LT Aerial Bunch Cable (3C X 95 SQMM)

LT Aerial Bunch Cable (3C X 95 Sqmm)
1.
LT AERIAL BUNCHED CABLE

1.1 SCOPE
This specification covers design, engineering, manufacture, assembly, stage testing, inspection & testing
before supply and delivery at site at of cross linked polyethylene (XLPE) insulated cables with aluminum
conductors and a messenger wire of aluminum alloy to be used for overhead LT distribution system. The
size arei) 3CX95 (Ph) + 1CX70 + 1CX16 (SL)
These cables are to be used for three (3) phase 4 wire systems with neutral solidly earthed rated voltage
up to and including 1100V.
This specification defines the requirements (electrical, mechanical properties etc.) and tests to be
performed on the LT Aerial Bunched cables.
1.2 REFERENCES
This specification shall be governed by following standards with all amendments unless otherwise
specified in this specification.
IS:8130 - Conductors for Insulated cables
IS:398 (Part IV) - Messenger conductor
IS:10810 - Methods of test for cables
IS:14255 - Aerial Bunched cables for 1100V
IS:10418 - Drums for Electric Cables
IEC 60502, Part 1, 2004 - Power Cables with extruded Insulation, cables for rated voltages of 1kV and
3kV
NFC 33-209 - Bundle Assembled Insulated Cables.
HD 626 (CENELEC standard) Overhead distribution cables of rated voltage Uo / U(Um): 0.6/1(1.2)
KV
NOTE: This specification has mostly considered references from Indian Standards. However, certain
references have also been derived from the above referred International standards wherever
deemed suitable in meeting the onerous site requirements of SBPDCL.
1.3
DEFINITIONS
1.3.1
A LT Aerial Bunched cable shall typically, at maximum, comprise of: Insulated phase conductors
(3 numbers), Insulated neutral conductor (1 number), Insulated street lighting conductor (1
conductor) and a insulated messenger wire (1 number).
Example:
i) Designation
3 x 95 (P) + 1 x 70 (M) + 1 x 16 (SL)
P=Phase Conductor
M= Messenger
SL=Street Light Conductor
ii) Size
3 x 95 sq. mm = 3-phase conductors.
1 x 70 sq. mm. = 1 messenger wire
1 x 16 sq. mm. = 1 lighting conductor
1.3.2 Messenger Wire: As defined in NFC 33-209 Wire or cable which has principal function of
supporting the cable in overhead systems and which may be separate or may be an integral part
of the cable which it supports. Messenger wire should also be insulated conductor.
1.4
Climate CONDITIONS:
The AB cable shall be suitable for satisfactory continuous operation under the following tropical
conditions:
1.5
Maximum ambient temperature: 50 C

Maximum ambient temperature in shade : 45 C
Relative Humidity
: 10 to 95%
Maximum annual rainfall : 1450 mm
Maximum wind pressure : 150 Kg/m.sq
Maximum altitude above mean seal level : 1000 meters
Isoceraunic level
: 50 days/year
Seismic level (Horizontal acceleration)
: 0.3g
Moderately hot and humid tropical climate
SPECIFICATIONS
1.5.1 Conductor
The Aluminum conductor shall be of circular cross section, stranded and compacted. They shall be of
H2 or H4 grade (complying with IS: 8130:1984) and per the following:
a) Upto and including 50 sq. mm. conductors = H2 grade.
b) All sizes above 50 sq. mm. conductors = H4 grade.
1.5.2
Messenger Wire
The messenger wire shall be insulated stranded, circular, aluminum magnesium silicon alloy type.
They shall have minimum 7 strands. They shall comply with IS 398 (part 4). Specific attention is made
to Tables 1, 2 & 3 of IS 398.
1.5.3
Conductor Insulation
a) The cross-linked polyethylene (XLPE) insulating shall be black in colour and to be stabilized
against deterioration caused by exposure to direct sunlight and ultraviolet radiation conforming
to requirement specified in Table 1 of IS : 14255 1995 or IEC 60502. XLPE insulation shall be
pressure extruded
b) The nominal value of the carbon black content of the sheath (insulation) shall be 2.5 with a
tolerance of + 0.5% (Table 20 of IEC : 60502-1, 2004)
c) The XLPE material shall be preferably of BOREALIS, DOW or any other make subject to the prior
written approval of the buyer.
d) The average thickness of insulation shall comply to Table 4 of IS : 14255 1995. For nominal
area of conductors above 95 sq. mm., the average thickness of insulation shall not be less than
the nominal value mentioned hereunder :
Nominal Area of Conductor (sq. mm.) Nominal Thickness (mm.)
95
1.5
e) All other requirements related to insulation shall comply to clause 7 of IS: 14255 1995.
1.5.4
Core Identification
The core identification shall be as per clause no. 8.1 of IS: 14255 1995. Ridges shall be provided
over phase core and neutral core also.
1.5.5
Laying of Cores
The assembly (laying up) of cores shall be as per clause 9 of IS : 14255 1995.
1.5.6
Embossing on cores.
All the cable shall have the following embossing on insulated neutral conductor for identification in
interval not more than 2 meters. Font size of letters to be min. 5 mm.
i.
ii.
iii.
Name or trade mark of manufacturer

Voltage grade
Type of cable, i.e LT ABC
iv.
v.
vi.
vii.
viii.
ix.
1.6
Size of phase conductor, i.e. 95 sqmm.

Size of messenger conductor, i.e 70 sqmm
Year and month of manufacturing.
Type of insulation, i.e XLPE
Name of purchaser
P.O. Number
TESTS
6.1
Routine test
6.2
Acceptance test
6.3
Type Test
a. Conductor resistance test.

b. Messenger resistance test.
c. High voltage test in water (Duration of
immersion > 10 minutes)
Sampling to be done as per IS: 14255:1995, Annexure-A.
a. Tensile test for phase and street light
conductor
b. Wrapping test for phase and street light
conductor
c. Conductor resistance test.
d. Direction and ratio of lay in the outer layer of
conductor
e. Breaking load test for messenger conductor
and street light conductor.
f. Messenger resistance test.
g. Elongation test for messenger conductor
h. Direction and ratio of lay for messenger
conductor.
i. Thickness of insulation.
j. Tensile strength and elongation at break of
insulation
k. Hot set test for insulation.
l. Carbon black content
m. Insulation resistance test at room temperature
and 90 deg.C .
n. High voltage test of core in water (Duration of
immersion > 1 hour.)
o. Lay length of complete cable
p. Chemical composition test for aluminum
conductor.
q. Dimensional test as per parameters specified
in the technical particulars.
q. Bend test for complete cable
Type test to be carried out on one randomly selected
sample from CPRI / ERDA. Type test is valid for five years.
a. All the type test as per IS: 14255:1995
b. UV radiation test as per ASTM standard. (sample shall

meet min. 80% retention after
exposure of 21 day as per ASTM standard)
IDENTIFICATION, PACKING AND MARKING

1.6.1
The AB Cable shall be wound on non-returnable wooden drums conforming to IS: 10418 with
latest amendments thereof. The drums should have supporting plate with bush at central
hole. The end of the cable shall be sealed by means of non-hygroscopic sealing material. The
marking of drum shall be in line with IS: 14255:1995.
1.6.2
The drums shall be of such construction as to assure delivery of cable in the field free from
displacement and damage and should be able to withstand all stresses due to handling and
the stringing operation so that cable surface is not dented, scratched or damaged in any way
during transportation and erection. The cable shall be properly lagged on the drums.
1.6.3
Details of drums length tolerance and short length shall be as follows.
Tolerance in drum length shall be 5%

Total Order quantity tolerance shall be 2%
Non standard length shall not be less than 250mtrs in one continuous length.
One drums non standard length to be acceptable.
ANNEXURE 1 / DATA SHEET FOR LT AB CABLE

Sl.
No.
Technical Parameter
YEARS OF MANUFACTURING
SIMILAR CABLE
TYPE TEST CERTIFICATES
Unit
Nos.
NBPDCL Specification
3 or more years of supply of
similar sizes and
design / higher sizes of cables.
(Furnish client list)
Furnish for all type tests as
mentioned in IS 14255 1995. The tests should have
been performed NOT earlier
than 5 years.
Type test certificate shall be
from CPRI/REDA/KEMA shall be
submitted.
GUARANTEED PERIOD.(FROM THE

DATE OF SUPPLY / DATE
OF COMMISSIONING)
66 / 60 MONTHS
APPLICABLE STANDARDS
IS14255:1995,
IS 398 (part 4): 1979,
IS 8130: 1984,
IS 10810:1990,
IS 10418:1982, IEC-60502,
NFC-33-209
HD 626 (Cenelec standard.)
VOLTAGE GRADE
1.1KV Grade
NO. OF CORES/TYPE
i) PHASE CONDUCTOR
3 (Al)
ii) NEUTRAL CONDUCTOR
1 (Al )
iii) MESSENGER
1 (Al Alloy)
iv) STREET LIGHTING CONDUCTOR
1 (Al )
CROSS-SECTIONAL AREA : sq. mm.
95 mm2
i) PHASE CONDUCTOR
(nom.) 95
ii) MESSENGER
(nom.) 70
iii) STREET LIGHTING CONDUCTOR
(nom.) 16
TYPE OF CONDUCTOR MATERIAL

i) PHASE CONDUCTOR
ii) MESSENGER
Vendor Data
As per clause of specification

Al Alloy conductor as per IS 398
(part 4 ) & IS 14255 :
1995
E.C grade AL H2 /H4 as per IS
8130 : 1984
95 mm2
Sl.
No.
8
Technical Parameter
Unit
Circular Stranded Compacted

Per Table 2 of IS 8130
Circular Stranded Per Table 2 of
IS 8130
Circular Stranded Compacted
Per Table 2 of IS 8130
ii) MESSENGER
10
Vendor Data
NUMBER OF STRANDS IN
i) PHASE CONDUCTOR
MINIMUM / NOMINAL DIAMETER

OF STRANDS
i) Phase Conductor
As per manufacturer standard
ii) Street light conductor
As per manufacturer standard
iii) MESSENGER
As per IS: 398, Part-4
LINEAR RESISTANCE OF
CONDUCTOR AT
20 deg.C (max)
(with the combination of phase
conductor and
others per sl. No. 6 above)
i) PHASE CONDUCTOR
iii) MESSENGER
95 mm2
ohm /
km
ohm /
km
ohm /
km
As per Table 2 of IS 8130- 1984

As per Table 2 of IS 398 (Part-4)1994
As per Table 2 of IS 8130- 1984
CONTINUOUS CURRENT CARRYING
11
CAPACITY IN AIR(at 40 Deg C

ambient)
conductor and
95 mm2
Amps
12
CONTINUOUS CURRENT CARRYING

CAPACITY IN AIR(at 50 Deg. C
ambient)
conductor and others per sl. No. 6
above)
95 mm2
Amps
13
SHORT CIRCUIT CURRENT RATING

FOR 1 Sec.
above)
95 mm2
Sl.
No.
Technical Parameter
Unit
Vendor Data
KA
14
15
BREAKING STRENGTH (min.)

i) MESSENGER
kN
36.640
ii) STREET LIGHTING CONDUCTOR :

16 sq. mm
kN
1.90
DIAMETER OF BARE (mm)

i) PHASE CONDUCTOR
16
17
18
19
20
21
iii) MESSENGER
Lay ratio and direction of lay of
conductor
i) Phase conductor
ii) Neutral conductor
iii) Messenger conductor
iv) Street light conductor
Type of insulation
i) Make of insulation
ii) Grade of insulation
COLOUR OF INSULATION
CARBON BLACK CONTENT (%)
EXTRUSION PROCESS
ISULATED CABLE OUSIDE DIAMETER
(mm)
i) PHASE CONDUCTOR
22
70 mm2
Messenger

CORE IDENTIFICATION
95 mm2
(min.)
(max.)
(min.)
(max.)
(nom.)
(nom.)
95 mm2
XLPE
Black
2.5% (MAX.)
PRESSURE EXTRUDER
95 mm2
(min.)
(max.)
(min.)
(max.)
(nom.)
Ridges per clause 8.1 of IS :
14255-1995
Ridges per clause 8.1 of IS :
14255-1995
None
i) PHASE CONDUCTOR
23
24
25

ASSEMBLY LAY LENGTH
ASSEMBLY LAY DIRECTION
CABLE IDENTIFICATION ON NEUTRAL
CORE
Font size of letters
70 mm2
Messenger
mm
Right Hand
Sl.
No.
26
27
Technical Parameter
WEIGHT OF THE CABLE
above)
STANDARD LENGTH PER DRUM
above)
Unit
27
Vendor Data
Kg/km
95mm2
mtr
28
TYPE / SIZE OF THE DRUM

above) (Include dimensions
details)
(Flange x Barrel x Traverse)
GROSS WEIGHT OF THE DRUM
above)
95mm2
400
Wooden Drum
kg
28
29
30
31
32
MARKING ON THE DRUM

BENDING RADIUS OF COMPLETE
CABLE
conductor and
Weight of bare core
i) Phase or neutral conductor
ii) Messenger conductor
iii) Street light conductor
Weight of insulated core
i) Phase or neutral core
ii) Street light core
CHEMICAL COMPOSITION
i) ALUMINIUM CONDUCTOR
ii) ALUMINIUM ALLOY CONDUCTOR
mm
Kg/km
Kg/km
Kg/km
Kg/km
Kg/km
AS PER IS 5484:1997
AS PER IS 9997:1991
Note: Bidder shall furnish the GTP format with all details against each clause. Bidder shall not
change the format of GTP or clause description.
ANNEXURE-2 / DOCUMMENTS SUBMITTAL REQUIREMENT

Drawings, Data and Manuals shall be submitted with the bid and after the bid in quantities and
procedures as specified in this document for approval and subsequent distribution after the
issue of LOI / PO / Award of Contract.
S.No
Description Of Drawing / Data / Manuals
With bid
( 1 sets of
hard copies)
1
2
3
4
5
6
7
8
9
10
11
12
13
Quality Assurance Plan along with

inspection and test program.
Completed technical data
schedule XLPE Cable current
ratings for different types of
installation inclusive of derating factors for ambient
temperature, grouping etc.
Manufacturer's catalogues giving XLPE
cable construction and various other
details.
Cable cross-sectional drawing for each
type of XLPE cable.
Type test certificates, where applicable,
and sample routine test reports
GTP duly filled as per Annexure-II.
Data sheet of XLPE compound
Detailed reference list of customers
already using equipment offered during
the last 5 years with particular emphasis
on units of similar design and rating
Details of manufacturers quality assurance
standards and program and ISO 9000
series or equivalent national certification
Deviations from this specification. Only
deviations approved in writing before
award of contract shall be accepted
Technical data schedule, with approved
revisions.
Calculations to substantiate choice of
electrical, structural, mechanical
component size/ratings
Detailed installation and commissioning
instructions
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Post bid
For review &
approval
(2 sets of hard
copies)
Prior to Dispatch
As built (2 sets of
hard copies and 1
CD-Rom )
Volume-II : Section-II (B)

Technical Specification
AERIAL BUNCHED CABLE HAVING XLPEINSULATED L.T. CABLE FOR WORKING VOLTAGE UPTO 1100
VOLT
1. SCOPE :
The specification covers design, manufacture, testing before despatch, transportation, supply and delivery
of ISI marked 1100V Aerial Bunched Cable having XLPE insulated Cable (three Power Core) with stranded
compact circular aluminium conductors twisted over an insulated aluminium alloy messenger wire for use as
overhead distribution feeders, with/without one street lighting core with stranded compacted circular
aluminium conductor XLPE insulated suitable for use on 3-Phase AC System conforming to IS-14255/1985
with up to date amendments.
2.
LOCATION:
Aerial bunched Cables for use in L.T. overhead lines are preferred than conventional L.T.overhead lines with
bare conductors as those are not subjected to frequent faults as happens with the bare conductors and also
to minimise problem of tree clearance etc. ABC System is safer and eliminates use of insulators and
associated hardwares required for bare conductors.
3.
APPLICABLE STANDARDS:
Unless otherwise stipulated in this specification, the following standard with up to date amendment shall be
applicable.
IS 14255-1995 Specification for AERIAL Bunched Cables for working Voltage Up to & including 1100 Volts.
IS : 8130 Specification for Conductors for Insulated Cables.
IS : 398 (Part-IV) Specification for Aluminium Alloy Conductor.
4.
RATED VOLTAGE :
The rated Voltage of LT AB Cables shall be 1100 Volts.
5.
CONDUCTORS :
The Aluminium Conductors for phase/street lightning conductor shall be H2 of H4 grade Aluminium
complying with the requirements of IS-8130-1984 with up to date amendments. For messenger wire
stranded All Aluminium Conductor shall be of heat treated Aluminium Magnesium-Silicon Alloy Wires
containing approximate 0.5% magnesium and 0.5% silicon conforming to IS-398 (Part-IV)/1984 with up to
date amendments. The stranded conductor shall be clean & reasonably uniform in size and shape and its
surface shall be free from sharp edges. Not more than two joints shall be allowed in any of the wires
forming every complete length of conductor and no joint shall be within 300 mm. of any other joint in the
same layer. The joint shall be brazed, silver soldered or electric or gas welded. No joint shall be made in the
conductor, once it has been stranded.
6.
INSULATION :
The Conductor (with protective barrier, wherever applied) shall be provided with cross linked polyethylene
applied by extrusion conforming to the standard Specification as per IS 4255/95.The average thickness of
insulation when measured in accordance with relevant clause of the specification, shall not be less than
standard value specified. Upper surface of Cable insulation should be Ultra Violet Ray resistant Colour of
insulation shall be black.
7.
CORE IDENTIFICATION :
The Phase Conductors shall e insulated with black weather resistant, XLPE suitable for 1100 Volt insulation.
The Phase Conductor shall be provided with one, two and three ridges for quick identification. The individual
cores thus formed shall then be laid up around insulated messenger wire. The insulated messenger wire
shall have four ridges as per IS 14255:1995. The insulated street lighting conductor shall not have any
identification mark.

8.
MESSENGER-CUM-NEUTRAL WIRE :
The insulated messenger wire shall be of aluminium alloy, generally conforming to IS 398 (Part-IV)/1994
and suitably compacted to have smooth round surface to avoid damage to the other insulating sheath of
phase conductor twisted around the messenger.
9.
LAYING UP :
Three Power Cores having Ridges one, two and three and one street lighting without any ridge, if any
should be twisted over insulated messenger wire with right hand direction of lay. This will from the Aerial
Bunched Cable. Lay ratio shall be as specified in IS:14255/ 1995.
10. TESTS FOR CABLES :

10.1 Type test reports not older than 5 years of at least two sizes of Aerial Bunched Cableswith & without
street lighting core being procured and as specified in relevant IS & IEEand detailed in Clause 5:1 got
conducted from independent recognised Test House shall be furnished by the bidders along with the bid.
The bid not accompanied with test reports may not be considered for evaluation.
TYPE TEST REPORTS SHALL CONTAIN DETAILS OFFOLLOWING TYPE TESTS AS PER IS 8130-1984 & IS
10810
1. Tests on Phase/Street Light Conductor :
i) Tensile Test
ii) Wrapping Test.
iii) Resistance Test.
2. Test on Messenger Conductor ;
i) Breaking Load.
ii) Elongation Test.
3. Physical Test for XLPE insulation :
i) Tensile Strength and elongation at break.
ii) Ageing in on even.
iii) Hot Set Test.
iv) Shrinkage Test.
v) Water Absorption (Gavimetric)
4. Test for thickness insulation.
5. Insulation performance (Volume resistivity) Test.
6. High Voltage Test.
Report of above and any other type test provided in the relevant Indian Standards shall also be supplied.
10.2 ROUTINE TEST ;
These shall be carried out on all sizes of all drums of unamoured Cables by the supplier as given in Clause
5.1 and shall be got approved before despatch.
The Cable shall be inspected and tested at the manufacturers works before despatch as per ISS mentioned
in schedule of requirement. The manufacturer shall arrange all the necessary machinery, apparatus and
labour required for the testing purpose.
The routine tests embodied in the respective ISS are as per list given below :

1. Conductor Resistance Test.
2. High Voltage Test at room temperature.
3. Cold Bend Test (optional)
Any other routine test provided in the relevant Indian Standards shall also got conducted by the suppler.
10.3 ACCEPTANCE TEST :
These tests as per relevant IS & IEC shall be carried out in the presence of the purchasers representative if
so desired by the purchaser. The following shall constitute the acceptance tests.
(a) Tensile Test (for phase/street light conductor)
(b) Wrapping Test (for phase/street light conductor)
(c) Breaking Load Test for messenger Conductor.
(d) Elongation test for messenger conductor.
(e) Conductor resistance test.
(f) Test for thickness of insulation.
(g) Tensile Strength and Elongation at Break Test.
(h) Hot Set Test for XLPE insulation.
(i) Insulation resistance test and
(j) High Voltage Test.
11. SEQUENTIAL MARKING :

Due to technical difficulty Marking of the Sequential Length is not required. Instead the Weight of Cable for
all sizes shall have to be mentioned for Per K.M. Length.
12. PACKING & MARKING :

The Cable shall be supplied on suitable sized wooden non-returnable drum of robust construction for each
length of Cables as per I.S. 10418. A layer of water proof paper shall be applied to the surface of the drums
and over the outer cable layer. A clear space at least 40 mm. shall be left between the Cable and Logging.
Wood preservative shall be applied to the entire drum. Each metre length shall be embossed with the Trade
Name of Manufacturer and the work Employer (RGGVY XII Plan Projects). Packing shall be sturdy to protect
the Cable from any injury during transportation handling and storage. Both Cable ends shall be sealed with
PVC/Rubber Caps to eliminate ingress ofmoisture. Each Cable Drum shall have following information
stencilled on it.
a) Manufacturers Name, Brand Name of Trade Mark.
b) Year of Manufacture.
c) Nominal Cross-Sectional area of the Cable Conductor.
d) Type of Cable and Voltage Grade.
e) Length of the Cable.
f) Number of the Cores.
g) ISI Certification Mark, IS reference.
h) Colour of outer sheath.
i) No. of lengths in Drum (if more than one)
j) Cable Code.
k) Direction of rotation of drum (by means of an arrow)
l) Approximate gross weight in Kg./Km.
The standard Drum Length will be 500 mtrs. in each Drum for all sizes subject to a tolerance of + 5%.
13. INSPECTION :
The Cable shall be inspected at manufacturers works before despatch as per IS-7098 (Part-I)/1988 (with
upto date amendments) & IS 14255/1995. All the acceptance testsembodied in the above shall be

performed by the Inspecting Officer. The Manufacturer shall arrange without making any extra charges with
all the necessary machinery, apparatus and labour requirement for the testing purpose. The Cable
requirement for testing shall be to Firms Account.
14.
LITERATURE AND MANUAL :
To be submitted as per General Terms & Conditions of Contract.
15.
GUARANTEED TECHNICAL PARTICULARS :
To be submitted along with Tender documents.

A.
DESCRIPTION OF 1.1 KV AERIAL BUNCHED CABLES :

Description
1100V Grade L.T. Aerial Bunched Cable having three

Power Core & One Neutral-Cum-messenger Core of
stranded compacted circular Aluminium Black coloured
XLPE insulated & Core identification by ridges, one,
two and three & four respectively. One Street Lighting
Core of stranded, compacted Circular Aluminium
Conductor, Black coloured XLPE insulated without any
identification mark. Messenger-CumNeutral Wire
should be of stranded compacted Circular Aluminium
Alloy Conductor conforming to IS 8130/1984, IS398(Part-IV)/1979 and IS-14255/1995 with upto date
amendments, if any.
Size
Ph.Wire + St.Light Wire + MessengerCumNeutral Wire
1)
2)
3)
4)
3x25
3x35
3x50
3x70
+
+
+
+
1x16
1x16
1x16
1x16
+
+
+
+
1x25
1x25
1x35
1x50
sq.mm.
sq.mm.
sq.mm.
sq.mm.
(Provision for street light conductor is

optional and as per requirement)
[ Sizes of Power Conductor & Messenger Wire may vary as per requirement ]
B.
ACCESSORIES REQUIRED FOR DRAWAL OF L.T. OVERHEAD LINE WITH1100V GRADE AERIAL
BUNCHED CABLES ON PCE POLE SUPPORT
Sl.No.
1
2
Description
Anchor Clamp (3-Bolt and 2 Bolt Type)
Eye hook with Suspension Clamp Assembly.
3
4
5
PCC Pole Clamp.

Insulation Piercing Connectors with cover or P.G.Connectors with insulation cover.
Water Proof pre-insulated Hexagonal Compression Connectors & Lugs.
NOTE: Offer for L.T. Aerial Bunched Cables should cover required accessories with details of dimensions,
materials and provisional quantity per K.M. of L.T. O/H Line.

DIMENSIONAL AND ELECTRICAL PARAMETERS:
LTABC: The standard sizes and technical characteristics for Single Core Cable.
Nominal Sectional Area of Conductors (sq.mm.)
Parameters
No. of Strands
16
Dia. of Compacted Conductor

(MM)
Approx. Mass (Kg./Km.)
Max. DC resistance at 200C
(ohm/km.)
Insulation Thickness (mm.)
25
35
50
70
4.4
5.5
6.8
7.9
9.4
65
95
12 7
170
1.20
0.868
0.641
0.443
1.2
1.2
1.5
1.5
85
100
120
155
42
1.91
1.2
Current rating at 400C in air.

60
Note : The resistance values given in the Table are the max. Permissible one.
TECHNICAL CHARACTERISTIC OF INSULATED MESSENGER-CUM-NEUTRAL WIRE FOR LT ABC :

Nominal
Sectional
Area (mm.)
Dia.of Compacted
Conductor (mm.)
Approx. mass
(Kg./Km.)
Max. D.C.
resistance
At 20C
(Ohm./Km.)
Minimum
Tensile
Strength (KN)
25
5.9
65
1.38
7.4
35
6.9
95
0.986
10.3
50
7.9
127
0.689
14.0
TECHNICAL SPECIFICATIONS FOR XLPE INSULATED and and PVC SHEATHED

H.T.(11KV) AERIAL BUNCHED CABLES
1. SCOPE :
The specification covers design, manufacture, testing before despatch, transportation,
supply and delivery of ISI marked 11 KV Grade XL PE insulated screened armoured all
aluminium conductor and PVC sheathed Power Cables suitable for effectively earthed
11KV Overhead Lines.
:
2. LOCATI ON
11KV Aerial bunched Cables are composite Cable especially intended for overhead line
use in forest areas where tree clearance poses a series problem and in other cases where
it is difficult to get clearance for bare conductor lines.
These Cables comprise of 3 XLPE insulated Single Phase Cables twisted around a bare
messenger wire, which will carry the weight of composite Cabl e.
3. APPLICABLE STANDARDS :
Unless otherwise stipulated in this specification, the foll owing standard with up to date
amendment shall be applicabl e.
IS 7098 (Part-II)-1985 Cross linked polyethylene insulated PVC sheathed Cables.
IS : 8130-1984 Conductors for Insulated Cabl es.
IS : 398 (Part-II)-1976 Galvanised Steel Wires.
IS : 398 (Part-IV)-1979 Aluminium All oy Conductors.
4. RATED VOLTAGE :
The rated Voltage of the Cables shall be 11KV and the maxi mum operating Voltage shall
be 12KV.
5. CONDUCTORS :
The Al uminium Conductors shall comply with the requirements as specified in
IS-8130-1984 with up to date amendments. The stranded conductor shall be clean &
reasonably uniform in size and shape and its surface shall be free from sharp edges. Not
more than two joints shall be allowed in any of the wires forming every complete length of
conductor and no joint shall be within 300 mm. of any other joint in the same l ayer.
Joints shall be brassed, silver soldered or electric or gas welded. No joint shall be made in
the conductor once, it has been stranded.
6. INSULAT ION :
The insulation shall be chemically cross linked polyethylene conforming to the physical,
electrical and ageing properties as required in the specification. Cross-linking may be
done by exposure to peroxide with nitrogen curing CCV line, method with intenti on to
ensure lowest tree formation. Only natural unfilled compound shall be used for
insulation. Thickness when measured in accordance with relevant Clause of the
Specification, shall not be less than the standard thickness value specified.
7. SCREENING :
The screening of insulated Cables shall consist of conductor screening and insulation
screening.
Screening Materials :
Two types of materials may be used for screening of Cables : non-metallic & metallic.
Conductor Screening :
Conductor screening shall be non- metallic and shall consist of a layer of extruded-semiconducting cross linked polythine compound of thickness no less than 0.5 mm.
Insulating Screening :
The insulation screening shall consist of non-metallic semi-conducting part in
combination with a metallic part. Non-metallic part shall be appli ed either directly over
the insulation of each core and shall consist of ei ther a semi-conducting tape or a layer of
extruded semi-conducting compound or a combination of these materials. The metallic
part shall be applied over the individual core. Metallic screening shall consist of either
tape or braid or concentric serving of wires or a sheath and shall be non-magnetic.
8. OUTER SHEATH :
Over the armouring/metallic screen the Cable shall be provided with extruded PVC outer
sheath. The composition of the PVC compound for outer sheath shall be Type ST2 of
IS-5831-1984. The col our of the outer sheath shall be black. The average thickness of the
sheath shall not be less than the standard values specified in the IS when measured as
laid in IS-7098(Part-II)/1985. The smallest thickness of the measured values of sheath
shall not fall below the standard value(s) specified with tolerance. Outer surface of the
Cable shall be ultra-violet Ray resistant.
9. CORE IDENTIFICATION :
The Core identification shall be done by Ridges one, two and three on PVC covering over
core.
10. BARE MESSENGER WIRE :
Bare messenger wire shall consist of combination of galvanised steel wires and
aluminium alloy wires. Central layer(s) shall be of galvanized steel wires and outer
layer(s) shall be of Aluminium Alloy Wires. Galvanised Steel Wires shall be tested as per
IS:398(Part-II)/1978 and
Aluminium Alloy Wires shall be tested as per
The number of strands and diameter of strand for Steel Wire &
IS:398(Part-IV) /1979.
Aluminium Alloy Wire for Bare Messenger Wire shall be calculated considering 100 mtrs.
Span Length on 9 mtrs. PCC Pole Support and Breaking Load of Messenger Wire.
11. LAYING UP :
Three Power Cores having Ridges one, two and three shall be twisted over bare
messenger wire with right hand direction of lay. This will from the Aerial Bunched Cabl e.
12. TESTS :
1. Copies of the type test certificates in respect of all the type tests as per IS:7098
(Part-II) 1985 for similar type of XLPE Cables from any Government recognised
Testing Labs, shall
be submitted along with the Tender.
LIST OF TYPE TESTS :
a)
ii)
iii)
iv)
i) Annealing test (for Copper)

Tensile Test (for Aluminium)
Wrapping Test (for Aluminium)
Resistance Test.
b)
c)
d)
i)
Tests for armouring wires/strips.

Test for thickness of insulation and sheath.
Physical tests for insulation.
Tensile strength and elongation at break.
ii) Ageing in air oven.

iii) Hot test.
iv) Shrinkage test.
v) Water absorption (Gravimetric)
e) Physical Test for outer sheath :
iii) Shrinkage Test.
iv) Hot deformation.
f) i) Bleeding and Blooming test (for outer sheath)
ii) Loss of mass in air ever, heat shock and thermal stability tests will be carried out
as per IS:7098, Part-II/1985.
g) Partial discharge test.
h) Bending test.
i) Dielectric Power Factor Test :
i)
ii)
j)
k)
As a function of Voltage.
As a function of temperature.
Insulation resistance (volume resistivity) test.
Heating cycle test.
l) Impulse withstand test.

m) High Voltage test.
n) Flammability test.
o) Col d Impact test.
p) List of type test for messenger wire :
i) Breaking load test on individual galvanised steel wire.
ii) Breaking load test on individual aluminium alloy wire.
13. ACEPTANCE TESTS :

The foll owing tests shall be carried out as acceptance tests :
a) Annealing test (for copper)
b) Tensile test (for aluminium)
c)
d)
e)
f)
Wrapping test (for aluminium)

Conductor resistance test.
Partial discharge test (for screened cables only)
g) High Voltage test.

14. ROUTINE TEST ;
The foll owing tests shall be carried out as routine tests :
a) Conductor resistance test (for aluminium and copper)
b) Partial discharge test (for screened cables only)
c) High Voltage Test.
Type test/acceptance test/Routine tests and any other tests required as per relevant
Indian Standards shall also be got conducted.
15. INSPECTION :
The Cable shall be inspected at manufacturers works before despetch as per IS -7098
(Part-II)/1985 (with upto date amendments). All the acceptance tests embodied in the
above shall be performed by the Inspecting Officer. The Manufacturer shall arrange
without making any extra charges with all the necessary machinery, apparatus and
labour requirement for the testing purpose. The cost requirement for testing shall be to
Firms Account.
Supplier shall provide non-erasable sequential marking of length on the Cable for each
metre of length with sequential marking machine having automatic length measuring
meter. The Cable supplied without sequential marking will not be accepted and no
deviation shall be allowed under any circumstances.
The Cable shall be supplied in suitable non-returnable wooden drums of suitable size in
standard lengths subject to a tolerance of + 5%.
The Cable shall be wrapped with
polythene under wooden covering. Each metre length shall be embossed with the Trade
Name of Manufacturer and the work NBPDCL. ISI mark Cable shall be
preferred.
The ends of the Cable shall be sealed by means of non-hygroscopic sealing material.
Each drum shall carry the following information either stenciled on flange or label
attached to it :
a) Manufacturers Name
b) Trade Mark, if any.
c) A reference to ISS i.e. IS-7098 (Part-II)/1985.
d) Length of the Cable on the drum.
e)
f)
g)
h)
i)
j)
k)
l)
Voltage Grade and type of the Cable.

Colour of outer sheath.
Nominal cross-sectional area of the Cable Conductor.
Purchase Order No. & date.
Name and address of Consignee NBPDCL.
Number of Cores.
Gross Weight of packed and net weight of the composite Cable.
Drum No. & its direction of rotation (with an arrow)
m) Year of Manufacture.
The standard Drum Length will be 250 mtrs. in each Drum for all sizes subject to a
maximum tolerance of + 5%
18. LITERATURE AND MANUAL :
19. GUARANTEED TECHNICAL PARTICULARS :
A.
DESCRIPTION OF 11 KV AERIAL BUNCHED CABLES :

Description
Size
Power Core Messenger Wire
11KV (E) Grade Aerial Bunched Cable with 3(three)

Power Cores Stranded, compacted Circular Aluminium
Conductor screened with Black extruded semi conducting Compound, natural coloured XLPE
insulated core screened with Black extruded semi3x120 mm. + 1x180 mm.
conducting compound and one layer of copper tape and
covered with Black extruded PVC (Core identification
by ridges one, two and three over PVC covering) and
one bare Messenger wire : combination of galvanized
steel wire and Al. Alloy wires conforming to
IS 3130/1984, IS-398(Part-II)/1976,
IS-398(Part-IV)/1979 and IS-7098(Part-II)/1985 with
upto date amendments, i f any.
B.
ACCESSORIES REQUIRED FOR DRAWAL OF OVERHEAD LINE WITH

11KV AERIAL BUNCHED CABLES ON PSC POLE SUPPORT
Sl. No. D e s c r i p t i o n
1. Anchor Clamp
2. Suspension clamp assembly.
3. Pole mounted support clamps.
4. Pole clamps.
5. Insulation piercing connectors with cover or P.G. connectors with insulation cover.
6. Facade hooks.
7. Cable Jointing Kit for straight through & end joints.
NOTE : Offer for 11KV A B Cables should cover required accessories with details of
dimensions, materials and provisional quantity per K.M. of 11KV O/H Line.
------- --- ------ --- --- --- --- ------ --- --------------------------------------------------------------------------------------
DIMENSIONAL AND ELECTRICAL PARAMETERS

HT ABC : The standard sizes and technical characteristics for Single Core Cable.
Parameters
35
50
70
Nominal
6.8
8
10
Conductor dia
(mm)
Max. DC
0.868
0.641
0.443
resistance at
200C (ohm/km.)
Nominal
3.6
3.6
3.6
thickness of
insulation (mm)
Max. Short
3.4
4.72
6.7
Circuit Current
for 1 sec. (KA)
Max. continuous
106
150
190
Load (Amps.)
Note : The resistance values given in the Table are the max. permissible one.
95
11.3
120
12.7
150
14.1
185
15.8
0.320
0.253
0.206
0.164
3.6
3.6
3.6
3.6
8.96
11.32
14.16
17.46
230
265
300
345
TECHNICAL CHARACTERISTIC OF BARE MESSENGER WIRE FOR HT ABC :

Technical
35
50
Characteristic
Nominal
105
105
Sectional Area
(mm)
Approx. mass
1800
2000
with finished
Cable (Kg/Km.)
Breaking Load (KN)
Earth fault
8
8
current
carrying
capacity for 1
sec.(KA)
Modulus of Elasticity (KN/mm.)
Efficient of linear expansion (approx.)Shape
Nominal Area of Conductor (sq.mm.)

120
150
185
70
95
180
180
180
210
210
2600
3000
3300
3800
4200
14
As per IS: 398 (Part-II)/1979

14
14
16
59
23 x 10 /0C
Stranded Compacted Circular
16
SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS FOR 11KV AB CABLES

Sl.No.
Description Size-1 Size-2 Size-3
1. Manufacturers Name & Address
2. Lists of Standard applicable.
3. Power/Messenger Core Conductors.
3.1 A. Nominal cross sectional area, no. of standards and strand dia.
i)
ii)
Power Cross(mm.)n/mm.
Messenger Core(mm)/n/mm.
B.
Max. DC resistance of conductor at 20
i)
ii)
Power Cross (Ohm/Km.)

Messenger Core (Ohm/Km.)
C.
Approximate diameter of Conductor.
i)
ii)
Power Cross (mm.)

Messenger Core (mm.)
D.
Approximate dia over insulation.
i)
Power Cores.
3.2 Insulation
i)
Power Cross (mm.)
a) Material.
b) Nominal thickness.
c) Method of application.
3.3 Conductor Screening ;
a) Material.
b) Nominal thickness
c) Method of application.
3.4 Insulation Screening :
a) Material
c) Method application.
3.5 Metallic Screening :
a) Material.
3.6 Outer Sheath :
a) Material.
b) Nominal thickness
4. Messenger Wire (Bare)
i)
Nom. Cross Sectional area (sq.mm.)
ii) Approx. breaking load (KN)
5. Current ratings
i) Continuous current carrying capacity of Cable in Air at
0 C (Amp.)
Ambient Temp. 40
6. Approx. Weight (Kg./Km.)
7. No. of Cores
i)
ii)
Power Core (No.)

Bare Messenger (No.)
8. Derating factor
Derating factors for variation in Air Temp.
0 C
Air Temp.
9. Rating Factor.
9.1 Identification of Power Cores
9.2 Laying.
10. Details of Power/Messenger Core
10.1
Conductor :
a) Material
b) Flexibility Class as per IS : 8130/84
c) Form of Conductor.
10.2 Insulation
a) Material.
b) Form of Conductor
11. Voltage Grade of Power Cable.
a) Service Voltage.
b) Neutral Earthing.
12. Maximum Conductor Temperature.
a) Continuous (in Deg.C)
b) Short time (in Deg.C)
13. Type of curing of XLPE Insulati on
14. Completed Cable :
Approx. overall diameter.
Approx. Weight/KM
15. Cable Drums :
a) Length/Drum/
b) Dimension of Drum.
c) Shipping Weight.
d) Marking of Cable Drums as per IS
Yes/No.

AERIAL BUNCHED CABLE HAVING XLPEINSULATED L.T. CABLE FOR WORKING VOLTAGE UPTO 1100
VOLT
1. SCOPE :
The specification covers design, manufacture, testing before despatch, transportation, supply and delivery
of ISI marked 1100V Aerial Bunched Cable having XLPE insulated Cable (three Power Core) with stranded
compact circular aluminium conductors twisted over an insulated aluminium alloy messenger wire for use as
overhead distribution feeders, with/without one street lighting core with stranded compacted circular
aluminium conductor XLPE insulated suitable for use on 3-Phase AC System conforming to IS-14255/1985
2.
LOCATION:
Aerial bunched Cables for use in L.T. overhead lines are preferred than conventional L.T.overhead lines with
bare conductors as those are not subjected to frequent faults as happens with the bare conductors and also
to minimise problem of tree clearance etc. ABC System is safer and eliminates use of insulators and
associated hardwares required for bare conductors.
3.
Unless otherwise stipulated in this specification, the following standard with up to date amendment shall be
applicable.
IS 14255-1995 Specification for AERIAL Bunched Cables for working Voltage Up to & including 1100 Volts.
IS : 8130 Specification for Conductors for Insulated Cables.
IS : 398 (Part-IV) Specification for Aluminium Alloy Conductor.
4.
RATED VOLTAGE :
The rated Voltage of LT AB Cables shall be 1100 Volts.
5.
CONDUCTORS :
The Aluminium Conductors for phase/street lightning conductor shall be H2 of H4 grade Aluminium
complying with the requirements of IS-8130-1984 with up to date amendments. For messenger wire
stranded All Aluminium Conductor shall be of heat treated Aluminium Magnesium-Silicon Alloy Wires
containing approximate 0.5% magnesium and 0.5% silicon conforming to IS-398 (Part-IV)/1984 with up to
date amendments. The stranded conductor shall be clean & reasonably uniform in size and shape and its
surface shall be free from sharp edges. Not more than two joints shall be allowed in any of the wires
forming every complete length of conductor and no joint shall be within 300 mm. of any other joint in the
same layer. The joint shall be brazed, silver soldered or electric or gas welded. No joint shall be made in the
conductor, once it has been stranded.
6.
INSULATION :
The Conductor (with protective barrier, wherever applied) shall be provided with cross linked polyethylene
applied by extrusion conforming to the standard Specification as per IS 4255/95.The average thickness of
insulation when measured in accordance with relevant clause of the specification, shall not be less than
standard value specified. Upper surface of Cable insulation should be Ultra Violet Ray resistant Colour of
insulation shall be black.
7.
CORE IDENTIFICATION :
The Phase Conductors shall e insulated with black weather resistant, XLPE suitable for 1100 Volt insulation.
The Phase Conductor shall be provided with one, two and three ridges for quick identification. The individual
cores thus formed shall then be laid up around insulated messenger wire. The insulated messenger wire
shall have four ridges as per IS 14255:1995. The insulated street lighting conductor shall not have any
identification mark.

8.
MESSENGER-CUM-NEUTRAL WIRE :
The insulated messenger wire shall be of aluminium alloy, generally conforming to IS 398 (Part-IV)/1994
and suitably compacted to have smooth round surface to avoid damage to the other insulating sheath of
phase conductor twisted around the messenger.
9.
LAYING UP :
Three Power Cores having Ridges one, two and three and one street lighting without any ridge, if any
should be twisted over insulated messenger wire with right hand direction of lay. This will from the Aerial
Bunched Cable. Lay ratio shall be as specified in IS:14255/ 1995.
10. TESTS FOR CABLES :

10.1 Type test reports not older than 5 years of at least two sizes of Aerial Bunched Cableswith & without
street lighting core being procured and as specified in relevant IS & IEEand detailed in Clause 5:1 got
conducted from independent recognised Test House shall be furnished by the bidders along with the bid.
The bid not accompanied with test reports may not be considered for evaluation.
TYPE TEST REPORTS SHALL CONTAIN DETAILS OFFOLLOWING TYPE TESTS AS PER IS 8130-1984 & IS
10810
1. Tests on Phase/Street Light Conductor :
i) Tensile Test
ii) Wrapping Test.
2. Test on Messenger Conductor ;
i) Breaking Load.
ii) Elongation Test.
3. Physical Test for XLPE insulation :
iii) Hot Set Test.
iv) Shrinkage Test.
v) Water Absorption (Gavimetric)
4. Test for thickness insulation.
5. Insulation performance (Volume resistivity) Test.
6. High Voltage Test.
Report of above and any other type test provided in the relevant Indian Standards shall also be supplied.
10.2 ROUTINE TEST ;
These shall be carried out on all sizes of all drums of unamoured Cables by the supplier as given in Clause
5.1 and shall be got approved before despatch.
The Cable shall be inspected and tested at the manufacturers works before despatch as per ISS mentioned
in schedule of requirement. The manufacturer shall arrange all the necessary machinery, apparatus and
labour required for the testing purpose.
The routine tests embodied in the respective ISS are as per list given below :

1. Conductor Resistance Test.
2. High Voltage Test at room temperature.
3. Cold Bend Test (optional)
Any other routine test provided in the relevant Indian Standards shall also got conducted by the suppler.
10.3 ACCEPTANCE TEST :
These tests as per relevant IS & IEC shall be carried out in the presence of the purchasers representative if
so desired by the purchaser. The following shall constitute the acceptance tests.
(a) Tensile Test (for phase/street light conductor)
(b) Wrapping Test (for phase/street light conductor)
(c) Breaking Load Test for messenger Conductor.
(d) Elongation test for messenger conductor.
(e) Conductor resistance test.
(f) Test for thickness of insulation.
(g) Tensile Strength and Elongation at Break Test.
(h) Hot Set Test for XLPE insulation.
(i) Insulation resistance test and
(j) High Voltage Test.

Due to technical difficulty Marking of the Sequential Length is not required. Instead the Weight of Cable for
all sizes shall have to be mentioned for Per K.M. Length.

The Cable shall be supplied on suitable sized wooden non-returnable drum of robust construction for each
length of Cables as per I.S. 10418. A layer of water proof paper shall be applied to the surface of the drums
and over the outer cable layer. A clear space at least 40 mm. shall be left between the Cable and Logging.
Wood preservative shall be applied to the entire drum. Each metre length shall be embossed with the Trade
Name of Manufacturer and the work Employer (RGGVY XII Plan Projects). Packing shall be sturdy to protect
the Cable from any injury during transportation handling and storage. Both Cable ends shall be sealed with
PVC/Rubber Caps to eliminate ingress ofmoisture. Each Cable Drum shall have following information
stencilled on it.
a) Manufacturers Name, Brand Name of Trade Mark.
b) Year of Manufacture.
c) Nominal Cross-Sectional area of the Cable Conductor.
d) Type of Cable and Voltage Grade.
e) Length of the Cable.
f) Number of the Cores.
g) ISI Certification Mark, IS reference.
h) Colour of outer sheath.
i) No. of lengths in Drum (if more than one)
j) Cable Code.
k) Direction of rotation of drum (by means of an arrow)
l) Approximate gross weight in Kg./Km.
The standard Drum Length will be 500 mtrs. in each Drum for all sizes subject to a tolerance of + 5%.
13. INSPECTION :
The Cable shall be inspected at manufacturers works before despatch as per IS-7098 (Part-I)/1988 (with
upto date amendments) & IS 14255/1995. All the acceptance testsembodied in the above shall be

performed by the Inspecting Officer. The Manufacturer shall arrange without making any extra charges with
all the necessary machinery, apparatus and labour requirement for the testing purpose. The Cable
requirement for testing shall be to Firms Account.
14.
LITERATURE AND MANUAL :
15.
GUARANTEED TECHNICAL PARTICULARS :

A.
DESCRIPTION OF 1.1 KV AERIAL BUNCHED CABLES :

Description
1100V Grade L.T. Aerial Bunched Cable having three

Power Core & One Neutral-Cum-messenger Core of
stranded compacted circular Aluminium Black coloured
XLPE insulated & Core identification by ridges, one,
two and three & four respectively. One Street Lighting
Core of stranded, compacted Circular Aluminium
Conductor, Black coloured XLPE insulated without any
identification mark. Messenger-CumNeutral Wire
should be of stranded compacted Circular Aluminium
Alloy Conductor conforming to IS 8130/1984, IS398(Part-IV)/1979 and IS-14255/1995 with upto date
amendments, if any.
Size
Ph.Wire + St.Light Wire + MessengerCumNeutral Wire
1)
2)
3)
4)
3x25
3x35
3x50
3x70
+
+
+
+
1x16
1x16
1x16
1x16
+
+
+
+
1x25
1x25
1x35
1x50
sq.mm.
sq.mm.
sq.mm.
sq.mm.
(Provision for street light conductor is

optional and as per requirement)
B.
ACCESSORIES REQUIRED FOR DRAWAL OF L.T. OVERHEAD LINE WITH1100V GRADE AERIAL
BUNCHED CABLES ON PCE POLE SUPPORT
Sl.No.
1
2
Description
Anchor Clamp (3-Bolt and 2 Bolt Type)
Eye hook with Suspension Clamp Assembly.
3
4
5
PCC Pole Clamp.

Insulation Piercing Connectors with cover or P.G.Connectors with insulation cover.
Water Proof pre-insulated Hexagonal Compression Connectors & Lugs.
NOTE: Offer for L.T. Aerial Bunched Cables should cover required accessories with details of dimensions,
materials and provisional quantity per K.M. of L.T. O/H Line.

DIMENSIONAL AND ELECTRICAL PARAMETERS:
LTABC: The standard sizes and technical characteristics for Single Core Cable.
Nominal Sectional Area of Conductors (sq.mm.)
Parameters
No. of Strands
16
Dia. of Compacted Conductor

(MM)
Approx. Mass (Kg./Km.)
Max. DC resistance at 200C
(ohm/km.)
Insulation Thickness (mm.)
25
35
50
70
4.4
5.5
6.8
7.9
9.4
65
95
12 7
170
1.20
0.868
0.641
0.443
1.2
1.2
1.5
1.5
85
100
120
155
42
1.91
1.2
Current rating at 400C in air.

60
Note : The resistance values given in the Table are the max. Permissible one.
TECHNICAL CHARACTERISTIC OF INSULATED MESSENGER-CUM-NEUTRAL WIRE FOR LT ABC :

Nominal
Sectional
Area (mm.)
Dia.of Compacted
Conductor (mm.)
Approx. mass
(Kg./Km.)
Max. D.C.
resistance
At 20C
(Ohm./Km.)
Minimum
Tensile
Strength (KN)
25
5.9
65
1.38
7.4
35
6.9
95
0.986
10.3
50
7.9
127
0.689
14.0

THIS SECTION COVERS TECHNICAL SPECIFICATION FOR LT SWITCH BOARD OF16,25,63 & 100 KVA
(SINGLE/ 3-PHASE) DISTRIBUTION TRANSFORMER
A. LT SWITCH BOARD FOR16 and 25 KVA (Single/ 3-Phase)DISTRIBUTION TRANSFORMER
1. GENERAL
This specification covers LT switchboards required for 415 Volts system voltage for 3 Phase 4 wires and single
phase 2 wires with neutral solidly grounded system. They are to be provided in distribution substations on
secondary side of transformer.
LT switchboard shall be provided with insulated handles.
The box shall have two compartments each lockable separately. The LT connections through copper
cable/conductor from LT bushing of DT shall terminate at SPN MCB/TP MCCB . The output fromSPN MCB/TP
MCCBshall be extended to the lower compartment of the box. In the lower compartment, LT buses including
neutral bus shall be mounted.
The switchboard shall comprise of MS outdoor housing containing incoming and outgoing feeders to match with the
capacity of the Distribution Transformer to be controlled as indicated below.
S.No.
A
B
C
Type of DTR
16 KVA 1-Phase DTR

16 KVA 3-Phase DTR
25 KVA 3-Phase DTR
Incomer
63 A SPN MCB
63 A TP MCCB
100 A TP MCCB
Outgoing
2 X 32 A SPN MCB
2X40 A TP MCCB
3 X 40 A TP MCCB
Mounting
Arrangement
Channel Frame
Channel Frame
Channel Frame
All outgoing LT feeders (numbers to be decided by utility based on number of service connection/
outgoing feeders) shall emanate from LT buses get connected toLT feeder through respective SPN MCB/TP
MCCB. Suitable no. of holes with cable glandsalong with IS approved gaskets shall be provided in the lower
compartment of thedistribution. Neoprene Rubber gasket shall be used in the door to avoid ingress ofmoisture
and other elements in the distribution box. The distribution box shall havepainting as per relevant IS standards.
The Switchboard shall be made of MS of thickness not less than 2.5 mm. door panel and 4 mm Body panel and
shall be dust, moisture, vermin and weather proof with degree of protection IP 55 as per IS: 13947 suitable for
outdoor use. Box shall be mounted on distribution transformer / pole structure.
All parts, doors, movable covers and panels shall be fitted all around with neoprene gaskets. The gaskets shall
be provided along a channel on periphery of the doors and covers. Ventilating louvers shall be provided with
brass screen and filters.
The Switchboard shall have neat appearance inside and outside with all equipment mounted flush having no
visible welds, with all exterior surfaces even and smooth.
The door is to be provided in front with internal hinges. Cable entries shall be from bottom. Cable gland plate
and gland shall be provided at the bottom plate. The wiring shall be such that terminals are accessible by use of
ordinary tools. Connections shall be provided with adequate clearance to avoid short circuits and risk of fire and

ease in connection and disconnection. All internal wiring should be with fire resistance low smoke PVC insulated
cables of copper core size 2.5 sq. mm minimum complying with IS: 1554.
2. GOVERNING STANDARDS
The equipment will be manufactured in conformity with the following Indian Standard Specification (latest editions).
IS:2950 A.C. Connectors
IS:8623/1993 Low Voltage Switchgear and Control gear Assemblies
IS:9676/1980 Temperature weather condition.
3. SPN MCB/TPMCCB
Incoming and Outgoing circuits shall be provided with SPN MCB/TP MCCB.
4. BUS BAR AND CONNECTIONS
Phase and neutral bus bar shall be provided along with links and connectors of electrolytic aluminium with 99.9
percent purity of approved make. The phase bus bars should be insulated with PVC or heat shrinkable sleeves of
phase code coloured i.e. red, yellow and blue or suitably painted with plastic insulating compounds.
The bus bars shall be suitably supported on insulators to stand the mechanical and electric forces on account of short
circuit on the system.
The bus bar conductors shall be uniform throughout its length and in no case tapered. The size shall be so chosen to
limit current density to 1.0 Amps per sq. mm.
The electrical contacts between bus bars and connecting link shall be bolted type and lavish contact surface shall be
provided. Bus bars shall be enclosed in a separate compartment with link arrangement for extension.
The neutral bus bar should be of the same size and current carrying capacity as that of phase bus bar.
All bus bar joints, live bolted connections; joints between cable terminals and switchgear terminals etc. shall be
covered with electric insulating non-corrosive sealing compound or heat shrinkable tapes to avoid accidental contact
and flashover.
5. EARTHING
Suitable Earthing arrangement shall be provided.
6. TESTS
Each type of LV Switchboard shall be completely assembled, wired, adjusted andtested at the factory as per the
relevant standards and during manufacture and oncompletion.
Routine Test
The tests shall be carried out in accordance with IS 13947 and 8623 include includingbut not necessarily limited to
the following:
(a) Visual Check
(b) Verification of Component Rating

(c) Other Checks
i) Easy Accessibility and Maintenance
ii) Colour Coding provided by coloured tapes.
iii) Bus bar dimensions
iv) Degree of Protection check by paper.
(d) Dimension check
(e) Insulation Resistance Tests
(f) Mechanical Operation Tests
(g) Bus bar support and clearances
(h) Continuity of circuits and Function
(i) Painting
(j) Overload Release setting of the Circuit Breakers
Type Test
All type tests shall be performed in accordance with IS 13947 and 8623
7. ENERGY METER
Each incoming panel shall be provided with the energy meter. (Details of the energy meter shall be given
separately by purchaser)
8. PROTOTYPE SAMPLE
A prototype sample of each category of the LV Switchboard should be initially manufactured and submitted for
approval of purchaser before taking up mass manufacture.

B. LT SWITCH BOARD FOR 63 and 100 KVA DISTRBUTION TRANSFORMERS
1. GENERAL
This specification covers LT switchboards required for 415 Volts system voltage for 3phase, 4 wires, neutral solidly
grounded system. They are to be provided in distribution substations on secondary side of transformer.
The switchboard shall comprise of MS outdoor housing containing incoming and outgoing feeders to match with the
capacity of the Distribution Transformer to becontrolled as indicated below.
Sl. No.
Transformer
Capacity
KVA
Full Load
Current
Amps
Incoming
Circuit
Configuration
Outgoing
Circuits
Configuration
Mounting
Arrangement
63
88 Amp
125 A TP MCCB
3 X 63 A TP MCCB
Channel Frame
100
139
200 A TP MCCB
2 X 63 A TP
MCCB& 1 X 100 A
TP MCCB
Channel Frame
The Switchboard shall be MS of thickness not less than 2.5 mm. door panel and 4 mm Body panel and shall be dust,
moisture, vermin and weather proof with degree of protection IP 55 as per IS: 13947 suitable for outdoor use. They
shall be of freestanding structure, independent floor mounting design or mounted on a channel frame at a suitable
height of about 1.2 meters from the floor. It shall have sufficient channel and angle re-enforcement to resist
vibrations and rigidity during transportation, erection and operation.
All parts, doors, movable covers and panels shall be fitted all around with neoprene gaskets. The gaskets shall be
provided along a channel on periphery of the doors and covers. Ventilating louvers shall be provided with brass
screen and filters.
The Switchboard shall have neat appearance inside and outside with all equipment mounted flush having no visible
welds, with all exterior surface even and smooth. The door is to be provided in front with internal hinges.
Cable entries shall be from bottom. Cable gland plate and gland shall be provided at the bottom plate. The wiring
shall be such that terminals are accessible by use of ordinary tools. Connections shall be provided with adequate
clearance to avoid short circuits and risk of fire and ease in connection and disconnection. All internal wiring should
be with fire resistance low smoke PVC insulated cables of copper core size 2.5 sq. mm minimum complying with IS:
1554.
The entire switchboard shall be suitable to withstand short circuit current equivalent to 25 MVA 415 Volts for one
second.
2. OPERATION AND SAFETY
All operations shall be from the front.
3. GOVERNING STANDARDS
The equipment will be manufactured in conformity with the following Indian Standard Specification (latest editions).
IS:2950 A.C. Connectors
IS:8623/1993 Low Voltage Switchgear and Control gear Assemblies

IS:9676/1980 Temperature weather condition;
4. TP MCCBFUSE SWITCH
Incoming and Outgoing circuits shall be provided with TP MCCBFuse Switch.
5. BUS BAR AND CONNECTIONS
Triple pole and neutral bus bar shall be provided along with links and connectors of electrolytic aluminium with 99.9
percent purity of approved make. The phase bus bars should be insulated with PVC or heat shrinkable sleeves of
phase code coloured i.e. red, yellow and blue or suitably painted with plastic insulating compounds.
The bus bars shall be suitably supported on insulators to stand the mechanical and electric forces on account of short
circuit on the system.
The main bus bars shall run horizontally at top and the branch bus bars vertically withconnections to the individual
breaker panels.
The bus bar conductors shall be uniform throughout its length and in no case tapered.The size shall be so chosen to
limit current density to 1.0 Amps per sq. mm. Sufficientventilation shall be conceived not to allow temperature rise
above 30 Deg. C.
The electrical contacts between bus bars and connecting link shall be bolted type and lavish contact surface shall be
provided. Bus bars shall be enclosed in a separate compartment with link arrangement for extension.
The neutral bus bar should be of the same size and current carrying capacity as that ofphase bus bar.
All bus bar joints, live bolted connections; joints between cable terminals andswitchgear terminals etc. shall be
covered with electric insulating non-corrosivesealing compound or heat shrinkable tapes to avoid accidental contact
and flashover.
6. EARTHING
Earthing arrangement shall be provided with earth bars of electrolytic aluminium and earthing terminals at two
ends similar to the arrangement described in General Technical Specification. The earth bar shall be of
electrolytic aluminium running from end to end of the switchboard terminating in two earthing terminals at the
two ends. Earthing shall be accomplished as described in General Technical Specification.
7. ENERGY METER
Each incoming panel shall be provided with the energy meter. (Details of the energy meter shall be given
separately by purchaser)
8. TESTS
Each type of LV. Switchboard shall be completely assembled, wired, adjusted and tested at the factory as per
the relevant standards and during manufacture and on completion.
Routine Test
The tests shall be carried out in accordance with IS 13947 and 8623 include including but not necessarily limited
to the following:
(a) Visual Check

(b) Verification of Component Rating
(c) Other Checks
i) Easy Accessibility and Maintenance
ii) Colour Coding provided by coloured tapes.
iii) Bus bar dimensions
iv) Degree of Protection check by paper.
(d) Dimension check
(e) Di-electric Test of circuits
(f) Insulation Resistance Tests
(g) Mechanical Operation Tests
(h) Bus bar support and clearances
(i) Continuity of circuits and Function
(j) Painting
(k) Verification of wiring
Type Test
All type tests shall be performed in accordance with IS 13947 and 8623
9. PROTOTYPE SAMPLE
A prototype sample of each category of the LV Switchboard should be initially manufactured and submitted for
approval of purchaser before taking up mass manufacture.
VOLUME -II : Section-II(B) 1

DISTRIBUTION TRANSFORMER
PART 1: GENERAL
1.
SCOPE
1.1 The specification covers the design, engineering, manufacture, stage inspection, testing, pre-delivery
inspection, supply, delivery, loading, unloading and performance requirements of 11/0.433 KV non-sealed type
aluminum wound BEE specified 3 Star Distribution Transformers for outdoor. The transformers shall be double
wound, three phase, CRGO M3 Grade (0.23mm) or better, oil immersed with ONAN cooling with Oil filled up to
maximum permissible level. The ratings required under this specification are 25 KVA, 63 KVA & 100 KVA with
Aluminum windings.
1.2 The equipment offered should have been successfully type tested within five years from date of tender and
the designs should have been in satisfactory operation for a period not less than one years as on the date of Bid
opening. Compliance shall be demonstrated (i) authenticated copies of the type test reports and (ii) performance
certificates from the users, specifically from Central Govt. / State Govt. or their undertakings.
2.
CODES & STANDARDS
2.1 Except where modified by this specification, the transformers shall be designed, manufactured and tested in
accordance with the latest editions of the following standards.
IEC/ISO
Indian Standard
IEC 71
IEC 76
IEC 137
Insulation Coordination
IS 2026
Power Transformers.
IS 1180
Outdoor Single phase Distribution Transformers up

to 500 KVA, 11/ 0.433 KV, Non- Sealed Type
IS 2099
Bushing for Alternating Voltages above 1000V
IEC 156
IEC 296
Method of determining Electri Strength of

Insulating Oils.
IS 335
IS 6792
IEC 354
Subject
IS 6600
Specifications for Unused Mineral Insulating Oils

for Transformers and Switchgear.
Method of determination of electric
insulating oils.
Loading Guide for oil immersed
strength of
Transformers
IEC 437
Radio Influence Voltage Measurement.
IEC 551
Determination of Transformer and Reactor Sound

Levels
Terminal and Tapping markings for power
transformers.
Guide to the Lightning and Switching impulse
testing of Power Transformers and Reactors
IEC 616
IEC 722
ISO 1460/BS 729
Galvanizing
This list is not to be considered exhaustive and reference to a particular standard or recommendation in this
specification does not relieve the Supplier of the necessity of providing the goods complying with other
relevant standards or recommendations.

3.
SERVICE CONDITIONS
The service conditions shall be as follows: (To be confirmed by PIA as per locality of project)
Hilly area
maximum altitude above sea level
Plane
area
1000m
maximum ambient air temperature
50 C
50 C
maximum daily average ambient air temperature
40 C
40 C
minimum ambient air temperature
-5 C
-30 C
5000m
maximum temperature attainable by an object exposed to the

sun
maximum yearly weighted average ambient temperature
32 C
32 C
maximum relative humidity
100%
100%
70
70
120
120
average annual rainfall
1500 mm
1500 mm
maximum wind pressure
260Kg/m2
260Kg/m2
average number of thunderstorm days

(isokeraunic level)
average number of rainy days per annum
per
annum
60 C
60 C
Environmentally, the region where the equipment will be installed includes coastal areas, subject to high relative
humidity, which can give rise to condensation. Onshore winds will frequently be salt laden. On occasions, the
combination of salt and condensation may create pollution conditions for outdoor insulators.
Therefore, outdoor material and equipment shall be designed and protected for use in exposed, heavily
polluted, salty, corrosive, tropical and humid coastal atmosphere.
4.
SYSTEM CONDITIONS:
The equipment shall be suitable for installation in supply systems of the following characteristics.
Frequency
Nominal system voltages
50 Hz 5%
11 KV System
LV System
Maximum system voltages
433/250 V
11 KV System
LV System
Minimum LV voltage
Nominal short circuit apparent power of the

system
(NEC)
11 KV System
11 KV
12 KV
476 V
392 V
500 MVA (IS:2026)

Insulation levels :
1.2/50 sec impulse withstand

Power frequency one minute withstand
(wet and dry)
Neutral earthing arrangements :
11 KV System
95 KV peak (As Per

BEE, Clause No.10 )
11 KV System
28 KV (rms)
LV System
3 KV (rms)
LV System
Solidly earthed
PART 2 : TECHNICAL
SPECIFIC TECHNICAL REQUIREMENTS
1 Rated KVA (ONAN rating)
25KVA. 63 KVA, 100 KVA 11/0.433 KV
2 No. of phases
3 Type of installation
Outdoor
4 Frequency
50 Hz ( 5% )
5 Cooling medium
Insulating Oil (ONAN)
6 Type of mounting
On Channels.
7 Rated voltage
a) High voltage winding
11 KV
b) Low voltage winding
0.433 KV
8 Highest continuous system voltage

a) Maximum system voltage ratio (HV / LV )
12 KV / 0.476 KV
b) Rated voltage ratio (HV / LV )
11 KV / 0.433 KV
9 No. of windings
Two winding Transformers
10 Type of cooling
ONAN ( Oil natural / Air natural )
11 KVA Rating corresponding to ONAN
100%
cooling system
12 Method of connection:
HV:
Delta
LV:
Star

13 Connection symbol
Dyn 11
14 System earthing
Neutral of LV side to be solidly earthed.
15 Percentage impedance voltage on normal:
% Impedance + Tolerance %
tap and KVA base at 750 C corresponding to
4.5 + 10%
HV/ LV rating and applicable tolerances
(No negative tolerance will be allowed)
16 Intended regular cyclic overloading of
As per IEC 76-1, Clause 4.2
windings
17 a) Anticipated unbalanced loading
Around 10%
b) Anticipated continuous loading of windings
110 % of rated current
(HV / LV)
18 a) Type of tap changer
NA
b) Range of taping
No Tap
19 Neutral terminal to be brought out
On LV side only
20 Over Voltage operating capability and
112.5 % of rated voltage ( continuous )
duration
21 Maximum Flux Density in any part of the
1.5 Tesla
core and yoke at rated KVA, rated voltage

i.e 11 KV / 0.433 KV and system frequency
of 50 HZ
22 Insulation levels for windings :a) 1.2 / 50 microsecond wave shape Impulse
HV: 95
LV: N.A.
withstand (KVP)
b) Power frequency voltage withstand (KVrms)
HV: 28
LV: 03
23 Type of winding insulation

a) HV winding
Uniform
b) LV winding
Uniform
24 Withstand time for three phase short circuit
2 Seconds
25 Noise level at rated voltage and frequency
As per NEMA Publication No. TR-1.
26 Permissible Temperature Rise over ambient

temperature of 500C
a) Of top oil measured by thermometer.
350C
b) Of winding measured by resistance.
400 C
27 Minimum HV clearances in air (mm) :a) Phase to Phase
280
b) Phase to ground
140
28 Bushings & Terminals

a) HV winding line end
12 KV oil filled porcelain communicating

type of bushings ( Antifog type )
b) LV winding
0.4 KV porcelain type of bushing

(Antifog type)
29 Insulation level of bushing
HV
LV
a) Lightning Impulse withstand (KVP)
95
Not applicable
b) 1 Minute Power Frequency withstand
28
voltage (KV rms )

c) Creepage distance (mm) (minimum)
25 mm/ KV
30 Material of HV & LV Conductor
EC grade Aluminum
31 Maximum current density for HV and LV

1.6 Amp/ mm2.
winding for rated current

32 Polarisation index i.e. ratio of megger
Shall be greater than or equal to 1.5, but
values at 600 sec. to 60 sec for HV to earth,
less than or equal to 5.
L.V to earth and HV to LV.

33. Core Assembly
Boltless type
34. Losses:- The losses shall not exceed the value given below
KVA
Rating
Load
losses at
75C
Watts
25
No-load
losses
(Fixed
loss)
Watts
100
63
180
1235
100
260
1760
685

6. TYPE OF TRANSFORMER
6.1 The transformers shall be of core type construction, double wound, three phase, oil immersed, 11/0.433KV, 50
Hz with natural oil and air cooling (ONAN) to be used as step down transformers for outdoor use. The design of the
tank, fittings, bushings, etc shall be such that it will not be necessary to keep the transformer energized to prevent
deterioration as the transformers may be held in reserve, outdoors, for many years.
7.
PERFORMANCE , CAPACITY AND SHORT CIRCUIT RATINGS
7.1
The following ratings are covered under this specification
25 KVA,11/0.433 KV, Aluminum wound

7.2 The transformer shall be capable of supplying a continuous load equal to its KVA rating, under the following
conditions :
Continuous steady load;
Design at maximum ambient air temperature of 50C;
40C average winding temperature rise and 35C top oil temperature rise for conventional breathing
transformers.
7.3 The transformer may be overloaded during emergency up to 150% of its continuous rating in accordance with
IEC Publication 354 or IS: 6600. Bushings. and other current-carrying parts shall also be designed for this
condition.
7.4 The transformer shall be capable of withstanding for two seconds without damage to any external short
circuit, with the short circuit MVA available at the terminals of either winding with rated voltage on the other
winding. If short circuit tests have been carried out on the particular design of transformer offered, the test results
shall be supplied with the bid.
7.5 The thermal ability to withstand short circuit shall be demonstrated by calculation.
7.6 The transformer shall be capable of withstanding the thermal and dynamic effects of short circuits, as
specified in IEC 76-5 or IS: 2026: Ability to withstand short circuits.
7.7 The maximum flux density in any part of the core and yoke at rated KVA, Voltage and frequency shall not
exceed 1.5 Tesla.
8. VOLTAGE RATIO & TAPPING RANGE
8.1
The transformers shall have the following ratio :the nominal voltage ratio shall be 11,000/ 433 V for 25 KVA, 63 KVA, 100 KVA 11/0.4KV transformers;
Tolerance on the voltage ratio shall be 0.5%.
transformers up to 100 KVA, 11/0.4 KV no tap changer is required.
8.2 The bidder shall state in the technical schedule, the percentage regulation at full load, power factor 1.0 and at
full load, power factor 0.85 lagging.
Transformers shall be suitable for parallel operation with each other.

9. PERCENTAGE IMPEDANCE
9.1 The Percentage of Impedance at 75C shall be 4.5 % for 25 KVA,63 KVA & 100 KVA transformers. No negative
tolerance on percentage Impedance is allowed.
10 LOSSES
The load losses shall not exceed the values given below:KVA Rating
25
63
100
No-load losses (Fixed

loss) Watts
100
180
260
Load losses at 75C

Watts
685
1235
1760
10.1 The above losses are maximum allowable and there should not be any positive tolerance. Transformer having
losses more than above values shall be rejected.
10.2 The offered transformer(s) should have been type-tested designed at CPRI/ NABL Accredited laboratory. The
bid shall be accompanied with type-test reports (short circuit test and Impulse test) conducted at Central Power
Research Institute / NABL Accredited laboratory for the offered transformers within five years from date of tender.
The short circuit test report(s) must contain the measured no load loss and load loss, determined by CPRI/ NABL
Accredited laboratory.
In case of any doubts, Employer reserves the right to verify the original type test reports of CPRI/ NABL Accredited
laboratory or ask the supplier to conduct the type tests at CPRI/ NABL Accredited laboratory at his (suppliers) cost
for re-confirmation of the test results particularly no load losses, load losses and percentage impedance.
10.3 If the bidder quotes lower values of losses than the CPRIs measured losses, he has to prove the same by
conducting the Impulse & short Circuit tests at CPRI/ NABL Accredited laboratory along with measurement of no
load losses and load losses at his own cost in presence of Contractor/manufacturer authorized representative
without any financial liability to Employer
10.4 However, if the loss figures will exceed the stipulated values as per specification, the transformer(s) shall be
out rightly rejected.
11. VECTOR GROUP
11.1 The transformers shall be connected delta-star, in accordance with vector group reference Dyn11 of IEC 76/
IS-2026
11.2 The LV neutral shall be brought out to a terminal bushing, which shall be identical to the phase bushings in all
respects.
12. LOSSES
12.1 Transformers would be out rightly rejected if losses exceed the values indicated at clause-10 above.
13. FLUX DENSITY
The flux density at rated voltage & rated frequency shall not exceed. 1.5 Tesla. The transformer must be capable
of operating at 10% over voltage and at frequency of 48.5 Hz without saturation.
14. INSULATION LEVELS
The insulation levels as defined in IEC 76-C/ IS: 2026 Insulation levels and dielectric test shall apply as per Table 2:

Table 2: Transformer insulation level
Basic Impulse voltage

Level (Kvp) (1.2/50
micro. sec.
Wave )
Power Frequency
voltage withstand level,
Wet and Dry
(KV)
HV
Winding
95
LV Winding
28
Not
Applicable
Bushings and terminals shall be adequate for the winding insulation tests and shall flash over externally before
puncture or internal failure can occur.
15. NOISE LEVEL
The average noise level of the transformers shall not exceed 51 db. The measurement shall be carried out in
accordance with IEC 551 at a distance of 300mm from the envelope of the transformer.
16. RADIO INFLUENCE VOLTAGE
The maximum radio influence voltage shall be 250 V, measured as specified in IEC 437.
17 CORE AND WINDINGS

17.1 Core
17.1.1 Stage level inspection for core construction shall be carried out by the owner.
17.1.2 Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure and the action
of hot transformer oil.
17.1.3 The core shall be constructed from high grade, non-ageing, Cold Rolled Grain Oriented (CRGO) silicon steel
of M3 Grade (0.23mm) or HIB grade laminations only. No other core materials shall be entertained. Bidders are
requested to note that only PRIME CORE M3 Grade (0.23mm) materials HIB grade is to be used. In no case, second
grade core material is to be used. The employer at his discretion, may select samples from the core laminations and
get the same tested in CPRI/ NABL Accredited laboratory to prove the quality of the core material.
17.1.4 For the above purpose, the supplier shall have to offer every batch of core laminations received from his
Sub-Vendor along with Invoice of the sub-vendor, Mills test certificate, packing list, Bill of landing, Bill of entry
certificate to customs etc. towards proof of prime core materials for verification by the Employers representative
without any cost to the Employer. Besides, the contractor must mention in his bid about the type of CRGO /
Amorphous laminations to be utilized for the offered transformers along with a copy of the specific core loss curve at
different flux densities.
17.1.5 Core materials should be directly procured either from the manufacturer or through their accredited
marketing organization of repute, but not through any agent.

The core and winding shall be capable of withstanding shocks during transport, installation and service. Provision
shall be made to prevent movement of the core and windings relative to the tank during these conditions and also
during short circuits.
17.1.6 The design shall avoid the presence of pockets which would prevent the complete emptying of the tank
through the drain valve. The core material offered in the tender to be checked for its correctness before core coil
assembly. For this, the tendered must ask for core and coil inspection before its tanking.
17.1.7 The laminations shall be free of all burrs and sharp projections. Each sheet shall have an insulting coating
resistant to the action of hot oil.
17.1.8 The insulation structure for the core to bolts and core to clamp plates shall be such as to withstand 2000 V
DC voltage for one minute.
17.1.9 The completed core and coil shall be so assembled that the axis and the plane of the outer surface of the
core assemble shall not deviate from the vertical plane by more than 25mm.
17.1.10 all steel sections used for supporting the core shall be thoroughly shot or sand blasted, after cutting,
drilling and welding.
17.1.11 the finally assembled core with all the clamping structures shall be free from deformation and shall not
vibrate during operation.
17.1.12
the core clamping structure shall be designed to minimize eddy current loss.
17.1.13
the framework and clamping arrangements shall be securely earthed.
17.1.14
the core shall be carefully assembled and rigidly clamped to ensure adequate mechanical strength.
17.1.15
Oil ducts shall be provided, where necessary, to ensure adequate cooling inside the core. The welding
structure and major insulation shall not obstruct the free flow of oil through such ducts.
17.1.16T the design of magnetic circuit shall be such as to avoid static discharges, development of short circuit
paths within itself or to the earth clamping structure and production of flux component at right angle to the plane of
the lamination, which may cause local heating. The supporting framework of the cores 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.
17.1.17 the construction is to be of boltless core type. The core shall be provided with lugs suitable for lifting the
complete core and coil assembly. The core and coil assembly shall be so fixed in the tank that shifting will not occur
during transport or short circuits.
17.2 INTERNAL EARTHING
17.2.1
All internal metal parts of the transformer, with the exception of individual laminations and their
individual clamping plates shall be earthed.
17.2.2
The top clamping structure shall be connected to the tank by a copper strap. The bottom clamping
structure shall be earthed by one or more the following methods:
a) By connection through vertical tie-rods to the top structure.
b) By direct metal to metal contact with the tank base.
c) By a connection to the structure on the same side of the core as the main earth connection to the tank.
17.2.3 The magnetic circuit shall be connected to the clamping structure at one point only and this shall be
brought out of the top cover of the transformer tank through a suitably rated insulator. A disconnecting link shall be
provided on transformer tank to facilitate disconnections from ground for IR measurement purpose.

17.2.4 Coil clamping rings of metal at earth potential shall be connected to the adjacent core clamping structure
on the same side as the main earth connections.
17.3
Windings
17.3.1 Winding shall be subjected to a shrinking and seasoning process, so that no further shrinkage occurs
during service. Adjustable devices shall be provided for taking up possible shrinkage in service.
17.3.2 All low voltage windings for use in the circular coil concentric winding shall be wound on a performed
insulating cylinder for mechanical protection of the winding in handling and placing around the core.
17.3.3 Winding shall not contain sharp bends which might damage the insulation or produce high dielectric
stresses. No strip conductor wound on edge shall have width exceeding six times the thickness.
17.3.4 The winding insulation shall be free from insulating compounds which are liable to soften, ooze out, shrink
or collapse. It shall be non catalytic and chemically inert in hot transformer oil during normal service.
17.3.5 The stacks of windings are to receive adequate shrinkage treatment.
17.3.6 The windings and connections are to be braced to withstand shocks during transport, switching, short
circuit or other transient conditions.
17.3.7 Permanent current carrying joints in the windings and leads shall be welded or brazed. Clamping bolts for
current carrying parts inside oil shall be made of oil resistant material which shall not be affected by acidity in the oil
steel bolts, if used, shall be suitably treated.
17.3.8 Terminals of all windings shall be brought out of the tank through bushings for external connections.
17.3.9 The windings shall be uniformly insulated and the L.V neutral points shall be insulated for full voltage.
17.3.10 The completed core and coil assemble shall be dried in vacuum at not more than 0.5mm of mercury
absolute pressure and shall be immediately impregnated with oil after the drying process to ensure the elimination
of air and moisture within the insulation. Vacuum may be applied in either vacuum over or in the transformer tank.
17.3.11 The winding shall be so designed that all coil assembles of identical voltage ratings shall be
interchangeable and field repairs to the winding can be made readily without special equipment. The coils shall have
high dielectric strength.
17.3.12 Coils shall be made of continuous smooth high grade electrolytic copper or aluminium conductor, shaped
and braced to provide for expansion and contraction due to temperature changes.
17.3.13 Adequate barriers shall be provided between coils and core and between high and low voltage coil. End
turn shall have additional protection against abnormal line disturbances.
17.3.14 The insulation of winding shall be designed to withstand voltage stress arising from surge in transmission
lines due to atmospheric or transient conditions caused by switching etc
17.3.15 Tapping shall not be brought out from inside the coil or from intermediate turns and shall be so arranged
as to preserve as far as possible magnetic balance of transformer at all voltage ratios.
17.3.16
Magnitude of impulse surges transferred from HV to LV windings by electromagnetic induction and
capacitance coupling shall be limited to BIL of LV winding.
17.3.17 The winding conductor shall be of Aluminum. The current density shall not exceed 1.6 Amp/ mm for
aluminium at normal full load current.

18. BUSHINGS AND TERMINATIONS

18.1 Bushings
18.1.1 Bushings shall be of the outdoor type and easily replaceable. Cemented in types will not be accepted. They
shall be sufficiently robust to withstand normal transport and erection hazards and shall confirm to IEC 137 /IS 3347
and 2099.
18.1.2 All bushings shall have a minimum creepage distance of 25 mm /KV and shall have a continuous rating of
200% of the transformer rating. The protected creepage distance shall not be less than 50% of the total.
The following minimum 11 KV clearance shall be provided:
External (Air) for 11 KV
Phase to phase
255 mm
Phase to earth
140 mm
18.1.3 The 11 KV bushings of transformers shall be provided with a bi-metallic terminal connector or suitable
device to receive 35100 mm AAAC or ACSR conductor directly without any bi-metallic action.
18.1.4 The dia of HT bushing stud should not be less than 12.5 mm. The secondary bushings of transformers shall
be fitted with non ferrous threaded terminals of dia not less than 20 mm. With the exception of brass the terminals
shall be protected from atmospheric deterioration by suitable tinning or by some other approved coating.
18.1.5 The terminals are to be supplied with one 16mm bolt, one conic spring washer, one matching flat washer,
one nut and one lock nut for each hole in the terminal plate.
18.2 Bushing Labels

18.2.1 The HV bushings shall be labeled U, V and W and the LV bushing u, v, w and n. Marking letters shall be at
least 12 mm high. The means of marking shall be either,
engraved metal plate; or
etched anodized aluminum.

Phase identification by adhesive stickers shall not be acceptable.
18.2.2 If labeling is to be carried out on the tank, it is preferred that one plate be used rather than individual
markings for each phase, in order to prevent incorrect phase markings. Labels shall conform to the requirements of
the section on labels in this specification.
18.3
Earthing Terminals
All transformers shall be provided with two earthing terminals conforming to relevant Standards and M12 ISO metric
bolt and nut which shall be non ferrous. It shall include a spring washer and lock washer.
19 TANK FABRICATION
19.1
All transformer sizes, the tank shall be of bolted type construction in accordance with IS 1180 (Part 2).
The tank shall be at atmospheric pressure at an internal temperature of 10C;
The tank shall be designed for an internal pressure of 100 Kg/m at 50C ambient conditions. It shall be capable
of withstanding an unlimited number of 24 hours cyclic variations of internal pressure from atmospheric to this
value.

The tendered shall state the top oil temperature at which the tank internal pressure shall reach the value of
100 kN/m and the value of steady load which will result in this top oil temperature with an ambient temperature of
45C.
Adequate space shall be provided at the bottom of the tank for collection of sediments.
19.2
Transformer tanks of all types shall be designed so that the completed transformer can be lifted and
transported without permanent deformation or oil leakage. Stiffeners provided on all the four side walls for rigidity
should be so designed that there is no accumulation of water.
19.3
The Tank shall be of rectangular shape with round edges fabricated from tested quality mild steel plates
with minimum thickness of 3.15 mm. for the side walls while top cover and the bottom plate of the tank shall have a
minimum thickness of 5 mm. The transformer tank and the top cover shall be designed in such a manner as to leave
no external pockets in which water can log, or any internal pocket where air/ gas can accumulate.
Edge of Top cover should be bend downwards so as to avoid water through cover plate gasket. The width of the
bend plate shall be 25mm minimum.
19.4
All sealing washers / gaskets shall be made of oil and heat resistant neoprene rubber or neoprene bonded
cork seals suitable for temperature as stipulated in this specification. Surfaces at gasketted joints shall be such that
an even face is presented to gasket, thereby eliminating the necessity for the gasket to take up surface
irregularities.
19.5
All pipes, radiators, stiffeners or corrugations which are welded to the tank wall shall be welded externally
and shall be double welded wherever possible. All welds shall be stress relieved.
19.6
The transformer tank shall be complete with all accessories, lifting lugs etc. and shall be designed to allow
the complete transformer filled with oil to be lifted by crane or jacks without risk of any damage and can be
transported by Rail/ Road without straining any joints and without causing any leakage of oil.
19.7
Provision of Cable End Box with suitable gland.
19.8 The height of the tank shall be such that minimum vertical clearance up to the top cover plate of 80mm is
achieved from the top of the yoke.
20 PRESSURE RELIEF DEVICES
Transformers shall be fitted with a pressure relief device in the form of explosion vent.
The tendered shall state the pressure at which it is designed to operate.
21 OIL LEVEL GAUGE

A suitable oil level gauge (Magnetic type of dia 100 mm) shall be fitted on the transformers and so located that it
can be easily read from ground level. The gauge fitted with the conservator shall be graduated for temperatures of
5C, 30C and +98C.
22 CONSERVATORS AND BREATHERS
All the transformers shall be provided with a conservator tank.
22.1 The conservator tank shall be so designed and located as to eliminate any trapping of air in the transformer or
pipe work. It shall be inclined at an angle of about 5 degrees to the horizontal towards the drain plug and the pipe
connecting the main tank to the conservator should project about 20 mm above the bottom of the conservator so as
to create a sump for the collection of impurities. Minimum oil level corresponding to 5C shall be well above the
sump level.

22.2 All transformers shall be fitted with a silica gel breather of weatherproof design at a convenient height with oil
seal at the bottom, draw in plug and filling holes with covers to isolate the silica gel from the atmosphere. The
breather pipe should be connected at top of the conservator tank with two bends at right angles. The cover of the
main tank and bushings turrets shall be provided with air release plug to enable the trapped air to be released.
23 FITTINGS AND ACCESSORIES
23.1 The following standard fittings and accessories shall be provided :
Rating, diagram and terminal marking plate.
Two earthing terminals.
Lifting lugs/ platform lugs.
Pressure relief device or explosion vent.
Silica gel breather.
A magnetic oil level gauge 100 mm dia for all transformers indicating three position ( 3) of oil - minimum. 5C,
30C and 98C.
Top filter valve with locking arrangement.
Bottom filter valve with locking arrangement.
Air release plugs at transformer top cover, bushing turrets etc.
Set of Radiators.
Conservator Tank
Bi-metallic terminals on the bushings for connection with over head ACSR/ AAAC conductor. The Specification and
brief details of the salient features of these terminals should be stated.
24 RATING AND CONNECTION PLATE
Each transformer shall be provided with a rating plate of weatherproof material showing the following items indelibly
marked :
type of transformer
standard to which it is manufactured (preferably IEC 76)
manufacturers name
transformer serial number
year of manufacture
rated frequency in Hz (50)
rated voltages in KV (11/0.433)
number of phases (3)
rated power in KVA
type of cooling (ONAN)
rated currents in A
vector group symbol (Dyn11)
1.2/50s wave impulse voltage withstand level in KVp
power frequency withstand voltage in KV
impedance voltage at rated current and frequency in percentage at 75C at normal tap
Measured load loss in KW at rated current and at 75C at normal tap
Measured no-load loss in KW at rated voltage and rated frequency
continuous ambient temperature at which ratings apply in C
top oil and winding temperature rise at rated load in C
winding connection diagram
Total weight in kg with complete oil filled.
Total weight of the transformer without oil
Volume of oil in liters.
weight of core and windings in kg; and
Name of the employer
DISCOM, RGGVY-XII Plan Programme
The rating plate shall conform to the requirements of the section of Labels in this specification.

25. BASE MOUNTING ARRANGEMENT

The under base of all transformers up to 100 KVA capacity shall be provided with two 75x40 mm channels, 460 mm
long with holes of 14 mm dia at a centre to centre distance of 415 mm to make them suitable for fixing on a
platform or plinth.
26 (a) PUNCHINGS: Non-erasable Punching and embossing of Volume of oil in litres, name of the Employer,
Name of the Supplier M/s -------------------------------, Year of Manufacture, Guarantee Period ( i.e. 2 years from the
date of installation )and Sl. No. of each transformer is to be made on top core channel, top cover, side walls and
name plates of transformers.
26 (b) 3 STAR LEVEL: In addition to above, the supplied Distribution Transformers must contain 3 Star Level
with style and information provided by the Bureu of Energy Efficiency (B.E.E), Ministry of Power, Government of
India.
27. PAINTING
27.1
All paints shall be applied in accordance with the paint manufacturers recommendations. Particular
attention shall be paid to the following:
27.2
a) Proper storage to avoid exposure as well as extremes of temperature.
b) Surface preparation prior to painting.
c) Mixing and thinning
d) Application of paints and the recommended limit on time intervals between coats.
e) Shelf life for storage.
27.3
All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks
or other defects.
27.3.1 All primers shall be well marked into the surface, particularly in areas where painting is evident, and the
first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray
according to the manufacturers recommendations. However, wherever airless spray is not possible, conventional
spray be used with prior approval of employer.
27.3.2 The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings and
similar such items.
27.4 Cleaning and Surface Preparation
27.4.1 After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly
cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting.
27.4.2 Steel surfaces shall be prepared by Sand/Shot blast cleaning or Chemical cleaning by Seven tank process
including Phosphating to the appropriate quality.
27.4.3 The pressure and Volume of the compressed air supply for the blast cleaning shall meet the work
requirements and shall be sufficiently free from all water contamination prior to any painting.
27.4.4 Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly
adherent mill-scale and shall only be used where blast cleaning is impractical.
27.5 Protective Coating
28.5.1 As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given
suitable anticorrosion protection.

27.6 Paint Material

Followings are the type of paints that may be suitably used for the items to be painted at shop and supply of
matching paint to site:
i) Heat resistant paint (Hot oil proof) for inside surface.
ii) For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2 coats of P.U
(Poly-urethane) paint. The color of the finishing coats shall be dark admiral gray.
27.7 Painting Procedure
27.7.1 All painting shall be carried out in conformity with both specifications and with the paint manufactures
recommendations. All paints in any one particular system. Whether shop or site applied, shall originate from one
paint manufacturer.
27.7.2 Particular attention shall be paid to the manufacturers instructions on storage, mixing, thinning and pot
life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush, roller, conventional or
airless spray and shall be applied under the manufacturers recommended conditions. Minimum and maximum time
intervals between coats shall be closely followed.
27.7.3 All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours whichever is
sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry and while the surface is warm.
27.7.4 Where the quality of film is impaired by excess film thickness, (wrinkling, mud cracking or general softness)
the supplier shall remove the unsatisfactory paint coatings and apply another.
As a general rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25%.
In all instances, where two or more coats of the same paints are specifies, such coatings may or may not be of
contrasting colors.
27.7.5 Paint applied to items that are not be painted, shall be removed at suppliers expense, leaving the surface
clean, un-stained and undamaged.
27.8 Damages to Paints Work
Any damage occurring to any part of the painting scheme shall be made good to the same standard of corrosion
protection and appearance as that originally employed. Any damaged paint work shall be made as follows:
a)
The damaged area, together with an area extending 25mm around its boundary, shall be cleaned down to
bare metal.
b)
A priming coat shall immediately applied, followed by a full paint finish equal to that originally applied and
extending 50mm around the perimeter of the originally damaged. The repainted surface shall present a smooth
surface. This shall be obtained by carefully chamfering the paint edges before & after priming.
27.9 Dry Film Thickness
To the maximum extent practicable, the coats shall be applied as a continuous film of uniform thickness and free of
pores. Over-spray, skips, runs, sags and drips should be avoided. The different coats may or may not be same color.
Each coat of paint shall be allowed to harden before the next is applied as per manufactures recommendations.
Particular attention must be paid to full film thickness at edges.

The requirement for the dry film thickness(DFT) of paint and the material to be used shall be as given below:
Sl.
No
Paint Type
1. Liquid paint
Area to be
painted
No of
Coats
Total Dry film

thickness(Min)
a) Zinc Chromate (Primer)
Out side
01
30 micron
b) P.U. Paint (Finish Coat)
Out side
02
45 each
inside
01
35/10 micron
c) Hot Oil paint
The colour of the finishing coat shall be Sky Blue/ Dark Admiral Gray/ Deep Green or any other colour as decided by
the Employer
28 SEALING GASKETS
All sealing washers / gaskets shall be made of oil and heat-resistant Nitrile/ Neoprene rubber/ synthetic rubber
bonded cork type RC-70C gaskets. Gaskets made of natural rubber or cork sheet are not permissible.
29 SUPRESSION OF HARMONICS
The transformer shall be designed with attention to the suppression of harmonic voltage, especially the third and
fifth.
30 TESTS
30.1 Routine Tests
Routine tests shall be carried out on all transformers and the tests shall be conducted in accordance with relevant
National/ International Standards. No sampling is allowed. In addition, tank tests in accordance with IS: 1180 shall
be carried out.
The following routine measurements and tests shall be carried out in presence of Employers authorized
representative(s):
a) Measurement of winding resistance.
b) Voltage ratio measurement and check of polarity and vector group. Bushing positions shall have permanent
markings at this stage of production;
c) Measurement of impedance voltages/ short circuit impedance at rated current and frequency
d) Measurement of load loss at full load and 75C;
e) Measurement of neutral unbalance current;
f) Temperature rise test on one transformer of each rating and measurement of hot resistance.
g) Measurement of no-load loss and no-load currents at full, 50%, 75%, 90%, 110%, 112.5% and 120% of rated
voltages;
h) Induced over voltage withstand test at 22KV for 60 sec on the HV windings;
i) Power frequency voltage withstand tests on HV and LV windings;

j) Magnetic balance test

k) Polarization Index test P.I. value shall be not less than 1.5. P.I. = IR at 600 sec / IR at 60 sec.
l) Oil leakage test: The criterion of leakage shall be discoloration by oil of whitewash applied externally to
suspected parts at an oil temperature of 90C or other method, as approved by the Employer;
m) Pressure test on transformer tank on one unit for each rating. Bushings and oil shall be subject to the following
routine tests.
n) Bushing routine test: in accordance with IEC 137/IS 3347;
o) Oil dielectric and moisture content test: conforming to IEC 156 or IS 335.
Routine test certificates shall include in addition to the test results, the employers order number, the transformer
serial number, outline drawing number and transformer KVA rating.
Any other applicable tests shall be conducted at the discretion of the Employer without any extra cost to Employer.
30.2 Type Tests
30.2.1 The measurements and tests should be carried out in accordance with the standard specified in each case
as indicated in the following table if the same tests were not conducted earlier at CPRI or any NABL accredited
Laboratory on the transformers of the offered design without any cost implication and employer.
Table 6: Transformer type tests

Type Test Standard
Temperature Rise Test
Impulse Voltage Withstand Test, including Full Waves and

Chopped Waves as listed below
Noise Level Measurement
Short Circuit Test
IEC 76/IS
2026/IS6600
IEC 76/IS 2026
IEC 551
IEC 76 / IS 2026
In accordance with IEC 76-3 the following sequence of impulses should have been/ should be applied;
One full wave at 50% BIL;

One full wave at 100% BIL;
One chopped wave at 50% BIL
Two chopped waves at 100% BIL and
Two full waves at 100% BIL.
30.2.2 If the type test report(s) submitted by the bidder do not fulfil the criteria, as stipulated in this technical
specification/ Bidders offer, the relevant type test(s) has/ have to be conducted by the Bidder at his own cost in
CPRI/ NABL accredited laboratory in the presence of employers representative(s) without any financial liability to
employer in the event of order placed on him.
30.2.3 The offeres transformer must be manufactured as per type tested design. A copy of type test certificate
must be submitted by manufacturer to Engineer/Employer. Transformers offered without type tested however
design shall not be accepted. In case manufacturer agrees for type testing of transformers, testing shall be
conducted on manufacturers cost. No claim shall be acceptable towards type testing. The transformers shall be
accepted only on acceptane of type testing results by employer.

30.2.4 The supplier shall furnish calculations in accordance with IS: 2026 to demonstrate the Thermal ability of
the transformers to withstand Short Circuit forces.
30.3
TEST VOLTAGE
Transformers shall be capable of withstanding the Power frequency and Impulse test voltage as described below:
Nominal
system voltage
Highest
System
voltage
Impulse Test
voltage
433 V (rms)
11 KV (rms)
Power
frequency
test
voltage
3 KV (rms)
12 KV (rms)
95 KV (Peak)
28 KV (rms)
31 COMPLIANCE WITH SPECIFICATION

The transformers shall comply in all respects with the requirements of this specification
32 COMPLIANCE WITH REGULATIONS
All the equipment shall comply in all respects with the Indian Regulations and acts in force.
The equipment and connections shall be designed and arranged to minimize the risk of fire and any damage which
might be caused in the event of fire.
33 INSPECTIONS AND TESTING
33.1 The Employer shall have free entry at all times, while work on the contract is being performed, to all parts of
the manufacturers works which concern the processing of the equipment ordered. The manufacturer shall afford
the Employer without charge, all reasonable facilities to assure that the equipment being furnished is in accordance
with this specification. After approval of Drawings by the Employer, the manufacture shall manufacture a Prototype
Model as per the Approved Drawing and offer the same for inspection. The Inspection of the Prototype Model shall
be carried out as per the Format prescribed at Clause 41 of our Tender Specification. The Supplier shall offer the
core, windings and tanks of each transformer for inspection by the Employers representative(s). During stage
inspection of the Prototype Model, all the measurements like diameter, window, height, leg centre, stack width,
stack thickness, thickness of laminations etc for core assembly, conductor size, insulation thickness, I.D., O.D.,
Winding height, major and minor insulations for both HV and LV windings, length, breadth, height and thickness of
plates of transformer tanks, the quality of fittings and accessories will be taken/ determined.
The Inspection Report for the Tests conducted by our Authorized Inspectors in presence of the manufacturers
representative, for the Prototype Model offered for inspection with suggested modifications, if any shall be
submitted to the undersigned for approval.
After Inspection, the Prototype Model shall be kept sealed, in the premises of the manufacturer till the completion of
delivery of final consignment, for future reference during subsequent Inspections.

The Supplier can offer for final inspection of the transformers subject to clearance of the stage inspection report by
the Employer.
33.2
The equipment shall successfully pass all the type tests and routine tests mentioned in the above Clauses
and those listed in the most recent edition of the standards given in Clause 2 of this specification.
33.3
The Employer reserves the right to reject an item of equipment if the test results do not comply with the
values specified or with the data given in the technical data schedule.
33.4
Routine tests shall be carried out by the Supplier at no extra charge at their works.
Adequate facility with calibrated testing equipment must be provided by the manufacturer free of cost to carry out
the tests. Type test certificates must be furnished along with the tender for reference of the Employer.
33.5
The Employer will witness all required tests. In order to facilitate this, the Supplier shall give the Employer
a minimum of 10 days notice that the materials are ready for testing.
33.6
The supplier shall submit to the Employer five signed copies of the test certificates, giving the results of the
tests as required. No materials shall be dispatched until material dispatch clearance is not issued by employer.
The test certificates must show the actual values obtained from the tests, in the units used in this specification, and
not merely confirm that the requirements have been met.
In the case of components for which specific type tests or routine tests are not given in this specification or in the
quoted standards in Clause 2, of this specification, The Supplier shall include a list of the tests normally required for
these components. All materials used in the Contract shall withstand and shall be certified to have satisfactorily
passed such tests.
33.7
The Employer at his discretion may re-confirm the Routine Test Results, particularly no load losses, load
losses and percentage impedance in his own laboratory or laboratory of his choice.
No inspection or lack of inspection or passing by the Employers Representative of equipment or materials whether
supplied by the Supplier or sub-supplier, shall relieve the Supplier from his liability to complete the contract works in
accordance with the contract or exonerate him from any of his guarantees.
However in case of future discrepancy, if any, after acceptance of equipments, observed at any stage during
guarantee period, the matter may be referred to Bureau of Energy Efficiency (B.E.E) for random testing of
equipments supplied. In such cases the observation of B.E.E shall be binding to both parties.
34 GUARANTEE
The supplier shall guarantee the following:
Quality and strength of materials used;
Satisfactory operation during the guarantee period from the date of commissioning, as per general terms
of condition of the contract.
Performance figures as supplied by the tendered in the schedule of guaranteed particulars;
The offered surface treatment shall protect the treated metal from corrosion for a period of not less than
five years from the date of delivery.
35 PACKING AND SHIPPING
35.1 Packing
The equipment and any supporting structures are to be transported adequately sealed against water ingress. All
accessories and spares shall be packed and securely clamped against movement in robust, wooden, non returnable
packing cases to ensure safe transit in rough terrain, cross country road conditions and in heavy rains from the
manufacturers works to the work sites/ earmarked destinations.

35.1.1 All accessories shall be carefully packed so that they are fully protected during transport and handling
operations and in storage. Internal surfaces of loose accessories shall be sealed by means of gaskets and blanking
off plates. All parts liable to rust shall receive an anti-rusting coat and shall be suitably protected. It shall be the
responsibility of the Supplier to make good any damage caused through insufficient packing. Each packing case shall
be indelibly marked, on two adjacent sides and on the top, with the following:
Individual serial number;

Employers name;
Contract number;
Destination;
A colour coded marking to indicate destination;
Suppliers name;
Description and numbers of contents;
Manufacturers name;
Country of origin;
Case measurements;
Gross and net weight in kilograms: and
All necessary slinging and stacking instructions.
35.1.2 Each crate or container shall be marked clearly on the outside of the case to show TOP and BOTTOM
positions with appropriate signs to indicate where the mass is bearing and the correct positions for slings. All
component parts which are separately transported shall have permanent identification marks to facilitate correct
matching and assembly at site. Welded parts shall be marked before welding. Six copies of each packing list shall be
sent to the Employer prior to dispatching the equipment.
35.2 Transportation
The contractor shall be responsible for the transport of all plant and equipment supplied by them and for the
transport of all goods to the various specified destinations including all road clearance, offloading, warehousing and
insurance. The Supplier shall inform himself fully as to all relevant transport facilities and requirements and loading
gauges and ensure that the equipment as packed for transport conform to these limitations. The Supplier shall also
be responsible for verifying the access facilities specified.
The contractor shall be responsible for the transportation of all loads associated with the contract works and shall
take all reasonable steps to prevent any highways or bridges from being damaged by his traffic and shall select
routes, choose and use vehicles and restrict and distribute loads so that the risk of damage shall be avoided. The
Supplier shall immediately report to the Employer any claims made against the Supplier arising out of alleged
damage to a highway or bridge. All transport accessories, such as riding lugs, jacking pads or blanking off plates
shall become the property of the Employer.
All items of equipment shall be securely clamped against movement to ensure safe transit from the manufacturers
facilities to the specified destinations.
The Supplier shall advice the storage requirements for any plant and equipment that may be delivered to the
Employers stores. The Supplier shall be required to accept responsibility for the advice given in so far as these
arrangements may have a bearing on the behavior of the equipment in subsequent service.
36 Hazardous substances
The Supplier shall submit safety data sheets for all hazardous substances used with the equipment. The Supplier
shall give an assurance that there are no other substances classified as hazardous in the equipment supplied. No oil
shall be supplied or used at any stage of manufacture or test without a certificate acceptable to the Employer that it
has a PCB content of less than 2 mg/ kg. The Supplier shall accept responsibility for the disposal of such hazardous
substances, should any be found. The Supplier shall also be responsible for any injuries resulting from hazardous
substances due to non compliance with these requirements.

37 SUBMITTALS
37.1 Submittals required to employer is for approval of manufacturing of transformer
The
following shall be for employer approval before start of manufacturing:

Completed technical data schedule;
Descriptive literature giving full technical details of equipment offered;
Outline dimensions drawing for each major component, general arrangement drawing showing component
layout and general schematic diagram;
Type test certificates (short circuit withstand test and impulse test) of the offered transformers conducted
at CPRI/ or any NABL Accredited laboratory without which proposal will be out rightly rejected.
Sample routine test reports;
Detailed reference list of customers already using equipment offered along with performance certificates of
such equipment, during the last 3 (three) years with particular emphasis on units of similar design
and
rating;
Details of manufacturers quality assurance standards and programme and ISO 9000 series or equivalent
national certification;
Deviations from this specification. Only deviations approved in writing before award of contract shall be
accepted;
List of recommended spare parts and consumable items for five year of operation with prices and spare parts
catalogue with price list for future requirements.
37.2
Submittals required after contract award
37.2.1 Programme
Five copies of the programme for production and testing
37.2.2 Operation and Maintenance Instructions
A copy of installation and commissioning instructions and of the operation and maintenance instructions and
troubleshooting charts shall be supplied with each transformer.
37.3
Drawings
37.3.1 Within 15 days of award of contract, the Supplier shall submit 4 complete sets of drawings as detailed
below describing equipment in details. These drawings would be duly approved by the Employer after due
securitization and approval will be communicated within 15 days of receipt of these drawings. After the drawings are
approved and communicated to the supplier, he would supply ten complete sets of final drawings.
37.3.2 All detail drawings submitted for approval shall be to scale not less than 1:20. All important dimensions
shall be given and the material of which each part is to be constructed shall be indicated on the drawings. All
documents and drawings shall be submitted in accordance with the provisions of this specification and shall become
the property of the Employer.
37.3.3 All drawings and calculations, submitted to the Employer, shall be on international standard size paper,
either A0, A1, A2, A3 or A4. All such drawings and calculations shall be provided with a contract title block, which

shall include the name of the Employer and shall be assigned an unique project drawing number; the contract title
block and project numbering system shall be agreed with the Employer.
37.3.4 Script sizes and thickness of scripts and lines be selected so that if reduced by two stages the alphanumeric
characters and lines are still perfectly legible so as to facilitate microfilming.
37.3.5 For presentation of design drawings and circuit documents IEC Publication 617 or equivalent standards for
graphical symbols are to be followed. The drawing approval will be communicated within 15 days from the receipt of
drawings from the Bidder and for any delay in furnishing the drawings, if delivery period will be delayed, no
extension of delivery time will be granted due to this.
37.3.6 The following drawings for each item are to be submitted as part of this Contract.
a.
b.
c.
d.
e.
Out line dimensional drawings of transformers and accessories

Assembly drawings and weights of main component parts.
Transportation drawings showing dimensions and weights of each package.
Drawings giving the weights for foundations each.
Drawing showing details such as clamping arrangements of core, core assembly showing oil duct section of HT
and LT coils with conductor size showing insulation arrangements of windings and their reinforcement to
withstand short circuit stresses, in side tank dimensions showing core assembly. Details of core and windings,
as enumerated at Cl. No. 17 of this part of Specification shall be indicated in the above drawings.
f. Schematic diagram showing the flow of oil in the cooling system as well as each limb and winding. Longitudinal
and cross- sectional views showing the duct sizes, cooling pipe etc. for transformer/ heat exchanger, drawn to
scale shall be furnished.
g. Large Scale drawings of high and low tension winding of the transformers showing the nature and
arrangements of insulation and terminal connection.
h.
Test Reports
38 FASTENERS
38.1 All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate Indian
Standards for metric threads, or the technical equivalent.
38.2 Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals. All nuts
and pins shall be adequately locked.
38.3 Wherever possible, bolts shall be fitted in such a manner that in the event of failure of locking resulting in the
nuts working loose and falling off, the bolt will remain in position.
38.4 All ferrous bolts, nuts and washers placed in outdoor positions shall be of anti-corrosive materials except high
tensile steel bolts and spring washers which shall be electro galvanized to service condition stated elsewhere in the
Specification. Appropriate precautions shall be taken to prevent electrolytic action between dissimilar metals where
bolts are used on external horizontal surfaces and where water can collect, methods of preventing the ingress of
moisture to the threads shall be provided. Each bolt or stud shall project at least one thread but not more than
three threads through the nut, except when otherwise approved for terminal board studs or relay stems. If bolts
nuts are placed so that they are inaccessible by means of ordinary spanners, special spanners shall be provided. The
length of the screwed portion of the bolts shall be such that no screw thread may form part of a shear place
between members. Taper washers shall be provided where necessary. Protective washers of suitable material shall
be provided front and back on the securing screws.
39. LABELS
39.1 All apparatus shall be clearly labelled indicating, where necessary, its purpose and service positions. The
material of all labels and plates, their dimensions, legend and the method of printing shall be subject to approval of

the Employer. The surfaces of all labels and plates shall have a mat or satin finish to avoid dazzle from reflected
light. Colours shall be permanent and free from fading. Labels mounted on black surfaces shall have white lettering.
Danger plates shall have white lettering on a red background. All labels and plates for outdoor use shall be of incorrodible material. Where the use of enameled iron plates is approved, the whole surface including the back and
edges, shall be properly covered and resistant to corrosion. They shall be engraved in English. Name plates shall be
white with black engraved lettering and shall carry all the applicable information specified in the applicable items of
the Standards. No scratching, corrections or changes will be allowed on name plates.
39.2 Name plates shall be provided of white background with black engraved lettering carrying all the applicable
information specified in the standards and other details as required by the Employer. The name plate inscription and
the size and lettering shall be submitted to the Employer for approval.
40.PROFORMA FOR STAGE INSPECTION OF DISTRIBUTION TRANSFORMERS
(A)
GENERAL INFORMATION:
1. Name of Firm :
2. Order No and Date :
3. Rating wise quantity offered :
4. Details of offer
(a) Rating
(b) Quantity
(c) Serial Numbers
5. Details of last stage inspected lot :
(a) Total quantity inspected
(b) Serial Numbers
(c) Date of stage inspection
(d) Quantity offered for final inspection of
6.
(A) Inspection of BEE 3 Star Level/ Embossing / Punching requirement: whether satisfies the Specification: deviation
if any to be mentioned
(B) Availability of material for offered quantity
(C) Position of manufacturing stage of the offered
QUANTITY :
(a) Complete tanked assembly
(b) Core and coil assembly ready
(c) Core assembled
(d) Coils ready for assembly
(i) HV Coils
(ii) LV Coils
NOTE:
(i) A quantity if more than 100 nos shall not be entertained for stage inspection
(ii) The stage inspection shall be carried out in case:(a) At Least 25% quantity offered has been tanked and
(b) Core coil assembly of further at least 30% of the quantity offered has been completed.
(iii) Quantity offered for stage inspection should be offered for final inspection within 15 days from the date of
issuance of clearance for stage inspection, otherwise stage inspection already cleared shall be liable for cancellation.

11KV AUTOMATICALLY SWITCHED CAPACITOR BANKS AT SUB-STATIONS

1. SCOPE
This specification covers 3-phase, 50 Hz, out-door type Automatically Switched Shunt Capacitor Banks
intended for installation at 33/11 KV and 66/11KV sub-stations. The equipment covered in this
specification comprises (i) Capacitor Bank, (ii) Automatic Control Unit, (iii) Capacitor Switches and
(iv) Auxiliary Equipment.
2. APPLICABLE STANDARDS
Unless otherwise modified in this specification, the capacitors shall comply with latest version of IS:2834.
The other components such as Capacitor Switches, Auxiliary Equipment shall comply with the latest
version of relevant Indian Standards.
A. CAPACITOR BANKS
3.
TEMPERATURE CATEGORY
The capacitor shall be suitable for upper limit of temperature category 500C as per IS:2834.
4. RATED VOLTAGE
4.1 The rated voltage of the 3-phase capacitor banks shall be12KV(phase-to-phase) and the individual capacitor
units shall be rated for 12/3 KV.
4.2 Supplier shall make extra allowance for voltage rise due to use of 6% reactors wherever provided, for
which necessary details will be provided by the purchaser.
5. RATED OUTPUT
5.1
The ratedout put of 3-phase capacitor banks shall be 600 KVAR and 1200 KVAR at the rated voltage of
12 KV intended for use on power transformers of 3.15 MVA and 5 MVA (see Clause 14.3).
5.2 The standard basic unit rating of capacitors (single phase) shall be 200 KVAR. The units shall be
connected in star formation with floating neutral.
6. PERMISSIBLE OVER LOADS
For capacitors covered in this specification, the maximum permissible overloads with regard to voltage,
current and reactive output shall not exceed the limits specified in IS:2834.
7. POWER LOSS
The power loss in capacitors shall not exceed 0.2 watt/KVAR (subject to a tolerance of +10%).
8. DISCHARGE DEVICE
Suitable discharge device shall be connected across the capacitor unit in accordance with the provision
of IS:2834.
The discharge device shall reduce the residual voltage from the crest value of the rated voltage to 50V
or less within 5 minutes after the capacitor is disconnected from the source of supply.
9. EARTHING CONNECTIONS
The container of each capacitor unit shall be provided with suitable earthing terminal clearly marked with
"Earth" Symbol.
AX

10. PROTECTIVE FUSES

The capacitor units shall be provided with either internal or external fuses, as per standard practice of
the manufacturer. In the later case, the manufacturer shall supply the external HRC fuses together
with fixing accessories; a set of six spare fuse links shall be supplied along with each capacitor bank.
11.
GENERAL REQUIREMENTS
11.1
The capacitors shall be of non-PCB type, using polypropylene film as the dielectric.
11.2
Complete mounting brackets supporting insulators and all other components for formation of capacitor
bank racks shall be supplied along with the capacitor units. Necessary foundation bolts/nuts shall
also be supplied.
11.3
The outside of the capacitor container and other structures should have smooth and tidy look and
should be coated with the weather-proof, corrosion-resistant paint of white or light grey shade.
12.
MARKING
The capacitor units shall be provided with a rating plate and terminal markings as stipulated in
IS:2834.
13.
TESTS
The switched capacitors shall be subjected to all the type, routine and acceptance tests in
accordance with IS:2834. In addition, Endurance Test as per IEC 871-2, 1981 shall be carried out
as a type test. (This test is under consideration for adoption by BIS).
B.
AUTOMATIC CONTROL UNIT (ACU)
14. SWITCHING ARRANGEMENT

14.1
The Automatic Control Unit shall be provided inside the control room to continuously monitor total load
KVAR on secondary side of the transformer and shall automatically switch ON or switch OFF the
capacitor
banks
through
the
operation of 11KV Capacitor Switch in accordance
with
the parameters given in clause 14.3. Overriding provision shall also be made for electrical switching
ON or OFF of the capacitor switch by the operator from the ACU panel.
14.2
In the case of 3.15 MVA transformer, the capacitor banks will be controlled by two 11KV automatic
capacitor switches each controlling a 600 KVAR bank. For 5 MVA transformer, the capacitor banks will
be controlled by two 11KV automatic switches; the 1st switch controlling 600 KVAR bank and the 2nd
switch controlling 1200 KVAR bank.
AX

14.3
The following scheme shall be adopted for automatic operation of 11KV capacitor switches/capacitor
banks:
S.No
1
1
Transformer
Capacity
Capacitor
Bank Size
2
1x3.15MVA
3
1200 KVAR
split into
600 KVAR
+
600 KVAR
4
600 KVAR
1200 KVAR
1300KVAR
(Switches-I&II ON)
1800 KVAR
split into
600 KVAR
+
1200 KVAR
600 KVAR
700 KVAR(Switch-I
ON, Switch-II OFF)
1x5 MVA
Capacity
to be
Switched
on
1200 KVAR
1800 KVAR
Status of
capacitor
switches when
load KVAR on
transformer
reaches
5
700 KVAR (Switch-I
ON, Switch-II OFF)
1300 KVAR(Switch-I
OFF, Switch-II ON)
1900 KVAR
(Switches-I & II ON)
Status of
Capacitor
Switches when
load KVAR drops
to
6
600 KVAR (Switches
I & II OFF)
1200 KVAR (SwitchII OFF, Switch-I

ON).
600 KVAR (SwitchesI & II OFF)
1200 KVAR (SwitchII OFF, Switch-I ON)

1800 KVAR (Switch-I
OFF, Switch-II ON)
NOTE :
1.
For more than one transformer, a separate capacitor bank for each transformer shall be provided.
2.
The required 11KV CTs and PTs for measurement of Load KVAR are normally available at the Sub-station
and will not form part of the equipment to be supplied against this Specification.
15. TIME DELAY

The switching ON operation will take place only if the KVAR value indicated in column 5 of the table in
clause No.14.3 persists (or is more) for a period of 5 minutes. The switching OFF operation will take
place if the KVAR value indicated in column 6 of the table persists (or is less) for a period
of 5 minutes. However, if the load drops to less than 80% of value specified in column 6, the
switching off operation of the relevant step will be instantaneous. In no case switching
ON operation will take place within a period of less than 5 minutes after the capacitor is switched
OFF due to any reason.
16.
CONTROLS
The automatic control unit shall instantly switch OFF the capacitor switch in the following
contingencies occurring in any of the phases :
i)
Voltage increases by 7% above the rated voltage of 12KV.
ii)
Power Transformer current imbalance (due to single phasing and for any other reasons) between any
of the two phases exceeding 20% of the lowest current of the 3-phases.
iii)
Current increases in any Capacitor unit by 30% above the rated current (only the relevant capacitor
switch will open).
AX

iv)
Current between any of the two phases of the capacitor bank differs more than 15% of the lowest
current of the 3-phases (only the relevant capacitor switch will open).
NOTE: Normal automatic functioning of the Capacitor Bank will resume :

In the case of (i) above, after the excessive voltage hasdropped to 3.5% above the rated 12 KV.
and
In the case of (ii) above, the power transformer current imbalance between any two phases reduces to
15%.
In case of (iii) & (iv) above, a suitable indication for the type of fault i.e. whether (iii) or (iv) above
will be provided on ACU Panel and the capacitor bank will not get automatically switched ON again
till the faulty condition is attended to and ACU is reset for its normal operation.
17. MONITORING FACILITY
A suitable ammeter with a selector switch to indicate the capacitor current in each phases of the
capacitor bank shall be provided on the ACU panel inside the control room. Indicating lamps will
also be provided to indicate ON & OFF status of each capacitor switch.
18. CONTROL POWER
The D.C.
control
voltage
for
operation
of
the
ACU
shall be taken from substation battery. The standard D.C. control voltages at the 33/11KV Sub-station and 66/11KV Substations are 24 Volts and 110V respectively.
Note: The purchaser will clearly specify the battery voltage if voltage other than that specified
above is to be adopted.
19. TEMPERATURE VARIATION
The control equipment and associated circuitry shall be suitable for operation in a temperature range
of 00 C to (+) 550C.
20. PROTECTION OF ACU
Besides in-built protection against line surges and transient over voltages, suitable fuses shall
be provided for protection against over current. The ACU shall remain fully functional during and
after line surges and transient over voltage.
21. CONTROL UNIT CASING
Except for the terminals, the Automatic Control Unit shall be enclosed in a suitable casing so as to
avoid ingress of dust.
AX

C. 11 KV AUTOMATIC CAPACITOR SWITCH

22.
SCOPE
This specification covers 11KV, 50Hz, out-door type automatic capacitor switches suitable for
switching capacitor banks of 600 KVAR and 1200 KVAR ratings or any other higher rating
specified.
23.
Unless otherwise stipulated in this specification the capacitor switch shall comply with the latest
version of IS:9920 (AC Switches for voltages above 1000V).
24.
RATED VOLTAGE
The rated voltage for the capacitor switch shall be 12KV. This represents the highest system
voltage corresponding to the nominal system voltage of 11KV.
25.
RATED CURRENT
The standard rated normal current shall be 200A.
26.
RATED CAPACITIVE SWITCHING CURRENT

The rated capacitive switching current shall not be less than 100 A.
Note : The capability of the switch shall also take into account the parallel switching of capacitor
bank steps.
27.
RATED SHORT TIME CURRENT

The rated short time symmetrical current for 1 second shall be 10KA (rms A.C. component).
28.
RATED MAKING CURRENT

The rated making current shall be 2.5 times the rms value of the a.c. component of rated short time
capacity.
29.
BASIC IMPULSE LEVEL (BIL)

The rated basic impulse level of switch to earth as also across the open terminals shall be 75 KV.
30.
CONTROL SUPPLY
The control power for closing the switch shall be 230V single phase AC supply.
mechanism shall be suitable for a voltage variation of (+) 10% to (-) 20%.
31.
DESIGN & CONSTRUCTION REQUIREMENTS
31.1
Type
The closing
The switches shall be of either vacuum or SF6 type.

31.2
The capacitor switches shall be of three phase construction and shall be suitable for remote
operation.
31.3
The capacitor switch shall be suitable for outdoor installation and shall have sealed weather proof type
construction.
AX

31.4
The capacitor switch shall be provided with a mechanical indicator to show whether the contact is in
open/closed position, locally, as also through indication on the ACU panel. Provision shall also be
made for manual closing and opening.
31.5
The metallic enclosure of the capacitor switch shall be provided with two earthing terminals
marked with the earth symbol.
31.6
The bushings provided on the switch shall have clamp type of terminals to directly receive aluminium
conductors
up
to
10mm
diameter in both horizontal
and
vertical
directions. The terminal arrangement shall be such as to avoid bimetallic corrosion.
32.
OPERATING MECHANISM
The operating mechanism shall be either solenoid or motor charged spring for which the control
supply shall be as per clause 30.
33.
MECHANICAL AND ELECTRICAL ENDURANCE

The switch shall be capable of performing not less than 10,000 mechanical operations and 10,000
electrical operations at 100A capacitive current without getting damaged.
34.
MARKING
The capacitor switch shall be provided with a legible and indelibly marked name plate with the
following :
a) Name of the manufacturer,
b) Type, designation and serial number.
c) Rated voltage and current.
d) Rated frequency.
e) Number of poles.
f)
Rated short time current (symmetrical).
g) Rated making current.

h) Rated capacitive switching current.
35.
TESTS
The switch shall be subjected to the following tests in accordance with the IS:9920 (Part-IV).
35.1
Type Tests
a)
35.2
Tests to verify the insulation level, including withstand tests at power frequency voltages
on auxiliary equipment.
b)
Tests to prove that the temperature rise of any part does not exceed the specified values.
c)
Making and breaking tests including tests for the rated capacitive current
d)
Tests to prove the capability of the switch to carry the rated short time current.
e)
Tests to prove satisfactory operation and mechanical/electrical endurance.
f)
Tests to provide satisfactory operation under ice conditions.
Routine Tests
a) Power frequency voltage dry tests.
b) Voltage tests for auxiliary circuits.
c) Measurement of the resistance of the main circuits.
d) Tests to prove satisfactory operation.
AX

D. AUXILIARY EQUIPMENT
36. CURRENT TRANSFORMER
The current transformers of suitable current ratio and burden for measuring the capacitor current
shall form part of the equipment to be supplied. These CTs shall form either an integral part of
capacitor switches or may be of separate outdoor type.
The accuracy class for the purpose of measuring the current shall be 1.0.
37. HRC FUSES
Suitable outdoor type 11KV HRC fuses along with the mounting insulators etc. to provide proper
protection for the entire installation (and also HRC fuses for protection of individual capacitor
bank step where internal fuses for capacitors are not provided) shall form part of the equipment to
be supplied. The rupturing capacity of the fuses shall be 12.5 KA.
38. SURGE ARRESTERS
5 KA, 9 KV metal oxide surge arrestor, conforming to REC Specification of 11KV and 33 KV Metal
Oxide Lighting Arrester shall be used for the entire capacitor bank for each transformer and will form
part of the equipment to be supplied.
39. INRUSH SUPRESSION SERIES REACTOR (I SSR)
Suitable Inrush Suppression Series Reactors shall be provided on each capacitor Bank steps to limit
the inrush current due to parallel switching within a safe limits.
40. SCHEMATIC DIAGRAM
A Schematic diagram showing typical arrangement of 11KV automatically switched capacitor bank
for a 5 MVA transformer at 33/11 KV sub-station is given in the Annexure.
41. INSTALLATION OPERATION & MAINTENANCE
The supplier shall provide :
i)
Necessary manual on installation, operation and maintenance as also the schedule for routine testing
or check ups of all the equipment covered by the installation.
ii) List of recommended spares indicating prices and specialised test equipments required for routine
testing of the system.
42. GUIDANCE FOR PROCUREMENT
The entire equipment covered in this specification shall be covered as a single package to avoid
theproblem of mismatching and responsibility for maintenance etc.
43. WARRANTY
The supplier shall guarantee satisfactory performance of the complete capacitor bank installation for a
period of 18 months from the date of supply or 12 months from the date of commissioning,
whichever is earlier. During the warranty period, all repairs/replacements shall be carried out free of
cost.
AX

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

AX

11 KV 350MVA 1250 AMP VCB SWITCHGEAR PANELS (MC VCB) - Indoor

1.1.
1.1.1.
INTRODUCTION
The section covers the specification of metal clad indoor vacuum type switchgear unit
with horizontal draw out circuit breaker as per IS 13118 [1991] / IEC 62271-100 or
latest amendment thereof.
1.1.2.
All the equipments shall be suitable for satisfactory operation in tropical climates and
dry dust laden atmosphere prevailing in the location where it shall be used against
the Contract. The equipment shall be able to with stand a wide range of
temperature variation in the required location.
1.1.3.
All the plant/apparatus/equipment supplied shall comply in all respect with the
requirement of Indian Electricity Act 2003 and Indian Electricity Rule 2003/IS and
latest amendment thereof during the execution of contract where-ever applicable.
1.2.
STANDARDS.
The circuit Breaker shall confirm to the latest revision with amendment available of
relevant standards, rules, and code. Some of which are listed herein for ready
reference.
Sl.
No.
1.
2.
3.
4.
5.
6.
7.
1.3.
1.3.1.
Standard
IEC62271-100
13118(1991)
IS-2705 (1992)
IS-3156 (1992)
IS-3231 (1987)
IS-1248
IS-375
Item
/IS-
IEC-60687/CBIP REPORT
NO-88 (JULY) 1996)
Switchgear
Current Transformer
Voltage Transformer
Relays
Ammeter & Voltmeter
Arrangement of Breakers Bus Bars
connection and auxiliary wiring.
Tri vector meter
main
CONSTRUCTION
The switchgear shall be of CRCA steel construction with sheet not less than 3mm
thickness for load bearing section and not less than 2 mm thickness for non-load
bearing and shall totally dust and vermin proof. However, if vendor has standardized
the thickness of enclosure other than above mentioned and it meets the performance
requirements and the design has been established through type test, the same shall
be accepted. The panels shall be rigid without using any external bracings. The
switchboard panels should comply with relevant IS/IEC and revision thereof and shall
be designed for easy operation maintenance and further extension. Bus bar,
metering circuit breaker chamber, cables and cable box chamber should have proper
access for maintenance, proper interlocks should be provided. All instruments shall
be non-draw out type and safe guard in every respect from damages and provided
with mechanical indicator of connection and disconnection position. The switchgear
BP

shall be completed with all necessary wiring fuses, auxiliary contacts terminal boards
etc.
1.3.2.
The arcing contacts and bus bar should be rated for 350 MVA for 3 seconds. Bus
bars shall be capable of connecting one switchgear panel to other through proper
insulated arrangement, which does not decrease the insulation strength of the bus
bar at the point of connection between two panels. The panels shall be modular in
design.
1.3.3.
The breakers should be able to be drawn out in horizontal position at ground level
[with vertical/horizontal isolation] when breaker is drawn out in horizontal position
none of the live components inside the 11 KV switchgear panel should be accessible.
The safety shutters shall be robust and shall automatically cover the live components
when the breaker is drawn out. The switchgear shall have complete interlocking
arrangements at the fully inserted and fully drawn out and test positions.
Withdrawal of the breaker should not be possible in ON position, it should not be
possible to close the circuit breaker in service unless the entire auxiliary and control
circuit are connected.
1.3.4.
Breaker should have three distinct positions inside the cubical; i.e. service, test and
isolated.
1.3.5.
Built-in/separate trolley mounted earthing switches for incomer and outgoing shall be
provided.
1.3.6.
All the high voltage compartments must have pressure discharge flap for the exit of
gas due to internal are to insure operator safety. All the HV compartment design
ensures conformity to IEC-60298 and must be type tasted for Internal Arc Test.
1.4.
BUS BARS AND CONNECTORS
1.4.1.
Bus bars and all other electrical connection between various components shall be
made of electrolytic copper of rectangular cross sections. The bus bars section shall
be ample capacity to carry the rated current of minimum 1250 Amp continuously
without excessive heating and for adequately meeting the thermal and dynamic
stresses in the case of short circuit in the system up to full MVA rating specified in
Para 3.2 above.
1.4.2.
All bus bars connections shall be firmly and rigidly mounted on suitable insulators to
withstand short circuit stresses and vibrations.
1.4.3.
Adequate clearance between 11 KV point and earth and between phase shall be
provided to ensure safety as per provision in Indian Electricity Rule 2003 and its
amendment thereof and also in accordance with the relevant Indian standard
specification and the same shall be capable of withstanding the specified high
voltage tests as per IS-13118/ IEC 62271-100 and amendment thereof.
1.4.4.
Sharp edges and bends either in the bus bars or bus bar connections shall be
avoided as far as possible. Wherever such bends or edges are un-avoidable, suitable
compound or any other insulation shall be supplied to prevent local ionization and
consequent flashover.
BP

1.5.
CIRCUIT BREAKER
1.5.1.
The vacuum circuit breaker shall be draw out type suitable for installation in the
switchgear cubicles (indoor). The breaker shall comply with IS-13118 (1991)/ IEC
62271-100 and latest amendment thereof. Construction of breaker shall be such
that the points, which require frequent maintenance, shall be easily accessible.
1.5.2.
The circuit breakers shall be spring operated, motor/manually charging of the spring
feature, manually released. VCB shall have spring closing mechanism for 3 pole
simultaneous operation. The speed of closing operation shall be independent of the
speed of hand operating level. The indication device shall show the OPEN and
CLOSE position of breaker visible from the front of cubical.
1.5.3.
The breakers shall be capable of making and breaking the short time current in
accordance with the requirement of IS 13118(1991)/ IEC 62271-100 and latest
amendment thereof and shall have three phase rupturing capacity of 350MVA for 3
second at 11 KV. The continuous current rating of breaker shall not be less than
1250 Amp for all items. The total break/make time shall be not more than 4 cycles
for break and 6 cycles for make time for all breakers.
1.5.4.
The vacuum circuit breakers shall ensure high speed extinction and adequate control
of pressure during breaking of current and also designed to limit excessive over
voltages.
1.5.5.
Comprehensive interlocking system to prevent any dangerous or inadvertent

operation shall be provided. Isolation of circuit breaker from bus bar or insertion into
bus bar shall only be possible when the breaker is in the open position.
1.5.6.
Vacuum Circuit Breaker shall have completely sealed interrupting units for
interruption of arc inside the vacuum. The vacuum bottle sealed for life shall be
provided with contact wear indicator.
Vacuum interrupter should have an expected life of 10000 operations at rated
current and should be capable for operating more than 100 times at rated short
circuit current.
Vacuum interrupter technical data particularly provided by the manufacturer should
also be provided with Bid.
1.5.7.
1.5.8.
1.6.
PROTECTION RELAYS
1.6.1.
All relays shall conform to the requirements of IS:3231/IEC-60255 or other applicable

standards. Relays shall be suitable for flush or semi-flush mounting on the front with
connections from the rear. The relay for entire project shall be of same type. The
protective relay shall be numerical type. Composite relay unit having O/C, E/F &
directional element etc shall be preferred.
1.6.2.
The protective relays mounted on the panels shall be of the draw out type. The
relays must be capable of resetting with out necessity of opening the case. The
relays shall be provided with flag indicators. Each functional element of a relay shall
be provided with its own flag indicator to enable the type of fault condition to the
identified.
BP

1.6.3.
Each of the incomer/outgoing switchgear units shall be provided with 3 elements of 5

Amp Non-directional, over current relays and 1 element non-directional, earth fault
relay with self/hand reset contacts. The O/C element shall have setting of 30 to
120% in seven steps and E/F element shall have setting of 10 to 40% in seven
steps. However, final decision regarding selection of steps and setting of relay shall
be decided during detail Engg. for proper co-ordination of protection system.
1.6.4.
High set instantaneous element of low transient over reach not exceeding 5%
should be incorporated in the O/C and Earth Fault relays for all the outgoing feeder
panels capable of adjusting the setting from about 5 to 20 times normal rating in the
O/C relays and 2 to 8 times in Earth Fault relays.
1.6.5.
During detail engineering provision for shunt trip or series trip relays shall be decided
by Employer for which contractor should not have any objection. Further, in this
case, the series trip relays auxiliary unit contracts in the tripping circuit should be
designed to handle current up to 150 Amp. and like wise trip coil voltage which
appears across open contact of the series-tripping unit, be limited to 150 volts.
1.6.6.
With CTs used as per Para 7.1 and taking into account the trip coil impedance of
breaker with the plunger DOWN and with plunger UP position, the VA burden of
relays offered etc. should be duly coordinated, so that the protection operates
without errors at fault current corresponding to the fault MVA of 350 for all the tap
position of the relays and the values of the impedance of the choke and resistance
which may be required should also be determined and incorporated.
1.6.7.
The protective relays shall withstand 20 times the maximum current for 3 second on
any tap setting. The over shoot time on removal of current setting shall not be
greater than 0.05 seconds.
1.7.
1.7.1.
CURRENT TRANSFORMERS:
The requirement of ratio, VA capacity, class or accuracy, limit factor etc. for resin
cast CTs installed in different type of units are tabulated below:
Item
Core/CT
Ratio
Incoming
Panel
Protection
600300/1A
Protection
600300/5A
600300/5A
600300/5A
600300/5A
Metering
Outgoing
Panel
Protection
Metering
VA
Burden
(min)
15
15
Knee
Point
Voltage
300
at
600/1A
tap
..
2.5
..
15
2.5
..
ALF
Class
of
accuracy
10
PS
10
5P
0.5
10
5P
0.5
BP

1.7.2.
Short time rating of CTs shall be 18.4 KA for 3 second. CTs shall be double core and
dual ratio. Saturation factor for metering core shall not exceed 2.5.
1.7.3.
The designed accuracy should be available even at the lowest ratios and all CTs shall
withstand fault current corresponding to 350 MVA for 3 sec.
1.7.4.
The secondary terminal of the current transformers shall be such that effective and
firm wire terminations are possible. Shorting links of adequate capacity shall be
provided at the terminal blocks for sorting of the leads from secondary terminals of
current transformers. The secondary terminal of the CTs shall be earthed at one
point.
1.7.5.
The secondary winding resistance of CTs shall be as low as possible but not greater
than 0.2 ohms per 100 turns.
1.7.6.
CTs shall confirm to IS 2705 with latest amendment, if any in all respect and will be
subjected to all routine and type test specified in the IS.
1.8.
CABLE GLANDS AND CLAMPING ARRANGMENT FOR HOLDING SUITABLE

CABLE BOXES
1.8.1.
Two nos, brass-wiping glands for each incomer and one no. Brass wiping gland for
each outgoing panel of adequate dimension for XLPE cable of 3 cores up to 400 sq.
mm size shall be supplied along with panels. For bus coupler no cable glands should
be provided.
1.8.2.
Suitable cable boxes as per requirement of cable shall be arranged by the purchaser
at his end. The panel shall however provide a flat of size 50X6 mm 2 with suitable
clamp made of 50X6 mm2 flat along with Nuts Bolts and Washers for holding the
cable boxes. The flat should be fitted at a suitable height with allotted arrangement
for adjustment of height from 300mm to 500mm at site. The clamp and flat shall
have suitable stud type arrangement for earthing cable and cable box.
1.8.3.
All control cable/wire entries shall be by means of suitable cable glands, such glands
shall be of brass and tinned.
1.9.
AUXILIARY/CONTROL WIRING
All the secondary wiring in the panel shall have high quality PVC insulation and the
same shall have conductor size of not less than 2.5 mm 2 of copper Colours of the
secondary/auxiliary wiring should confirm to IS 375/1963 and latest amendment
thereof if any. All wiring shall be neatly run and group of wiring shall be securely
fixed by clips so that wiring can be checked without necessity of removing the
clamps. Wiring between fixed and moving portion of the panel shall be run in
flexible tubes and the same shall be so mounted to avoid any damage to them due
to mechanical movements. Ferrules with number shall be provided on both end of
the wiring.
BP

1.10.
MARKING OF PARTS
For facilitating the erection, the several parts of the plant and equipment shall be
suitably marked.
1.11.
NAME PLATE AND DIAGRAM PLATES

All equipment shall have weather proof and non corrosive metal plates fixed in
suitable position with full particulars engraved thereon with white letters against
black background.
The firm shall affix a name plate on each Switchgear panel having following
information:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
1.12.
Manufacturers name and trade mark.

Unique No.
Type of Panel.
CT Ratio.
Rated Voltage.
Rated Insulation Level
Rated Frequency
Rated Normal Current
Rated Short Circuit Breaking Current.
Weight
Specification No.
Order No. and Date
Year of supply.
Property of SEBs
PAINTING
All metallic surface [except enameled and bright parts] exposed to weather shall be
given suitable primer coat and two coats of first quality paint of approved colour. The
supplier shall also supply adequate quantities of paints, Varnish etc. for use of finished
cost and for use of patching up any scratches received during transport, handling
erection testing and commissioning.
Instead of above proper powder coating after proper pre treatment is acceptable and
in that case earlier condition will not applicable.
1.13.
DETAILED FITTING AND MOUNTING

Detailed fittings and mountings of equipments in various switchgear panel shall be as
follows
1.13.1.
ITEM NO. 1 INCOMING PANELS RATING; 1250 AMP WITH CT RATIO 600300/5A or 600-300/1A
Each unit shall have the fittings and equipments as follows:
BP

1 No steel totally enclosed, fully interlocked, indoor industrial pattern, metal clad,
horizontal draw out, vertical/horizontal isolation floor mounting switch unit complete with
transportation truck having integral mechanism and all necessary supports each
equipped as under:
1 No Fabricated sheet steel housing.
1 No. Complete set of mechanical interlocks.
1 No. Set of isolating plugs and sockets [6 nos. rated for 1250 Amp. With
automatic safety shutters and pad locking arrangements. Facilities shall be
provided for proper opening of the safety shutter for cleaning, inspection and
testing.
1 No. 1250 Amp triple pole VCB fitted with isolating sockets, spring operated,
manually as well motor charged, manually/ electrically released spring closing
mechanism with mechanical ON/OFF indicators suitable for a rupturing capacity
of not less than 350 MVA at 11 kV for 3 seconds and fitted with one set of direct
acting trip coils suitable for operation with AC series trip relays.
1 No. Auxiliary switch with minimum four normally closed and four normally
opened contacts. The contact terminals shall be brought out and terminated at
Terminal Board irrespective of whether terminals are used or not.
3 Nos. 600-300/5-5 A ratio double core resin cast current transformer of required
Accuracy, for protection and metering as per Para 4.7.1 of specification. Alternatively
single core dual ratio 5 nos., CTs [3 nos. for protection and 2 nos. for metering] shall
also be acceptable.
1 No. Ammeter digital static ammeter suitably scaled and must suit CT ratio.
1 No. 3 phase resin cast, draw out type bus bar connected potential transformers of
Ratio 11000/110 volts class 0.5 accuracy having minimum 50 VA output per phase to
operate the A.C. static H.T. Tri-vector meter, voltmeter etc. and complete with HT fuse
and LT MCB with monitoring contacts.
1 No. Voltmeter round flush pattern digital static suitably scaled to suit the PT ratio.
1 No. 3 way and off voltmeter selector switch for reading the voltage between any two
phases on the voltmeter.
1 No. static digital Tri vector energy meter suitable for three phase 3 wire unbalanced load and CT, PT, ratio mentioned above, 0.5 accuracy class with load,
survey and TOD/Tariff and MRI facility. TVM shall be as specification attached
with this specification.
1 No. Non directional adjustable IDMT series trip O/C relay with definite minimum 3
seconds at 10 times plug setting. The relay shall be arranged for over current protection
with setting from 50 to 200% of 5A on all three over current elements mounted in draw
out case tropicalised with flag indicator.
BP

1 No. set of indicating lamps operating at 230V AC single phase one coloured RED and
other GREEN to show the closed or open position of circuit breaker.
1 No. 80 watts continuously rated tubular/strip type heater with manual ON/OFF switch
working on 230 VAC single phase supply.
1 No. set of copper bus bars of not less than 1250 Amp. Continuous rating.
1 No. multi way plug box for secondary wiring between the fix and moving glands.
1 No. set of independently operated automatic shutters for bus bar cable and voltage
transformers orifices, which shall be clearly leveled and individually pad-locked.
1 No. Sheet instruments panel mounted on the front of the unit with hinged access
doors and totally enclosed wiring terminals mounted there.
1 No. Complete set of self contained inter connectors, foundation bolts, fine Wiring,
wiring terminals board, sundries to complete the unit.
1.13.2.
ADDITIONAL FEATURE IN 600-300/ 1A INCOMERS FOR 10 MVA AND

HIGHER TRANSFORMERS (Applicable in case of installing 10MVA or above
transformer).
This switchgear shall be used with 10MVA, 33/11 KV Transformer having delta in
primary and grounded star in secondary, conventionally differential protections is
essential for the transformer. For 11 kV side 3 nos. CTs of 600-300/1 A [Class PS
and appropriate knee point voltage] and matching inter posting CTs (if required)
shall be provided in this switchgear panel. The mounting inter connection and
termination etc. for these additional devices/relays shall be covered in scope of
supply.
1.13.3.
CLARIFICATION
The total requirement of CTs for incomer of ratio 600-300/5A is as follows:
1.13.4.
3 CTs one for each phase of ratio 600-300/5A to connect to 3 nos., O/C relays.
2 nos. CTs one on R phase and other on B phase of ratio 600-300/5 A for
metering.
ITEM NO. 2 OUTGOING FEEDER PANEL WITH CT RATIO 600-300 /5A
The fittings and mountings shall be similar to item no. 1 above except the following:
The CT ratio will be 600-300/5A.
The voltage transformers voltmeter and voltmeter selector switch shall be deleted.
3 nos, CT operated overload releases are to be provided.
BP

1.13.5.
1 no. non directional triple pole adjustable IDMT, combined O/C and E/F [3 no. O/C and
1 no. E/F] AC series trip relay with instantaneous high set trip feature of low transient
over reach not exceeding 5% with definite minimum 3 seconds at 10 times plug setting.
The relay shall be arranged for over current protection with setting 30-120 % of 5 Amp.
And for earth fault protection with setting 10-40 % mounted on a draw out case
tropicalised with flag indicators. High set element of O/C shall have setting range of 5 to
20 times the rated current and the E/F elements shall be 2 to 8 times of rated current.
BUS COUPLER PANEL

Each unit shall have the fittings and equipment as follows:
1 No. All steel totally enclosed fully interlocked indoor industrial pattern, metal clad
horizontal draw out, horizontal/vertical isolation, floor mounting switch unit complete
with transportation truck having integral circuit breaker mechanism and all necessary
supports each equipped as under:
1 No. Fabricated sheet steel mounting.
1 No. Complete set of mechanical interlocks.
1 No. Set of isolating plug and sockets [6 nos. Rated for 1250 Amp.] with automatic
safety shutters and pad locking arrangement. Facilities shall be provided for proper
opening of the safety shutter for cleaning inspection and testing.
1 No. 1250 Amp. Triple pole VCB fitted with isolating sockets, spring operated, manually
charged, and manually released spring closing mechanism with mechanical ON/OFF
indicators suitable for a rupturing capacity of not less than 350 MVA at 11 kV for 3
second.
1 No. A set of Red and Green pigmy lamps for indicating opened and closed position of
breaker.
1 No. 3 way auxiliary switch with 4 normally closed and eight normally open contacts.
1 No. 80 watt. 230 VAC heaters with 6 Amp. Rotary cam switch.
1 No. Bus bar chamber with 1250 A rated copper Bus Bars.
1 No. A set of self aligning horizontal/vertical isolation type auxiliary plug and sockets.
1 No. Sheet steel instrument panel mounted on the front of the unit with hinged across
doors and totally enclosed wiring terminals mounted there.
The panel shall be without any metering protection CTs, cable box, series trip coils, and
relays.
The HT chambers [adopter chamber] will be gasketed to make it vermin proof. The gasket
shall be as specified in Section-I(Introduction and general technical requirements).
BP

NOTE Separate spring charging handle shall be provided and supplied with each set of the VCB.
1.14.
ANNUNCIATION SYSTEM
Alarm annunciation system shall be provided in the control board by means of visual
and audible alarm in order to draw the attention of the operator to the abnormal
operating conditions or the operation of some protective devices. The annunciation
equipment shall be suitable for operation on the voltages specified in this specification
i.e. 30 Volt DC for new substation or as existing DC supply system of the utility (This
shall be verified by the successful bidder before submission of the drawing for
approval).
Audible annunciation for the failure of DC supply to the annunciation system shall be
provided and this annunciation shall operate on 240 Volts AC supply. On failure of the
DC to the annunciation system for more than 2 or 3 seconds. (adjustable setting), a
bell shall sound. A separate push button shall be provided for the cancellation of this
audible alarm alone but the facia window shall remain steadily lighted till the supply to
annunciation system is restored.
A separate voltage check relay shall be provided to monitor the failure of supply (240V
AC) to the scheme mentioned in Clause above. If the failure of supply exists for more
than 2 to 3 seconds. this relay shall initiate visual and audible annunciation. This
annunciation shall operate on Annunciation DC and buzzer shall sound.
1.15.
TESTS
The design of circuit breaker shall be proven through all the routine and in accordance
with IS 13118: 1991/IEC 56 and any amendment thereof. Photocopy of all the test
reports must be enclosed with the tender. Type test report earlier than 7 year from
the date of tender opening shall not be acceptable.
TYPE TESTS:
Each circuit breaker shall comply with requirements of type tests prescribed in IEC
publication No.56.
i.
Short time and peak withstand current test.
ii.
Short circuit breaking capacity and making capacity.
iii. Capacitive current switching test: Cable charging current breaking test (Ur less than
or equal to 52 kV).
iv. Dielectric test i.e., power frequency withstand and impulse withstand test
v.
Temperature rise test.
vi. Mechanical Endurance Test at ambient temperature.

vii. Measurement of resistance of the main circuit.
viii. Internal arc test.
1.16.
COMMISSIONING CHECKS/TESTS
BP
10

After installation of panels, power and Control wiring and connect Contractor shall
perform commissioning checks. as listed below to proper operation of switchgear/panels
and correctness of all respects.
In addition the Contractor shall carry out all other checks and tests recommended by the
manufacturers.
1.16.1. GENERAL
i)
Check name plate details according to specification.
ii)
Check for physical damage
iii)
Check tightens of all bolts, clamps and connecting terminal
iv)
Check earth connections.
v)
Check cleanliness of insulators and bushings.
vi)
Check heaters are provided.
vii)
H.V. test on complete switchboard with CT & breaker/ contractor lubricated

in position.
viii)
Check all moving Parts are properly lubricated.
ix)
Check for alignment of busbars with the insulators to ensure alignment and
fitness of insulators.
x)
Check for inter changeability of breakers.
xi)
Check continuity and IR value of space heater.
xii)
Check earth continuity of the complete switchgear board.
1.16.2. CIRCUIT BREAKER
i)
Check alignment of trucks for free movement.
ii)
Check correct operation of shutters.
iii)
Check slow closing operation (if provided).
iv)
Check control wiring for correctness of connections, continuity and IR

values.
v)
Manual operation of breakers completely assembled.
BP
11

vi)
Power closing/opening operation, manually and electrically at extreme

condition of control supply voltage.
vii)
viii)
Closing and tripping time.

Trip free and anti-pumping operation.
ix)
IR values, resistance and minimum pick up voltage of coils.
x)
Simultaneous closing of all the three phases.
xi)
Check electrical and mechanical inter locks provided.
xii)
Checks on spring charging motor, correct operation of limit switches and

time of charging.
xiii)
Check vacuum (as applicable).
xiv)
All functional checks.
1.16.3. Current Transformers
i) Megger between windings and winding terminals to body.

ii) Polarity tests.
a. Ratio identification checking of all ratios on all cores by primary injection of current.
b. Magnetization characteristics & secondary winding resistance.
iii) Spare CT cores, if any to be shorted and earthed.

1.16.4. VOLTAGE TRANSFORMERS
i) Insulation resistance
ii) Ratio test on all cores.
iii) Polarity test
iv) Line connections as per connection diagram.
1.16.5.
CUBICLE WIRING
i)
Check all switch developments.
ii)
It should be ensured that the wiring is as per relevant drawings. All

interconnections between panels shall similarly be checked.
BP
12

iii)
All the wires shall be meggered to earth.
iv)
Functional checking of all control circuit e.g. closing, tripping, interlock,

supervision and alarm circuit including proper functioning of component/
equipment .
v)
Check terminations and connections. To check wiring related to CT and PT

circuits, carryout primary injection and then check for secondary value at
relay and metering instrument terminals.
vi)
Wire ducting.
vii)
Gap sealing and cable bunching.
1.16.6.
RELAYS
i)
Check internal wiring.
ii)
Megger all terminal body.
iii)
Megger AC to DC terminals
iv)
Check operating characteristics by secondary injection.
v)
Check minimum pick up voltage of DC coils.
vi)
Check operation of electrical/ mechanical targets.
vii)
Check CT connections with particular reference to their polarities for

differential type relays.
viii)
Relay settings.
1.16.7. METERS
i)
Megger all insulated portion.
Check CT & VT connections with particular reference to their polarities for power type
meter.
BP
13
1.
CABLE FAULT LOCATOR HT
21.1
General requirements:
The cable fault locator shall be capable of Locating / detecting all under-ground
transmission and distribution (Paper/Oilfield/PVC/XLPE) power cable faults up to
33kV network. The equipment should a properly wired and capable to detect open
circuit / short circuit / low-insulation / lashing / earth type cable faults in
underground cable. The equipment should be capable to deliver high output energy
that is necessary to ascertain easily to condition and break down faults in power
cables, joints, and terminations and long cable network. All constituent
equipments for cable fault locating set should be independent and
separate in nature for easy transportation.
A. Test Technique:
Test technique should be based on Differential Arc reflection so as to eliminate
unwanted and confusing reflections leaving only locations of fault. This differential
arc reflection technique should be possible without a need to use extra channel of
healthy phase.
Multi trace capturing (at least 10) should be possible with single shot of HV in Arc
reflection method and user should be able to select the best trace out of all stored
traces.
Fault conditioning (proof / burn and A.R.M) and fault pre-location techniques (TDR,
ARM and ICE) should be integrated into one package / unit for ease of use. Selection
of HV operations should be easy to use PLC control to avoid confusion.
Built in Arc reflection filter or Arc stabilization unit should be an inductive filter circuit
so that the output pulse has minimum attenuation in it.
The unit shall be versatile, capable supportive to locate faults in a wide variety of
power distribution cable networks through modern, integrated coupling for multiple
cable testing and fault locating technologies to reduce the fault locating time. The
unit shall be complete in all respects with all the necessary items,
accessories and test techniques and shall be ideal to ensure its maximum
performance to detect faults of conditions for short, medium or long

underground distribution cable networks.
B.
Technical Specifications / Requirements:
21.1.1 H.V. Surge wave tester or Impulse Generator

1. Surge Voltage Range :
a. 0-8kV continuously adjustable
b. 0-16kV continuously adjustable
c. 0-32kV continuously adjustable
2. Output Capacity
: Minimum 1000 joules at 8kV, 16kV & 32kV full range.
3. Surge Sequence
: 1.5, 3 & 6 secs, single / manual shot.
4. Indication
: Moving coil analog meter to indicate output kV & Over heat
LED indication.
5. Power Supply
: 230V10% 50Hz, 10% single phase
6. Accessories
:
a. 15 meters screened HV cable with clamp,
b. 6 sq mm yellow / green earthing cable
c. Mains supply cable 5 meters
21.1.2 High voltage pre-location
The instrument is for pinpoint location of all types of underground Cable faults up to 33 kV
power networks with acoustic method.
Built in Arc reflection Filter or arc stabilization unit should be inductive filter circuit so that
the output pulse has minimum attenuation to it.
Pre-Location:
Microprocessor based Cable fault locator. The equipment pre-locates the faults in
underground cable in Pulse Reflection method, Impulse Current method & Secondary
Impulse method in LT / HT underground all types cables up to 33kV.It is menu driven and
microprocessor based equipment.
1. Memory
2. Measuring Ranges
3. Accuracy
: Up to 50 memories.
: 60m to 30000m
: 1 % of full scale.
4.
5.
6.
7.
Modes
: TDR, Impulse Current, Secondary Impulse.
Power supply
: Internal rechargeable battery with external charger.
Ports
: RS232 port for Printer & PC
Accessories
:
Output Connection Cables for TDR application and other required connection cables,
Caring case & Operating Manual
ARC Reflection filter:

To pre-locate the high resistance and intermittent faults in conjunction with Digital cable
fault distance pre- locator and Surge Generator suitable for fault location under ARC
method.
1. Output Surge Voltage : 32kV.Max.
2. Output surge Capacity with surge tester
: 1500 Joules
3. Power supply : 230 V, 50Hz AC single phase
4. Indication
: Visual indication of ARC/SIM and Surge mode
5. Accessories
:
a. 5 meters screened HV cable with clamp,
b. 6 sq mm yellow / green earthling cable
c. Mains supply cable 2 meter
21.1.3 Fault Pin-pointing Instrument:

1. The surge wave receiver, for pinpoint location of cable faults by acoustic method in
LT/HT under Ground cables.
2. The unit shall be lightweight and to be provided in a suitable carrying case to hold all
the components and sensitive to detect direction of the faults up to a minimum
distance of 20 feet.
3. There should be background interface elimination via selectable filter band
4. Impulse sequence: Adjustable 3 to 30 sec. Single Shot
5. Acoustic Mute function
: To locate fault in crowded area.
6. Acoustic Freq. Range : 70 Hz to 3000 Hz (acoustic) broad band filter.
7. Display Indication
:
a. LCD bar-graph display with backlight facility
b. Indication of signal strength of acoustic & magnetic channels.
c. Internal battery level status.
8. Controls
: Separate controls for acoustic & magnetic & Power Supply
:
8x1.5V dry AA size batteries for 12V DC
9. Accessories
:
a. Ground Microphone , Connection leads, Special Headphone, Caring Sticks,
Charring case and Operating Manual
21.1.4 Cable Route Tracer System
The cable route tracer system shall be user friendly and suitable to locate the exact location
of underground cables and cables laid in PVC/GI along the busy roadside up to 10 km
maximum length, depth measurement up to 5 meter and ground survey of under-ground
cables to get quick accurate results.
Required Features:
Pinpointing active power lines and other utilities where AC is present
Operation in multiple Frequencies
Push button depth measurement up to 4 meters
High power at low frequency suitable to solve problems in multipoint grounding
situations
The cable route tracing system consisting of the following units:
1) Audio frequency Generator:
i)
Impedance
: from 0.5 to 1000 ohms selectable
ii)
Power output
: 1-2-4-8 watts selectable.
iii)
Output freq.
: 480Hz, 1.45 kHz & 9.82 kHz
iv)
Indications :
i. Meter Indication of related transmitted power
ii. Charging status of internal rechargeable battery.
v)
Power Supply
: 230 V, 50 Hz AC OR 12V 3.3Ah internal rechargeable
battery and Ext.12 V DC source
2) Audio frequency receiver:
i)
Receiving frequency
: Passive-50/60 Hz & Active- 480Hz, 1.45 kHz &
9.82 kHz
ii)
Gain
: up/down button for automatic centering
iii)
Wide band-band frequency
: 350 to 3000Hz.
iv)
Power Supply
: 1.5 x 8 AA size batteries for 12V DC.
v)
Accessories
:
Universal Search Coil, Transmitter coil, Identification coil, Special.
Head phones, Earth spikes, Connection leads, Mains supply cords,
Carrying case and Operating Manual
Cable Identification Instrument

For single & multi core cables, for identifying a particular cable from a bunch of cables for LT
/ HT network with help of generator, receiver and directional tong. Generator:
1. Impulse voltage
: 35V
2. Impulse current
: 60A
3. Sequence
: 2.5S
4. Power supply
: 230V AC & Rechargeable battery.
5. Receiver
: Sensitivity : 6 stage,
6. Indication : Analog Centre zero moving coil
7. Identification tongs: 150mm opening. Carrying case to be supplied.
21.1.5 Cable drum: 15m HV cable, Earthing cable and Power cable each
Detail List of Technical Specifications

Sl no
Particulars
1.0
Technical Specification of Strain Hardware fitting for 33 & 11 KV Disc

Insulator
2.0
3.0
4.0
5.0
6.0
7.0
Technical Specification of Hot dip Galvanized G.S. Solid Wire

Technical Specification of Earthing
Technical Specification of Hot dip Galvanized M.S. Stranded Wire
Technical Specification of Danger Board
Technical Specification of GI Earthing Pipe
Technical Specification of Galvanized Mild Steel Hexagonal Head
Bolt& Nuts
Technical Specification of PVC Insulated PVC Sheathed Al. Conductor
Cable
Technical Specification of 3ph, 11/0.4KV, 100KVA, 200 KVA outdoor
type distribution transformer
Technical Specification of PG Clamp
Technical Specification of Rail Pole 13M
Technical Specification of XLPE cables
Technical Specification of Cable jointing accessories.
Technical Specification of Laying & Installation
Technical Specification of 1.1 kV grade control & power cable
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
1.0
STRAIN HARDWARE FITTINGS 33 & 11KV DISC

INSULATORS
(FOR 33 KV and 11 KV LINES SUITABLE FOR USE WITH TONGUE & CLEVIS
DISC INSULATORS (CONVENTTIONAL TYPE FITTINGS)
1.1
1.
2.
3.
4.
5.
1.2
1.
2.
3.
4.
5.
1.3
1.
2.
3.
(A)
TEST CERTIFICATE
The following shall constitute the type tests for clamps.
Visual examination
Verification of dimensions
Slip strength tests
Ultimate strength tests
Galvanizing/Electroplating tests.
The type tests are intended to prove the general qualities and design of a given
type of insulator fittings. These tests should have not been conducted earlier,
than 5 years from the date of opening of tender.
ACCEPTANCE TESTS
The following shall constitute the acceptance tests:Visual examination tests
Galvanizing/electroplating test
Mechanical Tests
Ultimate Strength test
ROUTINE TESTS
The following shall constitute the routine tests:Visual examination tests
Mechanical routine tests on Conductor Tension clamp only
The routine tests will be carried out on each of insulator fittings to check
requirement which are likely to vary during production.
All the above three tests have been described in IS:2486 (Part-I)-1993.
Galvanizing tests for Hot Dip ferrous material shall be carried out in accordance
with IS:2633-1986 and satisfy the requirements in IS:4759-1984. Electrogalvanized ferrous fittings shall be checked in accordance with IS:1573-1986.
However one sample from each lot will be tested as per IS:4759-1984.
11KV STRAIN HARDWARE FITTINGS (T&C) TYPE
Each hardware fittings of the strain insulators shall comprise of:Hot dip galvanized cross arms & straps, properly profiled and suitable for use on
75/100 mm channel cross arms with 16mm dia hot dip galvanized bolts, nuts,
spring, washers, plain washer and 4mm dia split pin as per figures 26 of IS:2486
(Part-II)- 1984 and its latest amendment:
Spoil type clamp with clevis eye suitable for 33 KV and 11KV system for following
sizes of conductors:AAAC/ACSR
S.
Item
Stranding and Wire
Actual Area
No.
Dia of A.A. Alloy
i
AAA/ACSR
(37/2.88 mm)
200 Sq. mm
Conductor
(37/2.59 mm)
194.9 Sq mm
(Panther/Wolf)
ii
iii
AAA/ACSR
Conductor
(Dog)
ACSR Rabbit
(7/4.26 mm)
100 Sq. mm
(7/3.35 mm)
61.70 Sq mm
The ultimate strength of the clamp should not be less than 4500 Kg. The clamp
shall be made by process of Die-casting. The clamp made with process of sand
casting shall not be accepted.
All dimensions of cleaves and tongue connections shall be as per figure-25 of the
IS: 286 (Part-II) -1989 and its latest amendments.\
1.4
1.5
1.6
1.7
1.7.1
GENERAL REQUIREMENTS
All fittings shall be of same type and design manufactured under similar
conditions of production.
All forging and castings shall be of good finish and free from flaws and other
defects. The edges on the outside of fittings, such as the eye, clevis and holes,
shall be rounded. The clamp shall be manufactured by the process of die casting
or pressure die casting and shall be free from blow holes and other defects.
All ferrous fittings and the part other than those of stainless steel shall be
galvanized by the Hot Dip process. Only small fittings like, plain & spring
washers, nuts may be electroplated galvanized.
The nuts shall conform to property 4.8 of IS:1367 (Part-6)-1980.
The collar pins shall be provided with Galvanized Mild Steel Flat Washers in
addition to split pins.
The split pin to be used on the collar pin shall be of phosphor bronze conforming
to IS:7814-1975 or Stainless Steel conforming to IS:5577-1992 or brass
conforming to IS:410-1977 with a minimum hardness of 160 HV.
MARKING ON CLAMPS
The clamps shall have the following markings for their identification as per ISS.
Trade Mark of manufacturer
Please note that the marking should be legible and permanent (preferable die
caste).
PACKING
Strain clamps and related hardware shall be packed in double gunny bags or
wooden cases if deemed necessary. The gross weight of the packing shall not
exceed 50 Kg. Different fittings shall be packed in different bags or cases and
shall be complete with minor accessories fitted in place. All the nuts shall be
hand tightened over the bolt and screwed upto the farthest point with split pin in
position. The packing shall be fit to withstand rough handling during transit and
storage at destination.
CLAMPS & CONNECTORS
The conductor shall be AAA conductor Dog and Panther. The technical
parameters and other details of conductor.
CLAMPS & CONNECTORS:
Clamps & connectors shall conform to IS:5561. The clamps and connectors shall
be made of materials listed below:
For
connecting Aluminum alloy casting, conforming to designation
AAA/ACSR conductors
A6 of IS:617 and shall be tested for all tests as per
IS: 617
For
connecting
equipment
terminals
made of copper with
AAA/ACSR conductor
Bimetallic connectors made from aluminium alloy

casting conforming to designation A6 of IS:617
with 2mm thick Bimetallic liner and shall be tested
as per IS:617
For connecting GS shield Galvanized mild steel

wire
Bolts, Nuts & plain Hot dip galvanized mild steel for sizes M12 and
washers
above, and electro-galvanized for sizes below M12
Spring washers for items Electro-galvanized mild steel suitable for at
a to c
least service condition 4 as per IS:1573-1986.
All castings shall be free from blowholes, surface blisters, cracks and cavities. All
sharp edges and corners shall be blurred and rounded off.
No current carrying part of a clamp or connector shall be less than 10 mm thick.
They shall be designed and manufactured to have minimum contact resistance.
For Bimetallic clamps or connectors, copper alloy liner of minimum 2 mm
thickness shall be provided.
Flexible connectors, braids or laminated strips made up of copper/ aluminium for
the terminal clamps for equipment shall be suitable for both expansion or through
(fixed/ sliding) type connection of IPS Aluminium tube as required. In both the
cases, the clamp height (top of the mounting pad to center line of the tube)
should be same.
Size of the terminal/conductor for which the clamp/connector is suitable shall be
embossed/punched (i.e. indelibly marked) on each components of the clamp/
connector, except on the hardware.
Clamp shall be designed to carry the same current as the conductor and the
temperature rise shall be equal or less than that of the conductor at the specified
ambient temperature. The rated current, for which the clamp/ connector is
designed with respect to the specified reference ambient temperature, shall also
be indelibly marked on each component of the clamp/connector, except on the
hardware.
Clamps and connector shall be designed corona controlled.
Clamps & connectors shall conform to type tests and shall be subjected to
routine and acceptance tests on minimum 3 samples per lot as per IS:5561. Type
tests report for all clamps and connectors for temperature rise test, the
Contractor shall furnish tensile test.
2.0
HOT DIP GALVANISED GS SOLID WIRE:
The hot dip galvanized MS Solid wire of sizes 5 mm, 4 mm and 3.15 mm
diameters shall conform to the relevant ISS specification, briefed here below: 2.1
MATERIAL
The Mild Steel wire shall have the chemical composition maximum sulphur .055%, Phosphorus 0.055%, Carbon 0.25%.
Zinc shall conform to grade Zen 98 specified in IS:209-1966 & IS: 4826-1979
2.2
ZINC COATING
Zinc coating shall be in accordance with IS: 4826-1979 (Cl.4.2.1) for heavily
coated
hard quality.
2.3
GALVANIZING
Galvanizing shall be as per IS:2629-1985 and IS:4826-1979 with up to date
amendments.
2.4
UNIFORMITY OF ZINC COATING
Uniformity of Zinc coating shall be determined as per IS:2633-1972 with up to
date amendments.
2.5
TENSILE PROPERTIES
The tensile strength of the wire after, galvanizing shall be between 55-95
Kg/Sq.mm (heavily coated Hard as per IS:4826-1979 Tables-1) ensuring MS wire
Mechanical properties as per IS:28-1972 8.1 to 8.3.
2.6
FREEDOM FROM DEFECTS
To be ensured as per IS: 2629-1985 (Cl. 6.1) & IS:4826-1979 (Cl. 4.3) & with up
to date amendments.
2.7
TESTS
During the process of manufacture/ fabrication and finish all tests for chemical,
mechanical, galvanizing as per IS:280-1979, IS:1521-1972, IS:1755-1961,
IS:6745-1972 & IS:4826-1979 be carried out. Test certificate towards, chemical
composition (as per above) shall be submitted for each lot offered for inspection.
The following tests shall be conducted in presence of owners representative.
1. Visual Physical inspection and measurement of specified dimensions.
2. Coating test as per IS:1755-1961, IS:2629-1966, IS:2633-1972, IS:4826-1979
& IS: 6745-1972.
3. Adhesion test as per IS:1755-1961, IS:2629-1966, IS:2633-1972, IS:48261969 & 1979 IS:6745-1972.
4. Tensile strength and breaking load and elongation determined as per
IS:1521-1972 with up to date amendments.
2.8
PACKING
Packing shall be as per IS:280-1979 (Cl.3.1) and each coil shall be between 50100 Kg.
2.9
MARKING
As per IS:280-1972 (Cl.14.1 & 14.1.1) is required.
3.0
EARTHING
(AS PER IS:3043-1987)
3.1 Earthing shall generally be carried out in accordance with the requirements of
Indian Electricity Rules, 1956 amended from time to time and relevant
regulations under Electricity Supply Authority concerned. The drawings no
ADB/EZ- 33 & ADB/EZ- 34 for earthing are given in the bid document Vol. II.
3.2 In case of high and extra high voltages, the neutral points shall be earthed by not
less than two separate distinct connections with earth, each having its own
electrodes sub-station and will be earthed at any other point provided no
interference is caused by such earthing. If necessary, the neutral may be earthed
through suitable impedance.
3.3 As far as possible, all earth connections should be visible for inspection. Each
earthing system shall be so designed, that, the testing of individual earth
electrodes is possible. It is recommended that the value of any earth system
resistance shall be such as to conform to the degree of shock protection desired.
3.4 All materials, fittings etc., used in earthing shall conform to Indian Standard
Specifications, wherever they exist.
3.5 GENERAL REQUIREMENT AND PROCEDURES FOR EARTHING OF SUBSTATIONS:
3.5.1 The ground resistance for large sub-stations should not exceed 1 (one)
ohm, while in exceptional cases for small/remote sub-stations, a value up
to 2 (two) ohms may be allowed.
3.5.2 The joints/connections in the earthing system shall be welded only,
except the connections which require opening for testing/maintenance.
Such connections should be bolted tightly, using spring and ring washers
for proper contact pressure.
3.5.3 The MS flats to be provided for the horizontally laid earth grid should have
overlap welded joints, with length of welding at least twice the width of the
flat, e.g., 100 mm for 50 x 6 mm MS flats.
3.5.4 There should not be any dirt, grease, oil, enamel, paint or any such nonconductive coatings on the surfaces being joined or connected. Only
finished joints/ connections above ground may be provided with red oxide
or any other protective coating.
3.5.5 Underground earth electrodes and earth grid elements, when laid, should
have a clean metallic surface, free from paint, enamel, grease or any
such non-conductive coating.
3.5.6 As far as possible, all earth connections should be accessible for visual
inspection.
3.5.7 No cut-outs, links or switches other than linked switches arranged to
operate simultaneously on the earthed or earthed neutral conductor and
the live wire shall be inserted in the supply system.
3.5.8 The pipe/earth spikes electrodes should be driven into the ground to the
depth of 3 mtrs.
3.5.9 The strip electrodes, forming the horizontal grid, should be buried
underground to a minimum depth of 0.5 meter.
3.5.10
The path or earth wire should be out of normal reach of any person, as far
as possible.
3.5.11
In case of rocky top soil and sub-stratum, having very high resistivity, with
no scope of improvement by other means, the procedure given below
should be followed, strictly, carefully and invariably;
3.5.12
As least two bores of diameter little less than 40 mm, with a minimum
distance of 10 mtrs. between them, should be made in the ground at
suitable locations inside the S/s yard. The boring should be done until
soil sub-stratum rich in moisture and low in resistivity is encountered. GI
pipes of 40 dia should be descended in each bore, such that, the soil
mass around the pipes grips then tightly back filling of bores, if required,
with wet soil/clay may be done to ensure this condition. The GI pipes in
these deep bores should be interconnected with the main earthing grid of
the S/s through 50x6 mm MS flat. The GI pipes in the bores should also
be interconnected with each other. In extreme cases, the bore may have
to be made at remote locations i.e outside the S/s yard, with interconnections, through 50x6 mm flats, as explained before.
The procedures to be observed stringently for making connections and
joints between various elements of the earthing system are as follows:
i)
MS Flat to structure The MS flat should be welded to the
metallic portion (leg) of the structure after thoroughly cleaning the
surface to be welded.
ii)
GI wire to Structure The GI wire should be bolted to the
structure after making an eye formation and kept tight with the
help of spring and ring washers. Then, the entire arrangement
should be welded.
iii)
GI Wire to MS Flat The GI wire should be bolted and then
welded to MS Flat, as explained in sub-para of (i) above.
iv)
Earth spikes to MS Flat The earth spikes should be properly
welded to the MS flat.
v)
GI wire to GI pipe GI wire should be bolted to the GI pipe and
then welded, keeping in view the relevant precautions, mentioned
before.
3.6 EARTHING IN 33/11 KV SUBSTATION:

3.6.1 A grid of inter-connected conductors forming a closed loop/mesh is to be
installed using 50x6 mm MS flat for peripheral and branch conductor. Interconnections are made by welding them. This earth grid will be laid at a depth
of 0.5 mtr bonded to general mass of the earth by 3 mtrs long earth spikes of
dia. 25 mm and GI pipe 40 mm dia 3 mtrs long in the earthing pits driven
vertically.
3.6.2 It is to specify that the transformer neutral, apparatus frame work and other
non-current carrying metal work associated like transformer tank, switchgear
frame etc. are to be connected to earth grid. No part of the ground
connection leads should be embedded in concretes.
3.6.3 (i) Strucutre: At least two legs preferably diagonally opposite on each metal
structure shall be connected to earth grid with GI wire of 4/6 swg,
(ii) Isolators/Switches: The operating handle shall be connected to earth grid
independent of the structure earthing or through the steel mounting structure,
through 4 Swg. GI wire.
(iii) Lightning Arrester: The boxes of lightning arrestors shall be directly
connected to earth electrodes by 4/6 swg GI wire as short and as straight as
practicable, to ensure minimum impedance. Separate earth leads should be
used for L.A., in each phase. In addition there shall be a direct connections
as practicable from the earthed side of the lightning arrestors to the frame of
the apparatus being protected. Earth connections for lightning arrestors
should be in a separate pit, but in any case it must be connected with the
main mesh.
(iv) Power transformers: (a) The tank of the transformer shall be directly
connected to the main earth grid through 4/6 swg GI wire.
(b) The earthing of the neutral shall be by two separate distinct and direct
connections of stay wire7/8 or 7/10 swg may be used with proper lugs for
bushing
(c) The transformer track rails shall be connected to earth either
independently or by bounding to tank.
(v) Out door Kiosks, Circuit breakers: At least two legs preferably diagonally
opposite, of the supporting structure frame work of each circuit breaker unit
shall be connected to the earth grid, through 50x6 mm MS flats.
(vi) Fencing: All metal fencing wire-mesh and fencing poles (if metallic) where
provided shall be connected with the mesh.
(vii) CT/PT: (a) The base of the CT should be directly connected to the earth
grid through 4/6 swg GI wires.
(b) The base(neutral side) of the PTs should be directly connected to the
earth grid through 4/6 swg GI wires. Separate earth leads should be used for
PTs in each phase. The termination of leads on the PT neutral should be
bolted/clamped and not welded, to facilitate opening of the earth connection
for testing purposes.
(c) In addition, all bolted cover plates to which bushings are attached, within
the station grid area shall be connected to the earth grid.
3.7
Cables and supports: Armouring of armoured metal sheathed cables
within the station grid
area shall be connected to the earth grid.
3.8
Station transformer: The neutral earthing conductor used shall be 7/10 swg stay
wire.
3.9
The earthing pits (6 Nos) shall consist of 3 mtrs long 40 mm GI pipes (one no in
case of
black cotton soil and four no in case of rocky strata in each pit) buried
vertically inside the ground.
3.10
The dimensions of individual meshes in the grid may vary slightly according to
requirements of the lay-out, but the overall area (434 sq, mtrs) end to end
dimensions and
number of
meshes (13 Nos.) should be as per the drawing.
3.11
S.
No
1.
2.
3.
4.
5.
Schedule:
Particulars
50x6 mm MS Flat (2.36
kg/mtr)
Earth spike 3 mtr long 25 mm
dia
GI Pipe 40 mm Dia
GI wire 6 swg
Labour charges for complete
job
(For Black cotton soil)
(For Rocky strata)

Unit
Quantity
Kg
535.75
No
16
Mtr
Kg
LS
72
50
1 job
S.
No
1.
Particulars
Unit
Quantity
535.75
50x6 mm MS Flat (2.36

Kg
kg/mtr)
2.
Earth spike 3 mtr long 25 mm
No
16
dia
3.
GI Pipe 40 mm Dia
Mtr
18
4.
GI wire 6 swg
Kg
50
5.
Labour charges for complete
LS
1 job
job
Note: Labour charges includes pit digging, back filling by black cotton soil, muffing,
masonry, trench digging, laying, connecting, tightening & welding of MS Flat, GI
wire, pipe & earth spikes, earthing of equipments etc.
4.0
HOT DIP GALVANIZED MS STRANDED WIRE
The hot dip galvanized MS Stranded wire of sizes 7/3.15 mm diameters shall
conform to the relevant ISS specification as detailed below:
4.1
MATERIAL
MS Wire used for each strand shall have the chemical composition (maximum)
Sulphur & Phosphorus 0.055% and Carbon 0.25%.
Zinc shall conform to grade Zen 98 specified ARE 209-1966 & ARE 2141-1968,
1979 with up to date amendments.
4.2
ZINC COATING
Zinc coating shall be in accordance with IS:4826-1979 (heavily coated hard
quality Grade-4 as per table-1) with up to date amendments.
4.3
GALVANISING
Hot dip galvanizing shall be as per IS:2629-1985 & IS:4826-1979 with up to date
amendments.
4.4
UNIFORMITY OF ZINC COATING
Uniformity of Zinc coating shall be determined as per IS:2633-1986 with up to
date amendments.
4.5
TENSILE PROPERTIES
Tensile properties of each strand ensuring MS Wire mechanical properties as per
IS:280-1972 (Cl.8.1 to 8.3) and after galvanizing each wire shall be of tensile
strength minimum 700N/mm2 (71 Kgs/mm2).
Tensile strength, bending load, lay & elongation of each wire and full strand shall
conform to IS: 2141-1968 & IS: 2141-1972 in the tensile grade given above).
4.6
CONSTRUCTION
Construction shall be as per IS: 2141-1979 (Cl. 5.3.1 to 5.3.3)
4.7
FREEDOM FROM DEFECTS
Freedom from defects be ensured as per IS: 2141-1979 (clause 4.1.6
respectively).
4.8
TESTS ON WIRE BEFORE MANUFACTURE
As per IS:2141-1979 (Col.7.1 to 7.2.2) shall be done.
4.9
PACKING
Each coil shall be between 50-100 Kgs. Packed as per IS: 2141-1968 (Cl. 9.1)
6594-1979 & 2141-1979 (Cl. 11).
4.10 MARKING
As per IS: 2141-1968 (Cl.8.1 to 8.1.1) and IS: 2141-1979 (Cl.10 & 10.1) is
required.
5.0
DANGER BOARD:
As per provisions of IE Rules 1956, Danger Notice plates in Hindi or English and,
in addition, in the local language with the sing of skull and bones is required to be
provided on power line supports and other installations.
This specification covers Danger Notice Plates to be displayed in accordance
with Rule No.35 of Indian Electricity Rules, 1956.
Unless otherwise modified in this specification, the Danger Notice Plates shall
comply with IS 2551-1982 or the latest version thereof.
Dimension: Two sizes of Danger Notice Plates as follows are to be installed at
each substation:
a)
For display at 11 KV installations
- 250 x 200mm
The corners of the plate shall be rounded off. All lettering shall be centrally
spaced. The dimensions of the letters, figures and their respective position shall
be as shown in figs. 1 to 4. The size of letters in the words in each language and
spacing between them shall be so chosen that these are uniformly written in the
space earmarked for them. Under Rule No. 35 of Indian Electricity Rules, 1956,
the owner of every medium, high and extra high voltage installation is required to
affix permanently in a conspicuous position a danger notice in Hindi or English
and, in addition, in the local language, with the sign of skull and bones. The type
and size of lettering to be done in Hindi is indicated in the specimen danger
notice plates shown in Fig. 2 and 4 and those in English are shown in Figs. 1 and
3 of REC specification. Adequate space has been provided in the specimen
danger notice plates for having the lettering in local language for the equivalent
of Danger. 11000 and Volts.
The plate shall be made from mild steel sheet of at least 1.6mm thick and
vitreous enameled white, with letters, figures and the conventional skull and
cross-bones in signal red color (refer IS:5-1978) on the front side. The rear side
of the plate shall also be enameled.
TESTS: The following tests shall be carried out:
i)
Visual examination as per IS:2551-1982
ii)
Dimensional check as per IS:2551-1982
iii)
Test for weather proof-ness as per IS:8709-1977 (or its latest version).
6.0
GI EARTHING PIPE :
Earthing pipe should be made of 40 mm diameter ISI marked B class GI Pipe. 12

mm dia suitable holes on its circumference shall be made as per approved
drawing. The pipe should be in one piece. No joints or welding would be allowed
on its length. Clamps made of 50x6mm GI flat duly drilled with 12 mm size holes
should be welded at the top end for connection of earth conductor. The Earthing
pipe should not contain any joints in length.
Pipe used shall be 40mm NB diameter, ISI marked Galvanized Mild Steel Tubes
continuously welded Electric Resistance Welded ERW/High Frequency Induction
welded (HFIW)/Hot finished welded (HFW) type, conforming to IS:554-1985 with
latest amendment of MEDIUM quality (Class B).
MANUFACTURE: GI earth pipe (40 mm diameter & 4.5 metre long) shall be
made of tubes which shall be made from tested quality steel manufactured by
any approved process as follows:
a) Electric Resistance Welded (ERW).
b) High Frequency Induction Welded (HFIW) and
c) Hot finished Welded (HFW).
Tubes made by manual welding are not acceptable.
DIMENSIONS:
The dimensions and weights of tubes shall be in accordance with Table-I and
Table-II of IS:1239 (Part-I)-1990 with latest amendments, subject to tolerance
permitted therein. Necessary 12 mm diameter holes across the circumference
shall be provided as per approved drawing. Drawings shall be approved by the
owner before start of the manufacturing work. The tube, earthing pipe shall be
provided with 50x6mm GS clamps on one end, one clamp is to be welded with
the pipe and another is removable to enable measurement of earth resistance of
the pit. Other end of the earth pipe should be cut half in slop to make it a sharp.
GALVANIZING:
Tubes shall be galvanized in accordance with IS:4736-1986 with latest
amendment for hot dip zinc coating of Mild Steel Tubes. The minimum mass of
zinc coating on the tubes shall be in accordance with clause 5.1 of IS:4736-1986
(specification for hot dip zinc) and when determined on a 100mm long test piece
in accordance with IS:6745-1972 shall be 400 g/m2. The zinc coating shall be
uniform adherent reasonably smooth and free from such imperfections as flux,
ash and dross inclusions, bare patches, black spots, pimples, lumpiness, rust,
stains, bulky white deposits and blisters.
HYDRAULIC TEST:
(Before applying holes) Each tube shall withstand a test pressure of 5 M Pa
maintained for at least 3 seconds without showing defects of any kind. The
pressure shall be applied by approved means and maintained sufficiently long for
proof and inspection. The testing apparatus shall be fitted with an accurate
pressure indicator.
TEST ON FINISHED TUBES AND SOCKETS:
The manufacturer of finished tubes and sockets shall conduct the following tests.
1. The tensile strength of length of strip cut from selected tubes when tested in
accordance with IS:1894-1972, (Method for tensile testing of steel tubes), shall
be at least 320N/mm2.
2. The elongation percentage on a gauge length of 5.65/so (where so is the original
cross-sectional area of test specimen) shall not be less than 20%.
3. When tested in accordance with IS:2329-1985 (Method for Bend test on Metallic
tubes) the finished tube shall be capable of with standing the bend test without
showing any sign of fracture or failure. Welded tubes shall be bent with the weld
at 90 degree to the plane of bending. The tubes shall not be filled for this test.
4. Galvanized tubes shall be capable of being bent cold without cracking of the
steel, through 90 degree round a former having a radius at the bottom of the
groove equal to 8 times the outside diameter of tube.
5. Flattening Test on Tubes above 50 mm Nominal Bore: Rings not less than 40
mm in length cut from the ends of selected tubes shall be flattered between
parallel plates with the weld, if any, at 90 degree (point of maximum bending) in
accordance with IS:2328-1983. No opening should occur by fracture in the weld
unless the distance between the plates is less than 75 percent of the original
outside diameter of the pipe and no cracks or breaks in the metal elsewhere than
in the weld shall occur, unless the distance between the plates is less than 60%
of the original outside diameter. The test rings may have the inner and outer
edges rounded.
6. GALVANIZING TEST:
Weight of zinc Coating: For tubes thickness upto 6 mm the minimum weight
of zinc coating, when determined on a 100 mm long test piece in accordance
with IS:4736-1986 shall be 400 gm/m2.
The weight of the coating expressed in gram/m2 shall be calculated by
dividing the total weight of the zinc (inside plus outside) by the total area
(inside plus outside) of the coated surface.
Test specimen for this test shall be cut approximately 100 mm in length from
opposite ends of the length of tubes selected for testing. Before cutting the
test specimen, 50 mm from both ends of the samples shall be discarded.
7. Free Bore Test:: A rod 230 mm long and of appropriate diameter shall be passed
through relevant nominal bore of the sample tubes to ensure a free bore.
8. Uniformity of Galvanized Coating: The galvanized coating when determined on a
100 mm long test piece [see V (a) (iii)] in accordance with IS:2633-1986 (Method
for testing uniformity of coating on zinc coated articles) shall with stand 4 one
minute dips.
WORKMANSHIP:
The tubes shall be cleanly finished and reasonably free from injurious defects.
They shall be reasonably straight, free from cracks, surface flaws, laminations,
and other defects, both internally and externally. The screw tubes and sockets
shall be clean and well-cut. The ends shall be cut cleanly and square with the
axis of tube.
MARKING
The medium class of tubes shall be distinguished by Blue colour bands, which
shall be applied before the tubes leave the manufacturers works. Tubes shall be
marked with the standard mark.
7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
GALVANISED
- MILD STEEL HEXAGONAL HEAD BOLTS AND

NUTS
All bolts and nuts shall conform to IS: 6639-1972 and shall be galvanized as per
IS:1367 (Part 13) & IS: 2629-1985. All bolts and nuts shall have hexagonal
heads, the heads being forged out of solid truly concentric, and square with the
shank, which must be perfectly straight.
Bolts up to M16 and having length up to 10 times the diameter of the bolt should
be manufactured by cold forging and thread rolling process to obtain good and
reliable mechanical properties and effective dimensional control. The shear
strength of bolt for 5.6 grade should be 310 MPA minimum as per IS:12427.
Bolts should be provided with washer face in accordance with IS:1363 (Part I)
to ensure proper bearing.
Nuts should be double chamfered as per the requirement of IS:1363 (Part III)1984. The manufacturer should ensure that nuts should not be over tapped
beyond 0.4 mm oversize on effective diameter for size up to M16.
Fully threaded bolts shall not be used. The length of the bolt shall be such that
the threaded portion shall not extend into the place of contact of the component
parts.
All bolts shall be threaded to take the full depth of the nuts and threaded enough
to permit the firm gripping of the component parts but no further. It shall be
ensured that the threaded portion of the bolt protruded not less than 3 mm and
not more than 8 mm when fully tightened.
All nuts shall fit and tight to the point where shank of the bolt connects to the
head. Flat washers and spring washers shall be provided wherever necessary
and shall be of positive lock type. Spring washers shall be electro-galvanized.
The thickness of washers shall conform to IS: 2016-1967.
The Bidder shall furnish bolt schedules giving thickness of components
connected the nut and the washer and the length of shank and the threaded
portion of bolts and size of holes and any other special details of this nature.
To obviate bending stress in bolt, it shall not connect aggregate thickness more
than three time its diameter. Bolts at the joints shall be so staggered that nuts
may be tightened with spanners without fouling.
To ensure effective in-process Quality control it is essential that the manufacturer
should have all the testing facilities for tests like weight of zinc coating, shear
strength, other testing facilities etc, in-house. The agency should also have
proper Quality Assurance system which should be in line with the requirement of
this specification and IS 14000 services Quality System standard.
Fasteners of grade higher than 8.8 are not to be used.
RAW MATERIALS
MS round 16mm / 12mm used shall be tested for quality as per IS:2062 Gr. A.
i.
SPECIFICATION OF FINISHED PRODUCTS:
The bolts & Nuts shall be ISI Marked Mild Steel of galvanized Grade B and
shall be round with hexagonal head.
The Bolts and Nuts shall be manufactured by Hot/Cold forging process neatly
and cleanly finished and shall have metric threads as per IS:4218-1967 with its
latest amendments.
The dimensions of the bolts & nuts and tolerances should conform to IS:1363
with their latest amendments in all respect. The eccentricity and angular errors of
various elements shall be within specified limits as per IS:1367-1967 with its
latest amendments. The bolts & nuts shall be free from forging and threading
defects such as cuts, splits, burns, bulging, taper, eccentricity, loose fill etc.
which may affect their serviceability.
The bolt heads and nuts shall be chamfered on one face only and other face
shall be machined made.
Mechanical property requirement of tester shall conform to IS:1367 (Part-III)1979 property class 4.6 for bolts & property class-5 for nuts as per IS:1367 (Part
VI) 1980.
The bolts & nuts shall be supplied in well-cleaned conditions and suitably
protected against corrosion in individual bags of 50 kgs.
ii.
ACCEPTANCE TESTS
The Supplier/Manufacturer shall furnish test certificate from his own/recognized
Govt. Laboratory giving the results of tests as per IS:1367 (Part-III) 1979 &
IS:1367 (Part-VI) -1980 witnessed by the Employers representative for each lot
under inspection. The test certificate shall be in respect of the following for all
sizes of both bolts & nuts as applicable given below:Dimensional particulars (Sampling in accordance with IS:2614 for both bolts &
nuts (tolerance as per drawing).
Tensile strength test on full size (for bolts min. 400 N/ Sq.mm and for Nuts. Proof
Stress (Min 610 N/Sq. mm).
Power load test on full size bolts and M-12-51400 N for 15 Sec.
(with Head soundness tests for bolts (no fracture).
Brinell hardness tests or Rockwell Hardness or Vickers Hardness tests for bolts
min-114 & max. 209 or min. 67 & max. 95 or min. 120 & max. 220 respectively.
For nuts Vickers Hardness min. 130 & max. 302.
Galvanizing test- mass of zinc
PRE-DESPATCH INSPECTION AND TEST
The contactor shall arrange to carryout acceptance tests in presence of
inspecting officer in his own laboratory. In case testing facilities are not available
at his works he will make necessary arrangements for carrying out these tests at
a Govt. recognized lab at his own expense(s) and will provide all testing
arrangement for Boards representative to witness the tests.
iii.
MARKINGS
On the bolt head, there shall be identification marking of the manufacturer as well
as property class 4.6. If possible property class 5 shall be marked on Nuts
also. Further ISI Mark shall be marked on Gunny Bags for proper
identifications.
.
8.0 PVC insulated, PVC sheathed heavy duty galvanized,

stranded aluminium conductor, single flat steel armoured cable
(16 SQ.MM)
8.1
SCOPE
8.1.1 The specification covers the design, manufacture and testing and delivery of ISI
marked 1100 volt grade, weather proof 3.5 core 16 sq.mm., with stranded aluminium
conductor, PVC insulated, PVC sheathed heavy duty galvanized, single flat steel
armoured cable.
8.2
APPLICABLE STANDARD
8.2.1 All the cables shall conform to the requirements of following standards with latest
amendments, if any:i)
IS:1554 (Part-I) 1988
ii)
IS:8130-1984
iii)
IS:5831-1984
iv)
IS:3975-1979
v)
vi)
IS:10810-1984
IS:3961 (Part-II) 1967
vii)
viii)
IS:4905-1968
IS:10418-1972
8.3
PVC Insulated (Heavy Duty) electric Cables for

working voltages upto and including 1100 V
Specification for conductors for insulated electric
cables
Specification for PVC Insulation and sheath of electric
cables
Specification for mild steel wires, strips and taps for
armouring cables
Methods of test for cables
Recommended current ratings for PVC insulated and
PVC sheathed heavy duty cables
Methods for random sampling
Wooden drum for electric cables
GENERAL TECHNICAL REQUIREMENT
8.3.1 CONDUCTOR
Aluminium conductor used in power cables shall comply to the requirement to IS 81301984with latest amendments and shall be in accordance with clause 8.1 & 8.2 of IS 1554
(Part-I)-1988 with latest amendments.
8.3.2 PVC INSULATION, FILLER & INNER SHEATH
a)
PVC Insulation and sheath used shall comply to requirement of IS:5831-1984
with latest amendments.
b)
PVC insulatiion shall be suitable for continuous PVC conductor temperature of
70oC under normal operation & 160oC under short circuit conditions. Insulation shall
be of Type A PVC compound. The average thickness of insulation shall be not less
than nominal value specified
in Table 2 of IS:1554 (Part-I) 1988. The insulation
shall be applied by extrsion so that it fits closely on the conductor and it shall be
possible
to remove it without damage.
c)
The filler and inner sheath shall be of unvulcanised rubber or thermoplastic
material or proofed tape (for inner sheath only). Unvulcanised rubber or
thermoplastic material used shall not be harder than PVC used for insulation and
outer sheath. The material shall be chosen to be compatible with temperature
ratings of the cable and shall have no deleterious effect on any other
component of the cable.
d)
The laid-up cores shall be provided with inner sheath applied either by extrusion
or wrapping. It shall be ensured that the shape is as circular as possible. The
inner sheath shall be so applied that it fits closely on the laid up cores and it
shall be
possible to remove it without damage to the insulation. The
thickness of inner
sheath shall be as in Table-4 of IS 1554 (Part-I) 1988.
8.3.3 ARMOURING
The galvanized steel wires/strips shall comply with the requirement of IS: 3975-1979
with latest amendment. Armouring shall be applied over the inner sheath. The armour
wire/strips shall be applied as closely as practicable. A binder tape should be
provided on the armour. Type of armour and its dimension and procedure for its
laying and joints shall comply to the requirement of Clause-13.2,13.3, 13.1.3 & 13.4
respectively of IS:1554(Part-I)/1988. The D.C resistance of galvanized steel wire/strips
armour shall be measured and the result when corrected at 20oC shall comply with
approximate value given in Table-6 of IS:1554 (Pt-I)/1988.
8.3.4 OUTER SHEATH
The outer sheath shall be of type ST1 PVC Compound conforming to the
requirements of IS:5831-1984. The outer sheath shall be applied by extrusion
over the armouning and shall be so applied that it fits closely over armouring. It shall
be
possible to remove it without damage to inner sheath. The colour of outer sheath
shall be black. The minimum thickness of PVC outer sheath shall not fall below
the
nominal value (ts) specified in Table-7 of IS:1554 (Part-I) 1988 by more than 0.2
mm
Plus-minus 0.2 mtrs.
8.3.5 CORE INDENTIFICATION
Core shall be identified by different colouring of PVC in accordance with Clause10
of IS:1554 (Part-I) 1988.
8.3.6 IDENTIFICATION, PACKING & MARKING
Manufacturers Identification
In addition to manufacturers identification on cable as per clause-17.1 IS:1554
(Part- I)
following marking shall also be embossed over outer sheath at every
three metre :Cable size and voltage grade
Word BSEB & name of manufacturer at every 3 metre
The embossing shall be done in line throughout the length of the Cable and shall
be
legible and indelible.
8.3.7 Packing & Marking
a)
The cable shall be wound on a drum (ref. IS 10418-1972) of suitable size and
packed. The packing shall be robust for rough handling that is occasioned
during transportation by Rail/Road. The ends of the cable shall be sealed by means
of non-hygroscopic sealing material.
b)
The cable should carry the following information stenciled on the drum :1.
1.
2.
3.
4.
5.
Reference to Indian Standard IS:1554 (Part-I)

Manufacturers name, brand name or trade mark
Type of cable and voltage grade
Number of cores
Nominal cross-sectional area of the conductor
Cable code
6. Colour of cores
7. Length of cable on the drum
8. Number of lengths on drum (if more than one)
9. Direction of rotation of drum by means of an arrow
10. Approximate gross weight
11. Running end of cable
12. Country of Manufacturer &
13. Year of manufacture
14. ISI Certification Mark
The Cable (Drum) must bear ISI Certification Mark. In this connection, a certified
photo-stat copy of valid ISI marking License rights duly attested must be
submitted
along with the inspection offer as documentary evidence. In absence of
ISI License documents, the cable shall not be accepted.
8.3.8 Standard Length
The standard length of cable shall be 250 mtrs./500 mtrs. with plus minus 5%
tolerance.
8.4
TESTS
Following type tests, acceptance tests and routine tests are to be carried out in
accordance with clause-15 of IS/1554 (Part-I) 1988 with its latest amendments as
indicated below :8.4.1 TYPE TESTS
The following shall constitute type tests: Sl
.
A
i
ii
iii
B
i
ii
iii
iv
v
vi
vii
vii
i
C
Tests
TEST ON CONDUCTOR
Tensile Test
Wrapping Test
Conductor Resistance Test
TEST ON ARMOURING
WIRES/STRIP
Measurement
of
Dimension
Tensile Test
Elongation Test
Torsion Test (For round
wires only)
Winding Test (for strips
only)
Uniformity of zinc coating
test
Mass of zinc coating test
Resistance Test
For requirement Ref. For test method Ref. to

to
part No. of IS:10810
IS:8130-1984
IS:8130-1984
IS:8130-1984
2
3
5
Table-5 of IS:1554(PtI)/ 1988

IS:3975-1979
-do-do-
36
-do-
39
-do-
40
-do-do-
41
42
TEST FOR THICKNESS Clause 9,12,14 Table

OF INSULATION AND 2,4 & 7 of IS:1554(PtSHEATH
I)1988
PHYSICAL TEST FOR
INSULATION
AND
OUTER SHEATH
37
37
38
Sl
.
i
ii
iii
iv
v
vi
vii
E
F
Tests
Tensile
Strength
elongation at break
Aging in Air oven
Shrinkage Test
Hot deformation
Loss of mass in air oven
Heat shock test
Thermal stability
For requirement Ref. For test method Ref. to

to
part No. of IS:10810
& IS:5831-1984
7
-do-do-do-do-do-do-
ISULATION RESISTANCE IS-5831/1984

TEST
High Voltage Test
Clause
16.3
(Water immersion test)
IS:1554
(Part-I)
High Voltage Test
Clause
16.2
(at room temperature)
IS:1554
(Part-I)
Flammability Test
Clause
16.4
IS:1554
(Part-I)
11
12
15
10
14
Test method as per
IS:5831-1984 shall be
followed
43
of 45
of 45
of 53
The contractor shall be required to furnish the type test certificate from NABL
accredited Laboratory which shold not be more than three (3) years old at the
time of submission of bid.
23.4.2 Acceptance Tests
The following shall constitute acceptance tests:a)
Tensile Test (for aluminium)
b)
Wrapping Test (for aluminium)
c)
Conductor resistance test
d)
Test for thickness of insulations and sheath
e)
Tensile strength and elongation at break of insulation and sheath.
f)
Insulation resistance test
g)
High voltage test at Room temperature
All the above acceptance tests will be carried out by Employers
representative as per relevant ISS at the time of material inspection for the
purpose of clearing the lot offered by the bidder. Acceptance test shall be carried
out in each type and size of cable, on cable drum selected at random as per
following sampling plan :No. of drums in the lot
Upto 50
51 to 100
101 to 300
301 to 500
501 & above
No. of drums to be Permissible

taken as sample
defectives
2
0
5
0
13
0
20
1
32
2
no.
of
8.4.3
8.5
Routine Tests
The following shall constitute routine tests:a)
Conductor Resistance test
b)
High voltage test at room temperature
c)
The above routine tests shall be conducted by the bidder in accordance
with relevant ISS and test certificate as proof of it shall be submitted to
the Employer along with each inspection offer. In absence of routine test
certificate, the inspection offer shall not be considered valid and any or all
complication arising out of it Employer shall not be responsible.
Inspection
All the tests and inspection shall be made at the place of manufacturer
unless otherwise specially agreed upon by the contractor/manufacturer and
Employer. The contractor/manufacturer shall offer all reasonable facilities to the
Employer, without charges to satisfy him that the material is being furnished in
accordance with the specification. In order to ensure that quality of raw materials
used during manufacturing of PVC Cables as per requirement of IS:1554 (PtI)/1988, the Employers representative shall check quality of raw material, obtain
necessary invoices in proof that required quality of raw materials is being used.
The Employer reserves the right to have any or all types of acceptance test
carried out by NABL accredited laboratory. In case the material fails to pass the
test as per specification, the testing charges along with the other charges which
were actually incurred for arranging the test shall be recovered from the supplier.
9.0
A.
TECHNICAL SPECIFICATION OF THREE PHASE 11/0.433

KV, 100/200 KVA RATING OUTDOOR TYPE COMPLETELY
SELF PROTECTED DISTRIBUTION TRANSFORMERS.
SCOPE:
B.
This specification covers the design, engineering, manufacture, assembly, stage

testing, inspection and testing at manufacturers works before supply and delivery at
site of Oil immersed, Oil Natural Air Natural (ONAN) outdoor type 11KV/433 V, three
phase,
50 Hz, double wound core type, outdoor Type EC grade Aluminium
Wound Distribution Transformer of 100/200 KVA ratings, complete with fittings and
accessories for metering and protection unit on LT side of Distribution Transformer
for use in Distribution System.
9.1.1
The equipment offered shall be complete with all parts necessary for their effective
and
trouble free operation. Such parts will be deemed to be within the scope
irrespective of whether they are specifically indicated in the commercial order or not.
9.1.2 It is not the intent to specify herein complete details of design and construction. The
equipment offered shall conform to the relevant standards and be of high quality,
sturdy,
robust and of good design and workmanship complete in all respects and
capable to
perform continuous and satisfactory operations in the actual service
conditions at site and shall have sufficiently long life in service as per standard
requirements. The dimensional
drawings attached with the Technical Specification
in Volume II are generally of illustrative
nature. In actual practice, not withstanding
any anomalies, discrepancies, omissions, incompleteness, etc. in these specifications
and attached drawings, the design and
constructional aspects, including materials
and dimensions, will be subject to good
engineering practice in conformity with the
required quality of the product, and to such tolerances, allowances and requirements
for clearances etc. as are necessary by virtue
of various stipulation in that respect
in the relevant Indian Standards, IEC standards, I.E.
Rules and other statutory
provisions.
9.1.3 The Bidder / Supplier shall bind himself to abide by these considerations to the
entire satisfaction of the Employer and will be required to adjust such details at no extra
cost to the Employer over and above the tendered rates and prices.
9.1.4 Tolerances on all the dimensions shall be in accordance with provisions made in
the
relevant Indian/ IEC standards and in these specifications. Otherwise the same
will be governed by good engineering practice in conformity with required quality of the
product.
9.2
Unless otherwise modified in the specifications, the Distribution Transformers,

including various accessories, shall generally comply with the following Indian Standards
/ REC Specifications. The standard(s) shall be with latest amendment, if any.
Note: Wherever ISS are mentioned, equivalent or better International standards are also
acceptable :Sr.
Specification
Details about
No.
1
IS: 1180 (PART-I)
Specifications for outdoor type three phase distribution

transformers up to and including 100/200 KVA, 11 KV Class.
IS:6600-1978
Guide for loading of oil immersed Transformers
IS:335-1983
New insulation oils for Transformers
IS:3347 (Part-I
Dimension of Porcelain parts &

Transformer bushing (1.1 KV)- for LT
Sec. 1 & 2)
Metal
parts
for
IS:3347 (PART-III / Sec-1 & Dimensions of

Porcelain parts & Metal parts for
2)
Transformer bushing (17.5 KV)- for 11 kV
IS:7421
Porcelain Transformer Bushings for low voltage up to 1

KV.
IS:2099-1986
Porcelain Transformer bushing for AC volts above 1000

volts.
IS:3639-1966
Fittings & accessories for Transformers
IS:1866-1978
Code of practice for maintenance & supervision of insulating

oil in service.
10
IS:5484
Specifications for Aluminium wire rods.
11
IS:9335
Specifications for insulating kraft paper.
12
IS:1576
Specifications for solid insulating press Boards for electrical

purposes.
13
IS:616 (Part I)
Specification for paper covered Aluminium round conductors
14
IS:6162(Part II)
Specification for paper covered Aluminium rectangular

conductors
15
IS:104
Ready mixed paint, brushing zinc chromate, painting
16
IS:649
Testing of steel sheets and strips for magnetic circuits.
17
IS:2362
Determination of water content in oil for transformers.
18
IS: 4257
Dimensions for clamping arrangements for bushings.
19
IS 6160
Rectangular conductor for electrical machines.
20
IS:10028
Selection, Installation and maintenance of transformers
21
IS:3401
Silica gel
22
- REC Specification No. 2

- REC Specification No.
39/1993
- CEA Specification Chapter
4
Material conforming to other internationally accepted standards, which ensure

equal or
higher quality than the standards mentioned above would
also be acceptable.
9.3
SERVICE CONDITIONS:
The distribution transformers to be supplied against this specification shall be
suitable for
satisfactory continuous operation under the following climatic
conditions as per IS: 2026
(Part- I) latest revision.
i)
Peak ambient temperature
ii)
iii)
Maximum yearly weighted average ambient temperature

Maximum relative humidity
(Some time approaches saturation points)
iv) Minimum relative humidity
v)
Average number of thunder storm days per annum
vi) Average number of rainy days per annum
vii) Average annual rainfall
viii) Number of months of tropical monsoon conditions
ix) Maximum wind pressure
x) Altitudes
:
1000 mtrs
: 50C
: 35C
: 95 %
:
:
:
:
:
10%
40
90
125 cm
3 Months
: 100 Kg/mt
Not exceeding
9.4
PRINCIPAL PARAMETERS:
9.4.1
The Transformer shall be suitable for outdoor installation with three phase 50 Hz 11 KV
system in which the neutral is effectively earthed and should be suitable for outdoor
service as step down transformer under fluctuations in supply voltage up to (+) 10% to
minus (-) 15 % and frequency variation of +/- 3% from the rated frequency. The
transformer should be suitably designed for with-standing the unbalanced voltages
developed due to single phasing operation during load regulatory measures in 11KV
distribution system. It should be capable of withstanding the disturbance of back e.m.f.,
magnetic characteristic and consequential mechanical inter-play of forces, if any, under
such single phasing.
9.4.2
The 25 KVA Transformer shall confirm to the following specific parameters:

i)
Continuous rated capacity
: 200/100 KVA
ii)
System Voltage (Max.)
: 12.5 KV
iii)
Rated HT voltage
: 11 KV
iv)
Rated LT voltage
: 433 V (P-P) / 250 V (P-N)
v)
Frequency
: 50 Hz
vi)
No. pf phases
: THREE
vii)
Primary connection (HT)
: DELTA
viii)
Secondary connection (LT)
: STAR
ix)
Vector Group
: Dyn-11
x)
Percentage impedance at 75C
: 4.5 %
xi)
Taps (off circuits)
: TAPS NOT REQUIRED
xii)
Type of cooling
: ON AN
xiii)
Fault level of the system
: 500 MVA
9.4.3
Primary winding shall be DELTA connected and the secondary winding shall be
STAR connected (vector symbol Dyn-11), so as to produce a positive
displacement of 30 from the primary to the secondary vectors of the same phase.
The neutral of the secondary winding shall be brought out to a separate insulated
terminal. The transformers shall be Aluminium Wound (EC grade).
9.4.4
The transformer shall be designed and constructed to withstand without damage

the thermal and dynamic stresses of an external short circuit. The Manufacturer /
Supplier shall furnish all relevant design data and calculations in support of having
fulfilled this requirement as stipulated in IS:2026 (Part-I)
9.5
NO LOAD VOLATGE RATIO:
The No load voltage ratio(s) shall be 11/0.43 kV

9.6
LOSSES:
9.6.1 The No-load Loss and Load Loss for 11 KV Distribution Transformers of 25 KVA
rating shall not exceed the values indicated below:
RATING (KVA)
MAX. NO LOAD LOSS IN

WATTS (Fixed Losses)
200/100
100
MAX. LOAD LOSS IN

WATTS
(at 75C)
685
9.6.2 The above specified loss values are maximum guaranteed, without any positive
tolerance.
In case the actual loss values exceed the above guaranteed values, the
transformers shall
be rejected at the risk, cost and responsibility of the supplier.
9.7
9.7.1
TEMPERATURE RISE:
The temperature rise test shall be conducted by feeding total guaranteed losses
calculated at 100C as against 75oC in the ISS and tested in accordance with
IS:2026 or
equivalent standards and the same shall not exceed the limits of 50C
above ambient temperature (measured by resistance method) for transformer windings

and 40C above ambient temperature (measured by thermometer) for top oil. In case
the temperature rise exceeds the above values, transformers shall be rejected at risk,
cost and responsibility of the Supplier. The losses fed during temperature rise test for 25
KVA rating shall be as under:
RATING
200 KVA
Total Losses to be fed (No load losses + Load Losses Corrected to 100oC)
100 + 742
= 842 Watts
9.7.2 It must be noted carefully that readings for hot resistance after shut down shall
be taken separately for HV & LV windings, which means, after completing the readings
for one winding (HV or LV), the transformer shall be connected again and rated current
passed for another 60 minutes (min.) and shut down taken again to take hot resistance
readings for the remaining winding. This is in line with the requirement of CBIP manual,
to ensure proper resistance v/s time curves.
9.7.3 The Hot spot temperature at annual weighted average ambient temperature of
35o C shall not exceed 98o C, when calculated as per IS: 2026 (Part-II)
However, the transformer shall be designed for class A insulation.
9.8
UNBALANCE CURRENT:
The maximum value of unbalance current in transformers shall not exceed 2% of
full load current.
9.9
IMPEDANCE:
The percentage impedance at rated current and at 75C shall be 4.5 % with (+/-)
10 % tolerance.
9.10 TAPPINGS:
Taps as standard are to be provided in these transformers.
9.11 FREQUENCY:
Transformers shall be designed for normal frequency of 50 Hz, but shall be
capable of
giving the rated output with the variation of (+/-) 3 % from the rated
frequency.
9.12 ELECTRICAL CLEARANCES:
(A) EXTERNAL (IN AIR)
Minimum external electrical clearances after mounting the bimetallic terminal
connectors
in position shall be maintained, as under; however, positive tolerance
shall be acceptable without any ceiling.
Voltage
Medium
11000 Volt
433 Volt
AIR
AIR
Clearance
Phase to phase
Phase to earth
255 mm
140 mm
75 mm
40 mm
B) INTERNAL (IN OIL):

The following minimum internal clearances shall be maintained as per details
given hereunder:
PARTICULARS
a) Between HT outside surface & tank inside (non bushing side)
b) Between HT outside surface & tank inside. (HV bushing side)
c) Between HT outside surface & tank inside. (LV bushing side)
200 KVA
25 mm
40 mm
25 mm
d) Between HV windings & yokes (end insulation)

e) Between LV windings to core(Bare conductor)
f) From top of yoke to inside of top cover of tank (with gasket)
g) Between LT/HT winding (Radial bare conductor Clearance )
h) Phase to Phase Clearance between HV limbs
20 mm
3.5 mm
125 mm
11 mm
10 mm
The aforesaid external and internal clearances are minimum clearances and no
negative
tolerance on these clearances shall be allowed.
9.13
test
TEST VOLTAGE:
Transformers shall be capable of withstanding the power frequency and impulse
voltage prescribed below:
Nominal system
Voltage (RMS)
Highest system
voltage (RMS)
Impulse withstand
voltage
11 KV
0.433 KV
12.5 KV
----
75 KV (PEAK)
----
Power frequency
test voltage in
(RMS)
28 KV
3 KV
The Transformer shall have fully insulated windings designed for the above
impulse level.
9.14
HEAT DISSIPATION (COOLING) / RADIATOR CALCULATIONS & E T R

(ELLIPTICAL TUBE RADIATORS) PLACEMENT:
9.14.1 The transformers shall be capable of giving a continuous output without

exceeding the specified temperature rise as indicated in para 7 above. Elliptical tube
radiators of section 57 of gauge 18 (with tolerance as per relevant ISS) or pressed steel
radiators having sheet thickness of 1.20 mm (with tolerance as per relevant ISS) on the
transformers shall be acceptable.
9.14.2 The radiator tubes shall be arranged in two equal banks fixed at two opposite
non
bushing sides. The header pipe connecting radiator bank to the tank shall be
rectangular
in shape with approximate size of 100x20 mm (for Elliptical tube
radiators) or the header
pipe connecting radiator flange to the tank shall be of
round pipe of dia 32 mm (for pressed steel radiators). The placement of top header pipe
to the tank body shall be
above the top of yoke, to facilitate cooling for hot oil sump
over top yoke.
9.14.3 Cooling area of the tank/radiators should be sufficient to dissipate the guaranteed
losses (at 100C) satisfactorily. Necessary calculations in this regard shall be
furnished by the Bidder with their Bid. For the purpose of heat dissipation
calculations, the following criteria shall be adopted:
i) Plain surface of tank
500 W / m2
(Note: The area of top/bottom tank surface, headers, HV/LV bushing pocket shall
not be considered for purpose of above calculations).
ii) Elliptical tube of section
-55 watts/meter length.
9.14.4 There shall not be any price preference for providing of either type of radiators.
9.15 WINDING AND INSULATION:

i) MATERIALS:
Double paper covered aluminium conductors shall be used for 11 KV class
transformer of 200/100 KVA rating. The covering shall conform to IS:6162 (part I & II).
ii) CONSTRUCTION:
The High-tension windings shall be concentric with the Low-tension windings.
The
arrangement of the windings shall be robust in electrical and mechanical
construction and
shall permit free circulation of oil and avoid hot spots. The LT
conductor shall be
rectangular in shape. Two layers of electrical grade insulation
craft paper of 2 mm thickness or one
layer of min. 4 mm thickness shall be used
for interlayer insulation
both for HV and LV Coils. Insulation cylinder made from
electrical grade pre-compressed
board(s) having minimum total thickness of 1.5 mm
shall be used between HV and LV windings. Alternatively, 20 mm pressphan paper
making thickness of the cylinder 1.5 mm
having similar electrical properties may also
be used.
For phase barrier, 2 Nos. of 1 mm thick press board shall be used for covering
the tie rods. Tie rods shall be covered by kraft paper of suitable size in addition.
2 mm press board shall be used for base support insulation and core clamping
channel
insulation.
For bottom and top yoke insulation, only PC board of min. 2 mm thickness will be
used.
Also, vertical spacers between HV and LV coils and radial spacers (tickleys)/
blocks etc.
shall be of PC Board only.
Top layer of all HV coil shall be given one coat of air drying insulation varnish.
A tolerance up to plus/minus 1% shall be permissible on ID and OD and axial
length of HV and LV coils. However, the above tolerances are subject to maintaining
the min. required
clearances. The material and thickness of various insulation
provided for phase barrier, foot plate insulation, yoke insulation and core clamp
insulation shall be clearly indicated in
the drawing and in any case shall not be
inferior to those used in type tested transformers.
Minimum number of coils on HV side shall be 4 (four) per phase for 25 KVA
rating transformers. Dovetailed shaped radial spacers shall be placed between HV coil
sections,
suitably locked with vertical spacers around the circumference of the
coils. The number
of such spacers shall be minimum 4(four).
iii) INSULATION MATERIAL :
Electrical grade insulating Kraft paper of only Tribeni / Ballarpur / Cauvery or
equivalent/
better make shall be used subject to approval of the Employer. Press
Board used shall
be of senapathy whitely / Raman make or equivalent/ better
quality subject to approval of the purchaser. Perma wood or haldu wood blocks shall be
used for Top and Bottom yoke
insulation.
iv) CONNECTIONS AND TERMINATIONS:
a)
b)
A) HV Winding: The following method shall be adopted for taking out HV

connectionsThe coil series connections shall be made by soldering / brazing only, after
completely removing the insulation from the ends.
Starting and finishing leads of HT coils shall be covered with empire sleeve(s) of
proper size. These leads should be clamped with the body of the winding with the
help of cotton twine during manufacture of the coils.
All delta leads from the HT coils as well as HT line leads shall be taken out
through multiple paper covered (MPC) copper wires of sufficient cross section
area to impart the desired mechanical strength. The current density in HV
lead wire shall not exceed 0.8 A/mm. These lead wires shall be provided with
multi layer paper insulation of minimum 1.0 mm thickness i.e. increase in
diameter due to paper insulation shall not be less than 2 mm. The layer of glass
sleeves/ glass tape shall also be provided on the delta MPC wire and it should be
further covered with kraft paper.
c)
e)
All the above leads shall then be clamped tightly with cotton twine directly on to
the special frame/ bracket making Pie shape connection. This structure
could be made up of Bakelite/ Permalli wood/ laminated PC board flats, having
minimum size of 25x4.5 mm. Line leads leading to the HV bushing terminals
shall be directly clamped to the horizontal support bar of the Pie structure so
that any tension which may develop in the HT leads due to jerks or at the time of
making the connection, is not passed to the HT coils.
Delta joint and lead from delta joint to bushing rod shall be made by brazing only.
B) LV Winding :
a)
The LV connection shall be taken out by cut on the top yoke channel duly
reinforced to compensate for the mechanical strength.
b)
The layers in LT Coil may be either even or odd in numbers but minimum layers
shall be
two.
c)
LV star point shall be formed of aluminium flat of sufficient strength. Leads from
winding shall be connected to the flat by brazing.
d) Firm connection of LT winding to bushing shall be made of adequate size of L
shape flat. Connection of LT coils to L shape flat shall be by brazing only.
e) L shape Flat shall be clamped to LV Bushing metal part(s) by using nut, lock
nut and washer.
f ) Neutral of the Secondary winding (LV) shall be brought out to a separate
insulated bushing.
g ) For Aluminium windings, L&T, ALKAPEE Aluminium brazing rods with suitable
flux will be used.
9.16 CORE CONSTRUCTION & CORE COIL ASSEMBLY DETAILS:
(i)
The core shall be of high grade cold rolled grain oriented (CRGO) annealed steel
laminations, having low loss and good grain properties, coated with hot oil
proof insulation, bolted together to the frames
firmly to prevent vibration or
noise. All core clamping bolts shall be effectively insulated. The complete design
of core must ensure the permanency of the core losses with continuous working
of the transformers. The value of
the flux density allowed in the designs and
grade of laminations used shall be clearly stated, along with the curves. The
transformer core shall be constructed out of the prime
class of materials.
CRGO Lamination used shall be of prime grade and not second grade
steel
laminations.
(ii)
It will be mandatory for all the transformer manufacturers to use only PRIME
grade CRGO Laminations with specific loss of 0.89 watt per kg. at 1.5 Tesla or
any other combination
of better
grades with any thickness subject to
maximum specific loss of 0.89 watt per
kg. at 1.5 Tesla will also be
acceptable. The bidder shall furnish the core loss (watt/Kg.) and power (VA/Kg)
curves of the laminations used. The core shall be properly
stress relieved
by annealing in inert atmosphere. Thetransformer shall be suitable
for
over fluxing (due to combined effect of voltage and frequency) upto 12.5%
without
injurious heating. The operating flux density shall be such that
there is a clear safe margin of 12.5%. over the fluxing limit.
(iii)
Full mitred core construction technique shall be adopted. Top yoke & bottom
yoke pieces shall all be in one single piece and no cut pieces shall be
acceptable. The cross sectional area of yoke & limb shall be approximately
same.
(iv)
Transformer core shall not get saturated for any value of V/f ratio to the
extent of 115% of the rated value of V/f ratio (i.e. 11000/ 50) due to combined
effect of voltage and frequency without injurious heating at full load conditions.
The bidder shall furnish
necessary design data in support of this situation.
(v)
Flux density at rated voltage and frequency of core and yoke shall not be more
than 1.60 Tesla. The Over fluxing shall be limited to 12.5 % of rated value.
The No Load Current (magnetising current) at rated voltage and at 112.5% of

rated voltage shall not exceed the values given below:
Maximum permissible magnetising current in percentage of rated full load current
Transformer Capacity (In KVA)
At 100% rated voltage
200/100
3.25
At 112.5% rated
voltage
6.50
(B) CORE-COIL ASSEMBLY:

The core joints shall be interleaved and with full mitre design, as mentioned
above. Ample provision for free circulation of oil in the radial gap between the core & LV
coils shall be made. Eyes or lugs of sufficient size shall be provided for lifting core and
winding
assembly out of the tank. The core shall be effectively earthed through
tinned copper earthing plate bolted on core frame channels, after removing the channel
paint.
For top yoke channels, if cut or holes are made for taking LV connections,
suitable
reinforcement to channels shall be made by providing adequate size of
MS Flat of the thickness not less than 6 mm.
On the core-coil assembly, core clamping channels, tie rods, core studs, spacers,
assembly base supports, etc. shall be provided as per details given hereunder:
Sr.
No.
Item
Particulars
Minimum 4 Nos. of 12 mm each properly insulated and covered with
Kraft paper. Tie rods shall also be provided with lock nuts.
Minimum 4 Nos. of 12 mm each properly insulated and covered with
Kraft paper. The core studs shall also be provided with lock nuts.
a)
Tie rods
b)
Core studs
c)
Spacers
d)
Support of core 2 Nos. MS channels of 75x40 mm.
Minimum 4 Nos. dovetail type with min. peripheral coverage of 30%.
e)
assembly base
Channels
for
4 MS Channels of 75 x 40 mm size (applicable for CRGO
clamping
core
transformers)
coil assembly
Guides on all the four sides shall be provided to prevent shifting of the active
parts and
thereby accidental touching the tank. Alternatively brass nut arrangement
at the top of core coil assembly to lock the same with the transformer tank be
provided.
The assembly fixing brass nut(s) are to be welded, 20-30 mm off the centre line
(and diagonally) ofthe tanks, so that assembly movement during transport etc. is
prevented.
MS Channel, tie Rods etc should be painted with hot oil and corrosion
resistant paint after phospating.
All core-coil assembly shall be punched on core channel / a identity plate welded
on core
channel with following details:
1.
Name of Supplier:
2.
Order / TN No:
3.
Rating:
In case the above marking is not found on the core assembly of physically
opened
transformer selected for physical verification during final inspection then
no further
inspection shall be carried out and re-inspection charges shall be payable
by the Supplier.
9.17
TRANSFORMER TANK:
(a)
Transformer tank shall be rectangular in shape, robust in construction and with

adequate strength to withstand the pressures developed at the time of severe
fault conditions. The tank body shall be suitably stiffened to achieve the
objective. The tank sheet shall be electrically welded both from inside and
outside to impart proper mechanical strength and to prevent leakage of oil. All
joints of tank and fittings shall be oil tight and no bulging shall occur during
service. The tank design shall be such that the core and windings can be lifted
freely. The tank plates shall be of such strength that the complete transformer
when filled with oil may be lifted bodily by means of lifting lugs provided. The
stiffeners shall be welded full length. All the welding shall be continuous. The top
cover plate shall be sloping down by more than 15 mm, opposite LV bushings
side. The top cover instead of bending shall be extended by 5 mm by all the
sides beyond the flange of the top cover. Accordingly length of the lifting hooks
shall be extended. The top cover shall have no cut at point of lifting lug. No
negative tolerance in the tank dimensions is acceptable in actual supply. The
tank shall be fabricated by welding at corners. No horizontal or vertical joints in
tank side walls and its bottom and top cover will be allowed.
(b)
Minimum size of MS Sections to be used in construction of transformer tanks
shall be as
under:
Sr.
No.
1
I T E M S
200 KVA
Tank Cover plate thickness (mm)
5.0
2
3
Tank Sides wall thickness (mm)

Tank bottom plate thickness (mm)
3.15
5.0
5
5
6
No. of stiffeners (To be welded with one face

while the other side of the angle forms
inverted L)
Conservator body (mm)
Size of M. S. stiffener (mm)
Tank Top flange size (mm)
7
8
9
Cover Bolt Size

Cover Bolt spacings (Maximum)
Lifting lugs
10
Tank Base Channel (ISMC Type)
1
2.0
40x40x 6 angle
50 x 6 Flat
M10/ 3/8 x 1.5
75 mm
2 Nos.
8t mm flat
2 ( 75 x 40 mm)
NOTE: Each cover bolt shall be complete with two flat washers, one nut and one spring
washer.
The above mentioned M S sections shall be subject to tolerance as per ISS.
(c) Lifting Lugs: Two Nos. welded heavy duty lifting lugs of MS plate of 8 mm thickness,
suitably
reinforced by vertical supporting flat welded edge wise below the lug on
side wall shall be provided, these shall be so extended that cutting of bent plate is not
required
(d) Top cover gasket & Bolt :
i)
The gasket provided in between top cover plate and tank shall be of min. 6
mm thick neoprene rubberized oil resistant cork sheets conforming to type B
or C as per IS:4253 part II.
ii)
G.I. Nut bolts shall be of size M 10 x 40 mm / 3/8x1.5 long with two flat
washers, suitably spaced (as specified) to press the cover.
iii)
Height of the tank shall be such that minimum clear height of 125 mm is
achieved between top of yoke and under side of the tank cover (with gasket
in place).
iv)
All steel screws, nuts and fasteners exposed to atmosphere shall be either
galvanised or cadmium plated or electroplated.
v)
All sealing washers / gaskets shall be made of oil and heat resistant
neoprene or
nitrile rubber. Gaskets made of natural rubber sheet are not permissible. The
minimum thickness of gaskets shall not be less than 6 mm for tank cover and
4mm for HT/LT gasket washers.
vi)
Talbros make neoprene/nitrile based rubberized cork sheet grade RC-70-C
shall
only be used as gasket material. Alternatively, other makes of gaskets having
type designations as under can also be used, if Talbros make gasket is not
available:
S.
No.
1.
2.
3.
Name of the firm
Commercial name of gasket manufactured by the

firm.
M/s. Nu-Cork Products P. Ltd.

Nu-Cork
Gurgaon
M/s. Bharat Corrub Ind.
Chetak
Vadodara
M/s. Grindbeck. Gujarat
Zebra
(Neoprene) Nu-Cork 999 RC-70-C

(Neoprene)
RC-70-C
(Neoprene)
RC-70-C
4.
M/s Goodwill Rubber Ind. (P)

Mayur (Neoprene) RC-70C
Ltd., Calcutta.
(e) Tank shall be reinforced by continuously welded angle on all the four sides of the
walls, on the edge of tank, as specified above. The permanent deflection shall not be
more than 5 mm upto 750 mm length and 6.5 mm up to 1250 mm length when
transformer tank without oil is
subjected to the vacuum of 250 mm of Mercury.
(f)
PAINTING & FINISHING :
Steel surface shall be prepared by sand / shot blast or chemical cleaning
including
phospating, as per IS 3618. Heat resistance paint (Hot oil proof) shall be
provided inside
the tank. On external surface, one coats of thermo-setting powder
paint or 2 coats of Zinc
chromate followed by two coats of synthetic
enamel
paint of dark admiral grey shade,
confirming to shade No. 632 of IS: 5-1961, shall be
applied.
The requirement for paint and the material to be used shall be as below.
Paint Type
a) Powder Paint
b)
Thermo
Setting
Powder
LIQUID PAINT
a) Zinc Chromate (Primer)
b)synthetic Enamel or
powder coating
(finish
coat)
c) Hot Oil Paint
Area to be Painted
No. of coats
Inside
Outside
01
01
Outside
Outside
02
02
Inside
01
All steel screws, nuts and fasteners exposed to atmosphere shall be either
galvanized or cadmium plated.
9.18
FITTINGS & ACCESSORIES:
The following standard fittings shall be provided on each transformer:

Earthing terminals of M10/ 3/8x1.5 with tinned lugs and symbol (2 Nos.)
a) Lifting lugs
(2 Nos. for main tank).
b) Rating and terminal marking plate (non-detachable), details to be included
in one plate only. The plate shall be of stainless steel only, with details
clearly marked (1 No.)
c) Bi-metallic terminal connectors on HT/LT bushings and it may be ensured before
dispatch that connectors are fitted.
d) Oil level gauge of minimum 150 mm length of prismatic glass, indicating three
positions of oil, marked as follows, shall be provided:
1)
2)
3)
-5 C - Min.
30 C - Nor.
98 C Max.
e) Silica Gel Breather shall be aluminium/ metal (1 No.)

f) Thermometer pocket, 12.5 mm dia with cap. shall be provided (1 No.)
g) HV Bushings. These shall be of 17.5 KV/250 A class, with non adjustable, single
gap type arcing horns (3 Nos.)
h) LV Bushings. 1.1 KV class, 250A (M12 stem) (4 Nos.)
i)
Under carriage: For transformers of 25 KVA rating shall conform to REC

specifications.
j) Brass rod 12 mm diameter for HT
(3 Nos.)
k) Brass rod 12 mm diameter for LT
(4 Nos.)
Note: LV/ HV Connectors shall not be the integral part of the bushing stems.
9.19 CONSERVATOR:
9.19.1 The oil gauge and the breathing device shall be fixed to the conservator. In
addition, the cover of the main tank shall be provided with a self-sealing pressure
release device designed to operate at minimum pressure of 8 PSI (0.564 Kg./cm.
Sq.) to enable release of air trapped within the main tank, unless the conservator
is so located as to eliminate the possibility of air being trapped within the main
tank. The conservator shall be of cylindrical shape and it should be provided
above the HV bushing with a minimum clearance of 50 mm and suitably inclined
to maintain the clearance.
9.19.2 The total inner volume of conservator shall be minimum 10 ltr. for 25 KVA
transformer. The inside diameter of the pipe connecting the conservator to a
main tank shall be min. of 30 mm and it should be projected into conservator in
such a way that its end is approximately 25 mm above the bottom of conservator
so as to create a sump for collection of impurities. The min. oil level
(corresponding to 5 deg. C.) should be above the sump level. The connecting
pipe from conservator tank to main tank shall have a sloping flap so that oil falling
from pipe shall not fall directly on the active job.
9.20 SILICAGEL BREATHER:
9.20.1 Body of breather shall be of aluminium/ metal and inside container for
Silica gel shall be
of tin sheet. The breather shall be only from reputed and
approved manufacturer and as
per the approved drawing. The gel capacity
shall be of 250 grams. Inverted U shape pipe
shall be used for breather.
Mounting arrangement of the breather shall be flanged /
threaded type as per
details given in the illustrative drawing attached.
9.20.2 The design shall be such that the condition of Silica gel is clearly visible from a
distance,
even after 5 years of service.
9.21 H V BUSHING TERMINAL DETAILS :
9.21.1 3 Nos. 17.5 KV / 250 A class bushings, conforming to IS:3347 & IS:2099, shall
be fitted on a pocket made on top cover. These pockets shall be such that the
HV bushing i s tilted more towards the HV side. The bushing of R & B phases
may be tilted sidewise
also to maintain the required electrical clearances.
9.21.2 The clamping ring of HV bushing shall be of galvanised MS Sheet having
minimum thickness of 1.6 mm. The total weight of all the 12 aluminium caste
member of HV bushing shall not be less than 210 grams.
9.21.3 The inner porcelain portion of bushings shall be projecting approx. 50% of the
length inside the conical pocket.
9.21.4 The arcing horn(s) shall be single gap and fixed type. HV bushings shall be of
reputed make such as BEPCO, JAYSHREE, WSI, SESHASAYEE or any other
make - approved by the Employer. The HV bushings shall generally conform to
IS: 3347 and IS: 2099. Embossing showing the manufacturers name and month
& year of manufacture shall be clearly visible on HV bushings, even after fixing
on
transformer(s).
9.21.5 As mentioned earlier, suitable bi-metallic connectors shall be provided having
capacity of about 1.5 times the rated current of the transformer.
9.22 L V BUSHING TERMINAL DETAILS:

9.22.1 LV Bushing side shall be opposite to the HV Bushing side. 4 Nos. LV Bushings
(1.1 KV/ 250 A) shall be mounted on a special pocket on the tank wall. Projection
of the LV pocket shall be such that inner portion of the LV stem shall not project
more than 20 mm inside the tank, to facilitate unhindered lifting of the core coil
assembly. Bushing stem
of M12 size shall be of brass. Rest of the
components shall conform to the requirement of
IS:3347 (Part I/section 2).
The LV bushings shall be of reputed make such as JSI,
JAIPUR GLASS or
any other make approved by the purchaser. The LV bushings shall generally
conform to IS: 3347 and IS: 7421.
9.23
TRANSFORMER OIL:
9.23.1 The transformer shall be supplied complete with first filling of EHV Grade
transformer oil, up to the normal oil level. The oil shall conform to IS: 3351983 (latest amended) and should be ISI marked and having the specified
aging characteristics.
9.23.2 The transformer oil sample taken from the transformer shall be subjected to
testing as per provisions of IS:1866.
9.23.3 The oil manufacturers test certificate shall be made available at the time of
inspection
to the inspecting officer.
9.24 IDENTIFICATION DETAILS:
a)
Rating & terminal marking plate: Each Transformer shall be provided with non
detachable
name, rating and terminal marking plate fitted in a visible position.
All details shall be
given on one plate. Material of the plate shall be stainless
steel only. Thickness shall be 0.9 mm (with a tolerance of 0.1 mm). The plate
shall be made absolutely un-detachable either through welding or riveting or
through any other approved method.
Each HV & LV terminal shall be duly marked with its terminal numbers. (e.g. HV
terminal with capital letter 1U, 1V, 1W and LV terminal by corresponding small
letters) 2u, 2v, 2w and the neutral terminal by 2n). In the diagram to be given on
the name plate, the relative position of various terminals- when viewed from
top shall be clearly shown. Dispatch instruction will not be issued, unless all
these details are verified by the Inspecting Officer.
Besides other particulars, following details shall also be given on the name plate:
i)
P.O. No. - Month & year.
ii)
Sr. No. of transformer.
iii)
Date of despatch - month & year
iii)
Date of expiry of guarantee period month & year
iv)
Maximum Guaranteed No Load & Load Loss Figures
v)
Recommended fuse sizes for HV & LV sides.
vi)
Name & Full address of the manufacturer.
vii)
Weight of oil (In Kg).
viii)
Total Weight (In Kg).
ix)
Vol of oil (In Litre)
x)
Rating of the transformer.
xi)
Impedance volt. (%).
xii)
Volts at HV&LV.
xiii)
Frequency (Hz)
xiv)
Vector group (Dyn11)
ALL DETAILS ON THE NAME RATING AND DIAGRAM PLATE SHALL BE

INDELIBLY MARKED i.e. BY ENGRAVING, STAMPING or PUNCHING.
b)
Identification Plate: M.S. plate of size 75 x 75 x 2.5 mm having following details
punched with letters of size 8mm X 6mm shall be continuously welded to the main tank
body below the middle HV bushing and on top cover of tank in clearly visible position :
NBPDCL
.
TS No. ------- KVA ,
S.NO. .
MAKE
c)
Identification mark:- Serial Number of Transformer is to be engraved on
transformer tank just below the
name plate with the letter size of 10 mm x 8 mm.
9.25 GUARANTEED
TRANSFORMER:
AND
OTHER
TECHNICAL
PARTICULARS
FOR
9.25.1 Guaranteed Technical Particulars of the transformer offered shall be furnished in

A-4 size paper by the Bidder in the proforma appended herewith at Annexure.
Complete
details shall be furnished. Tolerances on weight, quantity and dimension
figures shall be 5% at
the tender stage, subject to maintaining the minimum
electrical clearances as per the
specification. However, no negative tolerance shall
be allowed on the short circuit type tested design. Electrical performance data shall
be subject to tolerances as per ISS, unless otherwise specified in this specification.
However, the No Load loss and Load loss figures shall be maximum guaranteed
without any positive tolerance.
9.26
TYPE TEST CERTIFICATES:
9.26.1 The bidder shall furnish type test certificates of the offered transformer with the
bid
which should not be more than 3 years old as on the date of opening of tender.
9.27
DRAWINGS AND OTHER DOCUMENTS:
9.27.1 The Bid shall be accompanied with the following drawings / Calculation sheets,
as
per the offered designs. The drawings shall be only on A-3 (420 x 297
mm) size paper and calculation sheet shall be on A-4 size paper only.
a) Name rating / diagram plate drawing.
b) Outline and general arrangement drawing.
c) Core-coil assembly drawing.
d) Core section (for limb and yoke) along with flux density calculation sheet /
drawing.
e) Cooling area calculation sheet.
f) Thermal Ability short circuit calculation sheet.
g) Core loss and magnetization curves of the laminations.
h) Heat dissipation calculations (heat dissipation by tank walls excluding top
and bottom should be 500 W/sq. meter.
9.28
QUALITY ASSURANCE PLAN:
9.28.1 The Bidder shall furnish the details in respect of the items specially indicated in
the
schedules prescribed herein and annexed with this specification, failing which the
offer is
liable for rejection.
9.29
INSPECTION AND TESTING:
(i)
The inspection and testing shall be conducted at the place of
manufacture. The
transformers shall be completely assembled and tested at
the factory. The inspection may be carried out by the Employer at any stage of
manufacturing. The Supplier shall grant free access to the Employers
representative at all reasonable times when the manufacturing work is in
progress. Inspection and testing of any material under this specification by the
Employer shall not relieve the Supplier of his obligation of supplying the material
in accordance with the specification and shall not prevent subsequent rejection if
the material is found to be defective.
( ii )
The Supplier shall afford the inspector representing the Employer
all reasonable facilities, without charge, to satisfy him that the material is being
manufactured in accordance with the specification. The bidders must have
adequate set of instruments for conducting testing as per ISS Specification. The
instruments for measurement of losses shall be of accuracy class of
0.5
or
better. The instruments shall be duly calibrated and Calibration Certificate should
not be older than one year on the date of presentation to the Inspecting Officer.
The calibration shall be arranged from NABL accredited testing house. A
comprehensive list of testing equipment/instruments indicating make, Sr.No.,
type, class of accuracy, calibrating agency, calibration date etc.
should
be
furnished along with the bid. The calibrated instruments shall be duly sealed by
calibrating agency to avoid any tampering with calibration and the details thereof
shall be clearly mentioned in the Calibration Certificate(s).
( iii )
The Supplier shall keep the Employer informed in advance, about the
manufacturing programme so that arrangements can be made for
inspection. The
Supplier shall give preferably fifteen days advance
intimation to enable the Employer
to
depute
his authorised
representative for stage inspection/ witnessing of various
tests on the
equipment/ material.
9.30
STAGE INSPECTION:
9.30.1 The Employers representative may carry out stage inspection of the
transformers during manufacturing/ assembling stage. The Employer shall have
absolute right to reject
the raw material/ component/ sub assemblies or complete
equipment not found to be conforming to the requirement of specification or being of
poor quality/ workmanship. The
stage inspection will particularly
include
the
following tests/ checks besides the general routine tests to be conducted during
manufacturing stages as per manufacturers standard
practice.
a) Physical inspection/checking of winding, insulating material, core material for
annealing and prime quality and other accessories / fittings of Transformer.
b) Measurement of core area and flux density.
c) Verification of H.V. & L.V. coils, Conductor size, I.D., O.D. Axial length, weight,
insulation covering etc.
d) Measurement of thickness of tank plates (Top, bottom and sides) and to

conduct Air pressure & vacuum tests as specified in the specification, to ensure
the adequate strength of the Transformer tank body.
e) Sample testing of core material for checking specific loss and thickness of
core plates.
f) Visual and dimensional check during assembly stage of core.
g) Check for proper provisions of spacers and bracings to arrest the movement of
core and winding assembly inside the tank.
h) Check complete transformer against approved outline drawing, provision for all
fittings, finishing etc.
9.30.2 The Employer at his option may collect the sample of the following raw material/
component for independent testing:
a)
CRGO Laminations - One specimen sheet of 300-500mm length and 50- 75mm
width (for each lot).
b)
HV winding wire
- 1250 mm length specimen for each type.
c)
LV winding wire
- 1250 mm length specimen for each type.
d)
Transformer oil.
- 2 samples of 5 litres each.
9.30.3 To facilitate stage inspection, the supplier should intimate complete schedule of
manufacturing programme of the transformers preferably 15 days in advance. At
least 25% of the transformers shall be offered in the shape of finished core - coil
assembly. The inspecting officers during the course of stage inspection may seal this
core - coil assemblies.
9.30.4 The manufacturing programme shall not be interrupted in case Employers
representative does not reach within seven days of the date of intimation.
9.31 ROUTINE/ ACCEPTANCE TESTS:
9.31.1 All the assembled/ finished transformers prior to despatch shall be subjected to
routine
tests as per IS: 2026. Minimum 25% of the offered lot size samples
subject to minimum 5 Nos will be taken for routine and acceptance tests. The Supplier
shall invariably furnish
manufacturers routine test certificate along with inspection
call of the offered transformers
for pre-despatch inspection. The inspection offers
without furnishing of routine test
certificates as per ISS of all the transformers
offered for final inspection shall not be
entertained, and any delay on
this
account shall be to Suppliers account.
9.31.2 The selected samples shall be subjected to the following routine / acceptance
tests at
the manufacturers works in accordance with the relevant ISS:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Insulation resistance
Separate source voltage withstand test
Induced over voltage withstand test
Measurement of windings resistance cold (at or near the test bed temperature)
Measurement of Voltage ratio and check of voltage vector relationship
Measurement of Impedance voltage and load losses at rated current and normal
frequency.
Measurement of No load losses at rated voltage and normal frequency.
Measurement of No load current at 100 % and 112.5% of rated voltage and
normal frequency.
Checking of rating and terminal marking plate.
10.
11.
12.
13.
Checking of weights, dimensions, fittings and accessories, tank sheet thickness,

oil quantity, material, finish, paint thickness and workmanship as per purchase
order and contract drawings.
Physical verification of core coil dimension, internal clearances, provisions of
required oil ducts in the HV and LV winding, conductor sizes, individual weights
of HV and LV winding core laminations etc., with reference to contract drawings
and type test report(s) by dismantling selected unit(s). The physical verification
shall be conducted on units equivalent to one unit per 25 Nos or part thereof of
offered quantity randomly selected from the offered lot. The dismantled unit(s)
after re-assembly shall be accepted by the purchaser after routine testing in
presence of his representative.
Oil dielectric strength (break down voltage) test.
Checking of manufacturers test certificates and invoices for major raw materials
shall be done and copies thereof duly signed by Suppliers representatives and
inspecting officers shall be enclosed with the inspection report.
9.31.3
Preferably Fifteen days clear notice shall be arranged for pre-despatch
inspection by Employers representative.
9.31.4
After successful inspection, the inspecting officer shall seal all the inspected
transformers by
numbered seals on diagonally opposite bolts of top cover
for identification. Before sealing, the inspecting officer will ensure that all the
offered transformers are complete and duly fitted with
name, rating and
diagram plate, identification plate (on tank body & Top cover) as specified in
this specification.
NOTE:
i)
INSULATION RESISTANCE MEASUREMENT:
Insulation resistance of selected samples shall be measured with a 2500

V Megger, of standard make such as M/s AVO, M/s Sakova, M/s Wako, M/s Evershed,
Vignole or Metrawatt. The minimum insulation resistance, in Mega Ohms, shall be as
indicated in the table below:
11000 Volts
(HV)
433 Volts
(LV)
ii)
200 C.
800
300 C.
400
400 C.
200
500 C.
100
600 C.
50
400
200
100
50
25
AIR PRESSURE TEST :
This test shall be conducted as type test at the time of inspection of first
lot, at the
manufacturers works. The pressure gauge and vacuum gauge shall be
duly calibrated and sealed by an independent recognised test lab(s).
The test procedure shall be as detailed below :
The tank shall be fixed with a dummy cover with all fittings including
bushings in position and shall be subjected to air pressure of 0.8 Kg./ cm (gauge
pressure), for 30
minutes.
not
Permanent deflection of flat plate, after pressure has been released, shall
exceed the values given below:
Length of plate up to
750 mm
751 to 1250 mm
iii)
Deflection
5.0 mm
6.5 mm
MAGNETIC BALANCE TEST:
This test shall be conducted as an additional test on one sample transformer

from each lot offered for inspection.
The application of low voltage to the middle limb will induce approximately equal
voltages
on the two end limbs. The application of voltage to the end limbs will
induce greater
voltage in the middle limb and less voltage in the other end limb.
Uniformity of induced voltages shall confirm the healthiness of the transformer windings.
The procedure for the test shall be as under:
a) Apply 250 Volts between LV terminals 2u-2n and measure voltages between
2v-2n & 2w 2n.
b) Apply 250 Volts between 2v-2n and measure voltages between 2u-2n & 2w2n.
c) Apply 250 Volts between 2w-2n and measure voltages between 2u-2n & 2v2n.
The measured voltages shall satisfy the conditions detailed as above.
iv)
OIL LEAKAGE TEST:

The oil leakage test shall be conducted on one unit selected from the offered lot.
Transformer complete in all respects shall be subjected to the pressure
corresponding to
0.5 Kg / cm and maintained for three hours. No leakage should
occur.
9.32
TYPE TESTS:
9.32.1
In addition to above tests, the following type tests shall be arranged by the
supplier in
accordance with IS:2026 (Part I to III).
i)
ii)
Short circuit test for dynamic and thermal ability: The short circuit test for
dynamic and thermal ability shall be arranged at CPRI, Bangalore/ Bhopal or
ERDA, Vadodara on one unit of each rating. The transformer(s) for the test
shall be selected/ sealed by our inspecting officer from the first lot which shall
be of minimum 20 Nos. (if ordered quantity is 500 Nos.) OR 50 Nos. (if
ordered quantity is more than 500 Nos.). The short - circuit test shall be
conducted only after successful routine tests including measurement of noload and load losses. The supply shall be accepted only after successful type
test on the selected transformer(s).
Impulse voltage withstand test: The impulse voltage withstand test shall be
arranged at any testing house accredited to NABL for the purpose of impulse
test. The test shall be conducted on one unit to be selected by our inspecting
officer from the first lot of 20 Nos. (if ordered quantity is 500 Nos.) OR 50
Nos. (if ordered quantity is more than 500 Nos.). The test shall conform to
the requirement of Clause 13 of IS: 2026 (Part-III). The supply shall be
accepted only after successful impulse test on the selected transformer(s).
9.32.2
No extra time shall be allowed for arranging these type tests. The cost of
above Type Tests shall be borne by the Supplier.
9.32.3
The programme indicating date and place of type test(s), be intimated to

enable Employer to depute his representative to witness the test if desired. The
testing house shall be advised to arrange to send type test results directly to
Employer along with drawings duly attested by the
testing authority for
scrutiny and approval. The type-tested transformer(s) shall also be
accepted as part of the supplies.
9.32.4
The requirement of arranging short circuit & impulse voltage withstand test
shall however, not to be insisted on the Suppliers who have arranged Dynamic &
Thermal
Ability to withstand Short Circuit Test/ impulse voltage withstand test
within last 3 years as on the date of opening of the tender on similar design and make.
9.33 RANDOM SELECTION AND TESTING (RST):
(i)
Inspection of material before dispatch or waiver of inspection will,
however, not relieve, the supplier from his responsibility to supply the material
strictly in accordance with the specification. The Employer shall have option to
test the samples selected at random from the lot of 25 No received at site and
shall be subjected to routine testing as per IS:1180 and 2026 (with latest
amendments) at MTRU, Jabalpur/ CPRI, Bhopal, CPRI, Bangalore/ERDA,
Vadodara/any other NABL accredited Laboratory.
(ii)
(iii)
(iv)
It is only after the results of randomly selected transformer are found

satisfactory; the clearance for installation of the transformer will be issued.
In case the selected transformer from the first lot fails in routine test, one unit
from the next lot shall be sent to the identified laboratory for carrying out
routine tests at suppliers cost. In case the transformer fails again in any or
all routine test, no further supply shall be accepted. and the transformers
available at site supplied against the current order shall have to be taken
back by the manufacturer at his own cost.
The Manufacturer will have to carry out suitable improvement in the design of
the transformer and get it type tested in presence of Employers
representative at his own cost. It is only after the transformer successfully
passes the type test, the supplies shall be resumed which shall again be
subject to random test as above before acceptance of the lot. This process
will continue in subsequent lots also. Further, the penalty towards delayed
supplies shall be to manufacturers account (if any).
9.33.1 The Employer may select transformer(s) from the supplied lot(s) at random for
conducting the routine tests, at any test house(s) as mentioned above. The
Supplier shall arrange these tests including loading, unloading and to & fro
transportation up to the test house(s). The charges for such tests shall be
reimbursable to the Supplier on actual basis on production of documentary
evidence in case the selected sample successfully withstands type test(s). In

case of otherwise, no charges will be reimbursed.
9.33.2
(i)
Measurement of No Load Losses and Load Losses
After pre-dispatch inspection of material at Suppliers works the transformers will

be subjected to the following test(s):
a)
One transformer will be selected out of every lot of 25 Nos. or part thereof for
measurement of No load Losses at rated voltage; No Load current (at 100% and
112.5% of rated voltage); Impedance voltage and Load Losses at rated current. The
testing shall be arranged either at Employers own testing lab and / or at independent
test lab. The testing charges for such tests hall be borne by the Employer. The test
results will be applicable to the respective lot of 25 Nos. or part thereof from which
sample was drawn.
b)
In case if dispatch instructions are less than 25 Nos. than one sample shall be
selected from
each store (s) and the test result so obtained shall be for the
quantity consigned / received by the store (s).
9.34
GUARANTEE PERIOD:
i)
If during the course of 36 months subsequent to the date of completion

or 1050 days of Operational Acceptance of the Facilities, which ever occurs first,
any of the transformer is found to be defective in materials or workmanship
or develops defects during service, the same will have to be replaced /
repaired by the supplier free of all charges. All necessary arrangements on
this account will be made by the Supplier.
(ii)
The said material if required to be replaced / repaired, shall be collected by

the Supplier/firm from area stores/ work from site at his own cost and at his
own responsibility. These material will like-wise be returned duly repaired /
replaced and tested subsequently by the Supplier to the destination
indicated on freight paid
basis at his cost in a reasonable time of 30
days from the date of intimation by the Area Stores.
(iii)
Unit once failed within the said guarantee period of 36 months and returned
to site duly repaired free of charges, shall be guaranteed for a minimum of
12 months or un-expired guarantee period left as on the date of failure of
the unit, whichever is later.
(iv)
In case unit again subsequently fails within the period of 12 months
and the total period of service given by the unit is more than 24 months
but less than 36 months, then the unit shall have to be repaired again free
of charges, by the Supplier. In case the unit further fails within 12 months
of its last return duly repaired, then the unit shall berepaired again free of
charges by the Supplier but the guarantee for the repaired unit, in this case,
shall be for the un-expired period out of 12 months.
(v)
The outage period i.e. period from the date of failure till the unit is
repaired, shall not be counted for arriving at the guarantee period of 36
months. The period of failure and repairs, thus, shall be excluded from the
guaranteed service of 36 months/ 12 months, as the case may be.
(vi)
Further, it is clarified that all the charges towards carrying out repairs
including packing / forwarding, loading / unloading shall be borne by the
Supplier.
(vii)
The actual cost of dismantling and replacement of the equipments with new
one shall be charged to the Suppliers account.
(viii) To & fro transportation cost of such failed equipments shall be borne by the
Supplier.
ix)
If the supplier does not lift and repair the failed transformer within a reasonable
time of 30 days from the date of intimation by the Employer, the same will be got
repaired at Suppliers cost through other Supplier/repairer.
9.35 ATTACHMENT DETAILS FOR TAMPER PROOF PROTECTION UNIT:

Tamper Proof Protection unit shall be manufactured in accordance with the
following standards as given in drawing no ADB/EZ-29 as given in Volume II.
The Enclosure Box shall comply with the requirement of I.S. 13947/I/1993 for
Degree of Protection I.P.- 33.
Three No. single pole MCCB shall be in accordance with I.S. 13947/II/1993
amended up to date.
General Technical Particulars:
The outdoor type distribution box is to be manufactured and supplied alongwith 3
No. SP MCCB with wiring in sheet steel cabinet duly powder coated. One no. LT
post insulator for neutral connections shall be provided.
Protection Box:
C.
The Enclosure shall be fabricated by using CRCA sheet steel of not less than 16
SWG thickness & shall comply with the requirement of I.P. 33 as per I.S.
13947/I/1993.
Box is to be provided with MCCB fixing arrangement such that front & back as
well as up
& down with tilting adjustment can be done to accommodate various type
& make of
MCCB. The box shall be provided to cover the LV bushing as shown in
the drawing.
9.35.1 MAIN FEATURES OF THE PROTECTION BOX:
The box shall be as per drawing no ADB/EZ-29 given in Volume II.
i) The single slide door panel shall be provided with slide opening.
ii) Name plate One door locking patti (25x40 mm) provided with MIG welded for
pad lock and sealing hole arrangement.
Louvres to be provided on both sides and in the bottom of MCCB Chamber.
v)
2 Nos. Earthing Bolt size 25x10mm each with 2 Nos. Washer and one Nut to
be provided.
2 Nos. Earth sticker or colour embossing with Earth Symbol to be provided.
1 Nos. hole provided at bottom in Cable Gland Hole. All hole meant for cable entry /
exit to be provided with rubber.
1 No. outcoming terminal lug size 35 sq.mm to be provided.
Danger Plate 125x38mm with Hindi Language with 440V AC.

Flat Gasket of size 20x2mm to be fixed with adhesive (fevibond) inside door.
All Hinges to be MIG Welded strictly.
All connecting wire ends should be fitted with proper lugs and properly connected
except meter terminals.
Single Panel Door.
Pad lock of 6 lever to be supplied and welded on the door of make
Harison/Jainson/Navtal.
NOTE:
All dimensions are in MM.
Box Door slide door opening.
Sheet steel thickness: 2.0 mm (min)
Paint shade: Exterior & Interior D.A. Grey shade 632 of IS:5
Degree of enclosure protection IP:33
Cable entry at bottom as per drawing.
All louvres to be provided with fine wire mesh from inside.
The size of box shown in mm. and may be more to suit the size of MCCBs.
General Arrangement of Chamber:
General arrangement of chamber of the box shall be kept as per drawing
covering the above aspects is given in drg. No ADB/EZ-29 given in Volume II.
Single Pole MCCB of 365 Amp. shall be provided. The wiring from L.V. Terminals
of Transformer to MCCB by 50 Sq.mm 4 Core aluminium armoured cable.
The complete protection box shall be covered with single panel door and the
panel door
shall be sliding type, fittings shall be provided with a lock of ISI mark and
with pad locking
and sealing arrangement.
9.35.2 SPECIFICATION OF MCCB:
The following makes of MCCB shall be acceptable :- Seimens / L & T / ABB / GE
Power / Schneider France / SPACEAGE _Hyundai/ HAVELS.
Single pole MCCB is to be provided on LV side for overload protection and
magnetic trip release for instantaneous tripping in the wake of short-circuits.
These MCCBs shall be confirming to I.S. 13947/1993 as amended up to date.
The rated un-interrupted current of MCCB shall be 630 Amp.
The MCCBs shall be manually independent & shall have quick make, quick
break Mechanism, the detailed specification of MCCB shall be as under:
Application
Outdoor (enclosed).
Utilization category
A (IS: 13947/1993) as amended upto date.
Type
Thermal-Magnetic trip free mechanism.
Number of poles
Single
Peak ambient temperature
50 C.
Rated insulation level
600 V.
Rated operational voltage
433 V.
Continuous current rating
600 A
Ultimate Short Circuit Breaking capacity (ICU)
10 KA at 0.4 P.F. at 240 V AC.
Rated service Short Circuit Breaking capacity (ICS)
10 KA at 0.4 P.F. at 240 V AC.
Power factor for Short Circuit (max.)
0.4 (lag.)
Application Standard
IS 13947 Part-2 (latest) - 1993
Time current characteristics
To co-ordinate with HV fuse.
The MCCB shall not cause any nuisance tripping due to switching current of
motor & capacitor loads.
The Bidder shall submit the type test reports as per I.S. 13947/1993 for test
sequence I,II & III complete with certified drawings, Oscillograms and approved
drawing from NABL approved laboratory along with the offer.
The MCCBs shall be marked with Brand Name of manufacture and Ics in KA by
embossing only whereas other particulars may be marked as per the
manufacturers
standard practice.
The contacts of MCCB should be self-wiping type so as to keep the contacts
clean and milli-volt drop low. The MCCB shall be provided with push to trip
facility.
The successful bidder shall be required to furnish the guarantee certificate of
three (3)
years obtained from the MCCB manufacture. The liability of guarantee
shall, however, be
that of the bidder/contractor. If during the course of 36 months
subsequent to the date of commissioning of MCCB, any of the goods is found to
be defective in
materials or workmanship or develops defects during service,
the same shall be
replaced / repaired by the bidder/contractor free of all charges.
All necessary arrangements on this account will be made by the bidder/contractor.
Acceptance Tests:
The following tests shall be carried out by the purchasers representative on MCCB on
the sample numbers equivalent to the number of transformer samples.
1.Overall Dimensional Checking.
2.High Voltage test at 3 kV for one minute.
3.Insulation resistance test.
Instruction and operation Manual
The successful bidder shall be required to submit 5 copies of Instruction and
Operation manual for each lot of 100 Transformers (or part thereof) supplied. This
instruction manual should give complete details about the pre-commissioning
tests/checks and
9.35.3
Signal Light (LED Indicating Lamp):
The MCCB enclosure shall be provided with LED indicating lamp (Three Nos.) to
indicate tripping of MCCB. An auxiliary relay with changeover contacts may be
used to connect LED indicating lamp to the transformer secondary terminals if
MCCB is not having auxiliary contacts. In case the MCCB trips or switched OFF,
the relay contacts are closed which turns ON the LED indicating lamp. When the
MCCB is reset and switched ON, the indicating lamp switches OFF. Signal light
shall be arranged to avoid damages while handling the MCCB enclosure at site.
ANNEXURE A
GUARANTEED TECHNICAL PARTICULARS FOR 200/100 KVA DISTRIBUTION
TRANSFORMERS.
Description
200 /100 KVA
Make & Manufactured by
To
be
furnished
Manufacturer.
Place of Manufactures
-do-
Voltage Ratio
11000 Volts /433 Volts 250 Volts
Sl.
No.
Ratings in
KVA
by
the
200 /100 KVA
Core material used & Grade
Shall be Prime grade CRGO or

superior grade
a) Flux density (Max.)
Not more than 1.6 Weber/sq. mm
b) Over fluxing without saturation
12.5%
(Curve to be furnished by the manufacturer in

support of this claim)
6
Max. temp. rise of

a) Windings by resistance
50 deg. Max.
temperature
over
ambient
b) Oil by Thermometer
40 Deg. Max.
temperature
over
ambient
Magnetizing (no load) current and losses in

watts.
a) Normal Voltage
Not to exceed 2% of FL current
b) Max. Voltage
To
be
furnished
manufacturer.
by
the
by
the
Core loss in watts at

a) Normal voltage (Max.)
100
b) Resistance of Winding
To
be
furnished
manufacturer
Resistance of winding at 20 deg. Cent (with

5% tolerance).
a) HV winding (ohms)
To
be
furnished
manufacturer.
b) LV winding (ohms)
-do-
10
Copper losses at full load (Watts) at 75 deg.

Cent (max.) :
685
11
Clearance:
As per Para 12 (B)
12
Efficiency at 75 deg. Cent.
13
a) 125%
Load
b) 100 %
Load
c) 75 %
Load
d) 50%
Load
e) 25%
Load
Regulation at
To
be
furnished
manufacturer.
by
the
by
the
-do-
a) Unit P.F.
b) 0.8. P.F. at 75 deg. Cent
14
% Impedance at 75 deg. Cent
4.5(Subject to tolerance as per IS

2026)
15
Flash Test HV 28 KV For 1 minute. LV

3KV/for 1 minute.
To be confirmed
manufacturer.
16
Over potential test Double Voltage &
-do-
by
the
Double freq. For 1 min

17
Impulse test of HV:
18
Weight content of (Min)
19
a)
Core lamination (kgs)
b)
Winding Copper (kgs)
c)
Tank and fittings KGs shall be

furnished.
d)
Oil
e)
Total Weight (Kgs)Shall be furnished

by the bidder
As per IS to be conformed.
(Ltrs).
Oil date
a) Qty. for first filling Ltrs (min)
To be furnished by manufacturer
b) Grade of oil used
EHV Grade conforming to latest

version of IS-335
20
c) Makers name
d) BDV at the time of filling
Transformers:
a) Overall LxBxH
b) Tank LxBxH
-do-
c) Thickness of plate for
21
1) Side plate mm (Min)
3.15mm
2) Top & Bottom plate
5.0 mm
Inter layer insulation provided in design for

1) Top and bottom layers
To be furnished by manufacturer.
2) In between all layers
-do-
3) details of end insulation
-do-
4) Whether wedges are provided at
-do-
50% turns of the coil.

22
Insulation materials provided

a) For conductors HV & LV
To
be
furnished
manufacturer
b) For core
23
by
the
-do-
Size of the winding used

HV
LV
a) SWG
b) Dia
-do-
c) Area
-do-
a) Strip size
b) No. of conductors Maintaining the

below Given area in parallel
c) Total area of cross section sq. mm
24.
Does the name plate give all particulars as

required in the tender
-do-
25.
Particulars of bushings
HV
1. Makers Name
To be furnished by manufacture.
2. Type IS-3347/IS-1180
3. Rating as per IS
a) HV
LV
b) LV
4. Dry flashover voltage at 50 C/S
-do-
5. Wet flashover voltage at 50 C/S
-do-
26
Details of taping provided on HV side
Not applicable
27
Radiation
1) Heat dissipation by tank walls
500 watts /sq.mm up to oil level
2) Elliptical tube of section 57
55 Watts/meter length
3) Dia & thickness of cooling tube
32mm Min. of gauge 18 SWG

(Length of cooling tube to be
furnished)
4) Whether calculation sheet for selecting

cooling area to ensure that the
transformer is capable of giving
continuous rated out put without
exceeding temperature rise is enclosed.
SOURCE OF MATERIALS / PLACES OF MANUFACTURE, TESTING AND

INSPECTION
---------- --- ------------------------------------------------------Sl.No.
testing
Item
Source of
Place of
Place of
Material
manufacture
& inspection
- - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----1. Lamination
2. Copper Aluminium
3. Core plates
4. Steel castings
5. Tank
6. Radiators
7. Insulating cylinders
8. Insulating paper
9. Bushing HV/LV
10. Oil
11. Insulated winding wire
12. a) Tap changer
b) Thermometer
c) Pressure relief vent
Signature of
Bidder:
Name:
ADDITIONAL DETAIL
SL.NO.
DESCRIPTION
1.
Core grade
2.
Core diameter
mm
3.
Gross Core area
sq cm
4.
Net Core area
sq cm
5.
Flux density
tesla
6.
Wt. of the Core
7.
Loss per kg. of core at

the specified Flux Density
8.
Core window height
9.
Centre to centre distance
10.
No. of L.V.Turns
11.
No. of H.V.Turns.
12.
Size of L.V.Conductor bare covered (mm)
13.
Size of H.V.Conductor bare covered (mm)
14.
No. of parallels
15.
Current density of L.V winding amps/mm2
16.
Current density of H.V winding amps/mm2
17.
Wt. Of the LV winding copper / aluminium
18.
Wt. Of the HV winding copper / aluminium for Transformer Kg.
19.
No. of LV coils / Phase
20.
No. of HV coils/ Phase
21.
Height of LV winding mm
22.
Height of HV winding mm
23.
ID/DD of LV winding mm
24.
ID/DD of HV winding mm
25.
Size of the duct in LV winding mm
26.
Size of the duct in HV winding
27.
Size of the duct between HV & LV
28.
HV winding to LV clearance
29.
HV winding to tank clearance
30.
Calculated Impedance
31.
HV to earth creepage distance
32.
LV to earth creepage distance
mm
mm
mm
mm
SCHEDULE
LIST OF SUPPLIES MADE SO FAR WITH FULL DETAILS OF GOODS SUPPPLIED
AND TO WHOM SUPPLIED
- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ---SCHEDULE
WEIGHT AND DIMENSIONS OF PACKAGES OF DESPATCH
- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --Sl.No.
Equipment
Contents of
Weight
Individual
Dimensions
Kg.
Packages
- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --SCHEDULE
DESCRIPTIVE LITERATURE AND FULL PARTICULARS OF THE EQUIPMENT
OFFRED
- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -----Sl.No.
Item No.
Description
10.0
1.
P G CLAMP
SCOPE
This specification covers Design, manufacture, testing at works and supply of
Aluminum Alloy Parallel Groove Clamps (PG Clamps) for 50 Hz System.
2.0
Technical Details :
Al. Alloy parallel groove clamps shall apply in all respects with the Indian
Standard or any other authorized standard.
Aluminum Alloy used in manufacture shall conform to IS-617/1959 & IS-1307 of
1961. Nuts and bolts used will conform to IS-1363 of 1967 and its latest
amendments.
The clamps shall be smooth and free from cavity. Blow holes and such other
defects which would cause unsatisfactory service. These shall have finish
avoiding sharp edges curvatures, ridges & damage the conductors in service.
All parts of the clamp shall either be internally resistant to atmospheric corrosion
or be suitably protected during storage and service. All ferrous metal parts shall
be hot deep galvanized as per IS-2633/ 196. The threads of nuts and bolts shall
be cut after galvanizing and shall be well oiled or greased.
The current rating of the clamps shall not be less than the current rating of the
conductor. The rated short time current shall be as per annexure-A of IS:2121
part(4). The frequency of the power supply is 50 C/S.
The conductivity of PG clamps shall be above that of power conductor. The
ultimate strength under tension shall be as per IS 2121. PG clamp shall be
capable of safely withstanding stress due to short circuit effect atmospheric
condition or vibration both on conductor and clamps.
The clamps shall be indelibly marked with rated current or any identifying marked
to enable full particulars of the clamps.
The material shall be inspected as per Test plan made by BSEB before dispatch.
11.0 TECHNICAL SPECIFICATION FOR RAIL POLE (13Mtr.)

1.0
1.1
1.2
2.0
RAIL POLES
The rail poles shall be 13Meters long & above as specified in the
schedules & should be 105 Ib/yd(13 mt height and above as per
requirement), rails of standard quality & dimensions respectively.
The poles shall be rousted & painted with one coat of red oxide paint &
two coats of aluminium paint.
Marking
The pole shall be clearly and indelibly marked with the following particulars
either during or after manufacture but before testing at a position so as to
be easily read after erection in position.
a)
Month and year of manufacture
b)
Transverse strength of pole in Kg.
c)
Makers serial No. and mark.
3.0 Drawings
3.1
The drawings submitted by the Contractor shall be approved/commented by the Owner
as the case may be within thirty (30) days of receipt of drawings in Owner's design
office. If the designs/drawings are commented by the Owner, the Contractor shall
submit revised design/drawings duly incorporating all comments within fifteen (15) days
of date of issue of comments.
3.2
Pole accessories drawings like name plate, danger plate, anti-climbing device etc. shall
be prepared by the Contractor and submitted to the Owner in three copies alongwith
one re-producable, for record. These drawings shall be prepared in A4 size only.
3.3
While submitting the drawings, the Contractor shall clearly indicate on each drawing
Specification No., Name of the line, letter reference no. and date on which the
submission are made. The same practice is also to be followed while submitting
distribution copies.
3.4
The Contractor shall furnish the drawings in fifteen (15) copies to the Owner for
necessary distribution within fifteen (15) days after the receipt of the approval from the
Employer.
12.0 TECHNICAL SPECIFICATION OF CABLE

1.0
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.6.1
1.1.6.2
1.1.6.3
1.1.6.4
1.1.6.5
1.1.6.6
1.1.6.7
1.1.6.8
1.1.7
1.1.7.1
TECHNICAL REQUIREMENTS
General
The cables shall be suitable for laying in soft soil, hard soil, rocky soil,
ducts, trenches, conduits and underground buried installation with
uncontrolled back fill and chances of flooding by water.
They shall be designed to withstand all mechanical, electrical and
thermal stresses under steady state and transient operating conditions.
The XLPE /PVC insulated power cables of sizes 240 sq. mm. and above
shall withstand without damage a 3 phase fault current of at least 18.6 kA
for at least 1 second, with an initial peak of 39 kA in one of the phases.
The armour for these power cables shall be capable of carrying 18.6 kA for
at least 1 second without exceeding the maximum allowable temperature
of PVC outer sheath.
The XLPE insulated cables shall be capable of withstanding a conductor
temperature of 250C during a short circuit without any damage. The PVC
insulated cables shall be capable of withstanding a conductor
temperature of 160C during a short circuit.
The Aluminium wires used for manufacturing the cables shall be true
circular in shape before stranding and shall be uniformly good quality,
free from defects. All aluminium used in the cables shall be of electrolytic
H2 grade confirming to IS 8130-1984.
The fillers and inner sheath shall be non-hygroscopic, fire retardant
material, shall be softer than insulation and outer sheath shall be suitable
for the operating temperature of the cable.
Progressive sequential marking of the length of cable in metres at every
one metre shall be provided on the outer sheath of all cables.
Strip wire armouring method (a) mentioned in Table 5, Page-6 of IS: 1554
(Part 1 ) 1988 shall not be accepted for any of the cables.
The cables shall have outer sheath of a material with an oxygen index of
not less than 29.
All the cables shall pass fire resistance test as per IS: 1554 (Part-I)
The normal current rating of all PVC insulated cables shall be as per IS:
3961.
Repaired or old cables shall not be accepted.
Allowable tolerance on the overall diameter of the cables shall be plus or
minus 2 mm or as per IS whichever is lower.
All cables shall be suitable for neutral solidly earthed system.
Outer sheath of 33kV/11 kV cable shall be bright orange in permanent
colour.
XLPE Insulated Power Cables
The XLPE insulated cables shall be of FR type, C1 category conforming to
IS: 7098 and its amendments read along with this specification. The
conductor shall be stranded aluminum circular/sector shaped and
compacted confirming to IS 8130 1984. In multi core cables, the cores
shall be identified by red, yellow, blue and black colored strips or
colouring of insulation. A distinct inner sheath shall be provided in all
1.1.8
1.1.8.1
1.1.8.2
1.1.9
1.2
1.3
1.4
2
2.1
2.2
multi core cables. For XLPE insulated cables, the inner sheath shall be of
extruded PVC to type ST-2 of IS: 5831. When armoring is specified for
single core cables, the same shall consist of aluminum wires/strips. The
outer sheath shall be extruded PVC to Type ST-2 of IS: 5831 for all XLPE
insulated cables.
Semi-conducting layers and copper screens shall be provided as
required. All armouring shall confirm to IS 3975: 1992
PVC Power Cables
The PVC insulated 1100V grade power cables shall be of FR type, C1
category, conforming to IS: 1554 (Part-I) and its amendments, read along
with this specification and shall be suitable for a steady conductor
temperature of 70C and 90C for XLPE . The conductor shall be
electrolytic grade stranded aluminium conforming to IS: 8130 -1984. The
Insulation shall be extruded PVC to type-A of IS: 5831. In multi core
cables, the cores shall be identified by red, yellow, blue and black
coloured strips or colouring of insulation. A distinct inner sheath shall be
provided in all multi-core cables. For multi-core armoured cables, the
inner sheath shall be of extruded PVC. The outer sheath shall be
extruded PVC confirming to IS 4831 to Type ST-1 of IS: 5831 for all
cables.
All armouring shall confirm to IS 3975: 1992.
Single core cable for connection between transformer and LT board shall
be unarmoured.
HT CABLE
XLPE insulated, armoured cable shall be conforming to IS 7098 (Part-II)
and IEC 60502-2 1998. Terminating accessories shall conform to IEC
61442 1997/IEC 60502-4 1998.
The construction of XLPE insulated, armoured HT cable shall be generally
conforming to IS 7098 (Part-II). Terminating accessories shall conform to
IEC 60840 - 1999.
The first semi-conducting layer on conductor, Insulation and the second
semi-conducting layer, shall all be extruded in a single one time process.
Homogeneity and absence of void should be ensured. The manufacturer
should ensure hot cross linking process with gas or radiant curing. Cold
(chemical) galvanising process known as Sioplast process would not be
acceptable.
CABLE DRUMS
Cables shall be supplied returnable (empty drums will be the property of
contractor) wooden or steel drums of heavy construction conforming to
IS:10481. Wooden drum shall be properly seasoned sound and free from
defects. Wood preservative shall be applied to the entire drum.
Standard lengths for each size of power and control cables shall be
500/1000 meters. The cable length per drum shall be subject to a
tolerance of plus or minus 5% of the standard drum length. The owner
shall have the option of rejecting cable drums with shorter lengths.
However, the total quantity of cables after taking into consideration of all
cable drums for each size shall be within the tolerance of 2%.
2.3
A layer of water proof paper shall be applied to the surface of the drums
and over the outer most cable layer.
2.4
A clear space of at least 40 mm shall be left between the cables and the
lagging.
Each drums shall carry the manufacturer's name, the purchaser's name,
address and contract number and type, size and length of the cable, net
and gross weight and year of manufacture stencilled on both sides of
drum. A tag containing the same information shall be attached to the
leading end of the cable. An arrow and suitable accompanying wording
shall be marked on one end of the reel indicating the direction in which it
should be rolled.
Packing shall be sturdy and adequate to protect the cables, from any injury
due to mishandling or other conditions encountered during transportation,
handling and storage. Both cable ends shall be sealed with PVC/Rubber
caps so as to eliminate ingress of water during transportation and
erection.
2.5
2.6
3
3.1
3.2
3.3
TYPE TESTS
All cables shall be subjected to all type, routine and acceptance tests listed
in the relevant IS.
The type tests on cables shall be conducted on each type and size of
cables offered.
Following type tests as per IS: 7098 (Part 1) 1988 including its
amendments and additional type tests shall be carried out on 33 kV & 11
kV grade XLPE insulated cables:
a) Tests on conductor
i)
Annealing test (for Copper)
ii)
Tensile test (for aluminium)
iii)
Wrapping test (for aluminium)
iv)
Resistance test
b) Test for armouring wires/strips
c) Test for thickness of insulation and sheath
d) Physical tests for insulation
i)
Tensile strength and elongation at break
ii)
Ageing in air oven
iii)
Hot set test
iv)
Shrinkage test
e) Physical tests for outer sheath
i)
Tensile strength and elongation at break
ii)
Ageing in air oven
iii)
Loss of mass in air oven
iv)
Shrinkage test
v)
Hot deformation
vi)
Heat shock test
vii)
Thermal stability
viii)
ix)
Physical tests for Inner sheath shall generally be same as

for Outer sheath but as per reel
x)
Insulation resistance (volume resistivity test)
f) High voltage test

g) Flammability test
h) Oxygen index and temperature index test on outer sheath
i) Short time current test on power cables of sizes 240 sq.mm and
above.
1) On conductor(s).
2) On armours.
Any other tests prescribed in the relevant IS/IEC.
3.4
Following type tests as per IS: 7098 (Part 2) - 1988 including its
amendments and additional type tests shall be carried out on XLPE
insulated HT cable up to 33kV earthed system:
a)
Tests on conductor
i)
Annealing test (for Copper)
ii)
Tensile test (for aluminum)
iii)
Wrapping test (for aluminum)
iv)
Resistance test
b)
Test for armouring wires/strips
c)
Test for thickness of insulation and sheath
d)
Physical tests for insulation
e)
Physical tests for outer sheath
f)
Partial discharge test
g)
Bending test
h)
Dielectric power factor test
i)
Heating cycle test
j)
Impulse withstand test
k)
High voltage test
l)
Oxygen index and temperature index test on outer sheath
Any other tests prescribed in the relevant IS/IEC.
3.5
Contractor shall submit type test reports with the bid as per
Technical Specification, Section: GTR for which test conducted once
are acceptable (i.e. The requirement of test conducted within last five
years shall only be applicable).
3.5.3
Terminating/jointing accessories as per IEC 60840:1999
a) Partial discharge test at ambient temperature;
b) Heating cycle voltage test
c) Partial discharge tests
-At ambient temperature
-At high temperature
d) Impulse voltage test followed by power frequency high voltage test
e) Test of outer protection for buried joints.
3.6
Acceptance Tests
The contractor shall offer each lot for acceptance tests to be witnessed by
Employer/BSEB representative as per test clause provided in General Technical
Requirement. The method of testing shall be as prescribed in the relevant IS/IEC.
13.0 CABLE JOINTING ACCESSORIES

1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
The cable jointing accessories shall include the end terminating kits, straight
through joints, and also any special tools and tackles required for making these
joints.
33 kV and 11 kV cable shall be used for converting 33 kV & 11 kV overhead line
to 33kV& 11 kV underground line of suitable size.
Straight through joints shall be used in 33kV&11 kV cable. The contractor shall
minimise the use of straight joints.
T offs and spur lines may be emanating from the main 11 kV feeder. These T
offs may be through different size cables. Ring Main Unit (RMU) and termination
kits shall be used for Tee off/ Distribution transformer connections on 11 kV
cables.
The straight through joints shall be either pre-moulded type or heat shrinkable
type complete with accessories. The joint shall preferably be built up from the
same material as the main cable and shall have electrical and mechanical
withstand capabilities same as or better than the main cable. The joints shall be
suitable for tropical climatic conditions specified in this specification.
The end termination shall be outdoor anti-fog type and shall be of tapex type or
pre-moulded type or heat shrinkable type complete with accessories. The
outdoor termination should be suitable for heavily polluted atmospheric
conditions with total creepage distance of 25 mm/ kV and protected creepage
distance of not less than 50% of the total creepage distance.
The detailed description on jointing procedure shall be furnished along with the
bid. The joints should preferably be carried out by the manufacturers jointers.
The details of the end termination/ straight through joints in service with the
period in service shall be furnished.
CABLE END TERMINATION ACCESSORIES

End termination accessories shall be as per IS 1255-1983.
1.3
TESTS ON ACCESSORIES
Type tests certificates shall be furnished to prove the general qualities and
design of given type of cable accessories. The type test shall conform to
relevant IEC/IS specifications.
14.0 LAYING AND INSTALLATION

14.1 Cable as per scope indicated in this specification, shall be laid underground in flat
formation
throughout the route as per relevant IS and approved drawing. However, as
per requirement of the
field, the cables shall also have to be laid:
1. In Hume Pipe or GI pipe.
2. In air at terminations in GI pipe of length 2.5 Mtrs.
3. At varying depths due to obstructions.
4. The cost of Hume pipe/GI pipe and accessories such as clamp etc. should be
included in the bid price.
14.2 The route plan of the cable is enclosed with bid documents to enable the bidder to
have a correct assessment of the work involved. The final route shall however be
site specific. The contractor shall prepare the final route drawing based on the
design and planning criteria provided in this document and get the same approved
from Employer/BSEB before starting the cable laying work.
14.3 TRENCHING
The cable trench work involves earth excavation for cable trench, back filling and
removal of excess earth from site. The work site shall be left as clean as possible.
The trench shall be excavated using manual and mechanical methods including air
compressor driven pneumatic drill as per field conditions. Most main roads are of
asphalt surface and some of the roads with cement concrete surface.
An air compressor with pneumatic drill or equivalent mechanical tool will be essential
if the road crossings are to be speedily made. Special system of laying Hume pipe
under road without digging the surface may be adopted if feasible.
Where paved footpaths are encountered, the pavement slabs shall be properly
stored and reinstated. Identification markers of other services shall be properly
stored and restored.
The sides of the excavated trenches shall, wherever required, be well shored up with
timber and sheeting.
Suitable wooden/ sheet steel barriers should be erected between the cable trench
and pedestrian/ motorway to prevent accidents. The barrier could be made out of
sheet steel or wood planks. These could be portable types of size 1.5 m long by 1.2
m (height). These should be painted with red and white coloured cross stripes.
Warning and caution boards should be conspicuously displayed. Red lights as
warning signal should be placed along the trench during the nights.
The excavated material shall be properly stored to avoid obstruction to public and
traffic movement.
The bottom of the excavated trench should be levelled flat and free from any object,
which would damage the cables. Any gradient encountered shall be gradual.
14.4 TRIAL HOLES:
The bidder shall excavate trial holes, for alignment purpose at appropriate distance
apart as warranted by the local conditions, keep a record of findings and close the
trial holes properly to avoid hindrance / accidents to pedestrian traffic. The final route
alignment of cable shall be decided based on the finding of the trial hole.
It is the responsibility of the contractor to maintain as far as possible the required
statutory clearances from other utility services.
Any damage caused, inadvertently to any utility services shall be the sole
responsibility of the contractor.
The scope also includes the Trench less laying of H.T.Cables
14.5
HANDLING
The inspection of cable on receipt, handling of cables, paying out, flaking, cushioning
with sand or sieved compacted native soil, back-filling, reinstatement of road
surfaces, providing and fixing joint markers, route markers , precautions of joint pits,
sump holes and all necessary precautions that are required shall be carefully
planned and in general conform to IS 1255-1983 or its equivalent.
14.6
DAMAGE TO PROPERTY
The contractor shall take all precautions while excavation of trench, trial pits etc., to
protect the public and private properties and to avoid accidental damage. Any
damage so caused shall be immediately repaired by contractor at his own cost and
brought to the notice of the concerned persons and to the Employer/BSEB .
- Contractor shall arrange third party liability insurance for the above purpose.
- The contractor shall bear all responsibilities and liabilities and shall bear all costs
of the damages so caused by him or by his workman or agents.
- At places where the cables cross private roads, gates of residential houses or
buildings, the cables shall be laid in RCC hume pipes.
14.7
CABLE ROUTE MARKERS/CABLE JOINT MARKERS

Permanent means of indicating the position of joints and cable route shall be
fabricated, supplied and erected.
Route Marker shall be provided at every 100 meter and at the turning points. Markers
provided shall be as per the field requirement. If the route passes through open
fields, markers should be conspicuously visible and above ground surface and
particularly along the Road berms except on road & pavements where they may
interfere in the movement of traffic or pedestrians.
The markers should incorporate the relevant information. The name of the owner,
voltage shall be marked on the route marker. The details shall be as per the drawing
enclosed.
The markers shall be of stone or tile construction. The design shall be such that it
cannot be pulled out. Tile type marker shall be used along the pavement. Stone/
PCC markers shall be used at other locations.
The stone/PCC markers shall be cut into proper size as per drawing, covered with
cement plaster with engraving of the information required.
14.8
DEPTH OF LAYING & SPACING BETWEEN CABLES:

Minimum depth of laying from ground surface to top of cable shall be as following:
o 11 kV cable
: 0.9 meter.
o 11kV, Cables at Road crossing
:1.0 meter.
o 11kV, Cables at Railway crossing (Measured from bottom of sleeper
to top of pipe.
:1.0 meter.
o 33kV Cable
:1.05meter
Wherever the proper depth is not achievable due to presence of other services or for
other reasons, the cable shall be laid deeper or in hume pipe or GI pipe as required
depending upon the site condition. The pipes shall be supplied by the Contractor
at no extra cost.
14.9
PAYING OUT THE CABLE

The excavated cable trench shall be drained of all water and the bed surface shall be
smooth, uniform and fairly hard before paying out the cable. The cable shall be
rolled in the trench on cable rollers, spaced out at uniform intervals. The paying out
process must be smooth and steady without subjecting the cable to abnormal
tension. The cable on being paid out shall be smoothly and evenly transferred to the
ground after providing the sand cushion. The cables shall never be dropped. All
snake bends shall be straightened. Suitable size cable stocking pulling eye shall be
used for pulling the cable. While pulling the cable by winches or machines, the
tension loading shall be by tension indicator and shall not exceed the permissible
value for the cable. The cable laying shall be performed continuously at a speed not
exceeding 600 to 1000 meter per hour.
The cable end seals shall be checked after laying and, if found damaGED, shall
immediately be resealed. Sufficient number of heat shrinkable cable end sealing
caps shall be stocked at site stores for testing and jointing work. The integrity of the
outer sheath shall be checked after the cable is laid in position.
14.10 SAND BEDDING and Brick

The cable shall be completely surrounded by well-compacted sand to such a
thickness and of such size that the cable is protected against damage. The thickness
of the cable sand should normally be a minimum of 7.5 cm in all directions from the
cable surface. Cable sand with a grain size less than 8 mm shall be preferred to offer
good protection to cable.
A brick (of brick class designation 75) layer of thickness 70 mm brick shall be
provided over the sand for protection of the cable as per the drawing in section 2.
14.11 FLAKING
The cables shall be flaked and left with slight extra lengths at jointing bays for
expansion and flexibility.
14.11.1
Sand Bedding shall be provided as detailed in section 2.10 and no special
thermal back filling is required.
14.11.2
BACK FILLING
Normally back filling shall consist of the material earlier excavated. However, bigger stones
or pieces of rock should be removed.
14.12
PREVENTION OF DAMAGE DUE TO SHARP EDGES

After the cables have been laid in the trench and until the cables are covered with
protective covering, no sharp metal tool shall be used in the trench or placed in such a
position that may fall into the trench.
Straight and curved rollers used shall have no sharp projecting parts liable to
damage the cable.
While pulling through pipes and ducts, the cable shall be protected to avoid damage
due to sharp edges.
The cables shall never be bent, beyond the specified bending radius.
14.13 ROAD, RAILWAY TRACKS, WATER PIPE LINE CROSSINGS
RCC Hume pipe shall be used for crossing of Road and cast iron or GI pipes for
railway track and water pipe line. One spare pipe at each location of 33kV & 11 kV
cable crossing shall be laid. Cable pipe size/ laying details shall be as per IS 12551983. The road cutting for cable trench, whether cement concrete, asphalt or
macadam road surface shall be undertaken after obtaining approval for cutting from
the road owning authorities, traffic police, telephone authorities and work should be
planned to be completed in the shortest possible time. Where necessary the work
shall be planned during night or light traffic periods. The railway track crossing design
shall be got approved from the railway authorities and the contractor shall do work in
coordination with them.
In the excavated trench across the road the pipes shall be laid, excavation backfilled
compacted and surface shall be redone in the shortest possible time.
Open Drain Crossing: Where ever the cable has to cross open drains, with long
span, the cable shall be laid in suitable size G. I. pipe properly joined with suitable
collars. The GI pipe shall be firmly supported on pillars, columns, or suitable support
of RCC foundation.
14.14 FOOT PATH CUTTING
The slabs, kerbstones, on the roads/ footpath shall be removed and reinstated
without damage.
14.15 REINSTATEMENT
After the cables and pipes have been laid and before the trench is backfilled, all joints
and cable positions should be carefully plotted in drawing and preserved and
provided to the Engineer of Employer/BSEB. The protective covers shall then be
provided, the excavated soil riddled, sieved and replaced. It is advisable to leave a
crown of earth not less than 50 mm and not more than 100 mm in the centre and
tapering towards the sides of the trench.
The temporary reinstatement of roadways should be inspected at regular intervals,
more frequently in rainy season and immediately after overnight rain for checking
settlement and if required, the temporary reinstatement should be redone.
After the subsidence has ceased the trench may be permanently reinstated and the
surface restored to the best possible condition.
In case of the road surface is cement concrete, asphalt or tarred macadam,
resurfacing may be done by the civic authorities against payment of the restoration
charges to be made by the contractor.
14.16 JOINTING BAYS

The bidder shall identify the location of the joint bays after carrying out detailed
survey of the cable route and excavation of the trial pits. The delivery lengths of the
cables shall match the location.
The joint bay should have a flat and level surface. At the bottom in a corner, a sump
pit shall be made, if necessary, for bailing out water.
The contractor shall follow standard practice in making joint bay, jointing and back
filling after making joint and testing for the voltage class required.
All works shall be carried out in presence and supervision of the Engineer of
Employer/BSEB.
14.17
TOOLS AND PLANTS

The successful bidder shall have all necessary tools, plant and equipment to carry
out the survey and cable installation work.
The bidders are instructed to give all the details of equipment at their disposal, to
carry out the work successfully and speedily.
14.18 BENDING RADIUS:
The minimum bending radius of XLPE insulated cables is as follows:
Cable
Bending radius
Three Core
15 x D
D means the overall diameter of the completed cable.
14.19
JOINTING AND TERMINATION OF CABLES
General: The cable jointing personnel and his crew shall have good experience in
the type of joints and terminations that are used. The jointing work shall commence
as soon as two or three lengths of cables have been laid. All care should be taken to
protect the factory-plumbed caps/ seals on the cable ends, and the cable end shall
be resealed whenever the end is exposed for tests.
Jointing of cables in carriage ways, drive ways under costly paving, under concrete
or asphalt surfaces and in proximity to telephone cables and water mains should be
avoided wherever possible.
Sufficient over lap of cables shall be allowed for making the joints.
The joint bay should be of sufficient dimensions to allow the jointers to work with as
much freedom of movement and comfort as possible. Sufficient space should be
kept below the cable to be jointed.
The joints of different phases shall be staggered.
All jointing shall be done by joint manufacturers jointers or under their supervision.
14.20 TENTS / COVERS
An enclosure or suitable protection cover shall be used in all circumstances wherever
jointing work is carried out in the open irrespective of the weather conditions. The
joint shall be made in dust free and clean atmosphere.
14.21 PRECAUTIONS BEFORE MAKING A JOINT/ END TERMINATION
The cable end seals should not be opened until all arrangement have been made for
jointing and all necessary precautions have been taken to prevent circumstances
arising out of rainy/ inclement weather conditions, which might become
uncontrollable.
If the cable end seals or cable ends are found to have suffered damage the cables
should not be jointed, without tests and rectification.
14.22 MEASUREMENT OF INSULATION RESISTANCE
Before and after jointing, the insulation resistance of both sections of cables shall be
checked.
14.23 IDENTIFICATION
The identification of each phase shall be clearly and properly noted. The cables shall
be jointed as per the design approved by the Employer/BSEB based on the proposal
submitted by the Contractor. Each cable shall have identification for phase and circuit
at joint bays.
14.24 MAKING A JOINT/ END TERMINATION
Comprehensive jointing instructions should be obtained from the manufacture of
jointing/end kits and meticulously followed.
The materials used in the joints/ end kits like ferrules, screen/armour continuity
bonds, lugs etc., shall be of good quality and conform to standards.
The jointing tools shall be appropriate and as per the requirement of jointing
XLPE/PVC cables.
14.25 CABLE TERMINATIONS
The cable terminations used are to be of outdoor type.
The preparation of the cable end for installing the terminations and the precautions to
be taken before fixing the terminations shall be followed as in the case of the cable
jointing procedures.
The instructions furnished by the termination manufacturer shall be strictly followed.
All terminations shall be done by joint manufacturers jointers or under their
supervision.
At cable terminating end, the following provisions for supply and erection are to be
included.
(i) A terminating structure should be provided where necessary for supporting the
cable to be terminated (except at the ring main unit ends)
(ii) A sufficient length of spare cable shall be left in the ground, for future needs.
(iii) The rise of the cable immediately from the ground shall be enclosed in 150 mm
dia PVC/GI pipe to protect against direct exposure to the sun.
(iv) The cable shall be properly fastened to the support using non-metallic clamps.
(v) Appropriate labels shall be fixed identifying the phase circuit, voltage and date of
commissioning etc., on the cable supporting structure.
(vi) The sealing end shall be mounted on insulators to isolate them from their
supporting steel work.
(vii) Protection from contact with the exposed metal work at the termination shall be
provided by resin bonded glass fibre shroud.
(viii) Providing earth stations with all required materials, like leads, connectors etc for
earthing of armour and screen.
14.26 BONDING OF SCREEN / ARMOUR
The screens and armour at both ends shall be brought out and solidly bonded to the
earth station.
All accessories and consumables used in the termination should be of good quality
and compatible with the cable.
14.27 CONNECTION OF RADIAL WATER BARRIER AND CABLE SCREEN
If the metallic radial water barrier is insulated from the metallic wire screen a
connection suitable to carry the currents occurring during operation must be installed
between metallic radial water barrier of the cable and metallic wire screen in joints
and sealing ends.
14.28
ERECTION OF CABLE TERMINATING STRUCTURES.
The terminating structure should be designed as per the requirement of the cable
end sealing, offered by bidder.
The mounting structure shall be of latticed GI suitably grouted to the ground.
After fixing the end termination, the cable shall be fixed to the support, with nonmagnetic material clamps to the required height securely.
The mounting structure includes the supports for cable end boxes, link boxes and
any other structure required for the intent of the contract.
All steel sections used shall be free from all imperfections, mill scales, slag
intrusions, laminations, fillings, rust etc., which may impair their strength, durability
and appearance. All materials shall be of tested quality only unless otherwise
permitted by the Employer/BSEB. The Contractor shall fabricate, provide and install
the structures.
14.29 TESTS AFTER INSTALLATION
All tests as prescribed in Clause-6 of IEC-840 shall be performed after installation of

cable. Following minimum tests shall be carried out:
Insulation Resistance of each cable drum length after paying but before jointing.
a) Serving insulation resistance after laying each cable length shall withstand a
voltage of 5 kV DC between each reinforcement and external conducting surface
for one minute. In addition, the serving insulation resistance shall be measured
and checked with the values obtained in the routine factory test.
b) On completion of the cable laying and jointing work, the complete installation
shall be tested with a D.C. voltage (high Voltage Test) as per IS 1255.
c) Conductor resistance of each cable of each complete circuit shall be measured
and compared with the values obtained during routine factory tests.
d) Test for 5 minutes with system voltage applied between the conductor and the
armour/ screen earthed.
e) Test for 24 hours with normal operating voltage of the system.
15.
33 KV, 3 CORE 400 Sq. mm. XLPE Cable
1.1. SCOPE
This specification covers requirement of 33 KV, 3x400 mm2 XLPE Cable. The
material has to be type tested as per relevant standard whenever applicable. The
test certificate issued from Laboratory recognized by Govt. of India will be accepted.
The cable should be manufactured through Dry Curing Process using Nitrogen
under controlled temperature & pressure.
1.2. APPLICABLE STANDARD:-
Except when it conflicts with the specific requirements of this specifications, the
cables, shall comply with latest version of IS: 7098 (PT-D)/ 1985 with latest
amendment specification for cross linked polythene insulated PVC sheathed cable.
The cable should be manufactured through Dry curing process using Nitrogen under
controlled temperature and pressure as medium.
Indian Standards
IS- 7098
Cross linked polyethylene insulated PVC sheathed cables.
IS- 5831 : 1984
PVC insulation & sheath of electric cables.
IS- 10810 : 1984
Methods of test for cables.
IS- 8130 : 1984
Conductors for insulated electric cables and flexible cords.
IS- 3975 : 1999
Mild steel wires, formed wires and tapes for armoring of cables.
1.3. RATED VOLTAGE AND TEMPERATURE:-
The rated voltage of the cables shall be 19 KV / 33 KV voltage grade and the
maximum operating voltage shall be 10 % higher than the rated voltage.
Maximum continuous operating temperature (combination of ambient temperature
and temperature rise due to load) shall be 900C under normal operation and 250oC
under short circuit conditions.
1.4. TYPE OF CABLES :
The type of cables under this specification shall be three cores armoured screened.
1.5. STANDARD SIZES OF CABLES.
The size of the cables required shall be 400 mm2, 33 KV (E), 3 cores.
1.6. CONTINUOUS CURRENT AND SHORT CIRCUIT RATINGS:-
Sl. No.
Size of 3 core cables

(mm2)
Continuous current carrying Short circuit rating for

capacity at max. Conductors duration of 1 second at
temp. of 90oC
max. temp. of 250oC.
K.A. (V.MS Value)
400 mm2
1.
In ground
(Amp)
In Air (Amp)
432
574
37.6
1.7. DETAILS OF CABLES
1.7.1. Conductor :
The cable conductor shall be round, stranded and compacted aluminum of nominal size
stipulated. The corresponding maximum Wire diameter & number of wires in the conductor
shall be as given in IS: 8130/1984.
Sl. No.
Sizes of 3 core
cables (Sq. mm)
Min. Number of Alum. Wire in the Max. resistance

circular compacted or shaped conductor at
conductor.
20oC ohm/Km.
1.
400 mm2
53
of
0.0778
1.7.2. Conductor screen

Conductor screening shall be provided over the conductor by applying non-metallic semiconducting tape or by extrusion of semi-conducting compound or 3 combination of the two.
1.7.3. Insulation
The insulation shall be of extended cross linked polyethylene (XLPE) of nominal insulation
thickness of 8.8 mm for 33kv and its properties shall conform to IS: 7098 (pt-II) with latest
amendment.
1.7.4. Insulation screen.

a) The insulation screen shall consist of two parts; namely metallic and non-
metallic, part shall be applied directly over the insulation of each core and shall
consist of either a semi-conducting tape or extruded semi-conducting
compound or a combination of the two or either material with semi-conducting
coating.
b) The metallic part shall consist of either tape, or braid or concentric serving of
wires or a sheath and shall be non-magnetic and shall be applied over the nonmetallic part.
1.7.5. Core Identification and laying up of cores.
The core identification and laying up of cores shall be as per IS: 7098 (pt-II). For
identification of different cores in three core cables, use of Colored stripes, red, yellow and
blue or use of numbered strips shall be employed.
1.7.6. Inner sheath:

The laid up cores shall be covered with inner sheath made of vulcanized/ un vulcanized
rubber or thermoplastic material, applied either by extrusion or wrapping. It shall be
ensured that the shape is as circular as possible. The thickness of inner sheath shall
conform to IS 7098 (pt-II) with latest amendment.
1.7.7. Armoring:
For three core cables, armoring may be applied over the inner sheath . The method, type,
dimensions, joints, conductance etc. of armour shall conform to IS: 7098 (pt-II) with latest
amendment.
1.7.8. Outer sheath:

The outer sheath shall be applied over the armoring. The material thickness and properties
of the outer sheath shall conform to IS: 7098 (pt-II).with latest amendment.
1.8. Tests:
1.8.1. The following tests shall be carried out on the cables as per IS: 7098 (PartII). With latest amendment.
a) Type tests:
i)
Tests on conductor
ii)
iii)
iv)
Tests for armoring wires/ strips.

Tests for thickness of insulation and sheath.
Physical tests for insulation.
v)

Aging in air oven.
Hot test.
Shrinkage test.
Water absorption
Physical tests for outer sheath:
vi)
vii)
viii)
Tensile test.
Wrapping test
Resistance

Aging in air oven.
Shrinkage test.
Hot deformation.
Bleeding and Blooming test.
Partial discharge test.

Bending test.
Dielectric Power Factor test.
As a function of voltage.
As a function of temperature.
ix)
x)
xi)
xii)
xiii)
xiv)
Insulation resistance test (Volume Resistivity)

Heating cycle test.
Impulse with stand test.
High voltage test.
Flammability test.
Short circuit test.
b) Acceptance tests.
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
Tensile test.
Wrapping test.
Hot set test for insulation.
Tensile strength and elongation at break test for insulation and sheath.
High voltage test.
Insulation Resistance (volume resistivity) test.
c) Routine tests.
i)
ii)
iii)

High voltage test.
d) Short circuit test:

The short circuit test shall be treated as one of the type test. This test is carried out on
one of the sizes of cables at a recognized testing. If the facilities for carrying out short
circuit test are available at the works of the manufacturers, the S.C. test shall be
carried out at his works and the same shall be acceptable.
The short circuit test shall be preceded and followed by the following tests so as to
ensure that the characteristics of the cable remains within the permissible limits even
after it is subjected to required short circuit rating:-
i)
ii)
iii)
Partial discharge test

High voltage test.
The above tests shall be carried out on a sample length of cable of approved size.
The manufactured cable will be acceptable only after such Sample test is carried out at
CPRI or at suppliers works and approved by the purchaser.
Alternatively the manufacturer shall submit a copy of the S.C. test certificate if the S.C.
test has been carried out earlier at CPRI or ERDA or any other accredited laboratory on
one of the sizes of each voltage grade.
1.9. PACKING AND MARKING:
1.9.1. Packing
The cables shall be supplied in wooden drums conforming to IS: 10418 with latest
amendment. The standard length of the cable in each drum shall be 0.200 KM 5%.
1.9.2. Marking:
The cable drum shall carry the information as per requirement of IS: 7098 (Part II) with
latest amendment.
1.9.3. The manufacturers name or trade mark, the voltage grade, year of
manufacture, etc. may be printed or embossed on the cable as stipulated in IS:
7098 (Part II) with latest amendment.
1.9.4. INSPECTION:
All the tests and inspection shall be made at the place of manufacturer unless otherwise
especially agreed upon by the manufactures and purchaser at the time of purchase. The
manufacturer shall afford the inspector representing the purchaser all reasonable facilities
without change, to satisfy him that material is being furnished in accordance with the
specification.
The purchaser has the right to have tests carried out at his own cost by an independent
agency whenever there is a dispute regarding the quality of supply.
Guaranteed technical particular:-
1.10.
The Guaranteed technical particulars of the cables in the format as per Annexure-A shall be
given by the bidder along with the tender. This is essential for consideration of the tender
failing which the tender will be rejected.
Annexure- A
GUARANTEED TECHNICAL PARTICULARS (Three Core, 33 KV XLPE cable 3x400 mm2)
Sr. Description
SBPDCLs
requirement
1.0 Type
2.0 Not Used

3.0 Applicable IS / IEC Standard followed
by vendor
4.0 Make
5.0 Type
6.0 Voltage Grade
7.0 Maximum Conductor temperature
IS 7098 Part-2 / IEC

60502-2
A2XWY
19 / 33 KV
A Continuous
90C
250C
Short time
8.0 Conductor
A Material and Grade
Size
Material: Electrolytic grade

stranded
Aluminium
conductor
/
Annealed
copper conductor
Grade: H4 as per IS: 8130
/ 84 ( For Al)
400 SQMM
Offered
No. of wires in each conductor Nos.
D Conductor Shape
E
Dia. of wires in each conductor before

compaction
Diameter over conductor
Maximum Conductor resistance at

20 C
9.0 Conductor Screen

A Material & type
B
C
Thickness (Approx.)
Diameter over conductor screen
As per Table 2 of IS
8130
Compacted Circular
Manufacturer
Standard( mm)
.mm
0.0778 (Ohms / km)
Extruded Semi Conducting

material (Tapes are not
acceptable)
0.50 mm.
. mm
D Make and grade of semi-conducting

compound
10.0 Insulation
A
B
C
D
E
Insulation material
Nominal thickness
Minimum thickness
Diameter over Insulation (Approx.)
Make and grade of Insulation
compound
11.0 Insulation Screen
A
i) Thickness of freely
strippable
Semi
conducting screen
ii) Make and grade of
semiconducting
compound
2.1.3
8.8 mm
7.82 mm
--- mm
0.50 mm.
Yes / No
iii) Printing
(Font size of Texts)
iii) Thickness &

width of
Copper tape
Thickness : 0.06 +/5 % or better

Width : ..mm
iv) Thickness
& other details of Water
swell- able tapes
a) 0.30 mm
b) Weight : 118 gm/
sqmm
c) Swell height shall be
12mm in 1min.
d)
Compatible
to
strippable
/
nonstrippable semicon, over
which, it is applied.
e) Make & Grade
Diameter over insulation screen (Approx)
.(mm)
Fault current carrying capacity of

copper tape (Necessary calculation
sheet shall be attached)
KA for Sec
D Diameter over laid up core (Approx.)

E
Cable core identification
mm
By colored strips over
cores applied helically /
longitudinally
12.0 Filler (Material and type)
All interstices, including

center interstices shall be
filled by PP filler. PVC filler
not acceptable. (Not
Applicable for Single
(Specify no. & size of filler at center &
Core cables)
core interstices)
13.0 Inner Sheath

A Material and type
B
Minimum thickness
Approx. dia. Over sheath
Extruded Inner Sheath of

Black PVC type ST-2
0.7 mm
.mm
14.0 Armour
A Minimum Number of Steel wires / GI
Strip
B
Dia. Of individual armour wire
As per Table 4 of IS
7098 Part-2
Thickness of GI strip / width of GI strip

(with zero negative tolerance)
D Approx. Eqvlt. Area
4 x 0.8 mm
E
F
G
H
Min. 90 %
.
mm
..
15.0
A
Area covered by armour

Lay ratio of armour
Dia. over armour Approx.
Fault current carrying capacity
Outer Sheath
Material and type
Thickness (Minimum)
C
D
Colour
Embossing
Sqmm
Extruded outer sheath of

PVC (ST-2) with termite
Repellant
As per Table-5 of IS
7098 Part-2
Blue
Yes / No
16.0
Approx. overall dia.
.mm
17.0
Standard drum length with tolerance
200 Mtr +/- 5%
18.0
Type of Drum
Steel / Wooden
19.0
20.0
a. Cable pulling Eye provided at one

running end
Required
b. End cap
Required
Weight
a) Net Weight of cable ( Approx.)
21.0
22.0
23.0
b) Weight of empty drum
Kg
c) Weight of Cable with drum
Kg
Continuous current rating for standard

I.S. condition laid Direct
a) In ground 30 C
. Amps
b) In duct 30 C
c) In Air 40 C
Short circuit current carrying capacity
for 1 sec of conductor
. Amps
. Amps
. K Amp
Electrical Parameters at Maximum

Operating temperature:
A
B
C
D
E
F
AC Resistance
Reactance at 50 C/s
Impedance
Zero sequence impedance
Positive sequence impedance
Negative sequence impedance
Capacitance
24.0
Recommended minimum bending

radius
25.0
Derating factor for following Ambient

Temperature in
a) At 30
b) At 35
c) At 40
d) At 45
e) At 50
26.0
i)
ii)
Iii)
iv)
27.0
.. Kg / Km
Ohm/Km
Ohm/Km
Ohm/Km
Ohm/Km
Ohm/Km
Ohm/Km
)
)
)
)
)
)
(Micro farad / KM)

--- x O/D
Ground / Air
C
C
C
C
C
Group factor for following Nos. of

cables laid
3
4
5
6
..(
..(
..(
..(
..(
..(
Touching Trefoil
Nos.
Nos.
Nos.
Nos.
Recommended pressure for laying

cable using power winch
30 N / mm2
28.0
Process of Cross linking of

Polyethylene
29.0
Type test (Applicable report no., date

with type & size of cable to be
mentioned)
Dry Cure only
Required
11/0.433kV, 200KVA & 315KVA DTRs
16.
2.1. SCOPE: - The specification covers the design, manufacture, testing and inspection before
despatch and delivery at site Stores.
The specification covers Oil immersed, Naturally Air cooled (type ONAN), outdoor type, three
phase, 50 Hz, 11/.433 KV, CORE TYPE, step down conventional distribution transformers of
capacities 200 & 315 KVA. Transformers should be suitable for service under frequency
fluctuation of 4% and voltage fluctuation +10% / -25% on HV side. The full load rated
current on HV & LV side at normal voltage ratio of each rating of transformers shall be as
under:S.
No.
RATING IN
KVA
RATED FULL LOAD CURRENT (IN

AMPS)
HV Side
LV Side
200
10.50
266.67
315
16.53
420.00
2.2. APPLICABLE STANDARDS:e) Unless otherwise modified in the specification, the transformers shall comply with the
requirement of ISS: 1180 (latest issue) 2026 (latest issue) and REC Specification
2/1978 and ISS: 2099 (latest issue). The bushings used shall conform to ISS: 2099 &
3347 (latest issue) except as modified herein.
f) Type:
The transformers shall be double wound, three phase oil immersed, oil
Natural Air Natural cooled (type ONAN), CORE TYPE suitable for outdoor
installation in tropical climate and shall be insulated with DPC insulation on
HV & LV windings. Insulation should be of temperature class as per the
temperature rise stipulated in this specification.
The neutral point of the secondary (LV winding) is intended for solidly
earthed system and should be brought out to a separate insulated terminal,
enabling external insertion of a current transformer in the earth lead to be
connected wherever required.
g) Climatic Conditions:
i)
(
Peak outdoor temperature
500 C (minimum)
ii)
(
Maximum Oil temperature
iii)
(
Maximum relative humidity
95%
(
Minimum relative humidity
10%
iv)
950 C (500 C + 450 C) Under Max.

Temperature, Max. Load conditions.
v)
vi)
vii)
viii)
ix)
Average
(
No. of thunder storm
days per annum
Average
(
number of rainy days
per annum
Number
(
of months of tropical
monsoon conditions.
(
Average annual rainfall
(
Wind pressure
40 days
90 days
3 Months
1450mm
150 Kg/m2
The transformer shall generally be for use in moderately hot and humid tropical
climate, conducive to rust and fungus growth.
2.3. RATINGS:
Primary voltage - 11 KV
Secondary voltage - 0.433 KV
The windings of the transformers shall be connected in delta on primary side and star on the
secondary side. The neutral of the LT winding shall be brought out to a separate terminal.
The vector group shall be Dyn-11
2.4.
OVER LOAD CAPACITY:

The transformers shall be suitable for over-load capacity as per IS: 6600 (latest amendment).
2.5.
TEMPERATURE RISE:Temperature rise for top oil over an ambient of 50 oC should be 45oC max. (Measured by
thermometer as per IS-2026) Temperature rise for windings over an ambient of 50 oC should
be 50oC max. (Measured by resistance in accordance with IS: 2026)
2.6.
NO LOAD VOLTAGE RATING:

The No Load Voltage ratio shall be 11000/433-250 Volts for all capacities
2.7.
TAPS:
For ratings 200 KVA to 315 KVA, tapping shall be provided on the higher voltage winding for
variation of HV voltage within range of (+) 3% to (-) 9% in the steps of 3%. Tap changing
shall be carried out by means of an externally operated self position switch and when the
transformer is in de-energized condition, switch position No.1 shall correspond to the
maximum plus tapping. Each tap change shall result in variation of 3% in voltage. Provision
shall be made for locking the taping switch handle in position. Suitable Aluminium anodized
plate shall be fixed for tap changing switch to know the position no. of tap.
2.8.
DESIGN AND CONSTRUCTION:

CORE:
(a) Material: - CRGO Sheet
(b) The core shall be of high grade cold rolled grain oriented annealed steel laminations
having low loss and good grain properties, coated with hot oil proof insulation, bolted
together and to the frames firmly to prevent vibration or noise. All core clamping bolts shall
be effectively insulated by Hot Oil paint/Varnish and paper. The complete design of core must
ensure permanency of the core losses with continuous working of the transformers. The
value of the flux density allowed in the design and grade of lamination used shall be clearly
stated.
(c) The transformer core shall not be saturated for any value of V/f ratio to the extent of
112.5% of the rated value of V/f ratio (i.e. 11 KV/50 Hz due to combined effect of voltage
and frequency) up to 12.5% on any tapping without injuries heating at full load condition and
should not get saturated. The supplier shall furnish necessary design data in support of this
situation.
(d) Flux Density: - Flux density at rated voltage and frequency shall not exceed 1.55 Webbers
per sq. meter. No load current at rated voltage and at 112.5% of rated voltage shall not
exceed the values given below:RATING
PERCENTAGE OF RATED FULL LOAD
IN KVA
CURRENT
100% OF RATED
112.5% OF RATED
VOLTAGE
VOLTAGE
200
2
4
315
Test for magnetic balance by connecting the LV phase by phase to rated phase voltage and
measurement of an, bn, cn voltages will be carried out.
(e) Details of Core: - The figures shown in the table are minimum acceptable values:S. No.
PARTICULARS
UNIT
RATING IN KVA
315
No. of steps (Min.)
No.
Dia. of Core (Min.)
mm
155
170
Effective Core Area
160
200
Core Clamping:
a.
Channel
mm x
100x50
125x65
b.
Core Clamping Bolt

(High Tensile) Dia.
/ Nos.
mm /
Nos.
16 /2 in Parallel
(Total 8 no s.)
16 /2 in parallel
(Total 8 nos.)
c.
Tie Bolts of MS Rod

Dia. / Nos.
mm /
Nos.
16 / 8
16 / 8
d.
Core Bolts & Tie Rods to be painted with Varnish/Hot oil paint and
effectively insulated
e.
Top & bottom yoke should be constructed in single piece of CRGO

laminations.
The top yoke channels to be reinforced by MS Flat of 50x6 mm at equal
distance, if holes cutting are done for LT Lead so as to avoid bending of
channel.
Core Base and bottom yoke shall be supported with 75x40 mm MS
channel properly bolted together. In no case, Flat or cut channels shall
be accepted.
All channels, top and bottom yoke Nut Bolts; Tie rods shall be painted
with Varnish/Hot oil paint before use.
Core should be properly earthed through copper strip. One end of
copper strip should be inserted deeply into core laminations and other
end bolted with the core clamping channel
f.
g.
h.
i.
2.9.
200
WINDINGS:
Cm2
a) Materials: - Double paper cover Aluminium Conductor shall be used for ratings upto 200
KVA. For ratings above 200 KVA double paper covered electrolytic copper shall be used.
b) Current Density for HV & LV should not be more than 2.8 A/sq. mm. for copper and 1.6
Ampere per sq. mm. for Aluminium Conductor in any part of the winding.
c) HV Cross section shall not be less than;i) 200 KVA 3.79 Sq. mm
ii)
315 KVA
3.40 Sq. mm
d) LV Cross section shall not be less than:i) 200 KVA 168.0 Sq. mm
ii)
315 KVA
156.0 Sq. mm
e) HV winding resistance at 20oC with 5% tolerance should not be more than:

i) 200 KVA
14.52 Ohms
ii)
315 KVA
7.07 Ohms
f) LV winding resistance at 20oC with 5% tolerance should not be more than:

i) 200 KVA
0.00456 Ohms
ii)
2.10.
315 KVA
0.00278 Ohms
LOSSES AND IMPEDENCE:

The losses and impedance for various ratings of transformers should be as shown below:Maximum Guaranteed No Load, Load Losses and Impedance:The Losses shall not exceed the value given below:Max. Losses Max. Losses
Rating
Max. No
Impedance
S.
at 50%
at 100%
In
Load
(%) at
No.
Loading
Loading
KVA
Loss (Watts)
75oC
(Watts)
(Watts)
1
200
500
890
2700
5
Note: All technical parameter including loss load should match the specification in compliant
with three star rating of BEE.
(i) The losses specified above are max permissible value and no plus tolerance would be
allowed.
(ii) The impedance for various ratings of Transformers should be as shown above subject to
tolerance as per I.S.1180 & 2026 (with latest amendments) and shall be calculated at 75oC
as per limits specified.
2.11.
INSULATION MATERIAL AND CLEARANCES:

(a) Materials: - Electrical grade insulating craft paper of Triveni/Ballarpur or equivalent
make subject to approval of the purchaser. Press board of Senapaty, white lay or Raman
make or equivalent subject to approval of purchaser. Perma wood or Haldi wood blocks shall
be used for top and bottom yoke insulation.
(b) Radial clearance of LV coil to core (bare conductor) shall not be less then:200 kVA
4.0 mm
315 kVA
4.5 mm
(c) Radial clearance between HV & LV shall not be less than 11 mm for ratings 63 KVA to 315
KVA.
(d) Phase to phase clearance between HV conductor shall not be less than 10 mm and
minimum of 2x1 mm press board must be provide to cover the Tie rods as phase barrier.
(e) The minimum electrical clearance between the winding and body of the tank (between
inside surface of the tank and outside edge of the windings) should be 30 mm.
(f) Minimum end insulation to earth shall be 25 mm.
(g) No. of coils HV/phase (minimum):
i) For 200 & 315 KVA - 6 Nos.
(h) Thickness of locking spacers between HV coils- 10 mm (Minimum)
(i) No. of axial wedges between LV and HV winding equi-spaced around L.V.- 8 for 200 KVA
- 12 for 315 KVA.
(j) Minimum external clearances after providing bimetallic clamps on Bushing terminals:
Phase to Phase
Phase to Phase
2.12.
HV
255 mm
140 mm
LV
75 mm
40 mm
TANK: The transformers tank shall be of robust construction and shall be built of
electrically welded M.S. Plates. All joints of tank and fittings shall be oil tight and no
bulging shall occur during service. The tank design shall be such that the core and
windings can be lifted freely. The tank plate shall be of such strength that the
complete transformer when filled with oil may be lifted easily by means of the lifting
lugs provided. Tank inside shall be painted by varnish/hot oil paint. Top cover shall
be slightly sloping (difference of heights should be 20 mm + 10%) towards H.V.
bushing and cover the top with end walls. Shape of the tank shall be rectangular
only. No other shape will be accepted. The tank shall be fabricated by welding at
corners. No Horizontal or vertical joints in tank side and its bottom or top cover will
be allowed.
(a)
(i) Side wall plate thickness : 4.0 mm above 100 KVA

(ii) Top and bottom plate thickness: 6.00 mm above 100 KVA
(b) Reinforced by welded angle of size 50x50x6 mm on all the outside walls on the edge of
tank to form three equal compartments in case of transformers above 100 KVA rating. One
face of reinforcement angle should be continuous welded with the tank surface such that
other side of the angle forms inverted L. The permanent deflection is not more than 5 mm
up to 750 mm. length & 6 mm. up to 1250 mm. length, when transformers tank without oil is
subjected to a vacuum of 760 mm. of mercury.
(c) Lifting lugs: 4 Nos. welded heavy duty lifting lugs of M.S. Plate 8 mm. thick suitably
reinforced by vertical supporting flat welded edgewise below the lug on the side wall, upto
the reinforcing angle, for transformers of 200 KVA rating and above.
(d) Pulling Lugs : 4 Nos. of welded heavy duty pulling lugs of M.S. Plates of 8 mm. thick shall
be provided on width side to pull the transformers horizontally upto 100 KVA and on length
side for above 100 KVA.
(e) Top cover Gasket & Bolts:
The Gasket in one piece shall be provided in between Top Cover Plate
and Tank shall be of 6 mm thick oil resistant Neoprene Rubberized Cork
sheets of best quality confirming to IS: 4352, Part -II for ratings above
100 KVA.
For ratings above 100 KVA GI Nut Bolts of 1/2" dia with one plain washer
shall be used for top cover fixing spaced at 4" apart.
The height of the tank shall be such that the minimum clear height upto
the Top Cover Plate of 120 mm is achieved from Top Yoke in case of
transformers upto 100 KVA. The above clearance is achieved from the live
part of the tap changer in case of transformers above 100 KVA.
The top cover of the main tank shall be provided with an air release plug
to enable air trapped within to be released.
h) Heat dissipation by tank walls excluding top and bottom should be 500W/m 2.
i) Heat Dissipation by fin type radiator made of 1.25 mm thick MS sheet, will be worked
out on the basis of manufacturers data sheet. Supplier should submit the calculation
sheet.
j) 2 Nos. Radiators shall be provided on both LV and HV sides and shall be of fin type.
They should be fixed at right angle to the sides and not diagonally.
k) Arrangement for studs provided for fixing of HV bushings should be in diamond shape
so that the arcing horns are positioned vertically.
2.13.
TOTAL MINIMUM OIL VOLUME:

S.
No.
RATING
IN KVA
OIL IN LITERS (Inclusive

of Oil absorption in CoreCoil Assembly)
PERMISSIBLE OIL
ABSORPTION
IN LITERS
200
400
15
315
500
19
NOTE: If the absorption of oil in core and winding Assembly is more than permissible value,
first filling of oil volume should be increased accordingly. Detail calculation of absorption
should be submitted.
2.14.
CONSERVATOR:
(a) The total volume of conservator shall be such as to contain 10% quantity of the oil.
Normally 3% quantity of the total oil will be contained in the conservator. Dimension of the
conservator shall be indicated in General arrangement drawing.
(b) Die cast Oil level indicator shall be provided on the side which is fully covered with
detachable flange with single gasket and tightened with M.S. Nut -Bolt and will be fixed on
the side of rating plate and drain valve.
(c) The pipe from the conservator tank connecting to main tank shall be of 30 mm internal
dia and shall have a slopping plate so that the oil falling from the pipe shall not fall directly on
the active job and shall fall on the side walls only. The pipe should project in the conservator
so that its end is approximately 20 mm above the bottom of the conservator. Thus slopping
plate should be fitted such that clearance from the yoke/live part of the tap changer is
maintained as prescribed i.e. 120 mm.
The conservator shall be provided with the drain plug and a filling hole, with cover. In
addition, the cover of the main tank shall be provided with an air release plug.
2.15.
BREATHER
Breather joints will be screwed type. It shall have die-cast Aluminium body with tin container.
Volume of breather shall be suitable for 500 gm. of silica gel for transformers upto 200 KVA
and 1 g for transformers above 200 KVA rating. After fitting breather, the thread must be
sealed with paint/compound to avoid air entry. The Breathers must be as per the technical
specifications, Guaranteed Technical Particulars and drawing enclosed.
2.16.
TERMINALS:
(a) For ratings above 100 KVA:
(i) Brass rods 12 mm dia for H.T. with necessary caps, nuts, check nuts and plain
thick washers of Brass.
(ii) Tinned copper rods 20 mm dia for 200 and 315 KVA and 30 mm dia for 500 KVA
transformers with necessary caps, nuts, check nuts and plain thick washers of tinned
copper for LT.
(b) H.T. and L.T. bimetallic connectors shall be provided with Transformer for all rating. The
technical specifications, Guaranteed Technical Particulars and drawings of these connectors
are shown in Annexure-VII(C). The type test certificates of the connectors being used shall
be produced at the time of inspection.
2.17.
BUSHINGS:
(i) For 11 KV - 12 KV Bushing will be used and for 433 volts 1.1 KV terminal bushing will be
used. Bushings of the same voltage class shall be interchangeable. Bushings with plain sheds
as per IS - 3347 shall be mounted on side wall of the tank and not on the top cover. Only
continuous sheet metal pocket shall be provided for mounting of all H.V. / L.V. bushings and
the same shall not be fixed on pipes. Sheet metal pocket shall be designed in such a way that
all HT bushings shall remain parallel and equidistance all through and inside connections of
windings to bushings shall remain within the pocket. Bushings having type tested as per IS3347 shall only be acceptable.
(ii) Internal Connections: In case of HV winding, all jumpers from windings to bushing
shall have cross section larger than the winding conductor (normally, 1.5 times). For copper
winding, joints will be made by using silver brazing alloy. For Aluminium winding, L & T
Alkapee Aluminium brazing rods with suitable flux will be used or alternatively joints will be
made by using tubular connectors properly crimped at three spots. Aluminium brazing rods to
be used, ring formed on other end and nut bolting on HV bushing stud.
LT star connection will be made by using 6mm thick Aluminium/Copper Flat and properly
brazed or bolted with the crimped lugs on windings by means of plain and spring washers
and lock nuts to the flat. Other end of the conductor is brazed on L shape 6mm thick
Aluminium /copper flat and flat nut bolted with neutral bushing stud. ALTERNATIVELY, for 63
& 100 KVA ratings all the three terminals of LV windings together with terminals for neutral
bushing shall be properly brazed and then covered with Aluminium tubular sleeve of suitable
length and cross sectional area duly crimped in order to provide sufficient strength to the
joint. The star connection should be wrapped with cotton/paper tape.
The connection for LV winding to bushings shall be made 6mm thick L shape Aluminium/
Copper flats nut bolted with LV Bushing stud.
For delta formation on HV side, copper wire having cross sectional area 1.5 times the HV
winding wire area should be used. SRBP tube/insulation paper should be used on delta
connection and on the portion of HV winding joining to HV bushing.
2.18.
ROLLERS:
For Transformers of rating 200 KVA and above four nos. flat rollers of 150 mm diameter and
50 mm width shall be provided.
2.19.
TANK BASE CHANNEL:

To be fitted across the length of the transformer:
For 200 & 315 KVA Transformers
Two channels of 100 mm x 50 mm
2.20.
TERMINAL MARKING PLATES AND RATING PLATES:

The transformers shall be provided with a plate showing the relative physical position of the
terminal and their markings engraved on it. The transformers shall be provided with nondetachable rating plate of Aluminium anodized material fitted in a visible position, furnishing
the information as specified in IS: 2026. The rating plate shall be embossed /engraved type
but not such printing. The relative position of tapping switch and corresponding voltages may
also be shown on the rating plate.
Further, MS plate of size 125x125 mm be got welded on width side of the transformer on
stiffener angle. On this plate Name of firm, Order No. & Date, Rating, Serial Number of
transformer, name of inspecting officer & his designation and date of despatch should be
engraved.
2.21.
FITTINGS:
The fittings on the transformers shall be in accordance to the Annexure-II of the TS.
2.22.
TRANSFORMER OIL:
The transformer shall be supplied complete with first filling of oil and the same shall comply
with IS: 335-1983 with latest version thereof and ageing characteristics specified. These
characteristics are shown in Annexure-I. Type tests certificate of oil being used shall be
produced at the time of inspection.
2.23.
SURFACE PREPARATION, PAINTING AND FINISHING:

(A) GENERAL
(i) All paints, when applied in a normal full coat, shall be fee from runs, sags, wrinkles,
patchiness, brush marks or other defects.
(ii) All primers shall be well marked into the surface, particularly in areas where painting is
evident and the first priming coat shall be applied as soon as possible after cleaning. The
paint shall be applied by airless spray according to manufacturers recommendations.
However, wherever airless spray is not possible, conventional spray be used with prior
approval of purchaser.
(B) CLEANING AND SURFACE PREPRATION:
(i) After all machining, forming and welding has been completed; all steel work surfaces shall
be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to
any painting.
(ii) Steel surfaces shall be prepared by shot blast cleaning (IS9954) to grade Sq. 2.5 of ISO8501-1 or chemical cleaning including phosphating of the appropriate quality (IS 3618).
(iii) Chipping, scarping and steel wire brushing using manual or power driven tools can not
remove firmly adherent mill-scale. These methods shall only be used where blast cleaning is
impractical. Manufacturer to clearly explain such areas in his technical offer.
(C) PROTECTIVE COATING:
(i) As soon as all items have been cleaned and within four hours of the subsequent drying,
they shall be given suitable anti-corrosion protection.
(D) PAINT MATERIAL:
(i) Following are the types of paint which may be suitably used for the items to be painted at
shop and supply of matching paint to site. Heat resistant paint (Hot oil proof) for inside
surface.
(ii) For external surfaces one coat of thermo setting powder paint or one coat of epoxy
primer followed by two coats of synthetic enamel polyurethane base paint. These paints can
be either air drying or stoving.
(E) PAINTING PROCEDURE:

(i) All prepared steel surfaces should be primed before visible re-rusting occurs or within 4
hours, whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the
surface is dry and while the surface is still warm.
(ii) Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or
general softness) the supplier shall remove the unsatisfactory paint coating and apply
another coating. As a general rule, dry film thickness should not exceed the specified
minimum dry film thickness by more than 25%.
(F) DAMAGE PAINT WORK:
(i) Any damage occurring to any part of a painting scheme shall be made good to the same
standard or 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 25 mm around its boundary,
shall be cleaned down to bare metal.
(b) A priming coat shall be immediately applied, followed by a full paint finish equal
to that originally applied and extending 50 mm 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 and after priming.
(G) DRY FILM THICKNESS:
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.
i) Each coat of paint shall be allowed to harden before the next is applied as per
manufacturers recommendation.
ii) Particular attention must be paid to full film thickness at the edges.
iii) The requirements for the dry film thickness (DFT) of paint and the materials to be used
shall be as given below:Total dry film
Area to
Sl.
No. of
thickness
Paint type
be
No.
coats
(min.)
painted
(microns)
1
Thermo setting powder paint Inside
01
30
outside
01
60
2
Liquid
paint
24.6
Epoxy
(primer)
24.7 P.U. Paint (Finish coat)
Hot oil paint/Varnish
Outside
Outside
Inside
01
02
01
30
25 each
35/10
(H) 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 3 years.
(I) COLOUR:The colour of the finishing coats for tank and radiators shall be Traffic Green conforming to
Shed no. 267, IS:5 of 2007 (colours for ready mixed paints) with conservator painted with
white colour.
2.24.
TEST & TEST CERTIFICATES:
The following routine tests and type tests are required to be carried out on the transformers:A) (i) Routine Tests:- Before despatch each of completely assembled transformer shall be
subjected at the manufacturers works to the following routine tests in accordance with the
details specified in IS:2026.
(a) Measurement of winding resistance.
(b) Ratio, polarity and phase relationships.
(c) Impedance voltage.
(d) No load losses and no load current.
(e) Load losses.
(f) Insulation resistance.
(g) Separate source voltage withstand.
(h) Induced over voltage with stand.
(ii) Unbalanced current test: The value of zero sequence current in the star winding shall not
be more than 2% of the full Load current in accordance with 26(d).
(iii) Pressure and vacuum test: The tank shall be fixed with a Dummy cover with all fittings
including bushing in position and be subjected to following pressure/vacuum created inside
the tank:(i) 0.8 Kg./cm sq. above atmospheric pressure for 30 minutes.
(ii) A vacuum corresponding to (-)0.7 Kg/cm sq. for 30 minutes.
Permanent deflection of flat plate, after pressure has been released, shall not exceed the
values given below:Length of plate Deflection:
Up to 750 mm 5 mm
751 to 1250 mm
6 mm
1251 to 1750 mm
8 mm
Supplier should ensure that each fabricated tank is subjected to pressure & vacuum test at
his work and confirmation to this effect is submitted in the test certificate along with routine
test certificate while offering the material for final/pre-dispatch inspection.
(iv) Vector Group Test: - All the transformers must be complied with requirements to confirm
the Vector Group of Dyn-11.
B) TYPE TESTS:
In addition to the routine tests as above, the following type tests shall be carried out on the
transformers in accordance with IS:1180 and 2026/1977 as amended from time to time:(a) Lightening impulse voltage withstand test
(b) Dynamic ability to withstand short circuit test.
2.25.
The suppliers may carefully note our following specific requirements of short circuits
& impulse voltage:
(a) Short Circuit Test and Impulse Voltage Withstand Test: The SBPDCL intends to procure
transformers designed and successfully tested for short circuit and impulse test. In case the
transformers proposed for supply against the order are not exactly as per the tested design,
the supplier shall be require to carry out the short circuit test and impulse voltage test at
their own cost in the presence of the representative of the SBPDCL. The supply shall be
accepted only after such test is done successfully, as it confirms on successful withstand of
short circuit and healthiness of the active parts thereafter on un-tanking after a short circuit
test. Apart from dynamic ability test, the transformers shall also be required to withstand
thermal ability test or thermal withstand ability will have to be established by way of
calculations. It may also be noted that the SBPDCL reserve the right to conduct short circuit
test and impulse voltage test in accordance with the ISS, afresh on each ordered rating at
SBPDCL cost, even if the transformers of the same rating and similar design are already
tested. This test shall be carried out on a transformer to be selected by the SBPDCL either at
their works when they are offered in a lot for supply or randomly from the supplies already
made to SBPDCL Area Stores. The findings and conclusions of these tests shall be binding on
the supplier.
In case the transformer does not pass in either of the tests and if the active part details are
not found to be in line with the design tested and approved, the following punitive measures
shall be taken:(i) 5% payment of the bill for the supplies already made will be recovered by the
SBPDCL.
(ii) For transformers already supplied, the guarantee period shall stand twice the
normal guarantee period incorporated in the order and the period of performance
Security Deposit shall be suitably extended to cover the extended guarantee period.
(iii) Further, supply of balance quantity of transformers will not be accepted by the
SBPDCL, till another transformer from the manufactured batch is satisfactorily tested
(OR transformers are modified according to the tested design) for both tests at your
cost and consequent to this if there is any delay in executing the order, the same
shall be to your account. SBPDCL reserves the right to take action as per terms and
conditions of the order.
(iv) The tests charges shall be borne by the firm. Please note that if the terms and
conditions detailed above regarding short circuit withstand test & impulse voltage test
on transformers and procedure for these tests are not accepted by you in full, action
will be taken as deemed fit as per the terms of the order.
(b) Temperature rise test: - Heat run test shall have to be conducted at suppliers cost on one
transformer of each rating in any offered lot during the course of supplies. In case of
transformers with tap, test shall be conducted on the lowest tap feeding corresponding losses
at 75oC.
To facilitate conduction of heat run test on any unit in any lot at any point of time during the
supplies, the manufacturers will provide a thermometer pocket which gets immersed in oil on
the side of the transformer in all the transformers. This pocket shall also be used for
connecting thermal sensing device to monitor the variations in temperature and whenever
required to operate the protective devices. The Sensor pocket shall be of 12mm diameter
with blanking screwed cap, removable at site. The depth of the projecting stem of this pocket
inside the transformer will be below oil level. It shall not infringe with electrical clearance nor
obstruct the un-tanking of the active part.
(c) Over Fluxing of Core:Transformer shall be subjected to test for over fluxing of core, wherever required by the
SBPDCLs inspecting officer.
(d) Test for spill current in neutral:The test will comprise of measuring current between shorted secondary phases and neutral
on applying impedance voltage at primary winding. The value should not exceed 2% of full
load current.
2.26.
ACCEPTANCE TESTS:
The following tests shall be witnessed by the Purchaser/Representative at the firms works:(i) All the routine tests as mentioned in 25(A) above shall be performed on minimum 10%
quantity of offered lot.
(ii) Heat run test On one unit out of total ordered quantity.
(iii) Verification of active parts on one unit of each rating of offered quantity along with
weighment of the complete unit.
2.27.
TESTING FACILITIES:
The tenderer should have adequate testing facilities for all routine and acceptance tests and
also arrangement for measurement of losses, resistance etc.
2.28.
INSPECTION:
(a) To ensure about the quality of transformers, the inspection shall be carried out by the
SBPDCLs representative at following two stages:(i) When the raw material is received, and the assembly is in process in the shop
floor.
(ii) At finished stage i.e. transformers are fully assembled and are ready for despatch.
(b) After the main raw-materials i.e. core and coil materials and tanks are arranged and
transformers are taken for production on shop floor and a few assembly have been
completed, the firm shall intimate the O/o C.E.(RE), SBPDCL, Patna in this regard, so that an
officer for carrying out such inspection could be deputed, as far as possible within seven days
from the date of intimation. During the stage inspection a few assembled core shall be
dismantled to ensure that the CRGO laminations used are of good quality. Further, as and
when the transformers are ready for despatch, an offer intimating about the readiness of
transformers, for final inspection for carrying out tests as per relevant I.S.S. and as in clause
25(A) above, shall be sent by the firm along with Routine Test Certificates. The inspection
shall normally be arranged by the O/o C.E.(RE), SBPDCL, Patna at the earliest after receipt of
offer for pre-delivery inspection.
(c) In case of any defect/defective workmanship observed at any stage by the SBPDCLs
Inspecting Officer, the same shall be pointed out to the firm in writing for taking remedial
measures. Further processing should only be done after clearance from the Inspecting
Officer/ this office.
(d) All tests and inspection shall be carried out at the place of manufacture unless otherwise
specifically agreed upon by the manufacturer and purchaser at the time of purchase. The
manufacturer shall offer the Inspector representing the Purchaser all reasonable facilities,
without charges, to satisfy him that the material is being supplied in accordance with this
specification. This will include Stage Inspection during manufacturing stage as well as Active
Part Inspection during Acceptance Tests.
2.29.
RANDOM TESTING OF TRANSFORMER:Random sample checking and testing of the transformer selected at random from the
supplies made to the Area Stores shall be done for verification of technical details, design,
routine test and losses as per approved G.T.P., drawings and technical specification of the
order. Please note that:(A) (i) Some of the transformers shall be selected randomly from the lot received in Area
Stores and shall be subjected to routine testing as per IS:1180 and 2026 (with latest
amendments) at MTRU, Jabalpur/ CPRI, Bhopal/CPRI, Bangalore/ERDA, Vadodara or any
reputed Govt. Laboratory.
(ii) It is only after the results of randomly selected transformers are found satisfactory, the
MRC shall be issued and the transformers of the lot shall be accepted/ issued to field units.
(iii) Serial number, name of the inspecting officer and his designation shall have to be
embossed by the manufacturer on the tank of every transformer.
(B) In case of emergency, the transformers are issued in the field before obtaining the test
results from the Laboratory and in the event of failure of any transformer in any/all routine
tests later on, the following action shall be taken for that particular lot/ order only:(i) 5% payment of the bill for the supplies already made will be recovered by
SBPDCL.
(ii) For transformers already supplied, the guarantee period shall stand twice the
normal guarantee period and the period of performance security deposit shall be
suitably extended to cover the extended guarantee period.
(iii) The supplier shall be intimated about the results of such test to make suitable
improvement in his manufacturing process and to ensure quality control.
(iv) If any transformer(s) are available in the area stores, these shall have to be
replaced by the manufacturer at his own cost.
(v) One unit of each capacity from the next lot shall be sent to the identified
laboratory for carrying out routine tests. In case the transformer fails again in any or
all routine test, no further supply shall be accepted and the transformers available at
area stores supplied against the current order shall have to be taken back by the
manufacturer at his own cost.
(vi) The manufacturer will have to carry out suitable improvement in the design of
the transformer and get it type tested in presence of Companys representative at his
own cost. It is only after the transformer successfully passes the type test, the
supplies shall be resumed. Further, the penalty towards delayed supplies shall be to
manufacturers account (if any).
(C) The Purchaser has all the rights to conduct the test including type tests, at his own cost
by an independent agency whenever there is dispute regarding the quality of supply or
interpretation of test results. In the event of failure of transformers in such tests, the
expenses incurred in testing shall be to the suppliers account as already mentioned above in
case of random testing.
2.30.
INSPECTION & TESTING OF TRANSFORMER OIL:

To ascertain the quality of the transformer oil, the original manufacturers tests report should
be submitted at the time of inspection. Also arrangements should be made for testing of
transformer oil, after taking out the sample from the manufactured transformers and tested
in the presence of purchasers representative.
2.31.
TEST REPORTS ON THE ANALYSIS OF RAW MATERIALS:

The supplier shall furnish details of source(s) of raw-materials, test certificates and report on
the analysis of electrolytic Copper/Aluminium used for the winding and the steel used for
core, insulation material and also other bought out items from sub-suppliers.
2.32.
DRAWINGS:
The dimensional drawing and internal construction drawing of each rating of transformer &
Silica gel Breathers for 500 gm and 1 Kg capacity and HT & LT bimetallic connectors shall be
submitted with the tender. Guaranteed and other technical particulars of the transformers
should also be submitted in A-4 size for our approval.
2.33.
GUARANTEE:
2.33.1.1.
2.33.2.
2.33.3.
The manufacturers of the transformer shall provide a guarantee of 36 months from

the date of receipt at the stores of the Utility or 30 months from the date of
commissioning, whichever is earlier. In case the Distribution transformer fails within
the guarantee period the purchaser will immediately inform the supplier who shall
take back the failed DT within 15 days from the date of the intimation at his own cost
and replace/repair the transformer within forty five days of date of intimation with a
roll over guarantee.
The outage period i.e. period from the date of failure till unit is repaired/ replaced
shall not be counted for arriving at the guarantee period.
In the event of the supplier's inability to adhere to the aforesaid provisions, suitable
penal action will be taken against the supplier which may inter alia include
blacklisting of the firm for future business with the purchaser for a certain period.
9.
Label design, manner of display of Star rating in the 200KVA Distribution
Transformer
9.1
Material of the label shall be non detachable weather proof type. The Design
of the Label, manner of display of label and its colour scheme will be in accordance with
the notification of Bureau of Energy Efficiency, New Delhi.
ANNEXURE-A - QUALITY ASSURANCE - INSPECTION OF TRANSFORMERS
To ensure about the quality of transformers, the inspection shall be carried out by
the representative of the SBPDCL at following two stages:(i) Where raw material is received, and the assembly is in process on the shop floor.
(ii) At finished stage i.e. transformers are fully assembled and are ready for dispatch.
After the main raw-materials i.e. core and coil materials and tanks are arranged and
transformers are taken for production on shop floor and a few assembly have been
completed, the firm shall intimate the O/o C.E.(RE), SBPDCL, Patna in this regard, so
that a team of officers for carrying out such inspection could be deputed, as far as
possible within fifteen days from the date of intimation. During the stage inspection a
few assembled core shall be dismantled to ensure that the CRGO laminations used
are of good quality and manufacturing is confirmed in line with approved Guaranteed
Technical Particulars/Drawings. The report of stage inspection is to be prepared in
the prescribed proforma.
A quantity of more than 100 Nos. shall not be entertained for stage inspection.
Further, the stage inspection shall be carried out in case:(a) At least 25% quantity offered has been tanked, and
(b) Core coil assembly of further atleast 30% of the quantity offered has been completed.
In case of any defect/defective workmanship observed at any stage by the SBPDCL

inspecting Officer, the same shall be pointed out to the firm in writing for taking
remedial measures. Further processing should only be done after clearance from the
Inspecting Officer/this office.
Quantity offered for stage inspection should be offered for final inspection in full
within 15 days from the date of issue of clearance for stage inspection, otherwise
stage inspection already cleared shall be liable for cancellation.
The checks to be exercised during the stage inspection have been listed in the stage
inspection proforma.
As and when the transformers are ready for despatch, an offer intimating about the
readiness of transformers for carrying out pre-despatch inspection as per relevant
I.S.S. and as in clause-25 (A) of Annexure-III, shall be sent by the firm. The
inspection shall normally be arranged by the SBPDCL at the earliest after receipt of
offer for pre-delivery inspection.
During the pre-despatch inspection, the routine tests as per IS:1180 & 2026 shall be
carried out at the works of the firm on randomly selected transformers in presence of
companys representative.
Further, one unit of each rating offered shall be dismantled at the time of predespatch inspection for physical verification for the constructional details. The report
of pre-despatch inspection is to be prepared in the prescribed Performa.
Please ensure that reports of stage inspection and pre-despatch inspection are prepared
strictly in the prescribed Performa and no detail is left blank. Incomplete report may cause
delay in supply of transformers which shall be to the suppliers account.
GUARANTEED TECHNICAL PARTICULARS FOR

CONVENTIONAL DISTRIBUTION TRANSFORMERS
S. No.
1
2
3
4
5
6
7
8
Particulars
System Voltage (Max.)
Rated Voltage HV
Rated Voltage LV
Continuous Max. Rating (kVA)
Normal Ration of Transformation
Method of Connection (Vector Group)
Max. Hot spot Temp. (ambient air temp. shall be
taken as 50o C
Max. Oil Temp. (ambient air temp. taken as 50 o C)
Max. Winding temp. (ambient air temp. taken as 50 o C)
10
Flux Density
11
12
Type of Transformer
CORE:
(a) Core material & grade

(b) No. of steps
(c) Dimensions of core steps
(d) Core diameter
(e) Core length (leg centre)
(f) Window height
(g) Insulation between bottom of core & base
channel
(h) Core height (inclusive of Base channel and
insulation in between)
(i) Gross core area
(j) Effective core area
(k) Nos. & Dimensions of steel channel used for
clamping of core
(l) Size & no. of:
(i) Core Bolts
(ii) Tie Rods
(m)Insulation of core bolts
(i) Core Bolts
(ii) Tie Rods
(n) Painting of core channel, core bolts & tie rods
(o) Whether top yoke is cut or holes are made for
200 kVA
315 kVA
-- 12 kV --- 11 kV --- 433 250 --- 11/0.433 KV -Dyn 11 -
95 o C -
100 o C -
1.55 Wb/m2 (Max.)

Core Type
LV connections. If yes, whether enforcement

is done
(p) Size of support channel for core base (cut
channels are not acceptable)
(q) Weight of core only (without Channels etc.)
(r) Whether yoke construction is in one piece:
(i) Top
(ii) Bottom
13
Magnetizing Current
(% of rated current)
(a) At 90% voltage

(b) At 100% voltage
(c) At 112.5% voltage
(d) Tolerance
14
Current Density
(i) HV winding
(ii) LV winding
15
Windings
(a) Material
(i) HV winding
(ii) LV winding
(b) Size of winding wires for
(i) HT
(ii) LT
(c) Type of insulation of
(i) HV winding
(ii) LV winding
(d) Internal & external diameter of
(i) HV coil
(ii) LV coil
(e) No. of coils/phase
(i) HV
(ii) LV
(f) No. of turns per coil
(i) HV
(ii) LV
E.C. Grade Aluminium upto

200KVA ratings and Electrolytic
Copper for 315KVA rating
(g) Method of connection of winding ends to

bushing terminals:
(i) For HV The one end of HV winding
brazed with copper wire and other end
of copper wire bolted with HV stud by
forming eye loop and using washer of
proper size
(ii) For LV Other end of LV winding crimped
with Al/Copper lugs and then bolted
with LV stud terminals with proper size
of washers
(iii) Method of forming of Star connection: All
the three ends of LV windings crimped
with proper size of Al/copper lugs and
then bolted with Al/copper Flat of 6 mm
thick & cotton tape wrapped over it
(h) Resistance/phase at 75 o C
(i) HV
(ii) LV
(i) Height of coils:
(i) HV
(ii) LV
(j) Wire used for delta formation:
(i) Material
(ii) Diameter (min. 1.5 times of the dia of HV
winding wire)
16
No load losses at normal ratio (KW) (Max.)
17
Load losses at normal ratio at 75oC (KW) (Max.)
18
Total losses at normal ratio (KW) (Max.)
19
Tolerance on losses at normal ratio
20
(i) Impedance voltage at normal ratio between HV & LV

windings at 75oC.
(ii) Tolerance
Impulse test level of HV & LV windings at 1.2/50 micro
second wave.
INSULATION OF MATERIAL:Insulation material used & its thickness:
a) Between core & LV
b) Spacers
c) Inter layer
d) Between HV & LV winding
21
22
No positive tolerance permissible
23
24
25
e) Between phases
f) End insulation
CLEARANCES:a) LV to Core (Radial)
b) Between HV & LV (Radial)
c) Phase to phase between HV conductor (with
providing min. of 2x1 mm Press Board to cover the
rods)
d) Between winding & body
i) Length wise
ii) Breadth wise
e) End insulation
f) Thickness of locking spacers between HV coils
g) Axial wedges between HV & LV coils
h) Clearance between top cover and top most live part
of tap changer for 200 KVA and above
i) No. of radial spacers per phase between HV coil
j) Size of duct between LV & HV
TANK
(a) Shape
(b) Thickness of tank sheets:
(i) Top & Bottom
(ii) Side walls
(iii) Collar
(c)Internal dimension of tank:
(i) Length (l)
(ii)Breadth (b)
(iii)Height (h1)
(h2)
(Difference between h1 & h2 should be 20mm)
(d) Gasket used between top cover and tank
(i) Material (Must be of best quality and oil resistant)
(ii) Thickness
(iii) Whether the gasket is joint-less and in one piece
(e) Pulling lugs
(i) No.
(ii) Thickness
(iii) Position of fixing
(f) Lifting Lug
(i) No.
(ii) Thickness
(g) Reinforcement of tank sides by providing angle of
size 50x50x6mm at two places for transformers above
100 KVA, respectively.
(h) Dia & thickness of flat rollers for 200 KVA and above
ratings Transformers.
(i) Whether all the transformer tanks which are to be
supplied are complied with the pressure and vacuum
tests as per technical specifications.
(j) Top cover of the tank provided with the:(a) Air release plug 1 no.
(b) Thermometer pocket 1 no.
(c) Top cover lifting lugs 2 nos.
BUSHING:
(a) Characteristics:
26
27
28
29
30
(i) Dry flash over voltage

HV
LV
(ii) Wet flash over voltage
HV
LV
(iii)Impulse flash over voltage
HV
LV
(b) Material of the complete bushing studs:(i) Bushing rods (HV/LV).
(ii) Caps, Nuts, Chuck nuts and washers (HV/LV).
(c) Size of bushing rods
(i) HV side
(ii) LV side
(d) Mounting on side walls or top cover
(e) Whether sheet metal pocket used for mounting HV
Bushings (pipe are not acceptable)
(f) External clearance of bushing terminals after
providing HT & LT bimetallic connectors on the bushing
rods.
Bimetallic Connectors (For all ratings)
(a) Normal current rating
(i) HV
(ii) LV
(b) Short time current rating for HV & LV
(c) Tensile strength for HV & LV both
(d) Whether HT & LT Bimetallic connectors are provided
as per specification, GTP & drawings enclosed.
BREATHER
(i) Whether Breathers are provided as per specifications,
GTP & drawings enclosed
(ii) Make
(iii) Capacity
CONSERVATOR:
(a) Dimensions
(b) Volume
(c) Internal Diameter of pipe used for connecting
conservator and tank
(d) Please confirm whether pipe projected into the
conservator 20 mm above the bottom of conservator
(e) Whether arrangement made so that oil does not fall
on the active parts.
RADIATORS:
(a) Nos. of Radiator
(b) Nos. of fins per radiator
(c) Size of fin
(d) Position of fixing
(i) Nos. on LV side
(ii) Nos. on HV side
Oil to be filled in:(a) Grade Characteristics as per Annexure-VI
(b) Transformer Tank
(i) Volume
(ii) Weight
----50Amps--- --50 Amps ------200Amps-- --630Amps-----3000 Amps one second--------110 Kg-------
-------- New EHV Gr-II -------
31
32
33
34
35
36
37
38
39
40
41
(c) Conservator
(i) Volume
(ii) Weight
(d) Total oil filled
(i) Volume
(ii) Weight
Overall dimension of Transformer:
(a) Length
(b) Breadth
(c) Height
Engraving of S. No. & name of firm :
(a) On bottom core clamping channel
(b) On Side wall & top cover of tank
(c) Date of dispatch on the Tank
MS Plate of size 125x125mm welded on side wall
stiffener of tank with engraving of :
i) Name of the firm
ii) Rating
iii) Serial Number
iv) Order No. & date
v) Date of despatch
vi) Name of Inspecting Offer
vii) Designation
Weight of windings only (Dry/ without oil soaking)
a) HV
b) LV
Weight of core & winding assembly with core channels,
core bolts, Tie rods, insulation etc. complete
Un-tanking weight of core & winding (including oil
absorption)Weight of tank & fittings including radiators,
conservators etc.
Weight of complete transformer including fittings & oil
[S. No. 35 + 37 + 30 d(ii)]
Dry film thickness of Paint:(i) Thermosetting powder paint:(a) (Inside) one coat (30 micron)
(b) (Outside) one coat (60 micron)
(ii) Liquid Paint:(a) Epoxy (Primer)
(Outside) one coat (30 micron)
(b) PU Paint (Finish coat)
(Outside) two coats (25 micron each)
(c) Hot Oil paint/Varnish
(Inside) one coat (35/10 micron)
Colour of transformer:(i) Conservator tank
(ii) Main tank & radiator
Reference of type test reports:
(a) Short circuit test
(i) Report no.& date
(ii) S. No. of DTR.
(b) Impulse test
(i) Report no. & date.
------ White-----Traffic Green,

Shed no. 267 of IS:5-2007
(ii) S. No. of DTR.

42
43
Top cover and side walls of the transformer tanks

should be welded with "U" clamps on four corners and
centre of both length sides.
Whether tap range of off load tap changer is from
(+)3% to (-)9% in steps of 3% on HV side for HV
radiator on 200 & 315 KVA transformers.
REMARKS:
1. Firm should furnish type test reports of the transformer manufactured as per Technical
Specifications.
2. The proforma should be filled up for the type tested design and submitted within 10 days positively
along with drawings for approval. The drawings & GTP be legible and neatly drawn.
Signature of Representative of the firm with seal
Name :Designation :
ANNEXURE-I - TECHNICAL SPECIFICATIONS AND GUARANTEED TECHNICAL

PARTICULARS OF EHV GR.II NEW INSULATING TRANSFORMER OIL
Insulating oil for Transformers & Switchgears shall be as per ISS-335-1993 (fourth revision)
incorporating upto date amendment and additional characteristics as incorporated below.
It will be pure hydrocarbon mineral oil, clean and sufficiently free from moisture and of other foreign
matter likely to impair its properties.
The test results for the characteristics of the oil when tested in accordance with ISS 335-1993 (fourth
revision) incorporating up-to-date amendment and additional characteristic required by us, shall be as
here-under:S.
No.
1
Schedule of
characteristics
(Clauses 5.1 and 9.1 of
ISS)
Appearance
Flash Point Pensky Marten

(Closed) (Min.)
Pourpoint (Max.)
Neutralization value
a) Total acidity, Max .
Requirement
of transformer oil
The oil shall be clear and
transparent & free from
suspended
matter
or
sediments
140oC
Reference to test
methods as per IS 335 1993 and with latest
amendments.
A representative & sample of
the oil shall be examined in
100mm
thick layer
at
27oC.
I S : 1448/ 1970
( - ) 6oC
I S : 1448/ 1970
0.03 mg KOH/ gm
I S : 1448/ 1967
b) Inorganic Acidity/ Alkalinity
NIL
I S : 1448/ 1967
Corrosive Sulphur
Non - corrosive
Annexure-B of IS:335/1993
Electric Strength (breakdown

voltage) (Min.):
a ) New unfiltered oil
30 KV (r m s )
I S : 335/ 1993
b ) New oil after filtration
60 KV (rms) [If the above

value is not attained, the oil
shall be filtered]
0.002
I S : 335/ 1993
35 x 1012 Ohm
1500 x 1012 Ohm cm
IS : 6103/ 1971
Dielectric dissipation factor

(tan delta) at 90 o C (Max.)
Specific
(Resistivity)
resistance
(Min.)
90oC
a)
at
b) at 27oC
Oxidation stability:
a) Neutralization value after

Oxidation (Max.)
0. 40 mg KOH / gm
b)
Total
oxidation
(Max.)
0.10% by weight
sludge
after
10
S.K. Value
11
Ageing characteristics after

accelerated ageing (open
beaker
method
with
copper
catalyst
)
:
a)
Specific
(resistivity)
Under consideration
cm
I S : 6262- 1971
Annexure
IS : 335 / 1993
Cof
Annexure
IS : 335 / 1993
Dof
IS : 12177 / 1987 (Method A)
resistance
i) at 27o C (Min.)
2.5 x 1012 Ohm
IS : 6103 / 1971
ii) at 90o C (Min.)
0.2 x 1012 Ohm
b) Dielectric dissipation factor

(Tan Delta) at 900C (Max.)
0.20
IS:6262/1971
c) Total acidity (Max.)
0.05 mg KOH/gm
IS:1448/1967
d) Total sludge value (Max)
0.05% by weight
Annex,-A of IS : 12177
12
Interfacial tension at 27oC

(Min.)
0.04 N/m
IS:6104/1971
13
Water content (Max.)
50 PPM
IS:13567/1972
14
Density at 29.5oC (Max.)
0.89 g/cm3
IS:1448/1977
15
Kinematic Viscosity at 27oC

(Max.)
27 Cst
IS:1448/1976
16
Presence
inhibitor
The oil shall not contain

Antioxidant additives
S:13631/1992
(B)
CHARACTERISTICS OF OIL IN THE TRANSFORMER
of
Oxidation
The important characteristics of the transformer oil after it is filled in the transformer (within
3 months of filling) shall be as follows : S.
No.
1
Characteristics
Requirement of Transformer Oil
Electric strength (breakdown voltage)
30 KV(Min.)
Dielectric dissipation factor (Tan Delta) at 90 0C
0.01(Max.)
Specific resistance (Resistivity) at 270C
Flash point, P.M. (closed)
140 0C (Min.)
Interfacial tension at 270C
0.03 N/m (Min.)
Neutralization value (total acidity)
Water content
10 x 1012 Ohm-cm
0.05 mg KOH/g(Max.)
35 PPM (Max.)
ANNEXURE-II-SCHEDULE OF FITTINGS FOR

CONVENTIONAL DISTRIBUTION TRANSFORMERS
The fittings on the transformers shall be as under:
1. Rating and diagram plate - 1 No.
2. Ear thing terminals with lugs - 2 Nos.
3. Lifting lugs 8 mm thick reinforced by welded plates edge wise below the lugs upto reinforcing
angle of the tank - 4 Nos. Above 100 KVA
4. Oil filling hole with cap on conservator - 1 No.
5. Conservator with drain plug - 1 No.
6. Thermometer pocket fitted with captive screwed top to prevent the ingress of water. - 1 No.
7. Aluminium Die cast Silica gel breather with tin container (500 gms. capacity upto 200 KVA and
1000 gms. for 315 & 500 KVA.) (As per specifications & drawings enclosed with the TS) - 1 No.
8. Platform mounting channel (with hole suitable for axle of roller for transformers of 200 KVA and
above rating) - 2 Nos.
9. Oil level gauge indicating three position of oil marked as below : a - Minimum (-)5o C; b - 30o C; c
- Maximum 98o C
10. Bushings : H.T. - 3 Nos.; L.T. - 4 Nos.
Each bushing should be provided with 3 Nos. of Brass/ tinned Copper nuts and 2 plain thick tinned
washers for connecting terminal.
11. Radiator - Details shall be given as per drawing (to be provided on L.V. side upto 100 KVA)
12. Arcing horn for H.T. Bushings - 6 Nos.
13. Pulling lugs - 4 Nos.
14. Drain valve with spot welded metallic cover to be provided - 1 Nos.
15. Explosion vent in case of transformers of 200 KVA and above - 1 No.
16. Rollers for 200 KVA and above - 4 Nos. (150 mm dia and 50 mm wide)
17. Air release plug (15mm) on top cover of the tank - 1 No.
18. Filter valve - 32mm dia for 200 KVA & above - 1 No.
19. Of f circuit tap changing switch with indicator handle and locking device with tap ranging from (+)
3% to ( -) 9% in steps of 3% on HV side for HV variation. Direction of rotation marked - 1 No.
20. Top covers lifting lugs - 2 Nos.
21. Bimetallic connectors for all ratings to be fitted on the studs (As per specifications & drawings
enclosed): HV - 3 Nos.; LV - 4 Nos.
Note: Transformers provided with Aluminium stems, caps, Nuts & Washers will not be accepted.
1.
2.
3.
4.
ANNEXURE-III-Technical Specification of Silica Gel Breathers for Distribution

Transformers
The Silica Gel Breather required for distribution transformers shall be Aluminium die casted
with tin container containing 500/ 1000 g of Silica Gel conforming to ISS 3401/1992 with its
latest amendments and it should be suitable for connecting to pipe thread.
The general dimensions/features of required Silica Gel Breathers are indicated in the enclosed
drawing. Silica Gel Breathers shall conform to the requirements of the enclosed drawing.
Silica Gel:- The Silica Gel required for distribution transformers shall be conforming to ISS
3401/1992 with its latest amendments.
3.1 The material shall be solid with grainy porous structure free from extraneous impurities.
The indicating type gel should be odourless, non toxic & non corrosive with stable chemical
and thermal characteristics. The inter-connected pores form a vast surface area; silica gel
should absorb moisture 40% or more of its weight at 100% humidity.
3.2. Bulk Density:-The bulk density of the material shall be more than 0.6 gm/ml.
3.3. Particle Size & Colour: - The material shall be blue in colour and its size should be
from 4 to 6 mm.
3.4. Loss on Drying: - The material when tested according to the method prescribed in ISS
shall not lose more than 5% of its mass.
3.5. Absorption capacity: - The material when tested according to the method prescribed
in ISS 3401- 1992 shall absorb minimum 27% of moisture on the basis of its mass.
3.6. PH Value: -The pH of aqueous extract of the material when determined by the method
prescribed is ISS 3401-1992 shall be not more than 8 and not less than 3.5.
3.7. Loss on attrition: - When subjected to the test according to the method prescribed in
aforesaid ISS not more than 2.5% of the material shall pass through the test sieve.
3.8. Chemical Requirements: - The gel shall also comply with the requirement prescribed
in the ISS 3401-1992.
Constructional Features for Silica Gel Breathers
S. No.
Particulars
Specification
1
Rating
2
3
Pipe
Connection
Thread
Material of Body
Silica gel content (gms.)
Aluminum
LM-6)
1000
Height in mm
290
Dia in mm
116
Window hole Dia in mm
20
Oil content in ml
200
Type of Die casting
Pressure/
casting
10
Type of Painting
Powder coating
Tolerances applicable
(i) Overall length 10 mm
(ii) Overall width 2 mm
(iii) Silica Gel 50 g
5.
Material of breather Body & Parts
Suitable for DTRs above

200 KVA rating
BSP
Alloy
gravity
(Grade
Die
i) Fabricated from high quality aluminum alloy LM-6 and powder coated for corrosion
resistance.
ii) Special grade nitrile gasket to ensure water proof and air tight joints.
iii) The glass/transparent polycarbonate window for visualizing Silica Gel & oil level should be
fixed by screws to the main body with gasket to prevent leakage of oil.
6.
Following details should be provided on name plates

Following details should be provided on each breather.
(i) Name of manufacturer and type of materials.
(ii) Mass of silica gel.
ANNEXURE-IV--TECHNICAL SPECIFICATION FOR BIMETALLIC CLAMPS
1.
SCOPE
This specification covers the design, manufacture, supply and testing of H.T./L.T. Bimetallic
Clamps suitable for HT/LT Brass/Copper studs of following Transformers:S. No.
Rating in
KVA
Rated full load current(in amps)
200
on HT side
10.5
315
16.53
on LT side
266.67
420
2.
MATERIAL
The material of bimetallic Clamps shall be of Aluminum and Brass. The brass used should be
of high strength & corrosion resistant. The connector should be design for the purpose of the
connecting together two dissimilar materials for preventing electrolytic corrosion.
2.1 All Aluminum and Aluminum alloys used in the manufacture of bimetallic clamps should
conform to IS-5082/1998. The brass used should be of high strength & corrosion resistant.
The connector shall be smooth and free from cavities, blow holes and such other defects
which would be likely to cause them to be unsatisfactory in service.
2.2 The connector shall be so designed and proportioned that they are capable of safely
withstanding stresses to which they may be subjected(including those due to short-circuit and
climatic conditions) and that the effects of vibration both on the conductor and the connector
itself are minimized. They shall be designed, manufactured and finished so as to avoid sharp
radii of curvature, ridges and excrescences which might lead to localized pressure on or
damage to the conductor in service.
2.3 The finish should be natural and free from flaws, rust, crevices, cracks & other defects
harmful for the joints.
All the edges and corners shall be rounded off to avoid corona effect due to sharpness. The
Bimetallic joints should be protected from the effects of electrolytic action. The resistance of
the clamps shall be very low. These should be free from burrs.
2.4 Sufficient contact pressure should be maintained at the joint by the provision of the
required number of bolts or other fixing arrangements. But the contact pressure should not
be so great as to cause relaxation of the joint by cold flow. The joint should be such that the
pressure is maintained within this range under all conditions of service. To avoid excessive
local pressure, the contact pressure should be evenly distributed by use of pressure plates/
washers or suitable saddles of adequate area and thickness.
2.5 All parts of connectors shall either be inherently resistant to atmospheric corrosion or be
suitably protected against corrosion, both during storage and in service.
2.6 The temperature rise of bimetallic Clamp above a reference ambient temperature of 400
C when carrying rated current shall not exceed 450 C.
2.7 The bolts should be of galvanized mild steel. The fit joint between Al. alloy & brass
component of the connector shall be high pressure.
3.
TENSILE STRENGTH: - The tensile strength shall be 60 Mpa (min).
4.
DIMENSION: - Dimension shall be as given in the drawing enclosed.
5.
MARKING
The connectors shall be indelibly marked with rated current or any identifying mark to enable
full particulars of the connector.
SCHEDULE-DETAILS OF TYPE TEST (SHORT CIRCUIT WITHSTAND AND LIGHTNING

IMPULSE VOLTAGE WITHSTAND TESTS) CONDUCTED SO FAR
S.
No.
Rating of
Transformer in
KVA
i.
200 KVA (Al.)

(Conventional)
ii.
315 KVA (Copper)

(Conventional)
Insulation
of
winding
Place and
Institution where
tested (with date
of test)
Short
Impulse
circuit
PLACE:
Whether
certificate
furnished (please
indicate No. &
Date)
SIGNATURE OF TENDERER
DATE:
SEAL OF THE FIRM:

NAME:
DESIGNATION/ STATUS:
Note for the Tenderer: In case of the impulse voltage & short circuit tests have been
conducted, the detailed test report along with copies of the drawings of the design approved
in type test should be furnished with the tender, failing which, it will be presumed that no
test has been carried out and offer for the rating shall not be considered. However, the type
test reports should not be older than five years otherwise offer shall be considered as if no
type test reports have been furnished and shall be dealt with accordingly. The photocopy of
type test report shall subsequently be matched with the original reports at the time of placing
order.
SCHEDULE-SOURCE OF PROCUREMENT OF MATERIALS, PLACE OF MANUFACTURE,
TESTING AND INSPECTION
SN
ITEM
TRANSFORMERS:
Copper
/
Aluminum
SOURCE
OF
PROCUREMENT
OF MATERIAL /
EQUIPMENT
PLACE
OF
MANUFACTURE
PLACE
OF
TESTING
AND
INSPECTION
2
3
4
5
Core laminations
Steel Sections
Tanks
Insulating
Press
Board
6
Insulating Paper
7
Bushing:
(a) HV
(b) LV
8
Oil
9
Insulated winding
wire
10 Terminal
connectors
PLACE :
DATE:
SEAL OF THE FIRM:
NAME :
SCHEDULE-SCHEDULE OF SUPPLY DURING LAST FIVE FINANCIAL YEARS
S.
No.
Financial
Year
2004-05
2005-06
2006-07
2007-08
2008-09
PLACE:
DATE:
11/0.433KV Distribution Transformers

25KVA
63KVA
100KVA
200KVA
and
higher
ratings
Total
Remarks
(Name of SEBs/
Discoms or any
other Power
Utilities to whom
supplied)
SEAL OF THE FIRM:
NAME:
SN
i.
SCHEDULE-PROFORMA FOR RATING-WISE TECHNICAL DETAILS OF THE 200 & 315 KVA
Particulars
Sr.no. of Date
No
Loa %ag Volta Details of core
Dia
/
Cross
DTRs on of type load
d
e
ge
Sectional Area of
whom
test
Loss
Los impe Ratio
bare
conductor
type test report
(Watt s
danc (KV)
used for HV/LV
has been
s)
(W e
Windings
carried
Max.
atts with
out
)
toler
Ma ance
SC IMP
SC I
HV
LV
x
as
M
Winding
Windi
per
Te P
ng
at
ISS
st
Design
Di dia Are
Area
75 at
T
a
) in a
in
C
75C
e
in
m
(in
mm2
s
m
m
mm
t
m
2)
Guarantee
--Report
11/0 Conventio
d technical
s
.433 nal
&
parameters
should
of
_____
not be
Core Type
DTRs as per
older
TS
than
(Alu.
five
Wound)
years
from
the
date
of
tender
openin
g.
Technical
parameters
of
_____ DTRs
as per type
test reports
DTRs
Whether
HV/LV
bushing
mounted
on top
No
(On side
walls
of
the tank)
Oil
volum
e
in
Ltrs
(Min.)
17
33kV & 11kV FAULT PASSAGE INDICATOR (FPI)
3.1. SCOPE:
Supply of overhead Fault Passage Indicators (FPI) for overhead lines to be installed on
33kV and 11 KV lines. The objective of this remote communicable FPI is to quickly
identification of the faulty circuit and automatic update to the SCADA control centre over
remote communication.
3.2.
PURPOSE:
To locate the exact passage of faults on overhead lines. The FPI shall indicate both
transient as well as permanent faults on the O/H lines
3.3.
OPERATION:
The Fault Passage Indicator shall operate on either passing over of the absolute
threshold current (user settable) or the current variation (di/dt). Upon the installation of
the indicator, the FPI shall adjust itself to the network frequency and voltage of perform
required function.
3.4.
FAULT TYPES:
The FPI shall detect and indicate both earth faults as well as phase to phase faults. In
addition to this, the FPI shall also detect and indicate transient and permanent faults.
3.4.1. INRUSH RESTRAINT:

The FPI shall be equipped to filter out the inrush current due to transformer
magnetizing currents thus avoiding the possible false indication of faults.
3.4.2. RESET:
Once the fault is cleared, the FPI shall reset itself upon the power return, it shall also have
a facility of resetting with settable time duration and the manual reset.
3.5.
TRANSIENT FAULT EVOLUTION:

If FPI is busy in flashing on transient fault and if the permanent fault occurs, the FPI shall
automatically change the priority and shall start flashing differently to show the
permanent fault; thus helping maintenance crew to review the priorities.
3.6.
These FPI shall be of pole mounted type and shall have four separate sensors for all the
three phases and for ground. These sensors shall be interfaced with common FPI
controller device through wired or wireless medium.
FPI shall have LED/flag to indicate the passage of fault current through sensor. There shall be
various features to reset the FPI LED/ Flag
a) Self reset after set reset time (Through inbuilt timer)
b) Self reset after restoration of voltage
c) Manual reset from local through push button
d) Remote reset from SCADA control centre by issuing command
It shall also be possible to test the FPI by manually setting the FPI LED/Flag through push button.
The FPI shall be capable to communicate the FPI status to SCADA control centre using GSM/CDMA
network over IEC-101/IEC-104 protocol. There shall be provision to power-up and connect the
modem to this FPI for communication with SCADA control centre.
It shall be possible to configure the FPI as per the requirement from remote SCADA control centre.
The necessary hardware and software required for the configuration of FPI shall be provided by
supplier.
3.6.1. Detail Characteristics

Sr No.
Details
Specific Requirements
Type
Spread spectrum low power license-free
Frequency
Free Band allowed in India
RF output
FCC part 15.249 and AS/NZS 4268:2003 approved

radio
Communication media
Embedded GPRS modem
Communication
protocol
Type
I(min), I(max), I(mean) and I(inst)
Number of HV lines
monitored per RTU
9 phases
Mechanical
enclosure
100 m
DNP3, IEC 870-5-103/104
Large
Small box Cabinet

9
Earth fault indication
(phase A, B, or C), (beginning time, ending time)
10
Phase fault or Imax
b Phase fault indication (phase A, B, or C),

(beginning time, ending time)
11
Transient
fault
detection if enabled
Transient fault indication and time stamping
12
Voltage loss indication
Voltage loss indication (phase A, B, or C) and time

stamping and Voltage recovery time indication
13
Equipment monitoring
Equipment monitoring
14
Local
radio
communication faulty
Communication with FPI Nos. XX faulty (after a

number of attempts) and time stamping
15
FPI battery alarm
Battery low in FPI no.x and time stamping
16
AC supply alarm
AC supply alarm External AC supply off
17
Inputs
6 digital inputs
18
Outputs
3 relay outputs 220 Vac/1 A
19
Local archive of Date

and
time
stamped
events and measures
100 events
20
Downloading
archive
Remote via SCADA application
21
Power supply
In built Battery of suitable rating
22
Operating temperature
25C to +70C
23
Storage temperature
40C to +85C
24
Net weight in kg
8 kg
25
Protection level
IP 54
26
Standards
Standards
27
Vibrations and shocks

test
IEC 68-2-6 and 68-2-29
28
EMI/EFI immunity
29
Salt spray and humidity

tests
of
local
IEC 801-3 and FCC Part 15

IEC 68-2-11 and 68-2-30
Barbed Wire
TECHNICAL SPECIFICATION FOR G.I. BARBED WIRE
STANDARDS:
Unless otherwise specified elsewhere in this specification, the rating as well as
performance and testing of the G.I. Barbed wire shall conform to the latest revisions
available at the time of placement of order of all the relevant standards but not
limited to as listed below.
IS:280:1978 Mild steel wire for general engineering purposes (third revision)
IS:1340:1977 Code of practice for chromate conversion coating of zinc and cadmium
coated articles and zinc base alloys (first revision)
IS:1521:1972 Method for tensile testing of steel wire (first revision)
IS:1755:1983 Method for wrapping test for metallic wire (first revision)
IS:2633:1986 Method for testing uniformity of coating of zinc coated articles(second revision)
IS:4826:1979 Hot dipped galvanized coating on round steel wires (first revision)
IS:12753:1989 Electro galvanized coatings on round steel wire - Specification
GENERAL TECHNICAL REQUIREMENTS:
GI Barbed wire shall be 2 PLY with a 2.5mm diameter. The barbs shall have a 2mm diameter and be
12.5mm in length. The barbs shall have four points and shall be formed by twisting two point wires,
each two turns, tightly around both line wires making altogether four complete turns (see Fig. 1).
G.I. Barbed wire shall be of type IOWA (Type A in the fig. below) with size and dimensions as
under:Line wire - 2.5 mm
Point wire - 2.0 mm
Distance between two bars shall be 75 mm ( + 12 mm ). Wire shall be medium
However, other specific technical particulars shall be as per Annexure- I
ANNEXURE-I
SPECIFIC TECHNICAL PARTICULARS FOR 2.5 MM X 2.0 MM G.I.BARBED WIRE
Sl.No.
Particulars
Particulars
Bidders Offer
Specified
1
Size of wire- mm
Line wire- 2.5 mm + 0.08 mm
Point wire- 2.0 mm + 0.08 mm
2
Type of Barbed Wire
Iowa Type
3
Tensile strength of line
390 to 590 N/mm
wire
4
Minimum breaking load
3.7 KN
of completed Barbed wire
5
Mass of complete
115 gms / Mtr.
Barbed wire (minimum)
6
Distance between two
(75 + 12 ) mm
Barbs
7
No. of lays between the
4
Barbs ( minimum )
8
Method of Galvanising
Hot dipped according to IS:4826 /1979 with
medium coating.
9
Mass of coating (minimum)
Line wire- 120 gms/Mtr
INDEX OF TECHNICAL SPECIFICATION

Serial
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Description of TS & GTP
Model GTP
Strain Hardware fitting for 33 & 11 KV Disc Insulator
Hot dip Galvanized G.S. Solid Wire
Earthing
Hot dip Galvanized M.S. Stranded Wire
Danger Board
GI Earthing Pipe
Galvanized Mild Steel Hexagonal Head Bolt& Nuts
PVC Insulated PVC Sheathed Al. Conductor Cable
3ph, 11/0.4KV, 100KVA, 200 KVA outdoor type distribution
transformer
PG Clamp
Rail Pole 13M
XLPE cables
Cable jointing accessories.
Laying & Installation
1.1 kV grade control & power cable
G.I. BARBED WIRE
SURGE ARRESTER
5MVA, 33/11 kV ONAN POWER TRANSFORMERS
33/11 kV ONAN 10 MVA POWER TRANSFORMERS
11 kV INSULATORS & INSULATOR FITTINGS
11KV LINE SECTIONALISERS/AB SWITCH
12 KV OUTDOOR VCB, 1200 A / 630A
INSULATORS PIN AND DISC INSULATORS
36 kV OUTDOOR VCB, 1250A
33 KV and 11 KV Post Insulator
AC Distribution Board
ACSR CONDUCTOR
BATTERY, BATTERY CHARGER AND DCDB
BAY MARSHALLING BOX
CONTROL & RELAY PANEL 33KV AND 11 KV
CIVIL WORKS AND SOIL INVESTIGATION
Current Transformer
ISOLATORS - 33KV (800A) & 11 KV (800A)
LATTICE, RAIL AND PIPE STRUCTURES
LIGHTING SYSTEM
Specification of LTDB
POWER AND CONTROL CABLES
39
40
41
42
43
CEMENT CONCRETE POLES FOR 11KV & LT OVERHEAD

POWER LINES TECHNICAL SPECIFICATION FOR PRESTRESSED
TECHNICAL SPECIFICATION OF STAY SET
TECHNICAL SPECIFICATION FOR AERIAL BUNCHED CABLE
ACCESSORIES FOR WORKING VOLTAGE UPTO AND INCLUDING
1100 VOLTS
HORN GAP FUSE
METER FOR CONTROL PANEL
CONTENTS
Section
Number
Section-4
Section-4
Section-4
Section-4
Section-4
Chapter
Number
1
2
3
4
Description
Specifications for 11 kV
Specification for PSC Pole
Specification for 11 kV Insulator
Specification for Stay Set
Specification for ACSR conductors
Section-4
Specification for Line Sectionaliser / AB switch
GUARANTEED TECHNICAL PARTICULARS

CONTENTS
S.No.
Description
Page No.
1.
Power Transformers
2.
VCB
10
3.
11 kV Outdoor Switchgear and Control Panel
13
4.
Current Transformers (CTs)
16
5.
Potential Transformers (PTs)
19
6.
ACSR Conductor
24
7.
PVC Cables 1100 V
27
8.
AB switch
28
9.
33 KV /11 KV Surge Arrestors
31
10.
Pin Insulator
34
11.
11 KV Disc Insulator (B & S)
36
12.
HT Guy Insulator
28
13
14
15.
G.I. Wire
Battery charger
Battery
39
40
41
16.
17.
Energy meter
Capacitor Bank
44
46

1.0 GUARANTEED TECHNICAL PARTICULARS FOR
POWER TRANSFORMERS
(TO BE FILLED IN BY THE BIDDER FOR EACH RATING OF TRANSFORMER)
S.No
Description
1.
Name of the Manufacturer
2.
Normal continuous rating
3.
Normal ratio of transformation
4.
PHASE CONNECTIONS
5.
a) HV Winding
b) LV Winding
c) Vector group reference number and symbol
MAXIMUM TEMPERATURE RISE

a) Of oil by Thermometer
b) Of Winding by resistance
c) By Hot spot temperature Indicator
d) Ambient Temperature adopted
6.
Limit for Hot spot temperature for which the

transformer is designed
7.
Temperature gradient between windings and oil
8.
Voltage to earth for which the star point will be

insulated
9.
Type of cooling
10.
MAXIMUM FLUX DENSITY IN IRON AT

NORMAL VOLTAGE, FREQUENCY AND
RATIO
11.
a) Core
b) Yoke
MAXIMUM CURRENT DENSITY IN

WINDING AT CMR
a) HV Winding Amps/sq.cm.
b) LV Winding amps / sq.cm
S.No
Description
12.
Magnetizing Current (HV) at normal voltage and

ratio (Amps)
13.
Power Factor of Magnetizing current at normal

voltage and frequency
14.
a) Guaranteed no load loss at normal ratio rated

voltage and frequency (Max.)
b) Guaranteed load loss at normal ratio, rated

output, rated voltage, rated frequency and
750C average winding temperature including
auxiliary losses, if any (Max.)
15.
Guaranteed total losses at}At Normal At lowest

At highest rated output, tap rated voltage, rated
frequency and 750C average winding temperature
including auxiliary losses if any (Max.)
16.
Total losses at rated output, rated voltage, rated

frequency and maximum attainable temperature at
site including auxiliary losses if any. (Max.)
18.
Efficiencies at normal ratio, rated voltage, rated

frequency and 750C average winding temperature
for the outputs of.
19.
20.
S.No
a) Full load
b) 3/4 Full load
c) 1/2 Full load
d) 1/4 Full load
Resistance per phase of (at normal tap)

a) HV Winding (Ohms)
b) LV Winding (Ohms)
Reactance per phase of (at normal tap)

a) HV Winding (Ohms)
b) LV Winding (Ohms)
Description
21.
Resistance voltage drop at 750C average winding

temperature expressed as percent of rated voltage.
22.
Reactance voltage drop expressed as percent of

rated voltage
23.
Impedance voltage at normal: at normal at lowest

at highest and 750C average winding tap
temperature expressed as percent of rated voltage.
(Indicate tap nos.)
24.
a) Between HV and LV winding
b) Positive Sequence HV
c) Positive Sequence LV
Regulation at full load at 750C

a) Unity Power Factor
b) 0.8 Power Factor (Lagging)
25.
Type of transformer (Core or Shell)
26.
Width of track gauge
27.
Core
a) Material of Core lamination
b) Thickness of Core Plates
c) Whether Core Plates are grain oriented cold

rolled
d) Insulation of core lamination
e) Insulation of core bolts
f) Insulation of core bolt washers
g) Insulation of core and plates
h) Details of oil ducts in cores
i) Whether in the plane and at right angle to

the plane of winding
ii) Across the plane of laminations
:
:
S.No
28.
Description
Windings
a) Type of Winding
i) HV Winding
ii) LV Winding
b) Insulation of HV winding
c) Insulation of LV winding
d) Insulation between HV & LV winding
e) Power frequency High Voltage Tests
i) Test Voltage for 1 minute withstand test on
High Voltage Windings (Induced)
ii) Test Voltage for one minute withstand test on
Low voltage windings
iii) Test Voltage for one minute withstand test
on Neutral end of high voltage winding
iv) Impulse test on High Voltage Winding 1/50
full wave withstand
v) Impulse test on low voltage winding 1/50 full
wave withstand
vi) Wave form for impulse test
g) Inter turn insulation HV/LV
i)
Extent of extreme and turns reinforcement
ii)
Extent of end turns reinforcement
iii) Extent of turns adjacent to tapping reinforced

iv) Test Voltage for ten seconds 50 cycles inter
turn insulation test on (i)
v)
Test Voltage for ten seconds 50 cycles inter

turn insulation test on (ii)
S.No
Description
vi) Test Voltage for ten seconds 50 cycles
inter turn insulation test on (iii)
vii) Test Voltage for ten seconds 50 cycles
inter turn insulation test on main body of
the winding
h) Type of Axial coil supports
i)
High Voltage Winding
ii)
Low Voltage winding
i) Type of radial coil supports

i)
High Voltage Winding
ii)
Low Voltage Winding
j) Whether HV windings are inter leaved

k) Details of special if any, made to improve stress
conditions
l) Size of cooling ducts
m) Drawings to scale indicating flow of oil in the
radial and axial ducts of each limb and winding
29.
Maximum out of balance force in winding on short

circuit at the terminals
30.
Thickness of Transformer tank plate:

a) Sides
b) Bottom
mm
mm
c) Radiator Plate mm
31.
Type and details of winding hot spot temperature

detector
32.
Power requirement of heater in conservator
33.
Buchholz relay description, data, range of settings

schematic diagram etc.
S.No
34.
Description
Bushings:
a) Type
b) Dry flash over voltage
c) Wet flash over voltage
d) Dry 60s withstand test voltage
e) Wet 60s withstand test voltage
f) Full wave withstand test voltage with 1.2/50
micro seconds wave (+) Positive (-) Negative
g) Creepage distance in air
h) Recommended gap setting mm
i) Weight of assembled bushing (Kgs)
j) Quantity of oil (ltrs.)
35.
Free space required at top for removal of bushings

(mm)
36.
Total volume of conservator liters
37.
Volume of conservator between the Highest and

lowest levels liters
38.
Cooling system
a) Type and make of Fan motors for forced air
cooling equipment
b) Rating and speed of motors
c) Efficiency of motors at full load
d) Temperature rise of motors at full load
e) Number of fan motors
39.
Period of continuous working at full load without

fans
40.
Continuous kVA rating without fans
41.
Calculated time constants

a) Natural cooling
b) Forced air cooling
S.No
42.
Description
Details of on load tap changing gear
a) Make
b) Type
c) Rating:
i)
Rated voltage
ii) Rated current

iii) Step voltage
iv) Number of steps
d) Approximate overall weight
e) Approximate overall dimensions (HxWxD)
f) Approximate overall quantity of oil litres
43.
Weight of copper required to complete the

transformer (Kgs.)
44.
Weight of steel required to complete the

transformer (Kgs.)
45.
Weight of fittings and parts detached for transport

(Kgs.)
46.
Weight of core and windings (Kgs)
47.
Weight of complete transformer with all fittings

and oil (Kgs.)
48.
Weight of complete transformer arranged for

transport of the heaviest package, if broken down
(Kgs.)
49.
Weight of oil in the transformer (Kgs.)
50.
Dimensions of the transformers in meters

a) Maximum height to top of bushings
b) Overall length
c) Overall breadth
d) Heaviest package for transport
S.No
Description
51.
Taps
52.
Fault levels for which the transformer is designed
53.
List of accessories and fittings being provided for

transformer
54.
Whether the materials covered by this Bid have

been fully type tested and if so, whether the copies
of the type test certificates enclosed to the bid
offer.
Yes/No.
55.
Whether oil temperature indicator provided
Yes / No
56.
Type and size of oil temperature indicator and

whether supervisory alarm contacts provided
57.
Type of oil level indicator and whether

supervisory alarm contact for low oil level
provided
58.
Type and size of Gas operated relay and whether

supervisory alarm and trip contacts provided and
their sizes and Nos.
59.
Whether winding temperature indicator with

supervisory alarm indicator and trip contacts
provided and their sizes and Nos.
60.
Ratio and type of C.T. used for winding

temperature indicator
61.
Type and size of Thermostat used
62.
No. of Breathers provided
63.
Type of dehydrating agent used for Breathers
64.
Capacity of Conservator vessel (litres)
S.No
Description
65.
Valve sizes and Numbers required/fitted
66.
Size of Rail gauge for installation in yard
67.
Wheel base
68.
a. Type and make of pressure relief device

b. No. of each type of devices per transformer unit
(Nos.)
c. Minimum pressure at which the device operates
(kPa)
69.
Performance Guarantee
THE FIRM ..............

SIGNATURE OF BIDDER ...........
DESIGNATION & SEAL ...........
DATE : ............

2.0

VACUUM CIRCUIT BREAKERS
(TO BE FILLED IN BY THE BIDDER FOR EACH RATING)
S. No
1.
Description
7.
Rated voltage and frequency

Rated short time withstand current and
its duration with breaker as housed in
thepanel
Making current (peak)
One minute power frequency withstand
voltage
Impulse withstand voltage
Maximum temperature rise over ambient
specified
Interchangeability of similar equipment
8.
Duty cycle
9.
Whether horizontal drawout (Yes/No)
10.
16.
Standard applicable
Whether anti pumping device provided
(Yes/No)
Whether control circuitry suitable for
monitoring of closing and tripping circuit
(Yes/No)
Maximum design voltage
a) Symmerical breaking capacity for
various breakers (in KA)
b) Asymmeterical breaking capacity for
various breakers (in KA)
a) Rated continuous current rating for
various breakers & corresponding
temperature
b) Rated continuous current rating for
various breakers at the specified
ambient temperature
Number of breaks/phases
17.
Type of material of contacts :
2.
3.
4.
5.
6.
11.
12.
13.
14.
15.
Unit
a) Main
21.
b) Arcing
Whether contacts silver are plated and
thickness of plating
Whether breaker designed to close and
latch on making current release ?
Whether trip free or fixed trip
mechanically and electrically
Type of closing
22.
Type of tripping
18.
19.
20.
10
S. No
23.
Description
Unit
Normal voltage of :
a) Closing/tripping mechanism
b) Spring charging motor
24.
Allowable variation of voltage for above
25.
Power required at normal voltage for

a) Trip coil
b) Closing coil
27.
c) Spring charging motor

Weight of circuit breaker with arc
extinguishing medium
Opening time in cycles
28.
Making time in cycles
29.
Opening time at :
26.
a) 10% of rated short circuit current

b) 50% of rated short circuit current
c) 100% of rated short circuit current
30. Heat dissipation at normal current (KW)
Whether 12 Nos. adjustable (either in
NO or NC) auxiliary contacts over
31.
and above those required for been
provided or not.
Current carrying capacity of auxiliary
32.
switches.
No. of breaker operations necessary
33.
(before inspection and maintenance of :
a) Switching at rated load
b) faults of 100% capacity
c) Faults of 50% capacity
d) Making under fault conditions
34.
35.
36.
Accessibility of line connection

Whether terminals suitable for XLPE
cable
Minimum value of pick up current for
a) Closing coil
38.
b) Tripping coil
Schematic control diagram of circuit
breaker enclosed
Make of interrupter
39.
Vacuum breakers (Technical details)
37.
a) Pressure inside the interrupter
mm Hg
11
S. No
40.
Description
Unit
b) Contract wear indication provided

(Yes/No)
c) mechanical facility for checking loss
of vacuum provided (Yes/No)
d) Vacuum monitoring relay provided
(Yes/No)
e) Adequate shielding against X-Ray
radiations provided. (Yes/No)
Switching over voltages generated by the
circuit breakers with and without surge
suppressors
THE FIRM ..............
DATE : ............
12
3.0
GUARANTEED TECHNICAL PARTICULARS FOR 11 kV OUTDOOR

SWITCHGEAR & CONTROL PANEL
(TO BE FILLED IN BY THE BIDDER FOR EACH TYPE)
1.
Tenderer name and address
2.
Validity of tender
3.
Guaranteed Delivery Schedule :
4.
Type
5.
Terms of payment
6.A
Circuit Breaker
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
6.B
:
:
Type & manufacturers name and address

Rated voltage
KV
Rated current
Amp
Rated frequency
C/S
Rated breaking capacity
MVA
Rated making capacity
MVA
Short time current rating for one sec.
1 minute power frequency with stand
voltage
.KV
Impulse withstand voltage
.KV(Peak)
Total break time
.ms.
Closing time
.ms
Ratio voltage for operating device
Number of tripping that breaker capable of
Performing without inspection, replacement
of oil contacts or other main parts
Current Transformer
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
XV.
XVI.

Rated voltage
KV
Rated primary current
Amp
Rated Secondary current
C/S
No. of cores
Rated output
Accuracy class
Accuracy limit factor
Instrument security factor
One second O/current factor
Rated current dynamic (Peak value)
Rated continuous current temperature
based over ambient
..0C
One minute power frequency wet
withstand test voltage
..KV
Impulse withstand test on secondary
Magnetisation curve of CT cores
Characteristics
a) Ratio & Phase angle curves
13
XVII
XVIII
XIX
XX
6.C
Potential Transformer
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
6.D
b) Magnetisation curves
c) Ratio correction factor curves
Turns ratio
Secondary impedance
Highest system voltage
Time period for which secondary winding
can be left open when rated primary current
is following in primary winding.

KV
No. of secondary winding
Rated Secondary voltage
volts
Ratio Burden
VA
Accuracy class
Maximum ratio error with rated burden
5 % normal primary voltage
.%
Quantity of oil
..Lit
Temperature rise at 1.1 times rated
voltage with rated burden with
..0C
Rated voltage factor & time
One minute power frequency
Withstand test voltage
..KV
Protective Relays
a) Manufacturers name & address :
b) Non-directional over current and earth fault
O/C relays
I.Name
II.Type
III.Current coil rating
IV.Tape range
V.VA Burden
VI.a) Highest tap
b) Lowest tap
VII.Time of operation at maximum
time dial setting at
VIII.Type of characteristic
IX.Trip contacts ratings (amp)
X.Whether seal in contact provided or not
XI.Description leaflet reference submitted.
XII.Impulse withstand test voltage
XIII.Over all dimensions
XIV.Total weight
XV.Mounting details
XVI.Characteristic curves
6.E
E/F relays
..KV (Peak)
..mm
...kg
11 KV Switchboard
I. Type & manufacturers name & address
II. Dimensions of Panels
14

III. Dimensions of supporting channels
IV. Thickness of steel plates proposes to be used
6.F
Switchboard wiring
I.
Size of wiring conductor for the following

a)
b)
c)
d)
II.
III.
IV.
V.
VI.
6.G
PT Circuits
CT Circuits
DC supply Circuits
Other Circuits.
Size of earthing bar safety earthing

Type of terminals provided on wirings
Wiring conductor aluminum/cooper
Size of main bus bars and current carrying capacity : mm x mm, ampere
Bus bar materials aluminum /cooper
Instrument and Meters

I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
Type of instruments and manufacturers name and address

Size
Whether magnetically shielded or not
Limits of error in the effective range
Maximum scale length
Whether tropicalised
Short time over load
VA Burden
a) Current coil
VA
b) Potential coil
.
VA
Temperature at which the instruments are calibrated
Description leaflet reference nos submitted
Makers name
Type of selector switch
THE FIRM ..............

DATE : ............
15

4.0

CURRENT TRANSFORMERS (CTs)
(To be filled in by the Bidder separately for each type and voltage rating)
1.
Type of tank/Installation
2.
Type of mounting
3.
Manufacturer's Name and address

and Country of Manufacture
4.
Conforming to standard
5.
a) i)
Primary and Secondary winding made out of
ii ) Primary windings Design density for short circuit current

Conductivity of metal used b) i)
Area of cross section of primary winding
ii) Area of cross section of secondary winding

c) Material used for providing secondary terminals
6.
Rated primary voltage (kV rms)
7.
Rated highest voltage (kV rms)
8.
Rated frequency (Hz)
9.
Rated primary current (A)
10.
Rated secondary current (A)
11.
Ratio taps (on secondary side only)
12.
Type of insulation
13.
Seismic acceleration (g)
14.
RIV at 1.1 x Rated voltage (mv)
15.
Tank material and Tank coating
16

16.
Hardware exposed to atmosphere
17.
Bolts, Nuts and Washers
18.
Porcelain housing and it make (Single piece only)
19.
Sealing (Nitrogen gas cushion/Metal Bellow)
20.
Instrument security factor
21.
Whether test tap provided
22.
Acceptable limit of temperature
23.
Acceptable partial discharge level at 1.1 times

the rated voltage
24.
Rated short time withstand

current for 1 sec. duration
(kA rms)
25.
Rated dynamic withstand

current (kAp)
26.
Rated continuous thermal

current (pu)
where pu = rated current
27.
1.2/50 micro-second
impulse withstand
voltage (kVp)
28.

withstand voltage (kV rms)
of primary winding (Dry)
29.

withstand voltage of
secondary winding
(kV rms)
30. a) Minimum total creepage

distance of insulator bushing (mm)
b)
Protected creapage of distance of

bushing (mm)
17
31.
Details of Cores
Core No. I II III IV V
31.1
Current Ratios A/A
31.2
Output burden (VA)
31.3
Class of accuracy
31.4
Accuracy limit factor
31.5
Min. knee point voltage (kpv) __ __ __ __ __
31.6
Secondary resistance
corrected to 75 deg.C
31.7
Max. exciting current at

__ __ __ __ __
20% of knee point voltage
-- -- --- -- --- -- --- -- -__ __ __ __ __

__ __ __ __ __
__ __ __ __ __
31.8 Application
32.
Weight of oil (Kg.)
33.
Total Weight (Kg.)
34.
Mounting details
35
Overall dimensions
36.
Characteristics (whether
graphs enclosed):
-- -- -- -- --
a. Ratio and phase angle curves

b. Magnetisation curves
c. Ratio correction factor curves
37.
Core
a)
b)
Area of cross section

Flux density at rated primary current and
rated burden.
Name of the firm .............

Signature of Bidder...........
Name & Designation & Seal ...........
Date .........................
18

5.0
SCHEDULE OF TECHNICAL & GUARANTEED PARTICULARS FOR POTENTIAL

TRANSFORMERS (PTs)
(To be filled in by the tenderer separately for each voltage rating)
Type
1.
Manufacturers type Designation
2.
Mounting of tank (Bottom)
3.
System rated voltage/highest voltage (kv)
4.
Rated primary voltage (kv)
5.
Secondary winding details:

a) No.of secondary
windings
Winding I
Winding II
Winding - I
b) Rated secondary voltage (v)

c) Rated burden (VA)
d) Class of accuracy
6.
Maximum ratio error with % rated burden

and 5% normal primary voltage.
7.
Maximum phase angle error % with rated

burden and 5% normal primary voltage.
8.
Temperature rise at 1.1 times rated voltage

with rated burden (oC)
9.
Rated voltage factor and time.
10.
Temperature rise for item 10 above (oC)
11.
Impulse withstand test voltage (kV) peak.
12.
One minute power frequency withstand test

voltage on primary (kV rms)
19
13.
One minute power frequency withstand test

voltage on secondary (KV rms)
14.
Total creepage distance of the bushing (mm)
15.
Protected creepage distance of the bushing (mm)
16.
Quantity of insulating oil (Litres)
17.
Weight of oil (Kg.)
18.
Total weight including oil (Kg).
19.
Mounting details
20.
Live parts to ground clearance
21.
Whether V.T. is sealed construction

with nitrogen at top.
22.
Overall dimensions:
Height
mm
Length
mm
Breadth mm
23.
Grade of oil.
24.
Voltage Transformers shall carry 25% above

the rated burden continuously without injury in
respect of voltage Transformers.

Name & Designation & Seal .
Date
.........................
20
6.0

ACSR CONDUCTOR
(To be filled in by the Bidder separately for each type)
S.NO.
Description
Unit
1.0
Makers Name, Address
2.0
Particulars of Raw Materials
2.1
Aluminium
a)
Minimum Purity of aluminum
b)
Maximum Copper Content
2.2
Steel Wires/Rods
a)
Carbon
b)
Manganese
c)
Phosphorus
d)
Sulphur
e)
Silicon
2.3
Zinc
a)
Minimum Purity of Zinc
3.0
Aluminum Strands after stranding
3.1
Diameter
a)
Nominal
mm
b)
Maximum
mm
c)
Minimum
mm
3.2
Minimum Breaking Load of Strand
kN
3.3
Maximum Resistance of 1m length of
4.0
Steel Strands after stranding
4.1
Diameter
a)
Nominal
mm
b)
Maximum
mm
Particulars
Ohm
21
S.NO.
Description
c)
Minimum
5.0
Galvanizing
a)
Minimum weight of zinc coating per
Unit
Particulars
mm
gm/m2
Uncoated wire surface

b)
Minimum number of one minute dips galvanized

strand can withstand in the preece test
Nos.
c)
Minimum number of twists in a guage length times

dia of wire which the strand can in the torsion test
(after stranding)
Nos.
6.0
ACSR Stranded Conductor
6.1
UTS of Conductor
6.2
Lay ratio of Conductor
a)
Outer Steel Layer
b)
12 wire aluminum layer
c)
d)
6.3
D.C. resistance of conductor at 20oC
6.4
Standard length of conductor
kN
Max.
Ohm/Km
M
22
S.NO.
6.5
6.6
7.0
7.1
a)
b)
c)
8.0
9.0
Description
Maximum length of conductor that can be
Tolerance on standard length of conductor
Direction of lay for outside layer
Linear mass of the Conductor
Standard
Minimum
Maximum
No. of Cold pressure butt welding available at
works
Performance guarantee
Unit
Meter
%
Particulars
Kg/Km
Kg/Km
KgKm
Nos.

Date .........................
23

7.0

PVC CABLES 1100 V
The tenderers shall quote with their tenders the following technical particulars:
a)
Makers name
b)
Brand name
c)
Radial thickness of insulation in mm
d)
Radial thickness of inner sheath in mm
e)
Radial thickness of outer sheath in mm
f)
Colour of outer sheath
g)
Nominal cross-section area of conductor in mm2
h)
Number of wires
i)
Dia of each wire in mm
j)
Conductor resistance in ohm/meter
k)
Nominal overall diameter in mm
l)
Standard coil length in meters
m)
ISI certification mark
n)
Other particulars as per requirement of ISS
o)

Date .........................
24

8.0
GUARANTEED TECHNICAL PARTICULARS OF

ISOLATORS/AB SWITCH
1.1
Tenderers Name and Address
1.2
Manufacturers Name and Address
1.3
Validity of Tender
1.4
Guaranteed delivery schedule
1.5
Terms of payment
1.6
Maximum permissible continuous service
:
:
:
voltage, KV
1.7
Continuous current rating

a) For 1 sec. KA
b) For 3 sec, KA
1.8
Rated peak short circuit current, KA, peak
1.9
Rated peak short circuit current of

earthing blade KA peak
1.10
Temperature rise corresponding to

a) Maximum current rating and 600C
ambient temperature
b) Short time current rating

i) For 1 sec, C
ii) For 3 sec, C
:
:
1.11
Fault current which can be made by

earth switch, KA:
1.12
Maximum current that can be safely

Interrupted between equipment and
bus-bars
:
Clearance in air (Minimum)
a) Between phases (Min)
b) Between line parts and earth
c) Distance between centres of outer
stocks of insulators (MM)
Power frequency withstand test voltage
for complete assembled switches
1.13
1.14
:
:
:
:
a) Against ground
i) Dry KV
25

ii) Wet KV
b) Across open contacts

i) Dry KV
ii) Wet KV
:
:
c) Between phases
i) Dry KV
ii) Wet KV
:
:
1.15 Particulars of main contacts in fixed (main

and earthing switch) and moving contacts
(main and earthing switch)
a)
b)
c)
d)
e)
Type
Material
Surface treatment
Contact area
Contact pressure
:
:
:
:
:
1.16 Current density at the minimum cross section

of switch blade
1.17
No. of operations without need for inspection
1.18
Type and material of connectors
1.19
Whether arcing contacts provided and if so,

give details and material used
Whether adjustable gap type arcing horns

provided and if so, give material used
1.21
Creepage distance of insulators stock, mm
1.22
Location and type of bearing
1.20
26
1.23
Weight of complete isolator

a) With earthing blade kg
b) Without earthing blade kg
1.24
1.25
1.26
:
:
Operating effort required for manual

operation kg
Type of interlocking between isolating
switch and earth switch
Details of mounting
:
:

Date .........................
27

9.0

SURGE ARRESTORS
Sl.
No.
1.
Description
Particulars
Name & Address of Supplier & Manufacturer

Surge Arrestor
Line Disconnector
Metal Oxide Block
Terminal Clamp
2.
Name & address of collaborator, if any
3.
Standard to which surge arrestors conforms
4.
Surge Arrestor
4.1
Voltage rating (KV rms)
4.2
Continuous Operating Voltagte (KV rms)

a)
Continuous Operating Voltage (KV rms)
b)
Leakage current at continuous operation voltage
c)
Partial discharge at 1.05 COV (PC)
d)
Permitted leakage current of arrestor beyond
which arrestor is faulty :
5.
Frequency (Hz)
6.
Nominal discharge current

(wave shape 8 / 20 micro second) (KA)
7.
Pressure relief rated current (KA rms)
28
Sl.
No.
8.
Description
Particulars
Steep current protection level at 10 KA

a)
Lighting impulse protection level at 5 KA and 10
KA (KVP)
b)
Switching impulse protection level with 40 x 80

micro-sec. Wave at 500/1000 A
9.
Long duration current impulse withstand capacity and

virtual duration
10.
Line discharge class
11.
Thermal runaway limit of arrestor
12.
Energy capability (kJ/KV)
13.
Pressure relief rating
14.
Dry arcing distance
15.
Reference current and reference voltage
16.
Arrestor housing
16.1
Power frequency one minute wet withstand voltage (kV

rms)
16.2
Lighting impulse dry withstand voltage (KVP)
16.3
Creepage distance
a)
Protected
b)
Total
16.4
Short circuit withstand capacity
16.5
Bending moment (mm)
29
Sl.
No.
17.
18.
Description
Particulars
Dis-connector
a)
Constructional Details
b)
Other information as applicable to surge arrestor
Surge monitor
a)
Constructional details
b)
Degree of protection
19.
Suitable for hot line washing
20.
Dimension & weight
22.
Details of packing
23.
Licence number and date for using ISI certification mark

if any
24.
Ammeter for discharge current

a)
Type & Make
b)
Accurancy
c)
Range (mA)
25.
Residual voltage
26.
Follow current
27.
Date .........................
30

10.0
GUARANTEED TECHNICAL PARTICULARS OF

PIN INSULATOR
(To be Filled by Tenderer)
S.NO.
Description
Manufacturers Name & Address
Type of insulator offered
Drawing Numbers
Over all Dimensions (mm)

a)
Height
b)
Out Diameter
Nominal System Voltage
(kV)
Highest System Voltage
(kV)
Minimum Failing Load (kN)
Dry Power Frequency Flashover Voltage (kV)
Wet Power Frequency Flashover Voltage (kV)
10
Puncture Withstand Voltage (Power Frequency) (kN)
11
Min. Creepage Distance (mm)
12
Impulse Flashover Voltage : (kV)
13
a)
1.2/50 Micro Sec. Wage of Positive Polarity
b)
1.2/50 Micro Sec. Wage of Negative Polarity
Particulars
Impulse Withstand Voltage : (kV)

a)
1.2/50 Micro Sec. Wave of Positive Polarity
b)
1.2/50 Micro Sec. Wave of Negative Polarity
14
Dry Power Frequency 1 Min. Withstand Voltage (kN)
15
Wet Power Frequency 1 Min. Withstand Voltage (kN)
16
Minimum Visible Discharge Test Voltage
17
Net Weight (Approx.) (Kg)
18
Standard According to which Porcelain Insulators be

Manufactured and Tested
19
Tolerance in Dimensions, if any (as per ISS)
20
Temperature Cycle Test (as per ISS)
21
Porosity Test (as per ISS)
22
31

Date .........................
32

11.0
GUARANTEED TECHNICAL PARTICULARS OF DISC INSULATOR

S.NO.
PARAMETER
2
3
Type of insulator offered

Drawing Numbers
Over all Dimensions (mm)

a)
Height
b)
Out Diameter
Nominal System Voltage
(kV)
Highest System Voltage
(kV)
Minimum Failing Load (kN)
8
9
Dry Power Frequency Flashover Voltage (kV)

Wet Power Frequency Flashover Voltage (kV)
10
Puncture Withstand Voltage (Power Frequency) (kN)
11
Min. Creepage Distance (mm)
12
Impulse Flashover Voltage : (kV)

a)
1.2/50 Micro Sec. Wage of Positive Polarity
b)
13
GUARANTEED VALUE
1.2/50 Micro Sec. Wage of Negative Polarity
Impulse Withstand Voltage : (kV)

a)
b)
1.2/50 Micro Sec. Wave of Positive Polarity

1.2/50 Micro Sec. Wave of Negative Polarity
14
Dry Power Frequency 1 Min. Withstand Voltage (kN)
15
Wet Power Frequency 1 Min. Withstand Voltage (kN)
16
Minimum Visible Discharge Test Voltage
17
Net Weight (Approx.) (Kg)
18
19
Standard According to which Porcelain Insulators be

Manufactured and Tested
Tolerance in Dimensions, if any (as per ISS)
20
Temperature Cycle Test (as per ISS)
21
Porosity Test (as per ISS)
33

Date .........................
34

12.0
GUARANTEED TECHNICAL PARTICULARS OF H.T. & LT GUY INSULATOR

(To be Filled by Tenderer)
S.NO.
PARAMETER
GUARANTEED VALUE
Type of insulator
Standards to which insulator will conform
Dimensions
Hole diameter (mm)
Color of glaze
Dry Power Frequency withstand Voltage (kV)
Wet Power Frequency withstand Voltage (kV)
Minimum failing load (Newton)
10
Minimum Creepage distance (mm)
11
Weight per piece (Kg)
12
Temperature cycle test (as per ISS)
13
Porosity test (as per ISS)
14
Tolerance, if any (as per ISS)

Date .........................
35

13.0
A.
GUARANTEED TECHNICAL PARTICULARS FOR G.I. WIRE

(TO BE FURNISHED BY BIDDER)
G.I.Wire
1.
Size of Wire
2.
Tolerance in size of wire
3.
Tensile strength
4.
Wrapping list
5.
Galvanising conforming to IS :
4826 1968
Signature of the ______________________

Tenderer____________________________
Common Seal
Date :
36
14. GUARANTEED TECHNICAL PARTICULARS OF BATTERY CHARGER
Sl.No.
Description
Units
Rated DC system voltage
Volts
Catalogue attached
Type designation
Applicable Standard
Rated input voltage with allowable

variation
a) Voltage
Volts
b) Frequency
Hz
c) Combined variation of frequency
& voltage
AC input current
a) Float
b) Boost
A
A
Rated direct current
Ripple content in DC output
Rated direct voltage
Volts
10
Type of load limiting feature
11
Transient voltage regulation
12
Power consumption
13
Efficiency of charger
14
Rectifier assembly
15
Type of semi-conductor material

Thyristor - Make/Type
16
Manual voltage regulator

Type
Voltage setting range
17
Degree of protection for charger

enclosure
18
Rectifier transformer
Type/Make
Rating
Insulation class
% age impedance
Temperature rise
19
Remarks
Volts
Contactors
37

Sl.No.
Description
Units
Remarks
Type/designation
20
AC MCCB
Type/Rating
21
DC MCCB
Type/Rating
22
Charger dimensions
Height
Depth
Width
mm
mm
mm
Enclosure sheet thickness
mm
23
Signature of the ______________________

Tenderer____________________________
Common Seal
Date :
15.0
GUARANTEED TECHNICAL PARTICULARS OF BATTERY

Sl.No.
Description
Units
Rated DC system voltage
Volts
Rated cell voltage
Volts
Number of cells
Nos.
Cell designation
Type of electrode
Specific gravity of electrolyte
Remarks
38

Sl.No.
Description
Units
Cell float charge voltage
Volts
Cell boost charge voltage
Volts
End Cell voltage
Volts
10
Nominal cell capacity at 5 Hrs rate
Ah
11
Material of container
12
Size of terminals
13
S/C rating of terminals/ connectors/ kA

leads
14
Current for charge to 90% capacity in 7 Amps

Hrs from fully discharged state
15
Recombination efficiency
16
Valve
regulated
recombination type
17
In case of catalytic recombination type,

frequency of replacement of catalytic
converter
18
Release pressure for valve regulated Kg/m2

type
19
Volume of electrolyte per cell
ml
20
Volume of reserve electrolyte per cell
ml
21
No of electrode plates per cell
Nos.
22
Type of racks
23
Cell dimension:
24
25
or
Remarks
%
catalytic
(a) Height
(b) Width
(c) Depth
mm
mm
mm
Rack Dimensions
(a)Height
(b)Width
( c)Depth
Mm
Mm
Mm
Recycling facilities for unserviceable

batteries available or not
Y/N
39
Signature of the ______________________

Tenderer____________________________
Common Seal
Date :
40

16.0..ENERGY METER
Sl No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
(a)
(b)
(C)
17.
18.
19.
20.
Description
Vendors Data
Vendors Data

Make / Type / Model No.
Country of Origin
Application
Rated Voltage
Rated Current
Maximum Continuous Current
Whether the meter measures Harmonic current
generated due to non linear loads. (Yes/NO)
Whether the meter records power due to Harmonic
Current (Yes/No)
Short time current rating
Frequency
Overload Capacity
Minimum starting current in % of Base current
Loss in Potential circuit
Loss in current circuit
Change in error due to
Variation in frequency
Variation in Temperature
Variation in voltage
Accuracy class
One minute power withstand voltage
Basic insulation level
Current rating of the terminal
41

Sl No.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
(a)
Description
Maximum size of cable which can be connected at
terminals
Are the terminals bi-metallic and suitable for
Aluminum Cables, (Yes / No)
Total weight of meter
HV withstand
Insulation resistance
Standard to which the meter conform
Type of energy registration mechanism
Insulation test (voltage 50 Hz for 1 min.)
Temp. coefficient from 10% of rated load to 100%
of rated load (0 deg. C to 55 deg. C)
Working range
Voltage
(b)
Current
31.
Auxiliary supply
32.
33.
34.
35.
Vendors Data
Vendors Data
Type of load (linear, non-linear, balanced

/unbalanced at any pf)
Display details
Display cycle (descriptive in order of display)
Process of display
36.
Sensitivity
37.
Memory Details
38.
Tamper & anomaly detection & alarm
42
Signature of the ______________________

Tenderer____________________________
Common Seal
Date :
17.Capacitor Bank
3*4 &, 3*2 KVAR, CAPACITOR BANK:-
GTP PARAMETER
1.
2
3
4
5
DATA
Name of the manufacturer and

type.
Country of manufacturer.
Country
of
origin
equipment.
Reference
standard
13925/1998(Part-I)
Maximum voltage (RMS)
which
the
capacitor
of
IS
can
43
10
withstand continuously in KV
Capacitor
Bank
rating
KVAR(600).
Rated voltage of capacitor unit
in KV (12 KV Phase to Phase)
KVAR of individual unit at
rated voltage (200)
Mode of connection capacitor
bank (connected in star with
floated neutral)
Capacitor unit.
11
Mode of fuse protection.
12
Type of discharge device and

its location.
Type of electrode.
6
7
8
9
13
14
Dielectric
loss
capacitor (Tan 13925)
Delta) as per IS
angle
in
of
26
27
15 Capacitor losses (less than or

equal to .2 W per KVAR ( Plus
Minus 10%))
16 Type of impreganant used
28
29
30
31
32
17.Type of dielectric (Polypropylene)

18.Insulation level power frequency test
.
19 Impulse withstands voltage in KVA
20
Numbers of units in each bank
and numbers
of units
phase (3 Units per bank)
21
Number and type of bushing
for capacitor units.
22
Creepage distance of bushing
in MM on rated voltage.
23
Discharge
device
residual
voltage in V (50)
24
Time (Less than 10 Minutes)
25
Terminal test 10 seconds for
DC voltage in KV.
33
per
34
One minute for AC voltage in

KV.
External fuse-type of fuse
(Expulsion type)
Whether indicating type.
Tolerance limit.
Degree of unbalance.
Quantity of oil in KG (Approx)
Weight of capacitor unit in KG
(Approx)
Dimension of capacitor unit
(Approx.) in MM (WxHxT)
Container (Sheet Steel) not
less than 1.6 MM
44
Name & Designation & Seal

Date.
D
a
t
e
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
45
46
SURGE ARRESTER
33kV VOLTAGE CLASS SURGE ARRESTORS
1.0
1.1
2.0
2.1
SCOPE
The specification covers the design, manufacture, shop & laboratory testing before
dispatch, supply, delivery, erection, testing & commissioning of 33kV voltage
level, 10 KA, Station class heavy duty, gapless metal (zinc) oxide single pole Surge
Arrestors complete with insulating bases, clamps, complete fittings & accessories
suitable for installation on outdoor type 33 kV switchgear, transmission lines, 33
kV transformers. Suitable brackets shall be fabricated and mounted on the
transformers for installing the surge arrestors.
STANDARDS
The design, manufacture and performance of Surge Arrestors shall comply with
IS: 3070 Part-3 and other specific requirements stipulated in the specification.
Unless otherwise specified, the equipment, material and processes shall conform to
the latest applicable Indian/International Standards as listed hereunder:
IS:2071-1993 (Part-1)
Methods of High Voltage Testing General

Definitions & Test Requirements.
IS:2629-1985
Recommended Practice for hot dip galvanizing on
Iron & Steel
IS:2633-1986
Method for Testing uniformity of coating of zinc
coated Articles.
IS:3070-1993 (Part 3) Specification for surge arrestor for alternating
current systems. Metal-Oxide lightening Arrestors
without gaps
IS:4759-1996
Specification for hot dip zinc coating on Structural
Steel and Other allied products.
IS:5621-1980
Hollow Insulators for use in Electrical Equipment.
IS:6745
Method for determination of mass of zinc coating on
zinc coated iron and steel articles
IEC 60099-4
Surge Arrestors
The equipment complying with any other internationally accepted standards
shall also be considered if it ensures performance equivalent to or superior to
the Indian Standards.
3.0 GENERAL REQUIREMENT
3.1
The metal oxide gap less Surge Arrestor shall be heavy duty station class suitable for
protection of 33kV switchgear, transformers, associated equipment and 33 kV lines
from voltage surges resulting from natural disturbance like lightning as well as
system disturbances including switching surges. They shall be single phase units
suitable for outdoor duty.
Page 1 of 14
3.2
The surge arrestor shall draw negligible current at operating voltage and at the
same time offer least resistance during the flow of surge current.
3.3
The surge arrestor shall consist of non-linear resistor elements placed in series and
housed in electrical grade porcelain housing of creepage distance of 900 mm. The
protected creepage distance shall not be less than 50% of total creepage. .
3.4
The assembly shall be hermetically sealed with suitable rubber gaskets with effective
sealing system arrangement to prevent ingress of moisture.
3.5
The surge arrestor shall be provided with one line and two earth terminals of suitable
size. The ground side terminal of surge arrestor shall be connected with 25x6
mm galvanized strip, one end connected to the surge arrestor and second end to a
separate ground electrode. The bidder shall also recommend the procedure which
shall be followed in providing the earthing/system to the Surge Arrestor.
3.6
The surge arrestor shall not operate under power frequency and temporary over
voltage conditions but under surge conditions, the surge arrestor shall change over to
the conducting mode.
3.7
The surge arrestor shall be suitable for circuit breaker performing O-0.3sec.-CO-3minCO- duty in the system.
3.8
Surge arrestors shall have a suitable pressure relief system to avoid damage to the
porcelain housing and providing path for flow of rated fault currents in the event of
arrestor failure.
3.9
The reference current of the arrestor shall be high enough to eliminate the influence
of grading and stray capacitance on the measured reference voltage.
3.10 The Surge Arrestor shall be thermally stable and the bidder shall furnish a copy of
thermal stability test with the bid.
3.11
The arrestors for 33 kV system shall be suitable for mounting on transformers, Bus,
Line. The supplier shall furnish the drawing indicating the dimensions, weights etc. of
the surge arrestors for the design of mounting brackets.
3.12
The arrestor shall be capable of handling terminal energy for high surges, external
pollution and transient over voltage and have low losses at operating voltages.
4.0
ARRESTOR HOUSING
4.1
The arrestor housing shall be made up of porcelain housing and shall be homogenous,
free from laminations, cavities and other flaws or imperfections that might affect the
mechanical and dielectric quality. The housing shall be of uniform brown colour, free
from blisters, burrs and other similar defects.
Arrestors shall be complete with fasteners for stacking units together, and terminal
connectors.
4.2
The housing shall be so coordinated that external flashover shall not occur due to
application of any impulse or switching surge voltage upto the maximum design value
Page 2 of 14
for arrestor. The arrestors shall not fail due to contamination. The 33 kV arrestors
housing shall be designed for pressure relief class as given in Technical Parameters of
the specification.
4.3
Sealed housings shall exhibit no measurable leakage.
4.4
The arrester shall be suitable for mounting on a bracket on the HT end of 33/11 kV
transformer or on a lattice steel supporting structure.
5.0
FITTINGS & ACCESSORIES
5.1
The surge arrestor shall be complete with fasteners for stacking units together and
terminal connectors.
5.2
The terminals shall be non-magnetic, corrosion proof, robust and of adequate size
and shall be so located that incoming and outgoing connections are made with
minimum possible bends. The top metal cap and base of surge arrestor shall be
galvanized. The line terminal shall have a built in clamping device which can be
adjusted for both horizontal and vertical take off. It should be suitable for ACSR
conductor.
6.0
TESTS
6.1
Test on Surge Arrestors

The Surge Arrestors offered shall be type tested and shall be subjected to routine
and acceptance tests in accordance with IS : 3070 (Part-3)-1993. In addition, the
suitability of the surge arresters shall also be established for the followings
(A) Acceptance tests:
i)
Measurement of power frequency reference voltage of arrester units.
ii)
Lightning impulse residual voltage on arrester units (IEC clause 6.3.2)
(B) Special Acceptance tests:
i)
Thermal stability test (IEC clause 7.2.2)
ii)
Aging & Energy capability test on blocks (procedure to be mutually agreed)
iii) Watt loss test.
(C) Routine tests:
i)
Measurement of reference voltage
ii)
Residual voltage test of arrester unit
iii) Sealing test
iv)
Verticality check on completely assembled surge arresters as a sample test on
each lot.
6.2
The maximum residual voltages corresponding to nominal discharge current of 10

kA for steep current, impulse residual voltage test, lightning impulse protection level
and switching impulse level shall generally conform to Annex-K of IEC-99-4.
Page 3 of 14
6.3
The bidder shall furnish the copies of the type tests and the characteristics curves
between the residual voltage and nominal discharge current of the offered surge
arrestor and power frequency voltage v/s time characteristic of the surge
arrestor subsequent to impulse energy consumption as per clause 6.6 of IS:3070
(Part-3) offered alongwith the bid.
6.4
The surge arrestor housing shall also be type tested and shall be subjected to routine
and acceptance tests in accordance with IS: 5621.
6.5
Galvanization Test
All Ferrous parts exposed to atmospheric condition shall have passed the type tests
and be subjected to routine and acceptance tests in accordance with IS:2633 & IS
6745.
7.0
NAME PLATE
7.1
The name plate attached to the arrestor shall carry the following information :
- Rated Voltage
- Continuous Operation Voltage
- Nominal discharge current
- Pressure relief rated current
- Manufacturers Trade Mark
- Name of Sub-station
- Year of Manufacturer
- Name of the manufacture
- Name of Client-APDP
- Purchase Order Number along with date
8.0
INSPECTION
8.1
All tests and inspection shall be made at the manufacturer's works unless
otherwise specifically agreed upon by the manufacturer and purchaser at the time of
placement of purchase order. The manufacturer shall afford to the inspector
representing the purchaser, all reasonable facilities, without charge to satisfy him
that the material being furnished is in accordance with these specifications. The
purchaser reserves the right to get any component/material being used by the
manufacturer of the Surge Arrestor tested from any recognised test house.
Page 4 of 14
8.2
The inspection by the purchaser or his authorised representative shall not relieve
the bidder of his obligation of furnishing equipment in accordance with the
specification.
9.0
DRAWINGS AND INSTRUCTION MANUALS

Within 15 days of receipt of the order, the successful tenderer shall furnish to the
purchaser the following drawings and literature for approval:
(i)
Outline dimensional drawings of Surge Arrestor and all accessories.
(ii)
(iii)
Drawings of terminal clamps.
(iv)
Arrangement of earthing lead.
(v)
Minimum air clearance to be maintained of line components to ground.
(vi)
Name plate
(vii)
Insulating base
(viii)
Instructions manual
(ix)
Drawing showing details of pressure relief valve
(x)
Volt-time characteristics of surge arrestors
(xi)
Detailed dimensional drawing of porcelain housing/Silicon polymeric

i.e. internal diameter, external diameter, thickness, height, profile,
creepage distance, dry arcing distance etc.
11.0 QUALITY ASSURANCE

11.1
Quality Assurance Programme

As per clause mentioned in General technical requirement.
11.2
Quality Assurance Document

The contractor shall be required to submit the quality assurance documents before
dispatch of the equipment. The authorised representative reserves the carryout Quality
Audit and Quality Surveillances of the System and procedures of the contractor/his
vendors quality management and control activities.
12.0 TECHNICAL PARTICULARS

12.1
The surge arrestors shall conform to the following standard technical requirements. The
Insulation values shall be enhanced considering the altitude of operation & other
atmospheric conditions.
Page 5 of 14
System Parameters :
12.2
12.3
Nominal system voltage

System earthing
33 kV
36 kV
Solidly earthed system
Frequency (Hz)
Lightning Impulse withstand Voltage (kVP)
50
170
Power frequency withstand Voltage (kV rms)

Connection to system
Type of equipment to be protected
70
Phase to earth
33 kV transformers
Surge Arrestors
Type of Surge Arrestor
Gapless Metal oxide

outdoor
Arrestor rating (kV rms)

Continuous Operating voltage (kV rms)
Standard Nominal Discharge Current Rating
(kA) (8x20 micro impulse shape)
Long duration discharge class
30
25
10
IP-55
Lightning Impulse at 10 kA
85
Energy capability corresponding to

a) Arrestor rating (kJ/kV)
4.5
b) COV (kJ/kV)
4.9
Peak current for high current impulse operating

duty of arrestor classification 10 kA
100 KA
Insulator Housing
(wet) (kV rms)
Lightning impulse withstand/tests voltage (kVP)
Pressure Relief Class
Creepage distance not less than
12.4
Class III
70
170
40
900 mm
Galvanisation
Fabricated Steel Aticles
-- 5 mm thick cover
-- Under 5 mm but not less than 2 mm thickness
610 g/m2
460 g/m2
-- Under 2 mm but not less than 1.2 mm
340 g/m2
Page 6 of 14
thickness
Castings
-- Grey Iron, malleable iron
Threaded works other than tubes & tube fittings
-- Under 10 mm dia
-10 mm dia & above
Page 7 of 14
610 g/m2
300 g/m2
270 g/m2
11kV VOLTAGE CLASS SURGE ARRESTORS
1.0
SCOPE
The specification covers the design, manufacture, shop & laboratory testing before
dispatch, supply, delivery, erection and commissioning of 11kV voltage station Surge
Arrestors for installation on outdoor type 11kV switchgear, transmission lines,
transformers etc. 11kV side of which is not enclosed in a cable box.
2.0
STANDARDS
The design, manufacture and performance of Surge Arrestors shall comply with IS:
3070 Part-3 and other specific requirements stipulated in the specification. Unless
otherwise specified, the equipment, material & processes shall conform to the latest
amendments of the following:
IS:2071-1993
(Part-1)
IS:20711974 (Part-2)
IS: 2629-1985
IS: 2633-1986
Methods of High Voltage Testing General Definitions & Test

Requirements.
Test Procedures.
Recommended Practice for hot dip galvanizing on Iron & Steel.

Method for Testing uniformity of
coating of zinc coated
Articles.
IS:3070-1993 Specification for surge arrestor for alternating current systems.
(Part 3)
Metal-Oxide lightening Arrestors without gaps.
IS: 4759-1996 Specification for hot dip zinc coating on structural steel and
other allied products.
IS: 5621-1980 Hollow Insulators for use in Electrical Equipment.
IS: 6745
Method for determination of mass of zinc coating on zinc coated
iron and steel articles.
IEC 60099-4 Surge Arrestors.
The equipment complying with any other internationally accepted standards shall
also be considered if it ensures performance equivalent to or superior to the Indian
Standards.
3.0 GENERAL REQUIREMENT
3.1
The metal oxide gap less Surge Arrestor shall be suitable for protection of 11 kV side
of power transformers, associated equipment and 11kV lines from voltage surges
resulting from natural disturbance like lightning as well as system disturbances
including switching surges.
3.2
The surge arrestor shall draw negligible current at operating voltage and at the
same time offer least resistance during the flow of surge current.
Page 8 of 14
3.3
The surge arrestor shall consist of non-linear resistor elements placed in series and
housed in electrical grade porcelain housing of specified Creepage distance of 300 mm.
The protected creepage distance shall not be less than 50% of total creepage.
3.4
The assembly shall be hermetically sealed with suitable rubber gaskets with effective
sealing system arrangement to prevent ingress of moisture.
3.5
The surge arrestor shall be provided with one line and two earth terminals of suitable
size. The ground side terminal of surge arrestor shall be connected with 25x6 mm
galvanized strip, one end connected to the surge arrestor and second end to a
separate ground electrode. The bidder shall also recommend the procedure which
shall be followed in providing the earthing/system to the Surge Arrestor.
3.6
The surge arrestor shall not operate under power frequency and temporary over
voltage conditions but under surge conditions, the surge arrestor shall change over to
the conducting mode.
3.7
The surge arrestor shall be suitable for circuit breaker performing O-0.3 min-CO-3
min-CO- duty in the system.
3.8
Surge arrestors shall have a suitable pressure relief system to avoid damage to the
porcelain housing and providing path for flow of rated fault currents in the event of
arrestor failure.
3.9
The reference current of the arrestor shall be high enough to eliminate the influence of
grading and stray capacitance on the measured reference voltage.
3.10
The Surge Arrestor shall be thermally stable and the bidder shall furnish a copy of
thermal stability test with the bid.
3.13
The arrestor shall be capable of handling terminal energy for high surges, external
pollution and transient over voltage and have low losses at operating voltages.
3.14
The surge arrestor shall be provided with line and earth terminals of suitable size. The
line side terminal shall be suitable for 100 mm2 (code Name : Dog) Aluminimum area,
6/4.72 mm Aluminimum + 7/1.75 mm Steel SCA conductor.
4.0
ARRESTOR HOUSING
4.1
The arrestor housing shall be made up of porcelain housing and shall be homogenous,
free from laminations, cavities and other flaws of imperfections that might affect the
mechanical and dielectric quality. The housing shall be of uniform brown colour, free
from blisters, burrs and other similar defects.
Arrestors shall be complete with terminal connectors and disconnectors.
4.2
The housing shall be so coordinated that external flashover shall not occur due to
application of any impulse or switching surge voltage upto the maximum design
value for arrestor. The arrestors shall not fail due to contamination. The 11kV arrestors
housing shall be designed for pressure relief class as given in Technical Parameters of
the specification.
Page 9 of 14
4.3
5.0
Sealed housings shall exhibit no measurable leakage.

ARRESTOR MOUNTING
The arrestors shall be suitable for mounting on 4 pole/2 pole structure used for
pole/plinth mounted transformer and for incoming and outgoing lines.
The arrestor shall be capable of handling energy from 11 kV lines of length ranging
from 1 km to 20 km.
6.0
FITTINGS & ACCESSORIES
6.1
The surge arrestor shall be complete provided with terminal connectors, disconnector.
6.2
The terminals shall be non-magnetic, corrosion proof, robust and of adequate size
and shall be so located that incoming and outgoing connections are made with
minimum possible bends. The top metal cap and base of surge arrestor shall be
galvanized. The line terminal shall have a built in clamping device which can be
adjusted for both horizontal and vertical take off. It should be suitable for ACSR
conductor.
7.0
TESTS
7.1
Test on Surge Arrestors
The Surge Arrestors offered shall be type tested and shall be subjected to routine and
acceptance tests in accordance with IS : 3070 (Part-3)-1993. In addition, the suitability of the
surge arresters shall also be established for the followings.
(A) Acceptance tests:
i) Measurement of power frequency reference voltage of arrester units.
ii) Lightning impulse residual voltage on arrester units (IEC clause 6.3.2)
(B) Special Acceptance tests:
i) Thermal stability test (IEC clause 7.2.2)
ii) Aging & Energy capability test on blocks (procedure to be mutually agreed)
iii) Watt loss test.
(C) Routine tests:
i) Measurement of reference voltage
ii) Residual voltage test of arrester unit
iii) Sealing test
iv) Verticality check on completely assembled surge arresters as a sample test on each lot.
7.2
The maximum residual voltages corresponding to nominal discharge current of 10

kA for steep current, impulse residual voltage test, lightning impulse protection level
and switching impulse level shall generally conform to Annex-K of IEC-99-4.
7.3
The bidder shall furnish the copies of the type tests and the characteristics curves
between the residual voltage and nominal discharge current of the offered surge
arrestor and power frequency voltage v/s time characteristic of the surge
Page 10 of 14
arrestor subsequent to impulse energy consumption as per clause 6.6 of IS:3070

(Part-3) offered alongwith the bid.
7.4
The surge arrestor housing shall also be type tested and shall be subjected to routine
and acceptance tests in accordance with IS :5621.
7.5
Galvanization Test
All Ferrous parts exposed to atmospheric condition shall have passed the type tests
and be subjected to routine and acceptance tests in accordance with IS:2633 & IS
6745.
7.6
Test on Surge Arrestor Disconnectors

The test shall be performed on surge arrestors which are fitted with arrestor
disconnector or on the disconnector assembly alone if its design is such as to be unaffected by the heating of adjacent parts of the arrestor in its normally installed portion
in accordance with IS:3070 (Part-3).
8.0
8.1
NAME PLATE
The name plate attached to the arrestor shall carry the following information :
- Rated Voltage
- Continuous Operation Voltage
- Normal discharge current
- Pressure relief rated current
- Manufacturers Trade Mark
- Name of Sub-station
- Year of Manufacturer
- Name of the manufacture
- Name of Client-APDP
- Purchase Order Number along with date
9.0 INSPECTION
9.1
All tests and inspection shall be made at the manufacturer's works unless
otherwise specifically agreed upon by the manufacturer and purchaser at the time of
placement of purchase order. The manufacturer shall afford to the inspector
representing the purchaser, all reasonable facilities, without charge to satisfy him
Page 11 of 14
that the material being furnished is in accordance with these specifications. The
purchaser reserves the right to get any component/material being used by the
manufacturer of the Surge Arrestor tested from any recognised test house.
9.2
The inspection by the purchaser or his authorised representative shall not relieve
the bidder of his obligation of furnishing equipment in accordance with the
specification.
10.0

Within 15 days of receipt of the order, the successful tenderer shall furnish to the
purchaser, the following drawings and literature for approval:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
Outline dimensional drawings of Surge Arrestor and all accessories.

Drawings of terminal clamps.
Arrangement of earthing lead.
Minimum air clearance to be maintained of line components to
ground.
Name plate
Instructions manual
Drawing showing details of pressure relief valve
Volt-time characteristics of surge arrestors
Detailed dimensional drawing of porcelain housing/Silicon polymeric
i.e. internal diameter, external diameter, thickness, height, profile,
creepage distance, dry arcing distance etc.
11.0
QUALITY ASSURANCE
11.1
Quality Assurance Programme

a) As per relevant clause of General technical requirement.
11.2
Quality Assurance Document

The contractor shall be required to submit the quality assurance documents before
dispatch of the equipment. The authorised representative reserves the carryout Quality
Audit and Quality Surveillances of the System and procedures of the contractor/his
vendors quality management and control activities.
12.0
TECHNICAL PARTICULARS
12.1
The surge arrestors shall conform to the following standard technical requirements.
The Insulation values shall be enhanced considering the altitude of operation & other
atmospheric conditions.
System Parameters
i)
Nominal system voltage

Page 12 of 14
11kV
ii)
12 kV
iii)
System earthing
iv)
Frequency (Hz)
50
v)
Lightning Impulse withstand

Voltage (kVP)
75
vi)
Power frequency withstand

Voltage (kV rms)
28
vii)
Arrestor duty
Station Class / Line class
-- Connection to system
-- Type of equipment to be protected
Phase to earth
transformers & outgoing lines
Effectively earthed system
12.2 Surge Arrestors

i)
Type
Gapless Metal oxide outdoor
ii)
Arrestor rating (kV rms)
iii)
Continuous Operating voltage

(kV rms)
Standard Nominal Discharge Current
Rating (kA) (8x20 micro impulse shape)
7.65
a) Station Class
b) Line Class
10 KA
5 KA
v)
IP 55
vi)
Steep current at 10 kA
45
vii)
Lightning Impulse at 10 kA
40
viii)
Energy capability corresponding to
iv)
a) Arrestor rating (kj/kV)

b) COV (kj/kV)
ix)
Peak current for high current

impulse operating duty of
a) arrestor classification 10 kA
b) arrestor classification 5kA
12.3 Insulator Housing

i)
4.0
4.9

Page 13 of 14
100 KA
65 KA
ii)
(Wet) (kV rms)
28
Lightning impulse withstand/tests voltage (KVp)
75
12.4 Galvanisation
i)
ii)
iii)
Fabricated Steel Articles

a) 5 mm thick cover
b) Under 5 mm but not less than 2 mm thickness
610 g/m2
460 g/m2
Castings
Grey Iron, malleable iron
610 g/m2
Threaded works other than tubes & tube fittings

a) Under 10 mm dia
b) 10 mm dia & above
300 g/m2
270 g/m2
Page 14 of 14
1.
33/11 kV ONAN 10 MVA POWER TRANSFORMERS
1.0
SCOPE
1.1
This specification covers design, engineering, manufacture, testing/inspection before

dispatch, forwarding, packing, transportation to site of three phase, 50 Hz, 10 MVA
33/11kV Step-down Outdoor ONAN Power Transformers with OFF-load Tap changer complete
with all accessories/fittings and spare parts as specified herein, for use in Power Sub-Station The
rated capacity of the transformer shall be on ONAN basis.
1.2
SPECIFIC TECHNICAL REQUIREMENTS (STANDARD CONDITIONS)
1
2
3
4
5
6
8
9
10
Rated MVA(ONAN rating)

No. of Phases
Type of Installation
Frequency
Cooling medium
Rated voltage
Highest continuous system voltage
a) HV side
b) HV Side
Type of tap changer
10 MVA
3
Outdoor
50 Hz
Insulating Oil
33kV
11kV
36kV
12kV
OFF-load tap changer
+5% to 15% of 2.5% each on HV
winding
On LV Side only
Range of tapings
Neutral terminal to be brought out
8.35% with tolerance limits as per

11
12
13
14
15
b)
16
17
18
19
20
21
1
Impedance on rated MVA base at 75 C

Type of insulation and insulation level
One minute frequency withstand test voltage
(kVrms)
Impulse withstand test voltage (kV peak)
Winding connection a)
LV Side
HV Side
Winding material
Vector group
Type of cooling
Neutral earthing
Winding temperature Indicator
Provision
for
Differential
Protection
IS
Uniform
33 kV/70, 11kV/28
170
75
Delta
Star
Electrolytic Copper
Dyn 11
ONAN
LV neutral shall be solidly earthed
One no
Yes
arrangement
22
Oil Temperature indicator
1.2.1
MAXIMUM TEMPERATURE RISE OVER AN AMBIENT OF 45

a)
One
Temperature rise of top oil

C (Measured by Thermometer)
500
Temperature rise of winding

=
550C
(Measured by resistance)
The rise in temperature of top oil and winding given above shall be reduced as per clause
o
3.2 & 3.3 of IS 2026 (Part-I) in case of increase in Ambient above 50 C and an increase in
altitude above 1000 m.
b)
1.2.2 RATING & SERVICES

a)
Over load capacity
1.2.3
As per IS: 6600
NOISE LEVEL AT RATED VOLTAGE & FREQUENCY

As per NEMA Publication No. TR-1
1.2.4
MARSHALLING BOX
A metal enclosed, weather, vermin and dust proof marshalling box fitted with required glands,
locks, glass door, terminal Board, heater with switch, illumination lamp with switch etc. shall
be provided with each transformer to accommodate temperature indicators, terminal blocks
etc. It shall have a degree of protection of IP 55 as per IS: 2147 (Refer Clause 3.12).
1.2.5
CAPITALIZATION OF LOSSES AND LIQUIDATED DAMAGES

The capitalization of guaranteed losses of the transformer shall be calculated and
considered while evaluating the bids. The guaranteed values of no load losses and load
losses shall be stated in the bid. Liquidated damages will be applied to successful bidder for not
achieving the quoted guaranteed figures. (See clause 6.0).
1.3
2
PERFORMANCE
i)
ii)
iii)
iv)
v)
vi)
vii)
1.4
Transformer shall be capable of withstanding for two seconds without damage to any
external short circuit, with the short circuit MVA available at the terminals.
The maximum flux density in any part of the core and yoke at rated MVA, voltage and
frequency shall be such that the flux density under 12.5% over voltage condition
shall not exceed 1.9 Tesla.
Transformer shall under exceptional circumstances due to sudden disconnection of the
load, be capable of operating at the voltage approximately 25% above normal rated
voltage for a period of not exceeding one minute and 40% above normal for a period of 5
seconds.
The transformer may be operated continuously without danger on any particular tapping
at the rated MVA 12.5% of the voltage corresponding to the tapping.
The thermal ability withstand short circuit shall be demonstrated by calculation.
With combined voltage variation of +12.5% and frequency variation of -5%, the flux
density shall not exceed 1.9 Tesla.
Transformer shall be capable of withstanding thermal and mechanical stress caused
by any symmetrical and asymmetrical faults on any winding.
AUXILIARY POWER SUPPLIES

The following power supplies shall be available at site :
i)
AC 3 phase, 415 volts, 50 Hz. earthed ii)
AC 1 phase, 230 volts, 50 Hz. earthed iii)
30V DC.
1.5 DRAWINGS/DOCUMENTS INCORPORATING THE FOLLOWING PARTICULARS

SHALL BE SUBMITTED WITH THE BID
a)
b)
c)
e)
g)
.6
MISCELLANEOUS
i)
ii)
3
General outline drawing showing shipping dimensions and overall dimensions, net
weights and shipping weights, quality of insulating oil, spacing of wheels in either
direction of motion, location of coolers, marshalling box and tap changers etc.
Height of centre line of HV and LV connectors of transformers from the rail top
level.
Dimensions of the largest part to be transported. d)
GA drawings/details of various types of bushing.
Type test certificates of similar transformers from CPRI/NTH/ERDA. f)
Illustrative & descriptive literature of the Transformer.
Maintenance and Operating Instructions.
Padlocks alongwith duplicate keys as asked for various valves, marshalling box etc.,
shall be supplied by the Supplier, wherever locking arrangement is provided.
Foundation bolts for wheel locking devices of Transformer shall be supplied by the
Supplier.
1.7 SCHEDULES
All Schedules annexed to the specification, shall be duly filled by the bidder separately.
1.8
ALTITUDE FACTOR
If the equipment is to be installed in the hilly area, necessary correction factors as given in the
Indian Standard for oil temperature rise, insulation level etc. shall be applied to the Standard
Technical Parameters given above.
1.9
NAME PLATE
Transformer rating plate shall contain the information as given in clause 15 of IS-2026
(Part-I). The details on rating plate shall be finalised during the detailed engineering.
Further each transformer shall have inscription of Purchaser name-BSPHCL.
2.0 GENERAL TECHNICAL REQUIREMENTS

2.1
CODES & STANDARDS

(i)
The design, material, fabrication, manufacture, inspection, testing before dispatch,
performance of power transformers at site shall comply with all currently applicable
statutory regulations and safety codes in the locality where the equipment will be
installed. The equipment shall also conform to the latest applicable standards and codes
of practice. Nothing in this specification shall be construed to relieve the contractor of
this responsibility.
(ii)
Transformers shall conform to the current applicable standards and codes of
practice as specified in clause No. 2.2.
2.2
The equipment, materials and service covered by this specification shall conform to the
latest applicable provision of the following standards:
IS:5
Colour for ready mixed paints
IS : 325
Three Phase Induction Motors
IS:335
IS:1271
IS:2026 (Part I to IV)

IS:2071
IS:2099
IS:2147
4
:
:
:
:
New insulating oil for transformers,

Switchgears
Classification of insulating materials for
electrical machinery and apparatus in
relation to their stability in services
Power Transformer
Method of high voltage testing
High voltage porcelain bushings
IS:2705
Current Transformers
IS:3202
Code of practice for climate proofing

Of electrical equipment
IS:3347
Dimensions for porcelain Transformer

Bushings
Gas operated relays
Fittings and accessories for power
Transformers
Electric Power Connectors
IS:3637
IS:3639
:
:
IS:5561
IS: 6600/BS: CP1010
Guide for loading of oil immersed

Transformers
IS: 10028
C.B.I.P. Publication
Code of practice for selection, installation

and maintenance of transformers, Part I, II
and III
Manual on Transformers
If the standard is not quoted for any item, it shall be presumed that the latest version of
Indian Standard shall be applicable to that item.
The equipment complying other internationally accepted standards, may also be considered if
they ensure performance superior to the Indian Standards.
2.3
DRAWINGS
a)
The Supplier shall furnish, the following drawings/documents incorporating name of

project and transformer rating.
i)
Detailed overall general arrangement drawing showing front and side

elevations and plan of the transformer and all accessories including radiators and
external features with details of dimensions, spacing of wheels in either direction
of motion, net weights and shipping weights, crane lift for un- tanking, size of
lugs and eyes, bushing lifting dimensions, clearances between HV and LV
terminals and ground, quantity of insulating oil etc.
ii)
Foundation plan showing loading on each wheel and jacking points with respect
to centre line of transformer.
iii)
GA drawings/details of bushing and terminal connectors.
iv)
Name plate drawing with terminal marking and connection diagrams. v)

Wheel locking arrangement drawing.
Transportation dimensions drawings.
vi)
5
vii)
Magnetization characteristic curves of PS class neutral and phase side

current transformers, if applicable.
viii)
Interconnection diagrams.
ix)
Over fluxing withstand time characteristic of transformer.
x)
GA drawing of marshalling box.
xi)
Control scheme/wiring diagram of marshalling box. xii)
Technical leaflets of major components and fittings. xiii)
As
built drawings of schematics, wiring diagram etc.
xiv) Setting of oil temperature indicator, winding temperature indicator. xv)
Completed technical data sheets.
xvi) Details including write-up of tap changing gear.
xvii) H.V conductor bushing.
xviii) Bushing Assembly.
xix)
xxi)
b)
Bi- metallic connector for connection to `Dog ACSR conductor. xx)

GA of LV cable Box.
Radiator type Assembly.
All
drawings/documents,
technical
certificates/results/calculations shall be furnished.
data
sheets
and
test
2.4
Any approval given to the detailed drawings by the purchaser shall not relieve the Supplier of
the responsibility for correctness of the drawing and in the manufacture of the equipment.
The approval given by the purchaser shall be general with over all responsibility
with Supplier .
3.0
GENERAL CONSTRUCTIONAL FEATURES
3.1
All material used shall be of best quality and of the class most suitable for working under the
conditions specified and shall withstand the variations of temperature and atmospheric conditions
without distortion or deterioration or the setting up of undue stresses which may impair
suitability of the various parts for the work which they have to perform.
3.2
Similar parts, particularly removable ones, shall be interchangeable.
3.3
Pipes and pipe fittings, screws, studs, nuts and bolts used for external connections shall be as
per the relevant standards. Steel bolts and nuts exposed to atmosphere shall be
galvanized.
3.4
Nuts, bolts and pins used inside the transformers and tap changer compartments shall be
provided with lock washers or locknuts.
3.5
Exposed parts shall not have pockets where water can collect.
3.6
Internal design of transformer shall ensure that air is not trapped in any location.
3.7
Material in contact with oil shall be such as not to contribute to the formation of acid in oil.
Surface in contact with oil shall not be galvanized or cadmium plated.
3.8
Labels, indelibly marked, shall be provided for all identifiable accessories like relays,
switches, current transformers etc. All label plates shall be of in corrodible material.
3.9
All internal connections and fastenings shall be capable of operating under overloads and
over-excitation, allowed as per specified standards without injury.
3.10
Transformer and accessories shall be designed to facilitate proper operation, inspection,

maintenance and repairs.
3.11
No patching, plugging, shimming or other such means of overcoming defects,

discrepancies or errors will be accepted.
3.12
Schematic Drawing of the wiring, including external cables shall be put under the prospane
sheet on the inside door of the transformer marshalling box.
3.13
Painting
3.13.1
All paints shall be applied in accordance with the paint

recommendations. Particular attention shall be paid to the following :
manufacturers
a) Proper storage to avoid exposure as well as extremes of temperature. b)

Surface preparation prior to painting.
c) Mixing and thinning
d) Application of paints and the recommended limit on time intervals between coats. e)
Shelf life for storage.
3.13.1.1
All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles,
patchiness, brush marks or other defects.
3.13.1.2
All primers shall be well marked into the surface, particularly in areas where painting is
evident, and the first priming coat shall be applied as soon as possible after cleaning. The
paint shall be applied by airless spray according to the manufacturers recommendations.
However, wherever airless spray is not possible, conventional spray be used with prior
approval of purchaser.
3.13.1.3
The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses,
light fittings and similar such items.
3.13.2
Cleaning and Surface Preparation
3.13.2.1
After all machining, forming and welding has been completed, all steel work surfaces
shall be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination
prior to any painting.
3.13.2.2
Steel surfaces shall be prepared by Sand / Shot blast cleaning or Chemical cleaning by
Seven tank process including Phosphating to the appropriate quality.
3.13.2.3
The Pressure and Volume of the compressed air supply for the blast cleaning shall meet the
work requirements and shall be sufficiently free from all water contamination prior to any
painting.
3.13.2.4
Chipping, scraping and steel wire brushing using manual or power driven tools cannot
remove firmly adherent mill-scale and shall only be used where blast cleaning is
impractical.
Protective Coating
As soon as all items have been cleaned and within four hours of the subsequent drying,
they shall be given suitable anticorrosion protection.
Paint Material
3.13.3
3.13.4
Followings are the type of paints that may be suitably used for the items to be painted at
shop and supply of matching paint to site:
i) Heat resistant paint (Hot oil proof) for inside surface.
ii) For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc
chromate followed by 2 coats of Synthetic Enamel paint. The color of the
finishing coats shall be dark admiral gray conforming to No. 632 of IS
5:1961
3.13.5
Painting Procedure
3.13.5.1
Al painting shall be carried out in conformity with both specifications and with the
paint manufacturers recommendations. All paints in any one particular system,
whether shop or site applied, shall originate from one paint manufacturer.
3.13.5.2
Particular attention shall be paid to the manufacturers instructions on storage, mixing,

thinning and pot life. The paint shall only be applied in the manner detailed by the
manufacturer e.g. brush, roller, conventional or airless spray and shall be applied under the
manufacturers recommended conditions. Minimum and maximum time intervals between
coats shall be closely followed.
3.13.5.3
All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours
whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the
surface is dry and while the surface is warm.
3.13.5.4
Where the quality of film is impaired by excess film thickness (wrinkling, mud
cracking or general softness) the supplier shall remove the unsatisfactory paint coatings and
apply another. As a general rule, dry film thickness should not exceed the specified
minimum dry film thickness by more than 25 %. In all instances, where two or more
coats of the same paints are specifies, such coatings may or may not be of contrasting colors.
3.13.5.5
Paint applied to items that are not be painted, shall be removed at suppliers expense,
leaving the surface clean, un-stained and undamaged.
3.13.6
3.13.6.1
Damages Paint Work

Any damage occurring to any part of the painting scheme shall be made good to the
same standard of corrosion protection and appearance as that originally employed.
Any damaged paint work shall be made good as follows:
3.13.6.2
a)
The damaged area, together with an area extending 25 mm around its

boundary, shall be cleaned down to bare metal.
b)
A priming coat shall immediately applied, followed by a full paint finish
equal to that originally applied and extending 50 mm around the perimeter of the
originally damaged.
3.13.6.3
The repainted surface shall present a smooth surface. This shall be obtained by
carefully chamfering the paint edges before & after priming.
3.13.7
Dry Film Thickness
3.13.7.1
To the maximum extent practicable, the coats shall be applied as a continuous film of
uniform thickness and free of pores. Over-spray, skips, runs, sags and drips should be
avoided. The different coats may or may not be of same color.
3.13.7.2
Each coat of paint shall allowed to hardened before the next is applied as per
manufacturers recommendations.
3.13.7.3
Particular attention must be paid to full film thickness at edges.
3.13.7.4
The requirement for the dry film thickness(DFT) of paint and the material to be used
shall be as given below:
S No
Paint Type
Powdered Paint
(a) Thermo
setting powder
Area to be
painted
Inside
outside
No of Coats
01
01
Total Dry Film

thickness(Min)
20 Micron
60 Micron
Liquid paint
a)
Zinc
Chromate(Prim
er
)
b) Syenthetic
Enamel(Fini
4.0 DETAILED DESCRIPTION
sh Coat)
4.1
Tank
c) Hot
4.1.1
The Transformer
tankOil
andpaint
cover
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
10
Out side
Outsid
e
inside
02
45 micron
02
35 micron
01
35 micron
shall be fabricated from high grade low carbon plate steel

of tested quality. The tank and the cover shall be of welded construction. The minimum top
&bottom thickness of tank plate shall be 12 mm and minimum side thick shall be 10 mm.
Tank shall be designed to permit lifting by crane or jacks of the complete transformer
assembly filled with oil. Suitable lugs and bosses shall be provided for this purpose.
All beams, flanges, lifting lugs, braces and permanent parts attached to the tank, shall be
welded and where practicable, they shall be double welded.
The main tank body of the transformer, excluding tap changing compartments and
radiators, shall be capable of withstanding pressure of 760 mm of Hg.
Inspection hole(s) with welded flange(s) and bolted cover(s) shall be provided on the tank
cover. The inspection hole(s) shall be of sufficient size to afford easy access to the lower
ends of the bushings, terminals etc.
All bolted connections to the tank shall be fitted with suitable oil-tight gaskets which shall
give satisfactory service under the operating conditions for complete life of the transformer.
Special attention shall be given to the methods of making the hot oil-tight joints between the
tank and the cover as also between the tank cover and the bushings and all outlets to
ensure that the joint can be remade satisfactorily and with ease, with the help of semiskilled labour. Where compressible gaskets are used, steps shall be provided to prevent overcompression.
4.1.7
Suitable guides shall be provided for positioning the various parts during assembly or
dismantling. Adequate space shall be provided between the cores and windings and the
bottom of the tank for collection of any sediment.
4.2
Tank Cover
The transformer top shall be provided with a detachable tank cover with bolted flanged
gasket joint. Lifting lugs shall be provided for removing the cover. The surface of the cover
shall be suitably sloped so that it does not retain rain water.
4.3
UNDER CARRIAGE
4.3.1
The transformer tank shall be supported on steel structure with detachable plain rollers
completely filled with oil. Suitable channels for movement of roller with transformer shall
be spaced
accordingly. rollers Wheels shall be provided with suitable rollers bearings,
which will resist rust and corrosion and shall be equipped with fittings for lubrication. It
shall be possible to swivel the wheels in two directions, at right angle to or parallel to the
main axis of the transformers.
4.3.2
Jacking pads shall be provided on the transformer. It shall be possible to change the
direction of the wheels through 90 degree when the transformer is lifted on jacks to
permit movement of the transformer both in longitudinal and transverse directions.
4.4
4.4.1
4.4.2
CORE
The core shall be wound or cut or stack type.
Stage level inspection for core construction shall be carried out by the owner.
4.4.3
Each lamination shall be insulated such that it will not deteriorate due to mechanical
pressure and the action of hot transformer oil.
4.4.4
The core shall be constructed either from high grade, non-aging Cold Rolled Grain Oriented
(CRGO) silicon steel laminations conforming to grade M4 or better or of amorphous metal.
The amorphous core shall be of high quality amorphous ribbons having very low loss
formed into wound cores of rectangular shape and clamped together by frames firmly
to prevent vibration or noise. The maximum flux density in any part of the cores and
yoke at normal voltage and frequency shall be such that the flux density with + 12.5 %
voltage variation from rated voltage and frequency variation of -5% shall not exceed 1.9
Tesla. The bidder shall provide saturation curve of the core material proposed to be used.
4.4.5
The bidder should offer the core for inspection and approval by the purchaser during the
manufacturing stage. Bidders call notice for the purpose should be accompanied with
the following documents as applicable as a proof towards use of prime core material:
a) Invoice of the supplier
b) Mills test certificate
c) Packing list d)
Bill of lading
11
e) Bill of entry certificate to customs

Core material shall be directly procured either from the manufacturer or through their
accredited marketing organization of repute and not through any agent.
4.4.6
The laminations shall be free of all burrs and sharp projections. Each sheet shall have an
insulating coating resistant to the action of hot oil.
4.4.7
The insulation structure for the core to bolts and core to clamp plates, shall be such as to
withstand 2000 V DC voltage for one minute.
4.4.8
The completed core and coil shall be so assembled that the axis and the plane of the outer
surface of the core assembly shall not deviate from the vertical plane by more than 25 mm.
4.4.9
All steel sections used for supporting the core shall be thoroughly shot or sand blasted, after
cutting, drilling and welding.
4.4.10
4.4.11
The finally assembled core with all the clamping structures shall be free
deformation and shall not vibrate during operation.
from
The core clamping structure shall be designed to minimize eddy current loss.
4.4.12 The framework and clamping arrangements shall be securely earthed.

4.4.13 The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical
strength.
4.4.14
Oil ducts shall be provided, where necessary, to ensure adequate cooling inside the core.
The welding structure and major insulation shall not obstruct the free flow of oil through such
ducts.
4.4.15 The design of magnetic circuit shall be such as to avoid static discharges, development of short
circuit paths within itself or to the earthed clamping structure and production of flux
component at right angle to the plane of the lamination, which may cause local heating. The
supporting framework of the cores 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.
4.4.16 The construction is to be of `core type. The core shall be provided with lugs suitable for lifting
the complete core and coil assembly. The core and coil assembly shall be so fixed in the tank
that shifting will not occur during transport or short circuits.
4.5
INTERNAL EARTHING
4.5.1
All internal metal parts of the transformer, with the exception of individual laminations, core
bolts and their individual clamping plates shall be earthed.
4.5.2
The top clamping structure shall be connected to the tank by a copper strap. The bottom
12
clamping structure shall be earthed by one or more of the following methods:

a)
c)
By connection through vertical tie-rods to the top structure. b)

By direct metal to metal contact with the tank base.
By a connection to the top structure on the same side of the core as the main earth
connection to the tank.
4.5.3 The magnetic circuit shall be connected to the clamping structure at one point only and this shall
be brought out of the top cover of the transformer tank through a suitably rated insulator. A
disconnecting link shall be provided on transformer tank to facilitate disconnections from
ground for IR measurement purpose.
4.5.4
4.6
Coil clamping rings of metal at earth potential shall be connected to the adjacent core clamping
structure on the same side as the main earth connections.
WINDING
4.6.1
Winding shall be subjected to a shrinking and seasoning process, so that no further

shrinkage occurs during service. Adjustable devices shall be provided for taking up possible
shrinkage in service.
4.6.2
All low voltage windings for use in the circular coil concentric winding shall be wound on a
performed insulating cylinder for mechanical protection of the winding in handling and
placing around the core.
4.6.3
Winding shall not contain sharp bends which might damage the insulation or produce high
dielectric stresses. No strip conductor wound on edge shall have width exceeding six times
the thickness.
4.6.4
Materials used in the insulation and assembly of the windings shall be insoluble, non
catalytic and chemically inactive in the hot transformer oil and shall not soften or the
otherwise affected under the operating conditions.
4.6.5
Varnish application on coil windings may be given only for mechanical protection and not
for improvement in dielectric properties. In no case varnish or other adhesive be used
which will seal the coil and prevent evacuation of air and moisture and impregnation
by oil.
4.6.6
Winding and connections shall be braced to withstand shocks during transport or short
circuit.
4.6.7
Permanent current carrying joints in the windings and leads shall be welded or brazed.
Clamping bolts for current carrying parts inside oil shall be made of oil resistant
material which shall not be affected by acidity in the oil steel bolts, if used, shall be suitably
treated.
4.6.8
Terminals of all windings shall be brought out of the tank through bushings for external
13
connections.
4.6.8.1
4.6.8.2
4.6.8.3
14
The completed core and coil assembly shall be dried in vacuum at not more than
0.5mm of mercury absolute pressure and shall be immediately impregnated with oil
after the drying process to ensure the elimination of air and moisture within the
insulation. Vacuum may be applied in either vacuum over or in the transformer tank.
The winding shall be so designed that all coil assemblies of identical voltage ratings shall
be interchangeable and field repairs to the winding can be made readily without special
equipment. The coils shall have high dielectric strength.
Coils shall be made of continuous smooth high grade electrolytic copper conductor,
shaped and braced to provide for expansion and contraction due to temperature
changes.
4.6.8.4
4.6.8.5
4.6.8.6
4.6.8.7
4.7
4.7.1
4.7.2
4.7.3
4.7.4
Adequate barriers shall be provided between coils and core and between high and low
voltage coil. End turns shall have additional protection against abnormal line disturbances.
The insulation of winding shall be designed to withstand voltage stress arising from
surge in transmission lines due to atmospheric or transient conditions caused by
switching etc.
Tappings shall not be brought out from inside the coil or from intermediate turns and
shall be so arranged as to preserve as far as possible magnetic balance of the
transformer at all voltage ratios.
Magnitude of impulse surges transferred from HV to LV windings by electro magnetic
induction and capacitance coupling shall be limited to B.I.L. of LV winding.
INSULATING OIL
The insulating oil for the transformers shall be of LHV grade, generally conforming to
IS: 335. No inhibitors shall be used in the oil.
The quantity of oil required for the first filling of the transformer and its full
specification shall be stated in the bid. The bidder shall quote the price of transformer
complete with first filling of oil plus 10% extra. However, the rate of transformer oil in
Rupee per litre shall be quoted separately also. The transformer oil shall be supplied in nonreturnable drums.
The design and materials used in the construction of the transformer shall be such as to
reduce the risk of the development of acidity in the oil.
The Supplier
specifications.
shall warrant that oil furnished is in accordance with the following
S.No
1
Characteristic
Appearance
2
3
Density at 200C
Kinematic Viscosity at
27 deg.C Max
Interfacial tension at 27
deg. C Min.
Flash Point
Pour Point Max.
Neutralisation
Value
(Total Acidity) Max.
Electric
strength
BreakDown
(voltage)
Min.
Dielectric dissipation factor
tan delta at 900 C
4
5
6
7
8
15
Requirement
The oil shall be clear &
suspended
matter
or
Sediment
0.89g/cm3 Max.
27 CST
IS: 1448
IS: 1448
0.03N/m
IS: 6104
136 deg.C
-6 deg.C
0.03 mg KOH/gm
IS: 1448
IS: 1448
IS: 335
Less than 72.5 kV
IS: 6792
0.03
IS:6262
Max
Method of Test
A representative sample of oil
shall be examined in a 100
mm thick layer at ambient temp.
10
Min.
specific
resistance(resistivity)
at
90 deg.C
11
12
Oxidation stability
Neutralisation value after
oxidation
Total
sludge
after
oxidation
13
14
15
4.8
Presence
Inhibitor
of
oxidation
Water content Max:
12
35 x 10
ohm cm
(min.)
IS: 6103
0.40 mg KOH/g
0.10% by weight max.
The oil shall not contain

anti-oxidant
Additives
Less than 25 ppm
IS:335
IS: 2362
VALVES
i)
Valves shall be of forged carbon steel upto 50 mm size and of gun metal or of cast
iron bodies with gun metal fittings for sizes above 50 mm. They shall be of full way
type with screwed ends and shall be opened by turning counter clockwise when
facing the hand wheel. There shall be no oil leakage when the valves are in closed
position.
ii)
Each valve shall be provided with an indicator to show the open and closed
positions and shall be provided with facility for padlocking in either open or closed
position. All screwed valves shall be furnished with pipe plugs for protection. Padlocks
with duplicate keys shall be supplied alongwith the valves.
iii)
All valves except screwed valves shall be provided with flanges having
machined
faced drilled to suit the applicable requirements. Oil tight blanking plates shall be
provided for each connection for use when any radiator is detached and for all
valves opening to atmosphere. If any special radiator valve tools are required, the
Supplier shall supply the same.
iv)
Each transformer shall be provided with following valves on the tank:

a)
b)
c)
d)
e)
Drain valve so located as to completely drain the tank.

Two filter valves on diagonally opposite corners, of 50 mm size.
Oil sampling valves not less than 8 mm at top and bottom of main
tank.
One 15 mm air release plug.
Valves between radiators and tank.
Drain and filter valves shall be suitable for applying vacuum as specified in the
16
specifications.
4.9
ACCESSORIES
4.9.1 Bushing
i)
All porcelain used in bushings shall be homogeneous, non-porous, uniformly

glazed to brown colour and free from blisters, burns and other defects.
ii)
Stress due to expansion and contraction in any part of the bushing shall not lead to
deterioration.
iii)
Bushing shall be designed and tested to comply with the applicable standards.
iv)
Liquid/oil-filled bushings shall be equipped with liquid level indicators and means for
sampling and draining the liquid. The angle of inclination to vertical shall not exceed 30
degree.
v)
Oil in oil-filled bushings shall meet the requirements of the transformer oil
standards.
vi)
Bushing rated for 400A and above shall have non-ferrous flanges and hardware. vii)
Fittings made of steel or malleable iron shall be galvanized.
Bushing shall be so located on the transformers that full flashover strength will be
utilized. Minimum clearances as required for the BIL shall be realized between live parts
and live parts to earthed structures.
viii)
ix)
All applicable routine and type tests certificates of the bushings shall be furnished for
approval.
x)
Bushing shall be supplied with bi-metallic/terminal connector/clamp/washers

suitable for fixing to bushing terminal and the PURCHASERS specified
conductors. The connector/clamp shall be rated to carry the bushing rated current without
exceeding a temperature rise of 550 C over an ambient of 500 C. The
connector/clamp shall be designed to be corona free at the maximum rated line to ground
voltage.
xi)
Bushing of identical voltage rating shall be interchangeable.
xii)
The insulation class of high voltage neutral bushing shall be properly coordinated with
the insulation class of the neutral of the low voltage winding.
xiii)
Each bushing shall be so coordinated with the transformer insulation that all
flashover will occur outside the tank.
4.9.2 Protection & Measuring Devices i)

Oil Conservator Tank
17
(ii)
(a)
The conservator tank shall have adequate capacity between highest and lowest
visible levels to meet the requirement of expansion of the total cold oil volume in the
transformer and cooling equipment.
(b)
The conservator tank shall be bolted into position so that it can be removed for cleaning
purposes.
(c)
The conservator shall be fitted with magnetic oil level gauge with low level
electrically insulated alarm contact.
(d)
Plain conservator fitted with silica gel breather.
Pressure Relief Device

The pressure relief device provided shall be of sufficient size for rapid release of any
pressure that may be generated in the tank and which may result in damage of the
equipment. The device shall operate at a static pressure of less than the hydraulic test pressure
of transformer tank. It shall be mounted direct on the tank. A pair of electrically insulated
contacts shall be provided for alarm and tripping.
(iii)
Buchholz Relay
A double float type Buchholz relay shall be provided. Any gas evolved in the transformer shall
collect in this relay. The relay shall be provided with a test cock suitable for a flexible pipe
connection for checking its operation. A copper tube shall be connected from the gas collector
to a valve located about 1200 mm above ground level to facilitate sampling with the
transformer in service. The device shall be provided with two electrically independent potential
free contacts, one for alarm on gas accumulation and the other for tripping on sudden rise of
pressure.
(iv)
Temperature Indicator
(a)
Oil Temperature Indicator (OTI)

The transformers shall be provided with a 150 mm dial type thermometer for top oil
temperature indication. The thermometer shall have adjustable, electrically independent
potential free alarm and trip contacts. Maximum reading pointer and resetting device
shall be mounted in the local control panel. A temperature sensing element suitably
located in a pocket on top oil shall be furnished. This shall be connected to the OTI by means
of capillary tubing. Accuracy class of OTI shall be + 1% or better. One NO electrical
contact capable of operating at 5 A ac at 230 Volt supply.
(b)
Winding Temperature Indicator (WTI)

A device for measuring the hot spot temperature of the winding shall be provided. It
shall comprise the following.
18
i)
ii)
iii)
iv)
v)
vi)
19
Temperature sensing element

Image Coil.
Auxiliary CTS, if required to match the image coil, shall be furnished and
mounted in the local control panel.
150 mm dial local indicating instrument with maximum reading pointer
mounted in local panel and with adjustable electrically independent ungrounded
contacts, besides that required for control of cooling equipment, one for high
winding temperature alarm and one for trip.
Calibration device.
Two number NO electrical contact each capable of opertaing at 5 A ac at 230
Volt supply.
4.9.3
Oil Preservation Equipment
4.9.3.1
Oil Sealing
The oil preservation shall be diaphragm type oil sealing in conservator to prevent
oxidation and contamination of oil due to contact with atmospheric moisture.
The conservator shall be fitted with a dehydrating filter breather. It shall be so
designed that,
i)
ii)
iii)
iv)
4.10
20
Passage of air is through a dust filter & Silica gel

Silica gel is isolated from atmosphere by an oil seal.
Moisture absorption indicated by a change in colour of the crystals of the
silica gel can be easily observed from a distance.
Breather is mounted not more than 1400 mm above rail top level.
MARSHALLING BOX
i)
Sheet steel, weather, vermin and dust proof marshalling box fitted with required
glands, locks, glass door, terminal Board, heater with switch, illumination lamp
with switch, water-tight hinged and padlocked door of a suitable construction shall be
provided with each transformer to accommodate temperature indicators, terminal blocks
etc. The box shall have slopping roof and the interior and exterior painting shall be in
accordance with the specification. Padlock alongwith duplicate keys shall be
supplied for marshalling box. The degree of protection shall be IP-55.
ii)
The schematic diagram of the circuitry inside the marshalling box be prepared and fixed
inside the door under a prospone sheet.
iii)
The marshalling box shall accommodate the following equipment:

a)
Temperature indicators
b)
Space for accommodating Control & Protection equipment in future for
the cooling fan (for ONAF type cooling, may be provided in
future))
c)
Terminal blocks and gland plates for incoming and outgoing cables. All
the above equipment except (c) shall be mounted on panels and back of panel wiring
shall be used for inter-connection. The temperature indicators shall be so mounted
that the dials are not more than 1600 mm from the ground level and the door (s) of
the compartment(s) shall be provided with glazed window of adequate size. The
transformer shall be erected on a plinth which shall be 2.5 feet above ground level.
iii)
To prevent internal condensation, a metal clad heater with thermostat shall be

provided. The heater shall be controlled by a MCB of suitable rating mounted in the
box. The ventilation louvers, suitably padded with felt, shall also be provided. The
louvers shall be provided with suitable felt pads to prevent ingress of dust.
iv)
All incoming cables shall enter the kiosk from the bottom and the gland plate shall not
v)
4.11
be less than 450 mm from the base of the box. The gland plate and associated
compartment shall be sealed in suitable manner to prevent the ingress of moisture from
the cable trench.
The control connection, wiring etc. shall be as per Clause 3.15 of this specification.
OFF- LOAD TAP CHANGER

The tap changing switch shall be located in convenient position so that it can be operated
locally from ground level. The switch handle will be provided with locking arrangement along
with tap position indication thus enabling the switch to be locked in position. Each transformer
shall be provided with voltage control equipment of the tap changing type of varying the
effective transformation ratio while the transformer is off load and without producing phase
displacement.
b) The tap which are to be provided on HV winding shall vary from plus 5% to minus 15%
in equal step of 2.5% each.
c) The position of off load tap changer chamber shuld be designed to ensure that the oil of tap
changer chamber does not mix-up with oil of main tank. Easy accessibility to the contact
of the tap changer through inspection opening for repair/replacement should be available.
d) Suitable oil level gauge shall be provided in the tap changer compartment.
4.12
FITTINGS
The following fittings shall be provided on the transformers:
i)
ii)
iii)
iv)
v)
21
Conservator with isolating valves, oil filling hole with cap and drain valve.
The conservator vessel shall be filled with constant oil pressure diaphragm oil
sealing system
Magnetic type oil level gauge (150 mm dia.) with low oil level alarm
contacts.
Prismatic/toughened glass oil level gauge.
Silica gel breather with oil seal and connecting pipe complete with first fill of
activated silica gel or Alumina mounted at a level of 1300 mm above ground
level.
A double float type Buchholz relay with isolating valve, bleeding pipe and a
testing cock, the test cock shall be suitable for a flexible (pipe connection for
checking its operation). A 5 mm dia. Copper pipe shall be connected from
the relay test cock to a valve located at a suitable height above ground
level to facilitate sampling of gas with the transformer in service.
Interconnection between gas collection box and relay shall also be
provided. The device shall be provided with two electrically independent
ungrounded contacts, one for alarm on gas accumulation and the other for
tripping on sudden oil surge. These contacts shall be wired upto
transformer marshalling box. The relay shall be provided with shut off
valve on the conservator side as well as on the tank side.
vi)
vii)
viii)
ix)
Pressure relief devices (including pressure relief valve) and necessary air
equalizer connection between this and the conservator with necessary alarm
and trip contacts.
Air release plugs in the top cover.
Inspection cover, access holes with bolted covers for access to inner ends of
bushing, etc.
Winding temperature (hot spot) indicating device for local mounting
complete in all respects. Winding temperature indicator shall have three sets of
contacts to operate at different settings :
a) To provide winding temperature `high alarm

b) To provide temperature too high `trip
x)
Dial thermometer with pocket for oil temperature indicator with one set of
alarm and one set of trip contacts and maximum reading pointer.
xi)
Lifting eyes or lugs for the top cover, core and coils and for the complete
transformer.
xii)
Jacking pads.
xiii)
Haulage lugs.
xiv)
Protected type mercury/alcohol in glass thermometer and a pocket to house the
same.
xv)
Top and bottom filter valves on diagonally opposite ends with pad locking
arrangement on both valves.
xvi)
Top and bottom sampling valves.
xvii)
Drain valve with pad locking arrangement.
xviii) Rating and connection diagram plate.
xix)
Two numbers tank earthing terminals with associated nuts and bolts for
connections to purchasers grounding strip.
xx)
Bi-directional flagged rollers with locking and bolting device.
xxi)
Marshalling Box (MB)
xxii)
Shut off valve on both sides of flexible pipe connections between radiator
bank and transformer tank.
xxiii) Cooling Accessories :
a)
Requisite number of radiators provided with :
- One shut off valve on top
- One shut off valve at bottom
- Air release device on top
- Drain and sampling device at bottom
- Lifting lugs.
b)
Air release device and oil drain plug on oil pipe connectors. xxiv)
Terminal marking plates for Current Transformer and Main Transformer.
xxv) Oil Preservation Equipment
xxvi) LA alongwith the fittings.
xxvii) Oil Temperature indicator.
xxviii) Bimetallic connector
Note:
22
(i)
The fittings listed above are indicative and any other fittings which are generally
required for satisfactory operation of the transformer are deemed to be included in the
quoted price of the transformer.

The contacts of various devices required for alarm and trip shall be potential free and
shall be adequately rated for continuous, making and breaking current duties as
specified.
4.13 RADIO INTERFERENCE AND NOISE LEVEL
Transformers shall be designed with particular care to suppress at least the third and fifth
harmonic voltages so as to minimise interference with communication circuits.
Transformer noise level, when energised at normal voltage and frequency shall be as per NEMA
stipulations.
(ii)
5.0
INSPECTION AND TESTING

(i)
The Supplier shall carry out a comprehensive inspection and testing programme
during manufacture of the transformer. An indicative of inspection is given under
clause No. 4.1. This is, however, not intended to form a comprehensive programme
(ii)
as it is Suppliers responsibility to draw up and carry out such a programme duly

approved by the purchaser.
The Supplier shall carry out type tests and routine tests on the transformers.
(iii)
Only one no of transformer will be subjected to type test at supplier cost from
CPRI/NTH/ERDA.
(iv)
The pre-shipment checks shall also be carried out by the Supplier. (v)
The requirements on site tests are as listed in the specifications.
(vi) Certified test report and oscillograms shall be furnished to the Purchaser/Consultants
for evaluation as per the schedule of distribution of documents. The Supplier
shall also evaluate the test results and rectify the defects in the equipment based on his
and the Purchasers evaluations of the tests without any extra charges to the Purchaser.
Manufacturers Test Certificates in respect of all associated auxiliary and ancillary
equipment shall be furnished.
(vii) The bidder shall state in his proposal the testing facilities available at his works. In case
full testing facilities are not available, the bidder shall state the method proposed
to be adopted so as to ascertain the transformer characteristics corresponding to full
capacity.
5.1
INSPECTION
i)
Tank and Conservator

a)
Inspection of major weld.
b)
Crack detection of major strength weld seams by dye penetration test.
c)
ii)
Check correct dimensions between wheels, demonstrate turning of wheels,

o
through 90 and further dimensional check.
Leakage test of the conservator.
Core
a)
23
Sample testing of core materials for checking specific loss properties,
d)
magnetization characteristics and thickness.

Check on the quality of varnish if used on the stampings. c)
Check on the amount of burrs.
Visual and dimensional check during assembly stage.
e)
Check on completed core for measurement of iron loss.
b)
f)
Visual and dimensional checks for straightness and roundness of core,

thickness of limbs and suitability of clamps.
g)
High voltage DC test (2 kV for one minute) between core and clamps. iii)
Insulating Material
a)
Sample check for physical properties of materials. b)
Check for dielectric strength
c)
Check for the reaction of hot oil on insulating materials.
iv)
Winding
a)
Sample check on winding conductor for mechanical and electrical

conductivity.
b)
Visual and dimensional checks on conductor for scratches, dent mark etc.c)
Sample check on insulating paper for PH value, electric strength. d)
Check
for the bonding of the insulating paper with conductor.
e)
Check for the reaction of hot oil and insulating paper.
f)
Check and ensure that physical condition of all materials taken for windings is
satisfactory and free of dust.
g)
Check for absence of short circuit between parallel strands.
v)
Checks Before Drying Process

a)
b)
Check condition of insulation on the conductor and between the windings.

Check insulation distance between high voltage connections, between high
voltage connection cables and earth and other live parts.
c)
vi)
vii)
Check insulating distances between low voltage connections and earth and
other parts.
d)
Insulating test for core earthing.
Checks During Drying Process
a)
Measurement and recording of temperature and drying time during vacuum
treatment.
Check for completeness of drying.
Assembled Transformer
a)
24
Check completed transformer against approved outline drawing, provision for

all fittings, finish level etc.
viii)
(ix)
b)
Jacking test on the assembled Transformer.
Oil
All standard test in accordance with IS: 335 shall be carried out on Transformer oil
sample before filling in the transformer.
Test Reports for bought out items
The Supplier shall submit the test reports for all bought out/sub Supplier items for
approval.
a)
Buchholz relay
b)
Sudden Pressure rise relay in OLTC
c)
Sudden Pressure rise relay on Main Tank
d)
Winding temperature indicators (for TX capacity >10 MVA)
e)
Oil temperature indicators
f)
Bushings
g)
Bushing current transformers in neutral (if provided)
h)
Marshalling box
i)
Any other item required to complete the works.
j)
Porcelain, bushings, bushing current transformers, wherever provided,
winding coolers, control devices, insulating oil and other associated
equipment shall be tested by the contractor in accordance with relevant IS. If
such equipment is purchased by the Supplier on a sub-contract, he shall have
them tested to comply with these requirements.
5.2.
25
FACTORY TESTS
i)
All standards routine tests in accordance IS: 2026 with dielectric tests
corresponding as per latest amendments to IS: 2026 shall be carried out.
ii)
All auxiliary equipment shall be tested as per the relevant IS. Test certificates shall be
submitted for bought out items.
iii)
High voltage withstand test shall be performed on auxiliary equipment and wiring
after complete assembly.
iv)
Following additional routine tests shall also be carried out on each transformer:
Magnetic Circuit Test
Each core shall be tested for 1 minute at 2000 Volt DC.
Oil leakage test on transformer
5.2.1
Routine Tests
Transformer routine tests shall include tests stated in latest issue of IS: 2026
(Part-I). These tests shall also include but shall not be limited to the following:
(i)
Measurement of winding DC resistance.
(ii)
(iii)
(iv)
Voltage ratio on each tapping and check of voltage vector relationship.

Impedance voltage at all tappings.
Magnetic circuit test After routine tests, each core shall be tested for 1 minute at 2 kV (DC) between all bolts,
side plates and structural steel work. Immediately prior to the dispatch of the transformer,
the magnetic circuit shall be pressure tested for 1 minute at 2 kV A.C. between the core
and the earth.
(v)
Load losses.
(vi)
(vii)
No load losses and no load current.

Absorption index i.e. insulation resistance for 15 seconds and 60 seconds
(R60/R15) and polarization index i.e. Insulation Resistance for 10 minutes and one
minute (R10 mt/R1 mt).
Induced over voltage withstand test.
Separate source voltage withstand test (applied potential).
Tan delta measurement and capacitance of each winding to earth (with all other
windings earthed) & between all windings connected together to earth.
Measurement of Zero sequence impedance.
(viii)
(ix)
(x)
(xi)
All routine & type tests should be done free of cost. If it is to be done on the cost basis, the same
may be indicated in the schedule of prices and delivery and this will be taken into account for
evaluation of prices.
Six (6) sets of certified test reports and oscillographs shall be submitted for evaluation prior to
dispatch of the equipment. The Supplier shall also evaluate the test results and shall correct
any defect indicated by his and Purchasers evaluation of the tests without charge to the
Purchaser.
5.3
TANK TESTS
a)
Oil leakage Test:

The tank and oil filled compartments shall be tested for oil tightness completely
filled with air or oil of viscosity not greater than that of insulating oil conforming to IS:
335 at the ambient temperature and applying a pressure equal to the normal pressure plus
35 KN/m2 measured at the base of the tank. The pressure shall be maintained for a
b)
26
period of not less than 12 hours for oil and one hour for air and during that time no leak
shall occur.
Pressure Test
Where required by the Purchaser, one transformer tank of each size together with its
radiator, conservator vessel and other fittings shall be subjected to a pressure
corresponding to twice the normal head of oil or to the normal pressure plus 35
KN/m2 whichever is lower, measured at the base of the tank and maintained for one
hour.
Vacuum Test
One transformer tank of each size shall be subjected to the vacuum pressure of 760 mm
of mercury. The tanks designed for full vacuum shall be tested at an internal pressure of
3.33 KN/m2 (25 mm of mercury) for one hour. The permanent deflection of flat
plates after the vacuum has been released shall not exceed the value specified in
C.B.I.P. Manual on Transformers (Revised 1999) without affecting the performance
of the transformer.
5.4
5.5
PRE-SHIPMENT CHECK AT MANUFACTURERS WORKS

i)
Check for proper packing and preservation of accessories like radiators,

bushings, explosions vent, dehydrating breather, rollers, buchholz relay, control
cubicle connecting pipes & conservator etc.
ii)
Check for proper provision of bracing to arrest the movement of core and
winding assembly inside the tank.
iii)
Gas tightness test to conform tightness.
PERFORMANCE
The performance of the transformer shall be measured on the following aspects.
27
i)
The transformer shall be capable of being operated without danger on any

tapping at the rated KVA with voltage variation of + 10% corresponding to the
voltage of the tapping.
ii)
The maximum flux density in any part of the cores and yokes at normal
voltage and frequency shall be such that the flux density on any tap position
with +12.5% voltage variations and 5% frequency variations shall not
exceed 1.9 wb/m2.
iii)
Radio interference and Noise Level
iv)
The transformer shall be designed with particular attention to the

suppression of third and fifth harmonics so as to minimise interference with
communication circuits.
5.6
FAULT CONDITIONS
(a)
5.7
The transformer shall be capable of withstanding for two (2) seconds

without damages any external short circuit to earth.
(b)
Transformer shall be capable of withstanding thermal and
mechanical stresses conveyed by symmetrical or asymmetrical faults on any
winding.
( c)
Transformers shall accept, without injurious heating, combined voltage and
frequency fluctuation which produce the 125% over fluxing condition for
one minute.
TEST WAIVAL, PROCEDURE AND COSTS
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
The purchaser, at his option, may waive impulse tests provided type test
reports of impulse tests carried out on essentially identical units in their
factory in India are furnished by the manufacturer.
No load losses and exciting current shall be measured at rated voltage, rated
frequency and at 90% and 110% of rated voltage, both before and after the
lightning impulse tests.
The method of test loading shall be described in the test report for
determination of both average and hottest spot temperature. Where the
winding temperature equipment is specified, data shall also be included for
calibration of hottest spot temperature indicator.
Resistance of each winding of each phase shall be measured at principal and at
all the taps and corrected to 750C.
Impedance voltage shall be measured at principal and at all taps,
No load Loss Measurement at 415 Volt.
Certified test report and oscillograms shall be furnished to the
Purchaser/Consultants for evaluation as per the schedule of distribution of
documents. The Supplier shall also evaluate the test results and rectify the defects
in the equipment based on his and the Purchasers evaluations of the tests without
any extra charges to the Purchaser. Manufacturers Test Certificates in respect
of all associated auxiliary and ancillary equipment shall be furnished.
(viii)
5.8
The bidder shall state in his proposal the testing facilities available at his works.
In case full testing facilities are not available, the bidder shall state the method
proposed to be adopted so as to ascertain the transformer characteristics
corresponding to full capacity testing.
WITNESSING OF TESTS AND EXCESSIVE LOSSES
i)
ii)
The Purchaser and/or his representative reserve the right to witness any or all tests, or to
accord waival at its sole discretion.
The Purchaser reserves the right to reject the Transformer if losses exceed the
declared losses beyond tolerance limits as per IS or if temperature rise of oil and winding
exceed the values specified.
5.9 CAPITALISATION OF LOSSES AND LIQUIDATED DAMAGES FOR
28
EXCESSIVE LOSSES
5.9.1
LOSSES:
Transformers with lower losses shall be preferred. The bidder shall indicate the values of load
and no load losses of the transformer in his bid. The no load loss in Killowatts and the load
losses in Kilowatts at rated full load current and frequency at 75 Deg.C. shall be guaranteed to 8
KW and 50 KW respectively with no plus tolerance. The above losses are maximum allowable.
5.9.2 CAPITALISATION OF LOSSES
For total cost evaluation, the capitalized cost of losses will be taken into account as per the
following:
Capitalised cost of Transformer = Initial cost of Transformer + Rs.A x WI + Rs. B x

Wc
Where :
WI = Iron loss in KW & A = 137408 Rupees for iron loss

WC = Copper loss in KW & B = 41222 Rupees for copper loss
The no load loss in KW at the rated voltage and frequency and the load loss in
KW at rated voltage, rated frequency, rated output and at 75 degree centigrade shall be quoted
and these figures shall be guaranteed.
i) Note: Liquidated damages for non-performance for transformers shall be recovered from
the contractor in case he is unable to achieve the quoted guaranteed figures at the above rate.
This shall supercede any other provision on this matter specified elsewhere in the
specification.
5.9.3
REJECTION
The Purchaser may reject any transformer if during tests or service any of the following
conditions arise:
i)
No load loss exceeds the guaranteed value.
ii)
Load loss exceeds the guaranteed value.
iii)
Impedance value exceeds the guaranteed value by + 10% or more.
iv)
v)
vi)
vii)
viii)
29
The difference in impedance values of any two phases during single phase short
circuit impedance test exceeds 2% of the average value guaranteed by the vendor.
Oil or winding temperature rise exceeds the specified value.
Transformer fails on impulse test.
Transformer fails on power frequency voltage withstand test.
Transformer is proved to have been manufactured not in accordance with the agreed
specification.
6.0
SPARE PARTS
In case the manufacturer goes out of production of spare parts, then he shall make available the
drawings of spare parts and specification of materials at no extra cost to the Purchaser to
fabricate or procure spare parts from other sources.
6.1
INSTRUCTIONS MANUAL
Eight sets of the instruction manuals shall be supplied at least four (4) weeks before the
actual dispatch of equipment. The manuals shall be in bound volumes and shall contain all the
drawings and information required for erection, operation and maintenance of the
transformer. The manuals shall include amongst others, the following particulars :
a)
Marked erection prints identifying the components, parts of the transformer as
dispatched with assembly drawings.
b)
Detailed dimensions, assembly and description of all auxiliaries.
c)
6.2
7.0
Detailed views of the core and winding assembly, winding connections and tapings, tap
changer construction etc. These drawings are required for carrying out
overhauling operation at site.
d)
Salient technical particulars of the transformer.
e)
Copies of all final approved drawings.
f)
Detailed O&M instructions with periodical check lists and Performa etc.
COMPLETENESS OF EQUIPMENT
i)
All fittings and accessories, which may not be specifically mentioned in the
specification but which are necessary for the satisfactory operation of the plant,
shall be deemed to be included in the specification and shall be furnished by the
contractor without extra charges. The equipment shall be complete in all details,
whether such details are mentioned in the specification or not, without any financial
liability to the Purchaser under any circumstances.
ii)
All deviations from this specification shall be separately listed under the requisite
schedules, in the absence of which it will be presumed that all the provisions of the
specification are complied with by the bidder.
TOOLS & TACKLES

All the necessary tools and tackles required for normal operation & maintenance shall be
supplied by the Supplier
30
TECHNICAL SPECIFICATION OF 11 kV INSULATORS & INSULATOR

FITTINGS
1.0
Scope
This Specification covers design, engineering, manufacture, assembly,
stage testing, inspection & testing before supply and delivery at site the
Pin insulators and disc insulators alongwith fittings for 11 kV lines.
2.0
Standards
The material shall conform in all respect to the relevant Indian standards
with latest amendments indicated below.
Indian Standards
Title
ISS: 731/1976
Porcelain insulators for overhead power

lines with a nominal voltage greater than
1000 V
ISS: 2486 (Part-1 to Part-4)
Metal fittings of insulators for overhead

power lines with nominal voltage greater
than 1000 V
In the event of the supply of insulators & fittings conforming to standards

other than specified, the Bidder shall confirm in his bid that these
standards are equivalent to those specified. In case of award, salient
features of comparison between the standards proposed by the Contractor
and those specified in this document will be provided by the Contractor to
establish their equivalence.
3.0
Qualifying Requirements for Insulator Manufacturer:

The contractor shall procure the insulators from the manufacturers who
have supplied 80% of BPS quantity for each type of insulators in last 5
years from the date of opening of bids.
4.0
Technical Description
4.1
General Requirements for 11 kV Pin & Disc Insulator
4.1.1
All insulators for 11 kV shall conform to Type B of latest version of IS:

731. Pin type insulator shall be as per REC specification no. 3/1993 (fig.
1) and the pin shall be as fig 3 of the same REC specification.
Page 1 of 16
4.1.2
Pin insulator shall consist of a single piece of porcelain, intended to be

mounted rigidly on a supporting structure by a pin, which passes up inside
the insulator. The pin type insulator shall have a top groove and shall be
threaded to take mild steel pins. The profile of threads shall be as per IS:
144
4.1.2.1
The strain insulators shall be of Ball & Socket (B&S) type or Tongue &
Clevis (T&C) type with details as per per REC specification no. 3/1993
(fig. 2). The strain insulator assembly shall be as per fig. 5 for T&C type
and as per fig. 6 for B&S type insulators. The strain clamps shall be as per
fig. 7 for B&S type and fig. 8 for T&C type insulators.
5.0
5.1
Insulator Materials
Porcelain
The porcelain used in the manufacture of shells shall be sound, free from
defects thoroughly vitrified and smoothly glazed. It should not engage
directly with hard metal.
5.2
Glaze
The finished porcelain shall be glazed in brown colour. The glaze shall
cover all exposed parts of the insulator and shall have a good lusture,
smooth surface and good performance under the extreme weather
conditions of a tropical climate. It shall not crack or chip by ageing
under the normal service conditions. The glaze shall have the same coefficient of expansion as of the porcelain body throughout the working
temperature range. The insulator shall be so designed that the stresses
due to expansion and contraction in any part of the insulator shall not
lead to deterioration.
5.3
Cement
Cement used in the manufacture of the insulator shall not cause fracture
by expansion or loosening by contraction. The cement shall not give rise
to chemical reaction with metal fittings and its thickness shall be as
small and uniform as possible. Proper care shall be taken to correctly
centre and locate individual parts during cementing.
6.0
Creepage Distance
The insulators shall be used for Normal and moderately polluted
atmosphere. The minimum creepage distance for both pin & strain type
insulator shall be 230 mm.
Page 2 of 16
7.0
Insulators Fittings
7.1
Pins:
7.1.1
The pins shall be of single piece obtained by the process of forging.

They will not be made by any process using more than one piece of
material. The pin will have good finish, free from flaws and other
defects. The finish of the collar shall be such that a sharp angle between
the collar & the shank is avoided. All ferrous pins, nuts and washers,
except those made of stainless steel, shall be galvanized. The threads
of nuts, and taped holes, when cut after galvanization shall be well oiled
or greased.
7.1.2
Test: The pins shall be tested as per IS 2486 (part-I): 1993

i)
ii)
iii)
Type Test:
a)
Checking of Threads on Heads
b)
Galvanizing Test
c)
Visual Examination
d)
Mechanical Test
Acceptance Tests:
a)
Checking of Threads on Heads
b)
Galvanizing Test
c)
Mechanical Test
Routine Test:
a)
7.2
Visual Examination
Helically Formed Pin Insulator Ties

These shall be used to hold conductor on the pin insulator and shall be made
of aluminium alloy or aluminized steel or aluminium clad steel wires and
shall conform to IS 12048:1987.
7.2.1
The ties shall be suitable for the AAAC equivalent to ACSR Rabbit & Weasel
conductors.
Page 3 of 16
7.2.2
Elastometer pad for insulator shall be used with the ties to avoid
abrasion of the conductor coming
7.2.3
Test: Ties shall be tested as per IS 12048 : 1987.
7.3
Helically Formed Conductor Dead End Grips
7.3.1
7.3.2
7.4
7.4.1
Fittings for Strain Insulators of Tongue & Clevis Type: This will consists
of:
a)
Cross arm strap conforming to IS: 2486 (part II): 1989
b)
Aluminium alloy die cast thimble clevis for attaching to tongue of

strain insulator on one end and for accommodating the loop of the
helically formed dead end fitting at the other end in its smooth
internal contour. The thimble shall be suitable for AAAC equivalent
to ACSR weasel & rabbit conductors. The thimble clevis shall be
attached to the insulator by a steel cutter pin used with a non ferrous
split pin of brass or stainless steel. The thimble shall have clevis
dimensions as per IS 2486 (part II): 1989.
c)
Helically formed dead end grip having pre fabricated loop to fit into
the grooved contour of the thimble on one end and for application
over the conductor at the other end. The formed fitting shall conform
to the requirement of IS 12048: 1987.
Nominal dimensions of Tongue & Clevis type insulator fittings shall be as

per dwg. referred in cl. 4.0.
Fittings for Strain Insulators of ball & socket Type
The fittings shall consist of :
a)
cross arm strap conforming to IS 2486 (part-II): 1989
b)
Forged steel ball eye for attaching the socket end of the strain
insulator to the cross arm strap. Forging shall be made of steel as per
IS 2004:1978
c)
Aluminium alloy thimble socket made out of permanent cast, high

strength aluminium alloy for attaching to the strain insulator on one
end and for accommodating the top of helically formed dead end
fittings at the other end in its smooth internal contour. The thimble
socket shall be attached to the strain insulator with the help of
locking pin as per the dimensions given in IS 2486 (part II) : 1989.
Page 4 of 16
d)
7.4.2
Helically formed dead end grip as described above in clause 6.3.1 (

c)
Nominal dimensions of Ball & Socket type insulator fittings shall be as per
dwg. referred in cl. 4.0.
7.5
The helically formed fitting for strain insulators shall be tested as per IS
12048: 1987 and other hardware fitting shall be tested as per IS 2486 (part
I) .
7.6
Failing Load
Mechanical Failing Load(For Pin Insulators only)
The insulators shall be suitable for a minimum failing load of 5 KN (for 11
kV) applied in transverse direction.
Electro Mechanical Failing Load(For Strain Insulators/String
Insulator Units)
The insulators shall be suitable for a minimum failing load of 45 KN (for
11 kV lines).
7.7
Chemical Analysis of Zinc used for Galvanizing

Samples taken from the zinc ingot shall be chemically analysed as per
IS:209-1979. The purity of zinc shall not be less than 99.95%.
7.8
Tests for Forgings

The chemical analysis hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognised procedures for these
tests. The sampling will be based on heat number and heat treatment batch.
The details regarding test will be as discussed and mutually agreed to by
the Contractor and Owner in Quality Assurance Programme.
7.9
Tests on Castings
The chemical analysis, mechanical and metallographic tests and magnetic,
particle inspection for castings will be as per the internationally recognised
procedures for these tests. The samplings will be based on heat number
and heat treatment batch. The details regarding test will be as discussed
and mutually agreed to by the Contractor and Owner in Quality Assurance
Programme.
Page 5 of 16
8.0
Interchangeability
The disc insulators inclusive of fittings shall be of standard design suitable
for use with the hardware fittings of any make conforming to relevant
Indian/International Standards.
9.0
Workmanship
9.1
All the material shall be of the latest design and conform to the best modern
practices adopted in the distribution voltage field. Contractors shall offer
only such insulators as are guaranteed by him to be satisfactory and
suitable for specified voltage level lines and will give continued good
service.
9.2
The design, manufacturing process and material control at various stages

shall be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish and elimination of sharp edges and
corners.
9.3
The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
9.4
In disc insulators, metal caps shall be free from cracks, seams, shrinks, air
holes, burrs and rough edges. All surfaces of the metal parts shall be
perfectly smooth with no projecting points or irregularities. All load
bearing surfaces shall be smooth and uniform so as to distribute the
loading stresses uniformly.
9.5
All ferrous parts shall be hot dip galvanised to give a minimum average
coating of Zinc equivalent to 600 gm/sq.m. and shall be in accordance
with the requirement of IS:2629-1985 and shall satisfy the tests mentioned
in IS:2633 1986. The zinc used for galvanising shall be of Grade Zn 99.95
as per IS:209-1979. The zinc coating shall be uniform, adherent, smooth,
reasonably bright, continuous and free from imperfections such as flux,
ash, rust stains, bulky white deposits and blisters. The galvanised metal
parts shall be guaranteed to withstand at least six successive dips each
lasting for one (1) minute duration under the standard creep test.
9.6
Before ball fittings are galvanised, all die flashing on the shank surface of
the ball shall be carefully removed without reducing the dimensions below
the design requirements.
9.7
In disc insulators, the design of the insulators shall be such that the shell
shall not engage directly with hard metal. The design shall also be such
that when units are coupled together there is no contact between the shell
of one unit and metal of the next adjacent unit. The design of the shell
Page 6 of 16
ribs shall be such that the security clip of the insulator can be engaged and
disengaged easily with hot stick without damaging the shell ribs.
9.8
Insulator units after assembly shall be concentric and co-axial within limits
as permitted by the relevant Indian Standards.
10.0
Equipment Marking
10.1
Each insulator shall be legibly and indelibly marked with the trademark of
the manufacturer and month & year of manufacture. The guaranteed
combined mechanical and electrical strength shall be indicated in kilo
Newton followed by the word kN to facilitate easy identification and to
ensure proper use.
10.2
The marking shall be on porcelain, and shall be printed, not impressed and
shall be applied before firing.
11.0
Bid Drawings
11.1
The Bidder shall furnish full description and illustration of the material
offered.
11.2
The Bidder shall furnish along with the bid the outline drawing (6 copies)
of each insulator unit including a cross sectional view of the insulator
shell. The drawing shall include but not limited to the following
information:
(a)
Dimensions with manufacturing tolerances
(b)
Minimum Creepage distance with positive tolerance
(c)
Protected creepage distance
(d)
Eccentricity of the disc

(i)
Axial run out
(ii)
Radial run out
(e)
Unit mechanical and electrical characteristics
(f)
Size and weight of Pin Ball Shank / ball and socket parts
(g)
Weight of unit insulator disc
(h)
Materials
(i)
Identification mark
Page 7 of 16
(j)
11.3
Manufacturer's catalogue number
After placement of award, the Contractor shall submit fully dimensioned

insulator drawings containing all the details as given in Clause No. 1.12.2
above, in four (4) copies to Owner for approval. After getting approval
from Owner and successful completion of all the type tests, the Contractor
shall submit 20 more copies of the same drawing to the Owner for further
distribution and field use at Owner's end.
12.0
TESTS AND STANDARDS
12.1
Tests
The following type, acceptance, routine tests and tests during manufacture
shall be carried out on the insulator individually and along with hardware
fittings. For the purpose of this clause:
12.1.1
Type tests shall mean those tests which are to be carried out to prove the
design process of manufacture and general conformity of the material to
this specification. These tests shall be carried out on samples prior to
commencement of commercial production against the specification. The
Bidder shall indicate this schedule for carrying out these tests in the
activity schedule.
12.1.2
Acceptance tests shall mean those tests which are to be carried out on
samples taken from each lot offered for pre-dispatch inspection for the
purpose of acceptance of that lot.
12.1.3
Routine tests shall mean those tests, which are to be carried out on each
insulator/hardware fitting to check requirements which are likely to vary
during production.
12.1.4
Tests during manufacture shall mean those tests which are to be carried
out during the process of manufacture and end inspection by the Supplier
to ensure the desired quality of the end product to be supplied by him.
12.1.5
The norms and procedure of sampling for these tests will be as per the
Quality Assurance Programme to be mutually agreed to by the Supplier
and Owner.
12.1.6
The standards and norms to which these tests will be carried out are listed
against them. Where a particular test is a specific requirement of this
specification, the norms and procedure of these shall be as specified in
Annexure-A of this Section or as mutually agreed to between the Supplier
and the Owner in the Quality Assurance Programme.
Page 8 of 16
12.1.7
For all types and acceptance tests, the acceptance values shall be the
values guaranteed by the Bidder in the Guaranteed Technical Particulars
of this proposal or the acceptance value specified in this specification
whichever is more stringent for that particular test.
12.1.8
For all type and acceptance tests, the Bidder shall guarantee only
minimum values in the Guaranteed Technical Particulars. Bidder shall be
required to achieve the same or higher values, as guaranteed, during
testing for all type and acceptance tests.
12.2
Tests on insulators
The flowing test shall be performed on insulators
12.2.1
Type Tests
The following type tests shall be conducted on a suitable number of
individual insulator unit, components, materials or complete strings:
(a)
Visual examination
(b)
(c)
Visible Discharge test (dry)
(d)
Impulse voltage withstand and flashover test (dry)
(e)
Power frequency voltage withstand and flashover test (i)dry

(ii) wet
(f)
Temperature Cycle test
(g)
Mechanical failing Load Test (for pin insulator only)- Refer

Annexure-A
(h)
24 hour Mechanical Strength Test for Strain Insulator
(i)
Puncture Test
(j)
Porosity Test
(k)
Galvanizing Test
(l)
Electro-mechanical failing test (for Strain Insulator only)Refer Annexure A
(m)
Thermal mechanical performance Test (for strain insulators

only) Refer Annexure-A
Page 9 of 16
12.2.2
12.2.3
12.2.4
Acceptance Tests
(a)
(b)
Temperature cycle test
(c)
Electro-mechanical failing test (for Strain Insulator only)Refer Annexure-A
(d)
Puncture Test
(e)
Porosity Test
(f)
Galvanizing Test
Routine Test
(a)
Visual Inspection
(b)
Mechanical routine test (for Strain Insulator only)
(c)
Electrical routine test (for Strain Insulator only)
(d)
Hydraulic Internal Pressure on shells (for Strain Insulator

only)-Refer Annexure-A
Test During Manufacture

On all components as applicable
(a)
Chemical analysis of zinc used for ) Annexure -A

Galvanizing
b)
Chemical analysis, mechanical
metallographic test and magnetic )

particle inspection for malleable
castings.
c)
Chemical analysis hardness tests )

and magnetic particle inspection)
d)
for forgings
Hydraulic Internal Pressure
Page 10 of 16
Annexure - A
tests on disc insulator shells
12.3
Testing Expenses
12.3.1
Testing charges for the type test specified shall be indicated separately in
the prescribed schedule
12.3.2
Bidder shall indicate unit type test charges for all type tests covered under
this specification separately, in the relevant schedule of Prices as
applicable.
12.3.3
In case of failure of any type test, the Contractor is either required to

modify design of the material and successfully carryout all the type tests
as has been detailed out in this specification or to repeat that particular
type test at least three times successfully at his own expenses.
12.3.4
Contractor shall indicate the laboratories in which they propose to conduct

the type tests. They shall ensure that adequate facilities are available in the
laboratory and the tests can be completed in these laboratories within the
time schedule guaranteed by them in the appropriate schedule.
12.3.5
The entire cost of testing for acceptance and routine tests and tests during
manufacture specified herein shall be treated as included in the quoted Exworks Price.
12.3.6
In case of failure in any type test, if repeat type tests are required to be
conducted, then all the expenses for deputation of Inspector / Owner's
representative shall be deducted from the contract price. Also if on receipt
of the Contractor's notice of testing, the Owner's representative does not
find 'PLANT' to be ready for testing the expenses incurred by the Owner
for re-deputation shall be deducted from contract price.
12.3.7
The Contractor shall intimate the Owner about carrying out of the type
tests along with detailed testing programme at least 3 weeks in advance of
the scheduled date of testing during which the Owner will arrange to
depute his representative to be present at the time of carrying out the tests.
12.4
Sample Batch for Type Testing
12.4.1
The Contractor shall offer material for sample selection for type testing
only after getting Quality Assurance Programme approved by the Owner.
The Contractor shall offer at least three times the quantity of materials
required for conducting all the type tests for sample selection. The sample
for type testing will be manufactured strictly in accordance with the
Quality Assurance Programme approved by the Owner.
Page 11 of 16
12.4.2
Before sample selection for type testing, the Contractor shall be required
to conduct all the acceptance tests successfully in presence of Owners
representative.
12.5
Additional Tests
12.5.1
The Owner reserves the right of having at his own expense any other
test(s) of reasonable nature carried out at Contractors premises, at site, or
in any other place in addition to the aforesaid type, acceptance and routine
tests to satisfy himself that the material comply with the Specifications.
12.5.2
The Owner also reserves the right to conduct all the tests mentioned in this
specification at his own expense on the samples drawn from the site at
Contractors premises or at any other test center. In case of evidence of
non compliance, it shall be binding on the part of the Contractor to prove
the compliance of the items to the technical specifications by repeat tests
or correction of deficiencies, or replacement of defective items, all without
any extra cost to the Owner.
12.6
Co-ordination for testing

The Contractor shall have to co-ordinate testing of insulators with
hardware fittings to be supplied by other Contractor and shall have to
guarantee overall satisfactory performance of the insulators with the
hardware fittings.
12.7
Guarantee
The Contractor of insulators shall guarantee overall satisfactory
performance of the insulators with the hardware fittings.
12.8
Test Reports
12.8.1
Copies of type test reports shall be furnished in at least six (6) copies
along with one original. One copy shall be returned duly certified by the
Owner only after which the commercial production of the concerned
material shall start.
12.8.2
Copies of acceptance test reports shall be furnished in at least six (6)

copies. One copy shall be returned duly certified by the Owner, only after
which the material shall be dispatched.
12.8.3
Record of routine test reports shall be maintained by the Contractor at his

works for periodic inspection by the Owners representative.
Page 12 of 16
12.8.4
Test certificates of test during manufacture shall be maintained by the

Contractor. These shall be produced for verification as and when desired
by the Owner.
12.9
Inspection
12.9.1
The Owners representative shall at all times be entitled to have access to

the works and all places of manufacture, where insulator, and its
component parts shall be manufactured and the representatives shall have
full facilities for unrestricted inspection of the Contractors and subContractors works, raw materials, manufacture of the material and for
conducting necessary test as detailed herein.
12.9.2
The material for final inspection shall be offered by the Contractor only
under packed condition as detailed in the specification. The Owner shall
select samples at random from the packed lot for carrying out acceptance
tests. Insulators shall normally be offered for inspection in lots not
exceeding 5000 nos. The lot should be homogeneous and should contain
insulators manufactured in the span of not more than 3-4 consecutive
weeks.
12.9.3
The Contractor shall keep the Owner informed in advance of the time of
starting and the progress of manufacture of material in their various stages
so that arrangements could be made for inspection.
12.9.4
No material shall be dispatched from its point of manufacture before it has

been satisfactorily inspected and tested unless the inspection is waived off
by the Owner in writing. In the latter case also the material shall be
dispatched only after satisfactory testing for all tests specified herein have
been completed.
12.9.5
The acceptance of any quantity of material shall be no way relieve the

Contractor of his responsibility for meeting all the requirements of the
specification and shall not prevent subsequent rejection, if such material
are later found to be defective.
13.0
Packing and Marking
13.1
All insulators shall be packed in strong seasoned wooden crates. The gross
weight of the crates alongwith the material shall not normally exceed 200
Kg to avoid handling problem.
13.2
The packing shall be of sufficient strength to withstand rough

handling during transit, storage at site and subsequent handling in the
field.
Page 13 of 16
13.3
Suitable cushioning, protective padding or spacers shall be provided to

prevent damage or deformation during transit and handling.
13.4
All packing cases shall be marked legibly and correctly so as to ensure

safe arrival at their destination and to avoid the possibility of goods being
lost or wrongly dispatched on account of faulty packing and faulty or
illegible markings. Each wooden case/crate shall have all the markings
stenciled on it in indelible ink.
Page 14 of 16
ANNEXURE A
1.0
Hydraulic Internal Pressure Test on Shells (if applicable)

The test shall be carried out on 100% shells before assembly. The details
regarding test will be as discussed and mutually agreed to by the
Contractor and Owner in Quality Assurance Programme.
2.0
Thermal Mechanical Performance Test (if applicable)

Thermal Mechanical Performance Test shall be performed in accordance
with IEC-383-1-1993 Clause 20 with the following modifications :
(1)
The applied mechanical load during this test shall be 70% of the
rated electromechanical or mechanical value.
(2)
The acceptance criteria shall be
(a)
X greater than or equal to R + 3S.

Where
3.0
Mean value of the individual mechanical failing load.
Rated electro-mechanical / mechanical failing load.
Standard deviation.
(b)
The minimum sample size shall be taken as 20 for disc insulator

units.
(c)
The individual electromechanical failing load shall be at least equal

to the rated value. Also puncture shall not occur before the
ultimate fracture.
Electromechanical/Mechanical Failing Load Test.

This test shall be performed in accordance with clause 18 and 19 of IEC
383 with the following acceptance
(i)
X greater than or equal to R + 3S

Where
X
Mean value of the electro-mechanical/mechanical/ failing

load.
Page 15 of 16
4.0
Standard deviation.
(ii)
The minimum sample size shall be taken as 20 for disc insulators

units. However, for larger lot size, IEC 591 shall be applicable.
(iii)
The individual electro-mechanical/mechanical failing load shall be

at least equal to the rated value. Also electrical puncture shall not
occur before the ultimate fracture.

Samples taken from the zinc ingot shall be chemically analysed as per
IS:209-1979. The purity of zinc shall not be less than 99.95%.
5.0
Tests for Forgings

forgings, will be as per the internationally recognised procedures for these
tests. The sampling will be based on heat number and heat treatment batch.
The details regarding test will be as discussed and mutually agreed to by
the Contractor and Owner in Quality Assurance Programme.
6.0
Tests on Castings
procedures for these tests. The samplings will be based on heat number
and heat treatment batch. The details regarding test will be as discussed
and mutually agreed to by the Contractor and Owner in Quality Assurance
Programme.
Shackle insulators shall be suitable for a minimum failing load of
11.5KN for type I insulator and 16.0KN for type 2 insulator.
Guy strain insulator type A shall be suitable for a minimum failing
load of 44KN whereas, type C shall be suitable for a minimum failing
load of 88 KN
Page 16 of 16
1KV LINE SECTIONALISERS/AB SWITCH

1.
SCOPE
This specification covers 3-pole, 11KV, 50Hz, pole-mounted manually
operated Line Sectionalisers/AB switch for outdoor installation in rural
electrification system.
2.
Unless otherwise stipulated in this specification
the line
sectionalisers/AB switch shall comply with the latest version of
IS:9921 (part I to V).
3.
RATED VOLTAGE
The rated voltage for the line sectionalisers/AB switch shall be 12 kV.
This represents the highest system voltage corresponding to the nominal
system voltage of 11 kV.
4.
RATED CURRENT
The standard rated normal current shall be 200/400 Amp.
5.
DESCRIPTION:
5.1
The sectionaliser shall be used to isolate the faulty section of 11 kV line.

This will be a off load device. The sectionaliser/AB switch shall be able
to be mounted on the 11 kV single or double pole structures.
5.2
The terminal connectors (bimetallic) shall be bolted type suitable for

AAAC rabbit & weasel conductors.
5.3
The post insulator shall conform to IS: 2544 (latest amendment).
5.4
Arcing horns (of 8 mm dia ) shall be provided at the terminal

connectors.
5.5
All moving & fixed contacts shall be of sliver plated copper.
5.6
Flexible copper braid of minimum weight of 350 gms./ meter shall be

used to connected the moving contact to the terminal connector.
5.7
The operating pipe shall be a GI pipe of 32 mm dia, minimum of B

Class quality.
5.8
To avoid the unauthorised operation of the sectionaliser/AB switch, a

locking arrangement shall be provided to block the movement of the
operating handle. The operating handle shall be provided at a height
_________________________________________________________________________________________________
Page 1 of 2
which is convenient to the operator without the aid of a ladder etc.

The operating handle shall have insulated grip and will be earthed.
5.10
All ferrous parts shall be galvanised as per relevant IS.
6.
OPERATION
6.1
The middle post insulator i.e. the insulator where the moving contact is
mounted, shall have elf lubricating rocker bearing arrangement. The
central post shall tilt on this bearing.
6.2
A pantograph shall be used between the moving post and the end post.
6.3
All the three poles shall be ganged operated. No single pole operation
shall be possible.
6.4
The phase to phase coupling for gang operation shall be through a

square tendom rod (25 x 25 x 2100). This will be of galvanised mild steel.
6.5
Provision shall be kept for the motorized operation of the sectionaliser/AB

switch in future.
7.0
5.9
TESTING
The sectionaliser shall be tested as per the referred IS.
_________________________________________________________________________________________________
Page 2 of 2
1.
12 KV OUTDOOR VCB, 1200 A / 630A
1.1
GENERAL
1.1.1
This section of specification covers the design, manufacture, assembly,

shop testing/inspection before dispatch, packing, forwarding, transportation to site,
insurance (during transit, storage and erection), storage, erection, supervision,
site testing and commissioning of 12 KV outdoor type vacuum circuit breakers
at various 33/11 kV substations.
1.1.2
The scope of supply shall also include necessary special tools and plants
required for erection, maintenance and necessary spares, required for normal
operation and maintenance of the circuit breakers for a period of five years.
1.1.3
The circuit breakers should be complete in all respects with insulators,

bimetallic connectors, interrupting chamber, operating mechanism, control cabinet,
interlocks, auxiliary switches, indicating devices, supporting structures, accessories,
etc., described herein and briefly listed in the schedule of requirements. The
spares/attachments which are necessary for the smooth functioning of the
equipment and specifically are not mentioned here shall be assumed to be
included the scope of supply.
1.2
STANDARDS
1.2.1
The circuit breaker shall conform in all respects to the requirements of latest
issue of IS/IEC specifications except for modifications specified herein. The
equipment manufactured according to any other authoritative standards which
ensure an equal or better quality than the provision of IS/IEC specifications shall
also be acceptable. The salient point of difference between the proposed standard
and provision of these specifications shall be clearly brought out in the tender. A
copy of English version of such specifications shall be enclosed with the tender.
1.2.2
The list of standards mentioned in this specification and to which the circuit
conform is given below:
S.
N.
IS
IEC
Description
1.
IS 13118
IEC-56
High Voltage A.C. Circuit Breakers
2.
IS 2099
IEC-137
Bushing for alternating Voltages above 1000 volts
3.
IS 12729
IEC-694
Common clauses for high voltages switchgear and

control gear standards
IEC-815
Specification for Creepage distances
4.
Page | 1
5.
S.
N.
IS-4379
IS
Identification of the contents of industrial gas

cylinders
IEC
Description
6.
IS-3072
Installation and maintenance of switchgear
7.
IS 9135
Guide for testing of circuit breakers with respect to

out of phase switching
8.
IEC 60
High voltage testing technique.
9.
IEC-17A
Study Group
Dec.1981
Sealing of interrupters/breakers
IEC227
PVC insulated cables upto and including 1000 volts
10.
IS-1554
11.
IS-5
12.
Colors for ready mixed paints and enamels
IEC 529
Degree of protection provided enclosure
IEC 34
AC motors
13.
IS 996
14.
IS 2629, ISO 1460

2633
1.3
SERVICE CONDITONS
1.3.1
CLIMATIC CONDITONS
Hot Dip Galvanising
The breakers and accessories to be supplied against this specification shall be

suitable for satisfactory continuous operation under the tropical conditions
described in General Technical Requirements.
Page | 2
1.3.2
AUXILIARY POWER SUPPLY

Auxiliary electrical equipment shall be suitable for operation on the following
supply system.
a)
Power Devices (like drive motors)
b)
DC Alarm, Control and Protective Devices
415 Volts, 3 phase 4 wire 50 hz, neutral grounded AC supply

110V/30 V DC, ungrounded 2 wire, or, 240 V AC
The above supply voltage may vary as indicated below and all devices shall be
suitable for continuous operation over the entire range of voltages
i)
AC Supply
Voltage + 10%/- -15%

Frequency 5%
Combined voltage and frequency +10% to 15%
ii)
1.4
DC Supply
-15% to + 10%
GENERAL REQUIREMENT OF 12 kV/OUTDOOR VACUUM

CIRCUIT BREAKERS
The vacuum type circuit breaker, shall have vacuum interrupters, designed to provide
a long contact life at all currents upto rated making and breaking current
during switching operation. The vacuum interrupters sealed for life shall be
encapsulated by porcelain insulators for out door installation requirement. The
breakers shall be suitable for out door operation under climatic conditions
specified without any protection from sun, rain and dust storm. Indoor type
breakers housed in sheet steel outdoor enclosure are not acceptable.
The vacuum interrupters of each phase shall be housed in a separate porcelain
insulator. The three identical poles shall be mounted on a common base frame and
the contact system of three poles should be mechanically linked to provide three pole
simultaneous opening/closing.
i)
The performance of breakers shall be adequately proven by type tests for

the designed rating at internationally reputed independent testing station.
ii)
The equipment shall be practically maintenance free over a long period.
iii)
All mechanical parts and linkages shall be robust in construction

and maintenance free, over at least 30,000 switching operations
Page | 3
except for lubrication of pins/articulated joints at interval of 5 years or 5000

operations.
1.4.1
iv)
Similar parts shall be strictly interchangeable. Parts requiring maintenance

shall be easily accessible, without requiring extensive dismantling of adjacent
parts.
v)
The circuit breaker shall be supplied complete with all auxiliary

equipment, meant necessary for the safe operation, routine and periodic
maintenance.
vi)
The breaker shall be totally restrike free under all duty conditions and shall
be capable of performing the duties without opening resistor. The details
of any device incorporated to limit or control the rate of rise of
restriking voltage across the circuit breaker contacts shall be stated. The
complete data for the phase factor, amplitude factor, etc., for rate of rise of
re-striking voltage shall be furnished in the tender
vii)
The breaker shall be suitable for three phase reclosing operation.
viii)
An operation counter, visible from the ground level even with the
mechanism housing closed shall be provided.
FIXED AND MOVING CONTACT

The fixed and moving contacts of the breaker have to ensure permanent full
contact during closing. All making and breaking contacts shall be hermetically
sealed and free from atmospheric effects.
The contacts metallurgy and geometry shall be such that there is minimum
contact burning and wear. Main contact shall have ample area and contact
pressure for carrying the rated current and rated short time current without
excessive temperature rise which may cause pitting or welding of the contacts.
The main contacts should have low contact resistance. The contact should be
self cleaning type, i.e., the layer of copper oxide should be cleaned during
rubbing of contacts. The contact area should be well defined, spring used for
contact shall be of gradually rising characteristic i.e., they should be soft.
The contacts should not provide contact grip,
i.e., electro-magnetic forces should not grip the contacts and oppose the
opening process. Separate main contacts and arcing contacts shall be provided
in order to have longer life of the contacts. The contours of the energized metal
parts of the breaker shall be such as to eliminate areas or points of high
electrostatic flux concentration.
The circuit breaker units shall be suitable for installation on outdoor
R.C.C. foundations. Ground clearance of the live parts of the breakers should be as
Page | 4
per India Electricity Rules, 1956.

1.4.2
RECOVERY VOLTAGE AND POWER FACTOR

The circuit breaker shall be capable of interrupting rated power with recovery voltage
equal to the rated maximum line to line service voltage at rated frequency and
at a power factor equal to or exceeding 0.15.
1.4.3
AUTOMATIC RAPID RECLOSING

12 KV circuit breaker shall be suitable for 3 pole rapid reclosing. The dead time of
the breaker shall be adjustable and the limits of the adjustment shall be stated in the
tender.
1.4.4
OUT OF PHASE SWITCHING
1.4.5
The circuit breaker shall be capable of satisfactory operation even under conditions of
phase opposition that may arise due to faulty synchronization. The maximum
power that the breaker can satisfactorily interrupt under Phase Opposition shall
be stated in the bid.
SEISMIC FACTOR
The insulators shall be capable to withstand the seismic acceleration of 0.5 g
in horizontal direction and 0.6g in vertical direction.
1.5
TEMPERATURE RISE
The maximum temperature attained by any part of the equipment when in
service at side and under continuous full load conditions and exposed to the direct
rays of the sun shall not exceed the permissible limits fixed by IEC. When the
standards specify the limits of temperature rise these shall not be exceeded when
corrected for the difference between ambient temperature specified in the approved
specification.
The limits of temperature rise shall also be corrected for altitude as per IEC and
stated in the bid.
1.6
INSULATOR SUPPORTS AND HOUSING

The basic insulation level of the external hollow insulator support shall be as per
Clause
1.26.1 of the Technical Parameters and these shall be suitable for use under
climatic conditions as per Clause 1.3.1 of this specification.
The porcelain used shall be homogenous, uniformly glazed including the
internal surface, thoroughly vitrified and free from cavities and other flaws.
Page | 5
The insulators shall be designed to have ample insulation, mechanical strength and
rigidity for satisfactory operation under conditions specified above. All bushings
of identical rating shall be interchangeable. The puncture strength of bushing shall
be greater than the flash over value. The design of bushing shall be such that the
complete bushing in a self-contained unit and no audible discharge shall be
detected at a voltage upto a working voltage (Phase Voltage) plus 10%. The
support insulator shall conform to IEC-137. Minimum clearance between phases,
between live parts and grounded objects shall be as per IS-3072-1975 and
should conform to Indian Electricity Rules- 1956.
The minimum creepage
distance for severely polluted atmosphere shall be 25 mm/KV. The protected
creepage distance shall be not less than 50% of total.
1.7
OPERATING MECHANISM GENERAL REQUIREMENTS

The operating mechanism shall be stored energy type in the form of spring
charged. The operating mechanism shall be capable to perform the
following functions efficiently.
i)
To provide means where the circuit breaker can be closed rapidly,

without hesitation at all currents from zero to rated making current capacity.
ii)
To hold the circuit breaker in closed position till the tripping signal is
received. iii) To allow the circuit breaker to open without delay immediately on
receiving tripping signal.
iv)
To perform 3 phase auto reclosers duty cycle.

The closing spring shall be automatically charged by motor immediately after
closing operation. In case of failure of supply to the spring charging motor,
the spring shall be chargeable by hand-crank.
The contact
pressure
spring and tripping spring shall be
charged/compressed during closing operation to ensure the breaker is ready to
open.
Mechanically ON/OFF indicator, spring charged indicator and
operation counter shall be provided on the front of the control cubicle. The
tripping spring shall ensure the tripping even in case of failure of any
auxiliary spring.
The supply of auto reclosing scheme control circuit equipment does not
form the part of this specification. The supplier shall however be required to
co- ordinate the same with the supplier of control and relay panels.
a)
Tripping/Closing Coils
The circuit breakers shall be provided with two trip coils and one closing
coil per breaker. First trip coil shall be utilized for tripping the breaker on
Page | 6
main protection fault detection. Whereas second trip coil shall be used to
trip the breaker when first trip coil fails to trip the breaker and backup
protection comes into operation and shall also be used to trip the breaker on
command. The trip coils shall be suitable for preclosing and after closing
trip circuit supervision. All the breakers shall have provision for independent
electrical operation of trip coils from local as well as remote through
local/remote selector switch. The breaker shall be provided with suitable
protection device against discrepancies in the operation of individual pole.
b)
Trip Free and Anti Pumping Features
The trip free mechanism shall permit the circuit breaker to be tripped by the
protective relay even if it is under the process of closing. An antipumping device to prevent the circuit breaker from reclosing after an
automatic opening shall be provided to avoid the breaker from pumping i.e.,
anti pumping relay should interrupt the closing coil circuit.
c)
Controls
The circuit breaker shall be controlled by a control switch located in the

control room. The control arrangement shall be such as to disconnect
the remote control circuits of the breaker, when it is under test.
Local/remote selector switch shall be provided for all breakers for selection
of Local control/remote control.
Provision shall be made for local manual, closing, tripping and spring
charging controls. Necessary equipments for local controls shall be housed
in the circuit breaker cabinet of weather-proof construction.
Each circuit breaker shall have a mechanical open/closed and spring
charge indicator. Lamps for indicating close, open and spring charged
position of the breaker shall also be provided.
Mechanical indicator, to show the òpen and `close position of the
breaker shall be provided in a position where it will be visible to a man
standing on
ground with mechanism housing open. An operation counter, visible from
the ground even with the mechanism housing closed, shall be provided.
Electrical tripping of the breaker shall be performed by shunt trip coils.
Closing coil shall operate correctly at all value of supply voltage between
85% and 110% of the rated voltage. Shunt trip coils shall operate correctly
under all operating conditions of the circuit breaker upto the rated breaking
capacity and at all values of supply voltage between 85% and 110% of
rated voltage. Bearings which require grease shall be equipped with pressure
type fillings.
Page | 7
Bearing pins, bolts, nuts and other parts shall be adequately pinned or locked
to prevent loosening or changing adjustment with repeated operation of the
circuit breaker. It shall be possible to trip the circuit breaker even in
the event of failure of power supply.
Operating mechanism and all accessories shall be enclosed in control
cabinet. A common marshalling box for the three poles of the breaker shall be
provided, along with supply of tubing, cables from individual pole operating
boxes to the common marshalling box, local.
1.7.1
SPRING OPERTED MECHANISM

The operating mechanism shall have all the necessary auxiliaries, apparatus for
operation and supervision, like motor starter with thermal overload release, one
closing coil, two trip coils, push button for local electrical operation,
local/remote control selector switch, push button for direct mechanical
tripping, auxiliary switches, antipuming contactors, operation counter, socket for
inspection, lamp and heater with switch.
In addition mechanical interlocking
system for interlocking with associated isolators shall be provided. Spring
charging motor shall be standard single phase universal motor suitable for 220
volts supply.
i)
Operating voltages for closing/tripping coils shall be 110/30 Volts DC or

the CB shall be of Series Trip type requiring no DC supply. The closing
coil for Series Trip type CB shall be operating on 240 Volts AC supply.
.
ii)
Operating voltages for heater elements shall be 240V AC 50 HZ. Other

features of the spring operated mechanism shall be as follows.
a) The spring operating mechanism shall have adequate energy stored in
the operating to close and latch the circuit breaker against the rated
making current and also to provide the required energy for tripping
mechanism in case the tripping energy is derived from the operating
mechanism.
b) The mechanism shall be capable of performing the rated operating
duty cycle of O-0.3Sec-CO-3 Min-CO as per IEC-56.
c)
The spring charging motor shall be AC/DC operated and shall not take
more than 30 sec., to fully charge the closing spring made for automatic
charging. Charging of spring by the motor should not interfere with the
operation of the breakers.
d) The motor shall be adequately rated to carry out a minimum of one
duty cycle. Also provision shall be made to protect the motor against
overloads.
Page | 8
e)
In case of failure of power supply to spring charging motor, the

mechanism shall be capable of performing one open-close-open
operation.
f) Mechanical interlocks shall be provided in the operating mechanism

to prevent discharging of the closing springs when the breaker is
already in closed position. Provision shall be made to prevent a closing
operation to be carried out with the spring partially charged.
g) Facility shall be provided for manual charging of closing springs.
1.7.2 CONTROL CABINET
The switchgear operating mechanism, the control equipment such as switch for local
electrical and manual closing and tripping the breakers, various control relays,
antipuming device, a set of terminal blocks for wiring connections, MCBs for
disconnecting the control auxiliary power supplies including relays, etc., shall
be enclosed in a cabinet to be mounted on a suitable structure at a convenient
working height at the end of the breaker in the outdoor switchyard.
a)
Enclosure
The enclosure shall be made out of cold rolled steel plates not less than 3 mm thick
and of light section structural steel. It should be weather proof as well as dust and
vermin proof.
The enclosure shall have degree of protection IP55. The cabinet shall have full
width and full length hinged doors mounted on the front that swing fully open.
The doors shall be provided with latches to securely hold it with the cabinet.
Doors shall be of sturdy construction, with resilient material covering, fully
perimeterically contacting the cabinet frame to provide dust protection and prevent
metal to metal contact except at the latch points. Filtered ventilation, shall be
provided along with the rigid supports for control and other equipment. Mounting
cabinet members and equipment shall not restrict easy access to terminal blocks for
terminating and testing external connection or to equipment for maintenance.
All screws and bolts used for assembling and mounting wire and cable
termination, supports, devices and other equipment shall be provided with lock
washers or other locking devices. All metal parts shall be clean and free of weld
splatter, rust and mill scale prior to application of double coat of zinc chromate
primer which should be followed by an under coat to serve as base and binder
for the finishing coat. The exterior of the cubicle shall be painted matty grey to
shade No.692 of IS-5 or shade No.631 and interior to white shade. Sufficient
quantity of paints shall also be supplied along with the cubicle to restore at site
any
damage
during
transportation.
Page | 9
The mounting structure shall be galvanized and shall be as per IS-802-II-1978.

b)
Heaters
Suitable heaters shall be mounted in the cabinet to prevent condensation. Heaters
shall be controlled by thermostat. ON/OFF MCB shall be provided. Heaters shall be
suitable for 240 V AC supply voltage.
c)
Lighting
One 20 watts fluorescent tube fixture and lamp holder working on 240 V 50 c/s
AC supply shall be provided in each switchgear control cubicle section and shall be
located to provide adequate interior lighting of the cubicle. A single-pole door
operated 20
Amp. `T rated lighting switch shall be provided for each cubicle. One duplex 220
volt
convenience outlet shall be provided inside each door or pair of doors inside
each cubicle.
The lighting and convenient outlet circuits shall be completely wired in conduit and
terminated on cubicle terminal blocks.
d)
Wiring and Cabling
1.
Unless otherwise specified control wire shall be stranded tinned

copper switchboard wire with 1.1 KV PVC insulation conforming to the
requirements of IS-1554.
2.
All the control circuit and secondary wiring shall be wired completely
and brought out preferably to a vertical terminal block ready for
external connections in the control cabinet. The control wire shall not be
of cross- section less than 2.5 mm2 copper.
3.
All spare auxiliary contacts of the circuit breaker shall be supplied wired
upto terminal block. Each terminal in terminal block shall be suitable for at
least 2 x 2.5 mm copper conductor.
4.
At least 20 number spare terminals shall be provided over and above

the number required.
5.
All wiring termination on terminal blocks shall be made through lugs.

For current and DC supply circuits disconnecting study type terminal blocks
will be provided. For other control circuits, non-disconnecting snap on
type terminal blocks shall be provided.
6.
All wires shall be identified with non-metallic sleeve or tube type markers
at each terminations.
Page | 10
7.
Terminal blocks shall be made up of moulded non-inflammable plastic

material with blocks and barriers moulded integrally have white marking
strips for circuit identification and moulded plastic covers.
e)
Grounding
A ground bus of copper bar not less than 6 mm by 25 mm shall be provided along
the inside of the front or rear of the each cubicle and equipment rack. The ground
bus shall be bolted to the frame of each panel in such a way as to make good
electrical contact with each panel or section. Earth terminals at two ends of the
cabinet shall be provided for connection of the ground bus to the station earth mat.
1.8
ACCESSORIES
Each circuit breaker assembly shall be supplied with the following accessories. i)
Line and earthing terminals and terminal connectors.
ii)
Bimetalic terminal connectors iii)
Control housing with:
a)
One auxiliary switch with adequate number of auxiliary contacts, but not
less than 20 nos. (10 No + 10 NC) for each breaker.
b)
Operation counter
c)
Position indicator (Close/Open/Spring Charged)
d)
Necessary cable glands e)
MCBs as required
f)
Manual trip device and local test push buttons
g)
Terminal blocks and wiring for all control equipment and accessories
h)
Adequate number of heaters for continuous operation to prevent
moisture condensation in the housing of operating mechanism
i)
Selector switch for local/remote control.
j)
Internal Illumination fluorescent lamp
j)
5 Amp plug point and socket
k)
Motor for spring charging
iv)
Rating and diagram plate as per IS
1.9
SUPPORTING STRUCTURE
The circuit breakers shall be supplied complete with hot dip galvanized steel
supporting structures, foundation and fixing bolts, etc. The structure shall be
made of steel MS angle section conforming to IS 226. The galvanizing shall be as
per IS. The mounting of the breaker shall be such as to ensure the safety of the
operating staff and should conform to Indian Electricity Rules, 1956. Minimum
ground clearance of live part from ground level shall be as per IE Rules.
The bidder shall submit detailed design calculations and detailed drawings in
Page | 11
respect of supporting structures suitable for the equipment offered. The tenders
shall specify the
loads which shall be transmitted to the equipment foundation under most adverse
operating conditions of the breaker.
All material for making connections between the circuit breaker and its control
shall also be included in the scope of supply.
Extension brackets shall be
provided for directly mounting 12 KV out door current transformers on the
circuit breaker unit. Facility to earth the circuit breaker structure at two points shall
be provided.
1.10 SURFACE FINISH
1.10.1
All interiors and exteriors of control cubicles and other metal parts shall be
thoroughly cleaned to remove all rust, scales, corrosion, greases or other adhering
foreign matter.
1.10.2 All metal surfaces exposed to atmosphere shall be given two primer coats of
zinc chromate and two coats of epoxy paint with epoxy base thinner. All metal
parts not accessible for painting shall be made of corrosion resisting material.
All machine finished or bright surfaces shall be coated with a suitable preventive
compound and suitably wrapped otherwise protected.
All paints shall be
carefully selected to withstand tropical heat and extremes of weather within the
limits specified. The paint shall not scale off or wrinkle or be removed by abrasion
due to normal handling.
All external paintings shall be as per shade No.631 of
IS:5.
1.10.3 All ferrous hardware, exposed to atmosphere, shall be hot dip galvanized.
1.11
GALVANISING
1.11.1 All ferrous parts including all sizes of nuts, bolts, plain and spring washers,
support channels, structures, shall be hot dip galvanized conforming to latest version
of IS:2629 or any other equivalent authoritative standard.
1.12
CABLE TERMINATION
Suitable cable glands for terminating the multicore cable, shall be provided at
the bottom of the control cabinet.
1.13
TERMINAL CONNECTIONS AND EARTH TERMINALS
1.13.1
Each circuit breaker connected with incoming and outgoing feeders shall be
provided with bolted type bi-directional bimetallic terminal connectors suitable for
ACSR conductor/ IPS Aluminium tube.
Page | 12
1.13.2
Each circuit breaker pole and control cabinet shall be provided with two
grounding terminals and clamps for receiving ground connections.
1.14
INTERLOCKS
Necessary interlocks to prevent closing or opening of the breaker under low
pressure of the contact spring and devices for initiating alarm shall be provided.
Provision shall also be made to enable electrical interlocking with the isolators
associated with the
breaker to prevent opening or closing of the isolators. The detailed interlocking
scheme based upon single line diagram of the substation shall be supplied with the
write-up. General requirement of interlock shall be as given below:
1.
Isolators should not be operated unless the associated circuit breaker is in

open position.
2.
Line isolator shaft close only when the corresponding circuit breaker and
earthing switch of the corresponding line are open.
3 The circuit breaker shall close only after all isolators associated with it have
been locked in closed position.Both electrical and Mechanical (castell type)
interlock shall be provided for this.
In case of double bus bar arrangement following additional requirement
for interlocking shall be provided.
1.
2.
3.
1.15
One bus bar selector isolator of any bay excepting the bus coupler bay
shall close only when,
a)
The circuit breaker of corresponding bay is open and
locked. b)
The other bus isolator of that bay is open.
When one bus isolator of any bay excepting the bus coupler bay is closed.
The other shall close only when the bus coupler circuit breaker and both the
bus isolators are closed.
Bus isolator of bus coupler bay shall operate only when the bus coupler
breaker is open.
EARTHING SYSTEM
50x6 mm GI flat earthing connections shall be included in the scope of supply.
The system shall comprise of the leads between the circuit breaker and station mat
and the interconnection between phases where necessary. All switchgear enclosures
should be bolted metal to metal and should carry the full earth return
Page | 13
current.Connection between phases at the earthing points shall be dimensioned for

carrying full earth return current.
1.16
VACUUM INTERRUPTER ASSEMBLY

Each pole of the circuit breaker shall be provided with vacuum interrupter, one for
each phase, hermetically sealed for life and encapsulated by ceramic
insulators.
The interrupter shall be provided with steel chromium arc chamber. A further shield
giving protection to the metal bellows shall also follow the travel of the moving
contacts to seal the interrupter against the surroundings atmosphere.
It shall have high and consistent dielectric strength of vacuum unaffected
by environment and switching operations. Bronzed
joints
should
ensure
retention of vacuum for life time. It shall have low and stable contact resistance
due to absence of
oxidation effects and shall ensure low power loss. The arcing voltage shall be low
and minimum contact erosion.
1.17
1.17.1 Within 30 days after the award of the contract, the contractor shall supply six sets of
drawings which will describe the equipment in details, for the approval of
purchaser. All the drawings and manuals should be in English Language and
dimensions and weights shall be in MKS units.
Following drawings and documents for each item are to be supplied as part of
the contract.
a)
General outline drawings, showing dimensions, front and side elevations

and plan of the circuit breaker and its local control panel.
b)
Outline drawing of support insulators showing dimensions and number of

sheds and creepage distance.
c)
Assembly and sub-assembly drawings with numbered
parts.
d)
Sectional views showing the general constructional features,

operating mechanism and are extinguishing chamber, etc.
e)
Dimension and assembly of important
auxiliaries. f) Detailed drawings of operating
mechanism.
g)
Test
certificates
and
oscillographs.
Page | 14
h)
Detailed drawings of mounting
structure. i) Spare parts and catalogue
j)
Wiring diagram showing the local and remote control scheme of
breaker. k)
Write up on working of control schematic of breaker.
l)
Foundation plan including weights of various components and impact
loadings for working foundation design.
Seven copies for each sub-station of the above drawings and instruction
manuals covering instructions for installations, operation and maintenance shall be
supplied by the contractor(s) without any extra cost.
1.18
Not Used
1.19
TESTS
1.19.1 TYPE TESTS

Each circuit breaker shall comply with requirements of type tests prescribed in
IEC publication No.56, type test reports as per stipulations of IEC-56,
performed by an independent testing agency shall be furnished along with the
tender.
Tender
not accompanied with the following type test certificates and other type test
certificates required as per IS and IEC shall be summarily rejected.
i)
test.
Short time and peak withstand current
ii)
Short circuit breaking capacity and making
capacity. iii) Single Capacitor Bank current switching
test.
iv)
Dielectric test i.e., power frequency withstand and impulse withstand
test
v)
test.
vi)
Test.
1.20
Temperature
rise
Mechanical
Endurance
ROUTINE TESTS
Routine Tests as per IEC-56 shall be carried out on each breaker in presence
of purchasers representative at the manufacturers expenses at his works except,
where agreed to otherwise. All test reports should be submitted and should be got
approved from the purchaser before despatch of the equipment.
Page | 15
1.21
SITE TESTS ON CONTROL AND AUXILIARY CIRCUIT

The following tests shall be conducted at
site.
1)
Voltage tests on control and auxiliary
circuit.
2)
Measurements of resistance of the main
circuit.
3)
Mechanical
Tests.
4)
test
1.22
Operation
Insulation Resistance
NAME PLATE
1.22.1 Equipment should be provided with name plate giving full details of
manufacture, capacities and other details as specified in the relevant IS.
Page | 16
12 kV, 1200 A/630 A VCB
1.23
TECHNICAL PARAMETERS
1.23.1 11 KV CIRCUIT BREAKERS

S.
NO.
DESCRIPTION
VALUES
i)
Rate voltage (KV rms)
11 KV
ii)
50
iii)
System neutral earthing
Solidly grounded system
iv)
Type of arc quenching medium
Vacuum
v)
Rated normal current at site conditions

(Amps)
630 A (For Feeder bays)
vi)
Number of poles
vii)
Installation
Outdoor type
viii)
Temperature rise
As per IEC 56 (Table-4)

Page-19
ix)
Rated short circuit
a) Interrupting capacity at 11 KV
25 KA
b) The percentage DC components
As per
IEC
56
(Ref.Page51 21 of IEC)
x)
Rated short circuit making capacity
62.5 KA
xi)
First pole to clear factor
1.5
xii)
Rated short time current
25 KA
xiii)
Rated duration of short circuit
3 Seconds
1250A (for Transformer Bay)
&
Page | 17
12 kV, 1200 A/630 A VCB

xiv)
Total break time for any current upto the

rated breaking current with limiting
condition of operating and quenching
media pressure (ms)
As per IS/IEC
xv)
Closing time (ms)
As per IS/IEC
xvi)
Mounting
Hot dip galvanized lattices

steel support structured
bolted type
xvii)
Phase to phase spacing in the switch yard

i.e, interpole spacing for breaker (min)
As per IS and IE Rule
xviii)
Required ground clearance from the

lowest line terminal if both the terminals
are not in same horizontal plane (cum)
xix)
Height of concrete plinth (mm)
xx)
Minimum creepage distance of support

insulator (mm)
300
S.
NO.
DESCRIPTION
xxi)
Standard value of rated transient

recovery voltage for terminal fault
As per IEC-56
xxii)
Standard value of rated line
RRRV
Characteristics
Surge
Peak
Factor
VALUES
Page | 18
12 kV, 1200 A/630 A VCB

for short line faults
Rated operating
a) duty cycle
O - 0.3 Second CO - 3
Minutes - CO
b) Auto reclosing
Suitable for three phase

Auto reclosing duty
xxiv)
Rated insulation level under heavy

pollution condition 1.2/50 micro second
lightening Impulse withstand voltage
(KV peak)to earth
75 KV
xxv)
Power frequency withstand voltage KV

(rms) to earth (KV rms)
28 KV
xxvi)
Rated characteristic for out of Phase

breaking
a) Out of phase breaking capacity
25% of
capacity
b) Standard values of transient recovery
As oper IEC-56
c) Operating mechanism
Spring
operated,
Anti
pumping and Trip free
mechanism
Three phase 415 Volts 50

C/S or single phase 50 C/S
240 volts
xxiii)
d)
Power
mechanism
available
for operating
Impedence
Factor K=1.6 A
KV/ms=0.214
Z(ohms) = 450
rated
breaking
Page | 19
12 kV, 1200 A/630 A VCB

xxvii)
S.
NO.
a) Rated supply voltage of closing and

operating devices and auxiliary circuits
1)
2)
b) Permissible voltage variation
1)
DESCRIPTION
110 V DC/30 VDC

Series Trip Type
system requiring no DC
supply. Closing in this
case shall be operating
on 240 Volts AC 50 C/S
single phase
3)
415 volts 50 Hz
three phase
In case of DC Power
supply voltage variation
shall be between 85% to
110%
of
normal
voltage.
2)
In case of AC power
supply voltage variation
VALUES
shall be of the normal

voltage as per IS-15%
to +10%.
c) Permissible frequency
3% from normal 50 Hz as
per IS 2026 part-I 1977 para
4.4
d) Combined variation of frequency and

voltage
15%
Page | 20
12 kV, 1200 A/630 A VCB

xxviii) Number of auxiliary contacts
10 Nos and 10 NC on each

pole Continuous current
rating 10 Amps,
DC
breaking rating capacity
shall be 2 Amps with circuit
time constant less than 20
ms at 220/110/30 volts DC
or 240 V AC.
xxix)
Number of coils
2 (Two) trip coils and 1

close coil
xxx)
Rated terminal load
100 kg. Static.

The breaker
shall be
designed to withstand the
rated terminal load, wind,
load, earthquake load and
short circuit forces
Page | 21
12 kV, 1200 A/630 A VCB
Page | 22
INSULATORS
PIN AND DISC INSULATORS
1.0
TECHNICAL DESCRIPTION
1.1
General Requirements
1.1.1
All insulators for 11kV and 33kV shall conform to Type B of latest version of
IS: 731.
1.1.2
Pin insulator shall consist of a single piece of porcelain, intended to be mounted

rigidly on a supporting structure by a pin, which passes up inside the insulator.
The pin type insulator shall have a top groove and shall be threaded to take mild
steel pins. The profile of threads shall be as per IS: 1445.
1.1.3
The strain insulators shall be of Ball and Socket type or Tongue and Clevis
type.
1.1.4
The string insulators shall only be of Ball and Socket type. For 33 kV string will
consists of 3 nos of 12 kV disc insulators.
1.1.5
Following type of guy strain insulators shall be used on guy wires of overhead
lines of different voltage levels:
Power Line Voltage
11kV
33kV
2.0
Designation of Insulators (as per

IS: 5300)
C (2 insulators to be used in series)
Qualifying Requirement for Insulator Manufacturer/Supplier

The manufacturer should have designed, manufactured, tested and supplied 70
electro-mechanical strength disc insulators and 10 KN Pin Insulators for 33kV
or above voltage transmission line of quantities not less than 1300 nos. and 1800
nos. respectively in the last ten (10) years as of the date of bid opening.
3.0
Materials
3.1.
Porcelain
The porcelain used in the manufacture of shells shall be sound, free from
defects thoroughly vitrified and smoothly glazed.
3.2.
Glaze
Page 1 of 12
The finished porcelain shall be glazed in brown colour. The glaze shall cover all
exposed parts of the insulator and shall have a good lusture, smooth surface and
good performance under the extreme weather conditions of a tropical climate. It
shall not crack or chip by ageing under the normal service conditions. The glaze
shall have the same co-efficient of expansion as of the porcelain body
throughout the working temperature range.
3.3.
Cement
Cement used in the manufacture of the insulator shall not cause fracture by
expansion or loosening by contraction. The cement shall not give rise to
chemical reaction with metal fittings and its thickness shall be as small and
uniform as possible. Proper care shall be taken to correctly centre and locate
individual parts during cementing.
4.
Creepage Distance
Medium polluted atmosphere
Highest System
Voltage
Pin Insulator
Strain Insulator
kV
mm
mm
12
230
320
36
580
900
5.
Disc Insulators
5.1.
Pin and Cap
5.1.1
Pins and Caps shall be made of drop forged steel and malleable cast iron/
spheroidal graphite iron/drop forged steel respectively, duly hot dip galvanised
and shall not be made by jointing, welding, shrink fitting or any other process
from more than one piece of material.
5.1.2
Pin and Cap shall be designed to transmit the mechanical stresses to the shell by
compression and develop uniform mechanical strength in the insulator. The cap
shall be circular with the inner and outer surfaces concentric, of such design that
it will not yield or distort under load conditions.
5.1.3
The pin ball shall move freely in the cap socket but without danger of accidental
uncoupling during erection or in position. The design of the disc should be such
that stresses due to expansion or contraction in any part of the insulator shall not
lead to deterioration.
5.2
Security clip
5.2.1
Security clip for use with ball and socket coupling shall be of R-shaped hump
type which shall provide positive locking of the coupling as per IS:2486-(PartPage 2 of 12
Ill)/ IEC:372. The legs of the security clips shall be spread after installation to
prevent complete withdrawal from the socket. The locking device should be
resilient, corrosion resistant and of suitable mechanical strength. There shall be
no risk of the locking device being displaced accidentally or being rotated when
in position- under no circumstances shall locking device allow separation of
insulator units or fittings.
5.2.2
Security clips shall be made of good quality stainless steel or phosphor bronze
as per IS:1385-1968. 2.5% extra Security clip shall be provided.
5.3
Ball and Socket Designation

The dimensions of the balls and sockets shall be of 16 mm designation in
accordance with the standard dimensions stated in IS:2486 - (Part - II).
6.0
Interchangeability
The disc insulators inclusive of fittings shall be of standard design suitable for
use with the hardware fittings of any make conforming to relevant
Indian/International Standards.
7.0
Maintenance
7.1
The insulators offered shall be suitable for employment of hot line maintenance
techniques so that the usual hot line operations can be carried out with ease,
speed and safety.
8.0
Workmanship
8.1
All the material shall be of the latest design and conform to the best modern
practices adopted in the distribution voltage field. Contractors shall offer only
such insulators as are guaranteed by him to be satisfactory and suitable for
specified voltage level and will give continued good service.
8.2
The design, manufacturing process and material control at various stages shall
be such as to give maximum working load, highest mobility, best resistance to
corrosion, good finish and elimination of sharp edges and corners.
8.3
The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
8.4
In disc insulators, metal caps shall be free from cracks, seams, shrinks, air holes,
burrs and rough edges. All surfaces of the metal parts shall be perfectly smooth
with no projecting points or irregularities. All load bearing surfaces shall be
smooth and uniform so as to distribute the loading stresses uniformly.
8.5
All ferrous parts shall be hot dip galvanised to give a minimum average coating
of Zinc equivalent to 600 gm/sq.m. and shall be in accordance with the
requirement of IS:2629-1985 and shall satisfy the tests mentioned in IS:2633
1986. The zinc used for galvanising shall be of Grade Zn 99.95 as per IS:2091979. The zinc coating shall be uniform, adherent, smooth, reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky
white deposits and blisters. The galvanised metal parts shall be guaranteed to
Page 3 of 12
withstand at least six successive dips each lasting for one (1) minute duration
under the standard preece test.
8.6
Before ball fittings are galvanised, all die flashing on the shank surface of the
ball shall be carefully removed without reducing the dimensions below the
design requirements.
8.7
In disc insulators, the design of the insulators shall be such that the shell shall
not engage directly with hard metal. The design shall also be such that when
units are coupled together there is no contact between the shell of one unit and
metal of the next adjacent unit. The design of the shell ribs shall be such that
the security clip of the insulator can be engaged and disengaged easily with hot
stick without damaging the shell ribs.
8.8
Insulator units after assembly shall be concentric and co-axial within limits as
permitted by the relevant Indian Standards.
9.0
Equipment Marking
9.1
Each insulator shall be legibly and indelibly marked with the trademark of the
manufacturer and month & year of manufacture. The guaranteed combined
mechanical and electrical strength shall be indicated in kilo Newton followed by
the word kN to facilitate easy identification and to ensure proper use.
9.2
The marking shall be on porcelain, and shall be printed, not impressed and shall
be applied before firing.
10.0
Bid Drawings
10.1
The Bidder shall furnish full description and illustration of the material offered.
10.2
The Bidder shall furnish along with the bid the outline drawing (6 copies) of
each insulator unit including a cross sectional view of the insulator shell. The
drawing shall include but not limited to the following information:
(a)
Dimensions with manufacturing tolerances
(b)
Minimum Creepage distance with positive tolerance
(c)
Protected creepage distance
(d)
Eccentricity of the disc

(i)
Axial run out
(ii)
Radial run out
(e)
Unit mechanical and electrical characteristics
(f)
Size and weight of Pin Ball Shank / ball and socket parts
(g)
Weight of unit insulator disc
Page 4 of 12
(h)
Materials
(i)
Identification mark
(j)
Manufacturer's catalogue number
10.3
After placement of award, the Contractor shall submit fully dimensioned

insulator drawings containing all the details as given in Clause No. 1.12.2
above, in four (4) copies to Owner for approval. After getting approval from
Owner and successful completion of all the type tests, the Contractor shall
submit 20 more copies of the same drawing to the Owner for further distribution
and field use at Owner's end.
11.0
TESTS AND STANDARDS
11.1
Tests
The following type, acceptance, routine tests and tests during manufacture shall
be carried out on the insulator individually and along with hardware fittings. For
the purpose of this clause :
11.1.1
Type tests shall mean those tests which are to be carried out to prove the design
process of manufacture and general conformity of the material to this
specification. These tests shall be carried out on samples prior to
commencement of commercial production against the specification. The Bidder
shall indicate this schedule for carrying out these tests in the activity schedule.
11.1.2
Acceptance tests shall mean those tests which are to be carried out on samples
taken from each lot offered for pre-despatch inspection for the purpose of
acceptance of that lot.
11.1.3
Routine tests shall mean those tests, which are to be carried out on each
insulator/hardware fitting to check requirements which are likely to vary during
production.
11.1.4
Tests during manufacture shall mean those tests which are to be carried out
during the process of manufacture and end inspection by the Supplier to ensure
the desired quality of the end product to be supplied by him.
11.1.5
The norms and procedure of sampling for these tests will be as per the Quality
Assurance Programme to be mutually agreed to by the Supplier and Owner.
11.1.6
The standards and norms to which these tests will be carried out are listed
against them. Where a particular test is a specific requirement of this
specification, the norms and procedure of these shall be as specified in
Annexure-A of this Section or as mutually agreed to between the Supplier and
the Owner in the Quality Assurance Programme.
11.1.7
For all types and accpetance tests, the acceptance values shall be the values
guaranteed by the Bidder in the Guaranteed Technical Particulars of this
proposal or the acceptance value specified in this specification whichever is
more stringent for that particular test.
Page 5 of 12
11.1.8
For all type and acceptance tests, the Bidder shall guarantee only minimum
values in the Guaranteed Technical Particulars. Bidder shall be required to
achieve the same or higher values, as guaranteed, during testing for all type and
acceptance tests.
11.2
Type Tests
The following type tests shall be conducted on a suitable number of individual
insulator unit, components, materials or complete strings:
(a)
(b)
Thermal mechanical performance test
(c)
Power frequency voltage withstand and flashover test (i) dry (ii) wet
(d)
Impulse voltage withstand and flashover test (dry)
(e)
Visible Discharge test (dry)
(f)
RIV test (dry)
(g)
Mechanical failing Load Test (for pin insulator only)
(h)
11.3
24 hr mechanical strength test (for strain / string insulator only)
Acceptance Tests
(a)
Visual examination
(b)
(c)
Temperature cycle test
(d)
Galvanising test
(e)
Mechanical performance test
(f)
Test on locking device for ball and socket coupling
(g)
Eccentricity test
(h)
Metallurgical Test
(i)
(i)
Grain size
(ii)
Inclusion rating
(iii)
Chemical analysis
)
)
)
)
)
(iv)
Microstructure
For Metal fittings

only
(in Black condition)
Mechanical Failing Load test (for Pin Insulator only)
Page 6 of 12
11.4
(j)
Electro-mechanical strength test (for Strain Insulator only)
(k)
Porosity test
(l)
Puncture test (for Strain Insulator only)
Routine Tests
11.5
(a)
Visual Inspection
(b)
Mechanical routine text (for Strain Insulator only)
(c)
Electrical routine test (for strain insulator only)
Tests During Manufacture

On all components as applicable
(a)
Chemical analysis of zinc used for

galvanising
)
)
(b)
Chemical analysis, mechanical,

metallographic test and magnetic
particle inspection for malleable
castings.
(c)
Chemical analysis hardness tests

and magnetic particle inspection
for forgings
(d)
Hydraulic Internal Pressure tests

on disc insulator shells
)
)
)
)
)
)
)
)
)
)
11.6
Test Voltages
11.6.1
The test voltages of insulators shall be as under :

Highest
System
Voltage
Visible
Wet Power
Discharge Frequency
Test
withstand Test
Annexure A
Annexure A
Power Frequency puncture

withstand test
Pin
Insulator
Strain/string
Insulators
Impulse
voltage
withstand
Test
KV(rms) Kv(rms)
KV(rms)
Kv(rms)
kV(rms)
Kv(rms)
12
35
105
1.3 times the

actural dry
flash over
voltage of
the insulator
75
Page 7 of 12
36
27
75
180
1.3 times the

actural dry
flash over
voltage of
the insulator
170
11.6.3
The withstand and flashover voltages are referred to the Reference

Atmospheric Conditions as per Indian Standards.
11.7
Failing Load
11.7.1
Mechanical Failing Load (For Pin Insulators only)

The insulators shall be suitable for a minimum failing load of 10 KN (for 33kV)
and 5 KN (for 11kV) applied in transverse direction.
Shackle insulators shall be suitable for a minimum failing load of 11.5KN for
type 1 insulator and 16.0 KN for type 2 insulator.
Guy strain insulator type A shall be suitable for a minimum failing load of
44KN whereas, type C shall be suitable for a minimum failing load of 88KN.
11.7.2
Electro-Mechanical Failing Load (For Strain Insulators/ String Insulator

Units)
The insulators shall be suitable for a minimum failing load of 45 KN (for 11kV
lines) applied axially and 70 /90 KN for 33 kV line.
11.8
Testing Expenses
11.8.1
Bidder shall indicate unit type test charges for all type tests covered under this
specification separately, in the relevant schedule of Prices as applicable.
11.8.2
In case of failure of any type test, the Contractor is either required to modify
design of the material and successfully carryout all the type tests as has been
detailed out in this specification or to repeat that particular type test at least
three times successfully at his own expenses.
11.8.3
Contractor shall indicate the laboratories in which they propose to conduct the
type tests. They shall ensure that adequate facilities are available in the
laboratory and the tests can be completed in these laboratories within the time
schedule guaranteed by them in the appropriate schedule.
10.8.4
The entire cost of testing for acceptance and routine tests and tests during
manufacture specified herein shall be treated as included in the quoted Ex-works
Price.
11.8.5
In case of failure in any type test, if repeat type tests are required
to be conducted, then all the expenses for deputation of Inspector / Owner's
representative shall be deducted from the contract price. Also if on receipt of the
Page 8 of 12
Contractor's notice of testing, the Owner's representative does not find 'PLANT'
to be ready for testing the expenses incurred by the Owner for re-deputation
shall be deducted from contract price.
11.8.6
The Contractor shall intimate the Owner about carrying out of the type tests
along with detailed testing programme at least 3 weeks in advance of the
scheduled date of testing during which the Owner will arrange to depute his
representative to be present at the time of carrying out the tests.
11.9
Sample Batch for Type Testing
11.9.1
The Contractor shall offer material for sample selection for type testing only
after getting Quality Assurance Programme approved by the Owner. The
Contractor shall offer at least three times the quantity of materials required for
conducting all the type tests for sample selection. The sample for type testing
will be manufactured strictly in accordance with the Quality Assurance
Programme approved by the Owner.
11.9.2
Before sample selection for type testing, the Contractor shall be required to
conduct all the acceptance tests successfully in presence of Owners
representative.
11.10
Not Used
11.11
Additional Tests
11.11.1
The Owner reserves the right of having at his own expense any other test(s) of
reasonable nature carried out at Contractors premises, at site, or in any other
place in addition to the aforesaid type, acceptance and routine tests to satisfy
himself that the material comply with the Specifications.
11.11.2
Contractors premises or at any other test centre. In case of evidence of non
compliance, it shall be binding on the part of the Contractor to prove the
compliance of the items to the technical specifications by repeat tests or
correction of deficiencies, or replacement of defective items, all without any
extra cost to the Owner.
11.12
Co-ordination for testing

The Contractor shall have to co-ordinate testing of insulators with hardware
fittings to be supplied by other Contractor and shall have to also guarantee
overall satisfactory performance of the insulators with the hardware fittings.
11.13
Not Used.
11.14
Not Used.
11.15
Not Used.
11.16
Packing and Marking
Page 9 of 12
11.16.1
All insulators shall be packed in strong seasoned wooden crates. The gross
weight of the crates alongwith the material shall not normally exceed 200 kg to
avoid handling problem. For marine transportation, crates shall be paletted.
11.16.2
The packing shall be of sufficient strength to withstand rough

handling during transit, storage at site and subsequent handling in the field.
11.16.3
Suitable cushioning, protective padding, or dunnage or spacers shall be provided

to prevent damage or deformation during transit and handling.
11.16.4
All packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and to avoid the possibility of goods being lost or
wrongly despatched on account of faulty packing and faulty or illegible
markings. Each wooden case/crate shall have all the markings stenciled on it in
indelible ink.
Page 10 of 12
ANNEXURE A
1.0
Hydraulic Internal Pressure Test on Shells (if applicable)

The test shall be carried out on 100% shells before assembly. The details
regarding test will be as discussed and mutually agreed to by the Contractor and
Owner in Quality Assurance Programme.
2.0
Thermal Mechanical Performance Test (if applicable)

Thermal Mechanical Performance Test shall be performed in accordance with
IEC-383-1-1993 Clause 20 with the following modifications :
(1)
The applied mechanical load during this test shall be 70% of the rated
electromechanical or mechanical value.
(2)
The acceptance criteria shall be
(a)
X greater than or equal to R + 3S.
Where
3.0
Mean value of the individual mechanical failing load.
Standard deviation.
(b)
The minimum sample size shall be taken as 20 for disc insulator units.
(c)
The individual electromechanical failing load shall be at least equal to

the rated value. Also puncture shall not occur before the ultimate
fracture.
Electromechanical/Mechanical Failing Load Test.

This test shall be performed in accordance with clause 18 and 19 of IEC 383
with the following acceptance
(i)
X greater than or equal to R + 3S

Where
(ii)
Mean value of the electro-mechanical/mechanical/ failing load.
Standard deviation.
The minimum sample size shall be taken as 20 for disc insulators units.
However, for larger lot size, IEC 591 shall be applicable.
Page 11 of 12
(iii)
4.0
The individual electro-mechanical/mechanical failing load shall be at

least equal to the rated value. Also electrical puncture shall not occur
before the ultimate fracture.

Samples taken from the zinc ingot shall be chemically analysed as
per IS:209-1979. The purity of zinc shall not be less than 99.95%.
5.0
Tests for Forgings

forgings, will be as per the internationally recognised procedures for these tests.
The sampling will be based on heat number and heat treatment batch. The
details regarding test will be as discussed and mutually agreed to by the
Contractor and Owner in Quality Assurance Programme.
6.0
Tests on Castings
procedures for these tests. The samplings will be based on heat number and
heat treatment batch. The details regarding test will be as discussed and
mutually agreed to by the Contractor and Owner in Quality Assurance
Programme.
Page 12 of 12
1.
1.1
36 kV OUTDOOR VCB, 1250A
SCOPE
1.1.1. This section of specification covers the design, manufacture, assembly, shop
testing/inspection before dispatch, packing, forwarding, transportation to site,
insurance (during transit, storage and erection), storage, erection, supervision, site
testing and commissioning of 36 KV outdoor type vacuum circuit breakers at
various 33/11 kV substations.
1.1.2. The scope of supply shall also include necessary special tools and plants required
for erection, maintenance and necessary spares, required for normal operation and
maintenance of the circuit breakers for a period of five years.
1.1.3. The circuit breakers should be complete in all respects with insulators, bimetallic
connectors, interruptingchamber, operating
mechanisms
control
cabinet, interlocks,
auxiliary
switches indicating
devices,
supporting structures, accessories, etc., described
herein and briefly listed in the schedule of requirements. The spares/attachments
which are necessary for the smooth functioning of the equipment and specifically
are not mentioned here shall be assumed to be included the scope of supply.
1.2
STANDARDS
1.2.1. The circuit breaker shall conform in all respects to the requirements of latest issue
of IS/IEC specifications except for modifications specified herein.he
equipment manufactured according to any other authoritative standards which
ensure an equal or better quality than the provision of IS/IEC specifications shall
also be acceptable. The salient point of difference between the proposed standard
and provision of these specifications shall be clearly brought out in the tender. A
copy of English version of such specifications shall be enclosed with the tender.
1.2.2. The list of standards mentioned in this specification and to which the circuit
conform is given below:
S.
N.
IS
IEC
1.
IS 13118
IEC-56
Desc
ripti
on Breakers
High Voltage A.C. Circuit
2.
IS 2099
IEC-137
Bushing for alternating Voltages above 1000 volts
3.
IS 12729
IEC-694
Common clauses for high voltages switchgear and

control gear standards
4.
IEC-815
Specification for Creepage distances
5.
IS-4379
Identification of the contents of

industrial gas cylinders
6.
IS-3072
Installation and maintenance of switchgear
7.
IS 9135
8.
IEC 60
High voltage testing technique.
9.
IEC-17A
Study Group
Dec.1981
Sealing of interrupters/breakers
IEC227
PVC insulated cables upto and including 1000

volts
10.
IS-1554
11.
IS-5
12.
1.3
Guide for testing of circuit breakers with

respect to out of phase switching
Colors for ready mixed paints and enamels
IEC 529
Degree of protection provided enclosure
13.
IS 996
IEC 34
AC motors
14.
IS 2629,
2633
ISO 1460
Hot Dip Galvanising
SERVICE CONDITONS
1.3.1. CLIMATIC CONDITONS

The breakers and accessories to be supplied against this specification shall be
suitable for satisfactory continuous operation under the tropical conditions
described in General Technical Requirement.
1.3.2. AUXILIARY POWER SUPPLY

Auxiliary electrical equipment shall be suitable for operation on the following supply
system. (Refer clause 7.1,7.2 & 7.3 of Section 1 for availability of Aux. power supply
available at different s/s)
a)
b)
Power Devices (like drive

motors)
DC Alarm, Control and
Protective Devices
415/240 Volts, 3 phase 4 wire 50 hz,

neutral grounded AC supply
110V/30V DC/ ungrounded 2 wire or 240
V AC
The above supply voltage may vary as indicated below and all devices shall be suitable for
continuous operation over the entire range of voltages
1.4
i)
AC Supply
Voltage + 10%/-15%
Frequency 5%
Combined voltage and frequency +10% to -15%
ii)
DC Supply
-15% to + 10%
GENERAL REQUIREMENT OF 36 KV/OUTDOOR VACUUM CIRCUIT

BREAKERS
The vacuum type circuit breaker, shall have vacuum interrupters, designed to provide a
long contact life at all currents upto rated making and breaking current during switching
operations.
The vacuum interrupters sealed for life shall be
encapsulated by porcelain insulators for out door installation requirement. The breakers
shall be suitable for out door operation under climatic conditions specified without
any protection from sun, rain and dust storm.
The vacuum interrupters of each phase shall be housed in a separate porcelain insulator.
The three identical poles shall be mounted on a common base frame and the contact
system of three poles should be mechanically linked to provide three pole simultaneous
opening/closing.
i)
The performance of breakers shall be adequately proven by type tests for the
designed rating at internationally reputed independent testing station.
ii)
The equipment shall be practically maintenance free over a long period.
iii)
All mechanical parts and linkages shall be robust in construction and

maintenance free, over at least 10000 switching operations except for
lubrication of pins/articulated joints at interval of 5 years or 5000 operations.
iv)
Similar parts shall be strictly interchangeable.

Parts requiring
maintenance shall be easily accessible, without requiring extensive dismantling of
adjacent parts.
v)
The circuit breaker shall be supplied complete with all auxiliary

equipment, meant necessary for the safe operation, routine and periodic
maintenance.
vi)
The breaker shall be totally restrike free under all duty conditions and shall be
capable of performing the duties without opening resistor. The details of any
device incorporated to limit or control the rate of rise of restriking voltage across
the circuit breaker contacts shall be stated. The complete data for the phase factor,
amplitude factor, etc., for rate of rise of re-striking voltage shall be furnished in the
tender.
vii)
The breaker shall be suitable for three phase auto reclosing operation.
viii)
An operation counter, visible from the

mechanism housing closed shall be provided.
ground level
even
with the
1.4.1. FIXED AND MOVING CONTACT

The fixed and moving contacts of the breaker have to ensure permanent full contact during
closing. All making and breaking contacts shall be hermetically sealed and free from
atmospheric effects.
The contacts metallurgy and geometry shall be such that there is minimum contact burning
and wear. Main contact shall have ample area and contact pressure for carrying the rated
current and rated short time current without excessive temperature rise which may cause
pitting or welding of the contacts.
The main contacts should have low contact resistance. The contact should be self cleaning
type, i.e., the layer of copper oxide should be cleaned during rubbing of contacts. The
contact area should be well defined, spring used for contact shall be of gradually rising
characteristic i.e., they should be soft. The contacts should not provide contact grip, i.e.,
electro-magnetic forces should not grip the contacts and oppose the opening process.
Separate main contacts and arcing contacts shall be provided in order to have longer
life of the contacts.
The contours of the
energized metal parts of the breaker shall be such as to eliminate areas or points of high
electrostatic flux concentration.
The circuit breaker units shall be suitable for installation on outdoor R.C.C. foundations.
Ground clearance of the live parts of the breakers should be as per India Electricity Rules,
1956./ CEA Safety Regulation.
1.4.2. RECOVERY VOLTAGE AND POWER FACTOR
The circuit breaker shall be capable of interrupting rated power with recovery voltage
equal to the rated maximum line to line service voltage at rated frequency and at a power
factor equal to or exceeding 0.15.
1.4.3. AUTOMATIC RAPID RECLOSING

36 KV circuit breaker shall be suitable for 3 pole rapid reclosing. The dead time of the
breaker shall be adjustable and the limits of the adjustment shall be stated in the tender.
1.4.4. OUT OF PHASE SWITCHING

The circuit breaker shall be capable of satisfactory operation even under conditions
of phase opposition that may arise due to faulty synchronization. The maximum power
that the breaker can satisfactorily interrupt under Phase Opposition shall be stated in the
bid.
1.4.5. SEISMIC FACTOR
The insulators shall be capable to withstand the seismic acceleration of 0.5 g in horizontal
direction and 0.6g in vertical direction.
1.5
TEMPERATURE RISE
The maximum temperature attained by any part of the equipment when in service at site
and under continuous full load conditions and exposed to the direct rays of the sun shall
not exceed the permissible limits fixed by IEC. When the standards specify the limits of
temperature rise these shall not be exceeded when corrected for the difference between
ambient temperature specified in the approved specification.
The limits of temperature rise shall also be corrected for altitude as per IEC and stated in
the bid.
1.6
INSULATOR SUPPORTS AND HOUSING

The basic insulation level of the external hollow insulator support shall be as per Clause
1.26.1 of the Technical Parameters and these shall be suitable for use under climatic
conditions as per Clause 1.3.1 of this specification.
The porcelain used shall be homogenous, uniformly glazed including the internal surface,
thoroughly vitrified and free from cavities and other flaws.
The
insulators shall be designed to have ample insulation, mechanical strength and rigidity for
satisfactory operation under conditions specified above. All bushings of identical rating
shall be interchangeable.The puncture strength of bushing shall be greater than the
flash over value. The design of bushing shall be such that the complete bushing is a
self-contained unit and no audible discharge shall be detected at a voltage upto a working
voltage (Phase Voltage) plus 10%. The support insulator shall conform to IEC-137.
Minimum clearance between phases, between live parts and grounded objects shall be as
per IS-3072-1975 and should conform to Indian Electricity Rules-1956. The minimum
creepage distance for severely polluted atmosphere shall be 25 mm/KV the protected
creepage distance shall be not less than 50% of total.
1.7
OPERATING MECHANISM GENERAL REQUIREMENTS

The operating mechanism shall be stored energy type in the form of spring charged.
The operating mechanism shall be capable to perform the following
functions efficiently.
i)
To provide means where the circuit breaker can be closed rapidly, without
hesitation at all currents from zero to rated making current capacity.
ii)
To hold the circuit breaker in closed position till the tripping signal is
received.
iii)
To allow the circuit breaker to open without delay immediately on

receiving tripping signal.
iv)
To perform 3 phase auto reclosure duty cycle.
The closing spring shall be automatically charged by motor immediately after

closing operation. In case of failure of supply to the spring charging motor, the
spring shall be chargeable by hand-crank.
The contact
pressure
spring and tripping
spring
shall be
charged/compressed during closing operation to ensure the breaker is ready to
open. Mechanically ON/OFF indicator, spring charged indicator and operation
counter shall be provided on the front of the control cubicle. The tripping spring
shall ensure the tripping even in case of failure of any auxiliary spring.
The supply of auto reclosing scheme control circuit equipment does not form the
part of this specification. The supplier shall however be required to co-ordinate the
same with the supplier of control and relay panels.
a)
Tripping/Closing Coils
The circuit breakers shall be provided with two trip coils and one closing coil per
breaker. First trip coil shall be utilized for tripping the breaker on main protection
fault detection. Second trip coil shall be used to trip the breaker when first trip coil
fails to trip the breaker and backup protection comes into operation and shall also
be used to trip the breaker on command. The trip coils shall be suitable for
preclosing and after closing trip circuit supervision. All the breakers shall
have provision for independent electrical operation of trip coils from local as well
as remote through local/remote selector switch. The breaker shall be provided with
suitable protection device against discrepancies in the operation of individual pole.
b)
Trip Free and anti pumping Features
The trip free mechanism shall permit the circuit breaker to be tripped by the
protective relay even if it is under the process of closing. An antipumping
device to prevent the circuit breaker from reclosing after an automatic opening
shall be provided to avoid the breaker from pumping i.e., anti pumping relay should
interrupt the closing coil circuit.
c)
Controls
The circuit breaker shall be controlled by a control switch located in the control
room. The control arrangement shall be such as to disconnect the remote control
circuits of the breaker, when it is under test. Local/remote selector switch shall be
provided for all breakers for selection of Local control/remote control.
Provision shall be made for local manual, closing, tripping and spring charging
controls.
Necessary equipments for local controls shall be housed
in the circuit breaker cabinet of weather-proof construction.
Each circuit breaker shall have a mechanical open/closed and spring charge
indicator Lamps for indicating, close, open and spring charged position of the
breaker shall also be provided.
Mechanical indicator, to show the òpen and `close position of the breaker
shall be provided in a position where it will be visible to a man standing on ground
with mechanism housing open. An operation counter, visible from the ground even
with the mechanism housing closed, shall be provided. Electrical tripping of the
breaker shall be performed by shunt trip coils.
Closing coil shall operate correctly at all value of supply voltage between
85% and 110% of the rated voltage.Shunt trip coils shall operate correctly
under all operating conditions of circuit breaker upto the rated breaking capacity
and at all values of supply voltage between 85% and 110% of rated voltage.
Bearings which require grease shall be equipped with pressure type fillings.
Bearing pins, bolts, nuts and other parts shall be adequately pinned or locked to
prevent loosening or changing adjustment with repeated operation of the circuit
breaker.It shall be possible to trip the circuit breaker even in the event of failure
of power supply.
Operating mechanism and all accessories shall be enclosed in control cabinet.
A common marshalling box for the three poles of the breaker shall be provided,
along with supply of tubing, cables from individual pole operating boxes to the
common marshalling box, local.
1.7.1. SPRING OPERTED MECHANISM
The operating mechanism shall have all the necessary auxiliaries, apparatus for operation
and supervision, like motor starter with thermal overload release, one closing coil, two trip
coils, push button for local electrical operation, local/remote control selector switch, push
button for direct mechanical tripping, auxiliary switches, antipuming contactors, operation
counter, socket for inspection, lamp and heater with switch.
In
addition
mechanical interlocking system for interlocking with associated isolators shall be
provided. Spring charging motor shall be standard single phase universal motor suitable
for 220 volts supply.
i)
Operating voltages for closing/tripping coils shall be 110 Volts DC or 30 Volts
DC or 240 Volts AC supply. The dc voltage as available at the substation shall be used. If
dc supply is not available at the substation, then 240 V AC will be used for circuit
breaker tripping/closing controls. The CB shall be of Series Trip type requiring no DC
supply. The closing coil for Series Trip type CB shall be operating on 240 Volts AC supply.
ii)
Operating voltages for heater elements shall be 240V AC 50 HZ. Other features
of the spring operated mechanism shall be as follows.
a)
The spring operating mechanism shall have adequate energy stored in the
operating to close and latch the circuit breaker against the rated making current
and also to provide the required energy for tripping mechanism in case the
tripping energy is derived from the operating mechanism.
b) The mechanism shall be capable of performing the rated operating duty

cycle ofO-0.3Sec-CO-3 Min-CO as per IEC-56.
c) The spring charging motor shall be AC/DC operated and shall not take
more than 30 sec., to fully charge the closing spring made for automatic
charging. Charging of spring by the motor should not interfere with the
operation of the breakers.
d) The motor shall be adequately rated to carry out a minimum of one duty
cycle. Also provision shall be made to protect the motor against overloads.
e)
In case of failure of power supply to spring charging motor, the

mechanism shall be capable of performing one open-close-open operation.
f) Mechanical interlocks shall be provided in the operating mechanism to prevent

discharging of the closing springs when the breaker is already in closed
position.
Provision shall be made to prevent a closing
operation to be carried out with the spring partially charged.
g) Facility shall be provided for manual charging of closing springs.
1.7.2. CONTROL CABINET
The switchgear operating mechanism, the control equipment such as switch for local
electrical and manual closing and tripping the breakers, various control relays, antipuming
device, a set of terminal blocks for wiring connections, MCBs for disconnecting the
control auxiliary power supplies including relays, etc., shall be enclosed in a cabinet to be
mounted on a suitable structure at a convenient working height at the end of the breaker in
the outdoor switchyard.
a) Enclosure
The enclosure shall be made out of cold rolled steel plates not less than 3 mm thick
and of light section structural steel. It should be weather proof as well as dust and
vermin proof. The enclosure shall have degree of protection IP55 as per IS 13947. The
cabinet shall have full width and full length hinged doors mounted on the front that swing
fully open. The doors shall be provided with latches to securely hold it with the cabinet.
Doors shall be of sturdy construction, with
resilient material covering, fully perimeterically contacting the cabinet frame to provide
dust protection and prevent metal to metal contact except at the latch points. Filtered
ventilation, shall be provided along with the rigid supports for control and other
equipment. Mounting cabinet members and equipment shall not restrict easy access to
terminal blocks for terminating and testing external connection or to equipment for
maintenance.
All screws and bolts used for assembling and mounting wire and cable termination,
supports, devices and other equipment shall be provided with lock washers or other locking
devices. All metal parts shall be clean and free of weld splatter, rust and mill scale prior to
application of double coat of zinc chromate primer which should be followed by an under
coat to serve as base and binder for the finishing coat. The exterior of the cubicle shall be
painted matty grey to shade No.692 of IS-5 or shade No.631 and interior to white shade.
Sufficient quantity of paints shall also be supplied along with the cubicle to restore
at site any damage during transportation. The mounting structure shall be galvanized
and shall be as per IS-802-II-1978.
b) Heaters
Suitable space heaters shall be mounted in the cabinet to prevent condensation. Heaters
shall be controlled by thermostat. ON/OFF MCB shall be provided. Heaters shall be
suitable for 240 V AC supply voltage.
c) Lighting
One 20 watts fluorescent tube fixture and lamp holder working on 240 V 50 c/s AC
supply shall be provided in each switchgear control cubicle section and shall be located to
provide adequate interior lighting of the cubicle. A single-pole door operated 20 Amp.
`T rated lighting switch shall be provided for each cubicle. One duplex 220 volt
convenience outlet shall be provided inside each door or pair of doors inside each cubicle.
The lighting and convenient outlet circuits shall be completely wired in conduit and
terminated on cubicle terminal blocks.
d) Wiring and Cabling
1.
Unless otherwise specified control wire shall be stranded tinned copper

switchboard wire with 1.1 KV PVC insulation conforming to the requirements of
IS-1554.
1.8
2.
All the control circuit and secondary wiring shall be wired completely and brought
out preferably to a vertical terminal block ready for external connections in
the control cabinet. The control wire shall not be of cross- section less than 2.5
mm2 copper.
3.
All spare auxiliary contacts of the circuit breaker shall be supplied wired upto
terminal block. Each terminal in terminal block shall be suitable for at least 2 x
2.5 mm copper conductor.
4.
At least 20 number spare terminals shall be provided over and above the number
required.
5.
All wiring termination on terminal blocks shall be made through lugs. For current
and DC supply circuits disconnecting stud type terminal blocks will be
provided. For other control circuits, non-disconnecting snap on type terminal
blocks shall be provided.
6.
All wires shall be identified with non-metallic sleeve or tube type markers at each
terminations.
7.
Terminal blocks shall be made up of moulded non-inflammable plastic material

with blocks and barriers moulded integrally have white marking strips for circuit
identification and moulded plastic covers.
e)
Grounding
A ground bus of copper bar not less than 6 mm by 25 mm shall be provided along the
inside of the front or rear of the each cubicle and equipment rack. The ground bus shall be
bolted to the frame of each panel in such a way as to make good electrical contact with
each panel or section. Earth terminals at two ends of the cabinet shall be provided for
connection of the ground bus to the station earth mat.
ACCESSORIES
Each circuit breaker assembly shall be supplied with the following accessories. i)
Line and earthing terminals and terminal connectors.
ii)
Bimetalic terminal connectors.
iii)
Control housing with:
a) One auxiliary switch with adequate number of auxiliary contacts, but not less than
20 nos. (10 No + 10 NC) for each breaker.
b) Operation counter
c) Position indicator (Close/Open/Spring Charged)
d) Necessary cable glands e)
MCB as required
f) Manual trip device and local test push buttons
g) Terminal blocks and wiring for all control equipment and accessories
h) Adequate number of heaters for continuous operation to prevent moisture
condensation in the housing of operating mechanism

i) Selector switch for local/remote control. j)
Internal Illumination fluorescent lamp
k) 5 Amp plug point and socket l)
Motor for spring charging
iv)
Rating and diagram plate as per IS
1.9
SUPPORTING STRUCTURE
The circuit breakers shall be supplied complete with hot dip galvanized steel supporting
structures, foundation and fixing bolts, etc. The structure shall be made of steel MS angle
section conforming to IS 226. The galvanizing shall be as per IS.
The mounting of
the breaker shall be such as to ensure the safety of the operating staff and should
conform to Indian Electricity Rules, 1956. Minimum ground clearance of live part from
ground level shall be 3700 mm.
The bidder shall submit detailed design calculations and detailed drawings in respect of
supporting structures suitable for the equipment offered. The tenders shall specify the
loads which shall be transmitted to the equipment foundation under most adverse operating
conditions of the breaker.
All material for making connections between the circuit breaker and its control shall also
be included in the scope of supply. Facility to earth the circuit breaker structure at two
points shall be provided.
1.10
SURFACE FINISH
1.10.1. All interiors and exteriors of control cubicles and other metal parts shall be
thoroughly cleaned to remove all rust, scales, corrosion, greases or other adhering foreign
matter.
1.10.2. All metal surfaces exposed to atmosphere shall be phosphated as per IS 6005 and there
after given two primer coats of zinc chromate and then two coats of epoxy paint with
epoxy base thinner. All metal parts not accessible for painting shall be made of corrosion
resisting material. All machine finished or bright surfaces shall be coated with a suitable
preventive compound and suitably wrapped on otherwise protected. All paints shall be
carefully selected to withstand tropical heat and extremes of weather within the limits
specified. The paint shall not scale off or wrinkle or be removed by abrasion due to normal
handling.
All external paintings shall be as per shade No.631 of IS:5.
1.10.3. All ferrous hardware, exposed to atmosphere, shall be hot dip galvanized.
1.11
GALVANISING
1.11.1. All ferrous parts including all sizes of nuts, bolts, plain and spring washers, support
channels, structures, shall be hot dip galvanized conforming to latest version of IS:2629 or
any other equivalent authoritative standard.
1.12
CABLE TERMINATION
Suitable cable glands for terminating the multicore cable shall be provided at the bottom of
the control cabinet.
1.13
TERMINAL CONNECTIONS AND EARTH TERMINALS
1.13.1.
Each circuit breaker connected with incoming and outgoing feeders shall be provided
with bolted type bi-directional bimetallic terminal connectors suitable for ACSR
conductor mentioned in `Technical Parameter clause 1.26.1.
1.13.2.
Each circuit breaker pole and control cabinet shall be provided with two
grounding terminals and clamps for receiving ground connections.
1.14
INTERLOCKS
Necessary interlocks to prevent closing or opening of the breaker under low pressure of the
contact spring and devices for initiating alarm shall be provided. Provision shall also be
made to enable electrical interlocking with the isolators associated with the breaker to
prevent opening or closing of the isolators. The detailed interlocking scheme based upon
single line diagram of the substation shall be supplied with the write-up. General
Requirement of interlock shall be as given below:
1.
Isolators should not be operated unless the associated circuit breaker is in open
position.
2.
Line isolator shall close only when the corresponding circuit breaker and earthing
switch of the corresponding line are open. Both electrical and mechanical
3.
The circuit breaker shall close only after all isolators associated with it have
been locked in closed position. Both electrical and Mechanical (casted type)
interlock shall be provided for this.
In case of double bus bar arrangement following additional requirement for

interlocking shall be provided.
1.
2.
One bus bar selector isolator of any bay excepting the bus coupler bay shall
close only when,
a)
The circuit breaker of corresponding bay is open and locked. b) The
other bus isolator of that bay is open.
When one bus isolator of any bay excepting the bus coupler bay is closed.
The other shall close only when the bus coupler circuit breaker and both the bus
isolators are closed.
3.
1.15
Bus isolator of bus coupler bay shall operate only when the bus coupler breaker
is open
EARTHING SYSTEM
50x6 GI flat earthing connections shall be included in the scope of supply. The system
shall comprise of the leads between the circuit breaker and station mat and the
interconnection between phases where necessary. All switchgear enclosures should be
bolted metal to metal and should carry the full earth return current. Connection between
phases at the earthing points shall be dimensioned for carrying full earth return current.
1.16
VACUUM INTERRUPTER ASSEMBLY

Each pole of the circuit breaker shall be provided with vacuum interrupter, one for each
phase, hermetically sealed for life and encapsulated by ceramic insulators. The interrupter
shall be provided with steel chromium are chamber. A further shield giving protection
to the metal bellows shall also follow the travel of the moving contacts to seal the
interrupter against the surroundings atmosphere.
It shall have high and consistent dielectric strength of vacuum unaffected by environment
and switching operations. Bronzed joints should ensure retention of vacuum for life
time.
It shall have low and stable contact resistance due to
absence of oxidation effects and shall ensure low power loss. The arcing voltage shall be
low and minimum contact erosion.
1.17
1.17.1. Within 30 days after the award of the contract, the contractor shall supply six sets of
drawings which will describe the equipment in details, for the approval of Purchaser. All
the drawings and manuals should be in English Language and dimensions and weights
shall be in MKS units.
Following drawings and documents for each item are to be supplied as part of the contract.
a)
General outline drawings, showing dimensions, front and side elevations and plan
of the circuit breaker and its local control panel.
b)
Outline drawing of support insulators showing dimensions and number of sheds

and creepage distance.
c)
Assembly and sub-assembly drawings with numbered parts.
d)
Sectional views showing the general constructional features, operating
mechanism and are extinguishing chamber, etc.

e)
Dimension and assembly of important auxiliaries.
f)
Detailed drawings of operating mechanism. g)

Test certificates and oscillographs.
h)
Detailed drawings of mounting structure. i)
Spare parts and catalogue
j)
Wiring diagram showing the local and remote control scheme of breaker. k)
Write up on working of control schematic of breaker.
l) Foundation plan including weights of various components and impact loadings
for working foundation design.
Seven copies for each sub-station of the above drawings and instruction manuals covering
instructions for installations, operation and maintenance shall be supplied by the
contractor(s) without any extra cost.
1.18
TESTS
1.18.1. TYPE TESTS

Each circuit breaker shall comply with requirements of type tests prescribed in IEC
publication No.56.
1.19
ROUTINE TESTS
Routine Tests as per IEC-56 shall be carried out on each breaker in presence of purchasers
representative at the manufacturers expenses at his works except, where agreed to
otherwise. All test reports should be submitted and should be got approved from the
Purchaser before despatch of the equipment.
1.20
SITE TESTS ON CONTROL AND AUXILIARY CIRCUIT

The following tests shall be conducted at site before commissioning.
1)
Voltage tests on control and auxiliary circuit.
2)
Measurements of resistance of the main circuit.
3)
4)
Mechanical Operation Tests.

Insulation Resistance test
1.21
NAME PLATE
1.21.1. Equipment should be provided with name plate giving full details of manufacture,
capacities and other details as specified in the relevant IS.
1.22
TECHNICAL PARAMETERS
1.22.1.
36 KV CIRCUIT BREAKERS
S.
NO.
DESCRIPTION
VALUES
i)
Rate voltage (KV rms)
36 KV
ii)
50
iii)
System neutral earthing
Solidly grounded system
iv)
Type of arc quenching medium
Vacuum
v)
Rated normal current at site conditions

(Amps)
1250 Amps
vi)
Number of poles
vii)
Installation
Outdoor type
viii)
Temperature rise
As per IEC 56 (Table-4)

Page-19
ix)
Rated short circuit
a) Interrupting capacity at 36 KV
25 KA
b) The percentage DC components
As
per
IEC
56
(Ref.Page51 21 of IEC)
x)
Rated short circuit making
62.5 KA
xi)
First pole to clear factor
1.5
xii)
Rated short time current
25 KA
xiii)
Rated duration of short circuit
3 Seconds
xiv)
Total break time for any current upto

the rated breaking current with
limiting condition of operating and
quenching media pressure (ms)
< 80 ms
xv)
Closing time (ms)
< 150 ms
xvi)
Mounting
Hot dip galvanized lattices

steel support structured
bolted type
xvii)
Phase to phase spacing in the switch

yard i.e, interpole spacing for breaker
(min)
400
&
xviii)
xix)
xxi)
xxiii)
xxiv)
xxv)
xxvi)
xxvii)
xxviii)
Required ground clearance from the :

lowest line terminal if both the
terminals are not in same horizontal
plane
Height(cum)
of concrete plinth (mm)
2820
150
Minimum creepage distance of support

insulator (mm)
Standard value of rated transient
recovery voltage for terminal fault
Standard value of rated line
900
As per IEC-56
RRRV
Characteristics
For short line faults
:
:
Rated operating
Surge
Impedence
Peak
Factor K=1.6 A
KV/ms=0.214
Z(ohms) = 450
a) duty cycle
b) Auto reclosing
:
:
Rated insulation level under heavy

pollution
condition
1.2/50 micro
Power
frequency
withstand
voltage
second lightening Impulse withstand
KV
(rms)
to earth
(KV
rms)
voltage
(KV
peak)to
earth
0-0.3Second-CO-3
Suitable
for three phase
Minutes-CO
Auto reclosing duty
170 KV
70 KV
Rated characteristic for out of Phase

breaking
a) Out of phase breaking capacity
b)
Standard values
recovery
c) Operating mechanism
of
transient
d)
Power available for operating
mechanism
S.
NO.
DESCRIPTION
:
:
25% of rated
capacity
As oper IEC-56
breaking
Spring
operated,
Anti
pumping and Trip free
Three
phase 415 Volts 50
mechanism
C/S or single phase 50 C/S
VALUES
240 volts
xxix)
a) Rated supply voltage of closing and

operating
devices
and
auxiliary
circuits
b) Permissible voltage variation
c) Permissible frequency
xxx)
d) Combined variation of frequency

and voltage
Number of auxiliary contacts
xxxi)
Number of coils
xxxii)
Rated terminal load
1)
2)
110 V DC/30 VDC

Series Trip Type
system requiring no
DC supply. Closing in
this case shall be
operating on 240 Volts
AC 50 C/S single
phase
3)
415 volts 50 Hz
three phase
1)
In case of DC
Power supply voltage
variationshall
be
between 85% to 110%
of normal voltage.
2)
In case of AC
power supply voltage
variation shall be of
the normal voltage as
per IS-15% to +10%.
3% from normal 50 Hz as
per IS 2026 part-I 1977
para 4.4
15%
10 NO and 10 NC on each
pole Continuous current
rating 10 Amps, DC at
110/30 volts DC or 240 V
AC
2 (Two) trip coils and 1
close coil
100 kg. Static.
The breaker
shall be
designed to withstand the
rated terminal load, wind,
load, earthquake load and
short circuit forces
POST INSULATOR
1.0
33 KV and 11 KV Post Insulator:
1.1
Post Insulators are required to provide rigid supports for bus bars part of
Isolators, AB Switches and other equipments/conductors in the sub-station.
1.2
Standard: Except where they conflict with the specific requirement of this
specification, the post insulators, the post insulators shall comply with the IS :
2544-1973, IS : 5350 Part-II 1969(latest) amendments.
1.3.0
Post Insulators: A Post Insulator consists of Post Insulator unit or an assembly

of such units and is intended to rigid support to a live part which is insulated
from earth or from another live part.
1.3.1
Mechanical Strength: The Post Insulators shall be suitable for the minimum
failing loads specified as under:
Sl.
No
Highest
System
voltage
Failing Loads(Min.)
Bending(N)
Torsion(Nm) Tension(N) Compression(N)
12 KV
5000
200
15000
30000
36 KV
4500
680
30000
40000
1.3.2
Puncture Voltage : The voltage at which a the puncture occurs.
1.3.2
Creepage distance : The minimum creepage distance shall be as under :

S.
No
2.0
Highest
Normal and
System Sl.No
moderately
Total
voltage
polluted
atmosphere
(total)
Heavily polluted atmosphere
12 KV
230 mm
380 mm
36 KV
580 mm
840 mm
Protected
420 mm
Atmospheric Conditions:The material offered shall be suitable for operation under the climatic conditions
indicated below:
a)
b)
c)
d)
Maximum temperature of air in shade

Minimum temperature of air in shade
Maximum temperature of air in sun
Maximum humidity
Page 1 of 5
43C
40C
60C
100%
e)
f)
g)
h)
i)
j)
Average number of thunderstorm Per annum

Average number of dust storms per annum
Maximum Rainfall per annum
Average rainfall per annum
Limits of ambient temperature over a period of 24 hours
Wind Pressure
k)
Attitude above MSL
50 days
20
1750 mm
1270 mm
32C
75 Kg/m2
not exceeding 1000
3.0 Reference atmospheric conditions at which Post Insulator or Post Insulator units
characteristics shall be expressed for the purpose of comparison shall be as given
below :
200 C
Ambient temperature
Barometric Pressure
1013 mille bar
Absolute humidity
11 g of water per cubic metric

corresponding to 63 % relative
humidity at 20 degree C.
3.1 Test for the purpose of this standard shall preferably be carried out under conditions
of temperature and humidity specified in IS : 196- 1966(revised) i.e. a temperature of
2720 C and relative humidity of 652 % and at the prevailing atmospheric pressure.
when this is not possible test m ay be carried out under conditions naturally obtaining
at the time of test. The barometric pressure, air temp. and humidity shall be recorded
for the purpose of correction. Correction of test voltage for atmospheric conditions is
given in Appendix-A of IS: 2544 1973.
3.2 General Requirements :
3.2.1 The porcelain shall be sound and free defects, thoroughly vitrified and smoothly
glazed.
3.2.2 Unless otherwise specified the glaze shall be brown in colour. The glaze shall cover
all the expose porcelain part of the insulator except those area which serve as
support or required to be left un-glazed.
3.2.3 Precaution shall be taken during design and manufacture to avoid the following :
a)
Stress due to expansion and contraction which may lead to deterioration .
b)
Stress concentration due to direct engagement of the porcelain with the metal
fittings.
c)
Retention of water in the recesses of metal fitting and
d)
Shapes which do not facilitate easy cleaning by normal methods.
3.2.4
Cement used in the construction of the post insulator shall not cause fracture by
expansion or loosening by contraction and proper care shall be taken to locate the
individual parts correctly during cementing. Further, the cement shall not give rise to
chemical reaction with metal fittings and its thickness shall be as uniform as possible.
Page 2 of 5
3.2.5
All ferrous metal parts except those of stainless steel, shall be hot dip
galvanized and the uniformity of zinc coating shall satisfy the requirements of IS :
2633 1964. The parts shall be galvanized after mechanising . The finished
galvanized surface shall be smooth.
3.2.6
The threads of the tapped holes in the post insulators metal fittings shall be cut
after giving anticorrosion protection and shall be protected against rest by greasing
of other similar means. All other threads shall be cut before giving anti-corrosion
protection. The tapped holes shall be suitable for bolts with threads having anti corrosion protection and shall confirm to IS : 4218(Part-I to VI). The effective length
of thread shall not be less than the nominal diameter of the bolt.
3.2.7
The post insulator unit shall be assembled in a suitable jig to ensure the correct
positioning of the top and bottom metal fitting relative to one another. The faces of
the metal fittings shall be parallel and at right angles to the axis of the insulator and
the corresponding holes in the top and bottom metal fittings shall be in a vertical plan
containing the axis of insulator.
4.0
Classification
The post insulators shall be of typeB according to their construction, which is

defined here under :
A post insulator or a post insulator unit in which the length of the shortest puncture
path through solid insulating material is less than half the length of the shortest flash
over path through air outside the insulator.
5.0
Standard insulation levels :
The standard insulator levels of the post insulator or post insulator unit shall be as under ::
Highest
system
voltage
Visible
discharge
test
Dry
one
minute
power
frequency
withstand
test.
Wet
one
minute
power
frequency
withstand
test.
Power
frequency
puncture
withstand
test.
12 KV 9 KV(rms)
(rms)
35 KV(rms)
35 KV(rms)
1.3 times the 75

actual
dry peak
flash
over
voltage
of
the
unit(KVrms)
KV
36 KV 27 KV(rms)
(rms)
75 KV(rms)
75 KV(rms)
1.3 times the 170

actual
dry peak
flash
over
voltage
of
the
unit(KVrms)
KV
Page 3 of 5
Impulse
voltage
withstand
test.
5.2
In this standard ,power frequency voltage are expressed as peak values divided by 2.
The impulse voltage are expressed as peak values.
5.3 The withstand and flashover voltage are referred to the atmospheric condition.
6.0
6.1
Tests:
The insulators shall comply with the following constitute the type tests :
a) Visual examination.
b) Verification of dimensions.
c) Visible discharge test.
d) Impulse voltage withstand test.
e) Dry power frequency voltage withstand test.
f) Wet power frequency voltage withstand test.
g) Temperature cycle tests.
f) Mechanical strength tests.
g) Puncture test.
h) Porosity test.
i) Galvanising test.
Type test certificates for the tests carried out on prototype of same specifications shall
be enclosed with the tender.
be subjected to the following acceptance test in the order indicated below :
6.2
Acceptance test : The test samples after having withstood routine test shall be
subjected to the at least following acceptance test in the order indicated below :
a) Verification of dimensions.
b) Temperature cycle tests.
c) Mechanical strength tests.
d) Puncture test.
e) Porosity test.
f) Galvanising test.
6.3
Routine tests: following shall must be covered as routine tests on each post insulator
or post insulator unit.
a) Visual examination as per Cl. No.- 9.12 of IS : 2544/1973
Page 4 of 5
b) Mechanical routine test as per Cl. No.- 9.14 of IS : 2544/1973

c) Electrical routine test as per Cl. No.- 9.13 of IS : 2544/1973
7.
Marking
7.1
Each post insulator shall be legibly and indelibly marked to show the following.
a)
Name or trade mark of the manufacturer.
b)
Month of year of manufacture.
c)
Country of manufacture.
7.1.1 Marking on porcelain shall be printed and shall be applied before firing.
7.2
Post insulator or post insulator units may also be mark with I.S.I. certification mark.
8.
Packing
All post insulators shall be pack in wooden crates suitable for easy but rough handling
and acceptable for rail, transport. Where more than one insulator is packed in a create wooden
separators shall be fixed between the insulators to keep individual insulator in position without
movement within the crate.
Page 5 of 5
TECHNICAL SPECIFICATION FOR 5MVA, 33/11 kV ONAN POWER

TRANSFORMERS
1.0
SCOPE
1.1
These specifications are to cover design, engineering, manufacture, shop

testing/inspection before dispatch, packing, forwarding, transportation to site, insurance
(during transit, storage and erection), storage, erection, supervision, site testing and
commissioning of three phase, 50 Hz, 5 MVA,33/11kV Step-down Outdoor ONAN,
Power Transformers complete with all accessories and fittings as specified herein, for
use in Distribution systems. The rated capacity of the transformer shall be on ONAN
basis.
1.2
SPECIFIC TECHNICAL REQUIREMENTS

1.
Rated MVA(ONAN rating)
5 MVA
2.
No. of Phases
3.
Type of Installation
Outdoor
4.
Frequency
50 Hz
5.
Cooling medium
Insulating Oil
6.
Rated voltage
33kV
11kV
Highest continuous system voltage

a) HV Side
b) LV side
36kV
12kV
8.
Type of tap changer
Off-load tap changer
9.
Range of tapings
+5% to 10% in 6 equal steps of

2.5% each on HV winding
10.
Neutral terminal to be brought out
On LV Side only
11 a
Impedance on rated MVA base at 75 7.15% with tolerance limits as per

0
C (5 MVA)
IS.
12.
13.
Type of insulation and insulation level

One minute power frequency withstand
test voltage (kVrms)
14.
16.
Impulse withstand test voltage (kV

170
75
peak)
Winding connection
a) HV Side
Delta
b) LV Side
Star
Winding material
Electrolytic Copper
17.
Vector group
7.
15.
33kV
70
Dyn 11
-1-
11kV
28
18.
Type of cooling
ONAN
19.
Neutral earthing
LV neutral shall be solidly earthed
20.
21
Winding temperature Indicator

Oil Temperature indicator
One no
One No.
22
Current Density
Maximum 2.5 Amp/sq.mm.
23
Flux Density
Maximum 1.69 Tesla at Normal

Voltage and frequency
1.2.1. MAXIMUM TEMPERATURE RISE OVER AN AMBIENT OF 50 0 C

a)
Temperature rise of top oil

(Measured by Thermometer)
50 0C
b)
Temperature rise of winding

(Measured by resistance)
55 0C
The rise in temperature of top oil and winding given above shall be reduced as per clause
3.2 & 3.3 of IS 2026 (Part-I) in case of increase in Ambient above 50 oC and an increase in
altitude above 1000 m.
1.2.2. RATING & SERVICES

a)
Over load capacity
As per IS: 6600.
1.2.3. NOISE LEVEL

As per NEMA Publication No. TR-1 at rated voltage & frequency.
1.2.4. CAPITALIZATION OF LOSSES AND LIQUIDATED DAMAGES

The capitalization of guaranteed losses of the transformer shall be calculated and
considered while evaluating the bids. The guaranteed values of no load losses and load
losses shall be stated in the bid. Liquidated damages will be applied to successful bidder
for not achieving the quoted guaranteed figures. (See clause 7.0).
1.3
PERFORMANCE
The performance of the transformer shall be measured on the following aspects.
i)
ii)
Transformer shall be capable of withstanding short circuit at the terminals for

two seconds.
Transformer shall under exceptional circumstances due to sudden disconnection
of the load, be capable of operating at the voltage approximately 25% above
normal rated voltage for a period of not exceeding one minute and 40% above
normal for a period of 5 seconds.
-2-
iii)
1.4
The transformer may be operated continuously without danger on any particular

tapping at the rated MVA 12.5% of the voltage corresponding to the tapping.
iv)
The thermal ability to withstand short circuit shall be demonstrated by
calculation.
v)
Transformer shall be capable of withstanding thermal and mechanical stress
caused by any symmetrical and asymmetrical faults on any winding.
vi)
The transformer shall be capable of being operated without danger on any
tapping at the rated KVA with voltage variation of + 10% corresponding to the
voltage of the tapping.
vii)
The maximum flux density in any part of the cores and yokes at normal voltage
and frequency shall be such that the flux density on any tap position with +12.5%
voltage variations and 5% frequency variations shall not exceed 1.9 wb/m2.
viii)
Radio interference and Noise Level
ix)
The transformer shall be designed with particular attention to the suppression of
third and fifth harmonics so as to minimise interference with communication
circuits
AUXILIARY POWER SUPPLIES
The following power supplies shall be available at site :
i)
ii)
iii)
1.5
AC, 3 phase, 415 volts, 50 Hz. earthed

AC, 1 phase, 230 volts, 50 Hz. earthed
30V DC.
DRAWINGS/DOCUMENTS
1.5.1. Following drawings/documents incorporating name of project and transformer

rating shall be submitted for approval.
i)
Detailed overall general outline drawing showing front and side elevations and plan of
the transformer and all accessories including radiators and external features with details
of dimensions, spacing of wheels in either direction of motion, net weights and shipping
weights, crane lift for un-tanking, bushing lifting height, clearances between HV and LV
terminals and ground, quantity of insulating oil etc.
ii)
Foundation plan showing loading on each wheel and jacking points with respect to centre
line of transformer.
iii)
GA drawings/details of bushing.
iv)
Name plate drawing with terminal marking and connection diagrams.
v)
Wheel locking arrangement drawing.
vi)
Transportation dimensions drawings.
vii)
GA drawing of marshalling box.
viii)
Control scheme/wiring diagram of marshalling box.
ix)
Technical leaflets of major components and fittings.

-3-
x)
Oil temperature indicator and winding temperature indicator showing.
xi)
Completed technical data sheets.
xii)
Details including write-up of tap changing gear.
xiii)
Bi- metallic connector for connection to conductor/cable.
xiv)
Maintenance and Operating Instructions.
xv)
As built version of the drawings and documents.
1.6
MISCELLANEOUS
i)
Padlocks alongwith duplicate keys as asked for various valves, marshalling box
etc., shall be supplied by the contractor, wherever locking arrangement is
provided.
ii)
1.7
Foundation rails, bolts, clamps for fixing rail, wheel locking devices of
Transformer shall be supplied by the Contractor.
ALTITUDE FACTOR
If the equipment is to be installed in altitude above 1000 meter, necessary correction
factors as given in the Indian Standard for oil temperature rise, insulation level etc. shall
be applied to the Standard Technical Parameters given above.
1.8
NAME PLATE
Transformer rating plate shall contain the information as given in clause 15 of IS-2026
(Part-I). The details on rating plate shall be finalised during the detailed engineering.
2.0
2.1
CODES & STANDARDS

General
(i)
2.2
The design, material, fabrication, manufacture, inspection, testing before

dispatch, erection, testing, commissioning and performance of power
transformers at site shall comply with all currently applicable statutory
regulations and safety codes in the locality where the equipment will be installed.
The equipment shall also conform to the latest applicable standards and codes of
practice. Nothing in this specification shall be construed to relieve the contractor
of this responsibility.
The equipment, materials and service covered by this specification shall conform to the
latest applicable provision of the following standards:
-4-
IS:5
Colour for ready mixed paints
IS:335
New insulating oil for transformers,

Switchgears
IS:1271
Classification of insulating materials

for electrical machinery and apparatus
in relation to their stability in services
IS:2026 (Part I to IV)
Power Transformer
IS:2071
Method of high voltage testing
IS:2099
High voltage porcelain bushings
IS:13947
IS:3347
:
:
IS: 3637
IS:3639
Dimensions for porcelain Transformer

Bushings
:
Degree of protection of enclausers
Gas operated relays
Fittings and accessories for power

Transformers
IS: 5561
Electric Power Connectors
IS: 6600
Guide for loading of oil immersed

Transformers
IS: 6005
Code of practice for phosphating of iron and

steel
IS: 10028
C.B.I.P. Publication
Code of practice for selection, installation

and maintenance of transformers, Part I,
II and III
Manual on Transformers
If the standard is not quoted for any item, it shall be presumed that the latest
version of the relevant Indian Standard shall be applicable to that item.
The equipment complying other internationally accepted standards, may also be
considered if they ensure performance superior to the Indian Standards. If the standard is
of language other than English, an English translation shall be provided
3.0
3.1
GENERAL CONSTRUCTIONAL FEATURES

All material used shall be of best quality and of the class most suitable for working
under the conditions specified and shall withstand the variations of temperature and
atmospheric conditions without distortion or deterioration or the setting up of undue
-5-
stresses which may impair suitability of the various parts for the work which they have
to perform.
3.2
Similar parts, particularly removable ones, shall be interchangeable.
3.3
Pipes and pipe fittings, screws, studs, nuts and bolts used for external connections shall
be as per the relevant standards.
Nuts, bolts and pins used inside the transformers and tap changer compartments shall be
provided with lock washers or locknuts.
3.4
3.5
Exposed parts shall not have pockets where water can collect.
3.6
Internal design of transformer shall ensure that air is not trapped in any location.
3.7
Material in contact with oil shall not react with oil or to contribute to the formation of
acid in oil. Surface in contact with oil shall not be galvanized or cadmium plated.
3.8
Labels, indelibly marked, shall be provided for all identifiable accessories like switches
etc. All label plates shall be of in-corrodible material.
3.9
All internal connections and fastenings shall be capable of operating under overloads
and over-excitation, allowed as per specified standards without injury.
3.10
Transformer and accessories shall be designed to facilitate proper operation, inspection,

maintenance and repairs.
3.11
No patching, plugging, shimming or other such means of overcoming defects,

discrepancies or errors will be accepted.
3.12
Schematic Drawing of the wiring, including external cables shall be put under the
prospane sheet on the inside door of the transformer marshalling box.
4.0
Surface Preparation And Painting Of Transformer Tanks, Radiators, Marshalling

Boxes, Core Clamps & Fabricated Parts
4.1
Surface Preparation for tank, Pipes, etc.:

All surfaces of transformer tank, pipes, etc shall be thoroughly blast cleaned with sand or
shot or grit in accordance with ISO 8501 Part 1 to a minimum standard of Sa2 to make
the surface free from visible oil, grease & dirt, mill scale, rust, paint coatings and foreign
matter. Machined areas and threaded components etc are to be covered during blasting to
prevent damage.
The air that is used for blasting should be dry and free from oil. The flanges, angles, tank
curbs and other such areas shall be preferably blast cleaned prior to fabrication and paint
these with one coat of primer. After adequate blast cleaning of each large surface where
blasting time is more than three hours, an overall blast cleaning is to be done on the entire
surface once more so that entire surface areas is exposed as fresh for first coat of primer
paint. The first coat of primer paint should be applied not later than 3-4 hours after
preparation of surface to avoid oxidation.
-6-
4.2
Surface Preparation for radiatorAll internal and external surfaces of radiator shall be thoroughly cleaned either by
chemical cleaning or by blast with sand or shot or grit in accordance with ISO 8501 Part
1 to make the surface free from visible oil, grease & dirt, mill scale, rust, paint coatings
and foreign matter. Suitable chemical should be used for chemical cleaning, if required.
The air that is used for blasting should be dry and free from oil. After adequate surface
cleaning, the first coat of primer paint/varnish should be applied not later than 3-4 hours
after preparation of surface to avoid oxidation.
4.3
Painting- external & internal surfacesPainting shall be carried out in closed and dust free area. The external surface shall be
coated with suitable layers of paint and to form an impermeable layer so that air and
water cannot reach the substrate. The paint selected shall be stable in outdoor condition
such as rain, sunlight, pollution etc. Paint used for primer, under coat and top or finish
coat should be from the same manufacturer and compatible to each other. In case in the
rare event, paint used for primer, under coat and finish coat are not from the same
manufacturer the compatibility test of the paint from different source shall be carried out.
Painting shall be applied as per the recommendation of the paint manufacturer. The
number of coats shall be such that the minimum dry film thickness (DFT) specified is
achieved. The DFT of painted surface shall be checked with a measuring gauge to ensure
specified DFT. Complete painting scheme for the transformer is tabulated below:
4.4
Painting-Transformer tank, pipes, radiator etc.:
SURFA
CE
PREPA
RATIO
N
Tank, pipes, etc. Blast
cleaning
(External
Sa2
surfaces)
PRIMER
COAT
INTERMEDI
ATE
UNDERCOA
T
FINISH
COAT
Epoxy base Epoxy

HB Aliphatic
Zinc primer MIO
(30-40 Polyurethan
e (min 50
(30-40 m)
m)
m)
Hot
oil --Tank (Internal Blast
cleaning resistant, nonsurfaces)
Sa2
corrosive
varnish
or
paint
or
epoxy
Chemica Epoxy base Epoxy
base PU
paint
Radiator
l / blast zinc primer zinc
primer (min 50m)
(External
cleaning (30-40m)
surfaces)
(30-40m)
(Sa2)
Radiator
and Chemica
Hot oil proof, --
-7-
--
TOTAL
DFT
COLOUR
SHADE
Min
m
155 697 shade as

per IS 5
Min
m
30 Glossy white
for paint
Min
110m
--
Matching
shade of tank/
different
shade
aesthetically
matching to
tank
--
pipes (Internal l
cleaning
surfaces)
if
required
4.5
low viscosity
varnish,
flushing with
transformer
oil.
Surface Preparation for Control cabinets/Marshalling Boxes-
4.5.1. Surface Preparation for all Transformer Control cabinets/Marshalling Boxes shall be
carried out confirming to following Indian standard in dust free area:
i)
IS: 3618: Degreasing by solvent wiping: Phosphate Treatment of Iron &Steel for
Protection against corrosion.
ii)
IS: 6005: Code of Practice for phosphating of Iron & Steel.
4.5.2. Chemicals: Suitable chemicals should be used and concentration of chemicals /weight of
Phosphate coating should be checked regularly as per recommendation of the chemical
manufacturer and applicable IS.
4.5.3. Inspection: The surface for application of paint should be dry, free from oil, dirt, acid &
loose adhering powder and reasonably smooth in finish without uncovered areas, rusty
surfaces and roughness.
4.6
Painting- Control cabinets/Marshalling Boxes -Enamel paint shall be used with total paint
thickness as minimum 80 microns.
5.0
DETAILED DESCRIPTION
5.1
Tank
5.1.1. The Transformer tank and cover shall be fabricated from high grade low carbon plate
5.1.2.
5.1.3.
5.1.4.
5.1.5.
5.1.6.
steel of tested quality of adequate thickness. The tank and the cover shall be of welded
construction. All welds shall be stress relieved. Stiffener shall be provided for general
rigidity. Tank surface shall be designed to prevent retention of water.
Tank shall be designed to permit lifting by crane or jacks of the complete transformer
assembly filled with oil. Suitable lugs and bosses shall be provided for this purpose.
All beams, flanges, lifting lugs, braces and permanent parts attached to the tank, shall be
welded and where practicable, they shall be double welded.
The main tank body of the transformer, excluding tap changing compartments and
radiators, shall be capable of withstanding pressure of 760 mm of Hg.
All bolted connections to the tank shall be fitted with suitable oil-tight gaskets which
shall give satisfactory service under the operating conditions for complete life of the
transformer. Special attention shall be given to the methods of making the hot oil-tight
joints between the tank and the cover as also between the tank cover and the bushings and
all outlets to ensure that the joint can be remade satisfactorily and with ease, with the help
of semi-skilled labour. Where compressible gaskets are used, steps shall be provided to
prevent over-compression.
Suitable guides shall be provided for positioning the various parts during assembly or
dismantling. Adequate space shall be provided between the cores and windings and the
bottom of the tank for collection of any sediment.
-8-
5.1.7. The tank shall withstand

i)
ii)
iii)
5.2
Mechanical shock during transportation.

Vacuum of 760 mmHg
Internal pressure which may developed during service
Tank Cover
5.2.1. The transformer top shall be provided with a detachable tank cover with bolted flanged
gasket joint. Lifting lugs shall be provided for removing the cover. The surface of the
cover shall be suitably sloped so that it does not retain rain water.
5.2.2. Inspection hole(s) with welded flange(s) and bolted cover(s) shall be provided on the tank
cover. The inspection hole(s) shall be of sufficient size to afford easy access to the lower
ends of the bushings, terminals etc.
5.2.3. Pockets shall be provided for bulbs of OTI & WTI. Air and Oil tightness shall be ensured
for the same.
5.2.4. The bolted openings shall be fitted with weather proof hot oil resisyant neoprene gasket
for complete tightness.
5.3
UNDER CARRIAGE
5.3.1. The transformer tank shall be supported on steel structure with detachable plain rollers
completely filled with oil. Suitable channels for movement of roller with transformer
shall be spaced
accordingly. Rollers wheels shall be provided with suitable rollers
bearings, which will resist rust and corrosion and shall be equipped with fittings for
lubrication. It shall be possible to swivel the wheels in two directions, at right angle to or
parallel to the main axis of the transformers.
5.3.2. Jacking pads shall be provided on the transformer. It shall be possible to change the
direction of the wheels through 90 degree when the transformer is lifted on jacks to
permit movement of the transformer both in longitudinal and transverse directions.
5.4
CORE
5.4.1. Stage level inspection for core construction shall be carried out by the owner.
5.4.2. The core shall be constructed either from high grade, non-aging Cold Rolled Grain
Oriented (CRGO) silicon steel laminations conforming to grade M4 or better. The
maximum flux density in any part of the cores and yoke at normal voltage and frequency
shall be such that the flux density with + 12.5 % voltage variation from rated voltage or
frequency variation of -5% shall not exceed 1.9 Tesla. The bidder shall provide
saturation curve of the core material proposed to be used.
5.4.3. The bidder should offer the core for inspection and approval by the purchaser during the
manufacturing stage. Bidders call notice for the purpose should be accompanied with the
following documents as applicable as a proof towards use of prime core material:
a) Invoice of the supplier
b) Mills test certificate
c) Packing list
-9-
d) Bill of lading
e) Bill of entry certificate to customs
Core material shall be directly procured either from the manufacturer or through their
accredited marketing organization of repute and not through any agent.
5.4.4. The laminations shall be free of all burrs and sharp projections. Each sheet shall have an
insulating coating resistant to mechanical pressure and the action of hot oil.
5.4.5. The insulation structure for the core to bolts and core to clamp plates, shall be such as to
withstand 2000 V AC voltage for one minute.
5.4.6. The completed core and coil shall be so assembled that the axis and the plane of the outer
surface of the core assembly shall not deviate from the vertical plane by more than 25
mm.
5.4.7. All steel sections used for supporting the core shall be thoroughly shot or sand blasted,
after cutting, drilling, welding and before painting.
5.4.8. The finally assembled core with all the clamping structures shall be free
from
deformation and shall not vibrate during operation.
5.4.9. The core clamping structure shall be designed to minimize eddy current loss.
5.4.10. The framework and clamping arrangements shall be securely earthed.
5.4.11. The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical
strength.
5.4.12. The design of magnetic circuit shall be such as to avoid static discharges, development of
short circuit paths within itself or to the earthed clamping structure and production of flux
component at right angle to the plane of the lamination, which may cause local heating.
The supporting framework of the cores 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.
5.4.13. The construction is to be of `core type. The core shall be provided with lugs suitable for
lifting the complete core and coil assembly. The core and coil assembly shall be so fixed
in the tank that shifting will not occur during transport or short circuits and the assembly
shall withstand these with ease.
5.5
INTERNAL EARTHING
5.5.1. All internal non alive metal parts of the transformer, with the exception of individual
laminations, core bolts and their individual clamping plates shall be earthed by
connecting to tank by copper strip.
5.5.2. The magnetic circuit shall be connected to the clamping structure at one point only and
this shall be brought out of the top cover of the transformer tank through a suitably rated
insulator. A disconnecting link shall be provided on transformer tank to facilitate
disconnections from ground for IR measurement purpose.
5.5.3. Coil clamping rings of metal at earth potential shall be connected to the adjacent core
clamping structure on the same side as the main earth connections.
5.6
WINDING
5.6.1.
Winding shall be subjected to a shrinking and seasoning process, so that no further

shrinkage occurs during service. Adjustable devices shall be provided for taking up
possible shrinkage in service.
- 10 -
5.6.2.
All low voltage windings for use in the circular coil concentric winding shall be
wound on a preformed insulating cylinder for mechanical protection of the winding
in handling and placing around the core.
5.6.3.
Winding shall not contain sharp bends which might damage the insulation or produce
high dielectric stresses. No strip conductor wound on edge shall have width
exceeding six times the thickness.
5.6.4.
Materials used in the insulation and assembly of the windings shall be insoluble, non
catalytic and chemically inactive in the hot transformer oil and shall not soften or the
otherwise affected under the operating conditions.
5.6.5.
Varnish application on coil windings may be given only for mechanical protection
and not for improvement in dielectric properties. In no case varnish or other adhesive
be used which will seal the coil and prevent evacuation of air and moisture and
impregnation by oil.
5.6.6.
Winding and connections shall be braced to withstand shocks during transport,

switching or short circuit.
5.6.7.
Permanent current carrying joints in the windings and leads shall be welded or
brazed. Clamping bolts for current carrying parts inside oil shall be made of oil
resistant material which shall not be affected by acidity in the oil steel bolts, if used,
shall be suitably treated.
5.6.8.
Terminals of all windings shall be brought out of the tank through bushings for
external connections. The leads used shall be rigidly supported and guide tubes shall
be provided where practicable.
5.6.9.
The completed core and coil assembly shall be dried in vacuum at not more than
0.5mm of mercury absolute pressure and shall be immediately impregnated with oil
after the drying process to ensure the elimination of air and moisture within the
insulation.
5.6.10.
The winding shall be so designed that all coil assemblies of identical voltage ratings
shall be interchangeable and field repairs to the winding can be made readily without
special equipment. The coils shall have high dielectric strength.
Coils shall be made of continuous smooth high grade electrolytic copper conductor,
shaped and braced to provide for expansion and contraction due to temperature
changes.
Adequate barriers shall be provided between coils and core and between high and
low voltage coil. End turns shall have additional protection against abnormal line
disturbances.
The insulation of winding shall be designed to withstand voltage stress arising from
surge in transmission lines due to atmospheric or transient conditions caused by
switching etc.
Tappings shall not be brought out from inside the coil or from intermediate turns and
shall be so arranged as to preserve as far as possible magnetic balance of the
transformer at all voltage ratios.
5.6.11.
5.6.12.
5.6.13.
5.6.14.
- 11 -
5.6.15.
5.6.16.
5.7
Magnitude of impulse surges transferred from HV to LV windings by electro

magnetic induction and capacitance coupling shall be limited to B.I.L. of LV
winding.
The assembly shall be designed to ensure free circulation of oil
INSULATING OIL
5.7.1. The insulating oil shall conform to IS: 335. No inhibitors shall be used in the oil.
5.7.2. The quantity of oil required for the first filling of the transformer and its full specification
shall be stated in the bid. The transformer shall be supplied filled with oil above winding
level and rest of the oil supplied in non-returnable drums.
5.7.3. The design and materials used in the construction of the transformer shall be such as to
reduce the risk of the development of acidity in the oil.
5.7.4. The contractor shall warrant that oil furnished is in accordance with the following
specifications.
S. No
1
2
3
Characteristic
Appearance
Requirement
The oil shall be clear &
suspended
matter
or
Sediment
Electric strength Break Less than 72.5 kV
Down (voltage) Min.
Water content Max:
Less than 25 ppm
Method of Test
A representative sample of oil
shall be examined in a 100
mm thick layer at ambient
temp.
IS: 6792
IS: 2362
All other characteristic shall be as per IS 335
5.8
VALVES
5.8.1. Valves shall be of forged carbon steel or Gun metal upto 50 mm. They shall be of full
way type with screwed ends and shall be opened by turning counter clockwise when
facing the hand wheel. There shall be no oil leakage when the valves are in closed
position.
5.8.2. Each valve shall be provided with an indicator to show the open and closed positions and
shall be provided with facility for padlocking in either open or closed position. All
screwed valves shall be furnished with pipe plugs for protection. Padlocks with duplicate
keys shall be supplied alongwith the valves.
5.8.3. All valves except screwed valves shall be provided with flanges having
machined
faced drilled to suit the applicable requirements. Oil tight blanking plates shall be
provided for each connection for use when any radiator is detached and for all valves
- 12 -
opening to atmosphere. If any special radiator valve tools are required, the Contractor
shall supply the same.
5.8.4. Each transformer shall be provided with following valves on the tank:
a)
b)
c)
d)
e)
Drain valve so located as to completely drain the tank.

Two filter valves on diagonally opposite corners, of 50 mm size.
Oil sampling valves not less than 8 mm at top and bottom of main tank.
One 15 mm air release plug.
Valves between radiators and tank.
Filter valves shall be suitable for applying vacuum as specified in the specifications.
5.9
ACCESSORIES
5.9.1. Bushing HV & LV

Porcelain Bushing on top of tank shall be provided on HV and for cable termination on
LV side.
i)
All porcelain used in bushings shall be homogeneous, non-porous, uniformly

glazed to brown colour and free from blisters, burns and other defects.
ii)
Stress due to expansion and contraction in any part of the bushing shall not lead
to deterioration or loosening of cemented joint.
iii)
The creepage distance shall be not less than 25 mm/kv and protected creepage
distance shall be not less than 50% of total.
iv)
Each bushing shall be capable to carry at least 200% of current of Continuous

Maximum Rating (CMR) of transformer and the short time current shall be of the
same as of transformer.
v)
Arcing horns are to be provided with adjustable horn gap except the neutral
bushing.
vi)
Clamps and fittings made of steel or malleable iron shall be galvanized.
vii)
Bushing shall be so located on the transformers that full flashover strength will
be utilized. Minimum clearances as required for the BIL shall be realized
between live parts and live parts and live parts to earthed structures.
viii)
All applicable routine and type tests certificates of the bushings shall be
furnished for approval.
ix)
Bushing shall be supplied with bi-metallic and bi directional/terminal connector

for connection to specified ACSR/AAC conductors.
x)
Bushing of identical voltage rating shall be interchangeable.
- 13 -
xi)
Each bushing shall be so coordinated with the transformer insulation that all
flashover will occur outside the tank.
5.9.2. Protection & Measuring Devices
(ii)
i)
Oil Conservator
(a)
The conservator shall have adequate capacity between highest and lowest visible
levels to meet the requirement of expansion of the total cold oil volume in the
transformer and cooling equipment.
(b)
The conservator shall be bolted into position so that it can be removed for
cleaning purposes.
(c)
The conservator shall be fitted with magnetic oil level gauge with low level
electrically insulated alarm contact.
(d)
It shall be provided with oil filling hole with cap on top and a drain valve at the
bottom.
Pressure Relief Device

A pressure relief device shall be provided of sufficient size for rapid release of any
pressure that may be generated in the tank and which may result in damage of the
equipment. The device shall operate at a static pressure of less than the hydraulic test
pressure of transformer tank. It shall be mounted direct on the tank. A pair of electrically
insulated contacts shall be provided for tripping when the device operates.
(iii)
Buchholz Relay
A double float type Buchholz relay shall be provided. Any gas evolved in the
transformer shall collect in this relay. The relay shall be provided with a test cock
suitable for a flexible pipe connection for checking its operation. A copper tube shall be
connected from the gas collector to a valve located about 1200 mm above ground level to
facilitate gas sampling with the transformer in service. The device shall be provided with
two electrically independent potential free contacts, one for alarm on gas accumulation
and the other for tripping on sudden rise of pressure.
(iv)
Temperature Indicator
(a)
Oil Temperature Indicator (OTI)

The transformers shall be provided with a 150 mm dial type thermometer for top oil
temperature indication with maximum reading pointer. The thermometer shall have
adjustable, electrically independent potential free alarm and trip contacts. Maximum
reading pointer and resetting device shall be provided in the marshalling box. A
temperature sensing element suitably located in a pocket on top of tank shall be
furnished. This shall be connected to the OTI by means of capillary tubing. Accuracy
class of OTI shall be + 2% or better.
(b)
Winding Temperature Indicator (WTI)
- 14 -
A device for measuring the hot spot temperature of the winding shall be
provided. It shall comprise the following.
i)
ii)
iii)
iv)
v)
5.9.3.
Temperature sensing element

Image Coil.
Auxiliary CTS, if required to match the image coil, shall be furnished
and mounted in the marshalling box.
150 mm dial local indicating instrument with maximum reading pointer
and resetting device mounted in marshalling box and with adjustable
electrically independent ungrounded contacts, one for high winding
temperature alarm and one for trip. Accuracy class of WTI shall be + 2%
or better.
Calibration device.
Oil Preservation Equipment
The conservator shall be fitted with a dehydrating silica gel filter breather. It shall
be so designed that,
i)
ii)
iii)
iv)
5.10
Passage of air is through a dust filter & Silica gel

Silica gel is isolated from atmosphere by an oil seal.
Moisture absorption indicated by a change in colour of the crystals of the
silica gel can be easily observed from a distance.
Breather is mounted not more than 1400 mm above rail top level.
MARSHALLING BOX
i)
Sheet steel (not less than 2 mm thick), weather, vermin and dust proof
marshalling box fitted with required glands, locks, glass door, terminal Board,
water-tight hinged and padlocked door of a suitable construction shall be
provided with each transformer to accommodate temperature indicators, terminal
blocks etc. The box shall have sloping roof and the interior and exterior painting
shall be in accordance with the specification. Padlock alongwith duplicate keys
shall be supplied for marshalling box. The degree of protection shall be IP-55.
ii)
The schematic diagram of the circuitry inside the marshalling box be prepared
and fixed inside the door under a prospone sheet.
iii)
The marshalling box shall accommodate the following equipment:

a)
b)
c)
Temperature indicators
Space for accommodating Control & Protection equipment in future for
the cooling fan (for ONAF type cooling, may be provided in future))
Terminal blocks and gland plates for incoming and outgoing cables.
All the above equipment except (c) shall be mounted on panels and back of panel
wiring shall be used for inter-connection. The temperature indicators shall be so
- 15 -
mounted that the dials are not more than 1600 mm from the ground level and the
door (s) of the compartment(s) shall be provided with glazed window of adequate
size.
The transformer shall be erected on a plinth which shall be 2.5 feet above ground
level.
5.11
i)
To prevent internal condensation, a metal clad space heater with thermostat shall
be provided. The heater shall be controlled by a MCB of suitable rating mounted
in the box. An 11 W CFL shall be provided for illumination with door operated
switch.
ii)
All incoming cables shall enter the kiosk from the bottom and the gland plate
shall not be less than 450 mm from the base of the box. The gland plate and
associated compartment shall be sealed in suitable manner to prevent the ingress
of moisture.
iii)
The control connection, wiring etc. shall be as per Clause 5.13 of this
specification.
OFF LOAD TAP CHANGER
(i)
The transformers shall be provided with Off- load Taps.
(ii)
The Transformer with off-load tap changing gear shall have taps ranging from
+5% to 10% in 6 equal steps of 2.5% each on HV winding for voltage
variation.
The tap changing switch shall be located in a convenience position at one side of
the tank so that it can be operated from ground level. The switch handle shall be
provided with locking arrangement along with a position indication.
(iii)
5.12
FITTINGS
The following fittings shall be provided on the transformers:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
Conservator with isolating valves, oil filling hole with cap and drain valve.
Magnetic type oil level gauge (150 mm dia.) with low oil level alarm contacts.
Prismatic/toughened glass oil level gauge.
Silica gel breather with oil seal and connecting pipe complete with first fill of
activated silica gel.
A double float type Buchholz relay with isolating valve, bleeding pipe and a
testing cock. The relay shall be provided with shut off valve on the conservator
side as well as on the tank side.
Pressure relief devices (including pressure relief valve) and necessary air
equalizer connection between this and the conservator with necessary trip
contacts.
Air release plugs in the top cover.
Inspection covers, access holes with bolted covers for access and inspection of
inner ends of bushing, core/coil assembly etc.
- 16 -
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
xix)
xx)
xxi)
xxii)
xxiii)
xxiv)
xxv)
xxvi)
Note: (i)
(ii)
5.13
Winding temperature indicating device for local mounting complete in all

respects.
Dial thermometer with pocket for oil temperature indicator.
Lifting lugs for the top cover, core and coils and for the complete transformer.
Jacking pads.
Haulage lugs.
Protected type mercury/alcohol in glass thermometer and a pocket to house the
same.
Top and bottom filter valves on diagonally opposite ends with pad locking
arrangement on both valves.
Top and bottom sampling valves.
Drain valve with pad locking arrangement and blanking plate.
Rating and connection diagram plate valve schedule plate.
Two numbers tank earthing terminals with associated nuts and bolts for
connections to purchasers grounding strip.
Bidirectional flanged rollers.
Marshalling Box (MB)
Cooling Accessories :
a)
Requisite number of radiators provided with :
One shut off valve on top
One shut off valve at bottom
Air release device on top
Drain and sampling device at bottom
Lifting lugs.
b)
Air release device and oil drain plug on oil pipe connectors.
Terminal marking plates for Main Transformer.
a)
Off-Load Tap Changer.
HV Bushing with terminal connector and arcing horn.
LV Bushing with terminal connector.
LV Neutral Bushing for ground connection.
The fittings listed above are indicative and any other fittings which are generally
required for satisfactory operation of the transformer are deemed to be included
in the quoted price of the transformer.
The contacts of various devices required for alarm and trip shall be potential free
and shall be adequately rated (minimum 230V and 5 amp) for regular making
and breaking current duties as specified.
CONTROL CONNECTIONS AND WIRING TERMINAL, BOARD AND FUSES
i)
Normally no fuses shall be used anywhere. Instead of fuses MCBs (both in AC & DC
circuits) shall be used. Only in cases where a MCB cannot replace a fuse due to system
requirements, a HRC fuse can be accepted.
ii)
All wiring connections, terminal boards, fuses, MCBs and links shall be suitable for
tropical atmosphere. Any wiring liable to be in contact with oil shall have oil resisting
insulation and the bare ends of stranded wire shall be sweated together to prevent seepage
of oil along the wire.
- 17 -
iii)
iv)
v)
Panel connections shall be neatly and squarely fixed to the panel. All instruments and
panel wiring shall be run in PVC. All wiring to a panel shall be taken from suitable
terminal boards.
When 400 volt connections are taken through junction boxes or marshalling boxes, they
shall be adequately screened and 400 volts Danger Notice must be affixed to the outside
of the junction boxes or marshalling box. Proper colour code for Red, Yellow, Blue
phases wires shall be followed. 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.
All box wiring shall be in accordance with relevant IS. All wiring shall be of stranded
single core copper (48 strands) of 1100 Volt grade and size as under:
CT circuits 2x2.5 sq.mm.
AC/DC Power circuit 1x2.5 sq.mm.
All other circuit - 1x2.5 sq.mm.
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
All wires on panels and all multi-core cables shall have ferrules, for easy identifications,
which bear the same number at both ends, as indicated in the relevant drawing.
The same ferrule number shall not be used on wires in different circuits on the same
panels.
Ferrules shall be of white 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 dampness or oil.
Stranded wires shall be terminated with tinned terminals, claw washers or crimped
tubular lugs. Separate washers shall be suited 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 items of relays and other apparatus is not impeded.
Where apparatus is mounted on panels, all metal cases shall be separately earthed by
means of stranded (48 No.) copper wire or strip having a cross section of not less than 2.5
sq. mm. Where strip is used, the joints shall be sweated.
The wiring diagram for marshalling box shall preferably be drawn as viewed from the
back and shall show the terminal boards arranged as in services.
Terminal blocks shall be 1100 volts 10 Amp grade moulded material complete with stud
type brass terminal, washers, nuts and identification strips.
Terminal block rows should be spaced adequately not less than 100 mm apart to permit
convenient access to external cables and terminations.
Terminal blocks shall be placed with respect to the cable gland (at a minimum distance of
200 mm) as to permit satisfactory arrangement of multicore cable tails.
Terminal blocks shall have separate pairs of terminals for 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. No live metal shall be exposed at the back of the terminal
boards.
All interconnecting wiring, as per the final approved scheme between accessories of
transformer and marshalling box is included in the scope of this specification and shall be
done by the Transformer supplier.
The schematic diagram shall be drawn and fixed under a transparent prospane sheet on
the inner side of the marshalling box cover.
All marking of terminals shall follow IS 11953
- 18 -
5.14
RADIO INTERFERENCE AND NOISE LEVEL

Transformers shall be designed with particular care to suppress at least the third and fifth
harmonic voltages so as to minimise interference with communication circuits.
Transformer noise level, when energised at normal voltage and frequency shall be as per
NEMA stipulations.
6.0
INSPECTION AND TESTING

(i)
(ii)
(iii)
The Contractor shall draw up and carry out a comprehensive inspection and
testing programme during manufacture of the transformer duly approved by the
purchaser.
The contractor shall carry out type tests, acceptance test and routine tests on the
transformers.
The pre-shipment checks shall also be carried out by the contractor.
(iv)
6.1
The requirements on pre commissioning site tests are as listed in the

specifications.
(v)
Six(6) sets of certified test report and oscillograms shall be furnished to the
Purchaser for evaluation. The Contractor shall also evaluate the test results and
rectify any defects in the equipment based on his and the Purchasers evaluations
of the tests without any extra charges to the Purchaser. Manufacturers Test
Certificates in respect of all associated auxiliary and ancillary equipment shall be
furnished.
(vi)
The bidder shall state in his proposal the testing facilities available at his works.
In case full testing facilities are not available, the bidder shall state the method
proposed to be adopted so as to ascertain the transformer characteristics
corresponding to full capacity.
INSPECTION
i)
Tank and Conservator
ii)
a)
Inspection of major weld.
b)
Crack detection of major strength weld seams by dye penetration test.
c)
Check correct dimensions between wheels, demonstrate turning of

wheels, through 90o.
Leakage test of the tank, conservator and radiator.
d)
Core
a)
iii)
b)
Sample testing of core materials for checking specific loss properties,

magnetization characteristics and thickness.
Check on the quality of varnish if used on the stampings.
c)
Check on the amount of burrs, if any.
d)
Visual and dimensional check during assembly stage.
e)
Visual and dimensional checks for straightness and roundness of core,

thickness of limbs and suitability of clamps.
f)
High voltage DC test (2 kV for one minute) between core and clamps.
Insulating Material
- 19 -
iv)
a)
Sample check for physical properties of materials.
b)
Check for dielectric strength
c)
Check for the reaction of hot oil on insulating materials.
Winding
a)
Sample check on winding conductor for conductivity.
b)
Visual and dimensional checks on conductor for scratches, dent mark etc.
c)
Sample check on insulating paper for electric strength.
d)
Check for the bonding of the insulating paper with conductor.
e)
Check for the reaction of hot oil and insulating paper.
f)
Check and ensure that physical condition of all materials taken for
windings is satisfactory and free of dust.
g)
v)
vi)
vii)
Check for absence of short circuit between parallel strands.
Checks Before Drying Process

a)
Check condition of insulation on the conductor and between the

windings.
b)
Check insulation distance between high voltage connections, between

high voltage connection and earth and other live parts.
c)
Check insulating distances between low voltage connections and earth

and other parts.
d)
Insulating test for core earthing.
Checks During Drying Process

a)
Measurement and recording of temperature and drying time during

vacuum treatment.
b)
Check for completeness of drying.
Oil
All standard tests in accordance with IS: 335 shall be carried out on Transformer
oil sample before filling in the transformer.
(ix)
Test Reports for bought out items

The contractor shall submit the test reports for all bought out/sub contracted
items for approval including for:
a)
Buchholz relay
b)
Pressure Relief device
- 20 -
6.2
c)
Winding temperature indicators
d)
Oil temperature indicators
e)
Bushings
f)
Marshalling box
g)
Off Load Tap changer
h)
Any other item required to complete the works.
i)
The equipment shall be tested by the contractor in accordance with

relevant IS. And test report submitted as in case of main items.
FACTORY TESTS
i)
All standards routine tests in accordance IS: 2026 with dielectric tests as per
latest amendments shall be carried out.
ii)
High voltage withstand test shall be performed on auxiliary equipment and

wiring after complete assembly.
iii)
Following additional routine tests shall also be carried out on each transformer:
Magnetic Circuit Test
Each core shall be tested for 1 minute at 2000 Volt AC.
6.2.1. Type Test

The transformer shall be subjected to the following type tests:
(1)
(2)
Temperature Rise Test
(3)
Short Circuit Test
(4)
Tank Vacuum test
(5)
Tank Pressure Test
(6)
Lightning impulse withstand test for line and neutral terminal
(7)
Measurement of acoustic noise level.
6.2.2. Routine Tests

Transformer routine tests shall include tests stated in latest issue of IS: 2026
(Part-I). These tests shall also include but shall not be limited to the following:
(i)
(ii)
(iii)
(iv)
(v)
Visual examination and checking the dimension

Measurement of winding DC resistance at principal taps and two extreme taps.
Voltage ratio on each tapping and check of voltage vector relationship.
Impedance voltage at all tappings.
Magnetic balance test
- 21 -
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
Load losses.
No load losses and no load current.
Absorption index i.e. insulation resistance for 15 seconds and 60 seconds
(R60/R15) and polarization index i.e. Insulation Resistance for 10 minutes and
one minute (R10 mt/R1 mt).
Induced over voltage withstand test.
Phase relation, polarity, angular displacement and phase sequence test
Separate source voltage withstand test (applied potential).
6.3 TANK TESTS

a)
Oil leakage Test:
b)
The tank and oil filled radiators shall be tested for oil tightness completely filled
with air or oil of viscosity not greater than that of insulating oil conforming to IS:
335 at the ambient temperature and applying a pressure equal to the normal
pressure plus 35 KN/m2 measured at the base of the tank. The pressure shall be
maintained for a period of not less than 12 hours for oil and one hour for air and
during that time no leak shall occur.
Pressure Test
Where required by the Purchaser, one transformer tank of each size together with
its radiator, conservator vessel and other fittings shall be subjected to a pressure
corresponding to twice the normal head of oil or to the normal pressure plus 35
KN/m2 whichever is lower, measured at the base of the tank and maintained for
one hour.
c)
Vacuum Test
One transformer tank of each size shall be subjected to the vacuum pressure of
760 mm of mercury. The permanent deflection of flat plates
after the vacuum has been released shall not exceed the value specified in
C.B.I.P. Manual on Transformers (Revised 1999).
6.4
PRE-SHIPMENT CHECK AT MANUFACTURERS WORKS

i)
Check for proper packing and preservation of accessories like radiators,
bushings, explosions vent, dehydrating breather, rollers, buchholz relay,
marshalling box, connecting pipes & conservator etc.
ii)
Check for proper provision of bracing to arrest the movement of core and
winding assembly inside the tank.
6.5
INSPECTION AND TESTING AT SITE:

The contractor shall carry out detailed inspection covering areas right from the receipt of
material upto commissioning stage. An indicative programme of inspection as envisaged
by the Engineer is given below. This is however not intended to form a comprehensive
programme as it is contractors responsibility to draw up and carry out such a
programme.
6.5.1. Receipt and Storage Checks
- 22 -
i)
Check and record condition of each package visible parts of the transformers etc
for any damage.
ii)
Check completed transformer against approved outline drawing, provision for all
fittings, finish level etc.
iii)
Jacking test on the assembled Transformer.
6.5.2. Installation Checks

i)
Inspection and performance testing of accessories like tap changers, etc.
ii)
iii)
Test on oil samples taken from main tank top and bottom and cooling system. Samples
should be taken only after the oil has been allowed to settle for 24 hours.
Check the whole assembly for tightness, general appearance etc.
iv)
v)
Oil leakage tests.

Jacking Test
6.5.3. Pre-Commissioning Tests

After the transformer is installed, the following pre-commissioning tests and checks shall
be done before putting the transformer in service.
i)
Dry out test
ii)
Megger Test
iii)
DC Resistance measurement of windings
iv)
Ratio test on all taps
v)
Phase relationship test (Vector grouping test)
vi)
Buchholz relay alarm operation test
vii)
Low oil level (in conservator) alarm
viii)
Temperature Indicators
ix)
Marshalling kiosk
x)
Magnetising current
6.5.4. The following additional checks shall be made:
i) All oil valves are in correct position closed or opened as required.
ii) Thermometer pockets are filled with oil.
iii) Oil is at correct level in the conservator.
iv) Earthing connections are made.
v) Colour of Silica gel is blue.
vi) Bushing arcing horn is set correctly and gap distance is recorded.
7.0
CAPITALISATION OF LOSSES AND LIQUIDATED DAMAGES FOR
EXCESSIVE LOSSES
7.1
LOSSES:
Transformers with lower losses shall be preferred. The bidder shall indicate the
guaranteed values of load and no load losses of the transformer in his bid.
The no load and load losses shall not exceed the values given in the following
table
KVA
Rating
5000
No Load losses (KW)

6.50
Load losses
(KW)
34.0
These losses are maximum allowable and there would not be any positive
tolerance. However, the manufacturer can offer losses less than above.
- 23 -
7.2
CAPITALISATION OF LOSSES
For total cost evaluation, the capitalized cost of losses will be taken into account as per
the following:
Capitalised cost of Losses = Rs.A x WI + Rs. B x Wc
Where :
WI = Iron loss in KW & A = 1,37,408 Rupees for iron loss

WC = Copper loss in KW & B = 41,222 Rupees for copper loss
The no load loss in KW at the rated voltage and frequency and the load loss in KW at
rated voltage, rated frequency, rated output and at 75 degree centigrade shall be quoted
and these figures shall be guaranteed.
7.3
REJECTION
The Purchaser may reject any transformer if during tests or service any of the following
conditions arise:
i)
8.0
Transformer is proved to have been manufactured not in accordance with the

agreed specification.
SPARE PARTS
In case the manufacturer goes out of production of spare parts, then he shall make
available the drawings of spare parts and specification of materials at no extra cost to the
Purchaser to fabricate or procure spare parts from other sources.
8.1
INSTRUCTIONS MANUAL
Eight sets of the instruction manuals shall be supplied at least four (4) weeks before the
actual dispatch of equipment. The manuals shall be in bound volumes and shall contain
all the drawings and information required for erection, operation and maintenance of the
transformer. The manuals shall include amongst others, the following particulars :
a)
Marked erection prints identifying the components, parts of the transformer as

dispatched with assembly drawings.
b)
Detailed dimensions, assembly and description of all auxiliaries.
c)
Detailed views of the core and winding assembly, winding connections and
tapings, tap changer construction etc. These drawings are required for carrying
out overhauling operation at site.
d)
Salient technical particulars of the transformer.
e)
Copies of all final approved drawings.
f)
Detailed O&M instructions with periodical check lists etc.
- 24 -
8.2 COMPLETENESS OF EQUIPMENT

i)
All fittings and accessories, which may not be specifically mentioned in the
specification but which are necessary for the satisfactory operation of the plant,
shall be deemed to be included in the specification and shall be furnished by the
contractor without extra charges. The equipment shall be complete in all details,
whether such details are mentioned in the specification or not, without any
financial liability to the Purchaser under any circumstances.
ii)
All deviations from this specification shall be separately listed under the requisite
schedules, in the absence of which it will be presumed that all the provisions of
the specification are complied with by the bidder.
8.3
TOOLS & TACKLES

All the necessary tools and tackles required for normal operation & maintenance shall be
supplied by the Contractor.
9.0 COMMISSIONING
The equipment shall be commissioned as per CBIP manual, IS 10028 and
manufacturers recommendations.
10.0
TRANSFORMER OIL
The Transformer shall be supplied complete with first filling of oil and 10 % extra.
- 25 -
AC Distribution Board
1.1
GENERAL
This specification covers the design, engineering, manufacture, shop testing,
inspection before dispatch, packing, forwarding, transportation to site, insurance
(during transit, storage and erection), storage, erection, supervision, site testing
and commissioning of indoor AC Distribution board for catering power supply to
33kV and 11kV equipment, illumination, battery charger and other auxiliary loads
of the sub-station. Incoming power supply to the board will be provided from
63KVA, 11/0.433 kV outdoor station transformer .
1.2
STANDARDS
The equipment shall be manufactured as per following standards:

IS:8623/1933 Low voltage Switchgear and controlgear assemblies.
IS:13947 Part 2 Low voltage circuit breakers.
1.3
CONSTRUCTIONAL FEATURE
Panels shall be completely metal enclosed and shall be dust, moisture and vermin
proof and fully compartmentalized. The enclosure shall provide a degree of
protection not less than IP-52 (for indoor) in accordance with IS: 13947. It should
be free standing, floor mounting type and smooth finished, made of cold rolled
sheet steel of thickness not less than 3 mm for weight bearing members of the
panels such as base frame, front sheet and door frames, and 2.0mm for sides,
door, top and bottom portions. There shall be sufficient reinforcement to provide
level transportation and installation. Design, materials selection and workmanship
shall be such as to result in neat appearance, inside and outside with no welds
rivets or bolt head apparent from outside, with all exterior surfaces tune and
smooth. The colour of the finishing paint shall be light grey in accordance with
shade no.692 of IS: 5 or in matching colour of other existing Panels. There shall
be space heater with thermostat, illumination lamp and one 3-pin, 15 Amp. Power
point with socket in the panel. For further requirement/detail of equipment &
component to be in the part of ACDB, which are not covered here, are with
station lighting specification.
The cable entries shall be from bottom. Gland Plates and electroplated brass cable
glands shall be provided. Cable clamping arrangements shall be provided.
The board shall be mounted on a base frame made of 75x50x6 mm ISMC painted
black. It shall be grouted to the floor. The board can also be wall mounted with
suitable mounting arrangements.
Page 1 of 3
1.4
PAINTING
1.41
All sheet steel work shall be phosphated in accordance with the IS:6005 "Code of
Practice for Phosphating Iron and Steel".
1.42
Rust, scale, oil, grease, dirt and swarf shall be removed by 7 tank process.
1.43
After phosphating, thorough rinsing shall be carried out with clean water followed
by final rinsing with dilute dichromate solution and oven drying.
1.44
The phosphate coating shall be sealed with application of two coats of ready
mixed, stoved type zinc chromate primer. The first coat may be "flash dried"
while the second coat shall be stoved.
1.45
After application of the primer, two coats of finishing synthetic enamel paint shall
be applied, each coat followed by stoving. The second finishing coat shall be
applied after inspection of first coat of painting. The exterior colour of paint shall
be of a slightly different shade to enable inspection of the painting. The final coat
should present a hard glass finish.
1.46
A small quantity of finished paint shall be supplied for minor touching up

required at site after installation of the panels.
1.47
In case the bidder proposes to follow any other established painting procedure like
electrostatic painting or powder coating, the procedure shall be submitted for
BSEB's review and approval.
1.5
TECHNICAL DETAIL
Incomer will be from 415 volt 3-phase, 4 wire, 200A MCCB of 10kA interrupting
capacity and 10 kA short time rating for 1 sec. The board shall have isolated bus
bar chamber for main bus bar at top, running throughout the length of the board
and TPN vertical busbar chambers for power supply to outgoing feeders. The bus
bar and connecting links etc. shall be of electrolytic aluminum. All nuts and bolts
shall be electro galvanized.
General feeder arrangement will be as follows but actual number of incomer and
outgoing feeder will be mentioned in BPS.
Incomer:
protection.
1no. 200 Amp TPN MCCB with Over Current and Short Circuit
Outgoing: 4No. 63 Amp. TPN MCCB and 2 Nos. 32Amp TPN MCCB of 10 kA
interrupting capacity and 10 kA short time rating for 1 sec. These will be provided
with Over Current and Short Circuit protection.
Metering module:
i)
Incommer Panel: 1 no. Metring module shall consist of voltmeter with

selector swith(1 no.), Ameter with selector switch(1no), indication lamps(3
nos) for phase health indication.
ii)
Outgoing Feeder Panel: 1 no. Ammeter with selector switch.
Page 2 of 3
1.6
EARTHING
One Earth bars of Aluminium shall be provided near the base. The earth bar shall
be connected to two earth terminals. The earth terminals shall be connected to
station earth.
Page 3 of 3
ACSR CONDUCTOR
1.0
1.1
1.1.1
1.1.2
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.3
1.3.1
TECHNICAL DESCRIPTION OF ACSR CONDUCTORS

DETAILS OF CONDUCTORS
The ACSR Conductors shall generally conform to IEC: 61089 or IS:
398 (Part-II-1996) except where otherwise specified herein.
The details of the ACSR Conductors of various sizes are given in
the enclosed Table-1
WORKMANSHIP
All the aluminium and steel strands shall be smooth, uniform and
free from all imperfections, such as spills and splits, die marks,
scratches, abrasions, etc., after drawing and also after stranding.
The finished conductor shall be smooth, compact, uniform and free
from all imperfections including kinks (protrusion of wires), scuff
marks, dents, pressmarks, cut marks, wire cross over, over riding,
looseness (wire being dislocated by finger/hand pressure and/or
unusual bangle noise on tapping), material inclusions, white rust,
powder formation or black spot (on account of reaction with trapped
rain water etc.), dirt, grit etc.
The steel strands shall be hot dip galvanized and shall have a
minimum zinc coating as specified in Table-I. The zinc coating shall
be smooth, continuous, of uniform thickness, free from
imperfections. The steel wire rods shall be of such quality and
purity that, when drawn to the size of the strands specified and
coated with zinc, the finished strands and the individual wires shall
be of uniform quality and have the same properties and
characteristics as required in the specification.
The steel strands shall be preformed and post formed in order to
prevent spreading of strands in the event of cutting of composite
core wire. Care shall be taken to avoid, damages to galvanization
during pre-forming and post-forming operation.
JOINTS IN WIRES
ALUMINIUM/AL-ALLOY WIRES
i.
ii.
1.3.2
During stranding, no aluminium wire welds shall be made for the

purpose of achieving the required conductor length.
No joints shall be permitted in any layer of finished conductor
STEEL WIRES
There shall be no joint of any kind in the finished wire entering into
the manufacture of the strand. There shall also be no strand joints or
strand splices in any length of the completed stranded steel core of
the conductor.
1 of 22
1.4
STRANDING
In all constructions, the successive layers shall be stranded in
opposite directions. The wires in each layer shall be evenly and
closely stranded round the underlying wire or wires. The outer most
layers of wires shall have a right hand lay. the ratio of the different
layers shall be within the limits given in Table-I.
1.5
TOLERANCES
The manufacturing tolerances in diameter of individual steel and
aluminium strand shall be as per table-I
1.6
1.6.1
MATERIALS
ALUMINIUM
The aluminium strands shall be hard drawn from electrolytic
aluminium rods of EC grade having purity not less than 99.5% and a
copper content not exceeding 0.04%. They shall have the same
properties and characteristics as prescribed in IEC: 889-latest
amendment.
1.6.2
STEEL
The steel wire
rods produced
or the electric
shall conform
composition:
strands shall be drawn from high carbon steel wire

by either the acid or the basic open-hearth process,
furnace process, or the basic oxygen process and
to the following requirements as to the chemical
S.No.
Element
% Composition
Carbon
0.50 to 0.85
Manganese
0.50 to 1.10
Phosphorous
Not more than 0.035
Sulphur
Not more than 0.045
Silicon
0.10 to 0.35
The Steel wire strands shall have the same properties and
characteristics as prescribed for regular strength steel wire in IEC:
888-Latest amendment.
1.6.3
ZINC
2 of 22
The zinc used for galvanizing shall be electrolytic High Grade Zinc of
99.95% purity. It shall conform to and satisfy all the requirements of
IS: 209-1979.
1.7
1.7.1
1.7.2
1.7.3
STANDARD LENGTH
The standard length of the conductor shall be 2000 meters.
Contractor shall indicate the standard length of the conductor to be
offered by them. A tolerance of + 5% on the standard length offered
by the Bidder shall be permitted. All lengths outside this limit of
tolerance shall be treated as random lengths.
Random lengths will be accepted provided no length is less than
70% of the standard length and the total quantity of such random
lengths shall not be more than 10% of the total quantity ordered.
Bidder shall also indicate the maximum single length, above the
standard length, he can manufacture in the guaranteed technical
particulars of offer. This is required for special stretches like river
crossing etc. The Owner reserves the right to place orders for the
above lengths on the same terms and conditions applicable for the
standard lengths during the pendency of the Contract.
1.8
TESTS AND STANDARDS
1.8.1
TYPE TESTS
The following tests shall be conducted once on a sample/samples of
each type of conductor (ACSR) from each manufacturing facility:
i.
UTS test on stranded

conductor
)
)
)
ii.
1.8.2
DC resistance test on
stranded conductor
Annexure-A
)
)
ACCEPTANCE TESTS
i.
Visual and dimensional

check on drum
)
)
)
ii.
Visual check for joints scratches )
3 of 22
Annexure - A
etc. and length measurement of )

conductor by rewinding
iii.
Dimensional check on
)
steel and aluminium/Al-alloy strands )
)
iv.
Check for lay-ratio )
Annexure - A
)
v.
Galvanising test on steel strands
)
)
vi.
Torsion and Elongation

tests on steel strands
)
)
)
vii.
Breaking load test on steel

and Aluminium strands
)
viii.
Wrap test on steel &

Aluminium strands
ix.
Aluminium strands
Procedure qualification
test on welded joint of
x.
Aluminium strands
IS : 398
)
)
)
)
Annexure-A
Note: All the above tests except (j) shall be carried out on aluminium
and steel strands after stranding only.
1.8.3
ROUTINE TEST
4 of 22
1.8.4
i.
Check to ensure that the joints are as per Specification.
ii.
Check that there are no cuts, fins etc. on the strands.
iii.
Check that drums are as per Specification.
iv.
All acceptance test as mentioned above to be carried out on

each coil.
TESTS DURING MANUFACTURE

i.
Chemical analysis of zinc )

used for galvanizing
)
)
ii.
iii.
Chemical analysis of
)
Aluminium used for
making Aluminium strands
Chemical analysis of steel )

used for making steel strands
)
)
)
Annexure-A
1.9
TESTING EXPENSES
1.9.1
The testing charges for the type tests specified shall be included in
the quoted unit price of conductor.
1.9.2
Contractor shall indicate the laboratories in which they propose to

conduct the type tests. They shall ensure that adequate facilities are
available in the laboratories and the tests can be completed in these
laboratories within the time schedule guaranteed by them.
1.9.3
In case of failure in any type test, the Contractor is either required to

manufacture fresh sample lot and repeat all the tests successfully
once or repeat that particular type test three times successfully on
5 of 22
the sample selected from the already manufactured lot at his own
expenses. In case a fresh lot is manufactured for testing, then the
lot already manufactured shall be rejected.
1.9.4
The entire cost of testing for the acceptance and routine tests and
tests during manufacture specified herein shall be treated as
included in the quoted unit price of conductor, except for the
expenses of the inspector/Owner's representative.
1.9.5
In case of failure in any type test, if repeat type tests are required to
be conducted, then all the expenses for deputation of
Inspector/Owner's representative shall be deducted from the
contract price. Also if on receipt of the Contractor's notice of testing,
the Owner's representative does not find 'the material or testing
facilities' to be ready for testing the expenses incurred by the Owner
for re-deputation shall be deducted from contract price.
1.10
ADDITIONAL TESTS
1.10.1
The Owner reserves the right of having at his own expenses any
other test(s) of reasonable nature carried out at Contractors
premises, at site or in any other place in addition to the aforesaid
type, acceptance and routine tests to satisfy himself that the
materials comply with the Specifications.
1.10.2
The Owner also reserves the right to conduct all the tests mentioned
in this specification at his own expense on the samples drawn from
the site at Contractors premises or at any other test centre. In case
of evidence of non-compliance, it shall be binding on the part of
Contractor to prove the compliance of the items to the technical
specifications by repeat tests, or correction of deficiencies, or
replacement of defective items all without any extra cost to the
Owner.
1.11
SAMPLE BATCH FOR TYPE TESTING
1.11.1
The Contractor shall offer material for selection of samples for type
testing only after getting Quality Assurance Plan approved from
Owners Quality Assurance Deptt. The sample shall be
6 of 22
manufactured strictly in accordance with the Quality Assurance Plan

approved by Owner.
1.11.2
The Contractor shall offer at least three drums for selection of

sample required for conducting all the type tests.
1.11.3
The Contractor is required to carry out all the acceptance tests

successfully in presence of Owners representative before sample
selection.
1.12
1.12.1
TEST REPORTS
Copies of type test reports shall be furnished in at least six copies
along with one original. One copy will be returned duly certified by
the Owner only after which the commercial production of the
material shall start.
1.12.2
Record of routine test reports shall be maintained by the Supplier at

his works for periodic inspection by the Owners representative.
1.12.3
Test Certificates of tests during manufacture shall be maintained by

the Contractor. These shall be produced for verification as and
when desired by the Owner.
1.13
INSPECTION
1.13.1
The Owners representative shall at all times be entitled to have

access to the works and all places of manufacture, where conductor
shall be manufactured and representative shall have full facilities for
unrestricted inspection of the Contractors works, raw materials and
process of manufacture for conducting necessary tests as detailed
herein.
1.13.2
The Contractor shall keep the Owner informed in advance of the

time of starting and of the progress of manufacture of conductor in
its various stages so that arrangements can be made for inspection.
1.13.3
No material shall be dispatched from its point of manufacture before

it has been satisfactorily inspected and tested, unless the inspection
7 of 22
is waived off by the Owner in writing. In the latter case also, the
conductor shall be despatched only after satisfactory testing for all
tests specified herein have been completed.
1.13.4
The acceptance of any quantity of material shall in no way relieve

the Contractor of any of his responsibilities for meeting all
requirements of the Specification, and shall not prevent subsequent
rejection if such material is later found to be defective.
1.14
TEST FACILITIES
1.14.1
The following additional test facilities shall be available at the

Contractors works:
i.
Calibration of various testing and measuring equipment

including tensile testing machine, resistance measurement
facilities, burette, thermometer, barometer etc.
ii.
Standard resistance for calibration of resistance bridges.
iii.
Finished conductor shall be checked for length verification

and surface finish on separate rewinding machine at reduced
speed (variable from 8 to 16 meters per minute). The
rewinding facilities shall have appropriate clutch system and
free of vibrations, jerks etc. with traverse laying facilities.
1.15
PACKING
1.15.1
The conductor shall be supplied in strong, wooden drums provided

with lagging of adequate strength, constructed to protect the
conductor against any damage and displacement during transit,
storage and subsequent handling and stringing operations in the
field. The Contractor shall be responsible for any loss or damage
during transportation handling and storage due to improper packing.
The drums shall generally conform to IS:1778-Latest amendment,
except as otherwise specified hereinafter.
8 of 22
1.15.2
The drums shall be suitable for wheel mounting and for letting off the
conductor under a minimum controlled tension of the order of 5 KN.
1.15.3
The Contractor should submit their proposed drum drawings along

with the bid.
1.15.4
The Contractor may offer more than one length of the conductor in a
single drum.
1.15.5
All wooden components shall be manufactured out of seasoned soft

wood free from defects that may materially weaken the component
parts of the drums. Preservative treatment shall be applied to the
entire drum with preservatives of a quality, which is not harmful to
the conductor.
1.15.6
The flanges shall be of two ply construction with 64 mm thickness

with each ply at right angles to the adjacent ply and nailed together.
The nails shall be driven from the inside face flange, punched and
then clenched on the outer face. Flange boards shall not be less
than the nominal thickness by more than 2mm. There shall not be
less than 2 nails per board in each circle. Where a slot is cut in the
flange to receive the inner end of the conductor the entrance shall
be in line with the periphery of the barrel.
1.15.7
The wooden battens used for making the barrel of the conductor
shall be of segmental type. These shall be nailed to the barrel
supports with at least two nails. The battens shall be closely butted
and shall provide a round barrel with smooth external surface. The
edges of the battens shall be rounded or chamfered to avoid
damage to the conductor.
1.15.8
Barrel studs shall be used for the construction of drums. The flanges
shall be holed and the barrel supports slotted to receive them. The
barrel studs shall be threaded over a length on either end, sufficient
to accommodate washers, spindle plates and nuts for fixing flanges
at the required spacing.
1.15.9
Normally, the nuts on the studs shall stand protruded of the flanges.
All the nails used on the inner surface of the flanges and the drum
9 of 22
barrel shall be counter sunk. The ends of barrel shall generally be

flushed with the top of the nuts.
1.15.10
The inner cheek of the flanges and drum barrel surface shall be
painted with a bitumen based paint.
1.15.11
Before reeling, card board or double corrugated or thick bituminised

water-proof bamboo paper shall be secured to the drum barrel and
inside of flanges of the drum by means of a suitable commercial
adhesive material. The paper should be dried before use. Medium
grade craft paper shall be used in between the layers of the
conductor. After reeling the conductor, the exposed surface of the
outer layer of conductor shall be wrapped with water proof thick
bituminised bamboo paper to preserve the conductor from dirt, grit
and damage during transport and handling.
1.15.12
A minimum space of 75 mm for conductor shall be provided

between the inner surface of the external protective tagging and
outer layer of the conductor.
1.15.13
Each batten shall be securely nailed across grains as far as possible

to the flange, edges with at least 2 nails per end. The length of the
nails shall not be less than twice the thickness of the battens. The
nails shall not protrude above the general surface and shall not
have exposed sharp, edges or allow the battens to be released due
to corrosion.
1.15.14
The nuts on the barrel studs shall be tack welded on the one side in
order to fully secure them. On the second end, a spring washer shall
be used.
1.15.15
A steel collar shall be used to secure all barrel studs. This collar
shall be located between the washers and the steal drum and
secured to the central steel plate by welding.
1.15.16
Outside the protective lagging, there shall be minimum of two binder

consisting of hoop iron/ galvanised steel wire. Each protective
lagging shall have two recesses to accommodate the binders.
10 of 22
1.15.17
The conductor ends shall be properly sealed and secured with the
help of U-nail on the side of one of the flanges to avoid loosening of
the conductor layers during transit and handling.
1.15.18
As an alternative to wooden drum Contractor may also supply the

conductors in painted steel drums. After preparation of steel surface
according to IS : 9954, synthetic enamel paint shall be applied after
application of one coat of primer. Wooden/Steel drum will be treated
at par for evaluation purpose and accordingly the Contractor should
quote in the package.
1.16
MARKING
Each drum shall have the following information stenciled on it in
indelible ink along with other essential data :
i.
Contract/Award letter number.
ii.
Name and address of consignee.
iii.
Manufacturers name and address.
iv.
Drum and lot number
v.
Size and type of conductor
vi.
Length of conductor in meters
vii.
Arrow marking for unwinding
viii.
Position of the conductor ends
ix.
Number of turns in the outer most layer.
x.
Gross weight of drum after putting lagging.
xi.
Average weight of the drum without lagging.
11 of 22
xii.
Net weight of the conductor in the drum.
xiii.
Month and year of manufacture of conductor
The above should be indicated in the packing list also.
VERIFICATION OF CONDUCTOR LENGTH
1.17
The Owner reserves the right to verity the length of conductor after
unreeling at least Two (2) percent of the drums in a lot offered for
inspection.
STANDARDS
1.18
1.18.1
The conductor shall conform to the following Indian/International

Standards,
which
shall
mean
latest
revisions,
with
amendments/changes adopted and published, unless specifically
stated otherwise in the Specification.
1.18.2
Sl.
In the event of the supply of conductor conforming to standards

other than specified, the Bidder shall confirm in his bid that these
standards are equivalent to those specified. In case of award,
salient features of comparison between the standards proposed by
the Contractor and those specified in this document will be provided
by the Contractor to establish their equivalence.
Indian Standard
Title
No.
International
Standards
1.
IS : 209-Latest
amendment
Specification for zinc
BS:3436- Latest
amendment
2.
IS : 398- Latest
amendment
Specification
for,
Aluminium
conductors
for
Overhead
Transmission Purposes
IEC:1089- Latest
amendment
1
BS:215Latest
amendment
3.
IS:398Latest
amendment
Aluminum Conductor Galvanised

Steel Reinforced
BS-215Latest
amendment
IEC:1089- Latest
Part-II
12 of 22
amendment
4.
IS : 1778- Latest
amendment
Reels and
Conductors
Bare
BS:1559- Latest
amendment
5.
IS : 1521- Latest
amendment
Method of Tensile Testing of

Steel Wire
ISO 6892- Latest

amendment
6.
IS : 2629- Latest
amendment
Recommended Practice for Hot

Dip Galvanising of Iron and Steel
7.
IS : 2633- Latest
amendment
Method of Testing Uniformity of

Coating on Zinc Coated Articles
8.
IS : 4826- Latest
amendment
Galvanised Coating on Round

Steel Wires
IEC : 888- Latest

amendment
BS:443Latest
amendment
9.
IS : 6745- Latest
amendment
Methods of Determination of
Weight of Zinc Coating of Zinc
Coated Iron and Steel Articles.
BS:433Latest
amendment ISO
1460 Latest
amendment
10.
IS : 9997- Latest
amendment
Aluminium Alloy Redraw Rods
IEC 104- Latest

amendment
11.
IS : 1841- Latest
amendment
EC Grade Aluminium
produced by rolling
12.
IS : 5484-1978
EC Grade Aluminium Rods

produced by continuous casting
and rolling
13.
Drums
Zinc Coated steel

stranded Conductors
13 of 22
for
Rods
wires
for
IEC : 888- Latest

amendment
14.
15.
IS:398 (Part-IV)
Hard drawn aluminium wire for

overhead line conductors
IEC : 889- Latest

amendment
Aluminium
conductor
IEC : 208- Latest

amendment BS3242Latest
amendment
Alloy
14 of 22
stranded
ANNEXURE-A
1
1.1.
TESTS ON ACSR CONDUCTORS

UTS TEST ON STRANDED CONDUCTOR
Circles perpendicular to the axis of the conductor shall be marked at two
places on a sample of conductor of minimum 5 m length between fixing
arrangement suitably fixed on a tensile testing machine. The load shall
be increased at a steady rate upto 50% of minimum specified UTS and
held for one minute. The circles drawn shall not be distorted due to
relative movement of strands. Thereafter the load shall be increased at
steady rate to minimum UTS and held for one minute. The Conductor
sample shall not fail during this period. The applied load shall then be
increased until the failing load is reached and the value recorded.
1.2.
D.C. RESISTANCE TEST ON STRANDED CONDUCTOR

On a conductor sample of minimum 5m length two contact-clamps shall
be fixed with a predetermined bolt torque. The resistance shall be
measured by a Kelvin double bridge or digital ohmmeter by placing the
clamps initially zero meter and sub-sequently one meter apart. The test
shall be repeated at least five times and the average value recorded.
The value obtained shall be corrected to the value at 20 C as per IS:398(Part-V)-1982. The resistance corrected at 200C shall conform to the
requirements of this Specification.
1.3.
CHEMICAL ANALYSIS OF ALUMINIUM AND STEEL

Samples taken from the Aluminium and steel ingots/coils/strands shall be
chemically/spectrographically analysed. The same shall be in conformity
to the requirements stated in this Specification.
15 of 22
1.4.
VISUAL AND DIMENSIONAL CHECK ON DRUMS

The drums shall be visually and dimensionally checked to ensure that
they conform to the requirements of this Specification.
1.5.
VISUAL CHECK FOR JOINTS, SCRATCHES ETC.

Conductor drums shall be rewound in the presence of the Owner. The
Owner shall visually check for scratches, joints etc. and that the
conductor generally conforms to the requirements of this Specification.
Two percent (2%) drums from each lot shall be rewound in the presence
of the Owner's representative.
1.6.
DIMENSIONAL CHECK ON STEEL AND ALUMINIUM

STRANDS
The individual strands shall be dimensionally checked to ensure that they
conform to the requirement of this Specification.
1.7.
CHECK FOR LAY-RATIOS OF VARIOUS LAYERS

The lay-ratios of various layers shall be checked to ensure that they
conform to the requirements of this Specification.
1.8.
PROCEDURE QUALIFICATION
ALUMINIUM STRANDS
TEST
ON
WELDED
Two Aluminium wire shall be welded as per the approved quality

plan and shall be subjected to tensile load. The breaking strength of the
welded joint of the wire shall not be less than the guaranteed breaking
strength of individual strands.
16 of 22
1.9.
CHEMICAL ANALYSIS OF ZINC

Samples taken from the zinc ingots shall be chemically/
spectrographically analysed. The same shall be in conformity to the
requirements stated in the Specification.
1.10.
GALVANISING TEST
The test procedure shall be as specified in IEC : 888. The material shall
conform to the requirements of this Specification. The adherence of zinc
shall be checked by wrapping around a mandrel four times the diameter
of steel wire.
1.11.
TORSION AND ELONGATION TESTS ON ALUMINIUM

ALLOY STRANDS/ STEEL STRANDS
The test procedures shall be as per clause No. 10.3 of IEC : 888. In
torsion test, the number of complete twists before fracture shall not be
less than 18 on a length equal to 100 times the standard diameter of the
strand. In case test sample length is less or more than 100 times the
stranded diameter of the strand, the minimum number of twists will be
proportioned to the length and if number comes in the fraction then it will
be rounded off to next higher whole number. In elongation test, the
elongation of the strand shall not be less than 4% for a gauge length of
250 mm.
1.12.
CHECK ON BARREL BATTEN STRENGTH OF DRUMS

The details regarding barrel batten strength test will be discussed and
mutually agreed to by the Contractor & Owner in the Quality Assurance
Programme.
1.13.
BREAKING LOAD TEST ON INDIVIDUAL ALUMINIUM

ALLOY AND GALVANIZED STEEL WIRES
17 of 22
The test shall be conducted on both Aluminium and Galvanized steel

wires. The breaking load of one specimen cut from each of the samples
taken shall be determined by means of suitable tensile testing machine.
The load shall be applied gradually and the rate of separation of the jaws
of the testing machine shall be not less than 25 mm/min. and not greater
than 100 mm./ min. The ultimate breaking load of the specimens shall be
not less than the values specified in the Specification.
1.14.
RESISTANCE TEST ON ALUMINIUM WIRE

The test shall be conducted on aluminium wires only, conforming
to procedure as per IEC: 889. The electrical resistance of one specimen
of aluminium wire cut from each of the samples taken shall be measured
at ambient temperature. The measured resistance shall be corrected to
the value corresponding to 20 degree C. by means of following formula.
1
R20 =
RT ------------------1+alpha x (T-20)
Where
R20 =
Resistance corrected at 20 degrees C.
RT
=
Resistance measured at T degrees C.
Alpha =
Constant mass temperature coefficient of resistance
0.004.
T
=
Ambient temperature during measurement
This resistance calculated to 20 degrees C. shall be not more than
the maximum value specified in the specification.
18 of 22
Table-1
Details of parameters of ACSR conductor
S.N.
Parameter
Wolf
DOG
Rabbit
Weasel
Squirrel
(No of strand/dia in mm) Al
30/2.59
6/4.72
6/3.35
6/2.59
6/2.11
(No of strand/dia in mm) Steel
7/2.59
1/1.57
1/3.35
1/2.59
1/2.11
158.10
105
52.88
31.61
20.98
194.90
118.5
61.7
36.88
24.48
Sectional area of aluminium (sq.mm.)

4 Total sectional area of conductor (sq.mm.)
Overall diameter mm
18.13
14.15
10.05
7.77
6.33
Approximate mass (kg/km)
726
394
214
128
85
19 of 22
S.N.
Parameter
Wolf
DOG
Rabbit
Weasel
Squirrel
Calculated D.C. resistance at 20 deg.

Centigrade (ohm/km)
0.1871
0.2792
0.5524
0.9289
1.394
Minimum UTS (kN)
67.34
32.41
18.25
11.12
7.61
Direction of lay of outer layer
Right hand
Right hand
Right hand
Right hand
Right hand
80
75
79
79
79
19.8x10-6
19.8x10-6
19.1x10-6
19.1x10-6
19.1x10-6
10
Modulus of elasticity (GN/m2)
11
Co-efficient of Linear expansion (Per C)
12
Details of aluminium strand :
Minimum breaking load of the strand

before stranding (kN)
0.89
2.78
1.43
0.89
0.63
Minimum breaking load of the strand after

stranding (kN)
0.85
2.64
1.36
0.85
0.60
Maximum DC resistance of strand at 20

deg C (ohms/km)
1.650
3.265
5.49
8.237
20 of 22
S.N.
Parameter
Wolf
DOG
Rabbit
Weasel
Squirrel
Weight (kg/km)
14.24
47.30
23.82
14.24
9.45
Diameter
Nominal
4.72
3.35
2.59
2.11
ii
Maximum
4.77
3.38
2.62
2.13
iii
Minimum
4.67
3.32
2.56
2.09
13
Details of Steel strand :
Minimum breaking load of the strand

before stranding (kN)
6.92
2.7
11.58
6.92
4.60

stranding (kN)
6.57
2.57
11
6.57
4.37
Weight (kg/km)
15.10
68.75
41.09
27.27
190
250
230
210
Galvanising
Zinc coating after stranding (g/m2)
ii
Minimum number of dips that the

galvanized strand can withstand in the
230
2 of one
2 of one
minute and 1 minute and 1
21 of 22
2 of one minute
and 1 of half
2 of one
minute and 1
2 of one
minute and
S.N.
Parameter
standard preece test (Nos.)
iii
Minimum number of twists in a gauge

length equal to 100 times dia of wire
which the strands can withstand in torsion
test after stranding
Diameter
Wolf
DOG
of half
minute
Rabbit
of half minute
minute
Weasel
Squirrel
of half minute
1 of half
minute
16
16
16
16
Nominal
1.57
3.35
2.59
2.11
ii
Maximum
1.60
3.42
2.64
2.15
iii
Minimum
1.54
3.28
2.54
2.07
14
Lay Ratio
Aluminium wire
Max
Min
Max
Min
Max
Min
Max
Min
Max
Min
12 wire Aluminium layer
16
10
14
10
14
10
14
10
14
10
18 wire Aluminium layer
14
10
Steel wire
28
13
28
13
22 of 22
ACSR CONDUCTOR
1.0
1.1
1.1.1
1.1.2
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.3
TECHNICAL DESCRIPTION OF ACSR CONDUCTORS

DETAILS OF CONDUCTORS
The ACSR Conductors shall generally conform to IEC: 61089 or IS: 398 (Part-II1996) except where otherwise specified herein.
The details of the ACSR Conductors of various sizes are given in the enclosed
Table-1
WORKMANSHIP
All the aluminium and steel strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, die marks, scratches, abrasions, etc., after
drawing and also after stranding.
The finished conductor shall be smooth, compact, uniform and free from all
imperfections including kinks (protrusion of wires), scuff marks, dents,
pressmarks, cut marks, wire cross over, over riding, looseness (wire being
dislocated by finger/hand pressure and/or unusual bangle noise on tapping),
material inclusions, white rust, powder formation or black spot (on account of
reaction with trapped rain water etc.), dirt, grit etc.
The steel strands shall be hot dip galvanized and shall have a minimum zinc
coating as specified in Table-I. The zinc coating shall be smooth, continuous, of
uniform thickness, free from imperfections. The steel wire rods shall be of such
quality and purity that, when drawn to the size of the strands specified and coated
with zinc, the finished strands and the individual wires shall be of uniform quality
and have the same properties and characteristics as required in the specification.
The steel strands shall be preformed and post formed in order to prevent spreading
of strands in the event of cutting of composite core wire. Care shall be taken to
avoid, damages to galvanization during pre-forming and post-forming operation.
JOINTS IN WIRES
1.3.1
ALUMINIUM/AL-ALLOY WIRES
i.
During stranding, no aluminium wire welds shall be made for the purpose of
achieving the required conductor length.
ii.
No joints shall be permitted in any layer of finished conductor
1.3.2
STEEL WIRES
There shall be no joint of any kind in the finished wire entering into the
manufacture of the strand. There shall also be no strand joints or strand splices in
any length of the completed stranded steel core of the conductor.
STRANDING
In all constructions, the successive layers shall be stranded in opposite directions.
The wires in each layer shall be evenly and closely stranded round the underlying
wire or wires. The outer most layers of wires shall have a right hand lay. the ratio
of the different layers shall be within the limits given in Table-I.
1.4
1.5
TOLERANCES
The manufacturing tolerances in diameter of individual steel and aluminium
strand shall be as per table-I
1 OF 17
1.6
MATERIALS
1.6.1
ALUMINIUM
The aluminium strands shall be hard drawn from electrolytic aluminium rods of
EC grade having purity not less than 99.5% and a copper content not exceeding
0.04%. They shall have the same properties and characteristics as prescribed in
IEC: 889-latest amendment.
STEEL
The steel wire strands shall be drawn from high carbon steel wire rods produced
by either the acid or the basic open-hearth process, or the electric furnace process,
or the basic oxygen process and shall conform to the following requirements as to
the chemical composition:
1.6.2
1.6.3
1.7
1.7.1
1.7.2
1.7.3
S.No.
Element
% Composition
1
Carbon
0.50 to 0.85
2
Manganese
0.50 to 1.10
3
Phosphorous
Not more than 0.035
4
Sulphur
Not more than 0.045
5
Silicon
0.10 to 0.35
The Steel wire strands shall have the same properties and characteristics as
prescribed for regular strength steel wire in IEC: 888-Latest amendment.
ZINC
The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95%
purity. It shall conform to and satisfy all the requirements of IS: 209-1979.
STANDARD LENGTH
The standard length of the conductor shall be 2000 meters. Contractor shall
indicate the standard length of the conductor to be offered by them. A tolerance of
+ 5% on the standard length offered by the Bidder shall be permitted. All lengths
outside this limit of tolerance shall be treated as random lengths.
Random lengths will be accepted provided no length is less than 70% of the
standard length and the total quantity of such random lengths shall not be more
than 10% of the total quantity ordered.
Bidder shall also indicate the maximum single length, above the standard length,
he can manufacture in the guaranteed technical particulars of offer. This is
required for special stretches like river crossing etc. The Owner reserves the right
to place orders for the above lengths on the same terms and conditions applicable
for the standard lengths during the pendency of the Contract.
1.8
TESTS AND STANDARDS
1.8.1
TYPE TESTS
The following tests shall be conducted once on a sample/samples of each type of
conductor (ACSR) from each manufacturing facility:
i.
ii.
UTS test on stranded

conductor
)
)
Annexure-A
2 OF 17
stranded conductor
1.8.2
ACCEPTANCE TESTS
i.
Visual and dimensional

check on drum
ii.
Visual check for joints scratches )

etc. and length measurement of
conductor by rewinding
iii.
Dimensional check on
)
steel and aluminium/Al-alloy strands )
iv.
Check for lay-ratio
v.
Galvanising test on steel strands )
vi.
Torsion and Elongation

tests on steel strands
)
)
Annexure - A
)
)
)
)
Annexure - A
)
)
)
)
)
vii.
Breaking load test on steel

and Aluminium strands )
viii.
Wrap test on steel &

Aluminium strands
Aluminium strands
ix.
x.
IS : 398
)
)
)
Procedure qualification )
test on welded joint of
Aluminium strands
)
)
Annexure-A
Note: All the above tests except (j) shall be carried out on aluminium and steel
strands after stranding only.
1.8.3
1.8.4
ROUTINE TEST
i.
Check to ensure that the joints are as per Specification.
ii.
Check that there are no cuts, fins etc. on the strands.
iii.
Check that drums are as per Specification.
iv.
All acceptance test as mentioned above to be carried out on each coil.
TESTS DURING MANUFACTURE

i.
Chemical analysis of zinc

used for galvanizing
)
)
3 OF 17
)
ii.
iii.
Chemical analysis of )
Aluminium used for
making Aluminium strands
Chemical analysis of steel
used for making steel strands
)
)
)
Annexure-A
)
)
1.9
TESTING EXPENSES
1.9.1
The testing charges for the type tests specified shall be included in the quoted
unit price of conductor.
1.9.2
Contractor shall indicate the laboratories in which they propose to conduct the
type tests. They shall ensure that adequate facilities are available in the
laboratories and the tests can be completed in these laboratories within the time
schedule guaranteed by them.
1.9.3
In case of failure in any type test, the Contractor is either required to manufacture
fresh sample lot and repeat all the tests successfully once or repeat that particular
type test three times successfully on the sample selected from the already
manufactured lot at his own expenses. In case a fresh lot is manufactured for
testing, then the lot already manufactured shall be rejected.
1.9.4
The entire cost of testing for the acceptance and routine tests and tests during
manufacture specified herein shall be treated as included in the quoted unit price
of conductor, except for the expenses of the inspector/Owner's representative.
1.9.5
In case of failure in any type test, if repeat type tests are required to be conducted,
then all the expenses for deputation of Inspector/Owner's representative shall be
deducted from the contract price. Also if on receipt of the Contractor's notice of
testing, the Owner's representative does not find 'the material or testing facilities'
to be ready for testing the expenses incurred by the Owner for re-deputation shall
be deducted from contract price.
1.10
ADDITIONAL TESTS
1.10.1
The Owner reserves the right of having at his own expenses any other test(s) of
reasonable nature carried out at Contractors premises, at site or in any other place
in addition to the aforesaid type, acceptance and routine tests to satisfy himself
that the materials comply with the Specifications.
1.10.2
Contractors premises or at any other test centre. In case of evidence of noncompliance, it shall be binding on the part of Contractor to prove the compliance
of the items to the technical specifications by repeat tests, or correction of
deficiencies, or replacement of defective items all without any extra cost to the
Owner.
4 OF 17
1.11
SAMPLE BATCH FOR TYPE TESTING
1.11.1
The Contractor shall offer material for selection of samples for type testing only
after getting Quality Assurance Plan approved from Owners Quality Assurance
Deptt. The sample shall be manufactured strictly in accordance with the Quality
Assurance Plan approved by Owner.
1.11.2
The Contractor shall offer at least three drums for selection of sample required for
conducting all the type tests.
1.11.3
The Contractor is required to carry out all the acceptance tests successfully in
presence of Owners representative before sample selection.
1.12
1.12.1
TEST REPORTS
Copies of type test reports shall be furnished in at least six copies along with one
original. One copy will be returned duly certified by the Owner only after which
the commercial production of the material shall start.
1.12.2
Record of routine test reports shall be maintained by the Supplier at his works for
periodic inspection by the Owners representative.
1.12.3
Test Certificates of tests during manufacture shall be maintained by the

Contractor. These shall be produced for verification as and when desired by the
Owner.
1.13
INSPECTION
1.13.1
The Owners representative shall at all times be entitled to have access to the
works and all places of manufacture, where conductor shall be manufactured and
representative shall have full facilities for unrestricted inspection of the
Contractors works, raw materials and process of manufacture for conducting
necessary tests as detailed herein.
1.13.2
The Contractor shall keep the Owner informed in advance of the time of starting
and of the progress of manufacture of conductor in its various stages so that
arrangements can be made for inspection.
1.13.3
No material shall be dispatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the
Owner in writing. In the latter case also, the conductor shall be despatched only
after satisfactory testing for all tests specified herein have been completed.
1.13.4
The acceptance of any quantity of material shall in no way relieve the Contractor
of any of his responsibilities for meeting all requirements of the Specification, and
shall not prevent subsequent rejection if such material is later found to be
defective.
1.14
TEST FACILITIES
1.14.1
The following additional test facilities shall be available at the Contractors works:
5 OF 17
i.
Calibration of various testing and measuring equipment including tensile

testing machine, resistance measurement facilities, burette, thermometer,
barometer etc.
ii.
Standard resistance for calibration of resistance bridges.
iii.
Finished conductor shall be checked for length verification and surface

finish on separate rewinding machine at reduced speed (variable from 8 to
16 meters per minute). The rewinding facilities shall have appropriate
clutch system and free of vibrations, jerks etc. with traverse laying
facilities.
1.15
PACKING
1.15.1
The conductor shall be supplied in strong, wooden drums provided with lagging of
adequate strength, constructed to protect the conductor against any damage and
displacement during transit, storage and subsequent handling and stringing
operations in the field. The Contractor shall be responsible for any loss or damage
during transportation handling and storage due to improper packing. The drums
shall generally conform to IS:1778-Latest amendment, except as otherwise
specified hereinafter.
1.15.2
The drums shall be suitable for wheel mounting and for letting off the conductor
under a minimum controlled tension of the order of 5 KN.
1.15.3
The Contractor should submit their proposed drum drawings along with the bid.
1.15.4
The Contractor may offer more than one length of the conductor in a single drum.
1.15.5
All wooden components shall be manufactured out of seasoned soft wood free
from defects that may materially weaken the component parts of the drums.
Preservative treatment shall be applied to the entire drum with preservatives of a
quality, which is not harmful to the conductor.
1.15.6
The flanges shall be of two ply construction with 64 mm thickness with each ply
at right angles to the adjacent ply and nailed together. The nails shall be driven
from the inside face flange, punched and then clenched on the outer face. Flange
boards shall not be less than the nominal thickness by more than 2mm. There
shall not be less than 2 nails per board in each circle. Where a slot is cut in the
flange to receive the inner end of the conductor the entrance shall be in line with
the periphery of the barrel.
1.15.7
The wooden battens used for making the barrel of the conductor shall be of
segmental type. These shall be nailed to the barrel supports with at least two nails.
The battens shall be closely butted and shall provide a round barrel with smooth
external surface. The edges of the battens shall be rounded or chamfered to avoid
damage to the conductor.
6 OF 17
1.15.8
Barrel studs shall be used for the construction of drums. The flanges shall be holed
and the barrel supports slotted to receive them. The barrel studs shall be threaded
over a length on either end, sufficient to accommodate washers, spindle plates and
nuts for fixing flanges at the required spacing.
1.15.9
Normally, the nuts on the studs shall stand protruded of the flanges. All the nails
used on the inner surface of the flanges and the drum barrel shall be counter sunk.
The ends of barrel shall generally be flushed with the top of the nuts.
1.15.10
The inner cheek of the flanges and drum barrel surface shall be painted with a
bitumen based paint.
1.15.11
Before reeling, card board or double corrugated or thick bituminised water-proof

bamboo paper shall be secured to the drum barrel and inside of flanges of the
drum by means of a suitable commercial adhesive material. The paper should be
dried before use. Medium grade craft paper shall be used in between the layers of
the conductor. After reeling the conductor, the exposed surface of the outer layer
of conductor shall be wrapped with water proof thick bituminised bamboo paper
to preserve the conductor from dirt, grit and damage during transport and
handling.
1.15.12
A minimum space of 75 mm for conductor shall be provided between the inner

surface of the external protective tagging and outer layer of the conductor.
1.15.13
Each batten shall be securely nailed across grains as far as possible to the flange,
edges with at least 2 nails per end. The length of the nails shall not be less than
twice the thickness of the battens. The nails shall not protrude above the general
surface and shall not have exposed sharp, edges or allow the battens to be released
due to corrosion.
1.15.14
The nuts on the barrel studs shall be tack welded on the one side in order to fully
secure them. On the second end, a spring washer shall be used.
1.15.15
A steel collar shall be used to secure all barrel studs. This collar shall be located
between the washers and the steal drum and secured to the central steel plate by
welding.
1.15.16
Outside the protective lagging, there shall be minimum of two binder consisting of
hoop iron/ galvanised steel wire. Each protective lagging shall have two recesses
to accommodate the binders.
1.15.17
The conductor ends shall be properly sealed and secured with the help of U-nail
on the side of one of the flanges to avoid loosening of the conductor layers during
transit and handling.
1.15.18
As an alternative to wooden drum Contractor may also supply the conductors in

painted steel drums. After preparation of steel surface according to IS : 9954,
synthetic enamel paint shall be applied after application of one coat of primer.
Wooden/Steel drum will be treated at par for evaluation purpose and accordingly
the Contractor should quote in the package.
7 OF 17
1.16
MARKING
Each drum shall have the following information stenciled on it in indelible ink
along with other essential data :
i.
Contract/Award letter number.
ii.
Name and address of consignee.
iii.
Manufacturers name and address.
iv.
Drum and lot number
v.
Size and type of conductor
vi.
Length of conductor in meters
vii.
Arrow marking for unwinding
viii.
Position of the conductor ends
ix.
Number of turns in the outer most layer.
x.
Gross weight of drum after putting lagging.
xi.
Average weight of the drum without lagging.
xii.
Net weight of the conductor in the drum.
xiii.
Month and year of manufacture of conductor
The above should be indicated in the packing list also.
1.17
VERIFICATION OF CONDUCTOR LENGTH

The Owner reserves the right to verity the length of conductor after unreeling at
least Two (2) percent of the drums in a lot offered for inspection.
1.18
STANDARDS
1.18.1
The conductor shall conform to the following Indian/International Standards,

which shall mean latest revisions, with amendments/changes adopted and
published, unless specifically stated otherwise in the Specification.
1.18.2
In the event of the supply of conductor conforming to standards other than

specified, the Bidder shall confirm in his bid that these standards are equivalent to
those specified. In case of award, salient features of comparison between the
standards proposed by the Contractor and those specified in this document will be
provided by the Contractor to establish their equivalence.
8 OF 17
Sl.
No.
1.
Indian Standard
Title
International
Standards
BS:3436- Latest
amendment
IS
:
209-Latest
amendment
Specification for zinc
2.
IS : 398amendment
Latest
Specification
for,
Aluminium
conductors for Overhead Transmission
Purposes
IEC:1089- Latest
amendment
1
BS:215Latest
amendment
3.
IS:398amendment
Part-II
Latest
Aluminum Conductor Galvanised Steel

Reinforced
BS-215Latest
amendment
IEC:1089- Latest
amendment
4.
IS : 1778- Latest
amendment
Reels and Drums for Bare Conductors
BS:1559- Latest
amendment
5.
IS : 1521amendment
IS : 2629amendment
IS : 2633amendment
IS : 4826amendment
Latest
Method of Tensile Testing of Steel Wire
ISO 6892- Latest

amendment
Latest
Recommended Practice for Hot Dip

Galvanising of Iron and Steel
Method of Testing Uniformity of
Coating on Zinc Coated Articles
Galvanised Coating on Round Steel
Wires
6.
7.
8.
Latest
Latest
9.
IS : 6745- Latest
amendment
Methods of Determination of Weight of

Zinc Coating of Zinc Coated Iron and
Steel Articles.
10.
IS : 9997- Latest
amendment
IS : 1841- Latest
amendment
IS : 5484-1978
Aluminium Alloy Redraw Rods
11.
12.
IEC : 888amendment
BS:443amendment
BS:433amendment
1460
amendment
IEC 104amendment
Latest
Latest
Latest
ISO
Latest
Latest
EC Grade Aluminium Rods produced by

rolling
EC Grade Aluminium Rods produced by
continuous casting and rolling
13.
Zinc Coated steel wires for stranded

Conductors
IEC : 888- Latest

amendment
14.
Hard drawn aluminium

overhead line conductors
IEC : 889- Latest

amendment
wire
9 OF 17
for
15.
IS:398 (Part-IV)
Aluminium Alloy stranded conductor
10 OF 17
IEC : 208- Latest

amendment BS3242Latest
amendment
ANNEXURE-A
1
1.1.
TESTS ON ACSR CONDUCTORS

UTS TEST ON STRANDED CONDUCTOR
Circles perpendicular to the axis of the conductor shall be marked at two places on a
sample of conductor of minimum 5 m length between fixing arrangement suitably fixed
on a tensile testing machine. The load shall be increased at a steady rate upto 50% of
minimum specified UTS and held for one minute. The circles drawn shall not be
distorted due to relative movement of strands. Thereafter the load shall be increased at
steady rate to minimum UTS and held for one minute. The Conductor sample shall not
fail during this period. The applied load shall then be increased until the failing load is
reached and the value recorded.
1.2.
D.C. RESISTANCE TEST ON STRANDED CONDUCTOR

On a conductor sample of minimum 5m length two contact-clamps shall be fixed with a
predetermined bolt torque. The resistance shall be measured by a Kelvin double bridge
or digital ohmmeter by placing the clamps initially zero meter and sub-sequently one
meter apart. The test shall be repeated at least five times and the average value recorded.
The value obtained shall be corrected to the value at 20C as per IS:398-(Part-V)-1982.
The resistance corrected at 200C shall conform to the requirements of this Specification.
1.3.
CHEMICAL ANALYSIS OF ALUMINIUM AND STEEL

Samples taken from the Aluminium and steel ingots/coils/strands shall be
chemically/spectrographically analysed. The same shall be in conformity to the
requirements stated in this Specification.
1.4.
VISUAL AND DIMENSIONAL CHECK ON DRUMS

The drums shall be visually and dimensionally checked to ensure that they conform to
the requirements of this Specification.
1.5.
VISUAL CHECK FOR JOINTS, SCRATCHES ETC.

Conductor drums shall be rewound in the presence of the Owner. The Owner shall
visually check for scratches, joints etc. and that the conductor generally conforms to the
requirements of this Specification. Two percent (2%) drums from each lot shall be
rewound in the presence of the Owner's representative.
1.6.
DIMENSIONAL CHECK ON STEEL AND ALUMINIUM STRANDS

The individual strands shall be dimensionally checked to ensure that they conform to
the requirement of this Specification.
1.7.
CHECK FOR LAY-RATIOS OF VARIOUS LAYERS
11 OF 17
The lay-ratios of various layers shall be checked to ensure that they conform to the
requirements of this Specification.
1.8.
PROCEDURE QUALIFICATION TEST ON WELDED ALUMINIUM STRANDS

Two Aluminium wire shall be welded as per the approved quality
plan and shall be subjected to tensile load. The breaking strength of the welded joint of
the wire shall not be less than the guaranteed breaking strength of individual strands.
1.9.
CHEMICAL ANALYSIS OF ZINC

Samples taken from the zinc ingots shall be chemically/ spectrographically analysed.
The same shall be in conformity to the requirements stated in the Specification.
1.10.
GALVANISING TEST
The test procedure shall be as specified in IEC : 888. The material shall conform to the
requirements of this Specification. The adherence of zinc shall be checked by wrapping
around a mandrel four times the diameter of steel wire.
1.11.
TORSION AND ELONGATION TESTS ON ALUMINIUM ALLOY STRANDS/

STEEL STRANDS
The test procedures shall be as per clause No. 10.3 of IEC : 888. In torsion test, the
number of complete twists before fracture shall not be less than 18 on a length equal to
100 times the standard diameter of the strand. In case test sample length is less or more
than 100 times the stranded diameter of the strand, the minimum number of twists will
be proportioned to the length and if number comes in the fraction then it will be rounded
off to next higher whole number. In elongation test, the elongation of the strand shall
not be less than 4% for a gauge length of 250 mm.
1.12.
1.13.
CHECK ON BARREL BATTEN STRENGTH OF DRUMS

The details regarding barrel batten strength test will be discussed and mutually agreed to
by the Contractor & Owner in the Quality Assurance Programme.
BREAKING LOAD TEST ON INDIVIDUAL ALUMINIUM ALLOY AND
GALVANIZED STEEL WIRES
The test shall be conducted on both Aluminium and Galvanized steel wires.
The breaking load of one specimen cut from each of the samples taken shall be
determined by means of suitable tensile testing machine. The load shall be applied
gradually and the rate of separation of the jaws of the testing machine shall be not less
than 25 mm/min. and not greater than 100 mm./ min. The ultimate breaking load of the
specimens shall be not less than the values specified in the Specification.
1.14.
RESISTANCE TEST ON ALUMINIUM WIRE

The test shall be conducted on aluminium wires only, conforming to procedure as per
IEC: 889. The electrical resistance of one specimen of aluminium wire cut from each of
the samples taken shall be measured at ambient temperature. The measured resistance
12 OF 17
shall be corrected to the value corresponding to 20 degree C. by means of following

formula.
1
R20
=
RT ------------------1+alpha x (T-20)
Where
R20
=
Resistance corrected at 20 degrees C.
RT
=
Resistance measured at T degrees C.
Alpha =
Constant mass temperature coefficient of resistance 0.004.
T
=
Ambient temperature during measurement
This resistance calculated to 20 degrees C. shall be not more than the maximum
value specified in the specification.
13 OF 17
SECTION 3, CHAPTER 16
ACSR Conductor
S.N
.
Parameter
Table-1
Details of parameters of ACSR conductor
DOG
Raccon
Rabbit
Weasel
Squirrel
(No of starnd/dia in mm) Al
6/4.72
6/4.09
6/3.35
6/2.59
6/2.11
(No of starnd/dia in mm) Steel
7/1.57
1/4.09
1/3.35
1/2.59
1/2.11
105
78.83
52.88
31.61
20.98
118.5
91.97
61.7
36.88
24.48
Sectional area of aluminium (sq.mm.)

4 Total sectional area of conductor (sq.mm.)
Overall diameter mm
14.15
12.27
10.05
7.77
6.33
Approximate mass (kg/km)
394
319
214
128
85
14 OF 17
ACSR Conductor
S.N
.
Parameter
DOG
Raccon
Rabbit
Weasel
Squirrel
Calculated D.C. resistance at 20 deg.

Centigrade (ohm/km)
0.2792
0.3712
0.5524
0.9289
1.394
Minimum UTS (kN)
32.41
26.91
18.25
11.12
7.61
Direction of lay of outer layer
Right hand
Right hand
Right hand
Right hand
Right hand
75
79
79
79
79
19.8x10-6
19.1x10-6
19.1x10-6
19.1x10-6
19.1x10-6
10
Modulus of elasticity (GN/m2)
11
Co-efficient of Linear expansion (Per C)
12
Details of aluminium strand :
Minimum breaking load of the strand before

stranding (kN)
2.78
2.08
1.43
0.89
0.63

stranding (kN)
2.64
1.98
1.36
0.85
0.60
Maximum DC resistance of strand at 20 deg C

(ohms/km)
1.650
2.194
3.265
5.49
8.237
Weight (kg/km)
47.30
35.51
23.82
14.24
9.45
15 OF 17
ACSR Conductor
S.N
.
Parameter
DOG
Raccon
Rabbit
Weasel
Squirrel
Diameter
Nominal
4.72
4.09
3.35
2.59
2.11
ii
Maximum
4.77
4.13
3.38
2.62
2.13
iii
Minimum
4.67
4.05
3.32
2.56
2.09
13
Details of Steel strand :
Minimum breaking load of the strand before

stranding (kN)
2.7
17.27
11.58
6.92
4.60

stranding (kN)
2.57
16.4
11
6.57
4.37
Weight (kg/km)
15.10
102.48
68.75
41.09
27.27
275
250
230
210
Galvanising
Zinc coating after stranding (g/m2)
190
ii
Minimum number of dips that the galvanized

strand can withstand in the standard preece test
(Nos.)
2 of one minute
and 1 of half
minute
2 of one minute
and 1 of half
minute
16 OF 17
2 of one minute and 1

of half minute
2 of one minute
and 1 of half
minute
2 of one
minute and 1
of half
minute
ACSR Conductor
S.N
.
Parameter
DOG
Raccon
Rabbit
Weasel
Squirrel
iii
16
16
16
16
16
Minimum number of twists in a gauge length

eaqual to 100 times dia of wire which the
strands can withstand in torsion test after
stranding
Diameter
Nominal
1.57
4.09
3.35
2.59
2.11
ii
Maximum
1.60
4.17
3.42
2.64
2.15
iii
Minimum
1.54
4.01
3.28
2.54
2.07
14
Lay Ratio
Aluminium wire
Steel wire
Max
14
28
Min
10
13
Max
14
-
17 OF 17
Min
10
-
Max
14
-
Min
10
-
Max
14
-
Min
10
-
Max
14
-
Min
10
-
BATTERY, BATTERY CHARGER AND DCDB

1.0
GENERAL TECHNICAL REQUIREMENTS
1.1
This section of specification covers the design, manufacture, assembly, shop

testing/inspection before dispatch, packing, forwarding, transportation to site,
insurance, storage, erection, supervision, site testing and commissioning of 30 V DC
system consisting of one float-cum-boost charger and one battery bank for indoor
application.
1.2
The contractor shall submit the drawings and get the owners approval before
proceeding.
2.0
STANDARDS
Except where modified by this specification, battery and battery charger and the
equipment mounted therein shall be designed, manufactured and tested in accordance
with latest editions of the following standards.
IEC:896
IS:1652
IEC:76
IEC:146
IEC:529
IEC:255
IEC: 337
IEC: 227
IEC:947-1
IS:2026
IS:3136
IS:13947
IS:3231
IS:8686
IS:6875
IS:1554
IS:13947-1
IEC:947-2
IEC:947-3
IEC:947-4
IEC:439
IS: 13947-2
IS: 13947-3
IS: 13947-4
IS:8623
IS:1901
IS:13703
IS:1300
IS:11353
IEC:269
IEC:800
IS:3043
IS:6005
3.0
Lead Acid batteries general requirements and methods

of test Tubular type
Transformers
Poly-crystalline semiconductor rectifier equipment
Degree of protection provided by enclosures
Electrical relays for power system protection
Static protective relays
Control Switches
PVC insulated cables upto and including 1100 volts.
Low voltage switchgear and control gear general
rules.
Low voltage circuit breaker
Low voltage AC switch fuse combination
Contactors
Low voltage switchgear and control gear assemblies
Visual indicating lamps
HRC cartridge fuse links upto 650 volts
Phenolic moulding material
Guide for uniform marking and identification of
conductors and apparatus terminals
Code of practice for earthing
Code of practice for phosphating of iron and steel
DC SUPPLY SYSTEM
The proposed 30 volt DC supply system shall consist of the battery and battery charger.
The battery charger, battery and load shall be normally connected in parallel and work
as a system.
Under parallel operating conditions, the battery shall float between the charger and load
with the transformer-cum-rectifier unit of the float charger supplying the required DC
load as well as maintaining the battery in fully charged condition. The battery shall act
as a back up source of power or contributing to total current during load peaks if it
exceeds the rated output of the transformer-cum-rectifier unit. Should the charger fail
due to loss of its AC supply or for other reasons, the battery shall immediately take
over feeding the load and shall continue to do so until the charger has been restored to
Page 1 of 10
service. Thus the charger and battery shall supply the load current either separately or
simultaneously as circumstances dictate.
In the event of battery being discharged, the boost charger shall be capable of recharging it at the ten hours rate. On completion of re-charge operation, the charger shall
revert to float charging. The charger shall have the additional facility of being able to
boost charge the battery at a constant voltage above that of the float charge level, under
manual supervision. The change from float charge operation to boost charging and vice
versa shall be effected by means of a float/boost charge selection switch.
Automatic charging of the battery shall be carried out in accordance with the (IU)
characteristic. The battery shall be charged with a constant current the magnitude of
which shall be the maximum output rating of the charger less the current being drawn
by the load (I characteristics). As soon as the battery terminal voltage rises to the float
voltage the charger shall switch to constant voltage operation (U characteristics). Boost
charging of a battery shall also be carried out in accordance with the (U) characteristics.
The facility to boost charge shall enable the constant voltage, at which the change from
I to U characteristic takes place, to be set at a higher level than the float charge voltage.
The setting of the constant current portion of the characteristic shall be adjustable at
least over the range of fifty percent of the rated output current to maximum rating of the
chargers. The constant voltage portions of the characteristics shall be pre-set at 2.30
volt per cell for the trickle charging. For boost charging the characteristics of the
constant voltage portion shall be pre set at 2.70 volt per cell. The settings shall be
adjustable.
4.0
BATTERY
4.1
The 30V DC Batteries shall be stationary Lead-Acid type consisting of 15 cells with
tubular positive plates. Tubular type batteries shall be Normal Discharge type. These
Batteries shall be suitable for a long life under continuous float operations at 2.15 to
2.25 volts per cell, and occasional discharges. The capacity shall be 100 Ampere Hours
at 10 hour discharge rate. The 30 V DC system is - ve earth system.
4.2
Cell Terminals: All cell terminals shall have adequate current carrying capacity and
shall be of lead alloy or lead alloy reinforced with copper core inserts. Cell terminal
posts shall be equipped with connection bolts having acid resisting bolts and nuts.
4.3
Container: Containers shall be made of glass or hard rubber or suitable plastic material
or glass fibre reinforced plastics or lead lined wood. Containers shall be robust, heat
resistant, leak proof, non-absorbent, acid resistant and free from flaws. Glass containers
shall be transparent. Electrolyte level lines shall be marked on container in case of
transparent containers. Float type level indicator shall be provided in case of opaque
containers. The marking for the electrolyte level should be for the upper, normal and
lower limits. The material of level indicator shall be acid-proof and oxidation proof.
4.4
Vent Plugs: Vent plugs shall be provided in cells. They shall be of anti-splash type,
having more than one exit hole and shall allow the gases to escape freely but shall
prevent acid from coming out. Suitable arrestors shall be provided to prevent spilling of
electrolyte.
4.5
Plates : The plates shall be designed for maximum durability during all service
conditions including high rate of discharge and rapid fluctuations of load. The
construction of plates shall conform to latest revisions of IS : 1651 or IS:1652 as
Page 2 of 10
applicable. Separators shall be provided to maintain the electrical insulation between

the plates and shall allow the electrolyte to flow freely. The positive and negative
terminal posts shall be clearly marked.
4.6
Sediment Space: Sufficient sediment space shall be provided so that cells will not have
to be cleaned out during normal life.
4.7
Cell Insulator: Each cell shall be separately supported on porcelain or hard rubber
insulators fixed on to the racks with adequate clearance between adjacent cells.
4.8
Electrolyte: The electrolyte shall be prepared from battery grade sulphuric acid
conforming to IS:226 and distilled water conforming to IS:1069. The cells shall be
shipped dry and uncharged. The electrolyte for initial filling shall be furnished
separately. A minimum of 10% extra electrolyte shall be supplied after completion of
initial charging.
4.9
Manufacturers Identification System

The following information shall be indelibly marked on outside of each cell :
4.10
Manufacturers name and trade mark
Country and year of manufacture
Manufacturers type designation
AH capacity at 10 hr. discharge rate
Serial Number
Upper, normal and lower electrolyte level in case of transparent containers.
Connectors and Fasteners

Lead or lead coated connectors shall be used for connecting up adjacent cells, rows and
end take off. Bolts, nuts and washers shall be effectively lead coated to prevent
corrosion. End take off connectors shall be provided from positive and negative poles
of the batteries to the Power cables. More than one cable may be required to be
connected to the battery terminals. Suitable arrangement for termination of multiple
cables shall be provided so as to avoid extra load on the battery terminals The cable
will be single core having stranded aluminium conductor and PVC insulation which
will be arranged by the contractor separately. Necessary wooden supports and lugs for
termination of these cables on Batteries shall also be supplied by the Contractor. All
connectors and lugs shall be capable of continuously carrying the 30 Minute discharge
current of the respective Batteries and shall be capable to carry 4 kA for 1 sec. Suitable
tapping point shall be provided in the battery for connection during boost charging to
avoid overvoltage to the load. Alternatively, dropping diodes shall be provided.
4.11
Battery Racks
Battery cells are to be mounted on Teak wood racks to be supplied by the contractor. It
should be made of straight grain hardwood, free from knots. It should be painted with
Page 3 of 10
acid proof paint. Racks shall have free access to the floor beneath making cleaning
possible. There shall be three rows of five cells each.
5.0
TESTS
5.1
Batteries shall conform to all type tests as per the latest issue of IS: 1651 or IS: 1652
(whichever is applicable depending on type of Battery being offered).
5.2
All Acceptance tests as required by the relevant Indian Standards shall be carried out at
site after completion of installation. The capacity tests shall be carried out for 10 hr.
discharge rating. The Contractor shall arrange for all necessary equipment, including
the variable resistor, tools, tackles and instruments. If a Battery fails to meet the
guaranteed requirements the OWNER shall have the option of asking the contractor to
replace the same with appropriate batteries at no extra cost and without affecting the
commissioning schedule of the employer.
5.3
If successful Contractor has not manufactured & commissioned the specified cell size,
they must manufacture & test the prototype in advance and obtain Employers approval
for the same.
5.4
Following type tests shall be carried out on each type of cells in the presence of
Employers representative, if desired by the OWNER:
i. Capacity tests
ii. Watt hour and AH efficiency tests
6.0
ACCESSORIES
6.1
The following information shall be given on the instruction cards supplied with the
Battery:
6.2
a)
Manufacturers instruction for filling and initial charging of the Battery together
with starting and finishing charging rate.
b)
Maintenance instructions.
c)
Designation of cell in accordance with IS: 1651 or IS: 1652 (whichever

applicable).
d)
Storing conditions of electrolyte and battery cells.
A complete Set of all the accessories and devices for maintenance of Batteries shall
be supplied along with each set of battery bank, as under:.
i)
ii)
iii)
2 Nos. of Hydrometers.
2 sets of Hydrometer syringes suitable for the vent holes in different cells.
2 Nos. of thermometers for measuring electrolyte temperature.
iv)
2 No. of Specific gravity correction chart.
Page 4 of 10
v)
2 Nos. of Wall mounting type holders made of teak wood for hydrometer and
thermometer.
vi)
2 Nos. of Cell testing voltmeter (3-0-3V) conforming to IS : 1248.
vii) 2 No. of Rubber apron.

viii) 2 Pairs of Rubber gloves
7.0
ix)
1 Set of spanners
x)
2 nos. Instructions cards
BATTERY CHARGER
The Battery Chargers as well as the automatic regulators shall be of static type. The
battery charger shall be capable of continuous operation at the rated load in float
charging mode. The chargers shall also be capable of Boost charging the associated
DC Battery at the desired rate.
7.1
The Battery Charger shall be provided with facility for both automatic and manual
control of output voltage and current. A selector switch shall be provided for selecting
the mode of output voltage/current control, whether automatic or manual. When on
automatic control mode during Float charging, the Charger output voltage shall remain
within +1% of the set value, for AC input voltage variation of +10%, frequency
variation of +5%, a combined voltage and frequency variation of +10%, and a DC load
variation from zero to full load.
7.2
The battery charger shall have constant voltage characteristics throughout the range
(from zero to full load) at the floating value of the voltage so as to keep the battery
fully charged but without harmful overcharge.
7.3
The charger shall have load limiters having drooping characteristic, which shall cause,
when the voltage control is in automatic mode, a gradual lowering of the output
voltage when the DC load current exceeds the Load limiter setting of the Charger.
The Load-limiter characteristics shall be such that any sustained overload or short
circuit in DC System shall not damage the Charger, nor shall it cause blowing of any
of the Charger fuses. The Charger shall not trip on overload or external short circuit.
7.4
Uniform and step less adjustments of voltage setting (in both manual and automatic
modes) shall be provided on the front of the Charger panel covering the entire float
charging output range specified. Stepless adjustments of the Load-limiter setting shall
also be possible from 80% to 100% of the rated output current for Charging mode.
7.5
It shall be possible to adjust the Boost charging current continuously over a range of 50
to 100% of the rated output current for Boost charging mode.
7.6
The Charger output voltage shall automatically go on rising, when it is operating on

Boost mode, as the Battery charges up. For limiting the output voltage of the Charger,
Page 5 of 10
a potentiometer shall be provided on the front of the panel, whereby it shall be

possible to set the upper limit of this voltage any where in the output range specified
for Boost Charging mode.
7.7
The Charger manufacturer may offer an arrangement in which the voltage setting
device for Float charging mode is also used as output voltage limit setting device for
Boost charging mode and the Load-limiter of Float charging mode is used as current
setting device in boost charging mode.
7.8
Suitable filter circuits shall be provided in all the chargers to limit the ripple content
(Peak to Peak) in the output voltage to 1%, irrespective of the DC load level, when
they are not connected to a Battery.
7.9
The continuous rating of the charger shall be 20 Amps but the contractor shall compute
the total load and if it is necessary, supply charger of higher rating.
8.0
MCCB
The Battery Charger shall have 1 No. MCCB on the input side to receive cables from
one source. It shall be of P2 duty and suitable for continuous duty. MCCBs should have
auxiliary contacts for annunciation/hooter on input AC supply failure..
9.0 RECTIFIER TRANSFORMER

The rectifier transformer shall be continuously rated, dry air cooled (A.N) and of class
F insulation type. The rating of the rectifier transformer shall have 10% overload
capacity.
9.1
Rectifier Assembly
The rectifier assembly complying with IS:3136 shall be fully controlled bridge type and
shall be designed to meet the duty as required by the respective Charger. The rectifier
shall be provided with heat sink having their own heat dissipation arrangements with
natural air-cooling. Necessary surge protection devices and rectifier type fast acting
HRC fuses shall be provided in each arm of the rectifier connections.
10.0
INSTRUMENTS
One AC voltmeter and one AC ammeter alongwith selector switches shall be provided
for all chargers. One DC voltmeter and DC ammeter (with shunt) shall be provided for
all Chargers. The instruments shall be flush type, dust proof and moisture resistant.
The instruments shall have easily accessible means for zero adjustment. The
instruments shall be of 1.5 accuracy classes complying with IS:1248.
11.0
AIR BREAK SWITCHES

One DC output switch shall be provided in all chargers. They shall be air break type
suitable for 500 volts AC/ 250 Volt DC. The contacts of the switches shall open and
close with a snap action. The operating handle of the switch shall be fully insulated
from circuit. ÒN and ÒFF position on the switch shall be clearly indicated. Rating of
Page 6 of 10
switches shall be suitable for their continuous load. Alternatively, MCCBs of suitable
ratings shall also acceptable in place of Air Break Switch.
12.0 FUSES
All fuses shall be HRC cartridge type. Fuses shall be mounted on mounted material fuse
carriers, which are in turn mounted on fuse bases. The Contractor depending on the
circuit requirement shall choose fuse rating. All fuses in the chargers shall be monitored.
Fuse failure annunciation shall be provided on the failure of any fuse.
13.0 BLOCKING DIODE
Blocking diode shall be provided in the positive pole of the output circuit of each
charger to prevent current flow from the DC Battery into the Charger.
14.0 ANNUNCIATION SYSTEM
Audio-visual indications through bright LEDs shall be provided in all Chargers for the
following abnormalities:
a) AC power failure
b) Rectifier/chargers fuse blown.
c) Over voltage across the battery when boost charging.
d) Abnormal voltage (High/Low)
e) Earth leakage
f) Any other annunciation if required.
Potential free NO Contacts of above abnormal conditions shall also be provided for
common remote indication CHARGER TROUBLE in Employers Control Board.
Indication for charger in float mode and boost mode through indication lamps shall be
provided for chargers. A potential free contact for float/boost mode shall be provided
for external interlocks.
15.0
NAME PLATES AND MARKING

The nameplates shall be white with black engraved letters. On top of each Charger, on
front as well as rear sides, larger and bold nameplates shall be provided to identify the
Charger. Nameplates with full and clear inscriptions shall also be provided on and
inside of the panels for identification of the various equipments and ease of operation
and maintenance.
16.0 CHARGER CONSTRUCTION

The Chargers shall be indoor, floor-mounted, self-supporting sheet metal enclosed
cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and
hardware. The Chargers shall be fabricated from 2.0mm cold rolled sheet steel and shall
have folded type of construction. Removable gland plates for all cables and lugs for
power cables shall be supplied by the Contractor. The lugs for power cables shall be
made of electrolytic copper with tin coat. Power cable sizes shall be advised to the
Contractor at a later date for provision of suitable lugs and drilling of gland plates. The
Charger shall be tropicalised and vermin proof. Ventilation louvers, if provided shall be
backed with screens. All doors and covers shall be fitted with synthetic rubber gaskets.
The chargers shall have hinged double leaf doors provided on front and on backside for
adequate access to the Chargers internals. All the charger cubicle doors shall be
Page 7 of 10
properly earthed. The degree of protection of Charger enclosure shall be at least IP-42
as per IS: 13947.
16.1 All indicating instruments, control switches and indicating lamps shall be mounted on
the front side of the Charger.
16.2
Each Charger shall be furnished completely wired upto power cable lugs and terminal
blocks and ready for external connections. The control wiring shall be carried out with
PVC insulated, 1.5 sq.mm. stranded copper wires. Control terminals shall be suitable
for connecting two wires, with 2.5 sq.mm stranded copper conductors. All terminals
shall be numbered for ease of connections and identification. Each wire shall bear a
ferrule or tag on each end for identification. At least 20% spare terminals shall be
provided for control circuits.
16.3
The insulation of all circuits, except the low voltage electronic circuits shall withstand
test voltage of 2 KV AC for one minute. An air clearance of at least ten (10) mm shall
be maintained throughout for such circuits, right up to the terminal lugs. Whenever this
clearance is not available, the live parts shall be insulated or shrouded.
17.0
PAINTING
All sheet steel work shall be pretreated, in 7 tanks process, in accordance with IS: 6005.
Degreasing shall be done by alkaline cleaning. Rust and scale shall be removed by
pickling with acid. After pickling, the parts shall be washed in running water. Then
these shall be rinsed in slightly alkaline hot water and dried. The phosphate coating
shall be `Class-C as specified in IS:6005. Welding shall not be done after
phosphating. The phosphated surfaces shall be rinsed and passivated prior to
application of stoved zinc chromate primer coating. After primer application, two coats
of finishing synthetic enamel paint of shade-692 (smoke grey) of IS:5 shall be applied,
unless required otherwise by the Employer. The inside of the chargers shall be glossy
white. Each coat of finishing synthetic enamel paint shall be properly stoved. The
paint thickness shall not be less than fifty (50) microns.
18.0
TESTS
18.1
Battery chargers including the components shall conform to all type tests as per
relevant Indian Standard. Performance test on the Chargers as per Specification shall
also be carried out on each Charger as per specification. Rectifier transformer shall
conform to all type tests specified in IS: 4540 and short circuit test as per IS: 2026.
Following type tests shall be carried out for compliance of specification requirements:
i)
ii)
iii)
iv)
v)
vi)
Voltage regulation test

Load limiter characteristics test
Efficiency tests
High voltage tests
Temperature rise test
Short circuit test at no load and full load at rated voltage for sustained shortcircuit.
vii) Degree of protection test
viii) Measurement of ripple by oscilloscope.
Page 8 of 10
18.2 The Contractor may be required to demonstrate to the Owner that the Chargers conform
to the specification particularly regarding continuous rating, ripple free output, voltage
regulation and load limiting characteristic, before dispatch as well as after installation
at site. At site the following tests shall be carried out:
i)
Insulation resistance test
ii)
Checking of proper annunciation system operation.
18.3
If a Charger fails to meet the specified requirements, the Contractor shall replace the
same with appropriate Charger without affecting the commissioning schedule of the
Sub-station, and without any extra cost to the owner.
18.4
The Contractor shall present for inspection, the type and routine test certificates for the
following components whenever required by the OWNER.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
Switches.
Relays/MCCBs
Instruments.
DC fuses.
SCR.
Diodes.
Condensers.
Potentiometers.
Semiconductor
Annunciator.
Control wiring
Push buttons for contactors.
Makes of above equipment shall be subject to Owner approval.
19.0 DC Distribution Board

The DCDB shall be an integral part of the charger panel. The DCDB partion shall be
isolated from the other part of the charger and shall have a separate door so that the
same can be accessed without being exposed to other part of the charger.
Incomer will be from 30V DC Battery set/Battery Charger. It shall have isolated bus bar
chamber for main bus bar at top, running throughout the length of the board and double
pole (DP) vertical busbar chambers for power supply to outgoing feeders. DP should
withstand the short circuit current envisaged for 30V system.
General feeder arrangement will be as
DC Bus: Copper bus shall be provided of suitable size.
Incomer:
rating
1 no. DP air break switch with HRC cartridge Fuse/MCCB of suitable
Outgoing: 6 no. outgoing feeders points with HRC Cartridge Fuse of suitable rating
Page 9 of 10
Metering module: The Metring module shall consist of voltmeter (1 no.), Ammeter (1
no), indication lamps (1no) for supply indication. They are to be mounted in-comer
panel.
The size of the bus and rating of fuses/MCCB shall be proposed by the contractor for
owners approval during detailed engineering.
20.0 EARTHING
Two earthing terminals shall be provided complete with nuts and washers near the base
for connecting to station earthing system by 30x6 mm GI flats.
Page 10 of 10
BAY MARSHALLING BOX

A.
BAY MARSHALLING BOX

1. GENERAL
Bay Marshalling Kiosk is envisaged for distribution of AC & DC Power supply to
switchyard equipments in switchyard of 33kV/11 kV Substation. All control cables to
and from control room to switchyard equipment shall be terminated to this kiosk enroute. This would facilitate location of any fault and early repair and replacement.
2. CONSTRUCTIONAL FEATURE
Panels shall be completely metal enclosed and shall be dust, moisture and vermin
proof and fully compartmentalized. The enclosure shall provide a degree of protection
not less than IP-55 (for outdoor) in accordance with IS: 13947. It should be free
standing, floor mounting type and smooth finished, cold rolled sheet steel of thickness
not less than 3 mm for weight bearing members of the panels such as base frame, front
sheet and door frames, and 2.0mm for sides, door, top and bottom portions. There shall
be sufficient reinforcement to provide level transportation and installation. Design,
materials selection and workmanship shall be such as to result in neat appearance,
inside and outside with no welds rivets or bolt head apparent from outside, with all
exterior surfaces tune and smooth. The colour of the finishing paint shall be light grey
in accordance with shade no.697 of IS: 5 or in matching colour of other existing Panels.
3. TECHNICAL DETAIL
This will consist of consisting of following incoming & outgoing AC & DC feeder.
AC Portion:
i. 1 No.- 3 Phase 415V, 200A incomer
ii. 1 No.- 3 Phase 415V, 32 A outgoing feeder through MCB
iii. 9 Nos.- 1- Phase 240V, 16 A outgoing feeder through MCB
DC Portion:
i. 1 No.- 30V,50A incomer with ON /OFF switch & fuse
ii. 10 No.- 30V, 10 Amp. outgoing feeder with fuse
Control Cable Portion:
Sufficient number of terminal blocks shall be provided with 10% spare terminals. The
terminal blocks and wiring shall be numbered as provided in C&R panel.
Page 1 of 1
CONTROL & RELAY PANEL 33KV AND 11 KV

1.1
Simplex Panel
The Control and Relay Panel Boards shall consist of Simplex panel, vertical independent, floor mounted
with equipment mounted on front and having wiring access from rear. In case of panel having width
more than 800mm, double leaf-doors shall be provided. Doors shall have handles with built-in locking
facility.
2.1
CONSTRUCTIONAL FEATURES
2.1.1
It is the responsibility of the Contractor to ensure that the equipment specified and such unspecified
complementary equipment required for completeness of the protective/control schemes be properly
accommodated in the panels without congestion. However, the width of panels that are being offered to
be placed in existing switchyard control rooms, should be in conformity with the space availability in
the control room.
2.1.2
Panels shall be completely sheet metal clad and shall be dust, moisture and vermin proof. The enclosure
shall provide a degree of protection not less than IP-4X in accordance with IS: 13947.
2.1.3
Panels shall be free standing, floor mounting type and shall comprise structural frames completely
enclosed with specially selected smooth finished, cold rolled sheet steel of thickness not less than 3 mm
for weight bearing members of the panels such as base frame, front sheet and door frames, and 2.0mm
for sides, door, top and bottom portions. There shall be sufficient reinforcement to provide level
transportation and installation.
2.4
All doors, removable covers and panels shall be gasketed all around with neoprene gaskets. Ventilating
louvers to be if provided shall have screens and filters. The screens shall be made of either brass or GI
wire mesh.
2.5
Design, materials selection and workmanship shall be such as to result in neat appearance, inside and
outside with no welds, rivets or bolt head apparent from outside, with all exterior surfaces tune and
smooth.
2.6
Panels shall have base frame with smooth bearing surface, which shall be fixed on the embedded
foundation channels/insert plates. Anti vibration strips made of shock absorbing materials that shall be
supplied by the contractor, shall be placed between panel and base frame.
2.7
Cable entries to the panels shall be from the bottom. Cable gland plate fitted on the bottom of the panel
shall be connected to earthing of the panel/station through a flexible braided copper conductor rigidly.
The gland shall confirm to IS 12943.
3.0
MOUNTING
3.1
All equipment on and in panels shall be mounted and completely wired to the terminal blocks ready for
external connections. The equipment on front of panel shall be mounted flush. No equipment shall be
mounted on the doors.
3.2
Equipment shall be mounted such that removal and replacement can be accomplished individually
without interruption of service to adjacent devices and are readily accessible without use of special tools.
Terminal marking on the equipment shall be clearly visible.
3.3
Contractor shall carry out cut out, mounting and wiring of the items supplied by others, which are to be
mounted in his panel in accordance with the corresponding equipment manufacturer's drawings. Cut
outs if any, provided for future mounting of equipment shall be properly blanked off with blanking plate.
3.4
The centre lines of switches, push buttons and indicating lamps shall be not less than 750mm from the
bottom of the panel. The centre lines of relays, meters and recorders shall be not less than 450mm from
the bottom of the panel
3.5
The centre lines of switches, push buttons and indicating lamps shall be matched to give a neat and
uniform appearance. Like wise the top lines of all meters, relays and recorders etc. shall be matched.
Page 1 of 10
4.0
PANEL INTERNAL WIRING
4.1
Panels shall be supplied complete with interconnecting wiring provided between all electrical devices
mounted and wired in the panels and between the devices and terminal blocks for the devices to be
connected to equipment outside the panels. When panels are arranged to be located adjacent to each
other all inter panel wiring and connections between the panels shall be furnished and the wiring shall be
carried out internally
4.2
All wiring shall be carried out with 1100V grade, single core, stranded FRLS tinned copper conductor
wires with PVC insulation conforming to IS 1554. The minimum size of the multi-stranded copper
conductor used for internal wiring shall be as follows:
All circuits except current transformer circuits and voltage transformer circuits meant for
energy metering and AC & DC power circuit- one no 2.5 sq. mm. per lead.
All current transformer circuits two nos. 2.5 sq. mm. per lead.
Voltage transformer circuit (for energy meters): Two 2.5 sq.mm. per lead.
AC/DC Power Circuit One 4 Sq.mm. per lead
4.3
All internal 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.
4.4
Auxiliary bus wiring for AC and DC supplies, voltage transformer circuits, annunciation circuits and other
common services shall be provided near the top of the panels running throughout the entire length of the
panels.
4.5
Wire termination shall be made with solderless crimping type and tinned copper lugs, which firmly grip
the conductor. Insulated sleeves shall be provided at all the wire terminations. Engraved core
identification plastic ferrules marked to correspond with panel wiring diagram shall be fitted at both ends
of each wire. Ferrules shall fit tightly on the wire and shall not fall off when the wire is disconnected from
terminal blocks. All wires directly connected to trip circuit of breaker or device shall be distinguished by
the addition of red coloured unlettered ferrule.
4.6
Longitudinal troughs extending throughout the full length of the panel shall be preferred for inter panel
wiring. Inter-connections to adjacent panel shall be brought out to a separate set of terminal blocks located
near the slots of holes meant for taking the inter-connecting wires.
4.7
Contractor shall be solely responsible for the completeness and correctness of the internal wiring and for
the proper functioning of the connected equipments
5.0
TERMINAL BLOCKS
5.1
All internal wiring to be connected to external equipment shall terminate on terminal blocks. Terminal
blocks shall be 1100 V grade and have 10 Amps continuous rating, moulded piece, complete with
insulated barriers, stud type brass terminals, washers, nuts, lock nuts and identification strips. Markings
on the terminal blocks shall be on marking strips and shall correspond to wire number and terminal
numbers on the wiring diagrams. All terminal blocks shall have shrouding with transparent unbreakable
material. All Marking shall confirm to IS 11353.
5.2
Disconnecting type terminal blocks for voltage transformer secondary leads shall be provided. Current
transformer secondary leads shall be provided with short circuiting and earthing facilities. These leads
should have testing facilities.
5.3
At least 20% spare terminals shall be provided on each panel and these spare terminals shall be
uniformly distributed on all terminal blocks.
5.4
Unless otherwise specified, terminal blocks shall be suitable for connecting the following conductors of
external cable on each side
All CT & PT circuits: minimum of two of 2.5mm Sq. copper.
AC/DC Power Supply Circuits: One of 4mm Sq. Copper.
All other circuits: minimum of one of 2.5mm Sq. Copper.
5.5
There shall be a minimum clearance of 250mm between the first row of terminal blocks and the
associated cable gland plate or panel side wall. Also the clearance between two rows of terminal blocks
edges shall be minimum of 150mm.
Page 2 of 10
5.6
Arrangement of the terminal block assemblies and the wiring channel within the enclosure shall be such
that a row of terminal blocks is run in parallel and close proximity along each side of the wiring-duct to
provide for convenient attachment of internal panel wiring. The side of the terminal block opposite the
wiring duct shall be reserved for the external cable connections. All adjacent terminal blocks shall also
share this field wiring corridor. All wiring shall be provided with adequate support inside the panels to
hold them firmly and to enable free and flexible termination without causing strain on terminals.
5.7
All necessary cable terminating accessories such as gland plates, supporting clamps & brackets, wiring
troughs and gutters etc. for external cables shall be included in the scope of supply.
6.0
PAINTING
6.1
All sheet steel work shall be phosphated in accordance with the IS:6005
Phosphating Iron and Steel".
"Code of Practice for
6.2
Rust, scale, oil, grease, dirt and swarf shall be removed by 7 tank process.
6.3
After phosphating, thorough rinsing shall be carried out with clean water
with dilute dichromate solution and oven drying.
6.4
The phosphate coating shall be sealed with application of two coats of ready mixed, stoved type zinc
chromate primer. The first coat may be "flash dried" while the second coat shall be stoved.
6.5
After application of the primer, two coats of finishing synthetic enamel paint shall be applied, each coat
followed by final rinsing
followed by stoving. The second finishing coat shall be applied after inspection of first coat of painting.
The exterior colour of paint shall be of a slightly different shade to enable inspection of the painting.
The final coat should present a hard glass finish.
6.6
A small quantity of finished paint shall be supplied for minor touching up required at site after
installation of the panels.
6.7
In case the bidder proposes to follow any other established painting procedure like electrostatic painting
or powder coating, the procedure shall be submitted for 's review and approval.
7.0
MIMIC DIAGRAM
7.1
Coloured mimic diagram and symbols showing the exact representation of the system shall be provided
in the front of control panels.
7.2
Mimic diagram shall be made preferably of anodised aluminium or plastic of approved fast colour
material, which shall be screwed on to the panel and can be easily cleaned. Painted overlaid mimic is
also acceptable. The mimic bus shall be 2 mm thick. The width of the mimic bus shall be 10mm for
bus bars and 7 mm for other connections.
7.3
Mimic bus colour will be decided by the BSPHCLand shall be furnished to the successful Bidder during
Engineering.
7.4
When semaphore indicators are used for equipment position they shall be so mounted in the mimic that
the equipment close position shall complete the continuity of mimic.
7.5
Indicating lamp, one for each phase, for each bus shall be provided on the mimic to indicate bus charged
condition.
Page 3 of 10
8.0
NAME PLATES AND MARKINGS
8.1
All equipment mounted on front and rear side as well as equipment mounted inside the panels shall be
provided with individual name plates with equipment designation engraved. Also on the top of each
panel on front as well as rear side, large and bold name plates shall be provided for circuit/feeder
designation.
8.2
All front mounted equipment shall also be provided at the rear with individual name plates engraved
with tag numbers corresponding to the one shown in the panel internal wiring to facilitate easy tracing of
the wiring.
8.3
Each instrument and meter shall be prominently marked with the quantity measured e.g. KVA, MW, etc.
All relays and other devices shall be clearly marked with manufacturer's name, manufacturer's type,
serial number and electrical rating data.
8.4
Name Plates shall be made of non-rusting metal or 3 ply lamicoid. Nameplates shall be black with
white engraving lettering.
8.5
All the panels shall be provided with nameplate mounted inside the panel bearing LOA No & Date,
Name of the Substation & feeder and reference drawing number.
9.0
MISCELLANEOUS ACCESSORIES
9.1
Plug Point:
A 240V, Single phase 50Hz, 15Amp AC socket with 15 Amps standard Indian plug, shall be provided in
the interior of each cubicle with ON-OFF switch.
9.2
Interior Lighting:
Each panel shall be provided with a 20 W fluorescent lighting fixture rated for 240 Volts, single phase,
50 Hz supply for the interior illumination of the panel controlled by the respective panel door switch.
9.3
Switches and Fuses:

Each panel shall be provided with necessary arrangements for receiving, distributing, protecting and
isolating DC and AC supplies for various control, signalling, lighting and space heater circuits. The
incoming and sub-circuits shall be separately provided with miniature circuit breakers (MCB). Selection
of the main and sub-circuit MCB rating shall be such as to ensure selective clearance of sub-circuit
faults. MCBs shall confirm to IS: 13947. Each MCB shall be provided with one potential free contact
and the same shall be wired for annunciation purpose. However voltage transformer circuits for relaying
and metering shall be protected by fuses. All fuses shall be HRC cartridge type conforming to IS: 13703
mounted on moulded structure plug-in type fuse carriers fitted to bases as per IS 1300 bases. Fuse carrier
base as well as MCBs shall have imprints of the fuse 'rating' and 'voltage'.
9.4
Space Heater:
Each panel shall be provided with a space heater rated for 240V, single phase, 50 Hz AC supply for the
internal heating of the panel to prevent condensation of moisture. The heater shall be complete with
thermostat controlled and a switch unit.
10.0
EARTHING
10.1
All panels shall be equipped with an earth bus securely fixed. The material and the sizes of the bus bar
shall be at least 25 X 6 sq.mm perforated copper strip with threaded holes at a gap of 50mm with a
provision of bolts and nuts for connection with cable armours and mounted equipment etc for effective
earthing suitable connectors for this purpose shall be provided. When several panels are mounted
adjoining 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 of Contractor. Provision shall be made for
extending the earth bus bars to future adjoining panels on either side.
10.2
All metallic cases of relays, instruments and other panel mounted equipment including gland plate, shall
be connected to the earth bus by copper wires of size not less than 2.5 sq. mm. The colour code of
earthing wires shall be green.
Page 4 of 10
10.3
Looping of earth connections which would result in loss of earth connection to other devices when the
loop is broken, shall not be permitted. However, looping of earth connections between equipment to
provide alternative paths to earth bus shall be provided.
10.4
VT and CT secondary neutral or common lead shall be earthed at one place only at the terminal blocks
where they enter the panel. Such earthing shall be made through links so that earthing may be removed
from one group without disturbing continuity of earthing system for other groups.
10.5
The earth bar shall be terminated into two earthling terminals of adequate size with nuts and washer for
connecting to the station earthing sytem.
11.0
INDICATING INSTRUMENTS
All instruments and meters shall be enclosed in dust proof, moisture resistant, black finished cases and
shall be suitable for tropical use. Frequency meters shall be provided with individual transducers and
these shall be calibrated along with transducers to read directly the primary quantities. They shall be
accurately adjusted and calibrated at works and shall have means of calibration check and adjustment at
site.
11.1.1
Unless otherwise specified, all electrical indicating instruments shall have circular 240 degree scale and
with a dial of 96mm x 96mm. They shall be suitable for flush mounting.
11.1.2
Instruments dial shall be with white circular scale and black pointer and with black numerals and
lettering. The dial shall be free from warping, fading, and decolouring. The dial shall also be free from
parallax error.
11.1.1.3
Instruments shall conform to IS:1248 and shall have accuracy class of 1.0 or better. The design of the
scales shall be such as to have resolution suitable for the application. The marking of centre zero Watt
/Var meters shall be IMPORT (on left) and EXPORT (on right) to indicate the direction of
active/reactive power flow towards or away from the substation bus bars respectively.
11.1.4
Digital frequency meters shall be of class: 0.5 and shall have digital display of 5 and 4 digits
respectively, with display size, not less than 25mm (height).
11.2
TRANSDUCERS
11.2.1
Transducers (for use with Indicating Instruments) shall in general conform to IEC: 688-1
11.2.2
The energy meter capability shall be used for measurement of active power, reactive power, voltage,
current and frequency in three phase four wire unbalanced system.
11.2.3
One 33 kV C&R panel shall be installed for each incomer of 33 kV (Line incomer and 33 kV side of
transformer). Each panel shall consist of energy meter, protection schemes, indication and control etc.
One 11kV C&R panel shall be provided for each 11kV outdoor type VCB for incomer and feeder.
11.2.4
Voltage signal (440 Volt ac L-L) for voltmeter, PF meter, frequency meter, KW meter etc to be provided
in the C&R panel and shall be tapped from the respective PTs through a separate / independent copper
cable.
11.3
ENERGY METER
Contractor shall provide Static TVM energy meter as per the technical specification covered in the
chapter of technical specification of TVM energy meter
11.4
ANNUNCIATION SYSTEM
11.4.1
Alarm annunciation system shall be provided in the control board by means of visual and audible alarm.
The annunciation equipment shall be suitable for operation on the voltages specified in this
specification.
511.4.2
The visual annunciation shall be provided by annunciation facia windows mounted flush on the top of
the control panels.
11.4.3
The annunciator facia shall be provided with translucent plastic window for alarm point with
approximate size of 35mm x 50mm. The facia plates shall be engraved in black lettering with respective
inscriptions. Alarm inscriptions shall be engraved on each window in not more than three lines and size
of the lettering shall not be less than 5 mm.
Page 5 of 10
11.4.4
Each annunciation window shall be provided with two white lamps in parallel to provide safety against
lamp failure. Long life lamps shall be used. The transparency of cover plates and wattage of the lamps
provided in the facia windows shall be adequate to ensure clear visibility of the inscriptions in the
control room having high illumination intensity (350 Lux), from the location of the operator's desk.
11.4.5
All Trip facia shall have red colour and all Non-trip facia shall have white colour.
11.4.6
The annunciation system shall work in co-ordination with the existing annunciation system (hooter or
bell) in the substation for R&M scheme. If the same is not provided, hooter shall be supplied for above
purpose.
11.4.7
Sequence of operation of the annunciator shall be as follows:

Sl
No
Alarm condition
Normal
Open
Off
OFF
Abnormal
Close
Flashing
ON
Accept
pressed
Close
Steady on Steady on
OFF
Fault contact
push
Reset
push
pressed
button
Visual Annunciation
Open
button
Lamp test
is
Audible
Annunciation
Hooter)
(by
OFF
Close
On
OFF
Open
Off
OFF
Open
Steady On
OFF
Open
Flashing
ON
Push button pressed

6
Alarm test
11.4.8
Audible annunciation for the failure of DC supply to the annunciation system shall be provided and this
annunciation shall operate on 240 Volts AC supply. On failure of the DC to the annunciation system for
more than 2 or 3 seconds. (adjustable setting), a bell shall sound. A separate push button shall be
provided for the cancellation of this audible alarm alone but the facia window shall remain steadily
lighted till the DC supply to annunciation system is restored.
11.4.9
A separate voltage check relay shall be provided to monitor the failure of supply (240V AC). If the
failure of supply exists for more than 2 to 3 seconds. this relay shall initiate visual and audible
annunciation. This annunciation shall operate on DC and buzzer shall sound.
11.4.10
The total number of windows shall be 16 and the matter for engraving shall be indicated to the
contractor in due course.
11.5
SWITCHES
11.5.1
Control and instrument switches shall be rotary operated type with escutcheon plates clearly marked to
show operating position and circuit designation plates and suitable for flush mounting with only switch
front plate and operating handle projecting out.
11.5.2
The selection of operating handles for the different types of switches shall be as follows :
Breaker
control switches
Pistol grip, black
Selector switches
Oval or knob, black
Instrument switches
Round, knurled, black
Page 6 of 10
11.5.3
The control switch of breaker shall be of spring return to neutral type. The switch shall have spring
return from close and trip positions to "after close" and "after trip" positions respectively. It shall be
necessary to press the switch before turning to close or command position.
11.5.4
Instrument selection switches shall be of maintained contact (stay put) type.
11.5.5
The contacts of all switches shall preferably open and close with snap action to minimise arcing.
Contacts of switches shall be spring assisted and contact faces shall be with rivets of pure silver or silver
alloy. Springs shall not be used as current carrying parts
11.5.6
The contact rating of the switches shall be as follows :

Description
Contact rating in Amps
Continuous
30/110 V DC or 240 volts AC

supply, 10 Amp
Make and carry

supply, 30 Amp.
Break for Resistive load

20 Amp.
supply,
11.6
INDICATING LAMPS
11.6.1
Indicating lamps shall be of multiple LED, panel mounting type with rear terminal connections. Lamps
shall have translucent lamp covers to diffuse lights coloured red, green, amber, clear white or blue as
specified. The lamp cover shall be preferably of screwed type, unbreakable and moulded from heat
resisting material.
11.6.2
Lamps and its parts shall be interchangeable and easily replaceable from the front of the panel.
11.6.3
The indicating lamps shall withstand 120% of rated voltage on a continuous basis.
11.7
SEMAPHORE INDICATORS
11.7.1
Position indicators of "SEMAPHORE" type shall be provided as part of the mimic diagrams on panels
for indicating the position of circuit breakers, isolating/earthing switches etc. The indicator shall be
suitable for semi-flush mounting with only the front disc projecting out and with terminal connection
from the rear. Their strips shall be of the same colour as the associated mimic.
11.7.2
Position indicator shall be suitable for DC Voltage as specified. When the supervised object is in the
closed position, the pointer of the indicator shall take up a position in line with the mimic busbars, and at
right angles to them when the object is in the open position. When the supply failure to the indicator
occurs, the pointer shall take up an intermediate position to indicate the supply failure.
11.7.3
The rating of the indicator shall not exceed 2.5 W.
11.7.4
The position indicators shall withstand 120 percent of rated voltage on a continuous basis.
12.0
RELAYS
12.1
All relays shall conform to the requirements of IS: 3231 or IEC-60255 or other applicable standards.
Relay shall be suitable for flush or semi-flush mounting on the front with connections from the rear.
Relays could be either electromechanical or electronics.
12.2
All protective relays shall be in draw out type in modular cases with proper testing facilities in the form
of blocks. Necessary test plugs shall be supplied loose and shall be included in Contractor's scope of
supply.
12.3
AC Voltage operated relays shall be suitable for 110 Volts VT secondary and current operated relays for
5 amp CT secondary. All DC operated relays and timers shall be designed for the DC voltage specified,
and shall operate satisfactorily between 80 percent and 110 percent of rated voltage. All relays shall
have adequate thermal capacity for continuous operation.
12.4
The protective relays shall be suitable for efficient and reliable operation of the protection scheme
described in the specification. Necessary auxiliary relays, timers, lockout relay etc. required for the
complete protection schemes described in the specification shall be provided. All protective relays shall
be provided with at least two pairs of potential free isolated output contacts. Auxiliary relays and timers
shall have pairs of contacts as required to complete the scheme. Contacts shall be silver faced with
Page 7 of 10
spring action. Relay case shall have adequate number of terminals for making potential free external
connections.
12.5
All protective relays, auxiliary relays and timers shall be provided with hand reset type contacts. They
shall also be provided with hand reset type external operation indicators with suitable inscription to be
informed in due course of time.
12.6
No control relay which shall trip the power circuit breaker when the relay is de-energised shall be
employed in the circuits.
12.7
Provision shall be made for easy isolation of trip circuits of each relay for the purpose of testing and
maintenance.
12.9
All protective relays and alarm relays shall be provided with one extra isolated pair of contacts wired to
terminals.
12.10.
The setting ranges of the relays offered, if different from the ones specified shall also be acceptable if
they meet the functional requirements.
12.11
Any alternative or additional protections or relays considered necessary for providing complete
effective and reliable protection should also be offered separately. The acceptance of this alternative/
additional equipment shall lie with the BSPHCL.
12.12
All relays shall have capability to withstand test voltage of 2 kV rms for one minute.
12.13
All relays and their drawings shall have phase indications as R-Red, Y-yellow, and B-blue
12.14
PROTECTIONS:
A)
Transformer protection panel:

I.
Two over current(IDMT characteristic with a definite minimum time of 3.0 seconds at
10 times setting and have a variable setting range of 50-200% of rated current) and one
earth fault relay. Contractor may offer a composite unit also having these features as
separate elements.
II.
One auxiliary relay which shall receive inputs from all transformer protections and send
command to trip coil of the circuit breaker through master trip relay.
III.
B)
C)
12.15
One high speed master trip relay
33 kV line panels.
I.
Two over current (IDMT characteristic with a definite minimum time of 3.0 seconds at
earth fault relay. The 33 kV lines are envisaged to operate in a synchronous ring having
feed at multiple points.
II.
There shall be high speed master trip hand reset lock out relay which shall receive inputs
from above relay and send command to trip coil of the circuit breaker directly.
11 kV Panels incoming and outgoing

I.
Two over current(IDMT characteristic with a definite minimum time of 3.0 seconds at
earth fault relay. The 33 kV lines are envisaged to operate in a synchronous ring having
feed at multiple points.
II.
There shall be high speed master trip hand reset lock out relay which shall receive inputs
from above relay and send command to trip coil of the circuit breaker directly.
SUPERVISION RELAY
Following supervision relay shall be provided having adequate contacts for providing alarm.
(a)
Trip circuit supervision
(b)
DC supply supervision
Page 8 of 10
(c)
AC supply supervision
13.0
TYPE TESTS
13.1
The following type tests shall be conducted on the Protective relays.

a)
Insulation tests as per IEC 60255-5
b)
High frequency disturbance test as per IEC 60255-4 (Appendix -E) -Class III (not
applicable for electromechanical relays)
c)
Fast transient test as per IEC 1000-4, Level III (not applicable for electromechanical
relays)
d)
Relay characteristics , performance and accuracy test as per IEC 60255
Steady state Characteristics and operating time
Dynamic
e)
Tests for thermal and mechanical requirements as per IEC 60255-6
f)
Tests for rated burden as per IEC 60255-6
g)
Contact performance test as per IEC 60255-0-20
13.2
Steady state & Dynamic characteristics tests on the relays (current differential protection relays), as type
test, shall be carried out based on general guide lines specified in CIGRE Committee 34 report on
simulator/network analyser/PTL.
14.0
CONFIGURATION OF C&R PANELS (33kV & 11kV)

Each panel shall consist of the following:
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Description of Relays
QUANTITY
Ammeter
1
with selector switch
0
Wattmeter
Pistol
1
grip CB control switch
3
Red indicating lamp for indicating close position
of CB
of Isolator
of Earth switch
Green indicating lamp for indicating open
position of CB
position of Isolator
position of Earth switch
Yellow indicating lamp for auto trip
Blue indicating lamp for spring charging
Annunciation
1
windows
with
associated
annunciation
5
relay
Push
1 buttons for Alarm accept/Reset/Lamp test
4
Mimic
1
to represent SLD with Seamaphore
indication
6
Voltmeter
9
with selector switch
Cut
1 out mounting and wiring for WTI and
selector
7
switch
TRANSFORMER
PANEL
1
BUS
COUPLER
-
FEEDER PANEL
1
1
1
1
1
1 no for each
Isolator
1 no for each Earth
switch
1
1 no for each
Isolator
1 no for each
Earth switch
1
1 no for each
Isolator
1 no for each Earth
switch
1
1 no for each
Isolator
1 no for each Earth
switch
1
1
1
1 no for each
Isolator
1 no for each
Earth switch
1
1
1
1 no for each
Isolator
1 no for each Earth
switch
1
1
1
1 LOT
1 LOT
1 LOT
1
1 LOT
Page 9 of 10
Sl.
No.
17
18
19
20
21
22
23
24
25
26
27
28
29
Description of Relays
QUANTITY
Energy
8
meter TVM
Trip
4 Circuit supervision relays
DC
1 supply supervision relay
8
AC
1 supply supervision relay
8
Flag
1 relays, aux relays, timers trip relays etc as
per
9 scheme requirement
Bus frequency meter(Digital)
Bus Healthy indication lamps
Auxiliary relay for Buchholz
21O/C 1 E/F realy
.
Static,
5
instantaneous 3 phase PT Fuse Failure
Relays. Rated Voltage-110VAC
Master
6
Trip Relays suitable for operation at 110
VDC with sufficient number and configuration
of contacts.
Auxiliary
7
Relays for Anti-pumping, Density
switch, Contact multiplier etc. as may be
required.
Power
1
Factor meter (Digital)
1
TRANSFORMER
PANEL
1
1
BUS
COUPLER
1
1
FEEDER PANEL
1
1
1
1 set
1 set
1 set
1
3
1
1
1 LOT
1 LOT
1 LOT
Note :
1
For transformer feeders, all equipments of control panel shall be provided separately for HV
and LV sides.
The above list of equipments mentioned for control panel is generally applicable unless it is
defined elsewhere and in case of bay extension in existing substations, necessary equipments
for matching the existing control panel shall be supplied
3.
Each line /HV side of transformer/LV side of transformer /TBC shall be considered as one
feeder for above purpose.
Page 10 of 10
1.
1.
CURRENT TRANSFORMER 12 kV, 1200-600-300/1-1-1 A

SCOPE
The scope of this specification covers design, manufacturing,
testing, supply, transportation, insurance (transit & storage), erection site
testing & commissioning of 12kV Current Transformer suitable for
outdoor service. Any parts not
specifically mentioned in this
specification but otherwise required for proper functioning of the
equipment should be included by the bidder in the offer.
2.
S
N
1
IS 2705(I-IV)
IS 2165
IS 2099
4
5
IS 3347
IS 2071
6
7
IS 335
IS 13947(Part I)
3.
IS
Indian electricity
Rules 1956/ CEA
regulations, 2010
IEC
IEC 185, IEC
44(4)
IEC 270, IEC

60
IEC 815
Item
Current transformers
Insulation coordination: Part 1
Phase to earth insulation coordination
Bushings
voltages
principles for
andalternating
rules
above 1 000 Volts
Dimensions for Porcelain Transformer
Methods
Bushings of High Voltage Testing
New insulating oils
Glossary of terms relating to metal
containers
Indian electricity Rules 1956/ CEA
regulations, 2010
Guide for the selection of insulators in
respect of polluted condition
AMBIENT CONDITIONS
The CT supplied against this specification shall be suitable for satisfactory
continuous operation under the tropical conditions mentioned in General
Technical Requirement.
4.
TECHNICAL PARAMETERS OF CT
a)
Type
b)
c)
d)
e)
Type of mounting
Rated Continuous capacity
Requirement for secondary Winding
f)
Current for 3 sec (KA rms)
g)
Rated dynamic withstand Current
(KA rms)
h)
Max temp rise
i)
Minimum creepage distance of
porcelain housing (mm) of highest
system voltage
j)
Withstand voltage between
Secondary terminal & earth
i)
Detail of Secondary Cores
Current ratio
Accuracy class
Burden (VA)
Instrument security Factor
Single phase, live/dead tank,

outdoor, oil filled & hermetically
sealed
Pedestal type
As specified in BPS
120 % of rated Primary current
As per IS 2705 Pt. I
25
62.5
As per IEC-185/ IS 2705
25 mm /KV
3 kV
Metering/ Protn.
1200-600-300/ 1-1-1 A
0.5/ 5P10
30 / 30
5/ 5
Note: The ratings indicated for instrument transformer are tentative only
and the contractor should verify this and supply equipment to meet the
requirements.
5.
PORCELAIN HOUSING
It shall be single piece of homogeneous, vitreous porcelain of high
mechanical & dielectric strength. It will be glazed with uniform Brown or
Dark brown colour with smooth surface finish. The clear height of
porcelain housing shall be at least 430 mm.
The contractor shall clearly detail in his bid the details of attaching the
metallic flange to porcelain, pressure release valve and also how primary
& secondary terminals shall be brought out.
6.
CORE
Core shall be made of high grade non aging, cold rolled grain oriented steel of
low hysterisis loss and permeability to ensure specified accuracy at normal and
over voltage. The flux density shall be limited so that there is no saturation
during service. The internal security factor should be low enough not to damage
the instrument in the event of short circuit or over voltage
7.
WINDING
PRIMARY WINDING:
It shall be made of double paper insulated high conductivity rigid copper
wire. The primary winding current density shall not exceed the limit of 1.6
Amp per sq. mm for normal rating. The insulation shall be free from
composition likely to flow, ooze or collapse in oil.
The design current density for short circuit current as well as conductivity
of metal used for primary winding shall be as per IS 2705. The calculation
for the selection of winding cross section shall be furnished by contractor.
The primary terminal shall be of standard size of 30 mm dia x 80 mm
length of heavily tinned (min. thickness 15 micron) electrolytic copper of
99.99 % conductivity.
SECONDARY WINDING:
It shall be made of insulated copper wire of electrolytic grade. Type of
insulation used shall be described in the offer. For multi ration design, the
multi ratio will be achieved by reconnection of the primary winding or
secondary winding. The excitation current of the CT shall be as low as
possible. The contractor shall furnish the magnetization curves for all the
cores.
The terminal box shall be dust free & vermin proof. The size of the terminal
box shall be big enough to enable easy access and working space with the
use of normal tools.
The secondary terminals studs shall be provided with at least 3 nuts and
two plain washers, these shall be made of brass. Duly nickeld. The min.
stud outer dia shall be 6 mm & length 15 mm. The min spacing between
the centers of the adjacent studs shall be 1.5 time the outer dia of the
stud.
8.
POLARITY
The polarity shall be marked on each CT at the secondary terminals in the
terminal box.
9.
TANK & HARDWARES

The CT will be dead/live tank type. The tank shall be fabricated of MS
steel sheet of min. 3.15 mm for sides & 5 mm for top & bottom. The tank
will be finished with min. 2 coats of zinc rich epoxy paint externally. The
inner surface shall be painted with oil resistance white enamel paint.
All ferrous hardwares, exposed to atmosphere shall be hot dipped
galvanized.
10.
INSULATION OIL
The first filling of oil in CT shall be in contractors scope. The oil shall be
as per IS 335.The ensure the prevention of oil, the contractor will give
the details supported by drawings:
1.
Location of emergence of Primary & Secondary terminals
2.
Interface between porcelain & metal tanks
3.
Cover of the secondary terminal box

Any nut & bolt and screw used for fixation of the interfacing porcelain
bushing for taking out the terminals shall be provided on flanges clamped
to the bushings & not on the porcelain directly.
If gasket joints are used, Nitrite Butyl Rubber gasket shall be used.
The grooves
shall be machined with adequate space for
gasket
under
pressure.
accommodating
The CT shall be vacuum filled with oil after processing. It will be properly
sealed to eliminate breathing & to prevent air & moisture from entering
the tank. The sealing methods/arrangement shall be described by
the contractor & be approved by the owner.
11.
OIL LEVEL INDICATOR

The CT shall be fitted with prismatic type oil sight window at suitable
location so that the oil level is clearly visible with naked eye to an
observer standing at ground level.
To compensate oil volume variation due to temperature variation,
Nitrogen cushion or the stainless steel bellows shall be used. Rubber
diaphragms are not permitted for this purpose.
12.
EARTHING
Two earthing terminals shall be provided on the metallic tank of size 16
mm dia & 30 mm length each with one plain washer & one nut for
connection to the station earth mat
13.
LIFTING & MOUNTING ARRANGEMENT

The CT shall be provided with two lifting eyes to lift the CT. This shall be so
positioned so as to avoid any damage to the CT during lifting for
instillation or transportation purpose. This shall be detailed in General
Arrangement drawing.
The CT shall be of pedestal mounting type suitable for outdoor installation
on steel/cement concrete structures. All the clamps, bolts, nut and washers
etc. required for mounting the lightning arresters on the structure shall be
supplied along with the arresters and shall be galvanized. The contractor
shall supply all the terminal connectors etc. required for connection to the
CT.
14.
TESTING
The following test shall be conducted on CT
1.
Megger between winding & winding terminals to body
2.
Polarity test
a.
Ratio identification checking of all ratios on all cores by primary

injection of current
b.
Magnetization characteristics & secondary winding resistance
1.
CURRENT TRANSFORMER - 33 kV, 800-400-200 /1-1-1 A
3.1
Scope
The specification covers the design, manufacture, testing at
manufacturers works and supply of 33 KV Current Transformers complete
with all accessories and spares required for their satisfactory operation
for various PSS , as detailed in the schedule of requirements enclosed.
3.2
Standards
The Current Transformers shall conform in all respects to IEC-186 & IS:
2705 part-I,II,III & IV (amended up to date) except where specified
otherwise. The equipment meeting any other authoritative standard which
ensures equal or better quality than the standard mentioned above shall
also be acceptable. Where the equipment offered conforms to any other
standard the salient features of difference between the standards adopted and
specified shall be clearly brought out in the tender.
3.3.
Ratings
33 KV Current Transformers
1 Normal System Voltage (KV)
33
2 Highest System Voltage (KV)
36
3 Earthing
Effective
4 1 min. Power Frequency with stand Voltage (KV)
5 Impulse with stand Voltage (KVp)
6 Short time Current Rating (KA/1 sec)
7
Current ratio
Accuracy class
Burden (VA)
70
170
25
Metering/ Protn./ Diff
Protection
800-400-200/1-1-1 (3 core)
0.5/ 5P10
20VA/20 VA/20VA
3.4
General
3.4.1
The Current Transformers shall be of single phase oil immersed self

cooled type suitable for the services indicated, conforming to the modern
practice of design and manufacture.
3.4.2
The core shall be of high grade non-ageing laminated steel of low

hysteresis losses and of high permeability to ensure high accuracy at both
normal and over current.
3.4.3
The transformer shall be sealed to climate breathing and shall prevent air
and moisture from entering the tank. These shall be provided with oil
level gauge and shall be equipped with pressure releasing device capable of
releasing abnormal pressure without damage to metal or porcelain housing.
3.5
Windings
3.5.1
The current transformer core to be used for metering instrumentation

shall be of accuracy class 0.5 suitable for commercial and industrial
metering as per the standard adopted. The saturation factor for this core
shall be low
enough not to cause any damage to the measuring
instrument in event of maximum short current.
3.5.2
The current transformer core to be used for O/C and E/F protection
shall be of 5P class. The core shall be designed for minimum saturation
factor of 10 for the highest setting. The magnetizing curves for the core
shall be furnished with the tender.
3.5.3
The current transformer core to be used for distance, differential and bus
bar protection shall be of Ps class.
3.5.4.
The rating of the secondary windings shall be 1 ampere. The secondary

terminal shall be brought out in a compartment for easy access. The
secondary terminals shall be provided with shorting arrangements. The
secondary taps shall be adequately reinforced to withstand the normal
handling without damage.
3.5.5
The current transformers shall be capable of carrying their rated

primary and secondary current continuously without the temperature rise
exceeding the limits laid down in the approved standards to which they are
designed and corrected to difference in ambient temperature at sites and that
given in the standard.
3.6
Temperature Rise
3.6.1
The current transformer shall be designed to limit the temperature of

winding and other parts as specified in Indian Standards when corrected for
the difference between the temperatures prevailing at sites and the
temperature specified by the standards. The temperature rise of a CT when
carrying primary current equal to rated continuous thermal current and the
rated burden shall not exceed the limits specified above.
3.7
Bushings
3.7.1
Oil filled/condenser type, porcelain bushing shall be used on the

current transformers. The porcelain shall be homogenous thoroughly
verified and impervious to moisture. The blazing of porcelain shall be
uniform brown colour free from blisters, burns and other similar
defects. Bushing shall have ample insulation, mechanical strength and rigidity
for the purpose for which they will be used. There shall be no undue stressing
of any part of bushings due to temperature changes and adequate means shall
be provided to accommodate conductor expansion. The bushings shall be so
designed that when operated at highest system voltage specified in clause 3.3,
there will be no electric discharge in between the conductors and the
bushings. No corrosion or injury shall be caused to conductor insulation or
supports by the formation of substances produced by chemical action. The
insulation on bushings shall be co-coordinated with that of the
current transformer such that the flash over if any, will occur only external to
the current transformers. The bushings should not cause radio interference
when operated at rated voltage .In general the bushings shall conform to the
latest issue of IS 2099 or equivalent.
3.7.2
Each of the bushings shall be complete with the following:- i Bio-metallic

expansion type terminal connector
ii Oil level side guage and convenient means of filling, sampling and
draining of oil.
iii Adjustable arcing horns.
iv Corona shields for 220,132 KV bushing, if required. v
End shields for even distribution of stresses
3.8
Insulation Oil
3.8.1
The quantity of insulating oil for first filling and complete specification for
insulating oil shall be stated in the tender. The oil shall conform to the latest
requirement of Indian Standard 335
3.9
Type of Mounting
The Current Transformers shall be suitable for mounting on steel structures.
The necessary flanges, nuts, bolts, etc for Current Transformers shall be
supplied and these shall be galvanized.
3.10
Protection against Earthquakes

Each transformer shall be designed to withstand repeated earth quake
2
acceleration of 0.15 and wind loads of 100 kg/m on the projected area (non
simultaneous) without damage and without impartment of operations.
3.11
Terminal Connectors
Terminal connectors shall be suitable for 0.4 ACSR Conductor. Suitable
terminal connector for earth connection shall also be supplied size of
Terminal connectors however shall be confirmed at the time of approval of
drawing.
3.12
Tests
3.12.1 Each Current Transformer shall be subjected to all tests as specified in
IS 2705, in presence of the purchasers representative.
3.12.2 Report of the following type tests as stipulated in IS 2705 shall
be supplied
a)
Short time current test
b)
Temperature rise test
c)
Impulse voltage test
d)
Instrument security current test (for measuring CTs)
e)
Composite error test (direct test) for protective CTs. All the test
report shall be submitted and got approved by the purchaser before dispatch of
the equipment.
3.13
Drawings and Instructions manual
3.13.1
The tenderer shall submit with the tender the following drawings to
enable the purchaser to assess the suitability of the equipment.
a)
c)
e)
General layout and assembly drawings of the equipment b)

Arrangement of terminal equipment
Schematic drawings of electric power to control circuit d)
Graph showing the performance of the equipment
Drawings necessary to demonstrate compliance with any
critical, dimensional requirements such as for transportation, fitting
with in the restricted space, clearance required etc.
3.13.2
These drawings shall show sufficiently over all dimensions clearance and
space requirements of all apparatus to be furnished to enable the
purchaser to determine the design and layout of the installation.
3.13.3
Soon after the award of the contract the manufacturer shall submit the
drawing duly describing the equipment in detail for approval.
The following drawings are to be supplied as part f the contract:a)
b)
c)
d)
e)
f)
3.13.4
Outline dimension drawings

Assembly drawings
Cross sectional view of the instrument transformer
Foundation diagram
Wiring diagram with polarity marks
Magnetization curves
Seven copies of the instructions manual covering instructions for

installation and maintenance check test shall be supplied by the contractor as
a part of the contract.
3.14 Spare Parts
The tenderer shall quote separately for spares recommended by them for
five years operation of equipment covered by this specification. The
purchaser will decide the actual quantity of spare parts to be ordered
on the basis of the list and the item wise prices for spares called for in
the price schedule.
3.15
Completeness of Equipment
Any fitting accessories or apparatus which may not have been specifically
mentioned in this specification but are usual or necessary in the equipment
for satisfactory functioning shall be deemed to be included in the contract
and shall be supplied without any extra cost. All plant and equipment shall
be complete in all details whether such details are mentioned in the
specification or not.
3.16
Galvanization
All the ferrous parts including nuts bolts etc shall be hot dip galvanized as
per IS 2629-1966 (As amended up to date).
3.17
Testing & Commissioning

If the purchaser desires, the tenderer shall depute engineer to site for
supervision of erection, testing and commissioning. The charges on account
of this shall be quoted along with the tender.
3.18
Guarantee
The equipment along with all accessories shall be guaranteed for a period of
18 months from the date of supply or 12 months from the date of
commissioning which ever is earlier. If any defect develops or is noted
during this period in any part of the equipment and accessories, the supplier
shall replace or repair the same to the satisfaction of the purchaser
expeditiously free of cost to the purchaser.
INSTRUMENT TRANSFORMERS
2.
CURRENT TRANSFORMER 12 kV, 600-300-150/5-5A
1.
SCOPE
The scope of this specification covers design, manufacturing, testing, supply,
transportation, insurance (transit & storage), erection site testing &
commissioning of 12kV Current Transformer suitable for outdoor service. Any
parts not specifically mentioned in this specification but otherwise required
for proper functioning of the equipment should be included by the bidder in the
offer.
2.
S
N
1
IS 2705(I-IV)
IS 2165
IS 2099
4
5
IS 3347
IS 2071
6
7
IS 335
IS 13947(Part I)
3.
IS
IEC
IEC 185, IEC
44(4)
IEC 270, IEC

60
Item
Current transformers
Insulation coordination: Part 1 Phase to
earth insulation coordination principles
Bushings
and rules for alternating voltages above 1
000 Volts
Dimensions for Porcelain Transformer
Bushings of High Voltage Testing
Methods
New insulating oils
Glossary of terms relating to metal
containers
Indian electricity Rules 1956/ CEA
regulations, 2010
Indian electricity
Rules 1956/ CEA
regulations, 2010
IEC 815
Guide for the selection of insulators in

respect of polluted condition
AMBIENT CONDITIONS
The CT supplied against this specification shall be suitable for satisfactory
continuous operation under the tropical conditions mentioned in General
Technical Requirement.
4.
TECHNICAL PARAMETERS OF CT
a)
Type
b)
c)
d)
e)
Type of mounting
Rated Continuous capacity
Requirement for secondary Winding
f)
Rated short time withstand Current
for 3 sec (KA rms)
g)
Rated dynamic withstand Current
(KA rms)
h)
Max temp rise
i)
porcelain housing (mm) of highest
system voltage
j)
Withstand voltage between Secondary
terminal & earth
i)
Current ratio
Accuracy class
Burden (VA)
Instrument security Factor
Single phase, live/dead tank,

outdoor, oil filled & hermetically sealed
Pedestal type
As specified in BPS
120 % of rated Primary current
As per IS 2705 Pt. I
25
62.5
As per IEC-185/ IS 2705
25 mm /KV
3 kV
Metering/ Protn.
600-300-150/ 5-5 A
0.5/ 5P10
30 / 30
5/ 5
Note: The ratings indicated for instrument transformer are tentative only and the
contractor should verify this and supply equipment to meet the requirements.
5.
PORCELAIN HOUSING
It shall be single piece of homogeneous, vitreous porcelain of high mechanical &
dielectric strength. It will be glazed with uniform Brown or Dark brown colour
with smooth surface finish. The clear height of porcelain housing shall be at
least 430 mm.
The contractor shall clearly detail in his bid the details of attaching the
metallic flange to porcelain, pressure release valve and also how primary
6.
CORE
Core shall be made of high grade non aging, cold rolled grain oriented steel of low
hysterisis loss and permeability to ensure specified accuracy at normal and over
voltage. The flux density shall be limited so that there is no saturation during service.
The internal security factor should be low enough not to damage the instrument in the
event of short circuit or over voltage
7.
WINDING
PRIMARY WINDING:
It shall be made of double paper insulated high conductivity rigid copper wire.
The primary winding current density shall not exceed the limit of 1.6
Amp per sq. mm for normal rating. The insulation shall be free from composition
likely to flow, ooze or collapse in oil.
The design current density for short circuit current as well as conductivity of
metal used for primary winding shall be as per IS 2705. The calculation for the
selection of winding cross section shall be furnished by contractor.
The primary terminal shall be of standard size of 30 mm dia x 80 mm length of
heavily tinned (min. thickness 15 micron) electrolytic copper of
SECONDARY WINDING:
It shall be made of insulated copper wire of electrolytic grade. Type of insulation
used shall be described in the offer. For multi ration design, the multi ratio will
be achieved by reconnection of the primary winding or secondary winding. The
excitation current of the CT shall be as low as possible. The contractor shall
furnish the magnetization curves for all the cores.
The terminal box shall be dust free & vermin proof. The size of the terminal box
shall be big enough to enable easy access and working space with the use of
normal tools.
The secondary terminals studs shall be provided with at least 3 nuts and two
plain washers, these shall be made of brass. Duly nickeld. The min. stud outer
dia shall be 6 mm & length 15 mm. The min spacing between the centers of
the adjacent studs shall be 1.5 time the outer dia of the stud.
8.
POLARITY
The polarity shall be marked on each CT at the secondary terminals in the

terminal box.
9.
TANK & HARDWARES

The CT will be dead/live tank type. The tank shall be fabricated of MS steel
sheet of min. 3.15 mm for sides & 5 mm for top & bottom. The tank will be
finished with min. 2 coats of zinc rich epoxy paint externally. The inner surface
shall be painted with oil resistance white enamel paint.
All ferrous hardwares, exposed to atmosphere shall be hot dipped galvanized.
10.
INSULATION OIL
The first filling of oil in CT shall be in contractors scope. The oil shall be
as per IS 335.The ensure the prevention of oil, the contractor will give the
details supported by drawings:
1.
2.
3.

Any nut & bolt and screw used for fixation of the interfacing porcelain bushing
for taking out the terminals shall be provided on flanges clamped to the bushings
& not on the porcelain directly.
If gasket joints are used, Nitrite Butyl Rubber gasket shall be used. The
grooves shall be machined with adequate space for accommodating
gasket under pressure.
The CT shall be vacuum filled with oil after processing. It will be properly sealed
to eliminate breathing & to prevent air & moisture from entering the tank.
The sealing methods/arrangement shall be described by the contractor & be
approved by the owner.
11.
OIL LEVEL INDICATOR

The CT shall be fitted with prismatic type oil sight window at suitable location
so that the oil level is clearly visible with naked eye to an observer
standing at ground level.

To compensate oil volume variation due to temperature variation, Nitrogen
cushion or the stainless steel bellows shall be used. Rubber diaphragms are
not permitted for this purpose.
12.
EARTHING
Two earthing terminals shall be provided on the metallic tank of size 16 mm dia
& 30 mm length each with one plain washer & one nut for
connection to the station earth mat
13.

The CT shall be provided with two lifting eyes to lift the CT. This shall be so
positioned so as to avoid any damage to the CT during lifting for instillation or
transportation purpose. This shall be detailed in General Arrangement drawing.
The CT shall be of pedestal mounting type suitable for outdoor installation on
steel/cement concrete structures. All the clamps, bolts, nut and washers etc.
required for mounting the lightning arresters on the structure shall be supplied
along with the arresters and shall be galvanized. The contractor shall supply all
the terminal connectors etc. required for connection to the CT.
14.
TESTING
The following test shall be conducted on CT
1.
Megger between winding & winding terminals to body
2.
Polarity test
a.
Ratio identification checking of all ratios on all cores by primary

injection of current
b.
Magnetization characteristics & secondary winding resistance
3.
1.0
POTENTIAL TRANSFORMER 33 kV & 11 kV

SCOPE
The scope of this specification covers design, manufacturing, testing, supply,
transportation, insurance (transit and storage), erection, site testing
& commissioning of 33 kV/12 KV Potential Transformer suitable for
outdoor service. Any parts not specifically mentioned in this specification but
otherwise required for proper functioning of the equipment should be included by
the tenderer in the offer.
2.0
Sl.
No.
IS
IS 3156
IS 2099
3
4
IS 3347
IS 335
5
6
IS 13947(Part I)
Indian electricity Rules
1956/ CEA regulations,
2010
3.0
IEC
IEC 186
Item
Voltage transformers
Bushings for alternating
voltages above 1 000 Volts
Dimensions for Porcelain
New
insulating
oils
Transformer
Bushings
Glossary of terms relating to
Indian
electricity Rules 1956/
metal containers
CEA regulations, 2010
IEC 815
Guide for the selection of

insulators in respect of polluted
condition
AMBIENT CONDITIONS
The PT supplied against this specification shall be suitable for
satisfactory continuous operation under the tropical conditions mentioned in
General Technical Requirement.
4.0
TECHNICAL PARAMETERS OF PT
a)
Rated primary Voltage
b)
Type
transformer
c)
36 kV
12 KV
Single phase potential
Voltage Ratio (kV)
33/0.11
d)
Rated voltage factor continuous
e)
O ne minute power freq.
Withstand voltage for
1.2 continuous
11/0.11
1.2
Primary Terminals
70 kV (rms) - 28 k V (rms)
Secondary winding
3 kV (rms) - 3 kV (rms)
f)
25 mm/kV of Highest Voltage g)

Core I
- Core I
Min. Creepgae Distance

Detail of secondary
Application
Metering
Accuracy
0.5
Burden (VA)
200
h)
sec
25 kA for 3 sec - 25 kA for 3
Short Time Rating
Metering
0.5
200
Note: The ratings indicated for instrument transformer are

tentative only and the contractor should verify this and supply equipment
to meet the requirements.
5.0
PORCELAIN HOUSING
It shall be single piece of homogeneous, vitreous porcelain of high mechanical &
dielectric strength. It will be glazed with uniform Brown or Dark brown colour
with smooth surface finish. The clear height of porcelain housing shall be at least
430 mm for 33kV /11 KV class PT.
The contractor shall clearly detail in his bid the details of attaching the metallic
flange to porcelain, pressure release valve and also how primary

6.0
7.0
CORE
Core shall be made of high grade non aging, cold rolled grain oriented steel of
low hysterisis loss and permeability to ensure specified accuracy at normal and
over voltage. The flux density shall be limited so that there is no saturation during
service. The internal security factor should be low enough not to damage the
instrument in the event of short circuit or over voltage
WINDING Primary
Winding:
It shall be made of double paper insulated electrolytic copper wire. The neutral end
of the winding shall be brought outside for earthing. The insulation shall be free
from composition likely to flow, ooze or collapse in oil.
The primary terminal shall be of standard size of 30 mm dia x 80 mm length of
heavily tinned (min. thickness 15 micron) electrolytic copper of
Secondary Winding:
It shall be made of insulated copper wire of electrolytic grade. The terminal
box shall be dust free & vermin proof.
The secondary terminals studs shall be provided with at least 3 nuts and two plain
washers, these shall be made of brass duly nickeld. The min. stud outer dia shall
be 10 mm & length 15 mm. The min spacing between the centers of the adjacent
studs shall be 1.5 times the outer dia of the stud.
Polarity:
The polarity shall be marked on each PT at the secondary terminals in the terminal
box. There shall be MCB of suitable rating at secondary terminals.
8.0
TANK & HARDWARES

It shall be fabricated of MS steel sheet of min. 3.15 mm thickness for sides
& 5 mm for top & bottom. The tank will be finished with min. 2 coats of zinc rich
epoxy paint externally after cleaning and application of primer. The inner surface
shall be painted with oil resistance white enamel paint.
All ferrous hardwares, exposed to atmosphere shall be hot dipped galvanized.
9.0
INSULATION OIL
The first filling of oil in PT shall be in Contractors scope. The oil shall be as per
IS 335.To ensure the prevention of oil, the contractor will give the details
supported by drawings:
1.
2.
3.
Any nut & bolt and screw used for fixation of the interfacing porcelain bushing for
taking out the terminals shall be provided on flanges clamped to the bushings &
not on the porcelain directly.
If gasket joints are used, Nitrite Butyl Rubber gasket shall be used. The grooves
shall be machined with adequate space for accommodating gasket under pressure.
The PT shall be vacuum filled with oil after processing. It will be hermatically
sealed to eliminate breathing and to prevent air & moisture from entering the
tank. The sealing methods/arrangement shall be described by the contractor &
be approved by the owner.
10.0
OIL LEVEL INDICATOR

The PT shall be fitted with prismatic type oil sight window at suitable location so
that the oil level is clearly visible with naked eye to an observer standing at
ground level.
To compensate oil volume variation due to temperature variation, Nitrogen
or any inert gas cushion shall be used. Rubber diaphragms are not permitted for
this purpose.
11.0
EARTHING
Two earthing terminals shall be provided on the metallic tank of size 16 mm dia &
30 mm length each with one plain washer & one nut for connection to the station
earth mat.
12.0

The PT shall be provided with two lifting eyes to lift the PT. This shall be so
positioned so as to avoid any damage to the PT during lifting for installation or
transportation purpose. This shall be detailed in General Arrangement drawing.
The PT shall be of pedestal mounting type suitable for outdoor installation on
steel/cement concrete structures. All the clamps, bolts, nut and washers etc.
required for mounting the lightning arresters on the structure shall be supplied
along with the arresters and shall be galvanized. The contractor shall supply all the
terminal connectors etc. required for connection to the PT.
13.0
TERMINAL BOX
A dust, vermin and weatherproof terminal box shall be provided at the lower end
of the voltage transformer for terminating the secondary windings. The box shall
have bolted cover plate complete with gasket. The terminal box shall have terminal
blocks, cable gland plate and cable glands with shrouds suitable for 6x2.5
sq.mm. PVC insulated and armoured control cable as per IEC:277 or IS 1554.
The terminal blocks shall have covering of moulded insulation material
complete with brass studs, washers nuts and lock nuts suitable for
termination
of 2x2.5 sq.mm.
wires. The termination shall be made by crimping lugs or bare wire with insulating
sleeves at ends.
The inside of the terminal box shall be accessible through a removable bolted
cover. The secondary taps shall be adequately reinforced to withstand normal
handling without damage. Suitable cable glands, supporting strip and clamps shall
be provided to support and accommodate control cables
The secondary terminal shall be provided with isolating and earthing
arrangements at the terminal block to be provided in the terminal box.
Temperature rise of the winding over the ambient shall be limited to 55oC The
terminal box enclosure shall have protection as per class IP55 of
IEC:529 or IS 13947.
14.0
TERMINAL CONNECTORS- PRIMARY SIDE

One rigid bolted type bimetallic terminal connector suitable for ACSR Wolf/Dog
made of aluminium or aluminium alloy suitable to receive conductor from

two different directions at 90 degree apart shall be provided and attached to
the terminal stud at the top.
15.0
TESTING
The following routine test shall be conducted on PT
16.0
1.
Insulation Resistance
2.
Ratio test on all cores
3.
Polarity Test
4.
any other tests prescribed in IS 3156.
Marking
Rating plates shall be as per IS 3156
17.0
ACCESSORIES
The fitting and accessories to be provided with each of the voltage
transformers shall include the following.
a.
Terminal Box
b.
Pressure Relief device
c.
Bi-directional and Bimetallic Terminal Connector on HV side d.

Earthing Terminals.
Insulating Oil
e.
f.
Oil Level gauge readable from ground level g.

Oil filling hole and cap.
h.
Name and rating plate
i.
Mounting nuts and bolts
j.
Any other fitting or accessory deemed essential.
CIVIL WORKS AND SOIL INVESTIGATION

1.0
GENERAL
The provisions of this section of specification shall only be applicable to the extent of
scope of works indicated in Bid Proposal Sheet (BPS). The intent of specification
covers the following:
Design, engineering, and construction of all civil works at sub-station. All civil works
shall also satisfy the general technical requirements specified in other Sections of this
Specification and as detailed below. They shall be designed to the required service
conditions/loads as specified elsewhere in this Specification or implied as per National/
International Standards.
All civil works shall be carried out as per applicable Indian Laws, Standards and Codes.
All materials shall be of best quality conforming to relevant Indian Standards and
Codes.
The Contractor shall furnish all design, drawings, labour, tools, equipment, materials,
temporary works, constructional plant and machinery, fuel supply, transportation and
all other incidental items not shown or specified but as may be required for complete
performance of the Works in accordance with approved drawings, specifications and
direction of Employer.
The work shall be carried out according to the design/drawings to be developed by the
Contractor and approved by the owner based on Tender Drawings Supplied to the
Contractor by the Owner. For all buildings, structures, foundations etc. necessary
layout and details shall be developed by the Contractor keeping in view the functional
requirement of the substation facilities and providing enough space and access for
operation, use and maintenance based on the input provided by the Owner. Certain
minimum requirements are indicated in this specification for guidance purposes only.
In case of R&M of existing substations, Contactor shall visit site to ascertain the
amount of repair and strengthening of structures and foundations, dismantling and new
construction of structures and foundations works are to be done before quoting.
Contractor must furnish the design and drawings in support of the activities mentioned
above that are to be carried out in the R&M of existing substation site.
However, the Contractor shall quote according to the complete requirements.
2.0
GEOTECHNICAL INVESTIGATION
2.1
The Contractor shall perform a detailed soil investigation to arrive at sufficiently

accurate, general as well as specific information about the soil profile and the necessary
soil parameters of the site in order that the foundation of the various structures can be
designed and constructed safely and rationally.
A report to the effect will be submitted by the Contractor for Owners specific approval
giving details regarding data proposed to be utilised for civil structures design.
Page 1 of 30
2.2
The Contractor should visit the site to ascertain the soil parameters before submitting
the bid. The topography is uneven steeply sloping at few places requiring cutting and
filling operations including slope stability and protection measures (if slopes
encountered). Any variation in soil data shall not constitute a valid reason for any
additional cost & shall not affect the terms & condition of the Contract. Tests must be
conducted under all the critical locations i.e. Control Room Building. Tower locations,
transformer etc.
3.0
SCOPE OF WORK
This specification covers all the work required for detailed soil investigation and
preparation of a detailed report. The work shall include mobilisation of necessary
equipment, providing necessary engineering supervision and technical personnel,
skilled and unskilled labour etc. as required to carry out field investigation as well as,
laboratory investigation, analysis and interpretation of data and results, preparation of
detailed Geo-technical report including specific recommendations for the type of
foundations and the allowable safe bearing capacity for different sizes of foundations at
different founding strata for the various structures of the substation. The Contractor
shall make his own arrangement for locating the co-ordinates and various test positions
in field as per the information supplied to him and also for determining the reduced
level of these locations with respect to the benchmark indicated by the Owner.
All the work shall be carried out as per latest edition of the corresponding Indian
Standard Codes.
3.1
Bore Holes
Drilling of bore holes of 150 mm dia. in accordance with the provisions of IS: 1892, to
10 m depth or to refusal which ever occur earlier (by refusal it shall mean that a
standard penetration blow count (N) of 100 is recorded for 30 cm penetration). For a
new substation, minimum two bore holes shall be done to find out the geological
profile of the area. If any unconformity encountered then more bore holes shall be
drilled with the approval of Engineer-in-charge for the new projects. However in case
deep pile foundations are envisaged the depths have to be regulated as per codel
provisions. In cases where rock is encountered, coring in one borehole per bay shall be
carried out to 1.5 M in bedrock and continuous core recovery is achieved.
Performing Standard Penetration Tests at approximately 1.5 m interval in the borehole
starting from 1.5 m below ground level onwards and at every change of stratum. The
disturbed samples from the standard penetrometer shall also be collected for necessary
tests.
Collecting undisturbed samples of 100/75 mm diameter 450 mm long from the
boreholes at intervals of 2.5 m and every change of stratum starting from 1.0 m below
ground level onwards in clayey strata.
The depth of Water table shall be recorded in each borehole.
All samples, both disturbed and undisturbed, shall be identified properly with the
borehole number and depth from which they have been taken.
Page 2 of 30
The sample shall be sealed at both ends of the sampling tubes with wax immediately
after the sampling and shall be packed properly and transported to the Contractors
laboratory without any damage or loss.
The logging of the boreholes shall be compiled immediately after the boring is
completed and a copy of the bole log shall be handed over to the Engineer-in-charge.
3.2
Dynamic Cone Penetration Test

Dynamic cone penetration tests of two numbers shall be carried out at new substation
only with the circulation of bentonite slurry at specified locations and a continuous
record of penetration resistance (NG) upto 10.00 meter from natural ground level or the
refusal shall be maintained by the Contractor IS: 4968 (Part-2) shall be followed for
carrying out the test and reporting results.
The location for tests shall be as directed by the Owner. On completion of the test, the
results shall be presented as a continuous record as the numbers of blows required for
every 300 mm penetration of the cone into the soil.
3.3
Electrical Resistivity Test

This test shall be conducted to determine the Electrical resistivity of soil required for
designing safe grounding system for the entire station area. The specifications for the
equipments and other accessories required for performing electrical resistivity test, the
test procedure, and reporting of field observations shall confirm to IS: 3043. The test
shall be conducted using Wagners four electrode method as specified in IS: 1892,
Appendix-B2. Unless otherwise specified at each test location, the test shall be
conducted along two perpendicular lines parallel to the coordinate axis. On each line a
minimum of 8 to 10 readings shall be taken by changing the spacing of the electrodes
from an initial small value of 0.5 m upto a distance of 10.0 m.
3.4
Water Sample
Representative samples of ground water shall be taken when ground water is first
encountered before the addition of water to aid drilling of boreholes. The samples shall
be of sufficient quantity for chemical analysis to be carried out and shall be stored in
airtight containers.
3.5
Back Filling of Bore Holes

On completion of each hole, the Contractor shall backfill all bore holes as directed by
the Owner. The backfill material can be the excavated material and shall be compacted
properly.
3.6
Laboratory Test
1.
The laboratory tests shall be carried out progressively during the field work
after sufficient number of samples have reached the laboratory in order that the
test results of the initial bore holes can be made use of in planning the later
stages of the field investigation and quantum of laboratory tests.
Page 3 of 30
2.
All samples brought from field, whether disturbed or undisturbed shall be

extracted/prepared and examined by competent technical personnel, and the test
shall be carried out as per the procedures laid out in the relevant I.S. Codes.
The following laboratory tests shall be carried out
3.7
a)
Visual and Engineering Classification
b)
Liquid limit, plastic limit and shrinkage limit for C- soils.
c)
Natural moisture content, bulk density and specific gravity.
d)
Grain size distribution.
e)
Swell pressure and free swell index determination.
h)
California bearing ratio.
f)
Consolidated undrained test with pore pressure measurement.
g)
Chemical tests on soil and water to determine the carbonates,

sulphates, nitrates, chlorides, Ph value, and organic matter and
any other chemical harmful to the concrete foundation.
h)
Rock quality designation (RQD), RMR in case of rock is

Encountered.
Test Results and Reports
3.7.1 The Contractor shall submit the detailed report in two (2) copies wherein information
regarding the geological detail of the site, summarised observations and test data, bore
logs, and conclusions and recommendations on the type of foundations with supporting
calculations for the recommendations. Initially the report shall be submitted by the
Contractor in draft form and after the draft report is approved, the final report in two (2)
copies shall be submitted. The test data shall bear the signatures of the Investigation
Agency, Vendor and also site representative of BSPHCL.
3.7.2. The report shall include but not limited to the following:
a)
A plan showing the locations of the exploration work i.e. bore holes, dynamic
cone penetration tests etc.
b)
Bore Logs: Bore logs of each bore holes clearly identifying the stratification and
the type of soil stratum with depth. The values of Standard Penetration Test
(SPT) at the depths where the tests were conducted on the samples collected at
various depths shall be clearly shown against that particular stratum.
Test results of field and laboratory tests shall be summarised strata wise as well
in combined tabular form. All relevant graphs, charts tables, diagrams and
photographs, if any, shall be submitted along with report. Sample illustrative
reference calculations for settlement, bearing capacity, pile capacity shall be
enclosed.
Page 4 of 30
3.10
4.0
Recommendations: The report should contain specific recommendations for the type
of foundation for the various structures envisaged at site. The Contractor shall acquaint
himself about the type of structures and their functions from the Owner. The
observations and recommendations shall include but not limited to the following:
a)
Geological formation of the area, past observations or historical data, if

available, for the area and for the structures in the nearby area, fluctuations of
water table etc. Slope stability characteristics and landslide history of the area
shall be specifically highlighted. Remedial measures to be adopted shall also be
given.
b)
Recommended type of foundations for various structures. If piles are

recommended the type, size and capacity of pile and groups of piles shall be
given after comparing different types and sizes of piles and pile groups.
c)
Allowable bearing pressure on the soil at various depths for different sizes of
the foundations based on shear strength and settlement characteristics of soil
with supporting calculations. Minimum factor of safety for calculating net safe
bearing capacity shall be taken as 3.0 (three). Recommendation of liquefaction
characteristics of soil shall be provided.
d)
Recommendations regarding slope of excavations and dewatering schemes, if

required. Required protection measures for slope stability for cut & fill slopes of
switchyard and approach road with stone pitching/retaining walls shall be
clearly spelt out. Calculation shall also be provided for stability adequacy.
e)
Comments on the Chemical nature of soil and ground water with due regard to
deleterious effects of the same on concrete and steel and recommendations for
protective measures.
f)
If expansive soil is met with, recommendations on removal or retainment of the

same under the structure, road, drains, etc. shall be given. In the latter case
detailed specification of any special treatment required including specification
or materials to be used, construction method, equipments to be deployed etc.
shall be furnished. Illustrative diagram of a symbolic foundation showing
details shall be furnished.
g)
Recommendations for additional investigations beyond the scope of the present

work, if considered such investigation as necessary.
SITE PREPARATION
The contractor shall be responsible for proper leveling of switchyard site as per layout
and levels of switchyard finalised during detailed engineering stage. The Contractor at
his own cost shall make the layout and levels of all structure etc from the general grids
of the plot and benchmarks set by the Contractor and approved by the Owner. The
Contractor shall give all help in instruments, materials and personnel to the Owner for
checking the detailed layout and shall be solely responsible for the correctness of the
layout and levels. Site leveling shall be in the scope of the contractor. Bidder may
decide the level of the sites. However, the level shall be such that it is 300 mm higher
than the highest flood level (HFL) of the site.
Page 5 of 30
Whenever for bay extension works the existing substation are to be modified or
strengthen, contractor should keep the R.L of extension part of the sub-station same as
EL of existing sub-station so that FFL shall be same for both and all the necessary
arrangements are to be carried out in this regard by the contractor.
5.0
SCOPE OF WORKS
This clause covers the design and execution of the work for site preparation, such as
clearing of the site, the supply and compaction of fill material, slope protection by
stone pitching/retaining walls depending on the site location/condition, excavation and
compaction of backfill for foundation, road construction, drainage, trenches and final
topping by brick soling/stone filling.
5.1
5.2
General
1)
The Contractor shall develop the site area to meet the requirement of the
intended purpose. The site preparation shall conform to the requirements of
relevant sections of this specification or as per stipulations of standard
specifications. Contractor shall also carry out necessary protection of slope of
switchyard area and approach road.
2)
If fill material is required, the fill material shall be suitable for the above
requirement. The fill shall be such a material and the site so designed as to
prevent the erosion by wind and water of material from its final compacted
position or the in-site position of undisturbed soil.
3)
Material unsuitable for founding of foundations shall be removed and replaced

by suitable fill material and to be approved by the Owner.
4)
Backfill material around foundations or other works shall be suitable for the
purpose for which it is used and compacted to the density described under
Compaction. Excavated material not suitable or not required for backfill shall be
disposed off in area's as directed by owner upto a maximum lead of 1 km.
Excavation and backfill

1.
Excavation and backfill for foundations shall be in accordance with the relevant
code.
2.
Whenever water table is met during the excavation, it shall be dewatered and
water table shall be maintained below the bottom of the excavation level during
excavation, concreting and backfilling.
3.
When embankments are to be constructed on slopes of 15% or greater, benches

or steps with horizontal and vertical faces shall be cut in the original slope prior
to placement of embankment material. Vertical faces shall measure not more
than 1 m in height.
4.
Embankments adjacent to abutments, culverts, retaining walls and similar

structures shall be constructed by compacting the material in successive uniform
horizontal layers not exceeding 15 cm in thickness (of loose material before
compaction). Each layer shall be compacted as required by means of
Page 6 of 30
mechanical tampers approved by the Owner. Rocks larger than 10 cm in any

direction shall not be placed in embankment adjacent to structures.
5.3
5.4
5.
Earth embankments of roadways and site areas adjacent to buildings shall be

placed in successive uniform horizontal layers not exceeding 20 cm in thickness
in loose stage measurement and compacted to the full width specified. The
upper surface of the embankment shall be shaped so as to provide complete
drainage of surface water at all times.
6.
The pitching shall be designed and provided for slope protection as per
approved drawings. The stone used shall be sound, hard, durable and fairly
regular in shape. Stones subjected to marked deterioration by water or weather
shall not be used. Suitable measures shall be provided to prevent erosion by
seepage of water. Largest stone procurable shall be used as approved by owner
for the work. Random rubble masonry (1:6) retaining walls shall be provided
wherever required as per site condition.
Compaction
1.
The density to which fill materials shall be compacted shall be as per relevant IS
and as per direction of Owner. All compacted sand filling shall be confined as
far as practicable. Backfilled earth shall be compacted to minimum 95% of the
Standard Proctors density at OMC. The sub grade for the roads and
embankment filling shall be compacted to minimum 95% of the Standard
Proctors density at OMC. Cohesion less material sub grade shall be compacted
to 70% relative density (minimum).
2.
At all times unfinished construction shall have adequate drainage. Upon

completion of the roads surface course, adjacent shoulders shall be given a
final shaping, true alignment and grade.
3.
Each layer of earth embankment when compacted shall be as close to optimum

moisture content as practicable. Embankment material, which does not contain
sufficient moisture to obtain proper compaction, shall be wetted. If the material
contains any excess moisture, then it shall be allowed to dry before rolling. The
rolling shall begin at the edges overlapping half the width of the roller each time
and progress to the center of the road or towards the building as applicable.
Rolling will also be required on rock fills. No compaction shall be carried out in
rainy weather.
Requirement for fill material under foundation

All foundations shall rest below virgin ground level and the minimum depth of
foundation below the virgin ground level shall be at least 500 mm. For small equipment
and minor foundations this may be reduced to 300 mm with specific approval of the
owner.
6.0
6.1
ANTIWEED TREATMENT & STONE FILLING

Scope of Works
Page 7 of 30
The Contractor shall furnish all labour, equipment and materials required for complete
performance of the work in accordance with the drawings specification and direction of
the Owner.
Brick soling/stone filling shall be done in the areas of the switchyard wherever
equipments and or structures are to be provided under present scope of work covering
entire fencing area.
Prevailing practice of stone filling or brick soling are to be adopted for the bay extension
works of existing substations. Contractor shall verify the existing practice prevailing at
site before quoting.
7.0
7.1
GENERAL REQUIREMENT
The material required for site surfacing shall be free from all types of organic materials
and shall be of standard quality, and as approved by the Owner.
The material to be used for brick soling /site surfacing shall be over burnet bricks of
regular size. Laying of brick in such away that depth of laying become half brick thick
and joints shall be filled with sand.
The material to be used for stone filling/ site surfacing shall be uncrushed/ crushed/
broken stone of 20 mm nominal size (upgraded single size) conforming to table 2 of IS:
383- 1970. Hardness, flakiness shall be as required for wearing courses are given
below.
(a) Sieve analysis limits/Gradation
Sieve size
% passing by weight
40mm
20mm
10mm
4.75mm
100
85-100
0-20
0-5
(b) Hardness
Abrasion value (IS: 2386 part-IV) not more than 40%
Impact value (IS: 2386 part-IV) not more than 30%
(c) Flakiness Index
As per (IS: 2386 part-IV) and maximum value is 25.
7.2
After all the structures/equipments are erected and antiweed treatment is complete, the
surface of the switchyard area shall be maintained, rolled/compacted to the lines and
grades as decided by Engineer-in-Charge. De-weeding including removal of roots shall
be done before rolling is commenced. Engineer-in-Charge shall decide final formation
level so as to ensure that the site appears uniform devoid of undulations. The final
formation level shall however be very close to the formation level indicated in the
drawing using half-ton roller with suitable water sprinkling arrangement to form a
smooth and compact surface.
7.3
A base layer of uncrushed/crushed/broken stone of 20 mm nominal size (ungraded

single size) shall be spread and rolled/compacted by using half ton roller with 4 to 5
Page 8 of 30
passes and water sprinkling to form a minimum 50 mm layer on the finished ground
level of the specified switchyard area excluding roads, drains, cable trench and tower
and equipment foundations as indicated in the drawing.
7.4
Over the base layer of site surfacing material, a final surface course of minimum 50
mm thickness of 20 mm nominal size (single size ungraded) broken stone as specified
above shall be spread and compacted by light roller using half tones steel roller (width
30" and 24" dia meter) with water sprinkling as directed by the Engineer-in-Charge.
The water shall be sprinkled in such a way that bulking does not take place.
7.5
In areas that are considered by the Engineer-in-Charge to be too congested with

foundations and structures for proper rolling of the site surfacing material by normal
rolling equipments, the material shall be compacted by hand, if necessary. Due care
shall be exercised so as not to damage any foundation structures or equipment during
rolling compaction.
7.6
Before taking up stone filling/brick soling, antiweed treatment shall be applied in the
switchyard area wherever stone filling/brick soling is to be done, and the area shall be
thoroughly de-weeded including removal of roots. The recommendation of local
agriculture or horticulture department shall be sought wherever feasible while choosing
the type of chemical to be used. Nevertheless the effectiveness of the chemical shall be
demonstrated by the Contractor in a test area of 10M x 10M (approx.) and monitored
over a period of two to three weeks by the Engineer-in-Charge. The final approval shall
be given by Engineer-in-Charge and final approval given based in the results.
7.7
The antiweed chemical shall be procured from reputed manufacturers.

The dosage and application of chemical shall be strictly followed as per manufacturer's
recommendation. The contractor shall be required to maintain the area free of weeds for
a period of 1 year from the date of application of 1st dose of antiweed chemicals.
8.0
SITE DRAINAGE
1.
2.
Adequate site drainage system shall be provided by the Contractor in new and
existing substation. In case of bay extension of existing substation, drainage
layout shall be prepared by the contractor in such away that it should satisfy the
technical parameters stated below while designing the drainage system so that
flow of water of the existing part of substation remain uninterrupted and the
same should be approved by the owner. The technical parameters stated below
also to be taken into account while designing the drainage system for new
substation as well.
The Contractor shall obtain rainfall data and design the storm water drainage
system, (culverts, ditches, drains etc.) to accommodate run off due to the most
intense rainfall that is likely to occur over the catchment area in one hour period
on an average of once in ten years. The surface of the site shall be sloped to
prevent the ponding of water.
.
The maximum velocity for pipe drains and open drains shall be limited to
2.4m/sec and 1.8m/sec respectively. However, minimum non-silting velocity of
0.6m/sec shall be ensured. Longitudinal bed slope shall not be milder than 1 in
1000.
Page 9 of 30
3.
9.0
For design of RCC pipes for drains and culverts, IS: 456 and IS: 783 shall be
followed.
4.
The Contractor shall ensure that water drains are away from the site area and
shall prevent damage to adjacent property by this water. Adequate protection
shall be given to site surfaces, roads, ditches, culverts, etc. to prevent erosion of
material by water.
5.
The drainage system shall be adequate without the use of cable/pipe trenches.
(Pipe drains shall be provided in areas of switchyard where movement of crane
will be necessary in operating phase of the substation).
6.
For pipe drains, concrete pipe of class NP2 shall be used. However, for road
crossings etc. higher strength pipe of class NP3 shall be provided. For rail
crossings, pipes conforming to railway loading standards or at least NP4 class
shall be provided. Manholes shall be provided at every 30m interval, at
connection points and at every change of alignment.
7.
Open surface drains shall be provided with Brick Masonry of minimum

thickness of 100 mm or more as per design condition for new substations and
for bay extension of existing substations, prevailing practice of existing
substations shall be adopted.
8.
Pipe drains shall be connected through manholes at an interval of max. 30m.

Effluents shall be suitably treated by the Contractor to meet all the prevalent
statutory requirements and local pollution control norms and treated effluents
shall be conveyed to the storm water drainage system at a suitable location for
its final disposal.
9.
Invert of the drainage system shall be decided in such a way that the water can
easily be discharged above the High Flood Level (HFL) outside substation
boundary at suitable location upto a maximum 50M beyond boundary wall of
substation or actual whichever occurs earlier and approved by Owner.
Contractor should provide Pumps for drainage of water (if required).
10.
All internal site drainage system, including the final connection/disposal to

owner acceptance points shall be part of Suppliers scope including all required
civil work, mechanical & electrical systems. The Contractor shall connect his
drain(s) at one or more points to outfall points as feasible at site.
11.
The drainage scheme and associated drawings shall be got approved.
ROADS AND CULVERTS

1.
The main approach road including modification of existing road to meet the site
conditions, roads for access to equipment and buildings with in substations
(including bay extension in existing substations) are in the scope of bidder.
Layout of the roads shall be based on General detail & Arrangement drawing
for the substation. If extra road is required for functional point of view, which
has not been mentioned in the layout drawing, Contractor should provide the
same with out extra cost to the owner.
Page 10 of 30
10.0
2.
All substation roads shall be constructed so as to permit transportation of all

heavy equipment. The roads shall have min. 3.75 m black topping.
3.
Road construction shall be as per IRC standards.
4.
Adequate provision shall be made for road drainage. Protection of cut and
embankment slopes of roads as per slope stability requirement shall be made.
5.
All the culverts and its allied structure (required for road/rail, drain trench
crossings etc.) shall be designed for class A loading as per IRC standard / IS
code and should be checked for loading.
6.
All roads shall be designed for class C of traffic as per IRC-37 Guide-lines for
the design of flexible pavements.
TRANSFORMER FOUNDATION
The Contractor shall provide a road system integrated with the transformer foundation
to enable installation and the replacement of any failed unit by the spare unit located at
the site. This system shall enable the removal of any failed unit from its foundation to
the nearest road. If trench/drain crossings are required then suitable R.C.C. culverts
shall be provided in accordance with I.R.C. Code/relevant IS.
If existing/failed transformer is required to be replaced by new one in augmentation/bay
extension works of existing substations then the foundation supporting that equipment
shall be strengthen by modifying the foundation itself or the foundation shall be
dismantle and recast new foundation as suited by contractor. However, contractor must
furnish the design calculation incorporating all those changes so that safety of the
structure and foundation remain adequate.
Similarly all types of equipment foundations with /without supporting structures shall
be treated in similar manner as stated for transformer foundations.
Contractor must access the amount of work involve for augmentation/bay extension of
existing substations while quoting.
12.0 FIRE PROTECTION WALLS

12.1
General
Fire protection walls shall be provided in accordance with Tariff Advisory Committee
(TAC) recommendations.
12.2
Application criteria
A firewall shall be erected between the transformers to protect each one from the
effects of fire on another as per TAC guidelines.
Also, if the free distance between the transformer, and auxiliary services transformers is
less.
Page 11 of 30
12.3
Fire resistance
The firewall shall have a minimum fire resistance of 3 hours. The partitions, which are
made to reduce the noise level, shall have the same fire resistance where the partitions
are also used as firewalls. The walls of the building, which are used as firewalls, shall
also have a minimum fire resistance of 3 hours.
The firewall shall be designed in order to protect against the effect of radiant heat and
flying debris from an adjacent fire.
12.4 Mechanical resistance

The firewall shall have the mechanical resistance to withstand local atmospheric
conditions. If this wall shall serve as a support for equipment such as insulators etc., its
mechanical rigidity must be increased. Connecting the walls by steel or other structures,
which may produce a reversing torque, if overheated, shall be avoided.
12.5 Dimensions
The firewall shall extend at least 2 m on each side of the transformer and at least 1 m
above the conservator tank or safety vent.
These dimensions might be reduced in special cases, and if TAC permits so, where
there is lack of space. A minimum of 2-meter clearance shall be provided between the
equipments e.g. transformer and firewalls.
The building walls, which act as firewalls, shall extend at least 1 m above the roof in
order to protect it.
12.6 Materials
The firewall may be made of reinforced concrete (M-20 grade), as per the system
requirements. Materials used must conform to the standards of the National Fire
Prevention Association & TAC norms.
13.0 CABLE & PIPE TRENCHES
1.
The cable trenches and precast removable RCC cover (with lifting arrangement)
shall be constructed using RCC of M20 grade for new substation whereas for
bay extension of existing substation size and material of cable trenches shall be
same as the existing one and precast removable RCC cover (with lifting
arrangement) shall be constructed using RCC of M20 grade. Cable trenches
must be designed for the design criteria stated below, whether it is of concrete
or brick for both new substations and bay extension works in existing
substations.
2.
The cable trench walls shall be designed for the following loads.
Page 12 of 30
(i)
(ii)
3.
Dead load of 100 kg/m length of cable support + 75 Kg on one tier at the
end.
Triangular earth pressure + uniform surcharge pressure of 1T/m2.
Cable trench covers shall be designed for self-weight of top slab + concentrated
load of 200 kg at centre of span on each panel.
4.
Cable trench crossing the road/rails shall be designed for class A. Loading of
IRC/relevant IS Code and should be checked for transformer loading.
5.
Trenches shall be drained. Necessary sumps be constructed and sump pumps if

necessary shall be supplied. Cable trenches shall not be used as storm water
drains.
The top of trenches shall be kept at least 100 mm above the finished ground
level for the new substation. The top of cable trench shall be such that the
surface rainwater does not enter the trench.
The top of trench shall be kept same as existing one to maintain uniformity of
the cable trenches structure in case of bay extension works of existing
substations.
6.
7.
All metal parts inside the trench shall be connected to the earthing system.
8.
Cables from trench to equipments shall run in hard conduit pipes.
9.
Trench wall shall not foul with the foundation. Suitable clear gap shall be
provided.
10.
The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular
to the run.
11.
All the construction joints of cable trenches i.e. between base slab to base slab
and the junction of vertical wall to base slab as well as from vertical wall to wall
and all the expansion joints shall be provided with approved quality PVC water
stops of approx. 230 x 5 mm size for those sections where the ground water
table is expected to rise above the junction of base slab and vertical wall of
cable trenches.
12.
Cable trenches shall be blocked at the ends if required with brick masonry in
cement sand mortar 1:6 and plaster with 12mm thick 1:6 cement sand mortar.
13.
Cable trench contains cable trey that shall be supported on ISA. The size and
spacing of angle section shall be as per design criteria mentioned above.
However minimum internal dimension of cable trench is 750mm wide and 600
mm in depth.
14.0
FOUNDATION /RCC CONSTRUCTION
14.1
General
1. Work covered under this Clause of the Specification comprises the design and
construction of foundations and other RCC constructions for switchyard structures,
Page 13 of 30
equipment supports, trenches, drains, jacking pad, control cubicles, bus supports,
transformer, marshalling kiosks, auxiliary equipments & systems, buildings, tanks,
boundary wall or for any other equipment or service and any other foundation
required to complete the work. This clause is as well applicable to the other RCC
constructions.
However, for the augmentation/bay extension works of existing substation, type of
RCC structures and foundations etc. shall be similar to one already existing at the
existing substation and for which design shall be furnished in support of safety of
those RCC structures and foundations etc. Contractor must access the amount of
work involved for the construction of switchyard structures, equipment supports,
trenches, drains, jacking pad, control cubicles, bus supports, transformer,
marshalling kiosks, auxiliary equipments & systems, buildings, tanks, boundary
wall or for any other equipment or service and any other foundation required to
complete the work for the existing substations.
2.
Concrete shall conform to the requirements mentioned in IS: 456 and all the
tests shall be conducted as per relevant Indian Standard Codes as mentioned in
Standard field quality plan appended with the specification
A minimum grade for PCC and RCC shall be used for all structural/loadbearing members as per latest IS 456.
3.
If the site is sloppy, the foundation height will be adjusted to maintain the exact
level of the top of structures to compensate such slopes.
4.
The switchyard foundations plinths and building plinths shall be minimum

250mm and 500 mm above finished ground level respectively.
5.
Minimum 75mm thick lean concrete shall be provided below all underground
structures, foundations, trenches etc. to provide a base for construction.
6.
Concrete made with Portland slag cement shall be carefully cured and special
importance shall be given during the placing of concrete and removal of
shuttering.
7.
The design and detailing of foundations shall be done based on the approved
soil data and sub-soil conditions as well as for all possible critical loads and the
combinations thereof. The Spread footings foundation or pile foundation as may
be required based on soil/sub-soil conditions and superimposed loads shall be
provided.
8.
If pile foundations are adopted, the same shall be cast-in-situ driven/bored or

precast or under reamed type as per relevant parts of IS Code 2911. Only RCC
piles shall be provided. Suitability of the adopted pile foundations shall be
justified by way of full design calculations. Detailed design calculations shall be
submitted by the bidder showing complete details of piles/pile groups proposed
to be used. Necessary initial load test shall also be carried out by the bidder at
their cost to establish the piles design capacity. Only after the design capacity of
piles has been established, the Contractor shall take up the job of piling. Routine
tests for the piles shall also be conducted. All the work (design & testing) shall
be planned in such a way that these shall not cause any delay in project
completion.
Page 14 of 30
14.2
Design
1.
Foundations shall be of reinforced cement concrete for new substation but for
the augmentation / bay extension works of existing substation it could be of
RCC/ PCC / MASONRY depending on type of structures and materials used for
the similar type of structures in those bay extension works of existing
substation. Design requirement shall be fulfilled by the contractor and furnished
for approval for both new substation and existing substation (for bay extension
works) as specified in the scope of work. The design and construction of RCC/
PCC / Masonry structures shall be carried out as per IS: 456 and relevant IS
code/CBIP manual/NBC etc and minimum grade of concrete shall be as per
relevant IS code. Higher grade of concrete than specified above may be used at
the discretion of Contractor without any additional financial implication to the
Owner.
2.
Limit state method of design shall be adopted unless specified otherwise in the
specification.
3.
For detailing of reinforcement IS: 2502 and SP: 34 shall be followed. Cold
twisted deformed bars (Fe=415 N/mm2) conforming to IS: 1786 shall be used
as reinforcement. However, in specific areas, mild steel (Grade I) conforming to
IS: 432 can also be used. Two layers of reinforcement (on inner and outer face)
shall be provided for wall & slab sections having thickness more than 150 mm.
Clear cover to reinforcement towards the earth face shall be minimum 40 mm.
4.
RCC water retaining structures like storage tanks, etc. shall be designed as
uncracked section in accordance with IS: 3370 (Part I to IV) by working stress
method. However, water channels shall be designed as cracked section with
limited steel stresses as per IS: 3370 (Part I to IV) by working stress method.
5.
The procedure used for the design of the foundations shall be the most critical
loading combination of the steel structure and or equipment and/or
superstructure and other conditions, which produces the maximum stresses in
the foundation or the foundation component and as per the relevant IS Codes of
foundation design. Detailed design calculations shall be submitted by the bidder
showing complete details of piles/pile groups or isolated /combined footings
proposed to be used.
6.
Design shall consider any sub-soil water pressure that may be encountered
following relevant standard strictly.
7.
Necessary protection to the foundation work, if required shall be provided to

take care of any special requirements for aggressive alkaline soil, black cotton
soil or any other type of soil which is detrimental/harmful to the
concrete/masonry foundations.
8.
RCC columns /pedestals shall be provided with rigid connection at the base.
9.
All sub-structures shall be checked for sliding and overturning stability during
both construction and operating conditions for various combinations of loads.
Factors of safety for these cases shall be taken as mentioned in relevant IS
Page 15 of 30
Codes or as stipulated elsewhere in the Specifications. For checking against

overturning, weight of soil vertically above footing shall be taken and inverted
frustum of pyramid of earth on the foundation should not be considered.
10.
Earth pressure for all underground structures shall be calculated using coefficient of earth pressure at rest, co-efficient of active or passive earth pressure
(whichever is applicable).
11.
In addition to earth pressure and ground water pressure etc., a surcharge load of
2T/Sq.m shall also be considered for the design of all underground structures
including channels, sumps, tanks, trenches, substructure of any underground
hollow enclosure etc., for the vehicular traffic in the vicinity of the structure.
12.
Following conditions shall be considered for the design of water tank in pumps
house, channels, sumps, trenches and other underground structures:
a)
Full water pressure from inside and no earth pressure & ground water
pressure & surcharge pressure from outside (application only to structures,
which are liable to be filled up with water or any other liquid).
b)
Full earth pressure, surcharge pressure and ground water pressure from
outside and no water pressure from inside.
c)
Design shall also be checked against buoyancy due to the ground water
during construction and maintenance stages. Minimum factor of safety of
1.5 against buoyancy shall be ensured ignoring the superimposed loadings.
13.
The foundations shall be proportioned so that the estimated total and differential
movements of the foundations are not greater than the movements that the
structure or equipment is desinged to accommodate.
14.
The foundations of transformer and circuit breaker shall be of block type

foundation. Minimum reinforcement shall be governed by IS:2974 and IS:456.
15. The tower and equipment foundations shall be checked for a factor of safety of 2.0
for normal condition and 1.5 for short circuit condition against sliding, overturning
and pullout.
14.3
Admixtures & additives

1.
Only approved admixtures shall be used in the concrete for the Works. When
more than one admixture is to be used, each admixture shall be batched in its
own batch and added to the mixing water separately before discharging into the
mixer. Admixtures shall be delivered in suitably labeled containers to enable
identification.
2.
Admixtures in concrete shall conform to IS: 9103. The water proofing cement
additives shall conform to IS: 2645. Owner shall approve concrete Admixtures/
Additives.
Page 16 of 30
15.0
3.
The Contractor may propose and the Owner may approve the use of a waterreducing set-retarding admixture in some of the concrete. The use of such an
admixture will not be approved to overcome problems associated with
inadequate concrete plant capacity or improperly planned placing operations
and shall only be approved as an aid to overcoming unusual circumstances and
placing conditions.
4.
The water-reducing set-retarding admixture shall be an approved brand of

Ligno-sulphonate type admixture.
5.
The waterproofing cement additives shall be used as required / advised by the

Owner.
GATES AND BOUNDARY WALL

1.
The Gate frame shall be made of medium duty MS pipe conforming to relevant
IS with welded joints.
2.
The gates shall be fabricated with welded joints to achieve rigid connections.
The gate frames shall be painted with one coat of approved steel primmer and
two coats of synthetic enamel paint.
3.
Gates shall be fitted with approved quality iron hinges, latch and latch catch.
Latch and latch catch shall be suitable for attachment and operation of pad lock
from either side of gates. Hinges shall permit gates to swing through 180 degree
back against fence.
4.
Gates shall be fitted with galvanized chain hook or gate hold back to hold gates
open. Double gates shall be fitted with centre rest and drop bolt to secure gates
in closed position.
5.
Gates shall be installed in locations shown on drawings. Next to the main gate, a
men gate (1.25 m wide, Single leaf) shall also be provided.
6.
Bottom of gates shall be set approximately 40mm above ground surface and
necessary guiding mechanism shall be fitted.
7.
The contractor shall design and construct boundary wall around substation area
as per requirements. The boundary wall shall be of height 2.0 M and shall be
made of brick wall in cement sand mortar 1:6.The thickness of wall depends on
the design calculation produced by contractor and approved by owner. The
boundary wall shall be plastered on both external and internal faces with cement
sand plaster 1:6 of thickness 18 mm and 12 mm respectively. An additional
barbed Y-shaped arm of MS angle 50x50x6 with 3-rows (6nos) barbed wire A4IS: 278. Expansion joints shall be provided as per codal requirements. MS
grating shall be provided at required locations for drainage purposes. Top and
bottom side of MS grating shall be supported on concrete block or beam. The
boundary wall shall be painted with minimum two coats of colour wash over a
base coat of white wash with lime. The steel work shall be given two coats of
synthetic enamel paint of approved make over one coat of primer. A tentative
drawing is enclosed for guidance purpose.
Page 17 of 30
8.
A Security room shall be provided at the entrance of switchyard. The minimum

dimension of the room shall be 3.0m lengths and 3.0m widths. The roof shall be
at RCC and aesthetically pleasing.
16.0
BUILDINGS - GENERAL REQUIREMENTS
16.1
General
The scope for new control room building includes the design, engineering and
construction including anti-termite treatment, plinth protection, DPC of Building
including sanitary, water supply with Boring, provision of Motor, water tank and other
necessary sanitary installations, electrification, false ceiling etc. of control room
building. The buildings shall be of RCC framed structure of concrete of M20 grade
(Min.). Following design criteria shall be adopted for design purposes for new
substation.
If any extension of the Control Room building is required in augmentation / bay
extension works of existing substation then extension part shall be compatible to
existing one structurally and architecturally but following design criteria shall be
adopted for design purposes for R&M of existing substation.
16.2
Control room Building

Minimum floor area requirements shall be 12x10 sq. mts. which may be increased at
the time of detailed engineering to suit project requirements. The layout of the control
room shall be finalised as per detailed engineering to suit project requirements .The
minimum dimension of different rooms required for C.R.building have been furnished
below.
Control room
Jes room
Battery room
Storeroom
W.C/Bath/W.B
Portico
An open space of 1 m minimum shall be provided on the periphery of the rows of
panel and equipment generally in order to allow easy operator movement and access
as well as maintenance.
Any future possibility of annexe building shall be taken care of while finalizing the
layout of the control room building.
Minimum headroom of 3 M below soffit of beams/false ceiling shall be considered for
rooms. The roof shall have four side sloping roof or flat roof as finalised during
detailed engineering.
16.2.1 Design
a)
The buildings shall be designed:

1.
To the requirements of the National Building Code of India, and the

standards quoted therein.
Page 18 of 30
2.
For the specified climatic & loading conditions.
3.
To adequately suit the requirements of the equipment and apparatus

contained in the buildings and in all respects to be compatible with the
intended use and occupancy.
4.
With a functional and economical space arrangement.
5.
For a life expectancy of structure, systems and components not less than
that of the equipment, which is contained in the building, provided
regular maintenance is carried out.
6.
Be aesthetically pleasing. Different buildings shall show a uniformity

and consistency in architectural design.
7.
To allow for easy access to equipment and maintenance of the

equipment.
8.
With, wherever required, fire retarding materials for walls, ceilings and
doors, which would prevent supporting or spreading of fire.
9.
With materials preventing dust accumulation.
b)
Suitable expansion joints shall be provided in the longitudinal direction

wherever necessary with provision of twin columns.
c)
Individual members of the buildings frame shall be designed for the

worst combination of forces such as bending moment, axial force, shear
force, torsion etc.
d)
Permissible stresses for different load combinations shall be taken as per

relevant IS Codes.
e)
All cable vaults shall be located above ground levels i.e. cable vaults
shall not be provided as basements in the buildings.
f)
The building lighting shall be designed in accordance with the

requirements of relevant section.
g)
One emergency exit shall be provided in control room building.
16.2.2 Design loads

Building structures shall be designed for the most critical combinations of dead loads,
superimposed loads, equipment loads, crane load, wind loads, seismic loads, and
temperature loads.
Dead loads shall include the weight of structures complete with finishes, fixtures and
partitions and should be taken as per IS: 1911.
Page 19 of 30
Super-imposed loads in different areas shall include live loads, minor equipment
loads, cable trays, small pipe racks/hangers and erection, operation and maintenance
loads. Equipment loads shall constitute, if applicable, all load of equipments to be
supported on the building frame.
For crane loads an impact factor of 30% and lateral crane surge of 10% (lifted weight
+ trolley) shall be considered in the analysis of frame according to provisions of IS:
875. The horizontal surge shall be 5% of the static wheel load.
The wind loads shall be computed as per IS 875, Seismic Coefficient method shall be
used for the seismic analysis as per IS 1893 with importance factor 1.5.
For temperature loading, the total temperature variation shall be considered as 2/3 of
the average maximum annual variation in temperature. The average maximum annual
variation in temperature for the purpose shall be taken as the difference between the
mean of the daily minimum temperature during the coldest month of the year and
mean of daily maximum temperature during the hottest month of the year. The
structure shall be designed to withstand stresses due to 50% of the total temperature
variation.
Wind and Seismic forces shall not be considered to act simultaneously.
Floors/slabs shall be designed to carry loads imposed by equipment, cables piping
travel of maintenance trucks and equipment and other loads associated with building.
Floors shall be designed for live loads as per relevant IS. Cable and piping loads shall
also be considered additionally for floors where these loads are expected.
In addition, beams shall be designed for any incidental point loads to be applied at any
point along the beams. The floor loads shall be subject to Owners approval.
For consideration of loads on structures, IS: 875 shall strictly adhere to. Any other
load coming in the structure, not mentioned in IS 875 shall be calculated as per
relevant IS code and NBC.
16.2.3 Submission
The following information shall be submitted for review and approval to the Owner:
1.
Design criteria shall comprise the codes and standards used, applicable climatic
data including wind loads, earthquake factors maximum and minimum
temperatures applicable to the building locations, assumptions of dead and live
loads, including equipment loads, impact factors, safety factors and other
relevant information.
2.
Structural design calculations and drawing (including construction/fabrication)

for all reinforced concrete and structural steel structures.
3.
Fully, dimensioned concept plan including floor plans, cross sections,

longitudinal sections, elevations and perspective view of each building. These
drawings shall be drawn at a scale not smaller than 1:75 and shall identify the
major building components.
Page 20 of 30
4.
Fully dimensioned drawings showing details and sections drawn to scales of

sufficient size to clearly show sizes and configuration of the building
components and the relationship between them.
5.
Product information of building components and materials, including walls

partitions flooring ceiling, roofing, door and windows and building finishes.
6.
A detailed schedule of building finishes including colour schemes.
7.
A door & window schedule showing door types and locations, door lock sets
and latch sets and other door hardware.
Approval of the above information shall be obtained before ordering materials or

starting fabrication or construction as applicable.
16.2.4 Finish Schedule
The finishing schedule is given in subsequent clauses.
16.2.5
Flooring
Flooring in various rooms of control room building shall be as for detailed schedules
given in Table 1
16.2.6 Walls
Control room buildings shall be of framed superstructure. All walls shall be non-load
bearing walls. Min. thickness of external walls shall be 230 mm (one brick) with 1:6
cement sand mortar.
16.2.7
Plastering
All internal walls shall have minimum 12mm and 15 mm thick 1:6 cement sand
plaster on either side of wall. The ceiling shall have 6mm thick 1:4 cement sand
plaster.
16.2.8
Finishing
All external surfaces shall have 18 mm cement plaster in two coats, under layer 12
mm thick cement plaster 1:5 and finished with a top layer 6 mm thick cement plaster
1:6 (DSR 13.19) with water proofing compound. The paint shall be antifungal quality
of reputed brand suitable for masonry surfaces for high rainfall zone. White cement
primer shall be used as per manufacturers recommendation.
Page 21 of 30
Internal finish Schedule is given Table - 1 below:

TABLE-1
Sl.No.
1.
2.
3.
4.
Location
Control Room,
Relay Room
Sub-station
Incharge, Office,
corridor, staff
room.
Battery room
Toilet
Flooring &
Skirting
150mm high
Precast
Terrazo tiles
(DSR02,
item no.
11.29A.2 &
11.31.2
Precast
Terrazo tiles
(DSR02,
item no.
11.29A.2 &
11.31.2
Acid and
Alkali
Resistant tiles.
DSR02
11.36 C. 1 &
11.36 C.1.1
Ceramic
glazed tiles in
flooring
DSR02
11.74
Wall Internal
Ceiling
Oil bound washable

distemper on
smooth surface
applied with 2mm
thick Plaster of
Paris putty.
(DSR02 13.40 A
& 13.77.2)
Oil bound washable
distemper on
smooth surface
applied with POP
putty. (DSR02
13.40 A & 13.77.2)
White
Wash
(DSR02
13.70.1)
Dado of acid
resistant tile 1.2 M
high & Paint above
1.2 M to ceiling.
DSR02 11.36 C.
2.1, 11.36C.2 &
13.96.1
Acid
resistant
Paint.
DSR02
13.96.1
DADO glazed tile

2.1M high for toilet
(DSR 02 - 11.73)
Doors, Windows,
Ventilators
1) Standard steel rolled

section frames with 5
mm glass. DSR02
10.12, 10.13 & 10.14
2) Flush door shutters DSR02 9.25.2
White
Wash
(DSR02
13.70.1)

mm glass. DSR02
10.12, 10.13 & 10.14
mm glass. DSR02
10.12, 10.13 & 10.14
White
Wash
(DSR02
13.70.1)
Painted with acid

resistant Paint. DSR02
13.96.1
mm glass. DSR02
10.12, 10.13 & 10.14
5.
Other areas not

specified
Terrazo tiles
(DSR02 11.29A.2 &
11.31.20
Oil bound
distemper,
DSR02 - 13.40A
& 13.77
White
Wash
(DSR02
13.70.1)
Note : DSR item references (DSR-2002) to be read with CPWD specifications are only for
material and workmanship guidance of the Contractors.
Page 22 of 30
16.2.9
Roof
Roof of the C.R. Building shall consist of Cast-in-situ RCC slab treated with a water
proofing system which shall be an integral cement based treatment conforming to
CPWD specification (item no. 25.8 of DSR 1997). The water proofing treatment shall
be of following operations:
(a) Applying and grouting a slurry coat of neat cement using 2.75 kg/m 2 of cement
admixed with proprietary water proofing compounds conforming to IS: 2645 over
the RCC slab including cleaning the surface before treatment.
(b) Laying cement concrete using broken bricks/brick bats 25mm to 100mm size with
50% of cement mortar 1:5 (1 cement: 5 coarse sand) admixed with proprietary
water proofing compound conforming to IS: 2645 over 20mm thick layer of
cement mortar of min 1:5 (Cement: 5 coarse sand) admixed with proprietary water
proofing compound conforming to IS: 2645 to required slope and treating similarly
the adjoining walls upto 300mm height including rounding of junctions of walls
and slabs.
(c) After two days of proper curing applying a second coat of cement slurry admixed
with proprietary water proofing compound conforming to IS: 2645.
(d) Finishing the surface with 20mm thick joint less cement mortar of mix 1:4 (1
cement: 4 course sand) admixed with proprietary water proofing compound
conforming to IS: 2645 and finally finishing the surface with trowel with neat
cement slurry and making of 300 x 300 mm square.
(e) The whole terrace so finished shall be flooded with water for a minimum period of
two weeks for curing and for final test. All above operations to be done in order
and as directed and specified by the Engineer-in-charge.
With average thickness of 120 mm and minimum thickness at khurra at 65 mm.
16.2.10
Glazing
Minimum thickness of glazing shall be 5.5 mm. as per IS: 2835 Sun film shall be
provided for all windows/doors of AC rooms if any.
16.2.11
Doors and Windows

The details of doors and windows of the control room building shall be as per finish
schedule Table-1 and tender drawing with the relevant IS code. Rolling steel shutters
and rolling steel grills shall be provided as per layout and requirement of buildings.
Paints used in the work shall be of best quality specified in CPWD specification.
16.2.12 Plumbing & Sanitation

(i)
All plumbing and sanitation shall be executed to comply with the requirements
of the appropriate byelaws, rules and regulations of the Local Authority having
jurisdiction over such matters. The Contractor shall arrange for all necessary
Page 23 of 30
formalities to be met in regard to inspection, testing, obtaining approval and

giving notices etc.
(ii)
PVC syntax or equivalent make Roof water tank of adequate capacity

depending on the number of users for 24 hours storage shall be provided.
Minimum 1 Nos. 500 liters capacity shall be provided.
(iii)
Galvanized MS pipe of medium class conforming to IS: 1239 shall be used for
internal & external piping work for potable water supply.
(iv)
Sand CI pipes with lead joints conforming to IS: 1729 shall be used for sanitary
works above ground level.
(v)
Each toilet shall have the following minimum fittings.

(a) WC (Western type) 390 mm high with toilet paper roll holder and all fittings
Or
WC (Indian Type) Orissa Pattern (580 x 440 mm) with all fittings (both types
of WCs shall be provided at alternate locations).
(b)
Urinal (430 x 260 x 350 mm size) with all fittings.
(c)
Wash basin (550 x 400 mm) with all fittings.
(d)
Bathroom mirror (600 x 450 x 6 mm thick) hard board backing
(e)
CP brass towel rail (600 x 20 mm) with C.P. brass brackets
(f)
Soap holder and liquid soap dispenser.
(vi)
All fittings, fastener, grating shall be chromium plated.
(vii)
All sanitary fixtures and fittings shall be of approved quality and type
manufactured by well known manufacturers. All items brought to site must bear
identification marks of the type of the Manufacturer.
(viii)
Soil, waste and drain pipes, for underground works shall be stoneware for areas
not subject to traffic load. Heavy-duty cast iron pipes shall be used otherwise.
(ix)
In case of R&M of existing substation, amount of work shall be envisaged

by contract for lump sum quotation.
17.0
MISCELLANEOUS GENERAL REQUIREMENTS
17.1
Dense concrete with controlled water cement ratio as per IS-code shall be used for all
underground concrete structures such as pump-house, tanks, water retaining structures,
cable and pipe trenches etc. for achieving water-tightness.
17.2
All joints including construction and expansion joints for the water retaining structures
shall be made water tight by using PVC ribbed water stops with central bulb.
However, kicker type (externally placed) PVC water stops shall be used for the base
Page 24 of 30
slab and in other areas where it is required to facilitate concreting. The minimum
thickness of PVC water stops shall be 5 mm and minimum width shall be 230 mm.
17.3
All steel sections and fabricated structures that are required to be transported on sea
shall be provided with anti corrosive paint to take care of sea worthiness.
17.4
All mild steel parts used in the water retaining structures shall be hot-double dip
galvanised. The minimum coating of the zinc shall be 750 gm/sq. m. for galvanised
structures and shall comply with IS: 2629 and IS: 2633. Galvanizing shall be checked
and tested in accordance with IS: 2633.The galvanizing shall be followed by the
application of an etching primer and dipping in black bitumen in accordance with BS:
3416.
17.5
A screed concrete layer not less than 100 mm thick and of grade not weaker than M10
conforming to IS: 456-1978 shall be provided below all water retaining structures. A
sliding layer of bitumen paper or craft paper shall be provided over the screed layer to
destroy the bond between the screed and the base slab concrete of the water retaining
structures.
17.6
Bricks having minimum 75kg/cm2 compressive strength can only be used for masonry
work. Contractor shall ascertain himself at site regarding the availability of bricks of
minimum 75kg/cm2 compressive strength before submitting his offer.
17.7
Doors and windows on external walls of the buildings (other than areas provided, with
insulated metal claddings) shall be provided with RCC sunshade over the openings
with 300 mm projection on either side of the openings. Projection of sunshade from
the wall shall be minimum 450 mm over window openings and 750 mm over door
openings.
17.8
Service ladder shall be provided for access to all roofs.
17.9
Angles 45x45x5 mm (minimum) with lugs shall be provided for edge protection all
round cut outs/openings in floor slab, edges of drains supporting grating covers, edges
of RCC cable/pipe trenches supporting covers, edges of manholes supporting covers,
supporting edges of manhole precast cover and any other place where breakage of
corners of concrete is expected.
17.10
Anti termite chemical treatment shall be given to column pits, wall trenches,
foundations of buildings, filling below the floors etc. as per IS: 6313 and other
relevant Indian Standards.
17.11
All rungs for ladder shall also be galvanised as per IS: 277 medium classes.
17.12
For all civil works covered under this specification, nominal mix by volume batching
as per CPWD specification is intended. The relationship of grade of concrete and
ratio of ingredients shall be as below:
-----------------------------------------------------------------------------------------Sl.No.
Mix
Cement
Page 25 of 30
Sand
Coarse aggregate of
20 mm down grade
as per IS 383
-----------------------------------------------------------------------------------------1.
M 10
1
3
6
2.
M 15
3.
M 20
1.5
-----------------------------------------------------------------------------------------The material specification, workmanship and acceptance criteria shall be as per

relevant clauses of CPWD specification and approved standard Field Quality Plan.
17.13
The details given in tender drawings shall be considered along with details available
in this section of the specification while deciding various components of the building.
17.14
Items/components of buildings not explicitly covered in the specification but required

for completion of the project shall be deemed to be included in the scope.
18.0
INTERFACING
The proper coordination & execution of all interfacing civil works activities like fixing
of conduits in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures,
fixing of supports/embedment, provision of cutouts etc. shall be the sole responsibility
of the Contractor. He shall plan all such activities in advance and execute in such a
manner that interfacing activities do not become bottlenecks and dismantling,
breakage etc. is reduced to minimum.
19.0
WATER SUPPLY
(i)
Contractor shall make its own arrangement for construction work.
(ii)
The contractor shall carry out all the plumbing/erection works required for
supply of water in control room building; the water supply shall include the
boring, provision of Motor, water tank and other necessary sanitary
installations.
(iii)
The details of tanks, pipes, fittings, fixtures etc for water supply are given
elsewhere in the specification under respective sections.
(iv)
A scheme shall be prepared by the contractor indicating the layout and details of
water supply which shall be got approved by the Owner before actual start of
work including all other incidental items not shown or specified but as may be
required for complete performance of the works.
(v)
Bore wells and pumps for water supply are in the scope of contractor meeting
the day-to-day requirement of the water supply.
If the water is supplied by Municipal Corporation then bore well for water
supply purposes is not required to be carried out by contractor. Contractor shall
also make necessary arrangement /formalities to receive water connection from
corporation.
(vi)
Page 26 of 30
20.0
SEWERAGE SYSTEM
(i)
Sewerage system shall be provided for control room building.
(ii) The Contractor shall construct septic tank and soak pit suitable for 5 users if
outside of Municipal Corporation zone. Otherwise, all necessary arrangement for the
disposal of sewerage to the Municipal Corporations end shall be arranged by the
contractor at his own cost for regularizing the disposal activity.
(iii)
The system shall be designed as per relevant IS Codes.
21.0
STATUTORY RULES
21.1
Contractor shall comply with all the applicable statutory rules pertaining to factories
act (as applicable for the State). Fire Safety Rules of Tariff Advisory Committee,
Water Act for pollution control etc.
21.2
Provisions for fire proof doors, no. of staircases, fire separation wall, plastering on
structural members (in fire prone areas) etc. shall be made according to the
recommendations of Tariff Advisory Committee.
21.3
Statutory clearance and norms of State Pollution Control Board shall be followed as
per Water Act for effluent quality from plant.
21.4
Requirement of sulphate resistant cement (SRC) for sub structural works shall be
decided in accordance with the Indian Standards based on the findings of the detailed
soil investigation to be carried out by the Bidder.
21.5
Foundation system adopted by Bidder shall ensure that relative settlement and other
criteria shall be as per provision in IS: 1904 and other Indian Standards.
21.6
All water retaining structures designed as uncracked section shall also be tested for
water tightness at full water level in accordance with clause no. 10 of IS: 3370 (Part-I).
21.7
Construction joints shall be as per IS: 456.
21.8
All underground concrete structures like basements, pumps houses, water retaining
structures etc. shall have plasticizer cum water proofing cement additive conforming
to IS: 9103. In addition, limit on permeability as given in IS: 2645 shall also be met
with. The concrete surface of these structures in contact with earth shall also be
provided with two coat of bituminous painting for water/damp proofing. In case of
water leakage in the above structures, Injection Method shall be applied for repairing
the leakage.
All building/construction materials shall conform to the best quality specified in
CPWD specifications if not otherwise mentioned in this specification.
21.9
21.10 All tests as required in the standard field quality plans have to be carried out.
22.0 FENCING OF DTs

Page 27 of 30
22.1 General
Fencing of the distribution transformer shall be designed for the most critical loading
combination taking care of wind force, stability, tension on wires, minimum
requirements as per this clause and relevant IS recommendations.
22.2
Areas requiring fencing

Fencing shall be provided all around distribution transformer plinth and pole mounted
both and fencing of switchyard area. Wherever necessary anti-reptile
fixture/arrangement shall be provided along with fencing.
22.3
Product materials for fencing

The minimum requirements are as follows:
22.3.1 Chain Link fence fabric in accordance to IS-2721

1.
Size of mesh
75 mm
2.
Nominal wire size
3.15 mm dia
3.
Width of chain link
2000 mm
4.
Class of zinc coating
medium
5.
Zinc coated after weaving.
21.3.2 Posts
Angle Section
Intermediate
: L 50 x 50 x 6
Straining posts
: L 65 x 65 x 6
Stay post
: L 50 x 50 x 6
1. All structural steel shall conform to IS: 2062 and shall be painted with a coat of
approved steel primer and two coats of synthetic enamel paint.
2. The Chain Link fabric shall be fixed to the post at the top and bottom of the fence by
welding/fixing 50 mm MS flat all through its length.
3. Fencing top shall be either of galvanised barbed wire or tape. Barbed wire shall
conform to IS: 278.
4. The barbed wire may consist of not more than two splices per reel. The barbed wire
shall be formed by twisting two line wires, one containing the barbs. The barbed wire
shall be designated as A-4 IS: 278 and shall be galvanized.
Page 28 of 30
5. Above chain link, 3-rows (6 nos) of barbed tape/wire shall be provided in each arm of
the Y shaped barbed arm at top.
6. With barbed tape/wire above the chain link fence, the total fence height shall be
minimum 2000 mm above finished gravel level.
7. Barbed tape/wire arms shall be same as intermediate and straining post.
8. Tension wire: single strand, high tensile, galvanised steel wire, 4 mm diameter.
9. Fittings and hardware: cast aluminum alloy or galvanized steel, malleable or ductile
cast iron turnbuckles to be drop forged.
10. For every 50 reels or part there of samples of the barbed wire/tape and the individual
line wires shall be put to tensile test and in case of failure to conform to the tensile
properties given below, two additional tests of each kind shall be made on the samples
cut from other reels.
11. GI chain link mesh shall be as per IS: 2721. Mesh size 75 mm and nominal wire size
shall be 3.15 mm diameter.
Tensile properties
Tensile strength of line wire
40 to 60Kgs/Sq.mm
Minimum Breaking load of

Complete barbed wire/tape
375Kgs.
On the results of these additional tests, the whole or portion of the barbed
wire/tape shall be accepted or discarded by the Purchaser, as the case may be.
22.4
INSTALLATION
1.
Contractor shall submit the fencing drawing Fence shall be installed along lines
shown on approved drawings.
2.
Post holes shall be excavated by approved methods.
3.
Intermediate posts shall be spaced 2.5 m apart measured parallel to ground

surface.
4.
Straining posts shall be installed at equal intervals not exceeding 25.0 m.
5.
Straining posts shall be installed at sharp changes in grade, at corners, at change

of direction and where directed.
6.
All corner post will have two-stay post and every tenth post will have a
transverse stay post.
7.
Posts shall be set in 1:2:4 plain cement concrete Blocks of minimum dimension
400 mm x 400 mm x 1000 mm deep Concrete work shall conform to relevant
Page 29 of 30
clause. Post shall be braced and held in plumb position and true alignment and
elevation until concrete has set.
8.
Fence fabric shall not be installed until concrete has cured a minimum of 7
days.
9.
Bottom and top of the fence fabric shall be fixed with MS flats of 50 mm x
6mm (min).
10.
Fence fabric shall be laid out with barbed edge on top, stretched tightly and
shall be fastened to intermediate, post gate and straining post with 50 x 6 flats.
11.
Fabric shall be secured to tension wires with tie wires at 400 mm intervals. Tie
wires shall be given not less than two twists.
12.
Barbed tape shall be spliced with standard wire splices.
13.
Barbed tape shall be stretched to have uniform tension.
14.
Barbed tape shall be attached to barbed wire arms with approved metal clips.
15.
Toe wall of one Brick/Random Rubble masonry, with notches over 75 mm thick
PCC (1:4:8) shall be provided below all fencing and shall be minimum 200 mm
above and 200 mm below finished ground level. All exposed surfaces of brick
toe wall shall be provided with 1:6 cement sand plaster and coated with two
coats of colour wash with a base coat of white wash with lime. Rubble masonry
toe wall shall be with raised & cut pointing and 50 mm PCC (1:2:4) band
coping.
Page 30 of 30
1.
ISOLATORS - 33KV (800A) & 11 KV (800A)
7.1.0. SCOPE
7.1.1.
This section of the specification is intended to cover design specifications for

manufacture and testing of 33 KV (800A) and 11 KV (800A) gang operated switch
(Isolators) with all fittings and accessories.
7.1.2. The Isolators are for outdoor installation suitable for

mounting on mounting structures and for use at sub-stations.
horizontal/vertical
7.1.3. Isolators shall be supplied with Earth Switch as and where specified.
7.2.0. GENERAL
7.2.1. The Isolators and accessories shall conform in general to IS 9921 (or IEC:
62271-102) except to the extent explicitly modified in specification.
7.2.2. All isolating switches and earthing switches shall have rotating blades and
pressure releasing contacts. All isolating and earth switches shall op erate through
90 angle from closed position to fully open position.
7.2.3. Complete isolator with all the necessary items for successful operation shall be
supplied including but not limited to the following:
(i). Isolator assembled with complete base frame, linkages, operating mechanism,
control cabinet, interlocks etc.
(ii). All necessary parts to provide a complete and operable isolator installation,
control parts and other devices whether specifically called for herein or not.
(iii). The isolator shall be designed for use in the geographic and meteorological
conditions as given in Section 1.
7.3.0. DUTY REQUIREMENTS
7.3.1. Isolators and earth switches shall be capable of withstanding the dynamic and
thermal effects of the maximum possible short circuit current of the systems in their
closed position. They shall be constructed such that they do not open under influence
of short circuit current.
7.3.2. The earth switches, wherever provided, shall be constructionally interlocked so
that the earth switches can be operated only when the isolator is open and vice
Page | 1
versa. The constructional interlocks shall be built in construction of isolator and

shall be in addition to the electrical and mechanical interlocks provided in the
operating mechanism.
7.3.3. In addition to the constructional interlock, isolator and ear th switches shall have
provision to prevent their electrical and manual operation unless the associated and
other interlocking conditions are met. All these interlocks shall be of failsafe
type. Suitable individual interlocking coil arrangements shall be provided. The
interlocking coil shall be suitable for continuous operation from DC supply and
within a variation range as stipulated elsewhere in this specification.
7.3.4. The earthing switches shall be capable of discharging trapped charges of the
associated lines.
7.3.5. The isolator shall be capable of making/breaking normal currents when no
significant change in voltage occurs across the terminals of each pole of isolator
on account of make/break operation.
7.3.6. The isolator shall be capable of making/breaking magnetising current of 0.7A at 0.15
power factor and capacitive current of 0.7A at 0.15 power factor at rated voltage.
7.4.0. CONSTRUCTIONAL DETAILS
7.4.1. All isolating switches and earthing switches shall have rotating blades and
pressure releasing contacts. All isolating and earth switches shall operate through
90 angle from closed position to fully open position.
7.4.2. Contacts:
a) The contacts shall be self-aligning and self-cleaning and so designed that
binding cannot occur after remaining closed for prolonged periods of time in a
he avily polluted atmosphere.
b) No undue wear or scuffing shall be evident during the mechanical endurance
tests.
Contacts and spring shall be designed so that readjustments in contact pressure
shall not be necessary throughout the life of the isolator or earthing switch. Each
contact or pair of contacts shall be independently sprung so that full pressure is
maintained on all contacts at all time.
c) Contact springs shall not carry any current and shall not lose their characteristics
due to heating effects.
d) The moving contact of double break isolator shall have turn-and -twist type or
other suitable type of locking arrangement to ensure adequate contact pressure.
7.4.3. Blades:
Page | 2
a) All metal parts shall be of non-rusting and non-corroding material. All current
carrying parts shall be made from high conductivity electrolytic
copper/aluminium. Bolts, screws and pins shall be provided with lock washers.
Keys or equivalent locking facilities if provided on current carrying parts, shall
be made of copper silicon alloy or stainless steel or equivalent. The bolts or
pins used in current carrying parts shall be made of non-corroding material. All
ferrous castings except current carrying parts shall be made of malleable cast
iron or cast-steel. No grey iron shall be used in the manufacture of any part of
the isolator.
b) The live parts shall be designed to eliminate sharp joints, edges and other
corona producing surfaces, where this is impracticable adequate corona
shield shall be provided..
c) Isolators and earthing switches including their operating parts shall be such that
they cannot be dislodged from their open or closed positions by short circuit
forces, gravity, wind pressure, vibrations, shocks, or accidental touching of the
connecting rods of the operating mechanism.
d) The switch shall be designed such that no lubrication of any part is required
except at very infrequent intervals i.e. after every 1000 operations or after 5
years whichever is earlier.
7.4.4. Insulators:
a) The insulator shall conform to IS: 2544 and/or IEC-60168. The insulators shall
have a minimum cantilever strength of 400 Kgs. for 33/11 kV insulators
respectively.
b) Pressure due to the contact shall not be transferred to the insulators after the
main blades are fully closed.
7.4.5. Base:
Each isolator shall be provided with a complete galvanised steel base provided with
holes and designed for mounting on a supporting structure.
7.5.0. EARTHING SWITCHES
7.5.1. Where earthing switches are specified
operating mechanism and auxiliary contacts.
these
shall
include
the
complete
7.5.2. The earthing switches shall form an integral part of the isolator and shall be mounted
on the base frame of the isolator.
7.5.3. The earthing switches shall be constructionally interlocked with the isolator so
that the earthing switches can be operated only when the isolator is open and
vice ve rsa. The constructional interlocks shall be built in construction of isolator
and shall be in addition to the electrical interlocks.
Page | 3
Suitable mechanical arrangement shall be provided for de-linking electrical

drive for mechanical operation.
7.5.4.
Each earth switch shall be provided with flexible copper/aluminum braids for
connection to earth terminal. These braids shall have the same short time current
carrying capacity as the earth blade. The transfer of fault current through swivel
connection will not be accept ed.
7.5.5. The frame of each isolator and earthing switches shall be provided with two reliable
earth terminals for connection to the earth mat.
7.5.6. Isolator design shall be such as to permit addition of earth switches at a future
date. It should be possible to interchange position of earth switch to either side.
7.5.7. The earth switch should be able to carry the same fault current as the main blades of
the Isolators and shall withstand dynamic stresses.
7.6.0. OPERATING MECHANISM
7.6.1. The bidder shall offer manual operated Isolators and earth switches..
7.6.2. Control cabinet/operating mechanism box shall be made of aluminum sheet of
adequate thickness (minimum 3 mm).
7.6.3. Gear should be of forged material suitably chosen to avoid bending/jamming on
operation after a prolonged period of non-operation. Also all gear and connected
material should be so chosen/surface treated to avoid rusting.
7.7.0. OPERATION
7.7.1. The main Isolator and earth switches shall be gang operated.
7.7.2.
The design shall be such as to provide maximum reliability under all service
conditions. All operating linkages carrying mechanical loads shall be designed for
negligible deflection. The length of inter insulator and interpole operating rods shall
be capable of adjustments, by means of screw thread which can be locked with a
lock nut after an adjustment has been made. The isolator and earth switches shall be
provided with over center device in operating mechanism to prevent accidental
opening by wind, vibration, short circuit forces or movement of the support structures.
7.7.3. Each isolator and earth switch shall be provided with a manual operating handle
enabling one man to open or close the isolator with ease in one movement while
standing at ground level. Detachable type manual operating handle shall be provided.
Suitable provision shall be made inside the operating mechanism box for parking
the detached handles. The provision of manual operation shall be located at a
height of 1000 mm from the base of isolator support structure.
7.7.4. The isolator shall be provided with positive continuous control throughout the entire
cycle of operation. The operating pipes and rods shall be sufficiently rigid to maintain
Page | 4
positive control under the most adverse conditions and when operated in tension or
compression for isolator closing. They shall also be capable of withstanding all torsional
and bending stresses due to operation of the isolator. Wherever supported the
operating rods shall be provided with bearings on either ends. The operating rods/
pipes shall be provided with suitable universal couplings to account for any angular
misalignment.
7.7.5. All rotating parts shall be provided with grease packed roller or ball bearings in
sealed housings designed to prevent the ingress of moisture, dirt or other foreign
matter. Bearings pressure shall be kept low to ensure long life and ease of operation.
Locking pins wherever used shall be rustproof.
7.7.6. Signaling of closed position shall not take place unless it is certain that the
movable contacts, have reached a position in which rated normal current, peak
withstand current and short time withstand current can be carried safely. Signaling of
open position shall not take place unless movable contacts have reached a position
such that clearance between contacts is atleast 80% of the isolating distance.
7.7.7. The position of movable contact system (main blades) of each of the Isolators and
earthing switches shall be indicated by a mechanical indicator at the lower end of the
vertical rod of shaft for the Isolators and earthing switch. The indicator shall be of
metal and shall be visible from operating level.
7.7.8. The contractor shall furnish the following details along with quality norms, during
detailed engineering stage.
(i) Current transfer arrangement from main blades of isolator along with
millivolt drop immediately across transfer point.
(ii)
Details to demonstrate smooth transfer of rotary motion from motor shaft

to the insulator along with stoppers to prevent over travel.
7.8.0. TEST AND INSPECTION

7.8.1. The switches shall be subjected to the following type test in accordance to with IS:
9920.
I)
Dielectric test (impulse and one minute) power frequency withstands voltage.
II) Temperature rise test

III) Rated off load breaking current capacity
IV) Rated active load breaking capacity
V) Rated line charging breaking capacity
VI) Rated short time current
VII) Rated peak withstand current
VIII) Mechanical and Electrical Endurance
Page | 5
7.8.2. The equipment shall be subjected to the following routine test.

I)
II)
Power frequency voltage dry test

Measurement of resistance of the main circuit
III) Operating test.

7.8.3. The porcelain will have pull out test for embedded component and beam strength
of porcelain base.
7.9.0. CONNECTORS
7.9.1. Each isolator shall be provided with appropriate number of bimetallic
clamping type connectors as detailed in the schedule of requirement. The maximum
length of jumper that may be safely connected or any special instruction considered
necessary to avoid under loads on the post isolators should be stated by the tenderer.
7.10.0. SUPPORTING STRUCTURES
7.10.1. All isolators and earthing switches shall be rigidly mounted in an upright position
on their own supporting structures. Details of the supporting structures shall be
furnished by the successful tenderer. The isolators should have requisite fixing
details ready for mounting them on switch structures.
7.11.0. PRE-COMMISSIONING TESTS
7.11.1. Contractor shall carry out following tests as pre-commissioning tests. Contractor
shall also perform any additional test based on specialties of the items as per the
field instructions of the equipment Supplier or Employer without any extra cost to
the Employer. The Contractor shall arrange all instruments required for
conducting these tests along with calibration certificates and shall furnish the list
of instruments to the Employer for approval.
(a) Insulation resistance of each pole.
(b) Manual operation and interlocks.
(c) Insulation resistance of control circuits and motors.
(d) Ground connections.
(e) Contact resistance.
(f) Proper alignment so as to minimise to the extreme possible the vibration
during operation.
(g) Measurement of operating Torque for isolator and Earth switch.
(h) Resistance of operating and interlocks coils.
(i) Functional check of the control schematic and electrical & mechanical
interlocks.
(j) 50 operations test on isolator and earth switch.
7.12.0. TECHNICAL DATA SHEET FOR ISOLATORS
Page | 6
SL No.
1
2
3
Nominal system voltage, kV

Highest system voltage, kV
Rated frequency, Hz.
Type of Isolator
5
6
7
8
10
11
Isolators class
Technical Particulars
33 kV
33
36
50
800
25
11kV
11
12
50
Double Break,
center pole
rotating
800
25
170
195
75
85
70
80
28
32
900
400
Double Break,
center pole rotating
Rated continuous current, A

Rated short time current, kA
Rated duration of short time
current, Second
Rated lightning impulse withstand
voltage, kV (peak)
i) To earth & between poles
ii) Across isolating distance
Rated 1 minute power frequency
withstand voltage, kV (rms)
i) To earth & between poles
ii) Across isolating distance
insulators, mm
Temperature rise
Page | 7
As per relevant IS
Specification of LTDB
1.0 Box Specification
1.1 The LT Distribution Box (LTDB) of adequate size not less than 850 mm x 650 mm shall
be provided with suitable mounting arrangements for fixing on DSS struture.
1.2 The LTDB will be made of MS Sheet of thickness 18 SWG for LTDB and 16 SWG for
Gland Plate and powder coating of 40-45 microns of Siemens grey shade after surface
pre-treatment. Pad locking bracket and common key lock (inside) will be provided with
insulated handle on front door.
1.3 LTDB shall conform to IP-55 degree of arrangement except for three opening, two for
transformer bushing and one key hole.
1.4 FSS may be embossed on the front cover of the LTDB and name plate to be provided on
LTDB.
1.5 Adequate size of fixed Glass window to be provided on the LTDB for taking the reading
of energy meter installed inside the LTDB.
1.6 Suitable arrangement shall be provided for installation of the following
equipments/materials inside LTDB.
(i)
MCCB
Capacity as per DT rating.
(ii)
Energy Meter
(iii)
CTs
(iv)
Copper Bus Bars Separate for incoming & outgoing
1.7 Suitable arrangement shall be made on the front cover of LTDB such that MCCB can be
operated without opening the LTDB Cover.
2.0 Bus Bar Specification
3.0
4.0
5.0
6.0
Separate Bus bars for incoming line from DT and for outgoing line from LTDB shall be
provided.
Copper Bus Bars of following size may be provided.
Cu Bus Bars for phase & Neutral - 25mmx4mm - 8 Nos.
Other materials to be provided are as follows :(i)
Body earth terminals M 8x40 - 2Nos
(ii)
MCCB 63A, 25kA,
Fixed TP - 1 No.
(iii)
DMC insulator for Bus bar support - 3 Nos. per Bus bar.
CANOPY
A Canopy is to be provided with slanting roof to protect from rain water.
Danger Plate to be provided on LTDB.
Drawings indicating all the above may be got approved by BSPHCL.
Page 1 of 1
LATTICE, RAIL AND PIPE STRUCTURES

1.0
GENERAL
1.1
The scope of specification covers design, fabrication, proto-assembly, testing,

supply and erection of galvanised steel structures for towers, beams, and
equipment support structures. Towers, beams and equipment support structure,
take off gantry shall be lattice type structure like ISMB; ISLC, Angle section etc
fabricated from structural steel conforming to IS 2062 (latest) and IS: 800.
Support structure for substation equipment shall be designed by the
Contractor/supplier, got it approved by the owner and shall be supplied with
equipment.
The scope shall include supply and erection of all types of structures including
bolts, nuts, washers, hangers, shackles, clamps anticlimbing devices, bird
guards, step bolts, inserts in concrete, gusset plates, equipment mounting bolts,
structure earthing bolts, foundation bolts, spring washers, fixing plates, and any
other items as required to complete the job.
The connection of all structures to their foundations shall be by base plates and
embedded anchor/foundation bolts. All steel structures and anchor/foundation
bolts shall be fully galvanized. The weight of the zinc coating shall be at least
0.610 kg/m2. One additional nut shall be provided below the base plate which
may be used for the purpose of leveling.
Similar type of structures shall be adopted in R&M of existing substation
extension. Contractor must furnish the design, drawings, proto corrected
drawings etc. in support of activities that are to be carried out at site. Contractor
should also visit site to ascertain the amount of activities involved at site before
quoting.
2.0
DESIGN REQUIREMENTS FOR STRUCTURES
2.1
For design of steel structures loads such as dead loads, live loads, wind loads
etc. shall be based on IS: 875,Parts I to V.
2.2
For materials and permissible stresses IS: 802,Part-I, Section-2 for angle section
and for other types (like ISMB, ISLC T-section etc.) IS: 800 shall be followed
in general. However, additional requirements given in following paragraphs
shall be also considered.
2.3
Minimum thickness of galvanized tower member shall be as follows:

Members
Minimum thickness
(mm)
Leg members, Ground wire
Peak members/Main members
Other members
Page 1 of 6
Redundant members
2.4
Maximum slenderness ratios for leg members, other stressed members and
redundant members for compression force shall be as per IS-802 for angle
sections otherwise IS: 800 shall be adopted for ISMB, ISLC, etc.
2.5
Minimum distance from hole center to edge shall be 1.5 x bolt diameter.
Minimum distance between center to center of holes shall be 2.5-x bolt
diameter.
The minimum bolt diameter shall be 12 mm. and welding shall be as per
IS:
816.
2.6
2.7
Step Bolts
In order to facilitate inspection and maintenance, the structures shall be
provided with climbing devices. Each tower shall be provided with step bolts
not less than 16mm diameter & 175mm long spaced not more than 450mm
apart, staggered on faces on one leg extending from about 0.5 meters above
ground level to the top of the tower. The step bolt shall conform to IS: 10238.
Ladders on towers with lighting appliances shall be provided with safety guards.
2.8
Design Criteria
a) All structures shall be designed for the worst combination of dead loads,
superimpose equipment load, live loads, wind loads as per code IS: 875,
seismic forces as per code IS: 1893 (latest), Importance factor of 1.5, loads
due to deviation of conductor, load due to unbalanced tension in conductor,
torsional load due to unbalanced vertical and horizontal forces, erection
loads, short circuit forces. Short circuit forces shall be calculated
considering a fault level of 25.0 kA. IEC-865 may be followed for
evaluation of short circuit forces.
b)
Switchyard gantry structures shall be designed for the two conditions i.e.
normal condition and short circuit condition. In both conditions the
design of all structures shall be based on the assumption that stringing is
done only on one side i.e. all the three (phase) conductors broken on the
other side.
Factor of safety of 2.0 under normal conditions and 1.5 under short
circuit condition shall be considered on all external loads for the design
of switchyard structures which are of lattice i.e. type using angle section.
c)
Vertical load of half the span of conductors/string and the earth wires on
either side of the beam shall be taken into account for the purpose of
design. Weight of man with tools shall be considered as 80 kgs. for the
design of structures.
d)
The distance between terminal gantry and dead end tower shall be taken
as 150 metres. The design of these terminal gantries shall also be
checked considering +/- 15 deg deviation of conductor in both vertical
Page 2 of 6
and horizontal planes. For other gantries the structural layout

requirements shall be adopted in design.
e)
The girders/portals shall be connected with lattice columns by bolted

joints as far as possible.
f)
All support used for supporting equipments shall be designed for the
worst combination of dead loads, erection load, Wind load / seismic
forces, short circuit forces and operating forces acting on the equipment
and associated bus bars as per IS: 806. The material specification shall
be as per IS: 1161 read in conjunction with IS: 806.
g)
Foundation bolts shall be designed for the loads for which the structures
are designed.
3.0
DESIGN DRAWINGS, BILL OF MATETRIALS AND DOCUMENTS
3.1
The Contractor shall furnish design, drawing and BOMs and shop
manufacturing drawings for every member to the Purchaser after award of the
Contract. However, Contractor shall have to prepare and submit any other
drawings, bill of materials (BOM) additionally required during design and
construction stage which the Purchaser feels necessary. In case Purchaser feels
that any design drawing, BOM are to be modified even after its approval,
Contractor shall modify the designs & drawings and resubmit the design
drawing, BOM as required in the specification.
3.2
The fabrication drawings to be prepared and furnished by the Contractor shall

be based on the design approved by the Purchaser or standard drawing
provided. These fabrication drawings shall indicate complete details of
fabrication and erection including all erection splicing details and typical
fabrication splicing details, lacing details, weld sizes and lengths. Bolt details
and all customary details in accordance with standard structural engineering
practice whether or not given by the Purchaser. The fabrication drawings shall
be submitted to the Purchaser. Proto shall be made only after approval of
fabrication drawings.
3.3
The fabrication work shall start only after the final approval to the Fabrication
drawing is accorded by the Purchaser. The design drawing should indicate not
only profile, but section, numbers and sizes of bolts and details of typical joints.
3.4
Such approval shall, however, not relieve the Contractor of his responsibility for
the safety of the structure and good connections and any loss or damage
occurring due to defective fabrication, design or workmanship shall be borne by
the Contractor.
4.0
FABRICATION OF STEEL MEMBERS
4.1
The fabrication and erection works shall be carried out generally in accordance
with IS 802. A reference however may be made to IS 800 in case of nonstipulation of some particular provision in IS 802. All materials shall be
completely shop fabricated and finished with proper connection material and
erection marks for ready assembly in the field.
Page 3 of 6
5.0
PROTO-ASSEMBLY
i)
The component parts shall be assembled in such a manner that they are
neither twisted nor otherwise. In order to minimize distortion in member
the component parts shall be positioned by using clamps, clips, dogs,
jigs and other suitable means and fasteners (bolts and welds) shall be
placed in a balanced pattern. If the individual components are to be bolted, paralleled and tapered drifts shall be used to align the part so that the
bolts can be accurately positioned.
ii)
Sample towers and equipment support structures shall be trial assembled

in the fabrication shop and shall be inspected and cleared by purchaser
based on the approved fabrication drawing before mass fabrication.
Pursuant to above the BOMs along with proto-corrected fabrication
drawings and shop manufacturing drawings for every member shall be
prepared and submitted by the main vendor to Purchaser as document
for information. Such BOM, which shall be duly certified by the main
vendor for its conformity to the approved design, shall be the basis for
Purchaser to carry out inspection.
6.0
BOLTING
i)
ii)
iii)
Every bolt shall be provided with a washer under the nut so that no part
of the threaded portion of the bolt is within the thickness of the parts
bolted together.
All steel items, bolts, nuts and washers shall be hot dip galvanised.
2.0% extra nuts and bolts shall be supplied for erection.
7.0
WELDING
2.7
The work shall be done as per approved fabrication drawings which clearly
indicate various details of joints to be welded, type of weld, length and size of
weld. A symbol for welding on erection and shop drawings shall be according
to IS: 813. Efforts shall be made to reduce site welding so as to avoid improper
joints due to constructional difficulties. Welding shall be done as per IS: 816.
8.0
FOUNDATION BOLTS
8.1
Foundation bolts for the towers and equipment supporting structures and
elsewhere shall be embedded in first stage concrete while the foundation is cast.
The Contractor shall ensure the proper alignment of these bolts to match the
holes in the base plate.
8.2
The Contractor shall be responsible for the correct alignment and leveling of all
steel work on site to ensure that the towers/structures are plumb.
8.3
All foundation bolts for steel structures, pipe structures are to be supplied by the
Contractor.
Page 4 of 6
8.4
All foundation bolts shall be fully galvanised so as to achieve 0.61 kg. per Sq.m.
of Zinc Coating as per specifications.
8.5
All foundation bolts shall conform to IS 5624 but the material, however shall be
MS conforming to IS: 2062.
9.0
STABILITY OF STRUCTURE
The Supplier shall be responsible for the stability of the structure at all stages of
its erection at site and shall take all necessary measures by the additions of
temporary bracings and guying to ensure adequate resistance to wind and also to
loads due to erection equipment and their operations.
10.0
GROUTING
The method of grouting the column bases shall be subject to approval of
Purchaser and shall be such as to ensure a complete uniformity of contact over
the whole area of the steel base. The Contractor will be fully responsible for the
grouting operations. Grouting shall be done only after the erection and
alignment have been checked and approved by the purchaser.
11.0
GALVANISING
11.1
All structural steel works and pipe supports shall be galvanised after fabrication.
11.2
Purity of zinc to be used shall be 99.95% as per IS: 209.
11.3
The Contractor shall be required to make arrangement for frequent inspection

by the Purchaser as well as continuous inspection by a resident representative of
the Purchaser, if so desired for fabrication work.
12.0
TOUCH-UP PAINTING
The touch up primers and paints shall consist of Red Oxide / Zinc chromate
conforming to the requirements of IS: 2074 with a pigment to be specified by
the Purchaser.
13.0
INSPECTION BEFORE DISPATCH

Each part of the fabricated steel work shall be inspected as per approved quality
plans and certified by the Purchaser or his authorized representative as
satisfactory before it is dispatched to the erection site. Such certification shall
not relieve the Contractor of his responsibility regarding adequacy and
completeness of fabrication.
14.0
TEST CERTIFICATE
Copies of all test certificates relating to material procured by the Contractor for
the works shall be forwarded to the Purchaser.
15.0
ERECTION
Page 5 of 6
The Contractor should arrange on his own all plant and equipment, welding set,
tools and tackles, scaffolding, trestles equipments and all other accessories and
ancillaries required for carrying out erection without causing any stresses in the
members which may cause deformation and permanent damage.
16.0
SAFETY PRECAUTIONS
The Contractor shall strictly follow at all stages of fabrication, transportation
and erection of steel structures, raw materials and other tools and tackles, the
stipulations contained in Indian Standard Code for Safety during erection of
structural steel work-IS: 7205.
17.0
GANTRY/PORTAL AND EQUIPMENT SUPPORT STRUCTURES

Structures are to be designed, supplied and erected, as described in preceding
paragraphs, without any extra financial implication to the Purchaser.
18.0
All tests mentioned in standard field quality plans have to be carried out and
conformity of materials and workmanship shall be ascertained.
Page 6 of 6
LIGHTING SYSTEM
1.0
SCOPE
The scope of work comprises of design, engineering, testing, supply, installation, site testing
and commissioning of various lighting fixtures complete with lamps, supports and
accessories, ceiling fans complete with regulators & accessories, lighting panels, lighting
poles complete with distribution boxes, galvanized rigid steel conduits, lighting wires, G.I.
Earth wire, receptacles, switchboards, switches, junction boxes, pull out boxes complete with
accessories.
1.1
All lighting fixtures shall be mounted on the structures and control room buildings and Main
Gate etc.. No tubular lighting poles shall be used for this purpose.
2.0
SYSTEM DESCRIPTION
The lighting system shall comprise of the following:
2.1
AC Normal Lighting
AC lights will be connected to AC lighting panels. All the lights connected to the AC lighting system in different areas will be connected to the main lighting distribution boards to be
supplied.
2.2
D.C. Emergency lighting (For New substation Only)
2.3
A few DC emergency lighting fixtures operated on the DC system will be provided in the
strategic locations including control room, battery room etc. These lights will be normally
'OFF' and will be switched 'ON' automatically when under voltage occurs in the AC main
lighting distribution board. All DC emergency lighting shall be designed for 30 Volt DC
system.
2.4
The Contractor shall install the following under AC normal lighting system for both new
substations and existing substations under R&M:
a) Fluorescent industrial tube lights each having tube light 2 x 36 Watts with reflectors of
make Philips/Crompton/Bajaj as per following details:
i)
Control Room ,Battery Room, Corridor & Landing -6 Nos.
b) In the Switchyard, main gate substation boundaries etc. total eight nos. High pressure
Sodium Vapour lamps of 250 W each (outdoor use) with all fittings and fixtures shall be
installed.
4 nos. on lighting poles and 4 nos. at the locations as directed by the Engineer inCharge
c) One number 18 exhaust fan with louvers shutter shall be provided in the battery room.
d) Four numbers 1400 mm sweep ceiling fan with electronic regulator shall be provided in
control room.
The exact locations of the above fixtures shall be decided during detailed engineering.
2.5
The following specific areas are included in the scope of lighting:

(i) 33 kV switchyard Area.
(ii) Control Room building.
(iii) Battery room
(iv) Street lighting (peripheral) inside switchyard fencing.
Page 1 of 11
2.6
A single line diagram and a detailed drawings showing the lighting layout of these areas shall
be prepared by the Contractor and submitted for approval. The above layout drawings will
include disposition and location of lighting fixtures, receptacles, switchboards, ceiling fan
points, etc. The conduit layout for substation buildings, cable schedule for substation yard
etc. for wiring of this equipment shall also be prepared by the Contractor.
2.7
Each cable and conduit run shall be tagged with number that appears in the cable and conduit
schedules. Cables and conduits shall be tagged at their entrance and/or exit from any piece of
equipment, junction or pull box, floor opening etc. Each cable core shall be properly ferruled
at both ends with high quality PVC ferrules.
2.8
The tag shall be made up of aluminium with the number punched on it and securely attached
to the cable by not less than two turns of 10 SWG G.I. wire. Cable tags shall be rectangular in
shape for power cables and circular shape for control cables.
2.9
Location of cables laid directly under ground shall be indicated clearly by cable marker made
of galvanized iron plate embedded in concrete block. The location of under ground cable
joints if any, shall be clearly indicated with cable marker with an additional inscription "cable
joint".
3.0
DESCRIPTION OF ITEMS
The Contractor shall supply and install the following equipment and accessories in
accordance with the specification.
3.1
Lighting Panels
433V AC lighting panel shall have 433V, 63A, 3 phase 4 wire incomer bus of electrolytic
aluminium, TP MCB with neutral link and 20A, MCB as outgoing feeders with the following
details. These panels are without lighting transformers.
S. No.
Type
Description
ACP-I
Indoor
ACP-2
Outdoor
ACP-3
Details of outgoing feeders

4nos.-20A,single pole MCB.
4nos. - 20A, single pole MCB and

1No., 20A, Triplepole MCB with
Neutral and suitable timer and
contactor for automatic switching.
Outdoor
street 2nos.- 20A, triple pole MCB with
lighting panel
Neutral and suitable timer and
contactor for automatic switching.
timer and contacto
Note: The number of outgoing feeders indicated above are indicative only and to be supplied
as per requirement on approval of purchaser. A composite panel
(combination of
ACP-2 & ACP-3) or only ACP-2 may be accepted during post award engineering if they are
found suitable and suffice the requirement.
3.2
Receptacles
Number
1
3
1
5A, 240V, Outdoor Receptacle

2 pole, 3- pin type
5/15A, 240V, Indoor Receptacle
3-pin type.
63A, 433V, Interlocked switch
socket, outdoor receptacle
Page 2 of 11
3.3
Switch Boards
Decorative type switch-board with switches & receptacle as stated above.
3.4
Conduits and accessories

Galvanized Rigid Steel Conduits of 19mm/25mm/32mm/40mm dia.
3.5
Junction boxes: As per requirement with sufficient spares.
3.6
Lighting poles - Tubler Poles (9 Mtr long)
3.7
Ceiling Fans-1400 mm Sweep with Electronic regulator
4.0
LIGHTING FIXTURES AND ACCESSORIES
4.1
General
All lighting fixtures and accessories shall be designed for continuous operation under
atmospheric conditions existing at site, without reduction in the life or without any
deterioration of materials, internal wiring.
4.2
Temperature Rise
All lighting fixtures and accessories shall be designed to have a low temperature rise
according to the relevant Indian Standards. The design ambient temperature shall be taken as
50 deg.C.
4.3
Supply Voltage
Lighting fixtures and accessories meant for 240V A.C. operation shall be suitable for
operation on 240V A.C. 50Hz, supply voltage variation of 10%, frequency variation of
5% and combined voltage and frequency variation of 10%.
Lighting fixture and accessories meant for 30V DC operation shall be suitable for operation
on 30V DC with variation between 90% to 110% rated voltage.
4.4
Lighting Fixtures
The lighting fixtures shall be Phillips or Bajaj or Crompton Greaves make only. The different
types of lighting fixtures are as indicated in clause 12.6 of this Section.
4.5
All fixtures shall be designed for minimum glare. The finish of the fixtures shall be such that
no bright spots are produced either by direct light source or by reflection.
All lighting fixtures shall be complete with fluorescent tubes / high pressure sodium vapour
lamps as specified and shall be suitably wired up.
All fluorescent lamp fixture shall be complete with all accessories like ballasts, power factor
improvement capacitors, lamps, starters, holders etc.
Sodium vapour lamp fixtures shall be complete with ignitor, ballasts, lamps and holders.
Each lighting fixture shall be provided with an earthing terminal suitable for connection to 16
SWG GI earthing conductors.
All light reflecting surfaces shall have optimum light reflecting co-efficient such as to ensure
the overall light output as specified by the manufacturer.
Height of fixtures should be such that it is easy to replace the lamps with normal ladder/stool.
In case the ceiling height is very high, the fixtures may be placed on the walls for ground
lighting or suspended on steel tubes..
4.6
4.7
4.8
4.9
4.10
4.11
5.0
ACCESSORIES
5.1
Reflectors
The reflectors shall be manufactured from anodised aluminium as applicable of not less than
22 SWG thickness. They shall be securely fixed to the fitting.
5.2
Lamp holders and Starter Holders
Page 3 of 11
5.3
(a)Lamp holders/starter holders for fluorescent tubes shall be of the spring loaded, low
contact resistance, bi-pin rotor type, resistant to wear and suitable for operation at the
specified temperature, without deterioration in insulation value, contact resistance. They shall
hold the lamp/starter in position under normal condition of shock and vibration.
(b)Lamp holders for HPSV lamps shall be of screwed type, manufactured in accordance with
relevant standard and designed to give long and satisfactory service.
Ballasts
a)The Ballasts shall be designed, manufactured and supplied in accordance with relevant
standard and function satisfactorily under site condition specified. The ballasts shall be
designed to have a long service life and low power loss.
b)Ballasts shall be mounted using self locking anti-vibration fixing and shall be easy to
remove without dismantling the fixtures. They shall be totally enclosed units.
c)The ballasts shall be of the inductive, heavy duty type, filled with thermosetting insulating
moisture repellent polyester compound filled under vacuum. The ballast wiring shall be of
copper wire. They shall be free from hum. Ballasts which produce humming sound shall be
replaced free of cost by the Contractor. Ballasts for high pressure HPSV lamps shall be
provided with suitable tapping to set the voltage within the range specified. End connections
and taps shall be brought out in a suitable terminal block, rigidly fixed to the ballast
enclosure.
d)Separate ballast for each lamp shall be provided in case of multi-lamp fixtures.
5.4
Starters
Starters shall have bimetal electrodes and high mechanical strength. Starters shall be
replaceable without disturbing the reflector or lamps and without the use of any tool. Starters
shall have brass contacts and radio interference suppressing capacitor.
5.5
Capacitors
a)The capacitors shall have a constant value of capacitance and shall be connected across the
supply of individual lamp circuits.
b)The capacitors shall be suitable for operation at supply voltage as specified and shall have a
value of capacitance so as to correct the power factors of its corresponding lamp circuit to the
extent of 0.98 lag.
c)The capacitors shall be hermetically sealed in a metal enclosure.
5.6
5.6.1
5.6.2
5.6.3
Lamps
The fluorescent lamps shall be 'Day-light-colour' type unless otherwise specified and shall
also be provided with features to avoid blackening of lamps ends. The Contractor should
clearly state these features in the bid.
High pressure sodium vapour lamps shall be colour corrected type with caps.
Flexible conduits if required, for any fixture shall be deemed to be included in Contractors
scope.
6.0
RECEPTACLES
a)All receptacles shall be of cast steel/aluminum, heavy duty type, suitable for fixing on
wall/column and complete with individual switch.
7.0
SWITCH AND SWITCHBOARD

(a)All switch boards/boxes shall be of bent steel construction, fabricated of 12 SWG sheet
with 6 mm thick bakelite or 3 mm thick Perspex sheet cover.
(b)Switch board/boxes located in office/building areas shall be flush mounted type or brick
wall with only the switch knob projecting outside.
Page 4 of 11
(c)Switch boards/boxes shall have conduit knock outs on both the sides and bottom..
Adequate provision shall be made for ventilation of these boxes.
(d)Flush type receptacles provided shall be so located that only the plug project outside.
(e)Switches shall be of piano key type having quick make and quick-break
complete with position indicator and shall conform to relevant Indian Standard.
mechanism
(f) All the components housed in the switchboard shall be wired to an outgoing terminal
block by 2.5 sq.mm. stranded copper wire The terminal block shall be adequately rated
(g)The exact number of switches including regulator for fans and layout of the same in the
switchboard shall be to suit the requirement during installation.
8.0
CONDUITS & CONDUIT ACCESSORIES
8.1
8.3
The conduits shall conform to IS:9537. All conduits shall be seemed by welding, shall be of
heavy gauge and shall be hot dip galvanized.
Flexible conduits wherever required shall be made with bright, cold rolled annealed and
electro-galvanized mild steel strips.
All conduits accessories shall conform to relevant IS and shall be hot dip galvanized.
9.0
JUNCTION BOXES
9.1
9.2
The junction boxes shall be suitable for mounting on walls, columns, lighting poles,
structures etc..
Junction boxes shall be of square/rectangular type of 1.6 mm sheet steel with minimum 6 mm
thick pressure die cast aluminum material LM-6 and shall have bolted cover with good
quality gasket lining.
9.3
The junction box and cover shall be hot dip galvanized.
9.4
The junction boxes shall be complete with conduit knockouts/threaded nuts and provided
with terminal strips .The junction boxes shall be suitable for termination of conduit/glands of
dia 20 mm, 25 mm, 32 mm, 40 mm on all sides. The junction boxes shall be provided with 4
way terminals suitable for two numbers 10 sq. mm. wire & for street lighting/switchyard
lighting suitable for 2 numbers 4C x 16 Sq.mm Al. cable.
The junction boxes shall have the following indelible markings
(i)
Circuit Nos. on the top.
(ii)
Circuit Nos. with ferrules (inside) as per drawings.
(iii)
DANGER sign in case of 433 volt junction box.
8.2
9.5
9.6
The outdoor junction boxes shall be weather proof type with gaskets conforming to IP-55 as
per IS:13947 (Part-I). The conduit connections shall also be properly sealed to prevent entry
of water. The indoor junction boxes shall conform to IP-52.
10.0
TERMINAL BLOCKS
Each terminal shall be suitable for terminating upto 2 Nos. 10 sq.mm. stranded Aluminum
Conductors without any damage to the conductors or any looseness of connections. Terminal
strips provided in street - lighting poles shall be suitable for terminating upto 2 nos. 4C x 16
sq. mm PVC insulated aluminum cables.
11.0
11.1
PULL OUT BOXES

The pull out boxes shall be suitable for mounting on walls, column, structures etc. The supply
of bolts, nuts and screws required for the erection shall be included in the installation rates.
The pull out boxes shall be circular of cast iron or 16 SWG sheet steel and shall have cover
with good quality gasket lining.
The pull out boxes and cover shall be hot dip galvanized.
11.2
11.3
Page 5 of 11
11.4
11.5
The pull out boxes shall be completed with conduit knock outs/threaded hubs and provided at
approximately 3 meters intervals in a conduit run.
The pull out boxes used outdoor shall be weather proof type with gaskets conforming to IP55 as per IS:13947 (Part-I).
12.0
12.1
LIGHTING PANELS (L.P.)

Each panel shall be provided with one incoming triple pole MCB with neutral link and
outgoing miniature circuit breakers as per clause 3.1. The panels shall conform to IS-8623.
The Outdoor and Street Lighting panels shall be provided with a timer device having twenty
four hour hand set dial with a facility for setting ON & OFF times. The main contacts shall
be rated equal to the rating of main contacts in the incomer. There will be a provision of
selecting either the manual control or the automatic control.
12.2
12.2.0
Constructional Features
Panels shall be sheet steel enclosed and shall be dust, weather and vermin proof. Sheet steel
used shall be of thickness not less than 2.00 mm (cold rolled) or 2.5 mm (hot rolled)
smoothly finished, leveled and free from flaws. Stiffners shall be provided wherever
necessary.
All outdoor panels and panels located in damp atmosphere shall have degree of protection not
less than IP-55 as per IS:13947 / (Part-I). All indoor panels shall have degree of protection
not less than IP-52 as per IS:13947 (Part-I).
The panels shall be of single front construction, front hinged and front connected, suitable for
either floor mounting on channels, sills or on walls/columns by suitable M.S. brackets.
Panels shall have a dead front assembly provided with hinged door(s) with padlocking
arrangement with single key supplied in duplicate.
All doors, removable covers and plates shall be gasketed all around with neoprene gaskets.
The panels shall be suitable for cable/conduit entry from the top and bottom. Suitable
removable cable gland-plate shall be provided on the top and bottom of panels. Necessary
number of double compression cable gland shall be supplied, fitted on to this gland plate.
The glands shall be screwed type and made of tinned brass.
The panels shall be so constructed as to permit free access to connection of terminals and
easy replacement of parts.
Each panel shall have a caution notice fixed on it.
Each panel shall be provided with a circuit directory plate (of anodized aluminium with the
inscriptions indelibly etched on the plate) which is fitted on the inside of the door.
Each lighting panel shall be provided with one no. ON indicating lamp for each phase
alongwith fuses.
12.2.1
12.2.2
12.2.3
12.2.4
12.2.5
12.2.6
12.2.7
12.2.8
12.2.9
12.3
12.4
12.5
Main Bus Bars

Bus bars shall be of aluminium alloy conforming to IS:5082 and shall have adequate crosssection to carry the rated continuous and withstand short circuit currents. Maximum
operating temperature of the bus bars shall not exceed 85 deg. C. The bus bars shall be able
to withstand a fault level of 9 kA for 1 sec. for AC panels and 4 KA for 1 sec. for DC panels.
Miniature Circuit Breaker (MCB)
a)
The miniature circuit breakers shall be suitable for manual closing, opening, automatic
tripping under overload and short circuit. The MCBs shall also be trip free.
b)
Single pole as well as three pole versions shall be furnished as required in the Schedule
of Lighting Panels.
c)
The MCBs shall be suitable for housing in the lighting panels and shall be suitable for
connection with stranded copper wire connection at the outgoing side by copper lugs.
For bus bar connection on the incoming side aluminium alloy strips shall be used..
d)
The terminals of the MCBs and the open close and trip conditions shall be clearly
and indelibly marked.
e)
The MCB shall generally conform to IS:8828.
Contactors
Contactors shall be of the full voltage, direct-on line air break, single throw, electro-magnetic
type. They shall be provided with atleast 2-NC and 2NO auxiliary contacts. Contactor
Page 6 of 11
12.6
12.7
shall be provided with the three element, positive acting, ambient temperature compensated
time lagged, hand reset type thermal overload relay with adjustable settings to suit the rated
current. Hand reset button shall be flush with the front of the cabinet and suitable for
resetting with starter compartment door closed. The contractor shall check the adequacy of
the Contactors rating wire with respect to lighting load.
Lighting Fixtures
S.No.
Type
Description
FC
SC
FI
SFI
IB
FF
FL
2x36W fluorescent lamp in

corrosion proof fixture consisting
of a canopy made
of fibre glass reinforced polyester (FRP)
with gasket a gear tray made of sheet steel and a reeded acrylic
cover fixed by toggle clips, similar to philips Cat.
No.TDC-10/236/ Bajaj Cat. No.BJI-236 G/ Crompton
Greaves
Cat No I FC-1124
HSB.
150W SON-T Tubular Sodium Vapour lamp in street lighting
luminare. A special optical
reflector clear acrylic cover, a
single piece die cast aluminium housing made out of LM6 and
corrosion resistance proof.
Similar to Philips Cat No. SRP-51
and Bajaj Cat No. BJMSC/150 / Crompton Greaves.
Cat No.
SSG 1515H .
2x36W fluorescent lamps in industrial reflector type fixture.
complete with accessories
and
suitable
for
pendent
Mounting, similar to Philips
Cat. No. TKC 24/236/Bajaj
Cat. No. : BJIV-236 /Crompton Greaves Cat No. 1VE 1224 HSB.
Whether proof integral Floor Lighting with housing made of
corrosion resistant die cast aluminium painted black. Grey powder
coated outside suitable for 150WSON-T lamp complete with all
accessories and suitable for termination with conduits/flexible Cat.
No. F69045 (C).Similar to Philips Cat. No.SNT 100/Bajaj Cat. No.
BGEMF-150W SV Crompton Greaves Cat No. FAD
11151H
9W CFL lamp in Bulkhead fixtures with Cast Aluminium alloy
body, suitable for column, wall and ceiling mounting finished
stove enamelled silver grey outside white inside, to be supplied
complete (preset front glass, wire guard, tropicalised, gasket and
E.S. Porcelain, lamp holder taped 3/4" E.T. for conduit entry)
similar to Philips Cat.No.FXC 101/ Bajaj Cat.No. BJBE19/Crompton Greaves.
2x36W fluorescent lamp with mirror optics in recessed mounting
type decorative fluorescent
fitting consisting of white stove
enamelled sheet steel housing with accessories and reflector
of aluminium sheet steel duty electro-chemically brightened
and anodised fitted with aluminium lamellae painted white.
Similar to Philips Cat.No.TBS-285/236 and Bajaj Cat.No. BJLM236/ Crompton Greaves Cat. No. CRFA 24 HSB
2x36W flourescent lampsin decorative lighting fixturewith
widespread mirror optics suitable for pendent mounting with twin
tube complete wit all accessories : similar to philips cat-No. TCS31/236and Bajaj Cat.No. BJSM-236/Crompton Greaves Cat
No.CSB W 1124 HSB.
Labels
a)The lighting panels shall be provided on the front with panel designation labels on a 3 mm
thick plastic plate of approved type. The letter shall be black engraved on white back ground.
Page 7 of 11
b)All incoming and outgoing circuits shall be provided with labels. Labels shall be made of
non-rusting metal or 3 ply lamicold. Labels shall have white letters on black or dark blue
background.
12.8
Earthing Terminals
12.8.1
Panels shall be provided with two separate and distinct earthing terminals suitable to receive
the earthing conductors of size 50x6 G.S. Flat.
12.9
Testing
All lighting panels shall have to be tested for the following items and test certificates shall be
furnished for the same:
(i) Wiring continuity test
(ii) High voltage (2.5 KV for 1 minute) and insulation resistance test
(iii) Operational test
(iv) Degree of protection
(v) Heat run test
13.
Not Used
14.
CEILING FANS AND REGULATORS
14.1
The contractor shall supply and install 1400 mm sweep ceiling fans complete with electronic
regulator and switch, suspension rod, canopy and accessories.
14.2
The contractor shall supply and install the switch and electronic regulator.
14.3
Winding of the fans and regulators shall be insulated with Class-E insulating material.
Winding shall be of copper wire.
14.4
Electronic regulator with smooth control shall be provided.
14.5
Fans and electronic regulators shall be of Crompton Greaves/Bajaj Electricals/Usha

Electricals make.
15.
LIGHTING WIRES
15.1
The wiring used for lighting shall be 1100 V grade, PVC insulated cables of reputed
manufacturers.
15.2
The conductor sizes for wires used for point wiring beyond lighting panels shall be single
core 2.5 sq.mm, 4 sq.mm and 6 sq.mm stranded copper wire of 1100V grade flexible PVC
insulated cords, unsheathed, conforming to IS:694.
15.3
The wires used for connection of a lighting fixture from a nearest junction box or for loop-in
loop-out connection between two fluorescent fixtures shall be single core copper stranded
conductor, with nominal conductor cross sectional areas of 2.5 sq. mm.
The wiring from ACDB to lighting panel shall be with 4x25 sq.mm. aluminium core 1100
volt grade cable.
15.4
15.5
The wires shall be colour coded as follows:

Red for R - Phase
Yellow for Y - Phase
Blue for B - Phase
Page 8 of 11
Black for Neutral

White for DC (Positive)
Grey for DC (Negative)
15.6
The wiring for outdoor steel tubular poles shall be done by 2x10 sq.mm. PVC armoured
aluminium core cable, 1100 V grade conforming to IS 1554. They shall run from LT ACDB
to an outdoor lighting panel and then to the junction boxes of the poles in trenches and laid
direct in ground.
15.7
PAINTING OF SHOP MADE ITEMS
15.7.1
All sheet steel work shall be phosphated in accordance with the procedure in IS:6005 'Code
of Practice for Phosphating Iron and Steel'.
Rust and scale shall be removed by pickling with dilute acid followed by washing with
running water, rinsing with slightly alkaline hot water and drying.
After phosphating through rinsing shall be carried out with clean water, followed by final
rinsing with diluted dichromate solution and oven drying.
The phosphate coating shall be sealed by the application of two coats of ready mixed stoving
type metal primer (comprising of red oxide and Zinc chromate in a synthetic medium). The
first coat may be 'flash dried' while the second coat shall be stoved.
After application of the primer, two coats of finishing synthetic enamel paint shall be applied
with each coat followed by stoving. The second finishing coat for the external of panels shall
be applied after completion of tests.
Both outside and inside of lighting panel, sheet metal fabricated junction boxes etc. and
outside of lighting fixtures shall be finished in light gray (IS-5 shade 631). Inside of lighting
fixtures, boxes and boards shall be finished in white.
Each coat of primer and finishing paint shall be of slightly different shade so as to enable
inspection of the painting.
The final finished thickness of paint film on steel shall not be less than 100 microns and shall
not be more than 150 microns.
Finished painted appearance on equipment shall present an aesthetically pleasing appearance,
free from dents and uneven surfaces.
15.7.2
15.7.3
15.7.4
15.7.5
15.7.6
15.7.7
15.7.8
15.7.9
16.0
TESTS AND TEST REPORTS

All the items covered under this section should be type tested, design, conforming to the
relevant standard.
17.0
LIGHTING SYSTEM INSTALLATION WORKS
17.1
General
17.1.1
In accordance with the specified installation instructions as shown on manufacturers
drawings or as directed by Owner, Contractor shall unload, erect, install, test and put into
commercial use all the electrical equipment included in the contract. Equipment shall be
installed in a neat, workmanship manner so that it is level, plumb square and properly aligned
and oriented. Tolerances shall be as established in manufacturers drawing or as stipulated by
Owner.
17.1.2
All apparatus, connections and cabling shall be designed so as to minimise risk of fire or any
damage which will be caused in the event of fire.
17.2
17.2.1
Conduit System
Contractor shall supply, store and install conduits required for the lighting installation as
specified. All accessories/fittings required for making the installation complete, including but
not limited to pull out boxes (as specified in specification.ordinary and inspection tees and
elbow, checknuts, male and female bushings (brass or galvanised steel), caps, square headed
make plugs, nipples, gland sealing fittings, pull boxes, conduits terminal boxes, glands,
gaskets and box covers, saddle terminal boxes, and all steel supporting work shall be supplied
by the Contractor. The conduit fittings shall be of the same material as conduits.
Page 9 of 11
17.2.2
17.2.3
17.2.4
17.2.5
17.2.6
17.2.7
17.2.8
17.2.9
17.2.10
17.2.11
17.2.12
17.3
17.3.1
17.3.2
17.3.3
17.3.4
17.3.5
17.3.6
17.3.7
17.3.8
17.3.9
17.3.10
17.4
17.4.1
17.4.2
17.5
17.5.1
17.5.2
All unarmoured cables shall run within the conduits from lighting panels to lighting fixtures,
receptacles. etc.
Size of conduit shall be suitably selected by the Contractor.
Conduit support shall be provided at an interval of 750 mm for horizontal runs and 1000 mm
for vertical runs.
Conduit supports shall be clamped on the approved type spacer plates or brackets by saddles
or U-bolts. The spacer plates or brackets in turn, shall be securely fixed to the building steel
by welding and to concrete or brick work by grouting or by nylon rawl plugs. Wooden plug
inserted in the masonary or concrete for conduit support is not acceptable.
Where conduits are alongwith cable trays they shall be clamped to supporting steel at an
interval of 600 mm.
For directly embedding in soil, the conduits shall be coated with an asphalt-base compound.
Concrete pier or anchor shall be provided wherever necessary to support the conduit rigidly
and to hold it in place.
For long conduit run, pull boxes shall be provided at suitable intervals to facilitate wiring.
Conduit shall be securely fastened to junction boxes or cabinets, each with a lock nut inside
and outside the box.
Conduits joints and connections shall be made through water-tight and rust proof by
application of a thread compound which insulates the joints. White lead is suitable for
application on embedded conduit and red lead for exposed conduit.
The entire metallic conduit system, whether embedded or exposed, shall be electrically
continuous and thoroughly grounded. Where slip joints are used, suitable bounding shall be
provided around the joint to ensure a continuous ground circuit.
Conduits and fittings shall be properly protected during construction period against
mechanical injury. Conduit ends shall be plugged or capped to prevent entry of foreign
material.
Wiring
Wiring shall be generally carried out by PVC wires in conduits. All wires in a conduit shall
be drawn simultaneously. No subsequent drawings of wires is permissible.
Wires shall not be pulled through more than two equivalent 90 deg. bends in a single conduit
run. Where required, suitable junction boxes shall be used.
Wiring shall be spliced only at junction boxes with approved type terminal strip.
For lighting fixtures, connection shall be teed off through suitable round conduit or junction
box, so that the connection can be attended without taking down the fixture.
For vertical run of wires in conduit, wires shall be suitably supported by means of
wooden/hard rubber plugs at each pull/junction box.
Maximum two wires can be terminated to each way of terminal connections.
Separate neutral wires are to be provided for each circuit.
AC and DC wiring should not run through the same conduit.
Outdoor wiring shall be by armoured cable laid in trenches or directly in ground.
Wiring from LT ACDB to lighting panels shall be laid in trenches.
Lighting Panels
The lighting panels shall be erected at the locations to be finalised during detailed
engineering.
Suitable foundations/supporting structures for all outdoor type lighting panels and necessary
supporting structures for indoor lighting panels shall be provided by the Contractor.
Foundation & civil works
Foundation for street lighting poles and panel foundation and transformer foundation shall be
done by the Contractor. The rates for these civil works shall be included in the erection rates
of respective items.
All final adjustment of foundation levels, chipping and dressing of foundation surfaces,
setting and grouting of anchor bolts, sills, inserts and flastening devices shall be carried out
by the Contractor including minor modification of civil works as may be required for
erection.
Page 10 of 11
17.5.3
Any cutting of masonary/concrete work, which is necessary shall be done by the Contractor
at his own cost and shall be made good to match the original work.
Page 11 of 11
CEMENT CONCRETE POLES FOR 11KV & LT

OVERHEAD POWER LINES TECHNICAL
SPECIFICATION FOR PRESTRESSED
1.0
PSC Poles
PSC poles shall be of solid rectangular type with an overall length of
8.0 M & 9.0M suitable for use in 11 KV overhead power lines, LT
power lines and double pole structures associated with the lines and
for 11/0.4 KV substations. The poles shall be designed for the
working load of 200/400 Kg.
2.0
Applicable Standards
Except when they conflict with specific requirements in this
Specification, the PSC poles shall comply with the relevant
provisions made in the following Indian Standards or the latest
versions thereof.
3.0
a)
IS: 1678, Specification for prestressed concrete poles for

overhead power, traction and telecommunication lines.
b)
IS : 2905, Method of test for concrete poles for overhead

power and telecommunication lines.
c)
IS: 7321, Code of Practice for selection, handling and erection

of concrete poles for overhead power and telecommunication
lines.
Terminology
For the purpose of this specification, following definitions shall
apply:-
3.1
Average Permanent Load

That fraction of the working load which may be considered of long
duration over a period of one year.
3.2
Load Factor
The ratio of ultimate transverse load to the transverse load at first
crack.
3.3
Transverse
The direction of the line bisecting the angle contained by the
conductor at the pole. In the case of a straight run, this will be normal
to the run of the line.
Page 1 of 11
3.4
Transverse Load at First Crack

For design, the transverse load at first crack shall be taken as not less
than the value of the working load.
3.5
Working Load
The maximum load in the transverse direction, that is ever likely to
occur, including the wind pressure on the pole. This load is assumed
to act at a point 600mm below the top with the butt end of the pole
planted to the required depth as intended in the design.
3.6
Ultimate Failure
The condition existing when the pole ceases to sustain a load
increment owing to either crushing of concrete, or snapping of the
prestressing tendon or permanent stretching of the steel in any part of
the pole.
3.7
Ultimate Transverse Load

The load at which failure occurs, when it is applied at a point 600 mm
below the top and perpendicular to the axis of the pole along the
transverse direction with the butt end of the pole planted to the
required depth as intended in the design.
4.0
Application
4.1
8.0 M Poles
These poles shall be used for 11KV & L.T. lines and in double pole
structures of Distribution Transformers in wind pressure zones of 50
kg/M2, 75 kg/M2 and 100 kg/M2 in accordance with REC
Construction Standards no. A-5 & B-6.
4.2
9.0 and more than 9 M Poles

These poles may be used for double pole structures of distribution
transformers, on both side of various crossings to maintain necessary
clearances, wherever required, as per REC Construction Standards F-2
to F-4 and for special locations in 11 KV and L.T. Lines, such as road
crossings etc.
5.0
Material
5.1
Cement
The cement used in the manufacture of prestressed concrete poles shall
be ordinary or rapid hardening Portland cement conforming to IS: 269 -
Page 2 of 11
1976 (Specification for ordinary and low heat Portland cement) or IS :

8041 E-1978 (Specification for rapid hardening Portland cement).
5.2
Aggregates
Aggregates used for the manufacture of pre-stressed concrete poles shall
confirm to IS : 383 (Specification for coarse and fine aggregates from
natural sources for concrete). The nominal maximum size of aggregates
shall in no case exceed 12 mm .
5.3
Water
Water should be free from chlorides, sulphates, other salts and organic
matter. Potable water will be generally suitable.
5.4
Admixture
Admixture should not contain Calcium Chloride or other chlorides and
salts which are likely to promote corrosion of pre-stressing steel. The
admixture shall conform to IS 9103.
5.5
Pre-Stressing Steel
The pre-stressing steel wires including those used as untensioned wires
should conform to IS: 1785 (Part-I) (Specification for plain hard-drawn
steel wire for prestressed concrete, Part-I cold drawn stress relieved
wire), IS: 1785 (Part-II) (Specification for plain hard-drawn steel wire) or
IS:6003 (Specification for indented wire for prestressed concrete). The
type designs given in the annexure are for plain wires of 4 mm diameter
with a guaranteed ultimate strength of 175 kg/mm2 and for plain wires of
5 mm diameter with a guaranteed ultimate strength of 160 kg/mm2.
All prestressing steel shall be free from splits, harmful scratches, surface
flaws, rough, aged and imperfect edges and other defects likely to impair
its use in prestressed concrete.
5.6
Concrete Mix
The concrete mix shall be designed to the requirements laid down for
controlled concrete (also called design mix concrete) in IS : 1343 1980 (Code of practice for prestressed concrete) and IS : 456 - 1978
(Code of practice for plain and reinforced concrete), subject to the
following special conditions;
a)
b)
Minimum works cube strength at 28 days should be at least 420

Kg/cm2.
The concrete strength at transfer should be at least 210
Kg/cm2.
Page 3 of 11
6.0
c)
The mix should contain at least 380 Kg. of cement per cubic
meter of concrete.
d)
The mix should contain as low a water content as is consistent

with adequate workability. If it becomes necessary to add water
to increase the workability, the cement content also should be
raised in such a way that the original value of water cement ratio
is maintained.
Design Requirements
The poles shall be designed for the following requirements:
a)
The poles shall be planted directly in the ground with a planting

depth as per IS : 1678. Wherever, planting depth is required to
be increased beyond the specified limits or alternative
arrangements are required to be made, on account of ground
conditions e.g. water logging etc., the same shall be in the scope
of the bidder at no extra cost to owner. The bidder shall furnish
necessary design calculations/details of alternative arrangements
in this regard.
b)
The working load on the poles should correspond to those that

are likely to come on the pole during their service life.
c)
The factor of safety for all poles 9.0 Mts. and above shall not be
less than 2.0 and for 8.0 M poles, the factor of safety shall not be
less than 2.5.
d)
The average permanent load shall be 40% of the working load.
e)
The F.O.S. against first load shall be 1.0.
f)
At average permanent load, permissible tensile stress in concrete

shall be 30 kg/cm2.
g)
At the design value of first crack load, the modulus of rupture

shall not exceed 53.0 kg/cm2 for M-40.
h)
The ultimate moment capacity in the longitudinal direction

should be at least one fourth of that in the transverse direction.
i)
The maximum compressive stress in concrete at the time of

transfer of pre-stress should not exceed 0.8 times the cube
strength.
j)
The concrete strength at transfer shall not be less than half, the
28 days strength ensured in the design, i.e. 400 x 0.5 =
200kg/cm2.
For model check calculations on the design of poles, referred to in

the annexure, a reference may be made to the REC Manual on
Manufacturing of solid PCC poles, Part-I - Design Aspects
Page 4 of 11
6.1
Dimensions and Reinforcements

The cross-sectional dimensions and the details of pre-stressing wires
should conform to the particulars given in the annexure.
The provisions of holes for fixing cross-arms and other fixtures
should conform to the REC specification No. 15/1979.
6.2
Manufacture
6.2.1
All pre-stressing wires and reinforcements shall be accurately fixed as

shown in drawings and maintained in position during manufacture.
The untensioned reinforcement, as indicated in the drawings, should
be held in position by the use of stirrups which should go round all
the wires.
6.2.2
All wires shall be accurately stretched with uniform prestress in each

wire. Each wire or a group of wires shall be anchored positively
during casing. Care should be taken to see that the anchorages do not
yield before the concrete attains the necessary strength.
6.3
Cover
The cover of concrete measured from the outside of pre-stressing
tendon shall be normally 20 mm.
6.4
Welding and Lapping of Steel

The high tensile steel wire shall be continuous over the entire length
of the tendon. Welding shall not be allowed in any case. However,
jointing or coupling may be permitted provided the strength of the
joint or coupling is not less than the strength of each individual wire.
6.5
Compacting
Concrete shall be compacted by spinning, vibrating, shocking or other
suitable mechanical means. Hand compaction shall not be permitted.
6.6
Curing
The concrete shall be covered with a layer of sacking, canvass,
hessian or similar absorbent material and kept constantly wet up to
the time when the strength of concrete is at least equal to the
minimum strength of concrete at transfer of prestress. Thereafter, the
pole may be removed from the mould and watered at intervals to
prevent surface cracking of the unit, the interval should depend on the
atmospheric humidity and temperature.
The prestressing wires shall be de-tensioned only after the concrete
has attained the specified strength at transfer (i.e. 200 or 210 kg/cm2,
Page 5 of 11
as applicable). The cubes cast for the purpose of determining the

strength at transfer should be cured, as far as possible, under
conditions similar to those under which the poles are cured. The
transfer stage shall be determined based on the daily tests carried out
on concrete cubes till the specified strength indicated above is
reached. Thereafter the test on concrete shall be carried out as
detailed in IS : 1343 (Code of practice for prestressed concrete). The
manufacturer shall supply, when required by the owner or his
representative, result of compressive test conducted in accordance
with IS : 456 (Code of practice for plain and reinforced concrete) on
concrete cubes made from the concrete used for the poles. If the
owner so desired, the manufacturer shall supply cubes for test
purposes and such cubes shall be tested in accordance with IS : 456
(Code of practice for plain and reinforced concrete).
The detensioning shall be done by slowly releasing the wires, without
imparting shock or sudden load to the poles. The rate of detensioning
may be controlled by any suitable means either mechanical (screw
type) or hydraulic.
The poles shall not be detensioned or released by cutting the
prestressing wires using flames or bar croppers while the wires are
still under tension.
6.7
Lifting Eye-Hooks or Holes

Separate eye-hooks or holes shall be provided for handling the
transport, one each at a distance of 0.15 times the overall length, from
either end of the pole. Eye-hooks, if provided, should be properly
anchored and should be on the face that has the shorter dimension of
the cross-section. Holes, if provided for lifting purposes, should be
perpendicular to the broad face of the pole.
6.8
Holes for Cross Arms etc

Sufficient number of holes shall be provided in the poles for
attachment of cross arms and other equipments.
7.0
Stacking & Transportation

Stacking should be done in such a manner that the broad side of the
pole is vertical. Each tier in the stack should be supported on timber
sleeper located as 0.15 times the overall length, measured from the
end. The timber supported in the stack should be aligned in a vertical
line.
Poles should be transported with their broad faces placed vertically
and in such a manner that shocks are avoided. Supports should be so
arranged that they are located approximately at a distance equal to
0.15 times the overall length from the ends. The erection of the pole
Page 6 of 11
should be carried out in such a way that the erection loads are applied
so as to cause moment with respect to the major axis, i.e. the rope
used for hoisting the pole should be parallel to the broader face of the
pole.
8.0
Earthing
8.1
Earthing shall be provided by having length of 8 SWG GI wire

embedded in concrete during manufacture and the ends of the wires
left projecting from the pole to a length of 100mm at 250 mm from
top and 150 mm below ground level.
8.2
Earth wire shall not be allowed to come in contract with the

prestressing wires.
9.0
Tests
9.1
Transverse Strength Test
9.1.1
Poles made from ordinary Portland cement shall be tested only on the
completion of 28 days and poles made from rapid hardening cement
only on the completion of 14 days, after the day of manufacture.
9.1.2
The poles may be tested in either horizontal or vertical position. If

tested in horizontal position, provisions shall be made to compensate
for the overhanging weight of the pole, for this purpose, the
overhanging portion of the pole may be supported on a movable
trolley or similar device.
9.1.3
The pole shall be rigidly supported at the butt end for a distance equal
to the agreed depth of planting
9.1.4
Load shall be applied at a point 600 mm from the top of the pole and
shall be steadily and gradually increased to the design value of the
transverse load at first crack. The deflection at this load shall be
measured.
9.1.5
A prestressed concrete pole shall be deemed not to have passed the

test if cracks wider than 0.1 mm appear at a stage prior to the
application of the design transverse load at first crack and the
observed ultimate transverse load is less than the design ultimate
transverse load.
9.1.6
The load shall then be reduced to zero and increased gradually to a

load equal to the first crack load plus 10% of the minimum ultimate
transverse load, and held up for 2 minutes. This procedure shall be
repeated until the load reaches the value of 80 per cent of the
minimum ultimate transverse load and thereafter increased by 5 per
cent of the minimum ultimate transverse load until failure occurs.
Each time the load is applied, it shall be held for 2 minutes. The load
Page 7 of 11
applied to prestressed concrete pole at the point of failure shall be

measured to the nearest five Kilograms.
9.1.7
The pole shall be deemed not to have passed the test if the observed
ultimate transverse load is less than the design ultimate transverse
load.
9.2
Measurement of Cover
9.2.1
After completion of the transverse strength test, the sample pole shall
be taken and checked for cover. The cover of the pole shall be
measured at 3 points, one within 1.8 meter from the butt end of the
pole, the second within 0.6 meters from the top and the third at an
intermediate point and the mean value compared with the specified
value.
9.2.2
The mean value of the measured cover should not differ by more than
(+) 1 mm from the specified cover. The individual values should not
differ by more than (+) 3 mm from the specified value.
9.2.3
If these requirements are not met, the workmanship with reference to

aligning of the end plates and prestressing wires and assembly of
moulds should be improved and inspection at pre-production stage
tightened suitably.
10.0
Sampling and Inspection
10.1
Scale of Sampling
10.1.1
Lot: In any batch, all poles of the same class and same dimensions
shall be grouped together to constitute a lot.
10.1.1
Sub-lot: If the number of poles in a lot exceed 500, the lot shall be
divided into a suitable number of sub lots such that the number of
poles in any sub-lot shall not exceed 500.
Page 8 of 11
The acceptance or
otherwise of a sub-lot shall be determined on the basis of the

performance of samples selected from it.
10.1.2
The number of poles to be selected from a lot or a sub-lot shall

depend upon its size and shall be in accordance with Col.1 and 2 of
the following table:
SAMPLE SIZE AND CRITERION FOR CONFORMITY
Size
of lot or sub-lot
Dimensional Requirement
Sample Size
No. of poles
for transverse
Permissible No. strength test
of
defective
samples
Upto 100
10
101 to 200
15
201 to 300
20
301 to 500
30
*The number of poles to be tested shall be subject to the agreement

between the owner and supplier.
10.1.3
These poles shall be selected at random. In order to ensure

randomness, all the poles in the lot or the sub-lot may be arranged in a
serial order and starting from any random pole, every rth pole may be
included in the sample, r being the integral part of N/n where N is the
size of the lot or the sub-lot and n is the sample size.
10.2
Number of Tests
10.2.1
All the poles as selected in 10.1.3 shall be tested for overall length,
cross-section and uprightness. The tolerance shall be (+) 15 mm on
overall length (+), 3 mm on cross sectional dimensions and 0.5 per
cent on uprightness.
10.2.1
The number of poles to be tested for transverse strength test shall be

accordance with Col. 4 of the above table. These poles may be
selected from those already tested in 10.2.1
10.3
Criteria for Conformity
10.3.1
A lot or sub-lot shall be considered as conforming to this specification

if the conditions under 10.3.2 and 10.3.2 are satisfied.
Page 9 of 11
10.3.2
The number of poles which does not satisfy the requirements of

overall length, cross-section and uprightness shall not exceed the
corresponding number given in Col.3 of Table in 10.1.2. If the
number of such poles exceeds the corresponding number, all poles in
the lot or sub-lot shall be tested for these requirements and those not
satisfying the requirements shall be rejected.
10.3.3
All the poles tested for transverse strength test shall satisfy the
requirements of the test. If one or more poles fail, twice the number
of poles originally tested shall be selected from those already selected
and subjected to the test. If there is no failure among these poles, the
lot or the sub-lot shall be considered to have satisfied the
requirements of this test.
11.0
Marking
The following marking should be given of the poles during its casting
at 3 meters height from bottom:Sr. no.
Particulars
FEEDER SEGREGATION
Name of agency
Month and year of manufacture
Transverse strength of pole in Kg
Makers serial No. and mark
Coloured indelible depth marker at 1.5 Meters from bottom

to verify planting depth
.
12.0
Drawings
12.1
The drawings submitted by the Contractor shall be

approved/commented by the Owner as the case may be within thirty
(30) days of receipt of drawings in Owner's design office. If the
designs/drawings are commented by the Owner, the Contractor shall
submit revised design/drawings duly incorporating all comments
within fifteen (15) days of date of issue of comments.
12.2
Pole accessories drawings like name plate, danger plate, anti-climbing

device etc. shall be prepared by the Contractor and submitted to the
Owner in three copies alongwith one re-producable, for record. These
drawings shall be prepared in A4 size only.
Page 10 of 11
12.3
While submitting the drawings, the Contractor shall clearly indicate on

each drawing Specification No., Name of the line, letter reference no.
and date on which the submission are made. The same practice is also
to be followed while submitting distribution copies.
12.4
The Contractor shall furnish the drawings in six(6) copies to the

Owner for necessary distribution within fifteen (15) days after the
receipt of the approval from the Owner.
Page 11 of 11
POWER AND CONTROL CABLES

1 .0
1.1 KV GRADE POWER & CONTROL CABLES
1.0.1
CRITERIA FOR SELECTION OF POWER & CONTROL CABLES
1.0.1.1
Stranded Aluminium conductor PVC insulated armoured cables shall be used for
main power supply purpose from LT Aux. Transformers to ACDB, between
distribution boards and for various other applications in switchyard area and control
room except for control/protection purposes.
1.0.1.2
For all control/protection/instrumentation purposes PVC insulated armoured control

cables of minimum 2.5 sq.mm. size with stranded Copper conductors shall be used.
1.0.1.3
Sizing of power cables shall be done keeping in view the continuous current,
voltage drop & short-circuit consideration of the system. Relevant calculations shall
be submitted by the contractor during detailed engineering for purchasers
approval.
1.0.1.4
Cables shall be laid conforming to IS:1255.
1.0.1.5
While preparing cable schedules for control/protection purpose following shall be

ensured:
1.0.1.6
Separate cables shall be used for AC & DC.
For different cores of CT & VT separate cable shall be used.
At least one (1) core shall be kept as spare in each copper control cable of
4C, 5C or 7C size whereas minimum no. of spare cores shall be two (2)
for control cables of 10 core or higher size.
For control cabling, including CT/VT circuits, 2.5 sq.mm. size copper cables shall
be used per connection. However, if required from voltage drop/VA burden
consideration additional cores shall be used. Further for potential circuits of energy
meters separate connections by 2 cores of 2.5sq.mm. size shall be provided.
2.0
TECHNICAL REQUIREMENTS
2.0.1
General
2.0.1.1
2.0.1.2
The cables shall be suitable for laying in racks, ducts, trenches, conduits and
underground-buried installation with uncontrolled back fill and chances of flooding
by water.
The XLPE insulated cables shall be capable of withstanding a conductor
temperature of 250C during a short circuit without any damage. The PVC
insulated cables shall be capable of withstanding a conductor temperature of 160C
during a short circuit.
Page 1 of 3
2.0.1.3
The Aluminium / Copper wires used for manufacturing the cables shall be
electrolytic grade and true circular in shape before stranding and shall be uniformly
good quality, free from defects. All aluminium used in the cables shall be of H2
grade.
2.0.1.4
The fillers and inner sheath shall be of non-hygroscopic, fire retardant material,
shall be softer than insulation and outer sheath shall be suitable for the operating
temperature of the cable.
Progressive sequential marking of the length of cable in meters at every one metre
shall be provided on the outer sheath of all cables.
2.0.1.5
2.0.1.6
Strip wire armouring following method (a) mentioned in the relevant ISS shall not
be accepted for any of the cables. For control cables only round wire armouring
shall be used.
2.0.1.7
The cables shall have outer sheath of a material with an oxygen index of not less
than 29 and a temperature index of not less than 250C.
2.0.1.8
All the cables shall pass fire resistance test as per IS: 1554 (Part-I)
2.0.1.9
The normal current rating of all PVC insulated cables shall be as per IS: 3961.
Repaired cables shall not be accepted.
2.0.1.10 Allowable tolerance on the overall diameter of the cables shall be plus or minus 2
mm.
3.0
XLPE Power Cables
3.0.1
The XLPE insulated cables shall be of FR type, C1 category conforming to IS:

7098 (Part-I) and its amendments read along with this specification. The conductor
shall be stranded aluminium circular/sector shaped and compacted. In multicore
cables, the core shall be identified by red, yellow, blue and black coloured strips or
colouring of insulation. A distinct inner sheath shall be provided in all multicore
cables. For XLPE cables, the inner sheath shall be of extruded PVC to type ST-2 of
IS: 5831. When armouring is specified for single core cables, the same shall consist
of aluminium wires/strips. The outer sheath shall be extruded PVC to Type ST-2 of
IS:5831 for all XLPE cables.
4.0
PVC Power Cables
4.0.1
The PVC (70C) insulated 1100V grade power cables shall be of FR type, C1
category, conforming to IS: 1554 (Part-I) and its amendments, read along with this
specification and shall be suitable for a steady conductor temperature of 70C. The
conductor shall be stranded aluminium. The Insulation shall be extruded PVC to
type-A of IS: 5831. A distinct inner sheath shall be provided in all multicore
cables. For multicore armoured cables, the inner sheath shall be of extruded PVC.
The outer sheath shall be extruded PVC to Type ST-1 of IS: 5831 for all cables.
5.0.
PVC Control Cables
5.0.1
The 1100 grade control cables shall be of FR type C1 category conforming to IS:
1554 (Part-1) and its amendments, read along with this specification. The
Page 2 of 3
conductor shall be stranded copper. The insulation shall be extruded PVC to type A
of IS: 5831. A distinct inner sheath shall be provided in all cables whether armored
or not. The outer sheath shall be extruded PVC to type ST-1 of IS: 5831 and shall
be gray in colour except where specifically advised by the Employer to be black.
5.0.2
Cores shall be identified as per IS: 1554 (Part-1) for the cables upto five (5) cores
and for cables with more than five (5) cores the identification of cores shall be done
by printing legible Hindu Arabic Numerals on all cores as per clause 10.3 of IS
1554 (Part-1).
6.0.
CABLE DRUMS
6.0.1
Cables shall be supplied on returnable wooden or steel drums of heavy

construction. Wooden drum shall be properly seasoned sound and free from defects.
Wood preservative shall be applied to the entire drum.
6.0.2
Standard lengths for each size of power and control cables shall be 500/1000
meters. The cable length per drum shall be subject to a tolerance of plus or minus
5% of the standard drum length. In case, the total requirement is less than 500
meters, non-standard drum length shall also be acceptable.
6.0.3
A layer of waterproof paper shall be applied to the surface of the drums and over
the outer most cable layer.
6.0.4
A clear space of at least 40 mm shall be left between the cables and the lagging.
6.0.5
Each drum shall carry the manufacturer's name, the purchaser's name, address and
contract number and type, size and length of the cable, net and gross weight
stencilled on both sides of drum. A tag containing the same information shall be
attached to the leading end of the cable. An arrow and suitable accompanying
wording shall be marked on one end of the reel indicating the direction in which it
should be rolled.
Packing shall be sturdy and adequate to protect the cables, from any injury due to
mishandling or other conditions encountered during transportation, handling and
storage. Both cable ends shall be sealed with PVC/Rubber caps so as to eliminate
ingress of water during transportation and erection.
6.0.6
7
7.0.1
TESTS
All cables shall conform to all type, routine and acceptance tests listed in the
relevant IS.
7.0.2
All power cables of sizes 240 sqmm and above shall meet the requirements of the
following additional tests and type tests may be conducted to prove their
capabilities.
8.0
short time current test on conductor(s) .
short time current test on armours(s).

For Power cables of voltage class 11 KV and above, suitable termination
arrangement through cable kits shall be provided by the contractor.
Page 3 of 3

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