clay building bricks.
IS.3102 - Classification of burnt clay solid bricks
IS.2180 - Burnt clay building bricks, heavy duty
IS.3495 - Method of tests for burnt clay building bricks
IS.2691 - Burnt clay facing bricks
IS.2212 - Code of practice for brick work.
IS.2645 - Integral cement water proofing compounds
IS.1443 - Code of practice for laying and finishing of cement
concrete flooring tiles
IS.2114 - Code of practice for laying in situ Terrazzo floor
Finish
IS.777 - Glazed Earthenware tiles.
IS.4021 - Timber door, window and ventilator frames
IS.2202 - Wooden flush shutters (solid, core type)

Part II
IS.1003 - Timber panelled and glazed shutters(Part-I& II)
IS.4020 - Methods of tests for wooden flush doors:

Type tests.
IS.1761 - Transparent sheet glass for glazing and
framing purposes.
IS.4351 - Steel door frames.
IS.1038 - Steel doors, windows and ventilators.
IS.1081 - Code of practice for fixing and glazing of metal
(steel and aluminium) doors, windows and
ventilators.
IS.5807 Method of test or clear finishes for wooden Furniture
(Part-I to III)
IS.1477 - Code of practice for painting of ferrous metals in buildings
and allied finishes (Part I & II)
IS.2338 - Code of practice for finishing of wood and wood-based
materials (Part-I).
IS.427 - Distemper, dry, colour as required.
IS.428 - Distemper, oil emulsion, colour as required.
IS.2395 - Code of practice for painting concrete, masonry
and plaster surfaces.
IS.3384 - Bitumen primer for use in water proofing and
damp proofing.
IS.1580 - Bituminous compound for water-proofing and
caulking purposes.
IS.1322 - Bitumen felts for water-proofing and damp
proofing.
IS.1346 - Code of practice for water-proofing of roofs with Bitumen felts.
2.3.0. BRICKWORK:

464
2.3.1 Bricks used in works shall conform to the relevant Indian Standards. They shall
be sound, hard, homogenous in texture well burnt in kiln without being vitrified,
table moulded, deep red, cherry or copper coloured, of regular shape and size
and shall have sharp and square edges and parallel faces. The bricks shall be
free from pores chics, flaws of humps of any kind, bricks containing unground
particles and/or which absorb water more than 1/6
th
of their weight when soaked
in water for twenty-four hours shall be rejected. Over-burnt or under-burnt bricks
shall be liable to rejection. The bricks shall give a clear ringing sound when struck
and shall have a minimum crushing strength of 50 Kg./Sq.cm. unless otherwise
noted in drawings. The classes and quality requirements of bricks shall be as laid
down in IS.3102.
2.4.2 The size of the brick shall be 22.86 x 11.43 x 7.62 cm. Unless and otherwise
specified, but tolerance upto +/- 3mm in each direction shall be permitted. However
bricks conforming in size to IS 1077 could be used. Bricks shall be provided with frogs.
Only full size bricks shall be used for masonry work. Brick bats shall be used only
with the permission of the ENGINEER to make up required wall length or for bonding.
Sample bricks shall be submitted to the ENGINEER for approval and bricks supplied
shall confirm to approved samples. If demanded by ENGINEER, brick sample shall be
got tested as per IS 3495 by CONTRACTOR at no extra cost to OWNER. Bricks
rejected by ENGINEER shall be removed from the site of works within 24 hours.

2.3.3.0 MORTAR
2.3.3.1. Mortar for brick masonry shall be prepared as per IS : 2250. Mix for cement
mortar shall be as specified in the respective items of work.
Gauge boxes for sand shall be of such dimensions that one completed bag of
cement containing 50kgs of cement forms one unit. The sand shall be free from
clay, shale, loam, alkali, organic matter and shall be of sound, hard, clean and
durable particles. Sand shall be approved by ENGINEER. If so directed by the
ENGINEER, sand shall be thoroughly washed till it is free of any contamination.

2.3.3.2 For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry condition.
Water shall then be added and mixing continued to give a uniform mix of required consistency.
Cement mortar shall preferably be machine mixed, though hand mixing in a thorough manner may
be allowed. The mortar so mixed shall be used within twenty five (25) minutes of mixing. The
mortar left unused in the specified period shall be rejected.

2.3.3.3 The CONTRACTOR shall arrange for test on mortar samples if so directed by the Engineer. Re-
tempering of mortar shall not be permitted.

2.3.4. WORKMANSHIP
2.3.4.1 All bricks shall be thoroughly soaked in clean water for at least one hour
immediately before being laid. The cement mortar for brick masonry work shall
be as specified in the respective item of work. Brick work 230mm thick and over
shall be laid in English Bond unless otherwise specified. 115mm thick wall shall
be laid with stretchers. For laying bricks a layer of mortar shall be spread over
the full width of suitable length of the lower course. Each brick shall be pressed
into the mortar and shoved into final position so as to embed the brick fully in
mortar. Bricks shall be laid with frogs upper-most.

465

2.3.4.2 All brick work shall be plumb, square and true to dimensions shown. Vertical joints
in alternate courses shall come directly one over the other and be in line.
Horizontal course shall be levelled. The thickness of brick courses shall be kept
uniform. For walls of thickness greater than 230mm both faces shall be kept in
vertical planes. All interconnected brickwork shall be carried out at nearly one
level (so that there is uniform distribution of pressure on the supporting structure)
and no portion of the work shall be left more than one course lower than the
adjacent work. Where this is not possible, the work shall be raked back
according to bond (and not saw toothed) at an angle not exceeding 45 Degree.
But in no case the level difference between adjoining walls shall exceed 1.25m.
Workmanship shall conform to IS : 2212.

2.3.4.3 Bricks shall be so laid that all joints are well filled with mortar. The thickness of
joints shall not be less than 6mm and not more than 10mm. The face joints shall
be raked to a minimum depth of 12mm by raking tools daily during the progress of
work when the mortar is still green, so as to provide a proper key for the plaster or
pointing to be done. When plastering or pointing is not required to be done, the
joints shall be uniform in thickness and be struck flush and finished at the time of
laying. Face of brickwork shall be cleaned daily and all mortar droppings
removed. The surface of each course shall be thoroughly cleaned of all dirt
before another course is laid on top. If the mortar in the lower course has begun
to set, the joints shall be raked out to a depth of 12mm before another course is
laid.

2.3.4.4 All brick work shall be built tightly against columns, floor slabs or other structural
members.

2.3.4.5 Where drawings indicate that structural steel columns are to be fire proofed with
brick work, the brick shall be built closely against all flanges and webs with all
spaces between the steel and brick work filled solid with mortar. Steel members
partly embedded in brick work and not indicated to be fire proofed with concrete,
shall be covered with not less than 12mm thick mortar unless directed otherwise
by Engineer.

2.3.5 Miscellaneous inserts in masonry, e.g sleeves, wall ties, anchors, conduits,
structural steel, steel lintels etc shall be installed by the CONTRACTOR at no
extra cost to the OWNER. Furnishing of any of these inserts by the
CONTRACTOR, will be paid for separately. Openings, arches, etc. shall be
provided as on the drawings. Chases, pockets etc. shall be provided as shown in
the drawings to receive windows, louvers, doors, frames etc. Wall ties and
flashings shall be built into the brickwork in accordance with the drawings and
specifications. It shall be clearly understood that the rates quoted by the
CONTRACTOR include for fixing of inserts, leaving openings, cutting chases in
brickwork for various trades etc.

2.3.6. FACING BRICK WORK :

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2.3.6.1. Facing bricks of the type specified shall be laid in the positions indicated on the
drawings and all facing brickwork shall be well bonded to the backing bricks. No
facing brickwork shall at any time be more than 600mm above the backing
brickwork.

2.3.6.2. All facing brickwork shall be pointed as the work proceeds and internal
faces of the brickwork shall be pointed with neat flush joint to give a fair
face.

2.3.6.3. Faced work shall be kept clean and free from damage, discolouration etc. at
all time. The CONTRACTOR shall fill carefully all holes with bricks similar to
the surrounding brickwork and point brick as required.

2.3.6.4. For facing brickwork, double scaffolding shall be used. No holes in
brickwork for scaffolding shall be permitted.

2.3.7. The green work shall be protected from rain by suitable covering. Bricks shall be
kept constantly moist on all faces for a minimum period of ten days. Brick work
shall not be raised more than one metre per day.

2.3.8. The rates quoted by the CONTRACTOR are exclusive of transoms and mullions.
CONTRACTOR shall provide the same as shown or indicated in the drawings.
These shall be generally provided only in half and full brick walls. Dimensions of
the transoms and mullions shall conform to the thickness of the wall. Concrete
work for transoms and mullions shall conform to the specifications for concrete
and shall be of grade M20.

2.3.9. Where shown on the structural drawings bricks for partition walls shall be stacked
adjacent to the structural member to pre-deflect the structural member before the
wall is built.

2.4.0. All joints in masonry shall be raked to a depth of 12mm with a hooked tool made
for the purpose when the mortar is still green and in any case within 48 hours
of its laying. The surface to be rendered shall be washed with fresh, clean,
water free from all dirt, loose material, grease, etc .and thoroughly wetted for 6
hours before plastering work is commenced. Concrete surfaces to be rendered
will however be kept dry. The wall should not be too wet but only damp at the
time of plastering. The damping shall be uniform to get uniform bond between
the plaster and the wall.

2.4.1. The proportion of the mortar shall be as specified under the respective items of
work. Cement shall be mixed thoroughly in dry condition and then just enough
water added to obtain a workable consistency. The quality of water, sand and
cement shall be as per I.S. Standards. The mortar thus mixed shall be used
immediately and in no case shall the mortar be allowed to stand for more than
25minutes after mixing with water.


467
2.4.2. Curing of plaster shall be started as soon as the applied plaster has hardened
enough so as not to be damaged. The decision as to when the plaster has
hardened, will be given by the ENGINEER. Curing shall be done by continuously
applying water in a fine spray and shall be carried out for at least 7 days.

2.4.3. Whenever the specification or the item of work calls for water
proofing, the CONTRACTOR shall provide the percentage of water-proofing
compound as specified in the items of work.

2.4.4. Where lath plaster is specified, it shall be paid for at the same rate as for plaster
work without metal lath except that separate payment for metal lath will be made.

2.4.5. Ceiling plaster shall be done before wall plaster and wall plaster shall commence
at top and work downwards.

2.4.6. Interior and Exterior plaster This plaster shall be laid in a single coat of 12mm
thickness. The mortar shall be dashed on the prepared surface with a trowel and
finished smooth by trowelling on the surface with neeru (lime cream). Neeru shall
be properly slaked fat lime. The standard of finish expected is high and shall
conform to IS:2394. Interior plaster shall be carried out on jambs, lintel and sill
faces, top and undersides, etc. as shown in the drawing or as directed by the
ENGINEER. Rate quoted for plaster work shall be deemed to include plastering
of all those surfaces. However, if the item of work includes plaster finish, no
separate payment would be made under Plastering work.

2.5.0. WATERPROOFING ADMIXTURE
If directed by the ENGINEER, the CONTRACTOR shall use approved water
proofing admixtures made by reputed manufacturer in the mortar for plaster work.
The quantity to be used etc, shall be in accordance with the manufacturers
instructions subject however to the approval of the ENGINEER. These
admixtures shall not contain calcium chloride unless specifically allowed by
Engineer and shall conform to IS : 2645. Payment shall be made for actual
quantity of such admixture used unless it is already covered in the rates for the
work concerned.

2.6.0. CERAMIC TILED WORK IN FLOORING

The type, quality, size, thickness, colour, etc. of the tiles for flooring and skirting
work shall be of test quality approved by the ENGINEER. For this purpose, the
CONTRACTOR shall provide the ENGINEER with necessary samples for his
selection.

2.6.1. Before the tiling work is commenced, the sub-surface shall be thoroughly cleaned
and washed of all loose materials, dirt, and scum or laitance and then well wetted
without forming water pools on the surface.

2.6.2 The tiles shall be laid on mortar bedding of about 20mm thick. The proportion of
mortar shall be one part of cement and 3 parts of sand. The tiles shall be fixed

468
on this bed one after another, each tile being gently tapped with a wooden mallet
till it is properly bedded and in level with the adjoining tiles. The joints shall be
perfectly straight and uniform in thickness. The tiles shall be laid perfectly in
level unless otherwise specified or required or desired by the ENGINEER. After
laying the tiles the joints shall be finished with white cement or cement of
approved colour.

2.6.3. For lime mortar, lime from burnt stone shall be used. It shall be free from ash and
impurities and be in the form of lumps and not powder when brought to site.
Lime which is damaged due to rain, soaking, moisture or air slaking will be
rejected.

2.6.4. Floor tiles laid adjoining the wall project 12mm under the plaster, skirting or
dado as may be required by the ENGINEER. Half tiles and pieces shall be
avoided as far as possible. After laying, the flooring shall be allowed to cure
undisturbed for seven days. Design traffic shall not be allowed on the floor at
least 14 days after laying the tiles.

2.6.5. About a week after laying the tiles, each and every tile shall be lightly tapped
with a small wooden mallet to find out if it gives a hollow sound. If it does, such
tiles along with any other cracked or broken tiles shall be removed and replaced
with a new tile to proper line and level. The same procedure shall be followed
again after the tiles are finally laid. For the purpose of ensuring that such
replaced tiles match with those earlier laid, it is necessary that the contractor
order enough extra tiles from the factory to meet this contingency.

2.6.6. For dado and skirting work, the vertical surface shall be thoroughly cleaned and
wetted. Thereafter it shall be evenly and uniformly covered with about 12mm
thick cement mortar. For this work the tiles as obtained from the factory shall
be of the size required and practically fully polished. The back of each tile to be
fixed shall be covered with a thin layer of neat cement paste and the tile shall
then be gently tapped, against the wall with a wooden mallet. This shall be
done from the bottom of the surface upwards. The joints shall be as close as
possible and the work shall be truly vertical and flush.

After the work has set, hand polishing with carborandum stones shall be done so
that the surface attains a high glossy finish corners and junctions shall be
finished true. True workmanship shall conform to IS:1443.

2.6.7. The work is subject to the approval of the ENGINEER. If any portion of
the work is rejected by the ENGINEER, the same shall be removed and redone
by the CONTRACTOR to the satisfaction of the ENGINEER at no extra cost to
the OWNER.

2.7.0. GLAZED TILE WORK :
The glazed tiles in paving and dado shall be of the best available first class
quality approved by the ENGINEER and they should be laid on a base of 12mm
thick cement mortar.The tiles shall be of standard size without warp and with

469
straight edges true and even in shape and size and of uniform colour. They
shall be laid truly vertical on walls and truly horizontal on floors or to slopes as
directed. The joint shall be very thin, uniform and perfectly straight. The joint
shall be floated with white cement as approved by the ENGINEER. At the top of
dado work, a coloured glazed tile border 75mm deep shall be provided as
approved by ENGINEER. The rate quoted for paving and dado work shall be
inclusive of angles, corner pieces and approved colour border on top. Glazed
tiles shall conform to IS:771.

2.8 INTEGRAL CEMENT FINISH ON CONCRETE FLOOR :

In all case where integral cement finish on a concrete floor has been specified,
the top layer of concrete shall be screeded off to proper level and tamped with
tamper having conical projections so that the aggregate shall be forced below the
surface. The surface shall be finished with a wooden float and a trowel with
pressure. The finish shall be continued till the concrete reaches its initial set. No
cement or cement mortar finish shall be provided on the surface. Where
specified, a floor hardener as approved by the ENGINEER shall be supplied and
used as recommended by the manufacturer.

2.9 WOOD WORK IN DOORS, WINDOWS, PARTITIONS, LOUVERS,
RAILINGS ETC :
2.9.1 Wood used for all work shall be the best of the respective class specified and
properly seasoned by at least 6 months air drying, suitable for joiners work, should be of
natural growth, uniform in texture, straight grained, free from sapwood, dead knots, open
shakes, boreholes, rot, decay and any and all other defects and blemishes.

2.9.2 The thickness specified for joiners wrought timbers are unless otherwise
specified, prior to planning and 3mm will be allowed from the thickness stated for
each wrought faces.

2.9.3 All joining shall be wrought on all faces and finished off by hand with sand paper,
with slightly rounded arises.

2.9.4 The joints shall be pinned with hard wood pins and put together with white lead.
Jointing shall be by means of mortice and tennon or dovetailed joints as
approved.

2.9.5 Any joiners work which shall split, fracture, shrink, or show flaws or other defects
due to unsoundness, inadequate seasoning or bad workmanship, shall be
removed and replaced with sound material at the CONTRACTORs expense.

2.9.6 Doors, windows, and ventilator frames, transoms and mullions shall be
rebated. All dimensions shall be as per drawings. The top framing member of
doors and top and bottom framing of windows and ventilators shall
project about 150mm in brickwork. The verticals of door frames shall project
about 50mm below finished floor. Surface coming in contact with brick work shall
be painted with bitumen as directed by the ENGINEER. Each of the door and

470
window frames shall be provided with 3 Nos. M.S.230 x 50 x 5mm flat split hold-
fasts on each side. These hold fasts shall be embedded in masonry or concrete
work. The work shall conform to IS:4021.

2.9.7 The doors shall be panelled or solid flush doors as described in the item of work. All
flush doors shall be supplied with approved fittings such as hinges, lock of approved
make with handles on both sides, anodised aluminium tower bolts, aldrop and latch
arrangements, door stoppers etc. and as detailed in schedule. Panelled doors shall
have the same fittings except lock, shall be provided. Each door leaf shall have
two 200mm tower bolts, two anodised aluminium or oxidised brass handles, rubber
bush and one door stopper mounted near the bottom of door. External flush doors shall
be made of weather-proof plywood. Flush doors shall conform to IS:2202 (Part-I)

2.9.8. Doors will generally have no sills but if a few have to be provided, the
CONTRACTOR shall do so at no extra cost to the OWNER.

2.9.9. The type of window shall be as specified. Each shutter shall have minimum one pair
of hinges, two tower bolts, one handle and peg stay. Ventilators shall have two
M.S. hold fasts and hinges, one handle at each and one small tower bolt in the
centre, where so directed by the ENGINEER.

2.9.10. The workmanship of all door and window shutters shall conform to the requirements
of IS:1003 (Part I & II) and IS:2203 (Part I). If required, flush door panels shall be
got tested as per IS: 4020.

2.9.11. Cupboards, almirahs and shelves shall be provided as shown in drawings.

2.9.12. The finish expected is of a very high order and the work shall be all inclusive
whether or not all detailed specifications have been spelt out and the work
shall be free from blemish.

2.9.13. Iron bars or grills are proposed to be provided in the windows or ventilators. Glass
louvered ventilators where specified shall be provided.

2.9.14. Glazed windows, louvers, ventilators and doors shall be provided with either clear or
pin headed glass 4mm thick which shall be free from all blemishes and shall
conform to IS:1761. It should be clearly understood that glass which does not
have uniform refractive index or which is wavy, will be rejected.
2.9.15 Wood work shall not be painted, oiled or otherwise treated before it
has been approved by the ENGINEER.

2.10 ALUMINIUM DOORS, WINDOWS AND FITTINGS
The aluminium doors, windows and fittings shall conform to IS:1948-1961.
2.11. PAINTING/POLISHING WOOD WORK AND IRON WORK.
2.11.1. Paint / Polish to be used for various items of work shall be of best quality and shall be
obtained ready mixed in sealed containers from approved manufacturer. The
CONTRACTOR shall obtain the ENGINEERs approval for the make and colour of

471
the paint he proposed to use. If required, polish for wood work shall be tested as
per IS:5807 (PART I & III)

2.11.2 All surfaces shall be thoroughly cleaned of all dirt, loose particles and rust
and approved, prior to application of paint. For wood surfaces, a priming coat
without colouring matter shall be first applied after which all holes, cracks, etc.
shall be made good with putty and all knots properly filled with quicklime.
Workmanship shall conform to IS:1477 (Part I & II) and 2330 (Part I)

2.11.3. Specified number of coats shall be applied and at least 24 hours shall elapse
between the application of successive coats. No painting shall be carried out on
exterior work in wet weather or on surfaces which are not entirely dry.

2.11.4. Painting / polishing rate shall include all necessary scaffolding, cradles and plant.
Measurements will be on the basis of sq.m for doors and windows, only the
projected area will be measured. If such painting / polishing is not already a part
of the item, without deducting for the glazed portions though not painted. The
CONTRACTORs rate should take this into account.

2.12. DISTEMPERING, WHITE, COLOUR WASHING AND PAINTING OF WALLS.

2.12.1. DISTEMPERING

The surface to be treated shall be thoroughly cleaned of all dirt and loose
particles etc. Inequalities and holes shall be filled with gypsum, which should be
allowed to set hard before distemper is applied.

Distemper shall be of well known brands of approved make. It shall be applied
by a board stiff brush in two coats over a coat of primer. The first and second
coat shall be applied only after the primer coat has thoroughly dried. The first
coat shall be of a lighter tint. The shade of the distemper shall be got approved
by the ENGINEER. Water bound and oil bound distemper shall conform to the
requirements of IS:427 and 428 respectively.

2.12.2. WHITE WASH
Walls to be thoroughly cleaned before white wash is applied. White wash shall
be of ordinary fat lime and of good quality. It shall be slaked with an excess of
water to the consistency of a cream and allowed to remain under water for 2
days. It shall then be strained through a cloth and 2kg of clean gum added for
every cubic metre of lime ready for white washing.

Each coat is to be applied with a brush. It shall be laid with a stroke of the brush
from the top, downwards, another from bottom upwards over the first stroke and
similarly, one stroke from the right and another from the left over the first brush
before it dries. Three such coats shall be applied.

2.12.3. COLOUR WASH

472
Colour wash shall be applied the same way as white wash. Necessary and
approved colouring matter shall be added to the white wash which has been
strained. Only wash sufficient for the days work shall be prepared each
morning. If the finished surface is powdery and comes off easily or the general
appearance is streaky, the work shall be rejected.

2.12.4. PAINTING
Paint to be used for the various items of work should be of approved make and
colour. It is imperative that the CONTRACTOR should obtain ENGINEERs
permission in regard to the make and colour of paint that he proposes to use for
the various items of work. The painting work shall be carried out as directed by
the ENGINEER, keeping however, in view the recommendations of the
manufacturers.

Where painting with plastic emulsion is specified all uneven surfaces shall be
made up by use of putty of appropriate quality, after the surface has been
thoroughly cleaned of all dust, dirt and sand papered. One primer coat and two
coats of emulsion paint shall be applied. Workmanship shall conform to the
requirements of IS:2395.

2.13.0 EXPANSION JOINTS, WATER STOPS, PREMOULDED JOINT FILLERS,
FLASHINGS
2.13.1 EXPANSION JOINTS
Expansion joints shall be provided with 20gauge copper strips/mild steel hot dip
galvanised strips of 250mm width at locations shown on drawings or as approved
by ENGINEER. The strips shall be bent to the shape indicated on the drawing
and embedded properly in masonry. The joint width shall be uniform throughout
and special care shall be taken to ensure proper bending at expansion joints.
Expansion joints shall be continuous and where two or more strips meet, they
shall be lapped to the extent of 75mm and joints properly soldered. The
expansion joints shall be filled with premoulded joint fillers and sealed with mastic
compound. For purposes of measurement, the laps provided will be neglected.
Wherever an expansion joint between the existing part and new part is proposed
the rate quoted shall be inclusive of making necessary connections with existing
part.

2.13.2 WATER STOPPERS :

Water stops shall be of rubber or PVC Bars of approved make. These shall be
provided at locations indicated on drawings. Water stops shall be lapped 100mm
and heat sealed to obtain continuity. Water stops shall be cleaned thoroughly of
all concrete and mortar coating as directed before resuming concrete work.
Water stops shall be in long lengths to avoid joints as far as possible.

2.13.3 JOINT FILLER :


473
Premoulded joint fillers shall be of a non-deteriorating and resilient type. A
sample of material shall be approved by the ENGINEER before being brought to
site. Installation shall be carried out properly and as directed.

2.13.4 FLASHINGS :
Metal or tar felt flashings shall be fixed as directed by the ENGINEER. Metal
flashings where provided shall be welded / soldered to obtain continuity. Tar felt
flashings shall be lapped for a minimum length of 150mm. Flashings shall be
measured and paid for in linear metres for the specified width disregarding laps
or joints.

2.14.0. WATER PROOFING WORK :
All surfaces to be water proofed shall be dry, clean, smooth and free from dust
and loose particles.

2.14.1. TAR FELT TYPE :

For a five layer treatment, bitumen primer conforming to IS:3394 shall be applied.
Over this primer coat, hot bitumen conforming to IS:1580 shall be applied at the
rate of 1.2 kg./Sq.m. Hessian based felt type-3 Grade-2 conforming to IS:1322
shall be spread and embedded in the previously laid bitumen while hot. Hot
bitumen will again be applied over the felt at the rate of 1.2 Kg./Sq.m. Pea size
gravel or grit shall be uniformly spread at the rate of 0.008cu.m./sq.m. The end
and side laps of each sheet shall not be less than 100 and 175mm respectively
and shall be firmly bonded with bitumen. The extreme ends shall be taken up
about 100 150mm along parapet wall and embedded in chases made in the
wall and brick masonry and made good in plaster. The standard of water
proofing shall comply with IS:1346. For seven layer treatment, one additional
layer of bitumen shall be laid before gravel layer in a manner described above for
five layer treatment.

D.3. SPECIFICATION FOR WATER SUPPLY AND SANITARY WORKS
3.1.0. SCOPE :
This specification covers the general requirements for supplying and laying of
water supply pipe line with necessary fittings and fixtures for buildings /
structures tapping off from potable water supply distribution system, supplying
and laying sewage pipe line with disposal works including provision of all fittings
and fixtures of sanitary works and such other related items of work forming a part
of the job, which may be required to be carried out though not specifically
mentioned above. The work under this specification shall consist of furnishing of
all tools, plants, labour, materials and any and everything necessary for
satisfactorily carrying out the work.

3.2.0 APPLICABLE CODES :
3.2.1. The following standards and codes are made part of this specification. All
standards, codes of practice referred to herein shall be the latest editions
including all official amendments and revisions.


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a. IS.458 - Concrete Pipes (with and without
reinforcements).
b. IS.554 - Dimensions for pipe threads where
pressure tight joints are required on the threads.
c. IS.651 - Salt glazed stoneware pipes and fittings.
d. IS.774 - Flushing cisterns for water closets
and urinals (valve-less siphonic type).
e. IS.775 - Cast iron brackets and supports
for wash basins and sinks.
f. IS.781 - Sand cast brass screw-down bib
taps and stop taps for water services.
g. IS.783 - Code of practice for laying of
concrete pipes.
h. IS.1068 - Electroplated coatings of nickel
and chromium on iron and steel.
i. IS.1239 - Mild steel tubes (Part-I) and Mild
steel tubulars and other wrought steel pipe fittings
(Part-II)
j. IS.1536 - Centrifugally cast (Spun) iron
pressure pipes for water, gas and sewage.
k. IS.1626 - Asbestos cement building pipes, gutters
and fittings (spigot and socket types).
l. IS.1703 - Ball valves (horizontal plunger type)
including floats for water supply purposes.
m. IS.1726 - Cast iron manhole covers and frames.
n. IS1729 - Sand cast iron spigot and socket soil,
waste and ventilating pipes, fittings, and
accessories.
o. IS.1742 - Code of practice for building drainage.
p. IS.2326 - Automatic flushing cisterns for urinals.
q. IS.2470 - Code of practice for design and
construction of septic tanks.
r. IS.2556 - Vitreous sanitary appliances
(Part-I to Part-XV)
s. IS.2963 - Non-ferrous waste fittings for wash
basins and sinks.
t. IS.3311 - Waste plug and its accessories for
sinks and wash basins.
u. IS.5329 - Code of practice for sanitary pipe
work above ground for buildings
v. IS.5434 - Non-ferrous alloy bottle traps for
marine use.

3.3.0 DRAWINGS

3.3.1. Drawings released for construction showing locations of sanitary and
water supply fixtures will be furnished to the CONTRACTOR and all drawings so
furnished shall form a part of this specification. Drawing will also furnish the

475
details of one/or more supply points outside the building for the water supply
system and disposal points/schemes for sanitary works. The CONTRACTOR
shall refer to these drawings for all information contained therein which pertains
to as required for this work. CONTRACTOR shall submit to
OWNER/ENGINEER for his approval, detailed working drawings showing layout
of water supply and sanitary works with necessary fittings and fixtures before the
actual construction is undertaken.

3.3.2 All Civil works will be measured and paid under respective items of work.

3.4.0. SANITARY INSTALLATION :

3.4.1. The work shall be carried out complying in all respect with any specific
requirements of the Local Body in whose jurisdiction the work is situated and as
approved by the OWNER/ENGINEER.

3.4.2. Any damage caused to the building, or to installations therein, either due to
negligence on the part of the CONTRACTOR or due to actual requirements of the
work, shall be made good and the building or the installation shall be restored to its
original condition by the CONTRACTOR. No extra payments shall be made for
such works except
when there is an item specifically included for such work in the schedule.


3.4.3. All sanitary and plumbing work shall be carried out by licensed plumbers.

3.4.4. On completion of the work, the site shall be cleaned and all rubbish disposed off
as directed by the ENGINEER.

3.4.5. All sanitary appliances including sanitary fittings, fixtures, toilet requisites shall
be of size and design as specified in the item of work and as per sample
approved by the ENGINEER.

3.4.6. All sanitary fittings and fixtures shall be acceptable to the ENGINEER/ OWNER
and if there are any variations, they shall satisfy the permissible tolerances in
dimensions/slope/contour as specified in relevant IS Codes /Standards.

3.4.7. All white glazed porcelain fixtures, such as wash basin sink, drain board, water
closet pan, urinal P trap etc., shall have hard durable white glazed finish. They
shall be free from cracks, indentations or other glazing defects. No chipped
porcelain fixtures shall be used. Joints between iron and earthenware pipes shall
be made perfectly air and water tight by chaulking with near cement mortar.

3.4.8. INDIAN TYPE WATER CLOSET (I.W.C)
This shall be the long pan pattern with separate foot-rests made of white glazed
earthenware, white glazed vitreous china or white glazed fire clay. The general
requirements shall conform to IS:2556 (Part III and Part-X). Each pan shall
have an integral flushing rim of suitable type. It shall also have an inlet or supply

476
horn for connecting the flush pipe. The flushing rim and inlet shall be of self-
draining type. It shall have a weep hole at the flushing inlet to the pan. The
flushing inlet shall be in the front unless otherwise specified or ordered by the
ENGINEER. The inside of the bottom of the pan shall have sufficient slope from
the front towards the outlet and the surface shall be uniform and smooth to
enable easy and quick disposal while flushing. The exterior surface shall be
unglazed and sufficiently rough or grooved at right angle to the axis of the outlet.
Pans shall be provided with a trap P or S type with a minimum 50mm water
seal and 50mm diameter vent horn. Pan shall be laid at the correct location and
level over a bed of lime concrete using brick aggregates (1 part lime mortar to 2
parts brick bats with lime mortar of 1 part lime to 2 parts of sand) or cement
sand admixture as specified in the drawings.

3.4.9 WASH BASINS

3.4.9.1. Wash basins shall be of Hi-lites colour glazed earthenware, Hi-lites colour
glazed vitreous China or Hi-lites colour glazed fire clay as specified and
conforming to IS:2556 (Part IV).

TYPE SIZE
Corner wash basin 400 x 400mm
Flat Back 550 x 400mm

3.4.9.2. Wash basin shall be of one piece construction, including as combined overflow.
All internal angles shall be designed so as to facilitate cleaning. Each basin shall
have a rim sloping inside towards the bowl on all sides except sides in contact
with the walls and shall have skirting at the back. Basins shall be provided with
single or double tap holes as specified. The tap holes shall be square. A
suitable tap hole button shall be supplied if one tap hole is not required in
installations. Each basin shall have a circular waste hole to which the interior of
basin shall drain. The waste hole shall be either rebated or levelled internally
with diameter of 65mm at top and a depth of 10mm to suit a waste plug having
64mm diameter. Each basin shall be provided with a non-ferrous 32mm waste
fitting. Stud slots to receive the brackets on the underside of the wash basins
shall be suitable for a bracket with stud not exceeding 13mm diameter, 5mm high
and 305mm from the back of basin to the centre of the stud. The stud slots shall
be of depth sufficient to take 5mm stud. Every basin shall have an integral soap
holder recess or recesses which shall fully drain into the bowl. The position of
the chain stay-hole shall not be lower than the over flow slot. A slot type of
overflow having an area of not less than 5sq.cm shall be provided and shall be
so designed as to facilitate cleaning of the overflow. The specifications for waste
plug, chain and stay shall be the same as given for sinks.

3.4.9.3. All the waste fittings shall be chromium plated. Bottle trap shall conform
to IS:5434. The chromium plating shall be of service grade No.2 conforming to
IS:1068.

3.5.0 CAST IRON SOIL WASTE AND VENT PIPES AND FITTINGS :

477
3.5.1. All cast iron pipes and fittings shall be of uniform thickness with strong
and deep socket, free from flaws, air-holes, cracks, sand-holes and other defects
and conform to IS:1536. The diameter specified shall be internal diameter of
pipe. The pipes and fittings shall be true to shape, smooth and cylindrical and
shall ring clearly when struck over with a light hand hammer. All pipes and
fittings shall be properly cleaned of all foreign material before being fixed.

17.5.2. All plug bends of drainage pipes shall be provided with inspection and cleaning
caps, covers which shall be fixed with nuts and screws. Pipes shall be fixed to the
wall by C.I. or MS holder bat clamps, unless projecting ears with fixing holes are
provided at socket end of pipe. The pipes shall be installed, truly vertical or to the
lines and slopes as indicated. The clamps shall be fixed to the walls by embedding
their hooks in cement concrete blocks (1:2:4) 10cm x 10cm by making necessary
holes in the walls at proper places. All holes and breakages shall be made good.
The clamps shall be kept 25mm clear of the finished face of the walls to facilitate
cleaning and painting of pipes.

3.5.3. The annular space between the socket and spigot shall be filled with a
gasket of hemp or spun yarn soaked in neat cement slurry. The joint shall then
be filled with stiff cement mortar 1:2 (1 cement : 2 find sand) well pressed with
caulking tool and finished smooth on top at an angle of 45
0
. The joint shall be
kept wet for not less than 7days by tying a piece of gunny bag kept moist. Joints
shall be perfectly air and water tight.

3.5.4. C.I. Pipes and fittings which are exposed shall be first cleaned and then painted
with a coat of red lead primer. Remaining two coats of paint shall be white zinc
base and approved colour.

3.5.5. The thickness of fittings and their socket and spigot dimensions shall conform to
the thickness and dimensions specified for the corresponding sizes of straight
pipes.

3.5.6. The connection between the main pipe and branch pipes shall be made by using
branches and bends with access for cleaning. Floor traps shall be provided with
25mm dia. puff pipe where the length of the waste is more than 1800mm or the
floor trap is connected to a waste stack through bends.

3.5.7. C.I. Pipe shall be measured along the centre lines of pipes including fittings such
as branches, plug bends, etc.

3.5.8. All cast iron pipes and fittings including joints shall be tested by a smoke test to
the satisfaction of the ENGINEEER and left in working condition after completion.
The smoke test shall be carried out as stated under. Smoke shall be pumped
into the pipe at the lowest end from a smoke machine which consists of bellows
and burner. The materials usually burnt is greasy cotton waste which gives out a
clear pungent smoke which is easily detectable by sight as well as smell if there
is a leak at any point of the pipe line.


478
3.5.9. Water test and air test shall be conducted as stipulated in IS:5329.

3.6.0 ASBESTOS CEMENT PIPES AND FITTINGS :
3.6.1 All A.C. soil waste vent pipes and fittings shall conform to IS:1626. The
pipes shall have spigot and socket ends. These shall be composed of an inert
aggregate consisting of clean asbestos fibre cemented together by ordinary
Portland cement conforming to IS:269 or Portland blast furnace slag cement
conforming to IS:455. No organic materials shall be added to the composition.

3.6.2 The pipes shall be straight and the ends of the pipes and fittings shall be
finished square to their axes. The finished pipes and fittings shall be true and
smooth, their inner and outer surfaces being as nearly as procurable, concentric.
They shall be in all respects, homogenous and free from impurities or other
imperfections.

3.6.3. The permissible tolerances on the thickness and external dimensions of
pipes and fittings including hydraulic test pressure of the pipes and fittings shall
conform to IS:1626.

3.6.4. All A.C. pipes and fittings shall be of approved make and with necessary
accessories, wherever required. The diameter wherever specified for pipes and
fittings shall be clear internal diameter. All gaps between pipes and fittings and
walls shall be filled with cement mortar 1:3 neatly finished for which no extra
payment will be made. All pipes and fittings shall be supported with standard
fixing brackets.

3.6.5. The annular space between the socket and spigot shall be filled with a gasket of
hemp or spun yarn soaked in tar. The joint shall then be filled with stiff cement
mortar 1:2 (1 cement : 2 fine sand) well pressed with caulking tool and finished
smooth on top with neat cement paste at an angle of 45
0
. The joint shall be kept
wet for not less than 7days by tying a piece of gunny bag kept moist. Joints shall be
perfectly air and water tight.

3.6.6 A.C. Pipes shall be measured along with centre lines of pipes
including fittings such as junctions, bends, etc.
3.6.7 Pipes and fittings shall be tested with a smoke test as specified in
Clause 7.5.8

3.7.0 STONEWARE PIPES AND FITTINGS :

3.7.1 All pipes with spigot and socket ends shall conform to IS: 651 and
shall be of Grade A as specified. These shall be sound, free from
visible defects such as fine cracks or hair cracks. The glaze of the
pipes shall be free from crazing. The pipes shall give a sharp clear note, when
struck with a light hammer. There shall be no broken blisters. The pipe
shall be handled with sufficient care to avoid damage to them.

3.7.2. Pipes shall be laid to the correct grade and alignment shown in the plan /

479
sections with their sockets up the gradient. Laying and jointing shall
conform to the general requirements specified in IS:651.


3.7.3. Stoneware pipe used for sewers shall be subjected to a test pressure of
1.5m head of water at the highest point of the section under test. The test shall
be carried out suitably by plugging the low end of the drain and the ends of the
connection if any and filling the system with water. A buckle bend shall be
temporarily joined in at the top end and sufficient length of vertical pipe joined to
it so as to provide the required test head or the top may be plugged with a
connection to a hose ending in a funnel which could be raised or lowered till the
required head is obtained and fixed suitably for observation. Where leakage will
be visible, the defective part of the work shall be removed and made good.

3.7.4. In measuring the length of sewer pipes, laid length between faces of manholes
shall only be measured omitting lengths of channels between inside faces of
walls of manholes or chambers.

3.8.0 P.V.C. PIPES AND FITTINGS :

3.8.1 All pipes with spigot and socket ends shall conform to IS:651 and shall be of grade
A as specified. These shall be sound, free from visible defects such as fine
cracks or hair cracks. The glaze of the pipes shall be free from crazing. There
shall be no broken blisters. The pipe shall be handled with sufficient care to
avoid damage to them.
3.8.2. Pipe shall be laid to the correct grade and alignment shown in the plan/sections
with their sockets up the gradient. Laying and jointing shall conform to the
general requirements specified in IS.

3.8.3 P.V.C. pipes used for sewers shall be subjected to a test pressure of 40m head of
water at the highest point of the section under test. The test shall be carried out
suitably by plugging the low end of the drain and the ends of the connections if
any and filling the system with water. A buckle bend shall be temporarily joined
in at the top and a sufficient length of vertical pipe joined to it so as to provide
with a connection to a hose ending in a funnel which could be raised or lowered
till the required head is obtained and fixed suitably for observation. Where
leakage is visible, the defective part of the work shall be removed and made
good.

3.8.4. In measuring the length of sewer pipes, laid length between faces of manholes
shall only be measured omitting lengths of channels between inside faces of
walls of manholes or chambers.

3.9.0 STOP COCK AND BIB COCK :
3.9.1. A Bib cock (Bib tap) is a draw-off tap with a horizontal inlet and free outlet and
stop cock (stop tap) is a valve with a suitable means of connections for insertions
in a pipe line for controlling of stopping the flow. They shall be of specified size
and shall be of the screw down type. The closing device should work by means

480
of a disc carrying a renewable non-metallic washer, which shuts against water
pressure on a seating at right angles to the axis of the threaded spindle. The
cocks shall open in anti-clockwise direction. When the bib cocks and stop cocks
are required to be chromium plated, the chromium plating shall be of service
Grade No.2 conforming to IS:1068. In finish and appearance, the plated articles
shall be free from plating defects such as blisters, pits, roughness and shall not
be stained or discoloured.

3.9.2. These fittings shall be of brass heavy class, chromium plated (C.P.) and of
approved manufacture and pattern with screwed or flanged ends as specified.
The fittings shall in all respects comply with the requirements of IS:781. The
standard size of brass fittings shall be designed by the nominal bore of the pipe
to which fittings are attached. A sample of each kind and all supplies made
according to the approved samples.

3.9.3. All cast fittings shall be sound and free from laps, blow-holes and fittings. Both
internal and external surfaces shall be clean, smooth, etc. Boring, plugging,
stopping or patching of the casting shall not be permitted. The bodies, bonnets,
spindles and other parts shall be axial, parallel, and cylindrical with surfaces
smoothly finished. The area of the water way of the fittings shall not be less than
the area of the nominal bore.

3.9.4. The fittings shall be fully examined and cleared of all foreign matter before
being fixed. The fittings shall be fitted in the pipe line in a workman-like manner.
The joint between fittings and pipes shall be made leak-proof. The joints and
fittings shall be leak proof when subjected to a pressure test specified by the
ENGINEER and the defective fittings and joints shall be replaced or redone.

3.10.0 GUARANTEE FOR WATER SUPPLY, SOIL VENT SYSTEM :

3.10.1 The CONTRACTOR shall deliver to the OWNER / ENGINEER upon completion of
his work under this CONTRACT, a written GUARANTEE.

i. That for a period of five (5) years after acceptance by the ENGINEER,
plumbing and drainage work shall be free from defective material and
workmanship.
ii. That for a period of five (5) years after acceptance by the ENGINEER, the
CONTRACTOR shall be responsible for the water / air tightness of all
joints.
iii. That he will, at his own expense, repair, replace all such defective work
and all other works damaged thereby, during the terms of GUARANTEE.


3.10.2 After completion of the work, the CONTRACTOR shall obtain and hand over to
the ENGINEER necessary certificates.


D.4.TECHNICAL SPECIFICATION - SPECIFIC REQUIREMENTS

481

Cement
IS : 269 - Specification for 43 grade ordinary Portland cement.

Material Storage
IS:4082 -Recommendations on stacking and storing of Construction materials at site.

Construction Safety
IS:7969 - Safety code for handling and storage of building materials.

Concrete Mix Design :
IS:10262 - Recommended guidelines for concrete mix de
SP:23 (S&T)- Handbook on concrete mixes.

Measurement
IS : 3385 - Code of practice for measurement of Civil Engineering works

4.1. STORING OF MATERIALS
All materials shall be stored in a manner so as to prevent its deterioration and
contamination which would preclude its use in the works. Requirement of
IS:4082 shall be complied with.

CONTRACTOR will have to make his own arrangements for cement and the
storage of adequate quantity of cement. If such cement is not stored properly
and has deteriorated, the material shall be rejected. Cement bags shall be
stored in dry weather proof shed with a raised floor, well away from the outer
walls and insulated from the floor to avoid moisture from ground. Not more than
15 bags shall be stacked in any tier. Storage arrangement shall be approved by
ENGINEER. Storage under tarpaulin shall not be permitted. Each consignment
of cement shall be stored separately and consumed in its order of receipt.

Each size of coarse and fine aggregate shall be stacked separately and shall be
protected from leaves and contamination with foreign material. The stacks shall
be on hard, clear, free draining bases, draining away from the concrete mixing
area.

CONTRACTOR shall make his own arrangements for water at site for
construction.

The reinforcement shall be stacked on top of timber sleepers to avoid contact
with ground/water. Each type and size shall be stacked separately.

4.2 CONCRETE
4.2.1 General
Concrete grade shall be designated on drawings. In concrete grade M20, the
number represents the specified characteristic compressive strength of 150mm
cube at 28 days, expressed in N/Sq.mm as per IS: 456. Concrete in the works
shall be DESIGN MIX CONCRETE or NOMINAL MIX CONCRETE. All plain

482
cement concrete works shall be nominal mix concrete and reinforced cement
concrete works of M20 grade and above of Design mix concrete.

4.2.2 DESIGN MIX CONCRETE :
Mix Design & Testing :
For Design Mix concrete, the mix shall be designed according to IS:10262 and
SP:23 to provide the grade of concrete having the required workability and
characteristic strength not less than appropriate values given in IS:456. The
design mix shall in addition be such that it is cohesive and does not segregate
and should result in a dense and durable concrete and also capable of giving the
finish as specified. For liquid retaining structures, the mix shall also result in
water tight concrete. The CONTRACTOR shall exercise great care while
designing the concrete mix and executing the works to achieve the designed
result.

The minimum cement content for Design Mix Concrete shall be as given below.
Grade of concrete Minimum Cement Content in
Kg/cu.m of concrete
M 20 360 & 315
M 25 400
The minimum cement content stipulated above shall be adopted irrespective of
whether the contractor achieves the desired strength with less quantity OF
CEMENT. The CONTRACTORs quoted rates for concrete shall provide for the
above eventuality and nothing extra shall become payable to the CONTRACTOR
in this account. Even in the case where the quantity of cement required is higher
than that specified above to achieve desired strength based on an approved mix
design, nothing extra shall become payable to the CONTRACTOR.

It shall be CONTRACTORs sole responsibility to carry out the mix designs at his
own cost. He shall furnish to ENGINEER at least 30days before concrete
operations, a statement of proportions proposed to be used for the various
concrete mixes and the strength results obtained. The strength requirements
of the concrete mixes ascertained on 150mm cubes as per IS:516 shall comply
with the requirements of IS:456.

4.3 Superstructure :
Brick work in CM 1:6 of chamber burnt II class bricks of size 9 x 41/2 x 3 of
bearing walls plastered with CM 1:5, 12mm thick inside and outside shall be
provided. All main walls shall be 230mm (1Brick) thick. The partition walls will
be in brick work in CM 1:4, 115 mm thick will have to be provided with
reinforcement bars as indicated in the drawing.

4.3.1 RCC lintels :

A continuous RCC lintel in M20 mix of 150mm thick using 20mm graded hard
granite stone shall be provided for the entire building except for the portion of grill
in service verandah. Necessary reinforcement for the drop in service verandah

483
shall be taken from the roof slab. The lintel beam shall be for full width of the
walls even on partition walls.

4.3.2. RCC Sunshade :

RCC sunshade in M20 mix using 20mm graded HBG stone shall be
600mm wide and shall be cast along with the continuous lintel beam as per
drawing.

4.4. ROOFING AND FLOORING :

The roof slab shall be of RCC M20 mix using 20mm graded hard machine
broken granite stone, 125 mm thick and reinforcement as shown in drawing. The
top of the roof slab will be provided with weathering course consisting of one
course of pressed tiles of size 200 x 200 x 20mm embedded in CM 1:3 mixed
with crude oil as specified in Tamil Nadu Building Practice of Tamil Nadu Public
Works department and pointed at top with CM 1:3 mixed with crude oil, over a
bed of brick jelly concrete in lime (proportion being 32:12.5 of 80 mm average
thickness). The underside of the roof shall be plastered with cement mortar 1:3,
12mm thick.

Ceramic tiled floorings shall be provided in the rooms detailed in clause 4.6 of
this section. The floor level of the above rooms should be suitably depressed to
allow for laying of tiles and mortar. The floor level of all rooms shall be
maintained uniform on completion of flooring works.

Flooring for bath and F.O.L. shall be anti-skid ceramic tile of size 200mmx200mm
with C.M 1:3,20mm thick immediately after the concrete is laid. Necessary water
proofing compound should be added for all flooring in F.O.L. and Bath.

The floor level in bath room and F.O.L. in all floors should be depressed by
50mm below the level of the general floor area.

The sunken portion of slab, if needed, below floor level in toilet rooms to receive
Indian type water closets (orissa pan type) shall be plastered with CM 1:3, 12mm
thick with admixture of approved water proofing compound and painted with two
coats of asphaltic paint.

4.5 M.S. sheets for centering for RCC slab works to be adopted instead
of wooden planks.
The entire centering arrangements for the RCC slabs and beams should be
checked and approved by the Boards Engineer before concrete is laid. All
centering and props shall be properly braced and cross braced in two directions
and well stayed or strutted on all sides enough to resist storm or sudden high
winds or any other unforeseen impact during execution. All RCC concrete shall
be vibrated with suitable vibrators depending on depth/ thickness of concrete .


484
The concrete for the entire building should be mixed only by using diesel or
electricity operated concrete mixers. Hand mixing by manual labour is not
permitted.

Necessary hooks for fixing fan may be provided at suitable locations in floor / roof
slabs while concreting for which no extra payment will be made. PVC conduits,
junction boxes and accessories should be laid before concreting wherever
necessary for concealed wiring.

4.6 FLOORING :
CERAMIC TILED FLOORING:
Ceramic tiled flooring using rectified tile of size400mmx400mm in CM 1:3, 20mm
thick bedding shall be provided in the room. Pointing to be done with the same
colour cement. Necessary samples of tile shall be provided by the contractor for
approval of the Engineer. The floor level should be suitably depressed to allow
for laying tiles and mortar so as to maintain uniform level for all rooms.

4.7. DOORS, WINDOWS & VENTILATORS :
All doors except toilet doors shall be of CW hollow core flush door with frame of
size 100x65mm and shutter using 75x30mm CW scantlings for frame work and
fixing 4mm thick commercial plywood on both sides, TW lipping on edges, fixing
1mm thick lamination of approved quality & design on both sides, Brass butt
hinges, Brass


parallel bolt, Brass handles on both sides, Brass door stopper etc and as per the
specification and sizes mentioned in the drawing and
painted with two coats of approved brand enamel paint over a coat of primer.
The fixtures to be provided as per the schedule of items for all doors.
Toilet doors shall be of PVC door with frame, Forex or equivalent, the frame
made out of hollow core door frame of size 50x47mm with a wall thickness of
5mm rigid foam sheet, mitre cut at two corners and joined with 2Nos of 150mm
long brackets of 15x15mm MS square tube & reinforced with 19x19mm MS
square tube of 19G and fixed to thr wall by drilling 100mm long MS screws using
PVC fasteners and PVC shutter made out of 30mm thick PVC rigid foam panel
door and PVC shutter made out of 30mm thick PVC rigid foam panel door and
shutter made from MS tubular frame of 19 G of size 19x19mm for styles and
15x15mm for top & bottom rails and covered with 5mm thick heat moulded PVC
'C' channel of size 50x30mm for styles with 5mm thick PVC sheet [width 75mm
for lock rail, bottom rail, top rail on either side]. The inner panelling should be
inserted with 5mm thick PVC sheet sealed with solvent cement adhesive to the
styles and rails with 5x25mm PVC sheet beading on either side and as per the
specification and sizes mentioned in the drawing .
All windows shall be of aluminium glazed windows with 5mm thick plain glass
and as per the specification & of sizes noted in the drawing. The fittings and
furniture shall be provided as per the specification MS grills for windows using
MS flats 25x5mm painted with one coat red oxide primer and of design approved
by the Engineer at site shall be provided inside.

485

All Ventilators are of Anodized aluminum fixed type ventilator, Zig-Zag type,
using Aluminium Box section 63x38xmmx0.85kg/m, 4mm thick machine frosted
glass, aluminium mesh fixed with aluminium beading clip
17.15x17.27x0.178kg/m, fixing rubber lining etc.

4.8 PLASTERING WITH CEMENT MORTAR :

Plastering with CM 1:5, 12 mm thick to be laid for the interior and exterior faces
of walls. Plastering with CM 1:3, 12 mm thick as shown in the drawing to be
provided.

Plastering specification laid down in IS:1661-1972 shall apply. For external
rendered finishes, the specification laid down in IS:2402-1963 shall apply.

4.8.1 PROPORTIONING :
The material used in the preparations of plastering mixer may be measured by
volume using gauge boxes.

4.8.2 QUANTITY OF WATER :

For general cement plaster work, the quantity of water required is about 70% by
weight of cement. IS:2250 1965 may be followed.

4.8.3 MIXING :
Cement and sand IS:1543-1960 shall be mixed only in the required proportion to
obtain a uniform colour. Water shall then be added to get the required
consistency for the plaster.

Mixing may be done either manually or mechanically. Hand mixing shall be
carried out on a clean, water tight platform. During mixing, the mortar shall be
heed back and forth for 10 to 15minutes, after the water is added. In machine
mixing, the mixer shall run atleast 5minutes after placing all the ingredients in the
drum.

The thickness of plaster work for single coat, both internal and external shall
12mm. For single coat plaster, the fineness modulus of sand should be as far as
possible, 1.5 and confirming to grading zone IV of IS:383-1970. Where only fine
sand is available, the fineness modulus of sand may be improved by mixing the
required percentage of coarse sand. The strength of plaster mix gets reduced
with the reduction in the fineness modulus of sand.

Should mortar crack or perish through neglect of watering or other fault of the
contractor, the work shall be removed and redone at the contractors expense or
should the contractor fail to water the work to the satisfaction of the Engineer-in-
charge of the work, the later may supply the requisite men to water the work
properly and charge the cost to the contractor.


486
4.9 COLOUR WASHING :
The outside of the walls and the entire building to be colour washed with two
coats using supercem pigments over a coat of primer. The inside of the walls to
be colour washed with two coats using Oil Bound Distemper over a coat of
primer

4.10 PAINTING :
All the wood work and M.S. grills to be painted with two coats of approved brand/
colour enamel paint. Painting has to be carried out as per the specification.
4.11 STAIR CASES
The stair-case shall be with RCC M20 mix waist slabs with flat intermediate
landing. The steps will be with brick work in cement mortar 1:5. MS hand Rails
for staircase using MS square 20x20mm and MS Pipe 40mm dia, painted with
one coat red oxide primer as per approved design and as directed by Engineer at
site, painted with one coat red oxide primer The width of flight should be as
indicated in the drawing.

4.12 DRAINS :

Suitable down-fall pipes 100mm dia of P.V.C. pipes (6kg/sq.cm) with necessary
clamps of plastic with screws of brass shall be provided and taken outside the
building up to basement level and finally connected to the outside drain.

4.13 SANITARY FITTINGS :

Lavatory shall be provided with Indian water closet of Orissa pan type and
European water closet in the places shown in the drawing. The pan of Indian
water closet set shall be of Hi-lites colour of 580x420mm size.

In order to clean the portion between the trap in the flush out latrine, and pipe,
suitable specials with eye should be provided. The cleaning of the section will be
done when necessary arises through this eye.

The plumbing shall be of best workmanship and the whole apparatus shall be
handed over in good condition after testing them to the satisfaction of the
Engineer.

The sewer connections shall be taken to the outside sewer line or to a distance
of 3metre from the outer face of the building, if the outside main sewer is not
within 3metre.

The quantities given in schedule and for drainage and sewage arrangements are
only tentative. These items of work have to be executed as per the decision and
direction of the Engineer at site according to site condition.

4.14 WATER SUPPLY :
The bath room, lavatory and the kitchen should be fitted with a 15mm C.P. brass
screw down bib cock tap connected to the PVC distribution main including

487
necessary bib-cock, collars, reducers, bends, elbows, connecting special pipe.
The rates quoted should be for the complete work including the labour for cutting,
and should be done to the entire satisfaction of the Engineer at site. The exact
size of distribution main valves and bib cock will however be decided by the
Engineer at site to suit site conditions. The quantities indicated in the schedule
for water supply items are tentative and are for tender comparison purposes All
PVC used for water supply should be of heavy duty and approved make with
necessary specials conforming to relevant I.S.S. 4985/1988 or latest editions with
working pressure 15kgf/cm
2
.

In all bathrooms, C.P. showers with shower arm 300mm ,necessary pipe line with
suitable wheel valve shall be provided.

Necessary RCC brackets have to be provided in the bathroom. Necessary floor
trap using 150mm dia brass grating to be provided as instructed by the Engineer
at site.

4.15 STEPS

Steps shall be of brickwork in CM 1:6 shall be provided wherever necessary.
ENDURA step/landing Tiles of approved colour/ design for steps set in CM
1:3,20mm thick with contrast colour shall be provided. The tread and rise of each
step shall be as indicated in the drawing.

4.16 FINISH OF THE BUILDING :

The building is to be finished to the high standard and neat in all respects as
directed by the Engineer at site.

4.17 SAMPLES FOR APPROVAL

Samples of all sanitary fittings, water supply fittings, such as bib-cocks, valves,
etc. shall be provided for the approval of the Engineer-in-charge before
installation. Sample of all furniture fittings for doors, windows, aluminium sections
for windows and joinery fittings in ventilator, cupboard, country wood shutters
shall be produced for the approval of the Engineer-in-charge before fixing.

4.18 GENERAL

The buildings shall be executed generally as per the approved drawings and
specification.

5. BORED CAST-IN-SITU CONCRETE PILES

5.1. SCOPE


488
5.1.1. This specification covers the furnishing of all materials, plant, labour,
equipment, tools and services for the complete and proper installation of
vertical concrete piles, as shown on the drawings or specified, including
all surveying and setting out necessary for correct location of piles,
furnishing everything necessary for forming working piles, test piles and
anchor piles (if required), excavations for pile cut-off of all piles to a true
plane at the elevation specified, load test of single pile and/or pile groups
designated for that purpose or as directed during the progress of the work
(unless otherwise specified) and clean-up of the working area. Contractor
shall also exhume test piles, before/after load tests, as directed by
Engineer, if so specified, for checking the quality of the pile shaft in case
of cast-in-situ piles. Contractor shall provide everything requisite and
necessary exhume the pile as instructed.

5.1.2. Access to the work areas be kept unobstructed and clear at all times so as not to
hamper the work of other trades.

5.1.3. Contractor shall, prior to submitting a proposal, acquaint himself fully in
regard to the scope of the work in accordance with the intent and
meaning of the borings and soil investigation report, where such bore hole
data and soil investigation report, are available, and drawings and
specifications, examine the premises sufficiently to compare them with the
drawings and specifications and satisfy himself as to the condition of the
site, obstructions, accessibility, etc. required in connection with the work.
Failure to comply with this requirement shall in no way relieve Contractor
of his responsibility to completely perform the work in accordance with the
specification.

5.1.4. Contractor shall on award of the contract, install test piles as directed by
Engineer and load test the same as per this specification and as directed
by Engineer. In the case of cast-in-situ piles, Engineer may direct
contractor to completely exhume some or all test piles, before or before
load testing, to examine the quality of the pile shaft. This shall be done
either by excavating around the pile or by pulling out or by a combination
of both methods.
5.1.5. If the quality of the pile shaft does not satisfy the requirements of this
specification and / or if the pile fails to attain the specified safe pile
capacity and if this can be attributed to defective workmanship and / or

489
negligence on the part of Contractor, all costs of mobilization, Installation
and testing of test piles, exhuming or test piles and any other work in
connection with the test piles shall be to the cost of Contractor.

5.1.6. In the event of test piles not satisfying the requirements of this
specification, Owner reserves the right to terminate the contract and to
award the contract to other parties.

5.1.7. The information given in the bore logs and soil investigation report, where
such bore logs and soil investigation report are available, is given to
Bidders / Contractor in good faith and Owner / Engineer will not be
responsible for any inaccuracies or discrepancies therein and shall not
entertain any claim whatsoever from Bidders / Contractor on this account.

5.1.8. Nothing contained in the contract documents shall relieve Contractor from
the responsibility of obtaining approval from Engineer for all pile
installation criteria.

5.1.9. Scope of this Specification covers bored cast in situ piles of circular cross
section. These piles shall be formed by boring to the specified depth as
shown and called for on the drawings or as directed by Engineer.
Execution on pile bore shall be any one of the methods outlined below.

a) Using percussion type of boring technique and bentonite slurry to stabilise
the hole, with temporary guide casing through unstable strata only upto a
maximum of 5m below working ground level.

b) Using Direct Mud Circulation or Reverse Mud Circulation method with
bentonite slurry as drilling mud and appropriate equipment and with
temporary guide casing through unstable strata, only upto a maximum of
5m below working ground level.

c) Using permanent rigid liners of steel or any other material approved by the
ENGINEER.

Temporary casings of length exceeding 5m below working ground level
shall not be used for forming the pile bores. Concrete piles formed shall
be free of any necking and excessive bulging. Contractor shall not
proceed with the work before obtaining instruction / clarification from the
Owner / Engineer.
5.2. APPLICABLE CODES AND SPECIFICATIONS


490
5.2.1. All applicable documents, including standards, codes, rules, laws,
regulations of regulatory bodies referred to herein shall be of latest issue
or edition and shall be considered part of this specification, except as may
otherwise be stated herein.

5.2.2. Unless otherwise stated herein and in specific technical requirements. the
design, materials and workmanship shall conform to the following
standards:

IS : 2911 : Code of practice for design and
construction of pile foundations.

a) Part I : Part I concrete piles, Section-2
(SEC.2-1979) Bored cast in situ piles.

b) Part -4-1985 : Part 4 Load test on piles

IS : 2131 1981 : Method of standard penetration
test for soils

IS : 456 2000 : Code of practice for plain
and reinforced concrete.

IS : 455 : Portland slag cement


IS : 269 1989 : Specification for ordinary, Rapid
hardening and low heat Portland cement

IS: 1489 1991 : Portland Pozzolana cement

IS:8112 1989 : High Strength ordinary Portland
cement

IS : 383 1970 : Specifications for coarse and fine
aggregates from Natural sources
for concrete

IS : 2386 1963 : Methods of Test for aggregates for
concrete

IS : 432 1982 : Specification for Mild steel and
medium Tensile steel bars and hand
drawn steel wire for concrete

491
reinforcement

IS : 1786 1985 : Specification for cold twisted
steel bars for concrete
reinforcement

IS : 3764 1992 : Safety code for excavation work


IS : 1200 1988 : Method of measurement of
building works Part-XXIII

5.3. MATERIALS

5.3.1. CONCRETE

5.3.1.1. All concrete work shall conform to IS 456 unless otherwise stated herein.
All aspects of concrete work including materials specifications, preliminary
mix designs, workability, inspection, testing etc. shall be as specified
Section D of this specification.

5.3.1.2. Cement used shall be ordinary port land cement of not less than 43 grade
conforming to I.S. 269. Where port land Pozzolana Cement is specified to be
used, only such cement which does not contain fly ash as Pozzolans, shall be
approved.

5.3.1.3. In case of piles where concrete is to be placed through tremie pipe, coarse
aggregates, as per I.S. 383, are preferable to crushed aggregates for better
workability.
5.3.1.4. Maximum size coarse aggregate shall be 20mm.

5.3.1.5 Concrete shall be M25 grade as per specification for concrete
work unless otherwise called for. Concrete, for piles in alkali
soil/ alkaline water, shall have a minimum 28 days 15cm works
cube compressive strength of 250 kg/cm
2
(25 N/mm
2
) and shall
not contain less than 400kgs. of cement per cum. of concrete in
piles.

5.3.1.6. Concrete, for piles formed in-situ, shall have sufficient slump (125 to
175m) to drop into place properly. The water-cement ratio including the
water contained in the aggregates, shall be limited to 0.5, unless

492
otherwise stipulated. Special plasticizing admixtures, if approved by
Engineer, shall be added to the concrete as per manufacturers
instructions to improve the slump, without impairing the specified strength.

5.3.1.7. Atleast one test shall be made for every 25 piles cast and not less than
one test shall be made for any one days concreting operation. Each test
shall consist of three works test cubes field cured. One cube shall be
tested at 7 days and the other two at 28 days. Records of all cube test
results shall be communicated to Engineer.

5.3.1.8. Owner reserves the right to reject piles of deficient concrete General Body
Meeting of the Society on 28.9.06 at 5.30 PM. strength. Such rejected
piles (installed or to be installed) shall be replaced by Contractor, by new
or additional piles and the cost of such replacement shall be wholly borne
by Contractor.

5.3.1.9. Engineer reserve the right to order a change in the mix or in the water-
cement ratio to obtain the specified strength and / or workability.

5.3.2. REINFORCEMENT

5.3.2.1. All reinforcement for use within the pile shaft, shall be as per drawings and
be associated and tied and or welded together and made up into cages
sufficiently rigid to withstand handling without damage and distortion.

5.3.2.2. Joints in longitudinal bars, if unavoidable, shall be made by lapping and
the laps shall be tack-welded to prevent distortion of the reinforcing cages
except for driven precast piles where they shall be butt-welded.

5.3.2.3. The projecting lengths of the longitudinal bars beyond the pile cut-off level
shall be equal to a minimum of 50 times bar diameter or such other length
as shown on drawings.
5.3.2.4. For precast driven piles, all the longitudinal bars shall be of the same
length and be fitted into the pile shoe. Shorter bars, to resist local bending
moments near the middle point of the pile or any other location, may be
added but shall be carefully arranged as sudden discontinuity of bars may
lead to cracks under heavy driving.

5.3.2.5. The lateral links / helix shall fit tightly against the longitudinal bars and be
fixed to them by welding or soft annealed 16 gauge black iron wire, the
free ends of which shall be turned into the interior of the pile.

5.3.2.6. The spacing of lateral reinforcement shall be such as to permit free flow of
concrete around it. For precast driven piles, the transition between closer

493
spacing and maximum spacing, shall be gradual over a length of three
times the diameter / side.

5.3.2.7. Concrete cover over all reinforcement including lateral links or helix, shall
be 50mm unless other wise shown on drawing. Care shall be taken to
preserve the correct over and alignment of reinforcement free from any
twist, throughout the whole operation of placing the reinforcing cage into
the bore hole and concreting the pile. The inside the dimension of the
reinforcing cage shall be adequate for operation of the tremie pipe when
used.

5.3.3. STEEL CASING
5.3.3.1. Temporary steel castings, used for driven cast-in-situ piles and for bored
piles using casings, shall be straight and shall have sufficient wall thickness
and strength to withstand without damage, distortion, etc. the handling
stresses and driving stresses set up in obtaining the specified depth and set
(in the cast of the former piles)and to resist harmful distortion of buckling
due to soil pressures developed during installation of pile or adjacent piles.
Joints shall be welded or lock
seamed. Screwed joints shall be permitted for casings for bored piles.
Casings and their joints shall be sufficiently water - tight.

5.3.3.2 Casings shall be of such diameter as to give the specified nominal
diameter of the pile. Casing lengths shall be the maximum consistent with
standard practice, transport, handling and driving facilities.

5.3.3.3 Detachable shoes used with the temporary steel casings for driven cast-
in-situ piles shall be of cast iron and for requisite strength of the standard
sizes used with the respective steel castings and the shoe shall be coaxial
with the steel casing.

5.3.3.4. Casings distorted from true and uniform shape, whether caused by driving
or earth and water pressure, resulting in a reduction of the cross
sectional area of the pile in excess of 10%, shall not be used on the work.


5.4. PILE CAPACITY, QUALITY AND TOLERANCES
5.4.1. Piles individually and in groups, installed in place, shall safely sustain the
load specified on the drawings. The capacity of the piles in place, shall be
tested by conducting routine tests as decided by Engineer on one or more
working piles. The safe load i.e pile capacity shall be assessed as defined
under Routine Tests on Working Piles herein after.


494
5.4.2. In the case of cast-in-situ piles, Contractor shall guarantee 90% of full
cross sectional area of the pile and also guarantee against occurrence of
necking or wasting, bulging, spelling of pile shaft concrete, exposure of
pile shaft reinforcement, honey combed/porous pile shaft concrete and
similar defects which will impair the strength and durability of the pile.

5.5. SETTING OUT

5.5.1. The CONTRACTOR will be furnished with one reference benchmark and
with two mutually perpendicular reference axes. The CONTRACTOR
shall locate accurately the position of piles and install stakes as directed or
as required by drawings with reference to the reference bench mark and
axes furnished. The CONTRACTOR shall make good to the satisfaction
of the ENGINEER, defective or in fructuous work arising out of error in
field layout, notwithstanding that such layout and staking may have been
checked and approved by the ENGINEER.

5.5.2. The CONTRACTOR shall check the co-ordinates of initial guide casing
or permanent liner position for each pile during and mmediately after placing
the casing on the ground prior to its
driving and confirm the same with the co-ordinates of that pile as
shown on the drawing.

5.6. CONTINUITY OF CONSTRUCTION

5.6.1. Any pile that is taken up for execution from boring to final concreting shall
be executed at a continuous stretch without interruption, stoppage of work
in between shifts will be permitted only during boring stage of the pile
execution if further boring is pending. Thereafter right from boring or
chiseling of the final portion of the length of the pile, through subsequent
activities of flushing, lowering of reinforcement cage, lowering of tremie,
preconcrete flushing and upto concreting, no halt whatsoever in the
execution of the pile will be permitted.

5.6.2. In case there is a halt of work during any of these activities except
concreting the CONTRACTOR shall take steps to bore an extended length
of further 300mm or as decided by the ENGINEER, or adopt any other
measure as decided by the ENGINEER.

5.6.3. If there is any stoppage of work during concreting, this pile shall be
abandoned altogether.
5.6.4. Cost of remedial measures and their consequences shall be borne by the
CONTRACTORs act of commission or omission.


495
5.7. BENTONITE DRILLING MUD

5.7.1. The bentonite powder shall be mixed thoroughly with clean, potable water
to make a suspension of density as specified. The temperature of the
water used and that of the bentonite fluid supplied to the pile bore shall not
be lower than 5C. where saline or chemically contaminated ground water
occurs, special precautions shall be taken as approved by the ENGINEER
to modify the bentonite suspension or pre-hydrate the bentonite with fresh,
potable water so as to render the fluid suitable for construction of piles.
The PH of the fluid shall range from 9.5 to 12. The density freshly
prepared bentonite suspension should be between 1.03 to 1.1gm/ml. The
density of the bentonite suspension after mixing with deleterious material
in the bore hole may go upto 1.25gm/ml. The marsh viscosity when
tested by a marsh cone shall be between 30 to 60 second. The
differential free swell shall be more than 540%. The bentonite
suspension fluid shall be continuously circulated and agitated using
circulating pumps to prevent deposition of suspension and coagulation.

5.7.2. The suspension fluid shall be regularly tested to ensure its suitability for
use as drilling mud. The frequency of testing the fluid and the method of
sampling shall be proposed by the CONTRACTOR for approval prior to
the commencement of the work. The frequency may subsequently be
varied as deemed necessary by the ENGINEER. These tests shall ensure
consistency of the fluid properties, after the mixing process, blending of
freshly mixed bentonite suspension and previously used betonite
suspension and any pricess which may be adopted to remove impurities
from previously used bentonite suspension.

5.8. PILE BORING:

5.8.1. Formation of pile bores:

5.8.1.1. Pile bores for bored cast in situ concrete piles shall be executed upto a
minimum depth specified in the Drawings or as modified by the
ENGINEER in writing during progress of boring. The pile shall achieve its
required capacity to take downward and upward force and horizontal
forces in combination as specified.

5.8.1.2. Pile bores shall be executed by any of the following methods:

a) using the Direct Mud Circulation or Reverse Mud Circulation
Methods with bentonite slurry as drilling Mud and appropriate
equipment.


496
b) Using percussion type of drilling and bentonite slurry to stabilize the
hole.

c) Using permanent rigid liners of steel or any other material approved
by the ENGINEER and boring through the liners

The BIDDER shall indicate along with his Bid which of the above methods
he proposes to adopt for this work. However the decision of the
ENGINEER regarding the method to be adopted for executing the bores
shall be binding on the CONTRACTOR.

5.8.1.3. Use of temporary guide casings through unstable strata is permitted only
upto a maximum of 5 m below ground level.

5.8.1.4. The CONTRACTOR shall ensure that bores formed are true to a cylindrical
shape to the extent possible and over cutting is

minimized. The CONTRACTOR shall also ensure that water cavities
behind temporary casings are altogether avoided so as to ensure quality
concrete for the pile shaft.

5.8.1.5. Boring shall not be carried out within a distance of five times the diameter
of the pile from a pile which has been freshly concreted within the past
forty-eight hours.

5.8.2. Direct mud circulation method:
5.8.2.1. The initial boring of about 1.5 m shall be done by bailer and the guide
casing shall then be lowered into the bore hole. The bore shall be filled
with bentonite slurry fed from bentonite installation.

5.8.2.2. The centre-line of the guide casing shall be checked with respect to the
reference points before proceeding with further boring. Further boring shall
proceed with the use of direct mud circulation chisel upto the founding
strata.

5.8.2.3. The chisel used to bore the hole, shall be of diameter appropriate for the
specified nominal diameter of the hole to be bored. The chisel shall be
connected to API rods of adequate diameter and thickness through which
bentonite slurry shall be pumped.

5.8.2.4. Bentonite slurry shall be pumped through the chisel rods by means of high
pressure pumps. The chisel shall have suitable ports for the bentonite
slurry to flow out at high pressure. The bentonite slurry and the cuttings,
which are carried to the surface by the rising flow of slurry shall pass

497
through a setting tank of adequate size to remove the cuttings and spoils
from the slurry before the slurry is re-circulated to the pile bore. A suitable
bentonite slurry mixing and re-circulation plant shall be designed and
installed.

5.8.3. Reverse mud circulation method

5.8.3.1. The CONTRACTOR shall adopt Reverse Mud circulation Method only
where strata encountered are such that there is no danger of loosening of
the sub-soil during the boring operations and the subsoil gradually
becomes denser and more compact with progressive depth, or where
bedrock is being penetrated at shallow depths. This methods shall be
adopted only if approved by the ENGINEER

5.8.3.2. The Method is essentially the same as the Direct Mud Circulation Method
except that the bentonite slurry shall be sucked through the chisel instead
of being pumped through it. Except for this, the specifications for Direct
Mud Circulation Method apply here also.

5.8.4. Bailer boring using bentonite slurry.
5.8.4.1. This process is essentially the same as the Mud Circulation Method
except that all boring shall be done by flap value bailer or flap valve bailer
and chisel upto the founding stratum, using bentonite slurry. Bentonite
slurry shall be allowed to flow into the guide casing through pipes or
channels, so that the guide casing is always kept filled with bentonite. The
material extracted by the bailer shall be left alongside the boring if so
directed by ENGINEER. Fresh bentonite slurry shall be allowed to flow
into the casing so that the top level of the bentonite is kept the same at all
times.

5.8.4.2. Except as modified herein above, the specification for Direct Mud
Circulation Method shall apply to Bailer Boring also.

5.8.4.3. Loss of drilling mud while boring:
In the event of a rapid loss of drilling mud in a pile bore, the
CONTRACTOR shall immediately draw the attention of the ENGINEER
and take necessary action as approved by the ENGINEER.

5.8.5 Auger boring
Augers are used cohesive and other soft soils above water table. Hand
augers are used for depths upto about 6 metres. Mechanically operated
augers are used for greater depths and they can also be used is gravelly

498
soils. Samples recovered from the soil brought up by auguers are badly
disturbed and are useful for identification purpose only.

5.8.5.1. Auger and shell boring

Cylindrical auguers and shells with cutting edge on teeth at the lower end
can be used for making deep borings. Hand operated rings are used for
depths upto 25m and the mechanical rigs upto 50m . Auguers suitable for
soft to stiff clays, shells for very stiff and hard clay and shells or sand
pumps for sandy soils, small boulders thin soft strata or rock, or cemented
gravel can be broken by chisel bits attached to drill rods. The hole usually
requires a casing.
5.8.5.2 Percussion boring

In this methods, soil and rock formation are broken by repeated blows of
heavy chisel or bit suspended by a cable or drill rod. Water is added to
the hole during boring if not already present, and the slurry of pulverised
material is bailed out at intervals.

5.8.6. Final post-bore flushing and cleaning:
On completion of the total length of the pile bore, the bore shall be
thoroughly cleaned and flushed.

5.8.6.1. If the pile bore has been executed by either of the mud circulation
methods, fresh bentonite slurry shall be pumped through the chisel resting
at the base of the bore to completely remove all currings and other loose
material from the base. During the flushing, the speed of

the bentonite circulation pump shall be raised to maintain high pressure.
Such flushing shall be continued for at least 20 minutes while occasionally
agitating the chisel. Flushing shall be continued beyond 20 minutes if the
return slurry indicates presence of cuttings still within the bore.
5.8.6.2. In case the pile bore has been executed by Bailer Boring with Bentonite
Slurry the bore shall be initially cleaned of loose material by light
tampering of the flap-valve bailer. Thereafter the bailer shall be withdrawn
and a string of AP1 rods shall be lowered up to the base of the bore and
bentonite slurry shall be pumped through under high pressures in the case
of the Mud Circulation Method. Agitation shall be effected by circular
movement of the string of rods around the pile bore. Flushing shall be thus
continued for at least 20 minutes. Flushing shall continue beyond 20
minutes till the return wash indicates that the bore is clean to the
satisfaction of the ENGINEER.


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21.8.6.3 Where permanent liners have been used, the bore shall be filled
with water that has been certified for concreting and a flap valve
bailer shall be used to remove the loose material light tamping. The
bailer shall then be withdrawn and a string of API rods shall be
lowered down to the base of the bore. The certified water shall
then be pumped through the string of rods at high speed for atleast
20 minutes. Agitation shall simultaneously be effected by a gentle
vertical movement and vigorous circular movement to the rods.
Flushing shall continue thus beyond 20 minutes till the return wash
indicates that the bore is clean to the satisfaction of the ENGINEER.
The water from within may be pumped out with approval of the
Engineer. However no pumping out shall be done if the ground water table
is above the bottom of the pile bore and/or if the subsoil around the bottom
of the pile bore is likely to be disturbed by pumping out the water.

5.9. PLACEMENT OF REINFORCEMENT CAGE:
5.9.1. Immediately after successful completion of final post-bore flushing and
cleaning, the reinforcement cage shall be lowered into the pile bore. All
care shall be taken during transporting, lifting and lowering of the cage
that the cage does not twist or distort out of alignment.

5.9.2. The cage shall be lowered into the pile bore by gravity and shall not be
forced linto the bore. Care shall be exercised that no collapse of any
portion of the unlined bore occurs while lowering. In case the total length
of the pile is such that handling of the entire length of the cage becomes
unwieldy, the cage shall be fabricated in two lengths. The location of such
jointing shall however be got approved by the ENGINEER in writing. After
the first section of the cage is lowered and held with the top of the bars
adequately outside the bore, the upper cage section shall be lifted, held
vertical and gradually lowered over the lower cage section so that the
main longitudinal reinforcement bars of the two cage sections are aligned
bar for bar. Jointing of the respective bars of the two cages shall be
effected as per Clause 5.3.2 above. The internal cage shall then be
lowered into the pile bore and into final position and held in place by slings
or suitable devices approved by the ENGINEER.

5.9.3. Longitudinal reinforcement above the ground level shall not be arbitrarily
bent for seating the concrete tremie hopper. If the reinforcement cage has
been fabricated longer than that required on the Drawing (in view of a
shorter pile bore than that envisaged earlier), the excess lengths shall be
cut. Outward flaying of the main reinforcement bars of the cage shall not
exceed 5 degrees with the vertical to avoid breaking of the bars while
rebending the reinforcement back into position after the concreting. In any
case, the internal radius of the bend shall not be less than five times the

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bar diameter. While flaying the reinforcement cage outwards, it shall be
ensured that the cover to reinforcement within the pile bore to be
concreted is maintained.

5.10 FINAL PRE-CONCRETING FLUSHING:

5.10.1 Immediately after the reinforcement cage is positioned, the concrete
tremie pipe shall be lowered into the pile bore concentrically within the
reinforcement cage, with the bottom of the tremie pipe just above the
bottom of the bore. The top of the tremie pipe shall be connected to a
high speed bentonite pump and flushing with bentonite slurry shall be
resumed. If concreting of the pile bore is to be done by concrete pump,
flushing shall be done through a string of API rods lowered into the pile
bore concentrically within the reinforcement cage with the bottom of the
string of rods just above the bottom of the pile bore.

5.10.2 The procedure for flushing shall be the same as that indicated in clause 5.8.6
above. At the end of such flushing the CONTRACTOR shall ensure that
heavy contaminated bentonie suspension, which could impair free flow of
the concrete from the tremic pipe or concrete pump trunk has not
accumulated in the bottom of the pile bore. The suspension shall be sampled
from the pile bore bottom by a suitable device approved by the ENGINEER and
the density of the suspension checked by a calibrated hydrometer. The
density of the sampled suspension shall not exceed 1.2gm/cc. In case this
value is exceeded, flushing shall be resumed as per Clause 5.8.6 till the
suspension is within the desired density range.

5.11. PILE CONCRETING

5.11.1. GENERAL
5.11.1.1. Concreting of pile bores shall be executed only through a tremle system of
concrete pump over the entire length of the pile. Tipping in of concrete
from ground level or above into the pile bore is prohibited even if the pile
bore is dry (as may perhaps be the case for pile bores with permanent
liners).

5.11.1.2. Only freshly mixed concrete shall be used. Placement of the concrete
shall be a continuous operation. The CONTRACTOR shall ensure that
concrete mixers of adequate capacity are provided at the site with
standby. If concrete pump is to be used for concreting a standby pump
shall be provided. The pile shall be abandoned if concreting operations
are suspended due to any reason by more than 20 minutes. It shall also
be ensured that there are no air pockets created within the concrete shaft.


501
5.11.2. TREMIE CONCRETING SYSTEM

5.11.2.1. Tremie pipe concreting shall be done as per IS.456 and IS:2911 (Part
I/Sec.2). The minimum diameter of the tremie pips shall be 200mm. The
steel hopper at the top of the tremie pipe shall have a volume in excess of
the total volume of the tremie pipe below. The neck of the hopper shall be
fitted with a steel plate covering the entire opening. Suitable
arrangements shall be made to remove the steel plate and uncover the
hopper neck aperture when the hopper is full of concrete. The hopper and
the entire length of the tremie pipe shall be thoroughly clean and free of
any encrusted concrete or internal protrusions such a sleeves, collars etc.
or any soil or debris. The entire tremie pipe-hopper system shall be water
tight.

5.11.2.2. After the final pre-concreting flushing has been successfully executed, the
tremie pipe shall not be extracted but shall continue to remain upto the
bottom of the pile bore. Suitable ramps or staging shall be provided to
facilitate easy and smooth feeding of the hopper with concrete either
manually or by mechanised means, The ramps of staging shall be flexible
enough to allow concrete feeding if the hopper is raised during concreting.

5.11.2.3 A sliding plug of polystyrene for similar material lighter than water and
approved by the ENGINEER shall be placed in the tremie pipe to
prevent direct contact between the first charge of concrete in the tremie
and the bentonite slurry. At the commencement of
concreting, the steel plate shall first cover the hopper neck while the
hopper iscompletely filled with concrete. The steel plate shall
then be removed and the concrete in the hopper allowed to flow
into the tremie pipe. Subsequent charges of concrete shall
be maintained as continuous as possible until the pile bore is
concreted as specified in Clause 5.11.5 below. The tremie pipe
shall at all times penetrate the concrete by minimum two meters
after placing of the concrete has commenced and shall not be
withdrawn from within the concrete until completion of concreting.
Care shall be exercised when vertical movement is imparted on the
tremie pipe to force the concrete down the tremie pipe. Such
movements shall be limited. The CONTRACTOR shall note that the
pile shall be abandoned if in the opinion of the ENGINEER, the
tremie pipe bottom has been raised above the concrete level within
the pile bore. While raising the tremie pipe, care shall be exercised
that the reinforcement cage is not disturbed from its position.

5.11.3. Concrete pump :

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5.11.3.1. If the concrete pump is used to feed the hopper of a tremie concreting
system Clause 5.11.2 shall apply.

5.11.3.2. If the concrete pump is used for placing concrete directly into the pile bore,
the trunk of the pump shall be placed upto the bottom of the pile bore
immediately after the string of AP1 rods used for final pre-concreting
flushing have been removed after successful flushing. The trunk shall at
all times penetrate the concrete after commencement of concreting by at
least two metres and shall not be withdrawn from within the concrete until
the completion of concreting. The CONTRACTOR shall note that the pile
shall be abandoned if in the opinion of the ENGINEER, the trunk has been
raised above the concrete level within the pile bore. While raising the
trunk, care shall be exercised that the reinforcement cage is not disturbed
from its position.

5.11.4. Lifting of temporary casing :
5.11.4.1. The temporary casing shall be carefully withdrawn only after the concrete
surface in the pile bore has risen to not less than three metres above the
bottom of the casing or not less than one metre above the level of ground
water whichever is higher. The casing shall be lifted only to the extent that
there is minimum one metre of concrete above the casing bottom. The
level of concrete shall be checked vis a vis the casing bottom and ground
water level by suitable methods as approved by the ENGINEER.

5.11.4.2 While withdrawing the temporary casing, care shall be exercised that
the reinforcement cage is not pulled out along with the casing. It shall also
be ensured that no voids or ground water pockets are formed around the
pile shaft during withdrawal. Adequate precautions shall be exercised to
ensure that the concrete is not lifted up along with the casing and that
no necking or waisting
occurs in the pile shaft. Special care shall be exercised when the
ground water level is high. During withdrawal, the movement of
the temporary casing shall be maintained in an axial direction
relative to the pile.

5.11.5. Completion of concreting:
Irrespective of the specified pile cut-off level, concrete shall be poured into
the pile bore until all the contaminated concrete at the top of the bore
overflows the top of the pile bore and beat concrete appears continuously
as overflow. Concreting shall then be terminated after permission of the
ENGINEER.

5.11 PILE CUT OFF AND EXTENSION :


503
5.12.1. Excavation for pile cut-off shall be done by the CONTRACTOR unless
indicated otherwise in Data Sheet A. The extent of excavation shall not
exceed the minimum necessary for the required pile cut-off. The
CONTRACTOR shall provide adequate side slopes / shoring at no extra
cost to the OWNER. In order to provide safe working space for pile cut-
off, Excavated material shall not be stacked near the edge of any
excavation. The material shall be stacked at spots designated by the
OWNER near the excavation within the plant limits at no extra cost to the
OWNER. Dewatering if required, will not be paid separately.

5.12.2. Pile cut-off to specified levels shown on the Drawing shall be done
by the CONTRACTOR for all piles at no extra cost. The
CONTRACTOR shall station an adequate work force at site for the same.

5.12.3. When cutting off and trimming piles to the specified cut-off level, the
contractor shall take care to avoid shattering or otherwise damaging the
rest of the pile. Any cracked or defective concrete shall be cut away and
the pile repaired in an approved manner to provide a full and sound
section at the cut-off level.

5.12.4. Minimum chipping of the pile shall be 600 mm or till sound concrete is met
with or specified cut-off level, whichever is greater. While chipping the
concrete, care shall be taken to ensure that the reinforcement is not
damaged in any way. If the reinforcement is damaged while chipping or
bending back, the CONTRACTOR shall rectify the same as directed by
the ENGINEER at no extra cost to the OWNER. If the specified cut-off
level is less than 600 mm below the ground level (which is the concrete
overflow level after all temporary casings are withdrawn) or if the cutoff
level is above the ground level, the concrete shaft shall be chipped by
minimum 600mm or till sound concrete is met with, whichever is greater.
Thereafter, if found necessary, additional reinforcement shall be jointed
as specified earlier in Clause 5.3.2 above. The pile shall then built up to
the specified cut-off level using suitable circular formwork & concrete of
grade specified for the pile shaft.

5.12.5 If due to any defective concreting, honey-combing, exposure of
reinforcement, snapping of reinforcement bars etc., stripping of pile
concrete is required to be done to a level lower than the specified cut-off
level to obtain dense and sound concrete, the pile shall be built up with the
good concrete of specified grade for the pile shaft upto the specified cut
off level by the CONTRACTOR at no extra cost to the OWNER. Such
building up including excavation, concreting, form work and compacted
backfiring shall be at CONTRACTORs cost.


504
5.12.6. On completing pile cut-off for any pile, all exposed reinforcement surface
shall be coated with cement wash at no extra cost to the OWNER.

5.12.7. The CONTRACTOR shall backfill all excavation done by him for pile cut-
off to levels specified by the ENGINEER or as shown on the Drawing,
These levels shall be lower that or at least equal to the original working
level.

5.12.8. Any over-excavation and backfilling of the same with consolidation shall
be at no extra cost to the OWNER.

5.13. TOLERANCES;

5.13.1. Positional:

5.13.1.1. For a pile cut off at or above ground level, the maximum permitted deviation
of the pile centre from the centre-point shown on the Drawing shall be 75 mm
in any direction. An additional tolerance for the pile head, cut off below ground
level will be permitted as below.

5.13.2. Vertical:
Tolerance of verticality shall be with in 1 in 75 for the completed pile
shaft.

5.13.3. Rake:
The equipment governing alignment of the inclined permanent casing and
boring tool shall be set to give the correct alignment of the pile to within a
tolerance of 1 in 50.

The maximum deviation of the finished pile from the specified rake shall
be 1 in 25 for piles raking up to 1:6 and 1 in 15 for piles raking more than
1:6.
5.13.4. Corrective measures:

5.13.4.1. No forcible corrections to piles to overcome errors of position or alignment
shall be attempted.

5.13.4.2 If after excavation for pile cut off, any pile or piles are found to
exceed the specified positional and/or alignment tolerances, these shall
be replaced or supplemented by the CONTRACTOR by additional pile(s) as
directed by the ENGINEER at no extra cost to the OWNER. Also if as a
result of pile(s) exceeding the specified permissible positional deviations,
and/or the consequent addition of any replacement pile(s), any pile cap is

505
required to be enlarged, the extra cost of such pile cap enlargement
shall be to the CONTRACTORs account.

5.14 ABANDONED PILE BORES AND REJECTED PILES :

5.14.1 Abandoned pile bores shall be filled with sand which constitutes fine
aggregate used for making concrete. If a permanent liner has already
been driven, the same shall be withdrawn progressively as the sand is
poured in. However no attempts shall be made to extract the liner if, in
the opinion of the ENGINEER, this can damage or set out of alignment
any other pile in the vicinity.

5.14.2. No attempt shall be made to forcibly extract a rejected pile shaft. Rejected
piles shall be cut off as directed by the ENGINEER. The CONTRACTOR
shall install replacement pile or piles in lieu of rejected piles as directed by
the ENGINEER.

5.14.3. Piles / casing / borings that are defective or exceed the tolerance
specified, shall be left in place or pulled out as directed by the Engineer,
without adversely affecting the performance of adjacent piles. In case
piles/casings can not be extracted, that shall be cut off as directed by the
Engineer.

5.14.4. The CONTRACTOR shall not be paid any additional amount for filling up
abandoned pile bores or cutting off rejected piles, provision of extra piles,
enlargement of pile cap etc., necessitated due to faulty work of the
CONRACTOR, filling of voids, etc.

5.15. PILE CAPACITIES :

5.15.1. Safe structural capacity of the pile shall be taken as the load calculated on
the basis of permissible concrete stresses and permissible steel stresses
as per IS : 456.

5.15.2. The total load carrying capacity shall be determined by conducting initial
load tests on piles installed to full length.

5.15.3. Pile load tests on both initial piles as well as working piles shall be carried
out to establish and prove these capacities.

5.16. PILE LOAD TESTS :

5.16.1. General :


506
5.16.1.1 Any number of test piles and working piles as specified in the schedule of
items or at the discretion of the ENGINEER shall be subjected to load
tests. The CONTRACTOR shall provide everything, necessary including
equipment, measuring devices, jacks, structural framework, kentledges
etc. This includes installation of test piles also and concreting of pile cap
either temporary or permanent over single or group of piles for testing
the piles. The pile cap concreting will not be paid for separately.

5.16.1.2 Load tests shall in general be carried out as per IS : 2911 (Part-4) except
as modified herein or directed otherwsie by the ENGINEER.

5.16.1.3. Piles to be load tested shall either be so designated on the Drawings or
specified / selected by ENGINEER in the field.

5.16.1.4. Test load shall be applied to the piles by any suitable means preferably by
a properly calibrated hydraulic jack with a remote control pump. Test load
applied to the piles shall be such that a constant load is maintained under
increasing settlement.

5.16.1.5. The required reaction may be derived from either a loaded platform or
anchor piles. Anchor piles shall not be closer than 6 times the pile
diameter on either side. Working piles shall not be used anchor piles.
Anchor piles, if provided, shall be at CONTRACTORS cost.

5.16.1.6. Load tests shall in general be carried out not earlier than 28 days from the
time of casting the pile and may be performed concurrently with the pile
installation operations if permitted by the ENGINEER.

5.16.1.7. The design and arrangement of application of loading etc. for all types of
load tests, shall be submitted by the CONTRACTOR to the ENGINEER for
his approval.

5.16.1.8. All load tests shall be conducted under the supervision of the ENGINEER.
All responsibilities for conducting the tests safely and properly shall rest
with the CONTRACTOR.

5.16.1.9. Arrangements shall be made to cast the test piles and conduct initial load
test on the same. On conformation of load test results, further testing of
piles shall be done.

5.16.1.10 Calibration of equipment

The CONTRACTOR shall ensure, that all the equipment / instruments are
properly calibrated, at the start of the tests, to reflect the correct values. If

507
so demanded by the ENGINEER, the CONTRACTOR shall have all or
such specific instruments tests at an approved testing laboratory at the
CONTRACTORS cost and the test report shall be submitted to the
ENGINEER. If the ENGINEER desires to witness / inspect such tests, the
CONTRACTOR shall arrange for this and also provide such access and
facilities for inspection as are required.

5.16.2 Initial load tests
5.16.2.1 Immediately on mobilisation to site, the CONTRACTOR shall prepare to
install piles for conducting initial vertical load (downward and pull-out) tests.

5.16.2.2 In case the cut off is below ground level, a suitable excavation shall be made
to provide access to the level after breaking off the unsound concrete as
specified earlier in Clause 5.12.

5.16.2.3 For the compression type of test, the pile head shall be cut off level and
capped by a R.C. cap to provide a horizontal plane bearing surface upon
which a steel plate shall be placed. Earth from under the pile cap shall be
scooped out so that pile cap has no soil support. Thereafter, the kentledge
and all other accessories outside the pit pertaining to and necessary for
conducting the test shall be set up. An easy access to the pile test head shall
be provided.

5.16.2.4 If the pile test head is below the ground water level, the CONTRACTOR shall
provide suitable sumps and dewater the pit so as to render the pit dry enough
to enable conducting the test. Any dewatering will be considered as part of
the test and the CONTRACTOR shall not be separately paid for the same.

5.16.2.5 The test load shall be so applied that it reaches the pile in a static manner.
The loading may be applied directly by kentledge or jacking against a reaction
system provided by means of kentledge, tension piles or ground anchors.
Where kentledge is used it shall be supported on a properly designed frame
or gantry such that there is no possibility of the load tilting or collapsing. The
foundations of this frame or gantry should be sufficiently far way from the test
pile so as not to affect its behaviour to any significant extent. Where tension
piles or ground anchors are used, they shall be located a minimum distance
of three times the test pile size from the centre of the test pile to the centre of
the pile / anchor.

5.16.2.6 The displacement of the test pile shall be related to a fixed datum. This may
consist of a reference beam (datum bar) supported by two foundations
positioned outside the zones of influence of the reactions support area.
The deflection measuring equipment must be set up in such a way that
any tilting of the test pile will not cause errors in the measurements.

508
Dial gauges shall be used for measuring deflection. The least count of the
dial gauges shall be at least 0.01mm. At least two but preferably four dial
gauges shall be used and shall be placed at diagonally opposite
corners.

5.16.2.7 The reference bars for the strain gauges shall be adequately rigid and on firm
supports. The supports for the reference bars shall be so located that they
are beyond the zone of influence of the loaded test pile (equal to three times
the pile size from pile edge) and the zone of influence of kentledge supports.
The bars shall be adequately stiffened and placed on supports in a manner
such that any effect due to ambient temperature variations and vibrations due
to traffic etc. are minimised. The reference bars and strain gauges shall not
be exposed to direct sun and the pit shall be protected by tarpaulin sheets
while the test is in progress.

5.16.2.8 The total test load shall be three (3) times the estimated safe load-carrying
capacity of the pile. Percentage of the above load shall be applied in equal
increments of 20 percent of the estimated safe load. Unloading may however
be in higher decrements with total number not less than five. At each load
increment, pile deflection shall be observed accurate to 0.02mm at an interval
of 2, 4, 8, 15, 30,60 and 120 minutes as the case may be upto a time when
the rate of deflection of the pile top reduces to 0.1mm in first half an hour or
0.2mm in one hour or till 2hours whichever occurs first. The load increment in
any case shall be maintained for 1 hour atleast. The design load as well as
the final load shall be maintained for 24 hours. At these load increments, after
the first hour, deflection readings shall be taken at every one hour interval.

5.16.2.9 During the release stage, each load decrement shall be maintained at least for
30 minutes & readings of deflection noted. When the load is fully released to
zero, measurements of rebound shall be continued till the deflection of the pile
top is not more than 0.1mm per half hour.

5.16.3. If the initial test pile (s) which is (are) load tested fails (fall) to attain the
specified safe structural capacity of piles and if this can be attributed to
defective workmanship and / or negligence on the part of the CONTRACTOR,
the OWNER reserves the right to terminate the contract and to award the
contract to other parties. In such an event, all costs of mobilization, installation
and testing of test pile(s) and any other work in connection with the test piles,
shall be borne entirely by the CONTRACTOR.

5.16.3.1. While executing the pile bore for all test piles, a record of bore log and
Standard Penetration Tests shall be maintained over the continuous length of
boring in an approved format. Sub soil samples and rock cuttings shall be
collected and systematically preserved. A complete log of the sub surface

509
profile shall be maintained during execution of boring for each and every pile
shaft and a copy of such log shall be maintained to the owner for scrutiny prior
to commencement of lowering of reinforcement cage

5.17. Load tests on working piles :

5.17.1. These tests shall be carried out on poles selected by the ENGINEER after
they have been cast. Tests to be carried out on working piles shall
essentially be ordinary compression type. The test will be similar to that
conducted on initial test piles, except that the capacity of the pile shall be
limited to 1.5 times the safe pile capacity, the maximum settlement during
test loading not exceeding 12mm.

5.17.2 The working pile shall be considered to have stood the test satisfactorily
if total settlement under final test load is not more than 12 mm and as stated
in IS 2911 Part IV.

5.17.3. If the pile does not satisfy these requirements and if this can be attributed
to defective workmanship or negligence on the part of CONTRACTOR, all
costs of the load test, the cost of providing and installing additional piles,
cost of additional or enlarged pile caps and other work necessitated
because of the defective pile, shall be at the cost of CONTRACTOR.

5.17.4 Records of load test results:

Within 48 hours of completion of each test, the CONTRACTOR shall
furnish a copy of all recorded test data to the ENGINEER. Upon
completion of pile load tests, the CONTRACTOR shall furnish the
ENGINEER at no extra cost with a pile test report in triplicate and this shall
include the following information where applicable.

(a) Identification of working pile/test as per Drawing.

(b) Co-ordinate axes of pile, elevation of bottom of pile, cut-off
Level of pile, type of pile, pile size.

(c) Pile Bore log Records.

(d) SPT Results

(e) Deviation from designated location / alignment.

(f) Jack gauge calibration curves from approved Test House.


510
(g) Tabulation of loads and settlement readings during the loading and
unloading of the pile.

(h) Graphic representations of the test results in the form of time-load-
settlement curves.
(i) Graphic analysis of Initial Cyclic test results to separate skin friction
and end bearing as set out in IS : 2911 (Part-IV)

(j) Remarks concerning any unusual occurrences during installation or
test loading of the working piles / test piles.

5.18 INDIRECT INTEGRITY TESTS FOR PILES

The ENGINEER may desire to get bored cast in situ piles subject to
integrity tests by indirect methods through another agency. The
CONTRACTOR shall give all cooperation in getting such tests
conducted. The ENGINEER reserves the right to give due weightage and
consideration to results of these tests which will affect the integrity of the
installed piles.

5.19. INSTALLATION RECORDS :

5.19.1. The CONTRACTOR shall submit each working day, detailed pile
installation records in duplicate for each pile installed in the enclosed
formats. The ENGINEERS piling plans will show all piles serially
numbered as per the piling layout plans. The cost of all labour, materials
and services called for herein shall be included in the CONTRACTORs
unit rates.

5.19.2 The details of the record shall include but not be limited to the list below :

PILE INSTALLATION RECORD :
A. Basic data :

1. Piling Layout Drawing No.

2. Pile Number

3. Location Co-ordinates

4. System / Structure


511
5. Pile Location vis-a vis Pile Group (Draw dimensioned sketch with
reference axes and shade the pile)

6. Pile Type : Vertical / Raker

7. Pile Nominal Diameter

8. Pile Tip Elevation

9. Pile Cut-off Elevation

10. Ground Level at Pile Location.

11. Grade of Concrete Specified

12. Reinforcement Details (Draw sketch if complex)

13. Safe Capacity of Pile Specified.

B. Pile bore data :

1. Date and Time of Start

2. Date and Time of Completion

3. Method of Boring

4. Inner Nominal Diameter of Temporary Casing / Permanent Liner

5. Length of Temporary Casing / Permanent Liner

6. Material of Permanent Liner.

7. Method of Jointing Temporary Casing / Permanent Liner

8. Treatment to Permanent Liner

9. Length Bored in Soil

10. Length Bored in Rock

11. Bore Log (Draw sketch or refer to separate sheet)

12. Details of Standard Penetration Test

512

13. Number of Subsoil Samples / Rock cuttings collected.

14. Ground Water Elevation

15. Any Artesian Conditions

16. Any Bore Collapse and Details

17. Any Loss of Drilling Mud and Details

18. Any other Details or Phenomena Observed.

C. Flushing Record :

1. Date and Time of Start of Final Post-bore Flushing.

2. Date and Time of Completion of Final Post-bore Flushing.

3. Remarks on inspection of Wash of Post-bore Flushing.

4. Date and Time of Start of Final Pre-concreting Flushing.

5. Date and Time of completion of Final Pre-concreting Flushing.

6. Remarks on Inspection of Wash of Pre-concreting Flushing.

D. Concreting Record :

: 1. Date and Time of Start of Concreting.

l 2. Date and Time of Completion of Concreting.

3. Grade of Cement and Name of Manufacturer

4. Date of Manufacture of Cement

. 5. Date of Concrete as mixed

.. 6. Grade of Concrete Specified

. 7. Slump of Mixed Concrete at pile Head

. 8. Cube-Test Results

513

._ 9. Method of Concrete Placement in Pile Bore.

. 10. Theoretical Volume of Concrete :
.: (Pile Tip to Top Pile as Cast)
.l 11. Actual Volume of Concrete : (Pile Tip to Top of Pile as Cast)

. 12. Ratio of Actual Volume to Theoretical Volume of Concrete :
. (Express as Percentage)

13. Any Delays during Concreting and Reasons.

. 14. Overflow Quantity

15. Any other details

5.20. CLEAN-UP :
5.20.1. All throughout the work, the CONTRACTOR shall take all steps to prevent
spillage of bentonite slurry on the site in areas outside the immediate
vicinity of boring. The slurry shall not be allowed to flow into any water
courses, nallahs, site drains or any public drains.

5.20.2. Any discarded and / or used bentonite shall be removed from the site
without any undue delay.

5.20.3. Upon completion of piling work, all casings, equipment, construction tools,
protective coverings and any debris resulting from the work shall be
removed from the premises.

5.20.4. All debris, empty containers, scrap timber etc. shall be removed as
directed by the ENGINEER / OWNER.

5.20.5. Exposed and finished concrete and dowel surfaces shall be left in a clean
condition satisfactory to the ENGINEER.
***







514

SECTION- VI

PRICE SCHEDULES







































515
ABSTRACT OF PRICE SCHEDULE



Sl.No.

Description

Amount
1 Supply of materials/Equipments from
offshore Schedule A1
In convertible currency
2 Supply of materials/equipments
Schedule from within the Purchaser
country A2
In Indian Rupees
3 Erection, Testing and Commissioning -
Schedule - A3
In Indian Rupees
4 Civil Works - Schedule - A4 In Indian Rupees
5 TOTAL COST OF THE PROJECT A1to A4 In Indian Rupees and in
convertible currency

( In words )

SIGNATURE OF CONTRACTOR

WITH COMPANY SEAL


516
Schedule A1
PRICE SCHEDULE for imported items
Sl.
No

Description Qty
CIF price in
respect of
Imported
goods
Gross import
duties/other
levies at
existing rates
(percentage
& amount)
Transport to
site/stores and
unloading,
handling charges
at Chennai port
for imported
items
Inland
insurance for
transit and 90
days storage
Total

Unit rate Unit rate Unit rate Unit rate
1 230 KV indoor GIS line bays with
all equipments
5 Nos

2 230 KV indoor GIS transformer
bays with all equipments
6 Nos

3 Indoor bus bar VTs and busbar
earthing switches etc.,
4 sets

4 GIS Accessories (230KV) As per
spec

5 Mandatory spares for 230KV GIS As per
spec

6 Tools & Tackles for maintenance of
GIS
As per
spec

7 123KV indoor GIS line bays with all
equipments
7 nos

8 123 KV indoor GIS transformer
bays with all equipments
3 Nos

9 Indoor bus bar VTs and busbar
earthing switches etc.,
5 sets

10 GIS Accessories (123 KV) As per
spec

11 Mandatory spares for 123 KV GIS As per
spec

12 110 KV indoor GIS terminations 9 nos


517
suitable for 630 sqmm aluminium
XLPE cable
13 110 KV outdoor terminations
suitable for 630 sqmm aluminium
XLPE cable
9 nos


SIGNATURE.
DESIGNATION..
COMPANY SEAL..
COMPANY.
DATE





















518
SCHEDULE A2

PRICE SCHEDULE for Indegeneous items

Sl.
No
Description Qty. Unit Ex-
works
Price

Unit Excise
Duty
And Cess on
E.D. in % and
amount
Unit Sales
Tax/VAT
in % and
amount
Unit Freight
& Insurance
charges

Unit FOR(D)
All inclusive
Price.
Total All inclusive F.O.R.
(D) Price inclusive of
E.D. Cess on E.D., S.T.
/VAT & F&I Charges

01
100 MVA
230/110 KV Auto
transformers
3
Nos.

02 Relay panel for
230 KV feeders
5 Nos
03 Relay Panel for
230 KV
Transformer
6
Nos.

04 Relay Panel for
110 kv feeders
7 nos
05 Relay panels for
110 KV
Transformer LV
3 nos
06 Bus bar
protection for 230
KV
1 no
07 Bus bar
protection for
110KV
1 no.
08 Synchronizing
bracket for
230KV
1 no
09 Synchronizing
bracket for
1 no.

519
110KV
10 SCADA for local
automation. SAS
1 lot
(as
per
spec)

11 A.C. Panel

1 No
12 DC panel 1 No.
13 220Volts, 535AH
Lead acid station
type Battery with
stand,hydrometer
& Voltmeter
02
Nos


14 Float cum
Booster charger
with change over
switch for 220V
535 AH battery
03
Nos

15 Multistrand
armoured copper
Control cables
including
adequate cable
glands and LT
power cables
LOT
16 Earthing system LOT
17 Fire fighting
system
LOT
18 EOT crane 5 MT 2 Nos
19 Air conditioning
system
lot

520
20 25 kva / 35A /
415V DG SET
with battery
2 nos
21 11KV/433V 250
KVA Station
Transformer with
RMU
1 No.
22 Illumination lot
23 Other misc items lot


SIGNATURE OF CONTRACTOR

WITH COMPANY SEAL




















521
SCHEDULE A3
CHARGES FOR ERECTION, TESTING & COMMISSIONING OF EQUIPMENTS

Sl.
No.
Description Qty.
Rate Per unit

service tax in
percentage &
amount
Total Amount
1 230 KV indoor GIS line bays with all
equipments
5 Nos
2 230 KV indoor GIS transformer bays with all
equipments
6 Nos
3 230KV bus bar VTs and busbar earthing
switches etc.,
4 sets
4 123KV indoor GIS line bays with all
equipments
7 nos
5 123 KV indoor GIS transformer bays with all
equipments
3 Nos
6 123 KV bus bar VTs and busbar earthing
switches etc.,
5 sets
7 110 KV indoor GIS terminations suitable for 630
sqmm aluminium XLPE cable
9 nos
8 110 KV outdoor terminations suitable for 630
sqmm aluminium XLPE cable
9 nos
9 100 MVA 230/110 KV Auto transformers 3 Nos.
10 Relay panel for 230 KV feeders 5 Nos
11 Relay Panel for 230 KV Transformer 6 Nos.
12 Relay Panel for 110 kv feeders 7 nos
13 Relay panel for 110 KV Transformer LV 3 nos
14 Bus bar protection for 230 KV 1 no
15 Bus bar protection for 110KV 1 no.
16 Synchronizing bracket for 230KV 1 no
17 Synchronizing bracket for 110KV 1 no.

522
18 SCADA for local automation. 1 no
19 A.C. Panel 1 No
20 DC panel 1 No.
21 220Volts, 535AH Lead acid station type Battery
with stand, Hydrometer & Voltmeter
02Nos


22 Float cum Booster Battery charger with change
over switch for 220v 535 AH battery
03Nos
23 Multistrand armoured copper Control cables
including adequate cable glands and LT power
cables
LOT
24 Earthing system LOT
25 Fire fighting system LOT
26 EOT crane 5 MT 2 Nos
27 Air conditioning system LOT
28 25 kva / 35A / 415V DG SET with battery 2 nos
29 11KV/433V 250 KVA Station Transformer with
RMU
1 No
30 Illumination lot
31 Other misc items lot

SIGNATURE OF CONTRACTOR











523

Break up details of prices. Customs duties & other levies, transport, insurance charges etc. payable for imported supplies.

FOB Cost
Port of
loading
CIF cost
port of
entry
Ocean
freight
charges
Marine
insuranc
e
charges
Customs
duties & other
levies (with
break up for
each
duty/levy)
Local taxes/
Levies if any
Handling at
Madras port,
Inland transport
and unloading
charges at stores
at Chennai
Inland transit &
storage Insurance
charges
Sl.No Description
p.u Total p.u. Total p.u.
Total
p.u.
Total
Rate(%)
p.u.Total
Rate (%)
p.u.Total
p.u. Total p.u. Total













COMPANY SEAL
SIGNATURE ..
DESIGNATION
COMPANY ...
DATE ..




524




SCHEDULE A4

SCHEDULE FOR CIVIL WORKS



























525
NAME OF WORK:- Construction of 230/110KV GIS SUB STATION cum office building Ground floor + Four Floor at Guindy Industrial
Estate Guindy Chennai - 600 032.

A B S T R A C T

SNo QUANTITY
DESCRIPTION OF WORK
RATE Service
tax
PER AMOUNT
Design of control room and office building including all
structural elements and analysis as per specification and
submission of drawings for execution all as per specification
and as directed by the Engineer.

1 Dismantling the RCC, PCC and Brick Masonry in cm any
met with during excavation for foundation trenches and
clearing the debris from site including all labour charges, T &
Ps etc., compete.

a 50.00 m3
Dismantling the RCC.
1 m3



b 50.00 m3
Dismantling the PCC.
1 m3



c 50.00 m3
Dismantling the Brick Masonry in cm
1 m3
2 1.00 Ope Mobilization of pilling equipments and all other accessories
for bored cost in situ piles
1 Ope
3 Installation of 600mm dia., vertical bored cast in situ piles of
length 6mts from cut off level using M30 concrete with
400Kg/m3 minimum cement content using 20mm HBG as
per ISS including providing temporary casing pipes, using
drilling mud circulation ( bentonite slurry of suitable
consistent ) for stabilizing the sides of bores and concreting
the piles shall be done through tremie pipe including water
arrangements etc., complete. (excluding reinforcement)

a 2270.00 m
Bored casting situ piles
1 m
b 50.00 m Same as item 3., but further depth of over 6mts 1 m
c 50.00 m Same as item 3., but for depth under 6mts 1 m
d 455.00 m
Empty boring in earth from GL to cut off level
1 m

526
4 1.00 Ope Demobilization of piling equipments and all other
accessories after completion of work.
1 Ope
5 1.00 Test Conducting initial load test of a single pile under initial load of
110 MT (2.5 X 44 = 110) tonne - factor of safety 2.5 as per
ISS 2911, Part-IV and other relevant codes inclusive of all
charges for extension or cutting of piles that may be
necessary, erecting loading platform, loading and unloading
the loads hire & transportation charges as directed by
Engineer at site for conducting the test, retaining the test
load load for 24 hours at 100% capacity, Testing equipments
and test certificates and calibration chart for pressure gauge
produced to the Executive Engineer before commencing day
of the test, calibration of pressure gauge must be done
before taking the load test. Testing equipments shall be got
tested at contractor's cost and test gauge must be done
taking up the 1st load including the cost of all materials,
lead, lift, labour, T&P etc complete
1 Test
6 3500.00 m3 Earth work excavation for foundation in soil with initial lead
of 10m and initial lift of 2m in Hard stiff clay, stiff black cotton,
hard red earth, shales, murram, gravel, stoney earth and
earth mixed with small size boulders including all materials
labour, T&Ps etc., complete.
1 m3
7 730.00 m3 Supplying and filling in foundation and basement with filling
Sand in layers of not more than 15 cm thick well rammed,
watered and compacted complete, as per standard
specification
1 m3
8 700.00 m3 Back filling with excavated earth wherever required
including labour for filling, watering and consolidating with all
lead, lift, etc, as per standard specification.
1 m3
9 2800.00 m3 Transporting the excavated earth and debris away from
site to a lead of 10Kms including cost of conveyance, loading
and unloading etc., complete, as per direction
1 m3
10 1500.00 m2 Applying Antitermite treatment to the foundation and
basement of the building as per standard specification of
different stages including cost of chemicals, lead, lift and
labour etc., complete as per direction of Engineer.
1 m2

527
11 295.00 m3 Laying plain cement concrete 1:4:8. using 40mm HBG
(machine broken) for foundation leveling course including
cost of all materials, lead, lift and labour complete as per
std.specification
1 m3
12 45.00 m3 Laying PCC1:3:6. using 12 to 20mm HBG (MB) for
TRANSFORMER PLINTH including cost of all materials,
lead, lift and labour complete as per std.specification.
1 m3
13 275.00 m3 Laying plain cement concrete 1:2:4. using 12 to 20mm
HBG (machine broken) for foundation leveling course
including cost of all materials, lead, lift and labour complete
as per std.specification
1 m3
14 Laying RCC in M30 design mix using 20mm to 12mm down
graded metal and 400Kg/m3 minimum cement content for
various types of work for pile cap and grade beam. Etc.,
including chipping the piles up to cut off level, shuttering,
strutting, cost of all materials, complete. (excluding
reinforcement)

a 720.00 m3
PILE CAP
1 m3



b 35.00 m3
GRADE BEAM
1 m3



c 95.00 m3 BASE CONCRETE / RAFT 1 m3



d 75.00 m3 COLUMN FOOTING & FOUNDATION 1 m3



e 15.00 m3 COLUMNS 1 m3



f 135.00 m3 SIDE WALL 1 m3



g 80.00 m3 COVER SLAB (DUCT) CAST-IN-SITU 1 m3
h 2.00 m3 STAIRCASE WAIST AND LANDING SLAB 1 m3

528
15 Laying reinforced cement concrete in M30 grade mix using
12 to 20mm down graded metal and 400kg of minimum
cement content for various types of works above GROUND
FLOOR to FOUTH FLOOR & HEAD ROOM with necessary
centering, strutting, form box vibrating, water arrangements,
including fixing of insert plate wherever necessary with all
materials and labour etc.,complete as per standard
specification [excluding cost of reinforcement & insert plate].

I GROUND FLOOR
a 106.00 m3 COLUMN 1 m3



b 3.50 m3 STAIRCASE WAIST AND LANDING SLAB 1 m3



c 120.00 m3 BEAM 1 m3



d 185.00 m3 ROOF SLAB 200mm thick 1 m3
II FIRST FLOOR
a 67.00 m3 COLUMN 1 m3



b 4.00 m3 STAIRCASE WAIST AND LANDING SLAB 1 m3



c 62.00 m3 BEAM 1 m3



d 47.00 m3 ROOF SLAB 150mm thick 1 m3



III SECOND FLOOR
a 46.00 m3 COLUMN 1 m3



b 4.00 m3 STAIRCASE WAIST AND LANDING SLAB 1 m3



c 62.00 m3 BEAM 1 m3



d 47.00 m3 ROOF SLAB 150mm thick 1 m3



IV THIRD FLOOR
a 46.00 m3 COLUMN 1 m3




529
b 3.50 m3 STAIRCASE WAIST AND LANDING SLAB 1 m3



c 65.00 m3 BEAM 1 m3



d 134.00 m3 ROOF SLAB 150mm thick 1 m3



V FOURTH FLOOR
a 46.00 m3 COLUMN 1 m3



b 3.50 m3 STAIRCASE WAIST AND LANDING SLAB 1 m3



c 65.00 m3 BEAM 1 m3



d 134.00 m3 ROOF SLAB 150mm thick 1 m3



VI HEAD ROOM
a 7.00 m3 COLUMN 1 m3



b 7.00 m3 BEAM 1 m3



c 14.00 m3 ROOF SLAB 150mm thick 1 m3
16 Laying reinforced cement concrete in M20 grade mix using
12 to 20mm down graded metal and 300kg of minimum
cement content for various types of works above GROUND
FLOOR to FOUTH FLOOR & HEAD ROOM with necessary
centering, strutting, shuttering, form box vibrating, water
arrangements etc., with all materials and labour complete as
per standard specification [excluding cost of reinforcement].

I GOUND FLOOR
a 8.50 m3 LINTEL & SILL BEAM 1 m3

b 3.00 m3 SUNSHADE & LOFT 1 m3



II FIRST FLOOR
a 9.00 m3 LINTEL & SILL BEAM 1 m3

b 5.00 m3 SUNSHADE & LOFT 1 m3

530



III SECOND FLOOR
a 9.00 m3 LINTEL & SILL BEAM 1 m3

b 5.00 m3 SUNSHADE & LOFT 1 m3



IV THIRD FLOOR
a 9.00 m3 LINTEL & SILL BEAM 1 m3

b 5.00 m3 SUNSHADE & LOFT 1 m3



V FOURTH FLOOR
a 10.00 m3 LINTEL & SILL BEAM 1 m3

b 9.00 m3 SUNSHADE & LOFT 1 m3



VI HEAD ROOM
a 0.50 m3 LINTEL & SILL BEAM 1 m3

17 14.00 m3 Laying reinforced cement concrete in 1:4:8, mix using 12 to
20mm down graded metal for DUMMY COLUMN of works
in FIFTH FLOOR & HEAD ROOM with necessary centering,
strutting, form box vibrating, water arrangements etc., with all
materials and labour complete as per standard specification
[excluding cost of reinforcement].
1 m3
18 20.00 m3 Providing precast RCC cover slabs in M20 grade mix of
various sizes and thickness using 12 to 20mm down graded
HBG (MB) including cost of all materials, formbox, casting,
curing, stocking, transporting in position with all lead, lift, neat
finish, etc., as per standard specification (excluding cost of
reinforcement).
1 m3
19 592.00 MT Supply, fabrication and placing in position of MS / RTS / TMT
grills for reinforced cement concrete works including cost of
steel, binding wire, labour, lead, lift, etc., complete.
1 MT
20 Building Brick Masonry in cm 1:6. using Fly Ash bricks
230x110x70mm at all levels including cost of all required
materials, labour, lead, lift, etc., complete as per std
specification and direction.


531
a 125.00 m3 FOUNDATION AND BASEMENT 1 m3



b 480.00 m3
GROUND FLOOR
1 m3



c 130.00 m3
FIRST FLOOR
1 m3



d 85.00 m3
SECOND FLOOR
1 m3



e 85.00 m3 THIRD FLOOR 1 m3



f 95.00 m3 FOURTH FLOOR 1 m3



g 30.00 m3 FIFTH OR HEAD ROOM 1 m3



21 Building Brick Masonry for partition walls 115mm width in
cm 1:4. using Fly Ash bricks 230x110x70mm at all levels in
Ground Floor including cost of all required materials, labour,
lead, lift, etc., complete as per std specification and direction.

a 2.00 m3 FOUNDATION AND BASEMENT 1 m3



b 6.00 m3
GROUND FLOOR
1 m3



c 4.00 m3
FIRST FLOOR
1 m3



d 4.00 m3
SECOND FLOOR
1 m3



e 4.00 m3 THIRD FLOOR 1 m3



f 13.00 m3 FOURTH FLOOR 1 m3



22 90.00 m Building brick Cornice work over parapet wall using Fly Ash
bricks 230x110x70mm in cm 1:4, abd plastering with cm 1:4,
12mm thick including cost of all materials, scaffolding, labour,
lead lift etc., complete as per drawing and specification
1 m

532
23 135.00 m2 Laying PCC 1:2:4 using 3 to 6mm HBG chips 50mm
(average) thickness for flooring including cost of all materials,
labour, lead, lift, etc., and thread lined as per standard
specification and direction (Wearing coat)
1 m2
24 735.00 m2 Laying Granolithic flooring 50mm thick in CC1:2:4, using 3
to 6mm HBG chips and mixing with ironite powder in the
ratio of 2kg / bag of cement including cost of all materials,
labour, lead, etc., and finish the top surface with extra
cement and thread line as per direction and specification
1 m2
25 140.00 m2 Flooring with Industrial tiles of approved quality (Johnson-
Endura) and colour, scratch resistant set in cement mortar
1:3 for flooring in control room including cost of industrial
tiles, all leads, lifts labour for laying fixing and finishing neatly
as per standard specification and as directed by the
Engineer-in-charge (Industrial tiles colour and shade to be
got approved by the Executive Engineer before use)
1 m2
26 2300.00 m2 Paving the road surface with hydraulic pressed concrete
tiles of any colour finish 80mm thick of approved design to
withstand for a load of 10 tonnes, to set in cm 1:3 and
pointing including cost of all materials, paving charges to
uniform level and slope transporting, stacking, curing, etc.,
complete as per direction.
1 m2
27 300.00 m2 Supplying and fixing of prepolished hydraulic pressed
non-skid, ( EUROCON ) vibrated concrete tiles of approved
design and colour 18mm thick set in cm 1:3, 10mm thick for
stepes etc., complete as per direction.
1 m2
28 Floor Finish with Vitrified tiles johnson, kajaria, nitco of
virtified tiles mat finish at required size and Anti-Skid tiles
for Toilet in all floors over a base layer of C.M. 1:3. 20mm
thick laid in-situ and pointed with same coloured cement for
Toilet etc., including cost of tiles and other materials, labour,
lead, lift etc, complete, and as directed by the Engineer

a 1450.00 m2 Virtified Tiles 600x600mm 1 m2



b 105.00 m2 Anti-Skid tiles for Bath & FOL 1 m2




533
29 125.00 m2 Floor Finish with acid resistance tiles in battery room
kajaria, nitco of virtified tiles mat finish at required size to set
C.M. 1:3. 20mm thick including cost of tiles and other
materials, labour, lead, lift etc, complete, and as directed by
the Engineer
1 m2
30 400.00 m2 Wall finish with glazed tiles of approved make (johnson)
colour set in CM 1:3, 20mm thick in Toilet etc, including cost
of all materials and labour charges complete as per
specification and direction.
1 m2
31 Supplying and fixing of Rolling shutters opening using 18
gauge M.S. Sheet TATA STEEL with Gear System
operation providing with locking arrangements on both sides,
tophood, guides, gear arrangements, operation rod, handles
and painting with one coat red oxide metal primer to the clear
opening, including cost of all materials, fabrication,
transportation, and fixing in position Godrej 7 levers locks
2Nos, for each shutter and labour charges complete., as
directed. (Clear opening)

50.00 m2 Rolling Shutter Gear type 1 m2

32 Supplying and fixing of CW door of size
1180x2100/915x2100mm single leaf flush door in Kongu
wood outer frame size 100x75mm and the shutter frame size
100x40mm for top rails, 150x40mm for lock rails and
200x40mm for bottom rails and fixed with 18mm thick water
proof plywood and 1mm thick lamination on both sides and
giving necessary beeding 20mm size alround the joints of
plywood bothsides, fittings and furniture of best quality,
150mm Ano, Alu.hinges (HD) 3Nos, 1No-250mm Alu.Aldrop,
2Nos-250mm Alu. tower bolts, 1No- stopper, 2Nos- handles
and 1No-Godrej 4lever Mirtice lock including cost of all
materials wood wrought and put up, labour charges and
painting with one coat wood primer etc, complete as per
direction.

a 13.00 m2
DOOR 1180X2100MM
1 m2



b 16.00 m2
DOOR 915X2100MM
1 m2

534
33 Supply and fixing of P V C Door frame with shutter of size
750x2100mm of approved quality and fibre make of single
leaf by single mould sintex make with furniture fittings
3nos.75mm Ano. Alu. - Hinges,1no.150mm aldrop, 2nos
tower bolt and 2nos handle including cost of all materials,
labour charges etc.,complete as per directed by Engineer.

21.00 m2
DOOR SIZE 750X2100MM
1 m2



34 195.00 m2 Supplying Fabricating and fixing in position of anodized
aluminum natural color matt finish glazed Sliding window
including ventilator head of size 1.18x1.48m in two tracks in
all floors with the following sizes. All the two shutters with
sliding arrangements, with gutter arrangements so as to
drain the water entry and made with extruded aluminum
section of bottom track of size 62x37mm with gutter
arrangements @ 1.218kg/m sice and top track of size
62x31.5mm @ 0.788kg/m for shutter plain top and bottom
section of size 40x18mm @ 0.38kg/m plain side vertical
section of 40x18mm @ 0.493kg/mm inter locking vertical
section of size 40x18mm @ 0.63kg/mm ventilator box frame
63x37mm @ 0.85kg/m switch lock, special rubber, L angle,
alu. Clip 17.15x17.27, 1.5mm thick @ 0.128kg/m screws &
fixing 4mm thickclear glass etc, complete and including cost
of all materials, accessories, lead, lifts, labour for fabrication
& fixing in position including drilling holes in RCC etc., In
accordance with ISI 1868, 1962 specification for an average
anodic film thickness not less than 5 microns.
1 m2
35 8.00 m2 Supplying and fabricating and fixing in position of anodized
aluminum natural color matt finish fixed type ventilator of size
1.18x0.58m N type Ventilator in anodized aluminium
rectangular tube of size 63x37mm of 0.850kg/m with 4mm
thick frosted glass ,aluminium mesh with alu. beading clip of
size 17.15x17.27mm @ 0.178kg/m fixing rubber lining etc,
including cost of all materials, Lead,lift,labour for
fabricating,fixing in position etc; including drilling holes in
RCC etc., In accordance with ISI 1868, 1962 specification for
an average anodic film thickness not less than 5 microns and
all the materials should be got approved from the Executive
Engineer before use.
1 m2

535
36 11.00 m2 Supplying and fabricating and fixing in position of anodized
aluminum natural color matt finish Louvered type ventilator
of size 1.18 x 0.58m The outer frame will be 62x38x2mm @
1.17kg/m and louvers with moving arrangements will be
made with alu. channels of size 62x38x2mm @ 1.27kg/m
with pairs of louvers 4mm thick alu. clips including cost of all
materials, lead,lift,labour for fabricating,fixing in position etc;
including drilling holes in RCC etc., In accordance with ISI
1868, 1962 specification for an average anodic film thickness
not less than 5 microns and all the materials should be got
approved from the Executive Engineer before use.
1 m2
37 72.00 m2 Supplying, Fabricating and fixing Aluminum partition partly
glazed & partly paneled (600x600mm) with 12mm thick
MDF Board two sides laminated and 5.5mm thick Machine
Frosted float glass ( Saint Gobin or equivalent ) using
aluminum box section 63x37mm @ 0.85kg/m and for bottom
section 95x45mm and 2mm thick including cost of all
materials, labour, lead, lift, T & Ps etc complete. In
accordance with ISI 1868, 1962 specification for an average
anodic film thickness not less than 5 microns and all the
materials should be got approved from the Executive
Engineer before use.
1 m2
38 220.00 m2 Supplying Fabricating and fixing Aluminum partition glazed
and 5.5mm thick Plain glass using aluminum section
63x37mm Top and Vertical and for bottom section 95x45mm
including cost of all materials, labour, lead, lift, T & Ps etc
complete
1 m2
39 9.00 m2 Supplying, Fabricating and fixing Aluminum partition partly
glazed & partly paneled (600x600mm) with 12mm thick
MDF Board both side melamine finish and 5.5mm thick
Machine Frosted float glass ( Mode, Saint Gobin or
equivalent ) using aluminum box section 63x37mm @
0.85kg/m and for bottom section 95x45mm and 2mm thick
including cost of all materials, labour, lead, lift, T & Ps etc
complete. In accordance with ISI 1868, 1962 specification for
an average anodic film thickness not less than 5 microns and
all the materials should be got approved from the Executive
Engineer before use.
1 m2

536
40 Supplying, fabricating and fixing in position of MS grills
gates, name boards, handrails and ladder, etc., at various
levels as per approved design of the Engineer, including cost
of steel and other required materials, labour charges,
transportation and fixing, taking grooves in BM/RCC, packing
the pockets with CC and painting with one coat metal primer
complete.

a 7500.00 kg Window grills, gates, staircase handrails and ladder 1 kg
b 135.00 m
50mm M S medium Class pipe for handrail
1 m



c 4000.00 kg Compound wall Flower Design gate. 1 kg



d 620.00 kg
M.S Channel and Angle
1 kg



e 2600.00 kg M.S.Flats 50mmx10mm thick for earth mat 1 kg



41 15.00 m2 Supplying and fixing of Name board using 18mm thick MS
board and 45x6mm angles and letter painting etc., including
cost of all materials, labour,etc.,complete.
1 m2
42 1400.00 kg Supplying and fixing of M. S. Rails 90 lbs for transformer
plinth including cutting to size and fixing to position,
transportation, cost of materials, labour, lead, lift etc.,
complete.
1 kg
43 Plastering with cement mortar over the concrete/BM
surfaces at all levels both outside and inside of the building
including cost of all materials, hacking the surfaces,
scaffolding, lead, lift, curing, etc., complete as per the std.
specification and direction.

a 4900.00 m2
Ceiling plastering with cm1: 3, 10mm thick
1 m2



b 660.00 m2 Floor finishes with cm 1:3, 20mm thick and thread lined. 1 m2
c 2200.00 m2 plastering in C.M. 1: 4, 12mm thick (Concrete surface) 1 m2
d 9900.00 m2 plastering in C.M. 1: 5, 12mm thick Inside/outside. 1 m2

537
44 930.00 m2 Laying weathering course with one course of Pressed Tiles
of size 230x230x20mm confirmed to ISI and approved quality
to set in cm 1:3, 10mm thick mixed with 200gm pidilite ready
mix water proof compound per bag of cement and pointed
with same mortar over the brick jelly concrete, 80mm thick
using 20mm brick jelly in the ratio 32:12.5 and well beaten
with wooden hammers, spraying lime water, kadukkai and
jaggery solutions as per std, specification, including cost of
all materials, labour, lead, lift, etc., complete as directed.
1 m2
45 Supplying, laying and jointing of PVC pipes of approved
brand and ISI quality for waterline, sewerling, and rain water
downfall pipe etc., including cost of all materials and GI
specials, fixing the pipes over BM/CC surfaces by taking
grooves and fixing wooden plugs, screws firmly with special
clamps as directed.

a 120.00 m
140mm 6kg/cm2
1 m



b 400.00 m
110MM 6kg/cm2
1 m



c 200.00 m 63MM 6kgf / cm2 1 m

d 100.00 m 32MM ID 15kgf / cm2 1 m



e 200.00 m 25MM ID 15kgf / cm2 1 m



f 300.00 m 20MM ID 15kgf / cm2 1 m
46 Supplying and fixing of GM wheelvalve of approved brand
and ISI quality wherever required including cost of all
materials, lead, lift and labour charges, complete as directed

a 4.00 Nos 32MM GM wheel valve 1 No

b 6.00 Nos
25mm GM wheel valve
1 No



c 8.00 Nos
20mm GM wheel valve
1 No
47 Supplying and fixing of CP/PVC Bibcock of best quality of
approved brand wherever required including cost of all
materials, lead, lift and labour charges, complete as directed.


538
a 15.00 Sets 20MM Brass Chromimum plated screw down Bibcock (
Heavy Type )
1 Set
6.00 Sets 15mm dia CP tap long body- LMR 1 Set
10.00 Sets CP towel Rail 600mm (Metro)- LMR 1 Set
b 20.00 Sets 20MM PVC (HD) Bibcock 1 Set
48 Supplying and fixing in of position P V C Nahini Trap / C I.
Gully of approved make & quality fixed over a bed with C. M.
1:3, and fixing stainless steel Grating including the cost of all
materials, labour, lead, lift, T & Ps etc., complete.

a 20.00 Sets
P V C Nahini Trap
1 Set



b 20.00 Sets C I. Gully 1 Set
49 Supplying and fixing of heavy duty C. I. Manhole cover with
pedastal square 600x600mm (HD) or RCC cover slab with
pedastal square for the sewer manholes including cost of all
materials, labour charges, etc., complete as per std.
specification and as directed by the Engineer.

a 15.00 Sets Heavy duty C. I. Manhole cover with pedastal square
600x600mm
1 Set

b 30.00 Sets
H D RCC Cover slab with pedastal square
1 Set



50 30.00 Sets Supplying and fixing in position wash basin of size
550x400mm of approved quality and make[Parryware of
equivalent]Hi-lite colour/white with 12/15mm dia brass CP
pillar tap, 32mm CP waste coupling 32mm PVC waste pipe,
12/15mm CP angle cock, 15mm brass nipple, 15mm nylon
connection 1No Soap container, 500x400mm size best
quality Ano. Alu.framed mirror, etc., fixing the washbasin in
the wall with GI/Alu. brackets, giving necessary water
connection including the cost of all materials, labour, lead, lift
T & Ps etc complete.
1 Set

539
51 6.00 Sets Supplying and fixing in position glazed EWC - HI - Lite
colour of approved make & quality with 'P' or 'S' trap [Parry
ware-ELITE- or equivalent With double flapped PVC Anti
Microbral Solid Seat cover PVC low level Slim Line Cistern
with all necessary fittings (viz) Brass nipple, CP angle cock,
Nylon connection, CP brass fittings etc& connecting to water
main complying with standard specifications including the
cost of all materials, labour, lead, lift, T & Ps etc complete.
1 Set
52 7.00 Sets Supplying and fixing of Water Closet 580x440mm ORIYA
pan suitable colour of approved make including cost of all
materials, traps etc., and labour for fixing etc., complete as
directed.
1 Set
53 19.00 Sets Lipped Mouth Porcelin Flat Back Urinal with all
accessories such as 32mm dia Bell mouth PVC connection,
15mm dia G.M. wheel value, 15mm dia 'B' Class G.I. waste
pipe, 15mm dia nylon connection, 15mm dia brass nipple
etc., including cost of all materials, traps etc., and labour for
fixing etc., complete. ( Make ,Model to be approved by
Dept.Engineer at site )
1 Set
54 13.00 Sets Supplying and fixing of white marble stones for partition of
size 600x1200x20mm thick including cost of all materials
and labour for fixing etc., complete as directed.
1 Set
55 2.00 Nos Supplying and fixing of white marble stones of size
450x600x20mm thick engravying the foundation details of
the substation with necessary borders and painting the
letters including cost of all materials, labour charges, etc.,
complete as directed.
1 No
56 Supply and erection of RCC pre cast well rings of dia
1200mm, 300mm height and 50mm thick for construction of
Rainwater Harvesting tank including cost of well rings, brick
jelly, stone jelly 40,20,12,10mm and sand, etc., lead, lift,
erection charges, labours etc., complete, as per direction and
specification.

a 10.00 Nos
Supply and erection of well rings
1 No



b 1.00 Nos
Supply and fixing of top cover
1 No

c 10.00 Nos
Supply and fixing of Exhaust Fan rings
1 No

540



57 5500.00 m2 White washing two coats with best quality of white Cement
over newly cement plastered surface, ceiling, sunshade,loft
bottom and other surface, including cost of all materials,
watering, curing, lead, lift, etc., complete, as per std
specification and as directed bythe Engineer.
1 m2
58 4850.00 m2 Wall paint two coats with approved cement paint with primer
over one priming coat of cement paint over cement plastered
wall inner surface, necessary curing including cost of all
materials, labour lead, lift, etc., complete, as per std.
specification and as directed by the Engineer.
1 m2
59 5750.00 m2 Wall paint two coats with approved cement paint
(Supercem) with primer over one priming coat of cement
paint over cement plastered wall outer surface,necessary
curing including cost of all materials, labour lead, lift, etc.,
complete, as per std. specification and as directed by the
Engineer.
1 m2
60 30.00 m2 Painting wood work with two coats of Synthetic Enamel
paint of approved quality over the one coat of wood primer
including cost of all materials, labour, lead, lift etc, complete
as per std specification and as directed by the Engineer.
1 m2
61 600.00 m2 Painting the new steel work with two coats best quality and
approved colour Synthetic Enamel paint over the Red
Oxide primer including cost of all materials, labour, etc.,
complete as per std. specification and as directed by the
Engineer.
1 m2
62 1.00 m2 Supplying and fixing of Cadapa slab Sink of Varies size,
(Clear) for minimum depth 0.45m and slab thickness 20mm
with 32mm dia 'B' Class G.I. waste water pipe and 32mm dia
C.P. waste coupling including cost of all materials and labour
for fixing etc., complete as directed.
1 m2
63 95.00 m2 Supplying and fixing of Cadapa slab for capboard of varies
size, and minimum slab thickness should be maintain 20mm,
including cost of all materials and labour for fixing etc.,
complete as directed.
1 m2

541
64 20.00 m Supplying and fixing of Ornamental handrail 1m height for
front ramp in stainless steel using 50mm dia pipe at top and
edge, 25mm dia two rows at middle and 25mm dia pipe for
verticals at every 1.00m C/C including cost of all materials,
transportation and fixing in position, labour charges,
complete as directed.
1 m
65 2.00 Sets Supplying and fixing of PVC water tank of approved brand
(sintex)5000 litre capacity in terrace floor as directed by
engineer including cost of sintex water tank, labour for fixing
in position, construction of BM for alround of tank, filling with
filling sand and plastered the top and side surface all
leads,lifts etc complete
1 Set
66 Supply and Erection of single phase Mono block / Duble
stage Jet Motor & Pump of ISI quality and approved make
for dewatering, borewell supply, sump to over head water
tank etc., with all accessories such as starter, main switch,
teakwood board for fixing of main switch, starter, fuse carrier,
indicator holder, switch, lamp, etc., earthing arrangements,
internal wiring from switch to motor, transportation, concrete
bed / steel brackets, labour charges etc., compete., as
directed by the Engineer.

a 2.00 Set
Duble stage 1.5HP Jet
1 Set



b 1.00 Set
1.0HP MONO BLOCK
1 Set



67 1.00 Set 12 persons lift from basement floor to fifth floor with
provision to stop in all floors including cost all materials
labour charges etc., compete., as directed by the Engineer.
1 Set
68 2.00 Set Supply and erection, testing and commissioning of 5T
capacity Electrically operated travelling ( E O T ) Crane
with 10m span and 25m longitudinal run double girder
including cost of all materials, transport, labour etc., complete
as per relevent IS
1 Set
69 2.00 Set Supply and erection of 3 tonne capacity mono rail 2nos
approximate run 15m each pully, chain block fixing
arrangements, lifting arrangements all materials , transport,
labour etc., complete including testing and commissioning as
per IS.
1 Set

542
70 20.00 Set Supply and fixing in position of the best belgium glass
mirror of size 1.52 X 0.75 m to the wall necessary screws
etc. complete in all respects.
1 Set
71 305.00 m3 Filling with quarry rubbish and quarry dust 25% of
approach road including cost of all materials, lead, lift, labour
etc., as directed
1 m3
72 300.00 m3 Supply and filling with gravel 300mm thick, watering and
consolidating, rolling with hand roller in every layer including
cost of all materials, hire charges for roller, labour for hard
packing the surface etc., complete as per std. specification.
1 m3
73 300.00 m3 Supply and filling with quarry rubbish and quarry dust 25%
of approach road 300mm thick, watering and consolidating,
rolling with hand roller in every layer including cost of all
materials, hire charges for roller, labour for hard packing the
surface etc., complete as per standard specification.
1 m3
74 125.00 m Supply and fixing in position of copper sheet 18 G thick as
per drawing in expansion joint in all floors for end column
and slab including cost of all materialssuch as asphalt pad,
all fillets etc. complete as per standard specification.
1 m
75 Supplying and fixing of Alu. Dyecasting letters to the
required sizes with necessary powder coating colouring with
emblem as per board's norms including cost of materials,
scaffolding and labour charges complete as directed.

a 1.00 No
TNEB emblem 1.20m dia
1 No



b 75.00 Nos
45cm size letters
1 No



c 75.00 Nos
30cm size letters
1 No



d 75.00 Nos
23cm size letters
1 No



76 40.00 Sets Supplying and providing of 300mm dia, flower pots
containing green plants as directed by the Engineer at site.
1 Set
77 6.00 Sets Supplying of Godrej Navtal lock Seven Lever with three
keys for locking office portion and Pump rooms as directed.
1 Set

543
78 450.00 m2 Aluminum composite panel works:Designing the system for
cladding the external wall with approved make of aluminum
composite panels --- 4mm thick(0.5 mm thick aluminum
sheet on top and bottom sandwiched with 3 mm thick core
material of anti toxic low density polyethylene) in combinaton
with solid and metallic colour panels, by using pre-assemble
extruded aluminum sections/brackets and aluminium
composite panel to withstand design wind pressure of 150
kg/sqm (Testing pressure shall be 1.5 times of the design
wind pressure of 150 kg/sqm) conforming to IS 875-Part III.
The system shall be designed to accomodate thermal
movement of the aluminium framing system including
supporting arrangements.Fastening devices and composite
panel resulting from the exterior skin temperature from 15 to
85 deg.celcius.Interior skin temperature from 15 to 30 deg.
celcius and to accomodate horizontal buiding movement of
maximum 10 mm per bay and vertical movement of
maximum 20 mm between floors and conforming that no
aluminium members shall be visible from outside.
1 m2
79 15.00 m Drain line connecting to main sewer line near by the main
gate of TNEB complex, Guindy with 200mm PVC pipe to
the requied depth. ( Minimum 1 m)
1 m
80 1450.00 m2 Design of archtectural rendering and providing
archtectural finish including cost of all materials, lead, lift ,
etc complete including scaffolding and plat form etc. with all
safety meaures.
1 m2
81 PIPING
I Supply , erection , testing and commissioning of MS pipes (
Medium grade) from fire water pump to all floors including
cost of fittings like elbows , flanges ,tees etc and painting the
entire system

a 1.00 No 150mm NB Medium class( LMR) 1 No
b 1.00 No 80mm NB Medium Class( LMR) 1 No
c 1.00 No 25 mm NB Medium CLASS( LMR) 1 No
II 1.00 Kg Structural Steel Supports for the above ground pipes( LMR) 1 Kg

544
III Supply , erection , testing and commissioning of Cost Iron
Butterfly Valves as per IS( LMR)

a 1.00 No 150 mm( LMR) 1 No
b 1.00 No 100mm( LMR) 1 No
IV Supply , erection , testing and commissioning of Cost Iron
Non Return value as per IS( LMR)

a 1.00 No 150mm( LMR) 1 No
b 1.00 No 100mm ( LMR) 1 No
82 HYDRANT COMPONETS
a 1.00 No Supply , Erection , testing & commissioning . 63 mm dia
oblique type single headed GM hydrant value with blank cap
chain as per IS
1 No
b 1.00 No Supply , Erection , testing & commissioning . 63 mm dia GM
short Branch pipe with nozzle as per IS
1 No
c 1.00 No Supply , Erection , testing & commissioning . 63 mm dia , 15
mtrs length CP Hose with Gunmetal Coupling as per IS
1 No
d 1.00 No Supply , Erection , testing & commissioning . MS Hose box
with glass and arrangement of key.
1 No
e 1.00 No Fire brigade inlet connection of 2 way connection with
necessary flangers, bolts ,nuts, to directly feed water through
the ring main through fire service vehicle.
1 No
f 1.00 No Wall mounted swinging type hose reel with high Pressure
rubber hose, double braided 19 mm dia, 22.5 mtrs with
nozzle.
1 No
83a 1.00 No Supply , Erection , testing & commissioning .Kirloskar make
Horizontal end suction centrifugal end suction jockey pump
rated of 180 LPM 70m WC bronze impeller , stainless steel
shaft gland packing coupled with suitable electric motor
TEFC 2900 RPM coupled with coupling , base plate,
coupling guard etc. except cost of foundation except cost of
foundation
1 No

545
b 1.00 No Supply , Erection , testing & commissioning .Kirloskar make
Horizontal end suction centrifugal Motor Driven main electric
pump set with Bronze impeller cast iron body stainless steel
shaft rated at 97m3/hr @ 70 mtr head coupled with suitable
SPDP Electric Motor 2900 PRM , 50HP ,37 KW complete
with base plate , coupled coupling guard etc. with all
accessories. except cost of foundation
1 No
c 1.00 No Supply , Erection , testing & commissioning of 97m3/hr .
70mtr, head Kirloskar make mode no. CE 80/40 .,125 mm
Horizontal end suction top discharge pump with Bronze
impeller coupled to Kirloskar type4R 1040,24V, water cooled
, radiator cooling Diesel engine developing 60HP/ 1800 rpm
with base plate, coupling guard and foundation bolts with all
accessories except cost of foundation
1 No
d 1.00 No DOL starter panel for the above main and jockey pump set. 1 No
e 1.00 No Control panel for DG pump set 1 No
f 1.00 No Cable laying for jockey , main and DG pumps(LS) 1 No
g 1.00 No Pressure gauge arrangement for auto purpose 1 No
h Supply, Erection testing & commissioning of C.I foot valve IS
with all accessories.

1.00 No 100 mm dia 1 No
1.00 No 150mm dia 1 No
i 1.00 No Sprinkler Bulb pendent type 1 No
j 1.00 No Priming Tank 1000ltrs 1 No

Total










546

DRAWINGS